Name Usama Babar

Section 1
Semester 6

Submitted to:
Department of Mechanical Engineering

SODA BOTTLE CHIPPER

MAHCINE
Machine Design and CAD II
Capital University of Science and Technology
 SODA BOTTLE CHIPPER MAHCINE

Abstract
We are well aware of the fact that the plastic usage has increased all over the world, however most of the
plastic goes wasted that is causing serious environmental problems and is causing diseases all over the
world. Some of the plastic is recycled, however these techniques are only being applied to the limited
parts of the world.
To overcome this problem, a solution is needed to be developed so that our environment may remain
hygienic. To ensure that, a plastic must be recycled. Plastic is melted and then formed in the shape that
can be used. To do that, plastic needs to be recovered from everywhere and needs to be formed into small
chips so that it may be used again.

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 SODA BOTTLE CHIPPER MAHCINE

Contents
Abstract........................................................................................................................................................ 1
Introduction ................................................................................................................................................. 3
Mechanism ................................................................................................................................................... 3
Design ........................................................................................................................................................... 4
Components used .................................................................................................................................... 4
Gears ........................................................................................................................................................ 4
Shafts. ....................................................................................................................................................... 4
Universal Bearings .................................................................................................................................. 4
Blades ....................................................................................................................................................... 5
Project 2d Drawing for shaft...................................................................................................................... 5
Modeling of the chipper machine on Creo................................................................................................ 5
2d Creo Drawing ......................................................................................................................................... 7
Assembly ...................................................................................................................................................... 7
Calculations for gear................................................................................................................................... 7
Bending stress .......................................................................................................................................... 7
Fatigue strength ...................................................................................................................................... 9
Cost analysis .............................................................................................................................................. 11
Ansys .......................................................................................................................................................... 12
Our machine .............................................................................................................................................. 12
Results ........................................................................................................................................................ 13

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 SODA BOTTLE CHIPPER MAHCINE

Introduction
A soda bottle chipper machine is a machine that cuts the plastic soda bottles into small plastic chips so
that they may be recycled. The large plastic bottle parts need to be broken down into small chips, and then
they might be sent out for further processing. It is very important retain only one type of plastic so that the
different types of plastics do not mix together. Mixed crushed plastics can be used only for low value and
low quality products such as junction boxes used in electrical work or plastic lumbers.

Figure 1- Soda bottle chipper machine

Environmental effects
Since burning plastic is very harmful, so it needs to be recycled. To recycle it, we need to melt it and use
it again. Now to chip the plastic, we need to develop a mechanism that converts the big plastic parts
into small plastic chips.

Mechanism
Following is the mechanism on which our machine operates.

 The machine cuts the plastic as the soda plastic bottle is fed to the machine.
 As soon as the bottle comes in contact with the blades, the blades start to cut the bottle.
 Small chips of plastics are formed.
 The machine is mechanically driven.

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 SODA BOTTLE CHIPPER MAHCINE

Design
Components used
Following are the components that are used to make the chipper machine.

 Two shafts.
 Two gears which come in contact with each other and are mounted on to the shafts.
 Two universal bearings.
 Eight blades, four blades are attached to each via cotter joint
 A handle by which the machine can be mechanically operated.

Gears
There are two gears meshing which are identical with same specifications.
Table 1- Parameters for each gear

Parameter Value
Outer Diameter 3.6 inches.
Pitch Diameter 3.44 inches
Number of teeth 31

Gears are made of steel and they are perfectly in mesh with one another.

Shafts.
Shafts are attached using universal bearings with gears and they are made of mild steel.
The diameter of the shaft is 0.5 inches while the length of the shaft is 11 inches.

Universal Bearings
Two universal bearings are attached to the shafts so that the shafts may rotate with eases. Universal
bearings are a type of needle bearings.
A needle roller bearing is a special type of roller bearing which uses long, thin cylindrical rollers
resembling needles.

Figure 2- Needle Bearing

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 SODA BOTTLE CHIPPER MAHCINE

Blades
Eight blades are connected to the shafts via cotter joint. They are placed after one another and they
overlap each other. The diameters of the blades is greater than that of gears.

Project 2d Drawing for shaft

Modeling of the chipper machine on Creo.

Figure 3- Creo Assembly

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 SODA BOTTLE CHIPPER MAHCINE

Figure 4- Creo Model Tree

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 SODA BOTTLE CHIPPER MAHCINE

2d Creo Drawing

Figure 5- Creo Drawing

Assembly
 Identical gears are used.
 Two shafts are placed at the centre distance of the gears.
 Two gears are mounted via Cotter joint on to the shaft.
 Four blades on each shaft are mounted via cotter joint.
 At the end universal joints are assembled.
 Handle is attached to rotate the chipper machine.
 Finally a stand is made for the chipper machine.

Calculations for gear

Bending stress
𝐶 = 3.44 𝑖𝑛𝑐ℎ𝑒𝑠
𝑝𝑑 = 3.54331 𝑖𝑛

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 SODA BOTTLE CHIPPER MAHCINE

𝑑𝑝 = 𝑑𝑔 = 3.44 𝑖𝑛

𝑎 = 0.11 𝑖𝑛
𝑏 = 0.1385 𝑖𝑛
𝑑𝑜𝑝 = 𝑑𝑝 + 2𝑎 = 0.76368 𝑖𝑛
𝑚 = 0.3185 𝑖𝑛
𝑧
𝑚𝑝 = = 0.97
𝑝𝑏
𝑁𝑝 = 31

𝑁𝑔 = 31

𝑚𝑔 = 1
𝜋
𝑝𝑐 = 𝑝𝑑
= 0.34 𝑖𝑛

𝑝𝑏 = 𝑝𝑐 𝑐𝑜𝑠∅ = 0.327 𝑖𝑛
𝑇𝑝 = 504 𝑙𝑏 − 𝑖𝑛
𝑇𝑝
𝑤𝑡 = = 293 𝑙𝑏
𝑟𝑝

𝑤𝑟 = 136 𝑙𝑏
w = 323 lb

Gear quality index Q = 6.

12
𝐹= = 1.33 𝑖𝑛
9
𝑘𝑎 = 1
𝑘𝑚 = 1.6
𝑣𝑡 = 𝑟𝑝 . 𝑤𝑝
𝑓𝑡
𝑣𝑡 = 2.251
𝑚𝑖𝑛
3
(12 − 𝑄𝑣 ).4
𝐵=
4
B = 0.826

A = 59.745

ky =0.617

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 SODA BOTTLE CHIPPER MAHCINE

𝑘𝑠 = 1

𝜎𝑏 = 12.41 × 103 𝑝𝑠𝑖

Fatigue strength
𝑤𝑡 𝑐𝑎 𝑐𝑚
𝜎𝑐 = 𝑐𝑝 √ 𝑐 .𝑐
𝐹𝐼𝐷 𝑐𝑣 𝑠 𝑓

F = 1.33

𝑘𝑣 = 0.612
I = 0.073

𝜎𝑐 = 88.22 × 103 𝑝𝑠𝑖

Bearings Calculation
RPM = 150

D = 20 mm = 0.787 in

l/d = 0.6

𝑛/ = 2.5 rps
𝑖𝑛
𝑈 = 𝜋𝑑𝑛 = 6.1
𝑠
L = 0.4722 in

∈𝑥 = 0.747
𝑂𝑛 = 20
K = 1.59

𝑃 = 54
 = 0.035
𝑃
𝑃𝑎𝑣𝑔 = 𝑙 𝑑 = 145 𝑝𝑠𝑖

𝜃max = 159.2
p = 129276.78 lb

∅ = 34.95°
𝑇𝑠 = 0.0544 𝑙𝑏 − 𝑖𝑛
𝑇𝑟 = 250.21 lb-in

Power loss = 0.59 hp

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 SODA BOTTLE CHIPPER MAHCINE

2 𝑇𝑟
𝜇= = 0.0049
𝑝𝑑
ℎ𝑚𝑖𝑛 = 16.9 𝜇 𝑖𝑛
Factor of safety

N = 195/54 = 3.6

Shaft calculation

N = 150 RPM
𝑃
𝑇= = 42 𝑙𝑏 − 𝑖𝑛
𝜔
𝐹𝑁 = 53.36 𝑙𝑏
𝐹𝑠 = 80.05 𝑙𝑏
𝐹𝑔 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 = −53.36 𝑙𝑏

𝑀𝐴 = 𝑅2ℎ + 𝐹𝑔 + 𝐹𝑠 𝑞 = 0

R2 =?

R1= ?

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 SODA BOTTLE CHIPPER MAHCINE

𝑅1𝑥 = 16.4 𝑙𝑏
𝑅1𝑦 = 32.016 𝑙𝑏

𝑅2𝑥 = −115.8115 𝑙𝑏
𝑅2𝑦 = −21.3114 𝑙𝑏

𝑆𝑒 = 27300 𝑝𝑠𝑖
𝐾𝑓 = 2.25
𝐾𝑓𝑠 = 1.57
32 𝑁𝑓 𝑀𝑎 2 3 𝑘𝑓𝑠𝑚. 𝑇𝑚 2 1/2 1/3
𝑑=( ((𝑘𝑓 ). + ( ) ) )
3.14 𝑆𝑓 4 𝑆𝑦

D = 0.787 in

Cost analysis
Table 2- Cost Analysis for the chipper machine

Components Cost (Rs)

Gears x 2 1000
Shafts x 2 1000
Universal Bearings x 4 1400
Blades x 8 2600
Assembling Cotter joints 1000
Total 7000

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 SODA BOTTLE CHIPPER MAHCINE

Ansys
Total deformation

//

Figure 6- Total Deformation analysis on AnsysOur machine

Figure 7- Fabricated Chipper machine

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 SODA BOTTLE CHIPPER MAHCINE

Since there are two shafts, and eight blades the torque is of main importance, larger the torque, greater
would be the cutting forces.
This machine does cut the plastic into small chips.

Results
This machine does cut the plastic into small chips. We have to feed the parts of the plastic bottles to the
machine so that it may cut the plastic.

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