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SWIFT TECHNICAL CAMPUS

PRODUCT INNOVATION-1
Coursework 2

Submitted To:- Asst. ProfessorVarindarMandley

Submitted by:-Rohit Kumar

Automotive Engg.
Level -1
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ACKNOWLEDGEMENT

I have taken efforts in this project. However, it would not have been possible
without the kind support and help of many individuals and organizations. I would
like to extend my sincere thanks to all of them.

I am highly indebted to “Asst. Professor VarinderMandley” for their guidance and

constant supervision as well as for providing necessary information regarding the
project & also for their support in completing the project.

I would like to express my gratitude towards my parents&classmates for their kind

co-operation and encouragement which help me in completion of this project.
I would like to express my special gratitude and thanks to Mr. Sunil Dhiman for
giving me such attention and time.

My thanks and appreciations also go to thosepeople who have willingly helped me

out with their abilities for developing the project.

Rohitkumar
Automotive Engg.
Level -1
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INDEX
Sr. no Topics Page no.
1 Abstract 4
2 Introduction 5
3 Project objective 5
4 Project scope 5
5 Project problem statement 6
6 Project planning 6
7 Project flow chart 7
8 Can Crusher 8
9 Features of can crusher 8
10 Various type of Can Crusher 8
11 Key Features of Design 18
12 Market Survey 19
13 Application of can crushers 24
14 Material consideration and their properties 25
15 Raw material used in Can Crusher 28
16 Assembling of Can crusher 29
17 Specification and Features 35
18 CAD drawing of Can crusher 36
19 Automation and Further modification 44
20 Force volume change 49
21 Force Required to crush a Can 50
22 How cast iron and steel is better than wood 51
23 Crushing Rate 52
24 Engineering Aspects 52
25 Innovation 53
26 Observation 53
27 Conclusion 54
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ABSTRACT

The study of manufacturing was very important in order to carried out this project
to ensure that student understand on what are needs to do. This project is about
designingand fabricating the Can Crusher to helps people easy to crush the
Aluminium,tin andsoda cans. This project involves the process of designing the
crusher usingconsidering forces and ergonomic factor for people to use. After the
design has complete,it was transformed to its real product where the design is used
for guideline. Theseprojects also require ensuring the safety for indeed of
publishing. Methods and processinvolve in this project for instance joining using
bending, welding, drilling, and cuttingprocess. This project is mainly about
generating a new concept ofCan Crusher thatwould make easier to bring anywhere
and easier to crush the tin. After all process hadbeen done, this crusher may help us
to understand the fabrication and designing processthat involve in this project.Even
though there are many types ofthe can crusher machine in the market, the
completion of this new model providesamore practical usage.
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Introduction:
The main purpose of this project is to understand the fundamental knowledge of
design and mechanism by using gear system and a simple mechanism
property.This project contains of designing and fabrication of can crusher machine.
There have many differences between this can crusher with current design in
marketplace.This project is to develop and improving it performance as well so
that there has no doubt about the design and concept. This design required little
forces to crush the aluminium cans, can crush a can at a time. In this project, it
requires lot of skills, information and also knowledge such as Computer Aided
Design software, Solid works software, using machine called shearing machine,
bending machine, vertical bend saw, bench work and welding process. This design
definitely would help the user. So, this design would through much process before
it get into prototype term in order to achieve the objectives and off course customer
need
A mechanical tin can crusher is basically one of the most aid able machines.
Ithelps to reduce the pollute environment of this world. Thus helps create a better
place tolive in. apart from that, this can crusher can actually be the future mode of
recyclesapart from the recycle bins. It can be placed every where, in the park,
houses, even incars, by using a smaller can crusher.
Therefore, This project interest and expose me the field of mechanism and design
engineering. To design the mechanical part of a can crusher and to fabricate the
mechanical part of the system.

Project objective:
The objective of the project is given below:
 To design and fabricate the can crusher that required low force
to crush the cans.
 To design and fabricate the can crusher that can crush a can at
a time a.
 To design and fabricate the can crusher that has storage to
locate the can after crush.

Project Scope:
Project Scopegive us a lot of advantages to learn new process to produce this
product and absolutely we could find lot of advantages neither we are realized
or not. The scope of this project can crusher is the most important part in project.
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Make sure scope is totally followed the line of this project to achieve, what the
project need. Thescope of work in this project are given below :-
 Literature review about the design from any possible resource.
 Design the model of can crusher.
 Fabricate the design using material that been selected.
 Test the design in demonstration.
 To design the mechanical part of a can crusher using CAD software Solid
Work.
 To design the can crusher which takes less effort of the worker.
 Develop the model of can crusher using bending process, welding process,
drilling process and cutting process .
 To fabricate the can crusher which crush more cans in less time.

Project Problem Statement:

When people footstep the tin after finishes their drink, the tin always not
looksymmetrically flat and it look messy. This condition sometime makes tin
produce thesharp adage will harm or injured the people.Furthermore, people
always throw the can anywhere. These conditions makespollution for this
environment, become bad surrounding and separate the ditches.
So this design is use to crush the can as flat as possible and try to reduce time,
cost consuming and the sharp edge also have bin bellow the crusher.The design
process enabled us to follow a systematic approach to design. The Most important
step of the design process is identifying the users need.

Project Planning:
This project is startingwith meet Asst. Professor VarinderMandleyin a first week,to
collect information and also other information from via internet, books and survey
at market,this literature review for the project must do for every week. The Gantt
chart (time management) and flow chart (process management)
will be developing on second week. This is done using Microsoft Excel using
Ganttchart system.
Theprogress of the project and guided by Asst. professor VarinderMandleyto solve
difficulty.The next task is research of literature review with the means of the
internet, books,available published articles and materials that is related to the title.
Designing phase start of by sketching few model models using manual sketch on
A4 papers. Do it comparison for choose the best concept. Software applications are
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downloaded from internet to design the model based on the sketches. Software
SolidWork helps to draw the better dimension.
The next step is the fabrication of make some method for this project.Choose
the material, make some list for the material and dimension. Do it planning of
fabrication process for this project.
After that, start the fabrication process. It would take seven weeks to get this
design and fabrication process alteration done. Make some analysis and testing for
the project. Do it correction for error this project. Finish the fabrication process
with painting process.
After that, the final report writing and final presentation will be the last task to be
Accomplished.

Project flow chart:

From the flow chart, this project started with the objective of the project. The
objective of the of the project must follow the title. The objective of this project
must fulfil the title then follow up with the review of design about can crusher and
then study a lot of investigation about can crusher. This is study including about a
crusher, type of crusher, what type of material which suitable to make a product.
This information have been collected and gathered done through various sources
such as on internet, books and others resources. With the design process project is
to be continued all the knowledge and lessons had been applied to make a good
design for the project of can crusher. After take several design sketched, design
consideration have been chosen by using Pugh’s concept selection. Engineering
drawing and solid modelling by using Auto Cad software the fabrication process
use drawing as a reference. The process consist of fabrication to all the parts that
have been designed by using various type of manufacturing process with the
dimensions. There are several manufacturing process such as drilling, welding,
bending, cutting, etc. During the this process, if there occur an error during
fabrication process so the process need to modification the process need to go back
to the previous step and the process flow again, until no error occur the process can
been continued smoothly until the final product finished. Then, the draft report
need to be submitted to the supervisor for double checking if there had an error.
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Q.1
Can Crusher:
A can crusher is a device used for crushing aluminum soda, soft drinks and beer
cans for easier storage in recycling bins. Most of the recyclers don’t require you to
crush cans, if you do recycle a lot, your normal bin may fill up quickly. The can
crusher gives you extra space by flattening either single or multiple cans. The first
can crusher was of course the human foot. People often stomped on cans to flatten
them down either for recycling or for greater space in the garbage can. This could
sometimes hurt if the foot did not come down properly on the can. But now there
are lot of can crushers available in the market. The simplest, usually about 10 US
dollars (USD) have you crush a single can at a time, by pulling on a lever that
brings weight down on the can until it is crushed nearly flat. For about 20 USD you
can find can crusher devices that will flatten numerous cans at the same time. This
type of can save time, especially if crushing the can by hand.

Features of can crusher:

Can crushers are powered by different methods, but all share similar features.
Cans are deposited or placed into a chamber outfitted with a device that crushes
the cans. The device can be a disk that smashes the cans from above, a metal unit
that gives the cans a two-sided "hug" to crush them, or a massive, mechanical
chamber that crushes cans on an assembly line.
Various type of Can Crushers available in the market:-
Can crushers have become important item these days. It is commonly used for the
purpose of smashing and flattening soda cans. However, nowadays, it is used for
various other purposes as well. Many people prefer to have beverages in aluminum
cans.A can crusher helps in recycling of hard metals like aluminum. It not only
saves space but time and money too. In the market, we can find both plastic and
metal can crushers, sometimes even a mixture of both. Such devices made of
recycled plastics arealso available in the market, these are environment friendly.
Hand and foot can crushers are manually functioned, but ones operated by foot are
definitely easier and of fun. Here it should be mentioned that hand can crusher
work in a more organized way and does not create a mess as the ones done by foot
do.
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Can crusher can be of many types according to how they works; it can be
mechanical, hydraulic, pneumatic and magnetic. Hydraulic can crusher work
without the use of water and certainly are devoid of any sound or calibrations. But
mostly the ones we commonly find in the market are electronic. There are various
companies like Ontario limited, Alan Ross Machinery Corporation, Can Cycler
equipment, Inc, etc. that have steadily taken up this recycling objective through the
products that they sell, and can crusher is one of them.

The various types of can crushers is given below:

I. Hand Operated Can Crusher:

This type of can crusher is operated by hand manually. These type of can crusher
made of wood and metal or plastic also. Metal made can crusher are mostly used,
but this type of can crushers are costly than wood type. The hand operating can
crushers are mostly used for smashing cans. The various types of hand operated
can crushers are given below:-

A. Hand operated Aluminium soda can crusher smasher:-

This hand operated crusher will quickly crush all aluminum soda & beer cans
large or small size. This type of can crusher having holes on its rear plates for
wall mounting. The given figure shows hand operated soda can crusher
smasher:

Fig.(I).A
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This type of can crusher consists of a channel rear section having holes for
wall mounting and two plates one is fixed at the lower end of the channel or
other is moves with the help of handle or link arrangement. The can is
placed in between the two plates and a load is applied on the
handledownwards(as shown in figure) that produces a force which easily
smash the can.

B. Pacific Mounted Aluminium Can Crusher Smasher (Beer and

Soda cans):-

The Aluminum Can Crusher instantly crushes most cans to about 1-inch.
Simply hold the handle and pull it down. Even more, the sturdy all-steel
construction is durable. It save valuable space both where you store the cans
and when you transport them. Now you can haul 5 times as many aluminum
cans. It means you'll have less trips to the recycling center and each trip will be
worth more money. Best of all, you'll be doing your part to help the
environment. Recycling is fun and easier than ever with the Crusher

Fig.(I). B
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 This type of can crusher make the recycling process more efficient with The
Aluminum Can Crusher.
 Instantly crushes all 12- and 16-ounce cans to about 1 inch, so space is saved
when storing and transporting them.
 Sturdy all-steel construction is durable, with an easy-to-grab handle that
makes it easy to operate.
 Simply hold the crusher's handle and pull it down to crush a can.
 Easy to hang on the wall and measures approximately 16 inches long.

C. Aluminum Bars Wall Mount Can Crusher Bottle Soda Opener

12 oz Recycle 2 in1:-
The working principle of this type of can crusher is same as the simple hand
operatedaluminium soda can crusher but the difference is this aluminum bars
wall mount can crusher do another work of opening soda bottles. This makes
it two in one can crusher.
Features:
 This is a Can crushers with Bottle Opener.
 This easy to use crusher and fits all 12 oz aluminum beverage cans.
 This can crusher uses heavy gauge steel with sift grip handle.

Fig.(I).C
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 It is simple and safe to operate.

 This saves storage space by crushing cans to approximate 20% of
original size.
 This type of can crusher can also be wall mounted (4 screws
included).
 This can crusher used for perfect recycling.
 Dimensions are: 13" H x 3.75" W x 3.25
D. Can Ram- Aluminum Can Crusher or 6-can Aluminium Can
Crusher:-
Can Ram- Aluminium can crusher is also known as 6-Can
aluminium can crusher. This type of can crusher is six times faster
than ordinary crushers! Wall-mounted can crusher holds up to 10 aluminum
cans, feeds them automatically into chamber and ejects each after crushing.
Makes it easy to store and transport cans for profitable recycling.
 Material: High strength nylon resin,
 Mount Type: Mounts to wall,
 Capacity: (10) Cans
Features:
 Crushes 10 cans in 10 seconds
 Holds 6 cans with only 2 moving parts
 Automatic chamber entry & ejection
 Rust-proof, high-tech nylon.

Fig..(I).D
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E. Pneumatic Can Crusher air powered norgren cylinder

Aluminum soda can recycling:
This is the Kevin Krusher 1.5, pneumatic/ air operated aluminum can
crusher. A hefty blast of air, usually pumped from some type of pressurized
tank, will move the crushing device in a quick and exact motion and crush
the can. The pneumatic tube is about the size of large, rolled-up
poster.Description:
 Pneumatic/Air Powered 12 or 16 oz Aluminum can crusher.
 6 1/2" minimum length in chamber to accomodate various can
lengths. 110-120 PSI required for optimal performance.
 Quality manufactured for durability, 6061 aluminum frame construction
 Zinc and black oxide coated assembly hardware.
 Anodized aluminum press and release valve with very high air
capacity, operated with the touch of a finger..
 Double action 1.5 diameter x 6" strokenorgren cylinder.
 All brass compression fittings.
 Can be mounted on the table or wall as shown in figures.
 Mounting hardware will be supplied.
 This is a must have for any home, garage, bar, shop or man-cave!
 The second picture shows both my 1.5 cylinder unit on left and the 2.0
cylinder unit on the right, this listing is for the 1.5 diameter cylinder unit.

Fig. (a) (Fig. II) Fig. (b)

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F. Hydraulic Can Crusher:

This type of can crusher uses hydraulic oil to crush cans. Its crushing
principle is similar to pneumatic can crusher but the difference is this uses
hydraulic fluid in place of air and a hydraulic pump in place of air
compressor. Hydraulic fluids, also called hydraulic liquids, are the medium
by which power is transferred in hydraulic machinery.
Features:
 Heavy duty rotor design.
 Unique hammer locking device.
 Interchangeable liners .
 Flexible application in primary and secondary crushing.

Fig. III
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G. Foot Operated Can Crusher:

The foot operated floor can crusher is a great way to recycle aluminium and
steel cans. The can crusher is easy to use and comes with a support bar
which is designed to prevent cans from being forced out of the can crusher
by the pressure of the foot plate being pushed down. The crusher also
features a piercing screw which can be adjusted to aid crushing harder cans.
Once the cans are crushed they can be sorted for recycling, a magnet is
featured on the can crusher to help distinguish between steel and aluminium
cans. If the magnet does not stick to the can it means it is aluminium. In the
given figures first shows the simple foot operated can crusher and second
shows the working of foot operated can smasher.
Features:
 Easy to use crusher.
 Foot operated.
 Suitable for most sizes of aluminium and steel cans.
 Magnet featured on can crusher to identify steel and aluminium cans.
 Size - 37cm (L) x 12cm (W).

Fig.(a) Fig.(b)
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H. Metal Can Crusher:

Metal can crusher is a new type, energy saving and environmental protection
of crushing equipment, which is applied to broke cans, lulu cans, pot,
bicycle, automobile shell, scrap iron, etc. That all kinds of metal thin
material is about 5mm or so. The most important role is made all kinds of
metal broken into a sphere, granular or flake that is easy to transport. A
metal can crusher is shown in figure .V:

Fig. H.
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Work Principle of Metal Can Crusher:

This equipment adopts hammer and the blade material break into a sphere,granular
or flake. Aliminum iron can be separated and through the dust removal equipment
that making the broken the sundry ruled out.

The Advantages of Metal Can Crusher:-

1 High capacity and low noisy

2 Simple operation and pollution-free
3 Strong applicability and wide crushing material.

I. Electric Can Crusher or Automatic Can Crusher:

The Automatic Can Crusher is designed as a battery operated, automatic,
aluminum, can crusher for domestic purposes. It’s a nifty recycler that works
on an 18volt dc power tool battery (and/or an AC adapter), and chomps on
40 cans on a full charge and yet hungry for more! Cans get crushed to
40%their original volume, and that’s quite neat. The electric can crusher is
shown in figure below:
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Key Features of Design:

Design plays an important role for the producing a good product. Design gives the
all information about the product. In can crusher the customer need less effort to
crush the cans and the crusher should be safe, good aesthetics, less cost and other
features. The key features of design in can crusher are given below:

 The can crusher takes less effort of the worker.

 High leverage design makes easy recycling.
 It is effective in colour.
 Cushion grip handle are used for soft gripping.
 It reduces the can size upto 85-90%.
 It is simple and safe to operate.
 The weight of the can crusher is less as possible.
 It is portable and easy to handle.
 It crushes cans in a less time or less effort.
 It crushes all sizes cans.
 Making recycle easy and fun.
 The crusher hopper holds 5-10 cans.
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 Compacting the material up to 30% of their original size.

 This aluminium can crusher saves space in recycling bin.
 It is modify with the help of other driving arrangements, such as motor
driven or engine driven.
 Heavy gauge materials used for long life.
 It is completed with fixings of wall mountings or table mounting.

Market Survey:
A market survey is a technique used in marketresearch that reveals the buying
behavior and purchasing power of consumers within a particular area. Market
research is any organized effort to gather information about markets or customers.
It is a very important component of business strategy. The term is commonly
interchanged with marketing research, marketing research is concerned specifically
about marketing processes, while market research is concerned specifically with
markets.
Market survey is a key factor to get advantage over competitors. Market research
provides important information to identify and analyze the market need, market
size and competition.
Market research, which includes social and opinion research, is the systematic
gathering and interpretation of information about individuals or organizations
using statistical and analytical methods and techniques of the applied social
sciences to gain insight or support decision making.
During market survey, I foundthat there are different types of can crusher are
available in the market, such as pneumatic can crusher, hydraulic can crusher,
mechanical can crusher and electrical can crusher. Different designs of the can
crusher shows the different working principles of can crushers there market value,
cost, and the effort to operate. This information help me to make a new design of
the can crusher.
I collect some information from the users to gain an understanding of their
knowledge regarding the topic as well as to observe inthepreferences for certain
aspects to improve the quality of our product .The main points discovered during
the market survey are given below:-
 Most people checks the effort for working of can crusher
 Most people check the can crusher crushing rate.
 Those that do check the depths, check it for the safety.
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 People are most interested for the Aesthetic appeal.

 Peoples interested in the long life of can crusher.
 The price of the can crusher should be minimum not too high.
Various question during the market survey and their answer information are given
below:
Question by me: Do you have can crusher?

Answer by seller: yes.

Question by me: Which type of can crushers you have?
Answer by seller: We have hand operated, foot operated, Pneumatic and electric
can crushers.
Question by me: What is the required air pressure for pneumatic can crusher?
Answer by seller: 6-8 bar and 88-115PSI(pound per square inch)
Question by me: Is there a guarantee with the pneumatic can crusher?
Answer by seller: Yes, There is guarantee of one year. If you have any problem
with respect to can crusher than you change the can crusher with in one year.
Question by me: What is the price of pneumatic can crusher?

Answer by seller: The price of pneumatic can crusher is 2500 Rupees.

Question by me: Does the pneumatic can crusher needs lubricant?
Answer by seller: No.
Question by me: How much force required to crush the cans?
Answer by seller: The force required to crush the cans is depend upon the volume
of air inside the can if the volume is greater, then the more force is required for
crushing.
Question by me: How many cans are crushed by the can crusher at a same time?
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Answer by seller: 6-10 cans at a time. It is mainly depends upon the size of the
hopper.
Question by me: What is the material of hand can operated can crusher?
Answer by seller: It is made of metal or plastic.
Question by me: What is the prices range of the can crushers you have?
Answer by seller:The price range of the can crusher is between 600-2700.
The given chart shows the prices of different can crushers:

The can crusher during the market survey are shows below:
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(a) Electric can crusher (b) Pneumatic can crusher

(c) Hand operated pacific mounted can crusher

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(d) Hydraulic can crusher (e) can crusher bin single pack

Applications of Can Crusher:

Lot of cans to be thrown out that one person can drink soda in a life time means
.This results tremendous amount of space here it not for the can crusher. With the
help of can crusher you can be sure that that the dimensions of the cans will be
greatly reduced.
you may have noticed can crushers in malls, hotels and even schools or offices.
They really enjoy using these things. Installing these can crushers on every corner
of the streets would go a long way to protecting Mother Nature and in turn
ourselves as well. Many countries will follow suit and learn from this. This could
make the entire world a much nicer and cleaner area to live in.
Here's a handy list I threw together that just might sell you on the idea of adding
one to your home.Can crusher make much more likely to recycle your used
beverages. Due to which reduced the spaces.
It is a really fun for the children to use this can crusher. Kids love the
satisfaction that comes with used a can of cola.
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Q.3
Material consideration and their properties:
I. Cast iron:
Cast iron is an alloy of iron and carbon, and is popular because of its low
cost and ability to make complex structures. The carbon content in cast iron
is 3% to 4.5% by weight. Silicon and small amounts of Manganese, Sulfur,
and Phosphorus are also present in it. The products of cast iron exhibit
reasonable resistance against corrosion. It is neither malleable nor ductile,
and it cannot be hardened like steel. It melts at about 2100 ºF, and has either
a crystalline or a granular fracture.

Types of cast iron:

 white iron
 grey iron
 ductile iron
 malleable iron

Properties of Cast iron are:

 Tensile Strength:
Different varieties of cast iron are used in the construction of machines and
structures. Cast iron having a tensile strength of 5 tons per square inch, or
less, is of no value for the purpose where strength is required. This type may
however be used for balance weights, foundation blocks, or for purposes
where weight alone is of consequence. Some varieties of cast iron show a
tensile strength as high as 19 tons per square inch, but on an average, the
strength is 7 tons per square inch. Addition of vanadium can increase the
strength of cast iron.
 High Compressive Strength:
Compressive strength is defined as the ability of a material to withstand
forces which attempt to squeeze or compress it. Cast iron shows high
compressive strength, which makes it desirable for use in columns and posts
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of buildings. The compressive strength of gray cast iron can be almost as

high as that of some mild steels .
 Low Melting Point:
Its melting temperature ranges from 1140 ºC to 1200 ºC. Nowadays, many
advanced melting, alloying and casting methods are being used, which can
bring the new irons formed, in competition with steel.
 Resistance to Deformation:
Cast iron structures show resistance to deformation and provide a rigid
frame. However, if one part of the casting after the iron is poured into the
molds, is very thin, and another very thick, the problem of the structure
breakdown becomes prominent. The reason for this is when the thin part
cools first and contracts, the thick part which cools down afterward causes
stress in the thin part, offering sufficient force to break it.
 Resistance to Oxidation:
Rust is formed by the reaction of iron and oxygen, in the presence of water
or air moisture. It leads to the corrosion of iron and its alloys, and any iron
mass in presence of water and oxygen, can eventually convert into rust and
later disintegrate. As cast iron offers resistance to oxidations, it provides a
solution to the problem of rust.

Specification of cast iron:

Density 7.8 g.cm-3 at 20°C
Melting point 1536 °C
Boiling point 2861 °C
Atomic mass 55.85 g.mol -1
Heat of fusion 13.81 kJ·mol−1

II. Steel:
Steel is composed primarily of iron with carbon as the major alloying element.
The greater the percentage of carbon, the stronger and stiffer the steel. High-
carbon steels are generally infeasible for use as workpiece materials in sheet
metal forming because of their high resistance to permanent or plastic
deformation. Most automotive stampings are produced from low-carbon steel,
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containing less than .15% carbon. In some applications resistance to plastic

deformation is desired, e.g., in springs.
The type of steel are given below:

Cold Rolled Steel As with most metals the alloy composition, heat treatment and
any mechanical processing (rolling in this case) are all important in determining
material behavior. The "drawing quality" steels are processed to produce uniform
deformation up to large deformations (deformation and uniform deformation is
discussed in detail below). One such deformation behavior improving process is
used in "aluminum killed" steel. Aluminum is used to remove oxygen from the
steel and so minimize the deleterious effects of oxygen on the extent of
deformation which can be imposed and on the uniformity of deformation. Steels
are available in 1/4 hard, 1/2 hard and full hard conditions.

Spring Steel has a high "elasticity," that is, a large amount deformation can be
imposed before the material takes on a permanent set or plastic deformation is
produced. These ideas are covered in detail below.

Stainless Steels contain alloying additions of nickel and chromium. Their cost is
high,but because of their fine surface appearance and resistance to corrosion, they
are used in forming special parts. Stainless steels with various heat treating tempers
are commonly available.

Properties of steel:
Strength

Yield strength:Yield strength is the most common property. The primary

designation relates to the yield strength, e.g. S275 steel is a structural steel
with a specified minimum yield strength of 275 N/mm².
Toughness:
It is in the nature of all materials to contain some imperfections. In steel these
imperfections take the form of very small cracks. If the steel is insufficiently tough,
the 'crack' can propagate rapidly, without plastic deformation and result in a 'brittle
fracture'. The risk of brittle fracture increases with thickness, tensile stress,
 Course work -2|27

stressraisers and at colder temperatures. The toughness of steel and its ability to
resist brittle fracture are dependent on a number of factors that should be
considered at the specification stage.
Ductility:-
Ductility is a measure of the degree to which a material can strain or elongate
between the onset of yield and eventual fracture under tensile loading.

Weldability:-

All structural steels are essentially weldable. However, welding involves locally
melting the steel, which subsequently cools. The cooling can be quite fast because
the surrounding material, e.g. the beam, offers a large 'heat sink' and the weld is
usually relatively small. This can lead to hardening of the 'heat affected zone'
(HAZ) and to reduced toughness. The greater the thickness of material, the greater
the reduction of toughness.

Specification of steel:

Modulus of elasticity, E 210,000 N/mm²

Shear modulus, G E/[2(1 + ν)] N/mm², often taken as
81,000 N/mm²
Poisson's ratio,v 0.3
Coefficient of thermal expansion, α 12 x 10-6/°C (in the ambient temperature
range).

Raw material used in Can Crusher:

1. 4 pieces of Angle armtwo of 30 inch. and two of 10 inch For the base, made
up of cast iron
2. Cylinder or sleeve made up of steel
3. Piston made up of steel
4. Connecting rod made up of cast iron
5. Crank shaft up of cast iron
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6. Two shafts made up of cast iron having 1.5 inch Diameter.

7. Handle with rotor of steel
8. Chain wheel Pinion(driving) gear having 14 teeth made up of cast iron.
9. Chain wheel Driven (bull) gear having 42 teeth made up of cast iron.
10. Four bushes made up of brass or bronze.
11. Nut bolts.
12. Hood or cover made up of sheet metal.
13. Hinge.
14. Round iron bars for hopper.
15. Angle arm for gear box and legs of base.

Q.5
Assembling of Can Crusher: In the assembly of can crusher various
manufacturing processes are involved which are given below:
1. The first step is draw the free hand sketch of the model on the paper to
ensure that the concept will be successful. After this, the sketched model is
converted into solid modelingand drawing using solidworks.
2. I collect the raw material for the can crusher such as angle arms for base,
sheet metal for the hood of gearbox, bushes for providing support to the two
rotating shafts, gears, handle for operating.
3. The next step is the measuring and marking of the material with the help of a
vernier caliper, measuring tape and try square for flatness checking. Scriber
is used for the marking.
4. After measuring and marking the extra material removed by machining from
the work piece with the help of lathe machine. Cutting of the raw material
with the help of power hacksaw.
5. After cutting process, the base frame of the can crusher is made with angle
arm by the welding process. The legs of the base have a washer welded to
the bottom for the purpose of mounting on table.
6. On the base frame, I place a cylinder or sleeve having a two cuts one is on
top, for inserting cans and other is on the bottom for the ejection of crushed
can automatically. The sleeve is mounted on the base frame with the help of
nuts and bolts.
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7. After sleeve mounting, a gear box pillers are made with angle arms and
welded on the base frame. The two bushes are mount on the base frame and
two are mount on the piller of the gearbox. The driven(crank shaft) shaft
moves in base frame lower brushes and the driving shaftmoves in upper
bushes. The driven(crank) shaft is fitted with balance weight which provides
smooth reciprocating motion to the piston and takes less effort of worker.
8. The driving gear(pinion)is welded on the driving shaft and the driven
(bull)gear is welded on the driven(crank) shaft. The two gears are chain
wheel gears and the power is transmitted by the chain from the driving gear
to driven gear. The driving power is given by the handle manually, the
handle is mounted on the driving shaft with the help of nut and bolt.
9. On the sleeve upper cut a hopper is welded made of round iron bars. The
purpose of hopper is to hold the auxiliary cans.
10. The piston is placed in the sleeve and join to the crank shaft with the help of
connecting rod. The piston face is tapered from front, this provides
automatic lift to the another can and prevent the can from bending.
11. The gearbox is covered with the sheet metal hood or cover and hinge on one
end for the purpose of greasing or oiling of bushes or crank pin.
The various photographs during the assemble of can crusher are as follows:
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Specification and Features of the AssembledCan Crusher is given

below:

SR.NO FEATURES SPECIFICATIONS

1 LENGTH OF THE BASE FRAME 30 INCH

2 WIDTH OF THE BASE FRAME 10 INCH
3 DIAMETER OF THE CYLINDER OR SLEEVE 3 INCH
4 LENGTH OF CYLINDER 15 INCH
5 DIAMETER OF PISTON 2.85 INCH
6 LENGTH OF PISTON 7 INCH
7 DIAMETER OF THE SHAFTS 1.5 INCH
8 LENGTH OF THE INPUT SHAFT 15 INCH
9 LENGTH OF THE OUTPUT() SHAFT 10.5 INCH
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10 NUMBER OF TEETH IN DRIVING(PINION) GEAR 14 TEETH.

11 NUMBER OF TEETH IN DRIVEN (BULL) GEAR 42 TEETH.
12 OUTER DIAMETER OF THE BUSH 2 INCH
13 INNER DIAMETER OF BUSH 1.7 INCH
14 LENGTH OF THE HANDLE 12 INCH
15 LENGTH OF THE CONNECTING ROD 11 INCH
16 MATERIAL OF GEARBOX HOOD SHEET METAL
17 MATERIAL OF BASE CAST IRON
18 MATERIAL OF SLEEVE AND PISTON STEEL

Q.6CAD drawings of the Can Crusher:

1. Base frame of can crusher:

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2. Cylinder or sleeve:

3. Piston:
4. Assembly of Crank(driving) shaft and Connecting rod:
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5. Driving shaft:

6. Chain wheel gear:

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7. Bush:

8. Handle:

9. Gearbox hood (cover):

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10. Hopper:
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11.Assembly of can crusher:

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Automation and Further Modifications In Can Crusher:

Automation:Automation is the use of machines, control systems and
information technologies to optimize productivity in the production of goods and
delivery of services. The correct incentive for applying automation is to increase
productivity, and/or quality beyond that possible with current human labor levels
so as to realize economies of scale, and/or realize predictable quality levels.

Advantages of automation:The main advantages of automation are:

 Increased throughput or productivity.
 Improved quality or increased predictability of quality.
 Improved robustness (consistency), of processes or product.
 Increased consistency of output.
 Reduced direct human labor costs and expenses.

Application and purpose of automation:

 Automation used in operations to reduce cycle time.
 Automation is used where a high degree of accuracy is required.
 Replacing human operators in tasks that involve hard physical or
monotonous work.
 Replacing humans in tasks done in dangerous environments (i.e. fire, space,
volcanoes, nuclear facilities, underwater, etc.)
 Performing tasks that are beyond human capabilities of size, weight, speed,
endurance, etc.
 Economic improvement: Automation may improve in economy of
enterprises, society or most of humanity.
 Reduces operation time and work handling time significantly.
 Frees up workers to take on other roles.
 Provides higher level jobs in the development, deployment, maintenance and
running of the automated processes.
In this project, the further modification points are described below:
1. Make it Motor or Engine driven instead of handle driven:
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The handle used in this can crusher takes more effort of the worker. For
reducing this effort the motor and engine can be used for the crushing
operation. The motor’s or engine’s output shaft is connected to the can crusher
input shaft with the help of chain wheel gears and V-belt pulley drive. The
motor speed is controlled by the regulators. The motor should be run at a speed
that it takes less time for Can crushing and protects the worker from any injury.
An Emergency switch is put on the top of the frame to stop the motor
immediately. The engine used for this purpose is of small single cylinder
engine. The engine’s output shaft is connects to the can crusher’s input shaft
with the help of V- belt pulley drive or with the help of spur and helical gears.
The speed of the motor for this purpose is 1000-1500 rpm. The below given

figure shows the motor or engine for this type of can crusher:-
(a) Motor (b) Engine

2. Use of Bearing instead of Bushes: The bearing and bushes provides

mechanical support to the rotating shafts of can crusher. Friction occurs
more in bushes as compared to the bearings. Bearing provides smooth and
steady operation to can crusher’s shafts while mitigating friction. The ball
bearing are suitable for the shafts of can crusher for power transmission. Ball
bearings transmits high power with no jerks and frictionless operation. The
two views of ball bearings are shown below:-
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A. Front viewB. Isometric view

3. Use of Flywheel on Crank Shaft: The use of flywheel on crank shaft

provides a balancing torque to the piston with the help of connecting rod.
The use of flywheel will balance the crank shaft.The flywheel provides
better speed and torque during the run of can crusher and provides better
crushing of cans in less time and less effort.

The given figures shows the CAD drawings of flywheel:-

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A. Front View B. Isometric View

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Flywheel

Force volume change:

A force acting on all particles (volume elements) of a given body and proportional
to the mass of the particles. A force can change the volume of an object. Some
objects are not very compressible. In case of can crushers, if the volume inside the
can is higher, then more force is required to crush a can but if the volume inside
the can is less, then less force is required to crush a can. The given figure shows
the change in volume of Can after applying force:
 Course work -2|46

The can has air pressure exerted on it both from outside and inside and those forces
are responsible for the can's subsequent demise.
Newton's second law deals with the sum of the forces. As long as the forces inside
and outside are balanced and equal, the can undergoes no change. When the forces
are unbalanced, changes in the shape of the metal can and will take place.
As the Can collapses, the volume of the Can decreases. The pressure of a gas is
related to the volume of its Can. At some point the diminished volume results in an
adequate pressure inside the Can to prevent continued collapse.

Force required to crush a can:

In this project (Can crusher)
Mass of the object(m)= 18kg
Distance travel by the piston in the sleeve or cylinder(d)= 12inch or 0.3048m
Time(t)= 4sec
Then,
velocity(V)= distance/time
Velocity(V)= 0.3048/4
V= 0.0762m/sec.
Hence,
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acceleration(a)= velocity/time
acceleration(a)=0.0762/4
acceleration(a)= 0.01905m/𝒔𝒆𝒄𝟐
we know,
Force(F)=ma {according to newton’s second law}
Therefore,
Force(F)=(18)*(0.01905)
F=0.3429N or (342.9)*𝟏𝟎−𝟑 N
Hence
Force required to crush a can is 0.3429N or 342.9mN(approx.)

How Steel is better than Wood:

- Steel framing material is significantly stronger than wood. In fact, it has the
highest strength-to-weight ratio as compared to wood.
- Steel's strength and resiliency is higher than wood.
- Individual members of a wood-frame react differently and in varying
degrees to climactic changes. The wood movement due to climatic changes
are expansion, contraction, warping, twisting, etc.
- Steel framing won't burn and add fuel to a fire..
- steel framing allows greater flexibility during design, construction and
remodeling.
- Steel products are all engineered to strict standards of strength and
consistency.
- steel is the most recycled material in the world. More steel is recycled than
paper, aluminum, glass and plastic combined.
- The steel is rot proof, termite proof, crack proof, split proof, warp proof, non
toxic and not fuel for fire as in case of wood.
 Course work -2|48

How Cast iron is better than Wood:

- Cast iron is a brittle form of iron which is higher in compression than wood.
It has a relatively low melting point, good fluidity, castability, excellent
machinability and wear resistance. Cast irons have become an engineering
material with a wide range of applications, including pipes, machine and
automotive parts.
- Cast iron retains high strength in fires, despite its low melting point. It is
usually around 95% iron, with between 2.1-4% carbon and between 1-3%
silicon. It does not corrode as easily as steel.

Crushing Rate:Crushing rate may be defined as the number of cans crushed per
unit time ‘or’ the rate at which cans are crushed.
In this project,
Time taken to crush a single can= 4sec.
Then,
Number of cans crushed in one hour=3600/4
Number of cans crushed in one hour= 900Cans.
Therefore,
Total can crushed in one hour is 900 with manual operation.
Hence,
The Crushing Rate is 900cans/hr.(approx.)

Engineering Aspects:Engineering aspects consider the ways in which systems

engineering can both be used to promote effective responses to the technical
aspects of contingency events. Engineering aspects gives information about the
appearance, features, ergonomic safe to operator analysis and working principles.
Working Principle: This project is works on the principle of reciprocating engine
i.e. the rotary motion of the handle is converted into to and fro motion of the piston
 Course work -2|49

but the difference is, the engine converts heat energy into mechanical energy with
the help of fuel but in this can crusher human effort gives a to and fro motion to the
piston with the help of crank shaft and connecting rod. Crank shaft converts rotary
motion into reciprocating motion of the piston with suitable leverage or gear
system. The hopper hold the cans. This can crusher reduces the size of can up to
85-90%. There is a ejection space in front of sleeve from which crushed can is
ejected by the reciprocating motion of the piston.

Innovation:The process of translating an idea or invention into a good or service

that creates value or for which customers will pay.
To be called an innovation, an idea must be replicable at an economical cost and
must satisfy a specific need. Innovation involves deliberate application of
information, imagination and initiative in deriving greater or different values from
resources, and includes all processes by which new ideas are generated and
converted into useful products.
In this project, the innovation is done by using motor or engine as a driving
member as discussed above ‘further modification.’ If we using a motor as a driving
member than speed regulators are used for controlling the speed of the motor. In
case of engine a gearbox is used for providing variation in speed and torque. An
emergency switch is also needed near the operator to stop the can crusher in case
of any accident.
In this can crusher we use helical gears for the purpose of smooth power
transmission and noiseless operation.

Observation:
During the market survey, I found that there are various types of can crushers
available in the market such as hand operated can crusher, foot operated can
crusher,pneumatic, hydraulic and electric can crusher. But out of these can
crushers hand operated and foot operated can crusher are mostly used due to there
less cost and less effort for operating.
These can crusher smashes the cans from 12oz to 17oz.This market survey enabled
me to study the wide range ofcan crushers and compare them on varying factors
such as the raw materials used, the functions such as operating principle,
 Course work -2|50

specifications and cost. During this survey, I see various design of different type of
can crushers. In the market various designs are available they are efficient,
soundless and takes less effort of operator or having facility of wall mounting or
mounting on table.The market survey helped me in understanding the individual
parts and also functioning of the hand and foot operated can crusher to some
extent.

Conclusion:
From the observation, I conclude that there are lots of type of Can crusher
available in the market. I notice that there are different design. Out of all the Can
crushers I take hand operated reciprocating can crusher and make free hand sketch
on the piece of paper and analyze the design, and makes its drawing in solid works.
After this by using suitable manufacturing process assemble the can crusher. This
project provides the knowledge about the manufacturing process and different
designs of leverage and power transmission with the use of v- belt drive or gear
mechanism. This project is quite successful and able to meet the all requirements.
 Course work -2|51

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 Course work -2|52

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