UNIVERSITY OF ZIMBABWE

A THIRD-YEAR PROJECT IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR A BSC HONOURS DEGREE IN
MECHANICAL ENGINEERING

TITLE: DESIGN OF A SMALL SCALE, MANUAL GRANITE STONE CRUSHER

BY
SAKALA TENDAI
REG NO: R141934A E-MAIL: sakala505@gmail.com
SUPERVISOR: ENG. T. CHIKUKU
COORDINATOR: ENG. T. MUSHIRI

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DECLARATION
I, Tendai Sakala hereby declare that this dissertation submitted for assessment is my own
composition.

Signature _____________
Date _________________

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DEDICATION
This project is dedicated to my family who supported and encouraged me in the course of this
great work and made the journey pleasant and successful.

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Acknowledgements
I would like to thank my supervisor Engineer Chikuku for his patience and guidance that made
this project possible. Worth thanking also are the are the quarry workers at Glenorah crushing
site who took their time to input to the design of the stone crusher. Without the help of my
colleagues this journey would have been much harder as their suggestions and ideas helped
shape the project.
Above all I thank God who give me the imagination, and creativity that made this project such
great work.

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ABSTRACT
This project is on the design of a manually operated stone crushing machine, specifically for
crushing granite rock. This machine is targeted towards people who are currently in the stone
crushing business but who use methods like the hammer and anvil to crush rock. Due to the
expensive nature of available stone crushers most individuals in the small-scale crushing industry
cannot afford these devices and hence resort to primitive ways of crushing that are both tedious
and potentially harmful. After careful analysis of current stone crushing mechanisms and
thorough study, a solution was developed that is safe, affordable and efficient. The developed
solution addresses the needs of the hammer stone crushers and provides a viable alternative.
Research was performed through the internet, the use of local libraries and also site visits to
stone crushing companies and various quarry sites that use the hammer and anvil approach.
University laboratories were used to conduct experiments and analyse crushing mechanisms.
This project is a problem solver to the small-scale stone crushing industry, not only making stone
crushing easier and more productive but also making it more desirable career choice for those
who were limited by risk of injury or low body strength.

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Contents
DECLARATION.........................................................................................................................2
DEDICATION.............................................................................................................................3
Acknowledgements......................................................................................................................4
ABSTRACT................................................................................................................................5
Chapter 1..........................................................................................................................................9
1.1 INTRODUCTION.................................................................................................................9
1.2 BACKGROUND.................................................................................................................10
1.3 PROBLEM STATEMENT..................................................................................................11
1.4 AIM......................................................................................................................................11
1.5 DESIGN OBJECTIVES......................................................................................................11
1.6 JUSTIFICATION................................................................................................................12
1.6.1 SAFETY.......................................................................................................................12
1.6.2 MECHANICAL ADVANTAGE..................................................................................12
1.6.3 EMPLOYMENT...........................................................................................................12
1.6 CONCLUSION...............................................................................................................13
Chapter 2 Literature Review..........................................................................................................14
2.1 Background..........................................................................................................................14
2.2 Available manual crushers...................................................................................................15
2.2.1 New Dawn Crusher.......................................................................................................15
2.2.2 Crazy crusher................................................................................................................16
2.3 Crushing technology and mechanisms................................................................................16
2.3.1Crushing Technologies..................................................................................................17
2.3.2 Mechanical Advantage.................................................................................................23
Chapter 3 Results of research........................................................................................................27
3.1 Interviews............................................................................................................................27
3.2 Determining forces..............................................................................................................28
3.2.1 Experiments..................................................................................................................28
3.2.2 The force capability of a human being.........................................................................33
Conclusion on forces.............................................................................................................34
Chapter 4 Methodology.................................................................................................................35
4.1 Literature review..................................................................................................................35

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 4.2 Concepts..............................................................................................................................35
4.3 Development of chosen Solution.........................................................................................35
4.4 Calculations and design of components..............................................................................36
4.5 Software used in project......................................................................................................36
Chapter 5 Concepts........................................................................................................................37
5.1 Concept 1.............................................................................................................................37
Lever arm concept.................................................................................................................37
5.2 Concept 2.............................................................................................................................38
Manual jaw crushing concept................................................................................................38
5.3 Concept 3.............................................................................................................................41
Cycling hammer mill concept................................................................................................41
5.4 Concept selection.................................................................................................................42
5.4.1 Binary dominance.........................................................................................................42
5.4.2 Justification of chosen solution....................................................................................45
Chapter 6 Development of Chosen solution................................................................................46
6.1 Operation principle in detail................................................................................................46
6.2 Development of chosen solution.........................................................................................47
6.2.1 New mechanism............................................................................................................47
Chapter 7 Design of Chosen Solution...........................................................................................49
7.1 Determining crusher dimensions and force relationships....................................................49
7.1.1 Static analysis of jaw crusher mechanism....................................................................49
7.1.2 Kinematic analysis of jaw crusher mechanism.............................................................51
7.1.3 Results from kinematic and dynamic analysis..............................................................54
7. 2 Part by part design (materials and sizes)............................................................................55
7.2.1 Design of flywheels......................................................................................................55
7.2.2 Gears.............................................................................................................................57
7.2.3 Jaw................................................................................................................................61
7.2.4 Design of shafts............................................................................................................63
7.2.5 Bearings........................................................................................................................73
7.2.6 Toggle...............................................................................................................................76
7.6 Stress analysis of critical components.................................................................................77
7.5.1 Wear plate.....................................................................................................................77

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 7.5.2 Front gear (with holes)..................................................................................................77
7.5.3 Flywheel.......................................................................................................................78
7.6 Bill of quantities..................................................................................................................79
Chapter 8 Conclusion and recommendations................................................................................80
List of figures.............................................................................................................................81
Appendix........................................................................................................................................83
APPENDIX A: FLYWHEEL....................................................................................................83
APPENDIX B: GEARS.............................................................................................................83
APPENDIX C: SHAFTS...........................................................................................................85
APPENDIX D: DATA ON KINEMATIC AND DYNAMIC ANALYSIS..............................87

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Chapter 1
1.1 INTRODUCTION
Stone crushing is reducing the size of large rocks into smaller rocks or gravel or dust.
Quarry stones in this project refer to granite ¾ inches (20mm) or less. These stones are
vital to the construction industry and when crushed are mainly used for road base
aggregate and in concrete mix [ CITATION Fre90 \l 12297 ].
The crushing process involves transferring a force amplified by mechanical advantage
through a material that has stronger bonds and resist deformation more, than the material
being crushed. Crushing devices hold material between two parallel or tangent solid
surfaces, and apply sufficient force to bring the surfaces together to generate enough
energy within the material being crushed so that its molecules separate from, or change
alignment in relation to, each other.[ CITATION Sat15 \l 12297 ]

Figure 1.0.1 Basic Principles of rock crushing

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1.2 BACKGROUND

The small-scale (hammer and anvil) stone crushing sector is an important part of the stone
crushing industry, it is not necessarily new but it is growing by the day along with the slight
boom in construction that can be attributed to the increase in the number of housing cooperatives
and similar schemes. The closing of major companies has resulted in high unemployment this
has resulted in people relying on informal work like stone crushing. This work requires no proper
qualifications and hence many people have resorted to it for a living. There is also a high demand
in construction materials like quarry stones due to the increase in the number of housing
cooperatives in recent years. These stone crushers obtain their granite rock from local dwalas by
exposing the parent rock (dwala) to extreme fluctuating temperatures through the burning of tires
over the dwalas. After cooling, pieces of rock can be chipped off using a sledge hammers, the
process is basically forced exfoliation. These chunks of rock are then crushed into the desired
aggregate to be sold for their various application.

Figure 1.2 Woman setting up tire to burn on Dwala

Rock crushers are used for breaking rock particles into smaller fragments. Rock materials of
different sizes, normally called aggregates, are used as building materials in a vast number of
products and applications in modern society. Infrastructure and building industries are heavily
dependent on rock material with specified characteristics as the basis for foundations, concrete

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structures, roads and so on. Hence this gives a strong incentive to facilitate the production of
aggregates at low cost, high quality and low environmental footprint[ CITATION Joh12 \l
1033 ].

1.3 PROBLEM STATEMENT

In Zimbabwe, there is no Stone Crushing equipment that suits the needs of small scale manual
stone crushers. Available crushing machines are expensive, hard to maintain and have additional
expenses like electric bills which also limit feasible locations of stone crushing sites. The result
is that small scale crushers have no option but to use the hammer and anvil method of stone
crushing, this method is not only unsafe but also very inefficient.

Figure 1.0.2 Woman manually crushing stones

1.4 AIM
The aim of this project is to design an affordable, manual, small scale quarry stone crushing
machine targeting manual stone crushers.

1.5 DESIGN OBJECTIVES

 To design a manual machine able to process on average 5 cubic meters of granite rock per
day.
 To design a durable machine that is also affordable for the chosen market with a price of
$1000 or less.
 To design a machine that is safe and simple in operation, addressing the challenges currently
being faced by hammer and anvil crushers.

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1.6 JUSTIFICATION
1.6.1 SAFETY
In any industry safety is one of the most important factors to be considered[ CITATION Chr16 \l
12297 ]. Every year in industry there is loss of millions of man and machine hours due to
industrial accidents, these statistics have made people to realise the importance of safety in
industry making it a prime objective[ CITATION Smr16 \l 12297 ] .Small scale quarries offer a
very unsafe environment for the worker and even visitors to the site. The use of hammers for
crushing results in high chances of self-inflicted injuries especially to the fingers holding the
rocks in place whilst they are being crushed. As the rocks are being crushed they can “fly” away
due to the impact of the hammer and can easily injure people around the work site. The machine
to be designed will be able to make stone crushing safer for the workers regarding the afore
mentioned safety concerns.

1.6.2 MECHANICAL ADVANTAGE

A machine is a device that transmits or modifies force or motion, it is anything that makes work

easier. A machine’s mechanical advantage is the number of times a machine increases a force
exerted on it. Using the hammer for crushing provides mechanical advantage but other
mechanism can provide even more and hence the design of this machine is to help make crushing
easier. This will not only make the work easier but also faster leading to more stones being
crushed for relatively the same amount of time. This will improve profits for those in the
industry and help them to offer product that is of high quality, comparable to the major crushing
companies that use more expensive machines.

1.6.3 EMPLOYMENT
Almost all African counties have job creation as a central policy[ CITATION Tea14 \l 12297 ].
In Zimbabwe with various major companies closing the situation calls for innovations that help
people to earn a living safely and legally. The manual quarry crusher will encourage people to
enter into the industry and make a living for themselves because it will come at an affordable
price, require less work and be much safer than the current rock crushing method being used by
small scale quarry workers. The importance given to employment creation is due to a prevalent
assumption that employment is proportional to both poverty reduction and stability of a nation or
economy. By increasing household incomes employment directly reduces poverty and indirectly
by stimulating the economy through the creation of demand, people can only spend money if
they have money.[CITATION Reb13 \l 12297 ]

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1.6 CONCLUSION
The fundamental goal for the design of a manual stone crusher is a design that meets the required
production requirements, operates at competitive cost, complies with today’s tough
environmental regulations, and can be built at a reasonable price despite the rising costs of
equipment, energy and construction labour.

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Chapter 2 Literature Review

2.1 Background
The very first stone crushers were hand held hammers and they have been dated as early as
30000BC [CITATION HDu15 \l 12297 ]. One of the first attempts at mechanizing hammer
movement was done by Leonardo Davinci on his machine below. The earliest patent for a
mechanised crusher was filed in America in 1830. It featured a somewhat an unrefined version of
the drop hammer that would later become an important device in the development of modern
mining.[ CITATION Rob10 \l 12297 ]

Figure 2.0.3 Model of Leonardo Davinci’s automatic hammer

There are different types of rock crushing operations depending on size and geographical
location alone as stated below.
The small category is usually characterised by self-employed people who use unconventional
methods of extracting and crushing their rocks. These methods include the use of the hammer
and anvil. These types of crushers are the main focus of this project as these methods are highly
unproductive and to some extent dangerous. They also lose customers due to not being able to
deliver crushed stone on demand.
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The medium enterprises can use the small mechanized crushing machines and can operate as a
group to assist each other to reach the high volumes of crushed rock that is needed by the
industry. The use of a mechanized crushing machine can be expensive, there is need for proper
facilities which are secure and have amenities like electricity. This therefore limits possible
locations for the site.
The large crushing enterprises in Zimbabwe include the few companies that survived the
economic melt-down such as Pomona Quarries in Harare. Some crushers are located at the
location where the crushed stone is needed a good example being Zim-Plats where large volumes
of ruck are crusher in order to extract other valuable minerals in the rock. These companies can
make use of very expensive equipment and they produce very large volumes even though they
sell their product at a much higher price than the small-scale companies mainly due to the quality
of the product and other services like free delivery for product that exceeds a certain amount.
Their location is mainly due to the availability of the raw material in large quantities and they
therefore usually have high transport expenses for delivery of product.

Manual stone crushers are those that are operated in a way that is not electrical that is they use
human effort instead of electrical power to crush stones. The principles of operation can be
similar to those that use electric motors. Manual stone crushers maximise on mechanical
advantage that can be obtained from various mechanisms like gears, pulleys and levers. Not
much has been done in the field of developing Manual stone crushers mainly because the
problem of hammer and anvil crushers is mostly rampant in third world countries where
resources may be scarce and in some instances, hammer and anvil operations may be deemed
illegal.

2.2 Available manual crushers

2.2.1 New Dawn Crusher

Figure 2.0.4 New dawn manual crusher and team of women crushing stone

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This crusher is one of the few manual stone crushers available, it is manufactured by a company
called New Dawn Engineering (Swaziland) and it works by a principle close to that of a jaw
crusher. The main disadvantage of this crusher is that it is not locally available. It does not have
any safety mechanisms should uncrushable material enter the crusher. The new Dawn crusher is
ideally operated by at least five individuals as seen in the above picture and it is said to be able to
produce 10 cubic metres of stone per day.
2.2.2 Crazy crusher

Figure 2.0.5 Crazy crusher laboratory stone crusher

Another type of manual stone crusher is the crazy crusher, it is mainly used in laboratories for
crushing rock samples for testing. It uses a lever to create the necessary force needed to crush
stone. Currently its design is still patent pending. The crazy crusher is very small and therefore
would not work for big quantities of rock. it also crushes stone into fine powder which is not
ideal as the desired level of crushing in this case is ¾ inches. The principle of operation is such
that when the pulley is lowered it creates a compressive force that then crushes the rock into fine
powder.
All manual crushing technology is somehow based on the same technology used in electrically
powered machines therefore a study of all crushing mechanisms has to be done.

2.3 Crushing technology and mechanisms

Crushers exist in various sizes and capacities which range from 0.1 ton/hr to 50 ton/hr.
[ CITATION Kun16 \l 12297 ] They can be classified based on the degree to which they can
fragment the starting material and the way they apply crushing force.

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A crusher can be considered as primary, secondary or fine crusher depending on the size
reduction factor.
a) Primary crusher – this is the first stage of the crushing process for large rocks and
stones, the input of these crushers is relatively wider and the output products are coarser
in size. Examples of primary crushers are jaw crushers and impact crushers.
b) Secondary crusher- The products from the primary crusher are further crushed in the
secondary crusher. Examples of these include cone crushers and disk crushers.
c) Fine/tertiary crushers-relatively small openings and are used to crush the feed material
into more uniform and finer product. Example - Gravity stamp[CITATION DEE10 \l
1033 ].
Below is a summary of crusher types of crushers due to their mechanism of crushing and
possible use.

Table 2.0.1 Summary data on different types of crushers

2.3.1Crushing Technologies

Various types of crushers are used in the stone crushing industry such as Jaw Crushers, Cone
Crushers, Roller Crushers and Impactor just to mention a few. So as not to reinvent the wheel the
current crushers and their mechanism will have to be studied as all crushing is the same. The
difference is only that most crushers are powered by a motor which can be powered by mains
electricity or an engine. Manual crushers are powered by human strength.

2.3.1.1 Jaw Crushers:

These are the most commonly used crushers and also the oldest as they have changed little from
the original design. In a Jaw Crusher, the feed is compressed between a stationary and a movable
surface. Below are a few of the most common types of jaw crusher.

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 Figure 2.0.6 Single and double toggle jaw crusher
• Double Toggle Crusher:
The Double toggle jaw crusher has a stationary jaw and a moving jaw pivoted at the top.
The crushing faces themselves are formed either of manganese steel or of chilled cast
iron for their great wear resistant properties. The feed material is added at the top and a
pressure is applied to it so that is crushed.
• Single toggle Jaw crusher:
The single-toggle crusher is the most commonly used type of jaw crusher mainly because
it is economic due to its light weight nature, it is therefore cheaper to buy and to operate
despite having a lower force than the double toggle jaw crusher. The crushing mechanism
is the same as the double toggle only that the movement of the jaw is achieved
differently.

2.3.1.2 Gyratory (Cone) Crushers

In Gyratory Crushers, the crushing force to the feed is applied between a stationary and a
movable surface. The crushing head is employed in the form of a truncated cone, mounted on a
shaft, the lower end is driven eccentrically providing the gyratory motion describing a circle,
whilst the upper end of which is held in a flexible bearing.[ CITATION Kus16 \l 12297 ]. The
crushing action takes place around the cone. And the material keeps being crushed until it has
reached a certain degree then it can fall through the gaps left due to the eccentricity of the
crusher.

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 Figure 0.7 Cone crusher

• Primary Gyratory Crusher:

In the primary gyratory crusher, the stress is applied to the feed by pressure as the conical
head periodically approaches the bowl. The primary Gyratory Crusher is a large, heavy
and expensive machine. It is used only for special materials and high through put. As the
crusher is continuously in action, the fluctuation in the stresses are smaller compared to
the jaw crusher but the power consumption is lower. It gives a finer and more uniform
product compared to the jaw crusher.
• Cone Crusher:
Cone crusher has a higher reduction ration of up to 18. They have a shallow cone as
compared to the gyratory, a uniform product size and good shape is ensured because of
the long parallel gap before aperture. The stroke of the gyratory is large and the speed of
rotation ranges between 200 - 300 rpm, the product is therefore cubic in shape. These
types of crushers are mainly used for fine crushing of hard and moderately hard
materials.

2.3.1.3Roller Crushers

In roller crushers, the operating principle is that stress to the feed is applied is applied
between the rollers or between a roller and a crushing surface.

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 Figure 2.0.8 double and single roller crusher operating principle

• Double Roll Crusher:

Double roll crusher consists of two rollers rotating towards each other that are separated
by an adjustable gap. The gap can be adjusted according to the size of input and also the
size of output required. Roller crushers work best with soft to moderately hard materials,
the feed size can be up to a meter with rollers of diameters up to 2 meters.
• Single-Roll Crusher:
In the single roll crusher, crushing is achieved by the feed material being input between a
roller and a surface (crushing plate) as illustrated above. The crushing plate is either held
by springs or a hydraulic system. Single-Roll crushers are used for coarse crushing of soft
to moderately hard material.

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2.3.1.4 Hammer Crusher

Figure 2.0.9 Hammer crusher

Hammer crushers consist of hammers which are attached to the rotor via pivots so that
when they hit a particularly large stone of hard material they can deflect and avoid
breaking. The criteria for crushing is such that only material that is smaller than the
grating can pass through and exit the crushing zone. Hammer crushers can process moist
material easily even though they tend to wear quickly as compared to impact crushers.
Due to the nature of hammer crushers and considering wear, they are used to crush soft
and moderately hard material. For crushers with the same throughout put, hammer
crusher units tend to be smaller than jaw or cone crushers. This is mainly due to the
simplicity of the crushing mechanism.[CITATION PGa09 \l 12297 ]

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2.3.1.5 Impact crusher

Figure 2.0.10 Impact crusher

Impact crushers as the name suggests use impact rather than pressure for crushing. Here
the material is held within a cage, with openings of the desired size at the bottom, end or
at sides to allow crushed material to escape through them. This type of crusher is
generally used to crush soft materials like seeds, coal and soft rocks like limestone. The
principal applied here is of Impact loading where the time of application of force is less
than the natural frequency of vibration of the body. The principle of impact loading is
dependent on the speed of contact between the material and the hammers, since the
hammers rotate at a high speed the time of contact between them and the material small
therefore for the same impulse a great force is applied and the material and it is crushed.
The shaft is considered to be subjected to torsion and bending. The grinding screen is also
designed for optimal output from the crusher. [CITATION DEE10 \l 1033 ].

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2.3.2 Mechanical Advantage

The core idea for the manually operated crusher is highly dependent in being able to supply
mechanical advantage to the operator. Therefore, it is imperative to briefly look at methods for
increasing the mechanical advantage of a person. There are many mechanisms of obtaining
mechanical advantage however a few of the main ones that may be beneficial to this project are
as follows.
2.3.2.1 Gears

Figure 2.0.11 gear drive mechanism

Gears are used to transmit power from one shaft to the next. As power is transmitted between
one gear to another any number of these three things can happen
1. The speed changes, if the second gear has more teeth than the first then angular speed
reduces
2. The force changes such that for a gear with more teeth as the speed decreases the force
increases since power remains the same for the system. This property then implies that
manipulating the speed, the torque and hence force of the system can be increased or reduced
due to the gear ratios thus mechanical advantage. From the equation
P= Tω where P is the Power
T is torque which is a function of force
3. Direction changes, as gears mesh the direction of rotation of the shafts also changes, hence if
the first shaft is moving clockwise then the second one will be counter-clockwise. Special gears
like bevel gears can be used to transmit power on shafts at an angle.

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2.3.2.2 Pulleys

Figure 2.0.12 pulley arrangements

A pulley is a simple machine that can increase the force applied to move a bigger load
thus offering mechanical advantage. Pulleys consist of a grooved rim through which a
cable or cord can pass through. Work is made easier firstly by the pulley’s ability to
change the direction of force as can be seen in figure 2.10, to lift the mass one is pulling
down. Second the number of pulleys and the arrangement of pulleys have an effect on the
force required for lifting a load, depending on the arrangement of pulleys the distance
moved is the one that is sacrificed to attain the mechanical advantage in lifting a load as
illustrated below

Figure 2.0.13 pulley arrangement halving effort required to lift a load

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2.3.2.3 Chain drives and belt-drive type mechanisms

Figure 2.0.14 typical chain drive and belt drive

A chain and belt drives work by the same principles of the gear with the exception that
instead of direct contact between the rotating wheels, for a chain drive the wheels are
linked by chains, for belt drives they are linked by belts which are mostly rubber but can
be animal skin or even fabric. This kind of drive system ensures that power can be
transmitted for longer distances. The other difference is that for chain and belt drives the
direction of rotation can be the same or it can be opposite like in gears depending on the
orientation of the driving mechanism. The mechanical advantage for such drives is
obtained from the difference in size of the sprockets(wheel) and the number of teeth in
the case for chains.
2.3.2.4 Levers

Figure 2.0.15 principles of a simple lever

A lever is a simple machine, basically a rigid bar that turns about a pivot or fulcrum. The
mechanical advantage of the lever system is due to the distance from the fulcrum. The principle
at work is that for a balanced system clockwise moments equal anticlockwise moments and since
moment is a function of force and distance to the fulcrum then
Where x1 is distance to the pivot from the effort

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 x2 is distance to the load
L is the load
F is the effort
Then Ex1=Lx2
If distance to pivot x1 increases, then the force F decreases to lift the same load L thus the
mechanical advantage.

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Chapter 3 Results of research

This Chapter serves to present necessary data determined through various research methods. In
order to successfully design a manual jaw crusher that is efficient and functional whilst suiting
the needs of the target market. Firstly, there was need to determine the capacity and rate of
production whilst using the hammer and anvil method of crushing so as to ensure the design was
a step forward and not backwards. There was also a need to determine whether there were any
features that were deemed necessary or unnecessary by the target market. All this and more was
catered for in the interview portion of research.
There was also a need to understand and determine the magnitude of various forces for instance
the force required to crush local granite. Another important result of research was the average
force that can be applied by a human. This force is paramount as it determines the limitations of
the design such as how much power will be available to crush and how long can the machine be
operational at a time. This information was obtained through experimentation and research in
online journals and books.

3.1 Interviews

Figure 3.0.16 Conducting an interview at Glen-Norah crushing site

General Questions asked

 What are the challenges faced in using the hammer and anvil method?

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  What is the rate of production?
 What are the general needs/requirements on machine to be designed?
Answers obtained
 Safety is a prime concern as one has to be very careful otherwise one can lose a
hand, there is also risk of inhalation of quarry dust.
 Some hammer and anvil crushers have also tried to find alternative methods but
generally the cost of the machines is very high and also the cost of maintenance is
not worth it.
 There is also the problem of getting a power source on site.
 Because the hammer and anvil method is slow, the crushers cannot meet high
demand of crushed rock and they lose customers to bigger companies due to
inadequate amount of rock available as the customer would have to wait for days
for enough crushed stone to be gathered.
 Average time taken to fill one wheel barrow with crushed granite is 1hr 30mins
that is not including time taken to retrieve stone from the dwalas and breaking
them into manageable sizes.
 Cost of one cubic metre of crushed stone is $24 and 1 cubic is equal to 12
wheelbarrows of stone.
 Sorting of stone to desired sizes is a major setback
The information obtained tallies with the main aims of the design of the manually operated stone
crusher.

3.2 Determining forces

3.2.1 Experiments

Determining the force required to crush granite, experimental analysis: ACV method

The aggregate crushing value(ACV) gives a relative measure of the resistance of an aggregate to
crushing under a gradually applied compressive load. With aggregate of an aggregate crushing
value higher than 30%, the result may be anomalous and, the ten per cent fine aggregate crushing
test value should be determined instead. The standard aggregate crushing test shall be made an
aggregate passing the 13,2mm BS test sieve and retained on the 9,5mm BS test sieve.

Apparatus
The following apparatus is required for the standard test.

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  An open-ended steel cylinder of nominal 150mm internal diameter, with a plunger and a
baseplate
 A straight steel tamping rod, of circular cross-section 16mm diameter, and 450mm to
600mm long, rounded at the end
 A balance 3000g accurate to 1 g
 BS sieves, sizes 13,2mm; 9,5mm; 2,36mm
 A compression testing machine, capable of applying force of 400kN at a uniform rate so
that maximum load is reached in 10mins.
 A rigid cylindrical metal measure, for measuring the sample, of internal diameter 115mm
and an internal depth of 180mm

Figure 3.0.17 open ended steel cylinder, plunger, base plate

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 Figure 3.0.18 13.5 and 9mm sieves and granite as labelled

Figure 3.0.19 Final sieved aggregate on scale

Preparation of test sample

1. The aggregate for the test was sieved through a 13,3mm sieve and was retained in a 9mm.
this was done until a quantity of 3kg was achieved (amount required for the test)

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 2. The quantity of aggregate to be used in the test was measured by filling the cylindrical
measure in three layers of approximately equal depth and tamping each layer 25 times
with a tamping rod and levelled off using the tamping rod as a straight edge.
3. The mass of the material in the measure was determined to be 2,798kg

Test procedure

 The test sample was added put into the cylinder whilst appropriately positioned on the
base plate. Each third of the sample was subjected to 25 light strokes with the tamping
rod making sure the strokes are evenly distributed over the surface of the aggregate and
dropping from approximately 50mm above the surface of the aggregate. The aggregate
surface was levelled off and the plunger inserted so that it rested horizontally on this
surface, taking care that it did not jam into the cylinder.
 The apparatus with the sample and plunger in place was placed between the platens of the
compression testing machine. The setup was then loaded uniformly to 350Kn
 All material was removed from the cylinder and sieved through a 2,36mm BS sieve until
no further significant material passed in 1 minute
 The mass of the sieved sample was determined to be 0.914kg
 Much care was taken to avoid loss of fines

Calculations and conclusions

To calculate the aggregate crushing value

B
Aggregate crushing value % = ×100
A
Where A= mass of surface dry sample
B=the mass of the fraction passing the 2,36mm BS sieve

0,914
ACV= × 100=32,7 %
2,798

Implications
Since ACV is greater than 30% then 10% fines aggregate crushing value is determined and the
load is determined by this formula
14 L1
L=
P+4
Where L is load to give percentage fines within the range 7.5 to 12.5%
L1 is first test load

31 | P a g e
 P is percentage fines obtained with the first load
14 ( 400 )
L= =152.58 kN
32.7+ 4
0.152 2
This force was applied to an effective area of π ( )=0.01767 m therefore force per square
4
meter is
152.58× 103
=¿ 8.643MN/m2
0.01767

Now for the effective area chosen for this machine, the feed material has a maximum feed face
size of
0.152m2
Therefore, implies a force of 0.025 ×8.643 ×10 6=¿215.85 kN at the jaws for gradually applied
load

Now the ACV gives an overview of the forces we expect to encounter in the crushing of granite,
since we obtain a relative measure of the resistance of granite to crushing under a gradually
applied compressive load then the force from the jaw crusher will definitely be less than
215.85kN as the force is a shock load. The shock load required to crush the granite is only a
fraction of the gradually applied force.

Determining the force from standard data

The material to be crushed is granite, therefore the machine to be designed can be made
specifically for this one material in mind. Generally, the strength of granite is known but further
experimentation will have to be carried out to determine forces relevant to the design of the
machine. The physical characteristics listed below represent strengths and abrasion resistance of
granites tested dry on their strongest plane and have been historically used for building and
structural use recommended by the national Building Quarries Association of America.

32 | P a g e
 Table3.0.2 Data on Granite
From the above table the modulus of rapture for granite is given as 10.34MPa, the
proposed maximum feed size is 0.15m×0.15m therefore the force expected from this
value if the jaws manage to be in contact with the feed completely is
10.34 ×10 6 ×(0.0225)=232.65 kN
Therefore, the average force due to gradually applied force
232.65+215.85
=224.25kN/m2 say 225kN
2
224.54kN/m2 is therefore the force required to crush granite with a gradually applied load
however, the impact force due to the movement of the jaw required to crush the stone
will only be a fraction of the gradually applied load. If a force is suddenly applied it
doubles the stress for instance placing a brick on a table (concepts simplified)
F
i.e. σ suddenlyapplied load =2
A
Where F is the force (weight if the brick)
A is the are the force is applied
Now an impact load which is a moving body striking another body such as the one
applied by crushing mechanisms for example hammering can cause many times stress
than if the load was gradually applied. (ME-subjects: Concepts simplified) The amount
by which the stresses caused by impact as compared to a gradually applied load depends
on many factors including the speed of impact and the materials that are colliding. For
crushing rock if the impact force is applied for one full second compared to the 10
minutes as in the above experiment. If the rate of change of momentum is to be
conserved thus impulse Ft will be conserved as well from Newton’s second law.
Mv=Ft
F1t1=F2t2
F1(600s) =F2(1s)
F2=600F1 that is considering time only and not velocity

33 | P a g e
 Thus, for this scenario the smallest ratio between the gradually applied load and the
impact load is 600:1. The ratio in time t1 from the gradually applied load and t2 for the
impact load gives 1:600 and thus the force F2 will result in 600 times more stress in the
material if all other variables remain constant.
225 000
=375 N say 400N
600
3.2.2 The force capability of a human being
Determination of Forces
Since the desired machine is going to be manual it is therefore vital to determine the average
force that a normal human can muster.
The average force of a human hand is a very debatable issue mainly because there are many
variables and humans all differ considerably. These factors include body strength, arm length
even body weight affects the average force one can exert on a body. The torque one can produce
depends on the length of the lever(crank), whether a person is pushing or pulling and also
whether the person is seated or standing. Many experiments have been performed to determine
this force and results range from as little as 20N to 300N of force for different groups of people.

According to Machine Design by Robert Norton, humans can apply up to 60lbf of force.
Converting
1 lb=0.453592 kg (google conversion)
1 lbf =1 lb × g where g is acceleration due to gravity
¿ 0.453592 ×9.81
¿ 4.44973752
∴ 60lbf =60 × 4.45
¿ 266.984 N

From the above data, the force to be used in this project as the average force that can be applied a
by a person is 150N. A simple experiment on fellow classmates lifting a 15kg mass determined
that all candidates could exert a force of 150N though duration of lift differed depending on
physical fitness of the candidate.

Conclusion on forces
For this project force required to crush granite gradually is 225kN
Impact force required is 400N
Average force from a human arm is 150N
34 | P a g e
Average force from pedalling used as 200N
NB: the relationship between the impact force required (400N) and the average force of a human
(150-200N) shows that without mechanical advantage it would be near impossible to crush
granite. Therefore, the aim for the success is for the machine to offer at least double the
mechanical advantage that is to ensure crushing will happen.

35 | P a g e
Chapter 4 Methodology

This chapter serves to explain the system of methods and the steps followed by the designer from
the beginning of the project until its completion. It gives a brief overview of the purpose or work
carried out in each section included in this research paper and its significance in coming out with
the best design.

4.1 Literature review

Research was done to come up with the best stone crusher of the given situation. This chapter
provided the necessary preliminary information for the designer to further understand in detail
the principles of operation of ava, the types of available stone crushers and the principles that
govern any crushing operation. Further information was found as to how to address the real
problems being faced by manual crushing personnel. The main tools of the Literature review are
Internet, Interviews and use of the local library to obtain relevant information. Lab visits were
also conducted to further understand the working principles of crushers by analysing the
laboratory crushers available at the University.

Interviews help to get real information on the problem and find possible solutions from people
involved with the problem. Firstly, the current rate of production which the machine should
easily exceed. The benefits expected from a manually operated crushing machine. The Internet is
the biggest source of information but has to be used wisely as not all information is reliable.
From the internet, current information on existing methods of crushing was obtained and journals
containing detailed calculations and findings on current crushing methods were made available.
Various textbooks were also used found from the local library. Relevant labs and experiments
were performed in order to determine the forces required to crush granite and the force average
force a person can muster in the effort to crush granite

4.2 Concepts
Three possible solutions were generated to meet the project’s requirements after a careful
analysis of information obtained from the literature review. Different crushing concepts were
implemented to create concepts that meet the design specifications of a manual, cheap and
effective crusher. Each concept had its merits and demerits and after further analysis and using
the Binary dominance matrix the best concept was chosen. Factors like functionality, reliability
and cost had the most weight in the determining the best concept.

36 | P a g e
4.3 Development of chosen Solution
Alterations will be made to the chosen solution to make it more functional and satisfy the needs
of the project.

4.4 Calculations and design of components

In the development of solution there will be rigorous calculation and analysis of the components
of the stone crusher and a detailed selection of materials to be used. There will be simulations
and stress analysis of components using Mat-Lab Software and SolidWorks.

4.5 Software used in project

Software Description Use

Auto-CAD is a drawing In drawing and the design of
software used for modelling the machine components
and engineering design

SolidWorks is a solid Design and simulation

modelling Computer Aided
Design program

MATLAB-Matrix Simulations and calculations

Laboratory performs
complex calculations

Microsoft Word is a Producing project document

desktop application from and adding labels to
the Microsoft cooperation diagrams
that creates documents
Publisher is a desktop Editing diagrams and adding
application from Microsoft labels
that emphasizes on page
layout for different types of
documents
Excel is a spreadsheet for Producing relevant graphs
data input and data analysis.
Numerical information is
easily organized. And can
be represented using graphs

37 | P a g e
Chapter 5 Concepts
5.1 Concept 1
Lever arm concept

Figure 5.0.20 isometric and exploded view

Figure 5.0.21 Plan and exposed back view

Operating principle

38 | P a g e
This manual crusher uses the principle of having one moving and one stationary jaw to crush
stone. The moving jaw is operated manually by pulling the lever and the mechanism is designed
such that the jaw will move forward as the lever is pulled back and vice-versa. The lever is made
long such that whatever force is applied on the it will be multiplied by the length giving us a
moment that will be the force needed to crush the desired granite. The distance will be the
multiplying factor giving us the required mechanical advantage to crush the rock.
Advantages
 The concept is simple in construction therefore cheap and easy to build
 It has few moving parts therefore easy to maintain
 It offers a safer crushing method as compared to the hammer and anvil

Demerits
 There is no form of energy store therefore too much of it can be lost per stroke
 May not work for shorter people

5.2 Concept 2
Manual jaw crushing concept

Figure 5.0.22 Concept 2 top view

39 | P a g e
 Figure 5.0.23 Concept 2 side view

Figure 5.0.24 Transparent isometric view

40 | P a g e
Operation method
This manual crusher uses the basic operation of the single toggle jaw crusher. The jaw crusher is
the closest in mechanized stone crushers to be able to produce the desired aggregate. It has a
stationary and a moving jaw and as the moving jaw closes the gap between the two, stone is
crushed by the compressive force due to this movement. Motion of the moving jaw is due to
rotation of the flywheel which in turn rotates an eccentric shaft connected to the jaw giving the
jaw a gyratory motion. This version also has a vibrating receiving tray to assist in the sorting of
the product, the bigger chunks of rock remain on the tray and slide off the tray whilst the smaller
ones drop first. It also has a tensioning spring to keep the jaw in place and the toggle plate to
transfer force and as a safety mechanism.

Advantages
 This crusher has two flywheels as energy stores therefore the effort applied is never
wasted and is used to provide extra crushing force.
 It is safe
 Provides great mechanical advantage to the crushing process
 Can be operated by two people at once to increase the power and rate of crushing
 Demerits
 It relatively has many components therefore may appear complicated to use
 The concept will be heavy due to the double flywheel design

41 | P a g e
5.3 Concept 3
Cycling hammer mill concept

Figure 5.0.25 Side view and isometric side view

Figure 5.0.26 Exposed isometric view and hammer and rotor assembly
Operation
This concept functions on the basis of impact crushing. The trouble with using impact to crush
stone is that high velocity is required and therefore a cycling mechanism has been implemented.
The crusher will be seated on a bicycle type mechanism that allows him/her to cycle whilst
turning the rotor. The rotor is connected to the hammers and also a flywheel for the conservation
of energy. Once an optimum speed is reached, stone to be crushed is added into the machine and

42 | P a g e
is impacted by the rotating hammers until it is the desired size, only then can it escape through
the sieves. The velocity ratio in this design is negative however though the hammers will rotate
slower than the cycling, they will rotate with more power that is required in the crushing process.
Advantages
 It is safe
 Uses simple principle
 Can be viewed as a form of exercise

Demerits
 The complete set up is cumbersome (there will need a seat for the cyclist etcetera)
 Gauging the correct crushing speed may prove difficult the crushers will need experience
first before they can fully utilize the machine.

5.4 Concept selection

5.4.1 Binary dominance

In choosing the best concept many factors have to be considered in order to provide the product
possible as required by the project.
A. Function
B. Reliability
C. Ease of maintenance
D. Ease of manufacture
E. Simplicity of operation
F. Safety
G. Ergonomics
H. Weight
I. Life span
J. Quality of product
K. Cost

In order to determine the best solution, the different concepts will be compared according to how
much they meet the above criteria. The first step will the ranking of the design criteria in order of
their relative significance. This will be done using the binary dominance method. This is done by
listing the criteria on the vertical and horizontal axes of a table. After comparison of a pair of

43 | P a g e
criteria a 0 or 1 will be placed in the boxes of the matrix based on the relative significance
[ CITATION Hur99 \l 12297 ].

A B C D E F G H I J K
A - 1 1 1 0 0 1 1 0 0 1
B 0 - 1 1 1 0 1 0 1 1 0
C 0 0 - 1 1 0 0 0 0 0 0
D 0 0 0 - 1 0 1 0 0 0 0
E 1 0 0 0 - 0 0 1 0 1 1
F 1 1 1 1 1 - 1 1 0 1 1
G 0 0 1 0 1 0 - 1 0 1 0
H 0 1 1 1 0 0 1 - 1 1 0
I 1 0 1 1 1 1 1 0 - 0 1
J 1 0 1 1 0 0 0 0 1 - 0
K 0 1 1 1 0 0 1 1 0 1 -
Table 5.0.3: Binary Dominance Matrix

CRITERIA TOTAL RANKING NEW ORDER

A 6 3 C
B 6 3 E
C 2 10 J
D 2 10 K
E 4 7 H
F 9 1 A
G 4 7 G
H 6 3 F
I 7 2 B
J 4 7 I
K 6 3 D
Table 5.0.4: Criteria Ranking

The table above shows the selection criteria according to their order of importance or
precedence. It shows the designer the things that have to be considered first when making the
final selection decision.

Criteria in order of importance, with reallocation of letters.

A. Safety
B. Life Span

44 | P a g e
 C. Function
D. Cost
E. Reliability
F. Weight
G. Ergonomics
H. Simplicity of operation
I. Quality of product
J. Ease of maintenance
K. Ease of manufacture

With the new order of significance, it is easier to visualize which concept best suits the project
requirements. For all criteria, each concept is given rating ranging from 1-10, this rating is
multiplied by the weight of the criteria which is obtained from the Binary dominance table. The
concept with the highest total will automatically become the chosen solution as it will have most
of the qualities desired by the project

CONCEPT RATING CONCEPT WEIGHT

CRITERI WEIGHT 1 2 3 1 2 3
A
A 9 6 9 7 54 81 63
B 7 7 9 8 49 63 56
C 6 6 7 7 36 42 42
D 6 10 9 8 60 54 48
E 6 5 8 7 30 48 42
F 6 9 8 6 54 48 36
G 4 5 7 8 20 28 32
H 4 9 9 7 36 36 28
I 4 6 10 9 24 40 36
J 2 9 7 6 18 14 12
K 2 10 8 6 20 16 12
401 470 407
Table 5.0.5 Ranking table

According to the Binary Dominance method, the second concept is the best.
5.4.2 Justification of chosen solution
As compared to the other concepts, concept two is a more practical solution to the manual
crushers problem. Firstly, it ranks high in safety which was one of the prime concerns of using
hammer and anvil method, this is mainly because the operators do not have to come in contact
with the stones to be crushed. All wear parts are replaceable and less expensive than the case for
the third concept in which even the casing will eventually wear and is expensive to replace. As

45 | P a g e
compared to the first concept which is by far the simplest in construction, Concept 2 is more
practical and is more likely to produce crushed stone more efficiently. Concept 2 can also be
powered by more than one person at a time, this ensures maximum effort in crushing and less
wear on the operators.

Chapter 6 Development of Chosen solution

Figure 6.0.27 the chosen solution

6.1 Operation principle in detail.

Jaw crushers crush using impact on the upper parts of the jaw, with a little shear towards the
bottom. Jaw crushers consist of two jaws, one stationary and the other reciprocating. The
opening between them is largest at the top (gape) and decreases towards the bottom (set). The

46 | P a g e
jaw moves on an eccentric shaft and the lower part is hinged on the toggles. The rock is thrown
between two jaws and crushed by mechanical pressure. Rotational motion drives the eccentric
shaft to rotate. This results in the attached jaw to approach and leave the other jaw in an
oscillatory manner, this action crushes, grinds and runs the feed. Hence the material moves
gradually towards the bottom and finally discharges from the discharge end. The fixed jaw
mounted in a “V” alignment is the stationary breaking surface. The swinging jaw exerts impact
force on the material by forcing it against the stationary plate. The space at the bottom of the “V”
aligned jaw plates is the crusher product size gaper size of the crushed product from the jaw
crusher. The rocks are crushed until they are small enough to pass through the gap at the bottom
of the jaws. The ores are fed to the machine from the top where the jaws are at the maximum
distance apart. As the jaws come closer the ores are crushed into smaller sizes and slip down the
cavity in the return stroke. As the cycle continues, further reduction of size is experienced and
the ore moves down further. This occurs until particles size is reduced to less than set of the
crusher. The toggle is used to guide the moving jaw and the spring retrieves the jaw from its
furthest displacement. The heavy flywheels are used for smoothening the operation of the jaw
crusher by storing excess energy and using it when there is a deficit.

6.2 Development of chosen solution.

In order to improve functionality of the crusher and for it to better suit the needs of
 Make device more compact
 Introduce gear system to make cranking easier

47 | P a g e
 Figure 6.0.28 Sketch plan view showing new mechanism for the crusher

6.2.1 New mechanism

The flywheels have crank handles as was with the original design however the flywheel shaft is
connected to spur gears that transfer power to the eccentric shaft thus there are now two shafts
instead of one. The ratio of the gears simply 1:2 so as to double the torque provided by the
human operator. These gears also further improve the smoothness of operating the crusher,
reducing shock to the operator cranking the mechanism. This is because the gears have their own
mass and hence inertia such that once they start moving they will tend to resist motion in the
backward direction.

48 | P a g e
 Figure 6.0.29 Exposed side view and plan view

Figure 6.0.30 Isometric view of crusher

49 | P a g e
Chapter 7 Design of Chosen Solution

Main parts, materials and function in brief.

Part Function Material
Body Contains and supports all the parts Ribbed Steel plates
Wear plates Actively crush the stones Manganese steel
Toggle spring Returns the jaw from its extreme forward position Alloy steel
Toggle Safety mechanism for uncrushable material Cast iron
Tension rod Helps with easy movement and reduces pressure Alloy steel
on toggles
Flywheel Stores kinetic energy Cast iron
Eccentric Supports the moving jaw(pitman) and transfers the Alloy steel
Shaft rotational motion onto the pitman
Flywheel shaft Supports the two flywheels and transmits torque to Alloy steel
the gears
Bearings Roller bearings reduce friction between the shaft Steel
and the pitman
Jaw plate Transfers the rotational movement of eccentric Alloy steel
shaft and turns it the reciprocating motion. Wear
plate is attached on it.
Gears Transfers the rotational motion from the flywheel High grade cast
shaft to the jaw shaft increasing the torque. iron
Table 7.0.6 parts and recommended materials

7.1 Determining crusher dimensions and force relationships

In order to determine the size of all other parts there is need for an overview of the desired
crusher dimensions.
For this manual jaw crusher, the recommended maximum feed size of an uncrushed granite
block is(150 mm ×150 mm ×100 mm), 100mm being the thickness of feed material. Due to the
method of extraction of granite from parent rock used in Zimbabwe these dimensions can easily
be achieved as the granite peels off in layers. In order to achieve the desired ¾ inch aggregate the
reduction ratio for the jaw crusher is determined to be 6:1 (table 2.1)

7.1.1 Static analysis of jaw crusher mechanism

This analysis is to obtain the relationship between the Driving Torque T2 and the torque acting
on the jaw, Jaw Torque T3, the difference on torque is brought about by the jaw crusher eccentric

50 | P a g e
shaft set-up. Static force analysis assumes no frictional and inertial forces acting on the
mechanism.

For static analysis

 T 2=¿crank torque about O2
 T 3=¿jaw torque about O 3 due to resistance of feed material being crushed
 F 1 , F2 , F3=¿ compressive forces in the links
 θ2=¿angle of crank
 θ3 =¿angle of swing jaw

Figure 7.0.31 free body diagram about O 2

51 | P a g e
 Figure 7.0.32 free body diagram about O 4

After completing analysis, a relationship between T 2∧T 3 can be obtained as

T 3 r2 sin ⁡(2 θ3 )
= ……… (equation 6.1) [ CITATION MFO15 \l
T 2 r 3 sin ⁡(θ2 +θ3 )
12297 ]

7.1.2 Kinematic analysis of jaw crusher mechanism

In kinematic analysis, the mechanism is studied as to how it moves and the corresponding torque
relationships can be determined.
In the kinematic model
 r 1 is the distance between O1∧O4
 r 2 is the eccentric shaft is taken as a short crank continuously rotating about fixed axis O2
 r 3 is the swing jaw modelled as a coupler link of length O3 O 4 with translational and
rotational motion
 r 4 is the toggle modelled as a rocker length O 4 O 1 oscillating about O 1

52 | P a g e
 Figure 7.0.33 Kinematic model for single toggle jaw crusher

For an understanding of the rocker motion relative to the fixed jaw is obtained by kinematic
analysis of the crusher as the crank goes through one cycle and all angular displacements being
taken as counter clockwise. The vector loop closure approach is illustrated below. With the
vector loop equation being r 1 +r 2 +r 3 +r 4=0

53 | P a g e
 Figure 7.0.34 vector loop closure method of analysis

After analysis through the vector loop closure method the following relation was obtained
2 r 1 r 2 cos ( θ 2−θ1 ) +2 r 2 r 3 cos ( θ 3−θ2 ) +2 r 3 r 1 cos ( θ3−θ 1) =r 24 −r 23−r 22−r 21 [ CITATION MFO15 \l
12297 ]
Further simplification and taking θ1 as 0 for this case we obtain

2 r 1 r 2 cos θ2 +2 r 3 r 1 cos θ 3−r 24+ r 23 +r 22 +r 21=−2 r 2 r 3 cos ( θ3−θ 2 )…… (equation 7.2)

Taking jaw crusher dimensions

r1 (mm) r2 (mm) r3(mm) r4(mm)
450 12 500 200
Table 7.0.7 jaw crusher dimensions
Equations 7.1 and 7.2 can be used to obtain the ratio of crank torque and also the throw of the
jaw crusher.
Using (7.2) for different values of θ2 for 0˚≤ θ2 ≤ 360 ˚ for one shaft revolution and substituting
values of r 1 , r 2 , r 3∧r 4 therefore we obtain corresponding values of θ3

54 | P a g e
Using (7.1) for corresponding values of θ2∧θ 3, and substituting r 1 , r 2 , r 3∧r 4 in the equation we
T3
obtain the ratio and therefore determine force transmission ratio of the jaw crusher.
T2
7.1.3 Results from kinematic and dynamic analysis

From normalized torque ratios T2 is related to T3 by the relationship

40T2<T3<60T3

From table 7.2

The throw of the crusher Lt¿12mm that is eccentricity of the eccentric shaft
For reduction ratio 6:1 determined above we set
Gape G¿0.2m
and obtain Set =0.03m

Considering a throw of 12mm we have Lmin= 0.018m (18mm)

Lmax¿0.030m (30mm)
Therefore, our crusher will be able to produce ¾ inch stone considering 1 inch=25.4mm
3
since × 2.54=19.1mm
4
The convention or rule of thumb for the width of the jaw is 1.3G¿ W <3 G where G is the gape
and W is the jaw width.
Therefore, using a factor of 1.5 to make crusher dimensions as small and practical as possible.
The jaw width 1.5 G=1.5 ¿0.2)
¿ 0.3 m

55 | P a g e
7. 2 Part by part design (materials and sizes)

7.2.1 Design of flywheels

Energy stored in a flywheel:

In the case of this design, the flywheel is directly attached to the crank therefore the input torque
is a product of the crank force and the radius of the flywheel. The flywheel should therefore be
as large as possible whilst the limiting factor is the reach of the average human hand that is
rotating the flywheel. The average human person can easily rotate a crank of radius 0.35m
therefore the flywheel radius should be 0.4m to give allowance to screw on the handle.

Figure 7.0.35 proposed flywheel dimensions

The rotational speed of the flywheel is dependent on the speed of cranking. For the purposes of
this project the assumption is that an average person can easily maintain a crank speed N of
60rpm that is one cycle per second.
For crushing machines fluctuation of speed K s =0.2 table A1 [ CITATION Khu05 \l 12297 ]

Work done wd=T ×θ

¿( F ×r )× θ
¿ 150 ×0.350 ×2 π
¿ 329.867 J
Where T¿torque provided
F¿force of cranking by human hand (150N discussed in chapter 3)
r¿radius of crank
θ=¿angle of sweep in radians

56 | P a g e
 The change in energy ∆ E=K E × wd
¿ 329.86 K E
Where K E=¿ coefficient of energy fluctuation which denotes the change in energy per cycle of
the flywheel

The energy can also be determined by the following formula

∆ E=m R 2 ω 2 K s
Where m=mass of flywheel
R=radius of flywheel=0.4m
ω=angular speed of rotation of flywheel
N×2π
ω=
60
60× 2 π
=
60
=2π
Determining the mass of flywheel rim from the energy equations
329.86 K E=m R2 ω2 K s for K E=0.2
329,86 (0.2)
m=
0 .42 ( 0.2)¿ ¿
=52.27kg
From the mass of the flywheel rim we can deduce its dimensions considering the general
convention that in general width(w)=2×thickness(t) of flywheel rim
The material for the flywheel is cast-iron (table 5.1) and its density ρ is 7250kg/m3 [ CITATION
Khu05 \l 12297 ]

Now mass =volume of rim × density of material

m=[ ( t rim × w ) × 2 πR ] × ρ but w=2 t rim

m=¿2t 2rim ×2 πR × ρ

52.27=2t 2 × 2 π ×0.4 ×7250

52.27=11600 π t 2

57 | P a g e
 ∴ t=0.0378 say 0.04m
w=0.08 m
Flywheel data
Diameter of flywheel¿ 0.8 m
Mass of rim¿ 52.27 kg
Mass of flywheel¿ 60 kg (considering the mass of the rim and center)
Rim thickness t rim=0.04 m
Width of rim¿ 0.08 m
Number of flywheels =2

7.2.2 Gears
For this mechanism, we are crushing one material of known strength therefore a simple single
speed gear speed ratio can be used. The idea is to make the machine easy to operate thus increase
output torque. So as to allow people who have low strength to be able to rotate the flywheel
handle and crush rock nonetheless.

7.2.2.1 Gear material

The cast iron is widely used for the manufacture of gears due to its good wearing properties,
excellent machinability and ease of producing complicated shapes by casting method. The cast
iron gears with cut teeth may be employed, where smooth action is not important.[CITATION
Khu05 \l 12297 ]. Since the machine will likely be prone to considerable vibrations, smooth
action is not very important. Cast-iron is also locally available and cheap.

7.2.2.2 Design of gear properties

For this mechanism tooth type chosen is 20̊ full depth involute system for its great strength
properties and ease of manufacture of involute gears as compared to cycloidal gears.
The desired velocity ratio is 2:1, so as to halve the speed whilst doubling the Torque applied to
the jaw, the relationship between Torque and Speed is given by P¿ T ω, the power in the system
remains constant hence if speed is reduced then Torque T increases.

Step 1: Design gear diameters considering available space (0.5m)

Where D p=¿pitch diameter of pinion

58 | P a g e
 D g=¿pitch diameter of gear
D p + D g ≤ 0.5m
gears should cover approximately 80% of available space ∴ 0.8× 0.5=0.4m
D p + D g=0.4 …….. (6.2.1)
Considering the velocity ratio 2:1 and that velocity is inversely proportional to diameter we have
Dp 1
= ……… (6.2.2)
Dg 2
Solving (6.2.1) and (6.2.2.) simultaneously, we obtain
D p=0.133 m
D g=0.266 m

Step 2: Gear teeth

Using information in table B2 the minimum number of teeth to avoid interference on a pinion for
20̊ full depth involute system is 18, therefore assuming a number of teeth on pinion(T1) as 20 we
can deduce number of teeth on the gear (T2)

T1 N2
Using the ratio =
T2 N1
60
T2= ×20 = 40 teeth
30
Where T 1=¿ number of teeth in pinion
T 2=¿number of teeth on gear
N 1=¿ speed of rotation of the pinion
N 2=¿ speed of rotation of the gear
D p (mm)
Module m¿
T1
133
=6.65
20
Hence m¿ 6 nearest standard value [ CITATION Khu05 \l 12297 ]

Now Verifying that number of teeth will not interfere

For no interference, the following relationship must hold true
59 | P a g e
 Pd
2 aw
T2
T 1≥
1 1
√ 1+ ( +2)sin2 φ−1
T2 T 2

Where aw¿1×module
T
Pd¿diametral pitch ( ¿
D
φ=¿ pressure angle.

( 0.150375939 )
2 ( 6) ×
40
T 1≥ 2
√1+0.025 ( 0.025+2 ) ( sin 20 )−1

T 1 ≥ 15.258 but T1¿ 20

∴ T1¿ 20 is true therefore number of teeth verified not to interfere

Step 3: Width of driving gear (pinion)
Torque¿ 52.5 Nm calculated above
Where WT¿tangential tooth load
P¿Power
v¿pitch line velocity
Cs¿service factor
Cv=velocity factor
σ w=maximum bending stress
σ o=allowable static stress
y=constant

π × m×T p × N p
v¿
60

60 | P a g e
 π ×6 × 20 ×60
¿
60
¿ 120 π mm
¿ 0.376991118 m

Service factor (Cs)¿1.8 for heavy shock for 8-10-hour day (Table B3)
P
∴WT¿ ×C s
v
329,867
¿ ×1.80
0.376991118
¿ 1574.9989N
3
C v= for ordinary cut gears operating less than 12.5m/s [ CITATION Khu05 \l 12297 ]
3+v
3
∴ Cv =
3+ 0.367991118
C v =0.88863
σ o =56 MPa for ordinary cast iron (table B4)
But σ w =σ o ×C v

σ w =56 ×106 × 0.88836

σ w =49.78416 MPa

Applying the Lewis equation (always applied on the pinion or weaker gear)
WT =σ w × b × π × m× y

WT
b=
σ w × π × m× y
1574.9989
b=
49.7481× 106 × π × 0.06 ×0.1084
b=0.01549438 say 0.016 m width of pinion

61 | P a g e
For optimum meshing the width of gear will be used as the same as that of the pinion hence
b¿ 0.016m
Step 4: Weight of gears so as to know their effect on the shaft
Density of cast iron ρ=¿7250kg/m3
mass=ρ ×V where V is the volume the gear
m1¿ ρ ×( A × b) where A is the surface area
π (0.133)2
m1¿7250× ×0.016
4
m1=1.6115 say 1.6kg for each pinion

π (0.266)2
m2=7250× × 0.016
4
m2¿ 6.446say 6.5kg for each gear
calculated data
Pinion
Gear type 20̊ full depth involute
Pitch diameter Dp ¿ 0.133 m
Width=0.016m
Weight= 1.6 kg
Gear
Gear type 20̊ full depth involute
Pitch diameter Dp ¿ 0.266 m
Width=0.016m
Weight= 6.5 kg
NB: the rest of the pinion and gear dimensions are self-generating using table B1 appendix
section
7.2.3 Jaw

The jaw of the crusher is responsible for transferring the rotary motion of the eccentric shaft and
applying the reciprocating motion to the wear plate, therefore it provides the crushing force of
the jaw crusher and hence it is a critical component.

62 | P a g e
Jaw width W¿ 0.3 Calculated above
Jaw thickness t=?
6.2.3.1 Determination of Jaw thickness
The jaw can be modelled after a beam with a moment equal to the transmitted torque T3.

Figure 0.36 Jaw representation

From analysis of forces through kinematic and static analysis

T3=60T2
T3¿ 60 ×52.5
= 3150Nm
So, taking Moment M as T3
And from bending theory we obtain
Mt
σ y=
2Ib
Where σ y = y eild strength of jaw material (250MN/m2 for light weight steel)
Using safety factor of 3

t=thickness of jaw
b d3 W t3
I b=second moment of area ∈this case
12 12

2 M ×12
Rearranging t =
W σ y /3

3150 ×12 ×3
t=
√ 0.3× 250× 103
t=0.0383say 40mm

63 | P a g e
7.2.4 Design of shafts
In the jaw crusher, the shafts transmit power and support critical components like the flywheels
and the moving jaw. The eccentric shaft also brings about the reciprocating motion of the jaw
that results in the reciprocating movement of the jaw hence they are critical components.

7.2.4.1 Flywheel shaft

Effect of pinion (driving gear) on shaft

Acting vertically Weight of gear=1.6*9.81=15.696N
Ft
Acting horizontally Normal force due power transmission WN=
cosα
Where α =¿ pressure angle of the gear
FT= normal load

T
F t=
r
52.5
¿
0.133/2
=789.47 N
789.47
W N=
cos 20
¿ 840.14N

Total force from gear on shaft from single pinion =15.696N vertically
= 840.14N horizontally

64 | P a g e
 Figure 7.0.37 free body diagram of flywheel shaft showing vertical forces

Input torque T2=52.5Nm

Solving for the vertical
Since the system is balanced RA=RB
RA + RB=588.6+15.696
=604.296N
For 0<x<0.1
Mx=-588.6x
For 0.1<x<0.2
Mx=604.2969(x-0.1)-588.6x
For 0.2<x<0.4
Mx=604.296(x-0.1)-588.6x-15.696(x-0.2)

65 | P a g e
 moments in the verti cal
distance moment 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
0 0
-10
0.1 -58.86
-20
0.2 -57.29
0.3 -57.29 -30
0.4 -57.29 -40
0.5 -57.29
-50
0.6 -57.29
-60
0.7 -58.86
0.8 0 -70

Graph 1 Mending moment diagram

Therefore, in the vertical Maximum bending moment is 58.86N

Horizontally

Figure 7.0.38 free body diagram in the horizontal

For 0<x<0.1
Mx=840.13x
For 0.1<x<0.3
Mx= 840.13x-840.13(x-0.1)

66 | P a g e
 moment in the horizontal
90
80
distance moment 70
0 0
60
0.1 0
50
0.2 84.013
0.3 84.01 40

0.4 84.01 30
0.5 84.01 20
0.6 84.01 10
0.7 0
0
0.8 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Graph 2 bending moment for eccentric shaft

Therefore, Maximum bending moment in the vertical is 84.01N
From analysis of both graphs the maximum bending moment can be found point 0.4 or point 0.1
(typical points of max bending) therefore comparing the two
M0.4=√ 84.012+ 57.292.=101.6 Nm
M0.1= √ ¿ ¿=58.86Nm
Therefore, max BM is 101.6Nm for the beam

Now the load is cyclic and fluctuating therefore we consider factors of combined shock and
fatigue for torsion Kt and for Bending Km
Considering table C1
Select Km=2.0 and Kt=2.0 for suddenly applied load with minor shock

Te¿ √( K m × M )2+ ¿ ¿

¿ √(2 ×101.6)2 +¿ ¿
=228.73Nm
πτ d 3
We know that Te =
16

67 | P a g e
 Table 7.0.8 Extract from Table C2 on properties of steel
Selecting steel 0.30 C from table of properties
σ y=550MN/m2
τ b=385MN/m2
Using safety factor 3
πτ d 3
=228.73
16
16 ×228,73
d 3=
π ×385 ×106 /3
d= √3 0.000009077
=0.02086m

1
We know that Me = (M +T e )
2
π d3 σb
And Me=
32
Using a safety factor of 3
Me¿ 1/2(101.6+228.73)
=165.17Nm
π d3 σb
=165.17
32
165.17 ×32
d 3=
π ×550 ×106 /3

68 | P a g e
d= √3 0.000091767
d=0.0209m
from both criteria, design for twisting and bending the minimum value of d=21mm
therefore, flywheel shaft diameter is say 25mm

7.2.4.2 Eccentric shaft

Effect of gear on shaft

Vertically due to the mass of the gear 6.1kg*9.81=59.841N
Ft
Horizontally due Normal force due power transmission WN=
cosα
All parameters as defined above
T
F t=
r
105
¿
0.266/2
=789.47 N
789.47
W N=
cos 20
¿ 840.14N

Forces on shaft due to the swing jaw, wear plate and rock being crushed
For wear plate and jaw plate
mass=ρ ×V
given width of setup =0.3m
length of jaw and wear plate =0.5m
density of jaw material =7200kg/m3
density of wear plate material =8200kg/m3
jaw thickness =0.04m
effective wear plate thickness =0.02m

mass = (7800× 0.04+8200 ×0.02 ¿ ×0.3 × 0.5

69 | P a g e
 =71.4 kg
Mass of granite being crushed
Considering that the shape the crushing mechanism approximates a triangular prism the volume
V occupied by granite is given by the relationship
1
×b × h ×w
2
Where b is the gape (0.2m)
h is the length of the jaw (0.5m)
w is the width of the jaw (0.3m)
Density of granite is 2650kg/m3
Mass =ρV
1
¿ ( 0.2× 0.5 ×0.3 ) ×2650
2
¿ 39.45 kg

Due to the presence of air gaps and irregular shape of rock the actual space occupied by the rock
will be approximately 60% of the full capacity therefore mass of rock is given by
60%×39.45=23.67kg
Combined mass of jaw, wear plate and stone is ≅ 23.67+ 71.4
∴ M =90 kg
Weight =90*9.81
=882.9N
To maximise the strength of the shaft double the weight will be used to represent the force as two
point loads at the ends of the jaws as this this where the jaw bearings will be located.

70 | P a g e
 Figure 7.0.39 vertical analysis free body diagram for eccentric shaft
Since the beam is symmetrically loaded RA=RB=946.66
For 0<x<0.1
Mx=946.66x
For 0.1<x<0.15
Mx946.66x-63.67(x-0.1)
For 0.15<x<0.2
946.66x-63.67(x-0.1)-882.9(x-0.15)

moment
12

distance moment 10

0 0
8
0.1 94.66
0.15 110.12 6
0.2 138.81
0.3 138.81 4
0.4 138.81
2
0.45 110.12
0.5 94.66
0
0.6 0 0 2 4 6 8 10 12 14

71 | P a g e
Horizontally

moment
90
80
70
60
length moment
50
0 0
0.1 84.01 40

0.2 84.01 30
0.3 84.01 20
0.4 84.01 10
0.5 84.01
0
0.6 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

Resultant Maximum bending moment= √ 84.012+ 138.12

161.65N

72 | P a g e
Considering table C1
Select Km=2.5 and Kt=2.0 for suddenly applied load with heavy shock

Te¿ √( K m × M )2+ ¿ ¿

¿ √(2.5 ×161.65)2 +¿ ¿
=455.43Nm
πτ d 3
We know that Te =
16

Using steel 0.3C as for the flywheel shaft

σ y=550MN/m2
τ b=385MN/m2
Using safety factor 3
πτ d 3
=455.43
16
16 × 455.43
d 3=
π ×385 ×106 /3
d= √3 0.000018073
=0.02624m

Using the bending moment criteria

1
We know that Me = (M +T e )
2
π d3 σb
And Me=
32
Using a safety factor of 3
Me¿ 1/2(161.56+ 455.43)
=308.495Nm
π d3 σb
=308.5
32
308.495 ×32
d 3=
π ×550 ×106 /3
73 | P a g e
d= √3 0.000017139
d=0.0258m
Taking the larger of the two, eccentric shaft minimum diameter is 26.2mm say 30mm

Summary: Minimum diameters for both shafts

Flywheel shaft=25mm
Eccentric jaw shaft=30mm

7.2.5 Bearings
Type of bearings used: Radial Cylinder roller bearings, chosen for their robust qualities.
All other 7.2.5.1 Flywheel shaft bearing
Bore diameter¿Flywheel shaft diameter (25mm)
Load on the bearing=Resultant of vertical and horizontal forces on shaft.
¿ √ 840.132 +604.262=1034.88 say 1035N
information determined using the SolidWorks Bearing Calculator shown below

74 | P a g e
 Figure 7.0.40 Flywheel shaft bearing
Information from bearing calculator (flywheel shaft)
Bearing Type SKF NU205 EC
Bore diameter 25
Outer diameter 52
Life in hours 1874297.13 hrs
Load on bearing 1035N

7.2.5.2 Jaw shaft at casing bearing

Bore diameter¿shaft diameter (30mm)
Load on the bearing=Resultant of vertical and horizontal forces on shaft.
¿ √ 946.662 +840.14 2=¿ ¿ 1265.72 say 1265.7N
All other information determined using the SolidWorks Bearing Calculator shown below

75 | P a g e
 Figure 7.0.41 Bearing on eccentric shaft and casing
Information on jaw shaft at casing
Bearing Type SKF NU206 EC
Bore diameter 30mm
Outer diameter 62mm
Life in hours 5312320.7 hrs
Load on bearing 1265N

7.2.5.3 Jaw shaft at casing bearing

Bore diameter¿eccentric shaft diameter (45mm)
Load on the bearing=Mass of jaw and material (882.9N)

76 | P a g e
 Figure 7.0.42 bearing inside the jaw
Information on bearing inside jaw from calculator
Bearing Type SKF NU209 EC
Bore diameter 45mm
Outer diameter 85mm
Life in hours 89072647 hrs
Load on bearing 882.9 N

7.2.6 Toggle

Taking a toggle plate width of 0.2m

Design for toggle thickness

77 | P a g e
Using data from table D1 it can be noted that the highest ratio T3/T2 is at θ3=159.496˚, therefore
using equation 11 appendix D, compressive F3 can obtained
T3
F 3= but T3/T2=-4421.31 from table D1(appendix)
r 3 sin ⁡(2× θ3 )
105 ×−4421.31
¿
0.5 sin ( 2 ×159.5 )
¿ 1415231.037

π 2× E × I g
Pcr =
L2g

Pcr × L2g
I g=
π 2× E
1415231.037 ×0.252 −8
I g= 2 9
=4.481× 10
π ×200 ×10
b t3
But also, Ig¿
12
−8
t¿ 3 12 × 4.481×10
√ 0.2
=0.0139m say 15mm
Where I g is toggle second moment of area
Pcr is the critical load for the crushing mechanism.

78 | P a g e
7.6 Stress analysis of critical components
7.5.1 Wear plate

Figure 7.0.43 Von Mises stresses on wear plate

The wear plate has to endure most in the design of the jaw crusher that is why it is made of
manganese steel so as to better endure the stresses applied to it.

7.5.2 Front gear (with holes)

Figure 7.0.44 Stresses on the main gear

79 | P a g e
This gear has been analysed as it is unconventional and has holes in it to reduce the weight of the
assembly. Evidently the holes do not result in failure of the gear. The centre of the gear has been
treated as stationary so as to decipher the maximum effects of the forces on the gear assuming
the shaft remains stationary due to presence of uncrushable material in the jaw crusher.

7.5.3 Flywheel

Figure 7.0.45 Stress analysis at flywheel/ crank

The flywheel is the main point of contact whence the driving force for operating the machine is
derived. The point of highest stress is the crank handle thus failure is most likely to occur there.
Stresses have been analysed assuming the centre of the flywheel is stationary such that maximum
stress due to applied force can be determined. From the Von Mises stress analysis, the flywheel
will not fail in service thus there is no need to change the design.

Item Process involved and desired Unit Quantity Total

dimensions price $ Price $
Casing Welding of steel plates (3*1m2 sheets) 200 1 200
Shafts Machining (high strength steel 1m each) 25 2 50
Moving Jaw Casting and machining (complex shape) 100 1 100
Wear plates Casting 25 2 50
Flywheel Casting and reinforcement 50 2 100
Spring Rolling 30 1 30
Toggle plate Machining 20 1 20
Bearings Assembled 20 6 120
Flywheel handle Cut steel shaft (0.3m) 5 2 10
Gears Casting 50 4 200

80 | P a g e
 23 $880
7.6 Bill of quantities
For better analysis, all values have been rounded.

The price is still in range of the objective $1000 therefore it is feasible and affordable.

NB. PLEASE FIND ATTACHED TO THIS DOCUMENT THE WORKING DRAWINGS.

Chapter 8 Conclusion and recommendations

The purpose of this project was to design a manually operated stone crusher that is efficient and
affordable so as to suit the needs of the target market which is small scale stone crushers that
depend on the hammer and anvil method of rock crushing. From the static and dynamic analysis
of the jaw crusher mechanism it was noted that the jaw crusher can provide up to 60 times the
mechanical advantage relating input and output torque, the use of gears also makes work easier
for the operator of the machine. All objectives were met resulting in an easier, affordable method
of crushing granite that is also safe. The combined weight of the machine is up to 200kg, due to
heavy components like the flywheels which weigh 60kgs a piece, the ribbed casing combined
with the jaws and wear plates provide the additional weight in order to balance the machine. It is
thus recommended that the machine be disassembled in transit and assembled at the crush site,
all components are modular hence assembling the machine is very simple.

81 | P a g e
In the course of this project other problems such as the effect of the method used to extract rock
from dwalas became evident. The burning of tyres results in pollution of the air and land, this
method also affects granite properties due to the drastic temperature changes. A better method of
stone extraction needs to be developed such that introduction of the machine into the public
market does not have a negative impact on the environment. A method of trapping granite dust
from crushing can be developed to increase profitability of the machine as the dust can be sold.

Figure 8.0.46 Land pollution and degradation due to burning of tyres while extracting granite

List of figures
FIGURE 1.0.1 BASIC PRINCIPLES OF ROCK CRUSHING 9
FIGURE 1.0.2 WOMAN MANUALLY CRUSHING STONES 11
FIGURE 2.0.1 MODEL OF LEONARDO DAVINCI’S AUTOMATIC HAMMER 14
FIGURE 2.0.2 NEW DAWN MANUAL CRUSHER AND TEAM OF WOMEN CRUSHING STONE 15
FIGURE 2.0.3 CRAZY CRUSHER LABORATORY STONE CRUSHER 16
FIGURE 2.0.4 SINGLE AND DOUBLE TOGGLE JAW CRUSHER 18
FIGURE 0.5 CONE CRUSHER 19
FIGURE 2.0.6 DOUBLE AND SINGLE ROLLER CRUSHER OPERATING PRINCIPLE 20
FIGURE 2.0.7 HAMMER CRUSHER 21
FIGURE 2.0.8 IMPACT CRUSHER 22
FIGURE 2.0.9 GEAR DRIVE MECHANISM 23
FIGURE 2.0.10 PULLEY ARRANGEMENTS 24
FIGURE 2.0.11 PULLEY ARRANGEMENT HALVING EFFORT REQUIRED TO LIFT A LOAD 24
FIGURE 2.0.12 TYPICAL CHAIN DRIVE AND BELT DRIVE 25
FIGURE 2.0.13 PRINCIPLES OF A SIMPLE LEVER 25

82 | P a g e
FIGURE 3.0.1 CONDUCTING AN INTERVIEW AT GLEN-NORAH CRUSHING SITE 27
FIGURE 3.0.2 OPEN ENDED STEEL CYLINDER, PLUNGER, BASE PLATE 29
FIGURE 3.0.3 13.5 AND 9MM SIEVES AND GRANITE AS LABELLED 30
FIGURE 3.0.4 FINAL SIEVED AGGREGATE ON SCALE 30
FIGURE 5.0.1 ISOMETRIC AND EXPLODED VIEW 37
FIGURE 5.0.2 PLAN AND EXPOSED BACK VIEW 37
FIGURE 5.0.3 CONCEPT 2 TOP VIEW 38
FIGURE 5.0.4 CONCEPT 2 SIDE VIEW 39
FIGURE 5.0.5 TRANSPARENT ISOMETRIC VIEW 40
FIGURE 5.0.6 SIDE VIEW AND ISOMETRIC SIDE VIEW 41
FIGURE 5.0.7 EXPOSED ISOMETRIC VIEW AND HAMMER AND ROTOR ASSEMBLY 41
FIGURE 6.0.1 THE CHOSEN SOLUTION 46
FIGURE 6.0.2 SKETCH PLAN VIEW SHOWING NEW MECHANISM FOR THE CRUSHER 47
FIGURE 6.0.3 EXPOSED FRONT VIEW AND PLAN VIEW 48
FIGURE 6.0.4 ISOMETRIC VIEW OF CRUSHER 48
FIGURE 7.0.1 FREE BODY DIAGRAM ABOUT O 2 50
FIGURE 7.0.2 FREE BODY DIAGRAM ABOUT O 4 51
FIGURE 7.0.3 KINEMATIC MODEL FOR SINGLE TOGGLE JAW CRUSHER 52
FIGURE 7.0.4 VECTOR LOOP CLOSURE METHOD OF ANALYSIS 53
FIGURE 7.0.5 PROPOSED FLYWHEEL DIMENSIONS 55
FIGURE 0.6 JAW REPRESENTATION 62
FIGURE 7.0.7 FREE BODY DIAGRAM OF FLYWHEEL SHAFT SHOWING VERTICAL FORCES 64
FIGURE 7.0.8 FREE BODY DIAGRAM IN THE HORIZONTAL 65
FIGURE 7.0.9 VERTICAL ANALYSIS FREE BODY DIAGRAM FOR ECCENTRIC SHAFT 70
FIGURE 7.0.10 FLYWHEEL SHAFT BEARING 73
FIGURE 7.0.11 BEARING ON ECCENTRIC SHAFT AND CASING 74
FIGURE 7.0.12 BEARING INSIDE THE JAW 75
FIGURE 7.0.13 VON MISES STRESSES ON WEAR PLATE 77
FIGURE 7.0.14 STRESSES ON THE MAIN GEAR 77
FIGURE 7.0.15 STRESS ANALYSIS AT FLYWHEEL/ CRANK 78
FIGURE 8.0.1 LAND POLLUTION AND DEGRADATION DUE TO BURNING OF TYRES WHILE EXTRACTING GRANITE 80
TABLE C.0.1 SHOCK AND FATIGUE FACTORS FOR BENDING AND TORSION 85
FIGURE D.0.2 NECESSARY DIAGRAMS FOR DERIVATION AND ANALYSIS 87

83 | P a g e
Appendix
This section contains information deemed necessary for the completion of this project but was
regarded as cumbersome.

APPENDIX A: FLYWHEEL

Table A1 Coefficient of fluctuation of speed for various mechanism[ CITATION Khu05 \l 12297 ]

APPENDIX B: GEARS

Table B1 standard gears and other dimensions[ CITATION Khu05 \l 12297 ]

84 | P a g e
Table B2 minimum number teeth to avoid interference[ CITATION Khu05 \l 12297 ]

Table B3 standard gear types and dimensions[ CITATION Khu05 \l 12297 ]

Table B4 service factor [ CITATION Khu05 \l 12297 ]

85 | P a g e
 Table B5 Allowable static stress

APPENDIX C: SHAFTS

Table C.0.47 shock and fatigue factors for bending and torsion

86 | P a g e
 Table C.2 Properties of some steels (Joseph Shigley’s Mechanical Engineering Design 7th edition)

87 | P a g e
APPENDIX D: DATA ON KINEMATIC AND DYNAMIC ANALYSIS

Derivations for dynamic Torque [ CITATION MFO15 \l 12297 ]

Figure D.0.48 Necessary diagrams for derivation and analysis

88 | P a g e
89 | P a g e
 Where T 2=¿crank torque about O2
T 3=¿jaw torque about O 3 due to resistance of feed material being crushed
F 1 , F2 , F3=¿ compressive forces in the links
O 2=¿ angle of crank
θ3 =¿angle of swing jaw
r 1 =distance between O 1∧O 4
r 2 =eccentric shaft is taken as a short crank continuously rotating about fixed axis
O2
r 3 =swing jaw modelled as a coupler link of length O3 O 4 with translational and
rotational motion
r 4 is the toggle modelled as a rocker length O 4 O 1 oscillating about O 1

90 | P a g e
The values for the crusher when input in the derived equations produce the values listed below

Table D.9 Typical values for dynamic Torque using similar dimensions and derived equations

References

91 | P a g e
Bell, R., 2010. History of Rock Crushers. [Online]
Available at: http://michelekirkman.over-blog.com/article-60370991.html
[Accessed 31 October 2016].
Chand, S., 2016. Industrial Safety: Definition, Need and Programmes for Industrial Safety.
yourarticlelibrary.com.
Dueitt, H., 2015. A 3 Million Year History of Construction Technology. [Online]
Available at: http://www.notevault.com/blog
[Accessed 31 October 2016].
Gautam S P, 2009. Comprehensive Industry. s.l.:Central Pollution Control Board.
Gupta, D., 2010. DESIGN AND ANALYSIS OF A HORIZONTAL SHAFT IMPACT CRUSHER.
s.l.:s.n.
Hurst, K., 1999. Concept Selection. In: Engineering Design Principles. New York: John Wiley
and Sons, pp. 53-63.
Jones, J., 2012. Stone crushing. Complexities of construction, 1(1), p. 123.
Khurmi R.S, G. J., 2005. A textbook of machine design. 14th ed. New Delhi: Eurasia Publishing
House.
Kunal, G. C. P. G. H. W. P. M. D. N. K., 2016. DESIGN & FABRICATION OF PULVERIZER
FOR NON-FERRIC ALUM. International Journal of Advances In Production And
Mechachanicasl Engineering (IJAPME), 2(3), p. 5.
Kusno Isnugroho, D. C. B. a. Y. H., 2016. A PRELIMINARY ASSESSMENT FOR THE
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