DESIGN AND FABRICATION OF CAN CRUSHING MACHINE

N.Nagarajan1, S.Srinivasan2, A.Balthilak3

1
Assistant Professor (Senior Grade), Department of Mechanical Engineering,
Nehru Institute of Technology, Coimbatore, Tamilnadu, India.
2
Assistant Professor, Department of Mechanical Engineering,
Nehru Institute of Technology, Coimbatore, Tamilnadu, India.
3
Assistant Professor, Department of Mechanical Engineering,
Nehru Institute of Technology, Coimbatore, Tamilnadu, India.

ABSTRACT rotary motion into reciprocating motion. All

At present can is being crushed manually parameters related to the design aspects were
which employs more time and more man considered and calculated as per requirements.
power. This can crusher can crush the As the use of motor was avoided, design
aluminium can and an operator is required to calculations were done for manually applied
handle the machine during the crushing load.
process. It can be used to crush two cans in Various stress factors were also
single rotation of the pulley. This consists of considered and suitable tolerances and factor of
V-belt pulley, one piston, connecting rod, safety was accordingly employed to reduce
slotted lever and base frame. In this there is chances of failure and increase the life and
one piston in which one half of the piston durability of the machine. Care was also taken to
crushes the can for half rotation of the pulley ensure minimum or negligible slipping of the
and the second half the piston crushes the can belt to achieve maximum efficiency.
for next half rotation. Quick return The objective of this project is to design
mechanism is used to convert the rotary and fabricate the can crusher which incorporates
motion into linear reciprocating motion. The the use of “ QUICK RETURN MECHANISM”.
cane is crushed with help of piston which is This can crusher is used to crush Aluminium
connected with the connecting rod, slider, V - cans for (200ml) its suitable disposal and
belt pulley with slotted bar. Fabrication of subsequent recycling.
“Can crusher” is done by assembling the The Quick return mechanism is a
parts. mechanical device which is used for crushing
Keywords: Cane crusher machine, cans. The can crusher on crushing the cans
Components, Belt Pulley, Quick return reduces the size of the cans and hence space is
mechanism used less and also since the mechanism is fast
moving process, so the work time is reduced for
1. INTRODUCTION men.
The Can crushing machine which is fabricated The reason for the development and the
incorporates the use of the “QUICK RETURN introduction of the quick return mechanism for
MECHANISM” for crushing two cans can crushing is given below. The quick return
simultaneously in one stroke, i.e.; one can is mechanism is one the improved devices used for
crushed during the forward stroke of the piston crushing cans.
and the other can is crushed during the return
stroke of the piston. This mechanism is most 2. PART DESCRIPTION
commonly used in shaping machines and slotted 2.1 Smaller pulley
machines. The quick return mechanism is an Smaller pulley (Fig 1) is used to connect the
inversion of the slider crank which converts handle and the larger pulley. V-belt is used to

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transfer the power from the handle to the larger the can by converting rotary motion to
pulley. This pulley is connected to the handle reciprocating motion.
through bearing. The handle joint is used to
transfer the power from the handle and the larger
pulley without any power loss. This part is
mainly used for the purpose of power
transmission from the handle to the belt to the
pulley for the effective reciprocating motion of
the piston to crush the cans during the forward
and the return stroke.

Fig .3. Slider

2.4 Connecting rod
Connecting rod (Fig 4) is used to transfer the
load from the slider to the piston and it should
bear the high load so it should be very strong.
This part plays a important role in transfering the
load. Construction of each part is mainly depent
upon this component this part plays an important
role in the transfer of load from the slider to the
Fig .1. Smaller Puller piston. The connecting rod is connected to the
crank which facilitates the working of the can
2.2 Larger pulley crushing machine. The connecting rod is
Larger pulley (Fig 2) is operated by the power essential as it forms the backbone of this device.
which is transferred from the smaller pulley by
using handle from belt these two pulleys are
connected by the V-belt.The power transferd
from this pulley used to crush the can by using
the QUICK RETURN MECHANISM. This
pulley is connected to the slot by which the Fig.4. Connecting Rod
cylinder is operated to crush the can. This part is 2.5 Cylinder
used to maintain the tension between the belt and Cylinder (Fig 5) act as a frame which carries the
the pulley to prevent the power loss due to the can and the piston over it is cutted partially and
slipping of the belt. there will be two holes on the two end of the
cylinder. The piston will slides over this cylinder
hence it should be lubricable the can after
crushing is will fall through hole which is present
in both end of the cylinder. The cylinder must be
made of a suitable material hard enough to crush
the Aluminium cans. The cylinder is made solid
at its ends and hollow inside to provide sufficient
force to crush the cans as well as reduce the total
cost of the product.
Fig.2. Larger Pulley
2.3 Slider
Slider (Fig 3) is used to transfer the power from
the larger pulley the slot is used to connect both
the larger pulley and slider and this slider is used
to connect the both the larger pulley and
connecting rod of the piston. Slider will slides
over the slot to transfer the energy the connecting
rod is pivoted to the slider and the power is
tranfered to the piston. Slider is the main part Fig.5. Cylinder
which transmits the power to the piston to crush

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2.6 Piston =2(270+90)

Piston (Fig 6) component is used to crush the Cmax=720mm
can with the help of load transferd from the Hence the design is safe
connecting rod with the help of cylinder. The STEP:6 LENTGH OF THE BELT (L)
piston slides over the cylinder and it travels from L=2C+ /2( + )+( − )
2
the one end to the other end of the cylinder.The /4C
cylinder is connected to to the connecting rod
through welding. mm
L=2*270+π/2(270+90)+(270-90)2/4*270
L=540+565.2+30
L=1135.2mm

(Refer PSGDB Page no 7.59)

The next standard value L=1219mm for A grade
belt length L=1255mm
Fig.6. Piston STEP:7 NEW CENTER DISTANCE (C)
Where,C=A+√ 2 −mm
3. DESIGN CALCULATION Where, A=L/4- /8(D+d) mm
3.1 Design Calculation for pulley and V-belt A =1255 /4-3.14/8(270+90)
drive A=313.75-141.3
Assume The Load is below 1KW Power A =172.45mm
To Select‘A’ Grade belt drive (Refer PSGDB Where, B = (D-d)2/8 mm
Page no 7.58) B = (270-90)2/8
To take dmin diameter pulley B=4050mm
dmin= 75mm (Refer PSGBD Page no 7 .62) C=172.45+ √172.452 – 4050
Where, demax =dmax *Fb mm C=332.72mm
The smaller diameter factor Fb is Assume 1.14 (or)
STEP:1 SPEED RATIO (i) C=340mm
The speed Ratio i=2.949 ASSUME, Speed for smaller pulley N1=356rpm
dmax = 125/1.14 Speed for larger pulley N2=120rpm
dmax =110mm STEP:8 BELT RATING FOR V-BELT
Let us take mean diameter dmean=90mm DRIVE (Br)
STEP: 2 LARGER PULLEY DIAMETER ‘A’ GRADE BELT
(D) Where, Br=(0.45V-0.09-19.62/de-0.765X10-
4 2
i=D/d V )V125 KW
2.949=D/90 De=90x1.14
D=2.949*90 De=102.6mm
D=270mm STEP: 9 VELOCITY (V)
STEP: 3 CENTER DISTANCE (C) Where, V= 1/60 M/S
Let us take for i=2.949 V =3.14X0.090X356/60
Where,C/D=1.0 (Refer PSGDB Page no 7.62) V=1.67 M/S
C=270mm Br= (0.45X (1.67)-0.09-19.62/102.3-0.765X10-
4
STEP:4 MINIMUM CENTER DISTANCE (1.67)2)1.67
(Cmin) Br= 0.109KW[FOR 1800]
C STEP:10 ARC OF CONTACT (ka)
min=0.55(D+d)+T
Where,ka= 180-(D-d) X 60/C
Ka = 180 - (270-90) X 60/270= 140’
mm For =140 in (PSGDB Page no 7.65) to take
=0.55(270+90)+8 Ka=0.9
Cmin =206mm Required 140 for belt rating= Br* /180
STEP:5 MAXIMUM CENTER DISTANCE = 0.109 x 140/180
(Cmax) Required belt rating 140= 0.0847 KW
Where, Cmax=2(D+d) mm Take correction factor Ks=1.2

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STEP:11 DESIGN POWER (Dp) Hence the design is safe

Where,Dp = Rp * Ks/Kl * Ka KW CHECKING FOR CRUSHING STRESS (σ)
Dp = 0.368*1.2/0.93*0.9 h/2)*(d/2)
Dp = 0.527 KW σ= MtX4/L *h*d
STEP:12 NUMBER OF BELTS σ=14.14X103X4/22.5X5X15
Where,N = Dp/Required for belt rating σ=33.9N/mm2<120N/mm2
N =0.527/0.337 Hence the design is safe
N=1.56
NUMBER OF BELT N=1 STEP:16 DIAMETER OF SHAFT (LARGER
Where, Pw=(N-1) e+2f PULLEY DS)
Pw= (1-1) 15+ 2X1 Mt = P*60/2πN2
Pw =20mm Mt = 60 x 527/ 2 x 3.14 x 120
STEP:13 BELT TENSION (T) Mt =41.95x103N-mm
T1 = Tight side of the Belt Twisting Moment
T2 = slack side of the Belt h = 5mm
POWER , P=(T1-T2)V L=10 to 56mm
T1/T2=θ=140X3.14/180 =2.44radians/sec Mt= σ
P=527W Mt =π/16*d3 τ
V=1.67M/S 527/1.67 = T1-T2 T1-T2 = 315.55 {For Mild steel Material τ=50N /mm2 & σ =
T1/T2= 0.3∗2.44 120 N/mm2 } d3 = 41.95 x 103x16/50x3.14 d =
T1/T2 = 2.08 20mm
2.08T2-T2 = 1.08T2 T2=292.19N DESIGN OF KEY ( REACTANGULAR
T1=2.08X292.19 SUNK KEY)
T1= 607.76 N Diameter of the shaftd =20mm,(Refer PSGDB
STEP:14 DESIGN OF SHAFT (SMALLER PAGE NO :5.16)
PULLEY dS) To takeb = 6mm,
Where,Mt = P*60/2 h = 6mm
N1 N-m L=10 to 56mm
Mt= 527*60/2*3.14*356 ForL = 1.5xd
Mt = 14.14 N-M L = 1.5x20
Mt = 14.14X103 N-mm L = 30mm
Twisting Moment CHECKING FOR SHEAR STRESS (τ)
Mt Mt = L* τ*b*d/2
=/16*d3 τ =Mt*2/L*d
τ = 41.95x103x2/30x6x20
N-m τ =23 N /mm2<50N/mm2
{For Mild steel Material τ=50N /mm2&= 120 Hence the design is safe
N/mm2 } CHECKING FOR CRUSHING STRESS (σ)
d3=14.14x103x16/50x3.14 Mt= σ*L*(h/2)*(d/2)
d = 15mm σ= MtX4/L *h*d
STEP:15 DESIGN OF KEY σ=41.95X103X4/30x6x20
( REACTANGULAR SUNK KEY) σ=46.6N/mm2<120N/mm2
Diameter of the shaft d =15mm, (Refer PSGDB Hence the design is safe
PAGE NO :5.16) 3.2 Design calculation for slotted lever
To take b = 5mm, STEP:1 DESIGN OF SLOTTED LEVER
For From Fig 7,
L = 22.5mm Time of cutting stroke / Time of return stroke is
CHECKING FOR SHEAR STRESS (τ) given by α / β
L = 1.5xd Assume cutting ratio = 5:3
L = 1.5x15 (α)/(360- α) = 5:3, (360- β)/ β =5:3
Mt = L* τ*bd/2 α =2250, β =134.980
=Mt*2/L*d α +β=360
= 14.14X103X2/22.5X5X15 Radius
=16 .96N /mm2<50N/mm2 CB1=CB1=CB=120mm

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sin90−( β /2)=( CB1/ AB) STEP:8 CALCULATION OF PISTON

sin90−(134.98/2)=( CB1/ AB) EFFORT (FP)
AB=313.44mm FP=FL-FI
STEP: 2 SLOTTED LEVER FL=Net load On the piston
AC=CQ FI=Acceleration of the piston
AQ=AC+CQ STEP:9 ACCELERATION OF THE
AQ=313.44+313.44 PISTON (FI)
AQ=AR1=AR2=626.8mm FI=m r2(COS +COS2 /n)N
STEP:3 TOTAL DISTANCE OF m=Mass of the reciprocating parts
CONNECTING ROD r=Radius of crank
R1R2 =2QA X CB/AC n=length of connecting rod/Radius of the crank
R1R2= 2X626.8X120/313.44 =2N2/60
R1R2 =480mm =2X3.14X120/60
AQ1=2ED ω= 12.56rad/sec
ED=626.8/2 W=50N m =5.09kg
ED=313.4mm r =120mm=0.120M l =240mm=0.240M
n =l/r=0.240/0.120 =2
FI =5.09 x .140 x (12.56)2 x (cos60-cos 2x60/2)
x0.12 FI =72.26N
STEP:10 NET LOAD ON THE PISTON (FL)
FL=Pressure X Area
ASSUMEPressure of the piston=1.5X105N/M2
Area of the piston
=

/4Xd2
Diameter of the piston, d=50mm=0.050M
FL =1.5X105X3.14X0.0702/4
FL=576.98N
Fig.7. Slotted lever mechanism STEP:11 PISTON EFFORT (FP)
FP=FL-FI
STEP:5 BENDING MOMENT OF THE FP = 576.98-72.26
SLOTTED LEVER FP=504.77N
Section modulus, Z = I/Y STEP:12 ANGLE OF CONNECTING ROD
Where, I=Moment of inertia Where,tan∅=sin∅/cos∅
I=bd3/12 tan∅= sin /√n2-sin2θ
ASSUME tan∅= sin60/(22-sin260)0.5
d=h tan∅=0.48
h=b/2 ∅=tan-1(0.48)
I=b*b3/96 ∅=25.65’
I=b4/96 STEP:13 FORCE ACTING THE ALONG
Mb=LOAD X DISTANCE THE CONNECTING ROD (FQ)
Mb =527X626.4 FQ = FP X n/ (n2-sin260)1/2
Mb=0.379X106N-mm FQ = 504.77X2/ (22-sin260)1 /2=559.9N
STEP:6 BREADTH (b) STEP:14 CRANK PIN EFFORT(FT)
0.379X106/b4/96=320/b FT=Fp X sin(θ+∅)/ cos∅
B =46mm FT =504.77 X sin(25.65+60)/cos25.65
STEP:7 THICKNESS OF SLOTTED FT=558.33N
LEVER STEP:15 THRUST ON CRANK SHAFT
h =b/2 BEARING(FB)
h=46/2=23 FB=FP X cos(θ+∅)/)/cos∅
h=23mm FB=504.77 X cos(60+25.65)/cos25.65
FB=42.47N

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STEP:16 CRANK EFFORT (T)

T=FP[sin θ+∅/cos∅]r
T=504.77[sin(60+ 25.65)/cos25.65]0.120
T=67.00NM
STEP:17 DESIGN OF BOLT
Select the materials for bolt C50 steel=P/A
τmax = Ssy/F.S
Take C50 material ,(Refer PSGDB page no 1.9)
τy = 380N/mm2
Ssy =yield strength is shear = yield
strain tension/2=Syt/2 F.S= factor Fig .9.Assembly 3D view
of safety
Assume factor of safety F.S=3
τmax =380/2x3
τmax=63.33N/mm2
Load P=266.27N
P1=P/n
n =Number of bolts P1=266.27/1=266.27
P1=266.27N
STEP:18 STRESS (σ )
σ=P2/A P2=Pxexl/n(l2) Fig .10. Fabricated product
P2=266.27x275x50/1x(50)2
P 2=1464.485N 5. RESULT AND CONCLUSION
σ =1464.48/A N/mm2 The Quick return mechanism has been fabricated
STEP:19 SHEAR STRESS (τ) and is checked for the stroke length obtained
τ =P1/A after machining the mechanism, the required
τ =266.27/A N/mm2 calculations are done. The required stroke length
τmax= √(σ/2A)2+ τ2 that needs to be obtained is 550mm. A cam
63.33=1/A ((1464.48/2)2+266.272)1/2 profile of 240 degree forward stroke is also
A=12.3mm2 obtained there for the required mechanism. After
A=(12.3/4) x dc2 dc2 =12.3x4/3.14 dc= 3.958mm doing the required calculations and stroke length
dc=0.8xd of 500mm is obtained. The obtained value is
d =dc/0.8 approximately equal to the required stroke
d=3.958/0.8d=4.9 (ReferPSGDBPageno.5’) length.
The next standard bolt diameter M5 & height of The forward and return stroke time is noted
the bolt=14mm Time obtained for forward stroke is 3.33 sec and
4. ASSEMBELY DIAGRAM AND the time obtained for return stroke is 1.66 sec.
FABRICATION OF MACHINE Thus the values obtained are satisfactory.
Component drawings and assembled drawing Thus Quick Return Mechanism is fabricated to
(Fig 9, Fig 10) are created with CAD package. obtain the required stroke length. The required
Then the components are manufactured and calculations are done to find out the position of
fabricated (Fig 11). the screw to get the required stroke length.

6. REFERENCE
1. V. Jayakumar –“KINEMATICS OF
MACHINERY”(2011)-5th edition-Lakshmi
Publications, Definition and basic concepts-
Quick return mechanism-pp1.42.

2. Vijayaraghavan-“DESIGN OF MACHINE
ELEMENTS”(2012)-Anuradha Publications-
Quick return mechanism,pp 5.95

Fig.8.Assembly 2D view

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3. PSG-Design Data Book of Engineers Maharashtra, India

pp.5.16,5.75,7.58-7.70.
7.Shadab Husain, Mohammad Shadab
4. V. Jayakumar-“DYNAMICS OF Sheikh 5th semester Mechanical Engineering
MACHINERY”(2016)-10th edition- Lakshmi Student, Anjuman college of
Publications, Definition and basic concepts- Engineering and technology Nagpur, India
Dynamic Force Analysis-pp(2.14-2.31). 8.Singh Pankaj, Surve Qais, Sayed Saif,
Sayed Jafar, Shaikh Nadeem B.E. Mechanical,
5 . Suryakant D. Thakur, Akshay B. Patel, Nitin H.J. Theem College of Engineering
K. Tilekar, Akash B. Wagh Department Of Boisar, Maharashtra, India
Mechanical Engineering, MET’s Institute of
Engineering, Bhujbal Knowledge City, Nashik, 9.Akshay Patel, Akash Wagh, Nitin
Maharashtra, India Tilekar, Suryakant Thakur Department Of
Mechanical Engineering, MET’s Institute of
6.Vishal N. Kshirsagar, Dr.S.K. Choudhary, Engineering, Bhujbal Knowledge City, Nashik,
Prof.A.P.Ninawe. MTech (pursuing) Mechanical Maharashtra, India.
Engineering Department ,KDK College of
Engineering Nagpur,

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