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(2020) 000–000
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Procedia CIRP 00 (2017)

Procedia 000–000
CIRP 91 (2020) 858–863
www.elsevier.com/locate/procedia

30th CIRP Design 2020 (CIRP Design 2020)

Design ofDesign
28th CIRP a small-scale
Conference,granite stone
May 2018, crusher
Nantes, France
aa a, aa a,b
A new methodology
Tauyanashe Chikuku ,to Royanalyze
N. Mushonga the functional
*, Tendai Sakala and physical
, Wilson R. Nyemba architecture
, Simon of
a, a,b

Chinguwaa,c a,c
existing products
Department of
Department
for an
aa
of Mechanical
assembly
Mechanical Engineering,
Engineering, University
University of
oriented
of Zimbabwe,
Zimbabwe, P
POO Box
product
Box MP
MP 167,
167, Mount
family
Mount Pleasant,
Pleasant, Harare,
identification
Harare, Zimbabwe
Zimbabwe
bb
Department
Department of
of Quality
Quality and
and Operations
Operations Management,
Management, Faculty
Faculty of
of Engineering
Engineering and
and the
the Built
Built Environment,
Environment, University
University of
of Johannesburg,
Johannesburg, Auckland
Auckland Park
Park Bunting
Bunting
cc
Department of
of Mechanical
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Mechanical Engineering
Engineering Science,
Science, Faculty
Faculty of
Road
Road Campus,
Campus, South
of Engineering
Engineering and
South Africa.
and the
Africa.
the Built
Built Environment,
Environment, University
University of
of Johannesburg,
Johannesburg, Auckland
Auckland Park
Park Kingsway
Kingsway
Department
Campus,
Campus, Auckand
Auckand Park
Park 2006,
2006, Johannesburg,
Johannesburg, South
South Africa.
Africa.
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding
* Corresponding author.
author. Tel.:
Tel.: +263713900710;
+263713900710; fax:
fax: +263-242-303280.
+263-242-303280. E-mail
E-mail address: nyasharoy@gmail.com
address: nyasharoy@gmail.com

* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu

Abstract
Abstract
Abstract
This paper
This paper describes
describes the
the design
design of
of aa manually
manually operated
operated granite
granite stone
stone crushing
crushing machine.
machine. This
This machine
machine is
is targeted
targeted for
for people
people who
who are
are currently
currently in
in
the
the stone
stone crushing
crushing business
business and
and use
use manual
manual methods
methods like
like the
the hammer
hammer and
and anvil.
anvil. Due
Due to
to the
the expensive
expensive nature
nature of
of available
available stone
stone crushers
crushers in
in
In today’s business
Zimbabwe
Zimbabwe environment,
small-scale
small-scale crushingthe
crushing trend people
business
business towards
people moreafford
cannot
cannot product
afford these
thesevariety
machines
machinesandandcustomization
and resort is
hence resort
hence unbroken.ways
to primitive
to primitive Dueof
ways oftocrushing
this development,
crushing that are
that both the
are both need of
tedious
tedious
agile and
andpotentially
and reconfigurable
potentially harmful.
harmful.production
After systems
After careful
careful emerged
analysis
analysis of to cope
of current
current stone
stonewith variousmethods
crushing
crushing products
methods andand
and productstudy,
thorough
thorough families.
study, To design
aa solution
solution was and optimize
was developed
developed that production
that is
is safe,
safe,
affordable
systems as welland
affordable as efficient.
and to chooseThe
efficient. thedeveloped
The solution
optimal product
developed addresses
solution matches, the
the needs
addresses product of
of the
needsanalysisthe hammer
methods
hammer stone
are crushers
stone needed. and
crushers provides
Indeed,
and mostaa viable
provides of the alternative.
viable known methods
alternative. Research
Research aim to
wasa performed
analyze
was performed through
product orthrough experiments,
one product family on
experiments, thethe
the usephysical
use of local
of local level.
libraries and site
Different
libraries and siteproduct
visits to
visits to families,
stone crushing
stone crushing companies
however, and various
may differ
companies and various quarry
largely quarry
in terms sites thatnumber
of the
sites that use the
use the and
naturehammer
hammer and
and anvil
anvil approach.
of components. This fact University
approach. impedes anlaboratories
University were
were used
efficient comparison
laboratories used to conduct
toand choice
conduct experiments and
and determine
of appropriate
experiments minimum
product family
determine minimum crushing
crushing forces
combinations needed
for the
forces for
production
needed for
various
various granite
granite stones.
stones. A
A portable
portable stone
stone crushing
crushing machine
machine was
was then
then designed
designed which
which meets
meets the
the minimum
minimum crushing
crushing
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster force
force of
of 225KN.
225KN. An
An additional
additional
theseallowance
allowance
products inof 10%
of new to
to carter
10% assembly carter for
for safety
safety of
oriented of the
the machine
product machine
familiesand
andforpotential
potential to
to crush
crush other
the optimization other stones
stones within
of existing within range of
of the
rangelines
assembly granite
theand
granite stone.
stone. The
the creation Theofsmall
futurescale
small scale granite
granite
reconfigurable
stone crusher
stone crusher was
was designed
designed to to crush
crush stones
stones of of approximately
approximately 25-135mm
25-135mm to to about
about 24-20.2mm
24-20.2mm in in size.
size. SOLID
SOLID WORKSWORKS was was used
used asas aa stress
stress
assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
analysis tool
analysis tool on
on the the gear
gear (main
(main crushing
crushing part)part) to
to determine
determine the the regions
regions where
where the
the gear
gear experiences
experiences maximum
maximum force force according
according to to Von-Misses
Von-Misses
a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
failure criteria.
criteria. It
failurebetween was
was observed
Itproduct observed the
thebyinner
inner diameter of
of the
diameterdesign the gear
gear assembly
assembly and
and the
the gears
gears themselves
themselves are prone
prone to high stress
stress which results in
in tearing
similarity families providing support to both, production system areplanners to
andhigh
product which resultsAn
designers. tearing
illustrative
off of
off of the
the material
material in in those
those regions.
regions.
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp
© 2020 The
2020 Presta
The
The France
Authors.
Authors. is then carried
Published
Published byby out B.V.
Elsevier
Elsevier to B.V.
give a first industrial evaluation of the proposed approach.
© 2020 Authors. Published by Elsevier B.V.
© 2017ThisThe
is Authors.
an open Published
access article byunder
Elsevierthe B.V.
CC BY-NC-ND
Peer-review
Peer-review under responsibility of the scientific committee
under responsibility of the scientific committeelicense
of
of the (http://creativecommons.org/licenses/by-nc-nd/4.0/)
the CIRP
CIRP Design Conference..
Design Conference
Peer-review underunder
Peer-review responsibility of theofscientific
responsibility committee
the scientific committeeof theof28th CIRPDesign
the CIRP DesignConference
Conference2020 2018.
Granite stone
Keywords: Granite
Keywords: stone crusher;
crusher; crushing
crushing force;
force; quarry
quarry stones.
stones.
Keywords: Assembly; Design method; Family identification

1. Introduction
1. Introduction As indicated
As indicated in
in Fig.
Fig. 1,
1, the
the crushing
crushing process
process involves
involves
1. Introduction transferring
of the product
transferring aa force
force which
rangewhich can bebe amplified
amplified
and characteristics
can by mechanical
mechanical
manufactured
by and/or
This
This paper
paper provides
provides aa problem
problem solversolver forfor aa small-scale
small-scale stone stone advantage
advantage through
assembled aa material
in this system.
through material that
In this has
has stronger
that context, bonds
the main
stronger with
with aa in
bondschallenge
crushing
Due to industry
crushing industry
the fast in
in Zimbabwe,
Zimbabwe,
development not
not only
onlyinmaking
the stone
making stone
domain crushing
crushing
of higher
higher resist
modelling to
to deformation
resistand analysis is as
deformation as
nowcompared
compared
not only to
to the
to material
the material
cope with being
being
single
easier
communication and
easier and moremore productive
andproductive
an ongoing but also
but also
trend making
making it more desirable
it more desirable
of digitization and crushed. Crushing
crushed. Crushing
products, devices
a limiteddevicesproduct hold
hold material
material
range between two
betweenproduct
or existing parallel
two parallel
families,
career choice
choice for those
those who
whoenterprises
were limited
limited by risk ofofimportant
injury oror or tangent
tangent solid
career
digitalization, for
manufacturing were areby risk
facing injury or
but also tosolid
be able surfaces, and
surfaces, and apply
to analyze apply sufficient
and tosufficient force
compare force to
to bring
bring the
products to the
define
low body
low body strength.
strength. StoneStone crushing
crushing is is reducing
reducing the the size
size of of large
large surfaces together
surfaces together to to generate
generate enough
enough energy
energy within
within the
the material
material
challenges in today’s market environments: a continuing new product families. It can be observed that classical existing
rocks into
into smaller
rocks towards smaller rocks
rocks or
orofgravel
gravel or
or dust.
dust. Quarry
Quarry stones
stones in this being
being crushed so that its
its molecules separate
separateoffrom, or change
tendency reduction product development timesinand this product crushed
families so are
thatregrouped
moleculesin function from,
clientsor or
change
features.
paper refer to granite ¾ inches (20mm) or less.
paper refer to granite ¾ inches (20mm) or less. These stones are These stones are alignment
alignment in relation to, each other [2]. However, the
in relation to, each other [2]. However, the
shortened
vital product lifecycles. In addition, there is an increasing However, assembly oriented product families are hardly to find.
vital to
to the
the construction
construction industry
industry and and when
when crushed
crushed are mainly convectional
are mainly convectional way way of of stone
stone crushing
crushing consists
consists ofof high
high chances
chances of of
demand of
used for customization,
for road
road base
base aggregatebeing
aggregate and at
and in the same
in concrete
concrete mix time
mix [1]. in
[1]. a global On the product
self-inflicted injuries family
injuries such
such as level,
as injuring products
injuring fingers differ
fingers when mainly
when holding
holding thethe two
in
used self-inflicted
competition with competitors all over the world. This trend, main characteristics: (i) the number of components and (ii) the
which is inducing
2212-8271 © 2020
2020 Thethe
The development
Authors. Published byby from
Elsevier macro
B.V. to micro type of components (e.g. mechanical, electrical, electronical).
2212-8271 © Authors. Published Elsevier B.V.
markets, results
Peer-review underin diminished
responsibility of lot
the sizes
scientific due
committee to ofaugmenting
the CIRP Design
Peer-review under responsibility of the scientific committee of the CIRP Design Conference Classical
Conference 2020. methodologies considering mainly single products
2020.
product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and
production system, it is important to have a precise knowledge comparison of different product families. Addressing this
2212-8271 © 2020 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th CIRP Design
Design Conference
Conference 2020
2018.
10.1016/j.procir.2020.03.119
 Tauyanashe Chikuku et al. / Procedia CIRP 91 (2020) 858–863 859
2 Chikuku et al./ Procedia CIRP 00 (2020) 000–000

rocks and eyes due to flying stones during impact. Not only is special qualifications and hence many people have resorted to
this unsafe to the person at hand but also to the people around. it for a living. There is also a high demand in construction
As a result, there was a need to design a machine that is more materials like quarry stones due to the increase in the number
efficient, secure and environmental friendly during operation. of housing cooperatives in recent years. These stone crushers
As part of the research, interviews were conducted so as to get obtain their granite rock from local dwalas by exposing the
a better understanding of the working environment. General parent rock (dwala) to extreme fluctuating temperatures
questions asked such as: through the burning of tires over the dwalas (Fig. 2). After
•What are the challenges faced in using the hammer and cooling, pieces of rock can be chipped off using a sledge
anvil method? hammers, the process is basically forced exfoliation. These
•What is the rate of production? chunks of rock are then crushed into the desired aggregates to
•What are the general needs/requirements on machine to be be sold for their various application.
designed?

Fig. 2. Setting up tyre to burn Dwala

Fig. 1. Basic Principles of rock crushing [2]

Some of the responds given were: Rock crushers are used for breaking rock particles into
smaller fragments. Rock materials of different sizes, normally
Safety is a prime concern as one has to be very careful called aggregates, are used as building materials in a vast
otherwise one can lose a hand, there is also risk of inhalation of number of products and applications in modern society.
quarry dust. Some hammer and anvil crushers have also tried to Infrastructure and building industries are heavily dependent on
find alternative methods but generally the cost of the machines rock material with specified characteristics as the basis for
is very high and also the cost of maintenance is not worth it. foundations, concrete structures, roads and so on. Hence this
There is also the problem of getting a power source on site. gives a strong incentive to facilitate the production of
Because the hammer and anvil method is slow, the crushers aggregates at low cost, high quality and low environmental
cannot meet high demand of crushed rock and they lose footprint [3].
customers to bigger companies due to inadequate amount of
rock available as the customer would have to wait for days for 3. Previous designs
enough crushed stone to be gathered. Average time taken to fill
one-wheel barrow with crushed granite is 1hr 30mins that is not Fig. 3. presents a manual stone crusher which was designed
including time taken to retrieve stone from the dwalas and by New Dawn Engineering (Swaziland). The main
breaking them into manageable sizes. The cost of one cubic disadvantage of this crusher is that it is not locally available and
metre of crushed stone is USD$24 and 1 cubic is equal to 12 has poor safety mechanisms incase an uncrushable material
wheelbarrows of stone. Sorting of stone to desired sizes is a enter the crusher. The new Dawn crusher is also operated by at
major setback. least five individuals and it is said to be able to produce 10 cubic
The information obtained tallies with the main aims of the metres of stone per day.
designing a machine that provides better working conditions
and safer environment.

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 in Zimbabwe has resulted in
high unemployment rate and this has resulted in people relying
on informal work like stone crushing. This work requires no Fig. 3. New Dawn Engineering manual stone crusher [4]
860 Tauyanashe Chikuku
Chikuku et al./ et al.
Procedia CIRP/ Procedia
00 (2020)CIRP 91 (2020) 858–863
000–000 3

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.

Fig. 5. Open ended steel cylinder, plunger, base plate.

Fig. 4. Crazy crusher

4. Methodology

4.1. Experimental results

In order to come up with the design, experimental work was Fig. 6. Final sieved aggregate on scale.
carried out to determine parameters such as the minimum force
required to start crushing, size of the aggregate obtained at
different loads. By considering the aggregate crushing value The granite was put under gradual load and it was observed
(ACV) which gives a relative measure of the resistance of an that 225KN was the minimum load under which the granite was
aggregate to crushing under a gradually applied compressive crushed to 20.2 mm.
load. It was observed that they was a gradual decrease in ACV
as the aggregates decreased in size. The standard aggregate Impact force required is 400N
crushing test shall be made an aggregate passing the 24mm BS Average force from a human arm is 150N
test sieve and retained on the 20.2mm BS test sieve. Average force from pedalling used as 200N

The relationship between the impact force required (400N)

4.2. Apparatus and the average force of a human (150-200N) shows that
without mechanical advantage it would be near impossible to
The following apparatus is required for the standard test. crush granite. Therefore, the aim for the success is for the
•An open-ended steel cylinder of nominal 150mm internal machine to offer at least double the mechanical advantage that
diameter, with a plunger and a baseplate is to ensure crushing will occur.
•A straight steel tamping rod, of circular cross-section
16mm diameter, and 450mm to 600mm long, rounded at the 5. Governing equations
end
•A balance 3000g accurate to 1 g According to Chakrabarty [8] The constitutive equations of
•BS sieves, sizes 24mm; 20.2mm; the elastic-plastic deformation of a material is based on
•A compression testing machine, capable of applying force combining the Hooke’s law and either the Incremental or
of 400kN at a uniform rate so that maximum load is reached in Deformation theory which are stated as below.
10mins.
•A rigid cylindrical metal measure, for measuring the According to Hooke’s law:
sample, of internal diameter 115mm and an internal depth of � 1 + 𝑣𝑣 1 − 2𝑣𝑣
𝑑𝑑𝑑𝑑�� =� � 𝑠𝑠̇�� + � � 𝜎𝜎̇�� 𝛿𝛿�� (1)
180mm 𝐸𝐸 3𝐸𝐸
Based on Prandtl-Reuss Incremental Theory (IT):
 Tauyanashe Chikuku et al. / Procedia CIRP 91 (2020) 858–863 861
4 Chikuku et al./ Procedia CIRP 00 (2020) 000–000

1 − 2𝑣𝑣 3 𝐸𝐸� 2𝑞𝑞 − 𝑝𝑝 𝑠𝑠

𝐸𝐸𝜀𝜀̇�� = (1 + 𝑣𝑣)𝑠𝑠̇�� + � � 𝜎𝜎̇�� 𝛿𝛿�� 𝑐𝑐�� = �1 − � � � (6e)
3 (2)
2 𝐸𝐸� 𝜎𝜎� 𝜎𝜎�
3𝜎𝜎�̇ 𝐸𝐸
+ � − 1� 𝑠𝑠��
2𝜎𝜎� 𝐸𝐸� 𝐸𝐸� 𝐸𝐸� 𝐸𝐸� 𝑠𝑠 �
𝑐𝑐�� = 3 − (1 − 2𝑣𝑣) + 9 �1 − � � (6f)
According to the Deformation theory (DT):
𝐸𝐸� 𝐸𝐸 𝐸𝐸� 𝜎𝜎�

3𝐸𝐸 1 − 2𝑣𝑣 1 − 2𝑣𝑣 Let 𝜎𝜎� = −𝑝𝑝, 𝜎𝜎� = −𝑞𝑞, 𝜏𝜏�� = −𝑠𝑠 at the point of bifurcation.
𝐸𝐸𝜀𝜀̇�� = � + � 𝑠𝑠̇�� + � � 𝜎𝜎̇�� 𝛿𝛿��
2𝐸𝐸� 2 3 Assuming that the material is in a state of plane stress i.e.
(3)
3𝜎𝜎�̇ 𝐸𝐸 𝐸𝐸 𝜎𝜎� = 𝜏𝜏�� = 𝜏𝜏�� =0, the effective stress 𝜎𝜎� can be expressed
+ � − � 𝑠𝑠 as:
2𝜎𝜎� 𝐸𝐸� 𝐸𝐸� ��
𝜎𝜎� � = 𝜎𝜎�� − 𝜎𝜎� 𝜎𝜎� + 𝜎𝜎�� + 3𝜏𝜏��
� (7)
Where:
𝜀𝜀̇�� is the change in strain and 𝑖𝑖 𝑎𝑎𝑎𝑎𝑎𝑎 𝑗𝑗 = 1,2 or 3
𝜎𝜎̇�� is the change in stress
𝜎𝜎�̇ is the change in the effective stress G. H. Handelman and W. Prager [10] carried out serval
𝑣𝑣 poison ratio experiments focusing on the plastic deformation analysis of a
𝐸𝐸� is tangent modulus material (plate under compressive load) in order to assess the
𝐸𝐸� = 𝜎𝜎� ⁄𝜀𝜀̅ difference between the IT and DT. They observed that their
𝑠𝑠̇�� is the stress deviator tensor given by: results obtained by DT were in good agreement with the
𝐼𝐼 experimental results. Based on studies carried out by
𝑠𝑠�� = 𝜎𝜎�� − 𝛿𝛿�� Handelman the present study only focused on using DT.
3
By further manipulating the above equation, the stress rate The basic integral of uniqueness of a material under
corresponding to the strain rate in the can be expressed as: deformation is given by the strain energy function given by
𝜎𝜎̇� 𝛼𝛼 𝛽𝛽 𝒳𝒳 𝜀𝜀̇� Chakrabarty [8] as:
� 𝜎𝜎̇� � = 𝐸𝐸 � 𝛽𝛽 𝛾𝛾 𝜇𝜇 � � 𝜀𝜀̇� � (4)
𝜏𝜏̇ �� 𝒳𝒳 𝜇𝜇 𝛿𝛿 𝛾𝛾̇��
Where The corresponding parameters 𝛼𝛼, 𝛽𝛽, 𝛾𝛾, 𝛿𝛿, 𝜇𝜇, 𝒳𝒳 depend on the type of 1
plasticity theory used i.e. IT or DT and 𝐸𝐸 is the Young modulus. 𝑈𝑈 = ��𝜎𝜎̇� 𝜀𝜀̇� + 𝜎𝜎̇� 𝜀𝜀̇� + 𝜏𝜏̇�� 𝛾𝛾̇�� �𝑑𝑑𝑑𝑑 (8)
1 2
𝛼𝛼 = (𝑐𝑐 𝑐𝑐 − 𝑐𝑐��� ) (5a) The potential energy V for the material subjected to uniform
𝜌𝜌 �� �� in-plane compressive stresses is given as:
1 1 𝜕𝜕𝜕𝜕 � 𝜕𝜕𝜕𝜕 �
𝛽𝛽 = (𝑐𝑐�� 𝑐𝑐�� − 𝑐𝑐�� 𝑐𝑐�� ) (5b) − � �𝜎𝜎� ℎ � � + 𝜎𝜎� ℎ � �
𝜌𝜌 2 𝜕𝜕𝜕𝜕 𝜕𝜕𝜕𝜕
1 (9)
� ) 𝜕𝜕𝜕𝜕 𝜕𝜕𝜕𝜕
𝛾𝛾 = (𝑐𝑐�� 𝑐𝑐�� − 𝑐𝑐�� (5c) + 2𝜏𝜏�� ℎ � � � �� 𝑑𝑑𝑑𝑑
𝜌𝜌 𝜕𝜕𝜕𝜕 𝜕𝜕𝜕𝜕
1
𝒳𝒳 = (𝑐𝑐�� 𝑐𝑐�� − 𝑐𝑐�� 𝑐𝑐�� ) (5d)
𝜌𝜌 By using calculus of variation, Solid Works is able to use the
1 Euler-Lagrange differential equations associated with the
𝜇𝜇 = (𝑐𝑐�� 𝑐𝑐�� − 𝑐𝑐�� 𝑐𝑐�� ) (5e)
minimization of the total potential energy functional with
𝜌𝜌
1 respect to the arbitrary variation of the displacement function
� )
𝛿𝛿 = (𝑐𝑐�� 𝑐𝑐�� − 𝑐𝑐�� (5f) w, which is given by:
𝜌𝜌
𝑐𝑐 𝑐𝑐 𝑐𝑐 δ(U+V)=0 (10)
𝐸𝐸 �� �� ��
𝜌𝜌 = �𝑐𝑐�� 𝑐𝑐�� 𝑐𝑐�� � (5g)
𝐸𝐸� 𝑐𝑐
�� 𝑐𝑐�� 𝑐𝑐�� The aggregate crushing value is calculated by the following
According to the deformation theory: equation:
Aggregate crushing value % = B/A×100 (11)
𝐸𝐸� 𝑞𝑞� 𝑠𝑠 �
𝑐𝑐�� = 1 − 3 �1 − � � � + �� (6a)
𝐸𝐸� 4𝜎𝜎� 𝜎𝜎� Where:
1 𝐸𝐸� A= mass of surface dry sample
𝑐𝑐�� = − �1 − (1 − 2𝑣𝑣) B=the mass of the fraction passing the 2,36mm BS sieve
2 𝐸𝐸
(6b) load is determined by:
𝐸𝐸� 𝑝𝑝𝑝𝑝 𝑠𝑠 �
− 3 �1 − � � � + � �� L=(14L_1)/(P+4) (12)
𝐸𝐸� 2𝜎𝜎� 𝜎𝜎�
3 𝐸𝐸� 2𝑝𝑝 − 𝑞𝑞 𝑠𝑠 Where:
𝑐𝑐�� = �1 − � � � (6c)
2 𝐸𝐸� 𝜎𝜎� 𝜎𝜎� L = load to give percentage fines within the range 7.5 to
𝐸𝐸� 𝑝𝑝� 𝑠𝑠 � 12.5%
𝑐𝑐�� = 1 − 3 �1 − � � � + � � (6d) L1 = first test load
𝐸𝐸� 4𝜎𝜎� 𝜎𝜎�
P = percentage fines obtained with the first load
862 Tauyanashe Chikuku et al. / Procedia CIRP 91 (2020) 858–863
Chikuku et al./ Procedia CIRP 00 (2020) 000–000 5

In the case of this design, the flywheel is directly attached to bottom of the jaws. The ores are fed to the machine from the
the crank therefore the input torque is a product of the crank top where the jaws are at the maximum distance apart. As the
force and the radius of the flywheel. An average human person jaws come closer the ores are crushed into smaller sizes and slip
can easily rotate a crank of radius 0.35m with radius of flywheel down the cavity in the return stroke. In following cycle, further
0.4m to give allowance to screw on the handle. reduction of size is experienced and the ore moves down
further. The process is continued till particles size is reduced to
The energy stored in a flywheel is calculated by [5]: less than the bottom opening. The toggle is used to guide the
moving jaw. The retrieving motion of the jaw from its furthest
∆𝐸𝐸 = 𝑚𝑚𝑅𝑅 � 𝜔𝜔 � 𝐾𝐾� (13) end of travel is by springs for small crushers or by a pitman for
larger crushers. For a smooth movement of the moving jaws,
Where: heavy flywheels are used.
m=mass of flywheel
R=radius of flywheel=0.4m
𝜔𝜔=angular speed of rotation of flywheel

The gear diameter was designed considering available space

(0.5m) and the velocity ratio 2:1[5]

𝐷𝐷� + 𝐷𝐷� ≤ 0.5 (14)

Where
𝐷𝐷� =pitch diameter of pinion
𝐷𝐷� =pitch diameter of gear
Fig. 7 Sketch plan view showing mechanism for the crusher
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.
The thickness of the jaw was calculated from equation 5 [5].

𝑀𝑀𝑀𝑀
𝜎𝜎� = (15)
2𝐼𝐼�
Where:
𝑀𝑀 is the bending moment
𝑡𝑡 is the thickness of the jaw
𝐼𝐼� second moment of inertia

6. Design

6.1. Operating and principle in detail

Fig. 8. Exposed (a)Side view (b) Plan (c) Isometric view
The mechanism of jaw crusher is to crush using impact on
the upper parts of the jaw, with a little shear towards the bottom. The flywheels have crank handles as was with the original
Jaw crushers consist of two jaws. One fixed and the other design however the flywheel shaft is connected to spur gears
reciprocating. The opening between them is largest at the top that transfer power to the eccentric shaft thus there are now two
(gape) and decreases towards the bottom (set). The jaw moves shafts instead of one. The ratio of the gears simply 1:2 so as to
on an eccentric shaft and the lower part is hinged on the toggles. double the torque provided by the human operator. These gears
The rock is thrown between two jaws and crushed by also further improve the smoothness of operating the crusher,
mechanical pressure. Rotational motion drives the eccentric reducing shock to the operator cranking the mechanism. This is
shaft to rotate. This makes the attached jaw to approach and because the gears have their own mass and hence inertia such
leave the other jaw repeatedly, to crush, rub and grind the feed. that once they start moving they will tend to resist motion in the
Hence the material moves gradually towards the bottom and backward direction.
finally discharges from the discharge end. The fixed jaw
mounted in a “V” alignment is the stationary breaking surface. 6.2. Stress analysis on the main gear
The swinging jaw exerts impact force on the material by forcing
it against the stationary plate. The space at the bottom of the Fig. 9 indicates a simulation done by Solid Works of the
“V” aligned jaw plates is the crusher product size gaper size of mild steel gear, stressing out the regions expressing high and
the crushed product from the jaw crusher. The rocks are crushed low amounts of stress during crushing. By assuming the gear
until they are small enough to pass through the gap at the will undergo elastic-plastic deformation (deformation theory)
 Tauyanashe Chikuku et al. / Procedia CIRP 91 (2020) 858–863 863
6 Chikuku et al./ Procedia CIRP 00 (2020) 000–000

and according to the Von-Mises failure criteria the gear will [3] Quist, J, Cone crusher modelling and simulation. Development of a virtual
experience maximum stress at the root of the gear with stresses rock crushing environment based on the discrete element method with
ranging from 6.767 to 9.473MPa. It was also observed that the industrial scale experiment validation. Goteborg, Chalmers University of
regions surrounding the key way will also experience high Technology. 2012.
stresses as a results of the high torque and resistance [4] New Dawn Engineering. (2017). Rock crushing assembly instruction
experienced during crushing. manual. Swaziland: New Dawn Engineering.
[5] Khurmi R.S, G. J., 2005. A textbook of machine design. 14th ed. New Delhi:
Eurasia Publishing House.
[6] Hurst, K., Concept selection in engineering design Principles. 1999, New
York: John Wiley and Sons, pp. 53-63.
[7] Jones, J., Stone crushing. Complexities of construction, 2012, 1(1), p. 123.
14th ed. 2004, New Delhi: Eurasia Publishing House.

[8]. Chakrabarty. Applied Plasticity,. 2010

[9] Oduori, M., Mutuli, S. and Munyasi, D. , Analysis of the single toggle jaw
crusher kinematics, Journal of Engineering, Design and Technology, 2015,
Vol. 13 No. 2, pp. 213-239.
[10] G. H. Handelman and W. Prager, “Plastic buckling of a rectangular plate
under edge thrusts,” 1949

Fig. 9 Stresses on main gear

7. Conclusions

The purpose of this paper 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. 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.

Acknowledgements

The authors wish to acknowledge the assistance from the

construction company, Design Team as well as other small sale
contractors from where the data was collected and eventual
testing of the mortar spraying machine. The researchers would
also want to appreciate the residents of Budiriro in Harare
whose homesteads and construction sites were visited. In
addition, the authors are also grateful for the financial support
provided by the Royal Academy of Engineering to promote
such innovations through conferences and publications.

References

[1] Moavenzadeh, F, Concise encyclopedia of building and Construction

Materials. Masettuses : MIT Press, 1990.
[2] Satyendra, 2015. Ispat Guru. [Online] Available at:
http://ispatguru.com/crushers-and-their-types