Professional Documents
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CHAPTER ONE
1.1. Introduction
The term "plastic", derived from the Greek word "plastikos" actually applies to any pliable
substance that can be shaped or molded, for example, wax, clay, asphalt and amber.
Most of the plastics we use today have been developed within the last 50 years or so. The majority
of them are man-made and are usually described as synthetic products, or in other words, they are
made by a process of building up from simple chemical substances.
Today's plastics are generally made by industrial chemists from various chemical compounds
derived from lime, salt, water, petroleum or coal. Their special properties are light weight; high
impact and tensile strengths; resistance to corrosion, salt water and most chemicals; suitability for
use over a wide range of temperatures and for electrical insulation. Some plastics are not fully
synthetic as they are produced simply by modifying natural materials. Examples are celluloid and
cellulose acetate, both derived from cellulose (as in cotton wool) and plastics derived from casein,
a complex protein which comes from cow's milk
Plastic is light, easy to store and transport, comes in an endless variety of textures and shapes, and
can hold almost anything. These properties make plastic attractive to manufacturers. Plastic is in
almost everything we touch. It’s used to make our clothes, cars, toys, and household products.
Many of the food, health, and beauty products we enjoy come in plastic packaging. Plastic may be
convenient for manufacturers and consumers alike, but this convenience carries a significant cost.
Plastic is made from petroleum and the production, consumption, and disposal of petroleum
products contribute significantly to global warming and a host of other environmental and human
health problems.
Plastics are complex chemical compounds with thousands of different varieties, and therefore
much more difficult to recycle than simpler materials like glass, aluminum, or paper. In order for
plastic to be recycled, it must be collected, sorted by exact type, kept clean, processed, and
delivered to a manufacturer that has the intention and capacity to use the material to make a new
product.
Plastic bottles have specific manufacturing and performance advantages over other packaging
materials like aluminum, steel and glass that have helped plastics expand their market share of
packaging materials. Without question, plastic bottles have come a long way since their first
commercial uses in the late 1940’s. The introduction of high-density polyethylene (HDPE) and
polyethylene terephthalate (PET) polymers expanded plastic bottling applications. Plastics then
surpassed glass as the go-to packaging choice for a wide array of products and brands. The
importance of plastic bottles is unquestioned.
However, while plastics are “the workhorse material of the modern economy,” the material has
drawbacks. After use almost all plastic products become litter generating significant economic
costs (and losses) while negatively impacting natural systems like the oceans and contributing to
unsightly litter that can negatively affect tourism. They also play the main role in affecting the
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environmental hygiene and soil fertility. Thy are also causes of air pollution when burnt since they
are complex chemical compounds.
Plastic bottles and jars represent approximately 75 percent of all plastic containers, by weight.
While PET and high-density polyethylene (HDPE) represent approximately 86 percent of the
plastic container market and are able to serve the bottling needs of most products on the market
today, other types of plastics, including bioplastics and recycled plastics, are used for
a wide range of bottling and packaging needs in a variety of industries, and are recyclable.
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1.4. Methodology
By collecting, cleaning, sorting, size reduction, and finally feeding the shredded plastic flakes
to one of the machines.
By comparing different materials using specific criteria. Weighted method is used.
By checking the strength of different components of the machine and using optimum safety
factor.
By using locally available and low cost materials as much as possible.
By collecting waste plastic materials from the surrounding and using for the recycling
process.
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CHAPTER TWO
LITERATURE REVIEW
[1] AlirezaAkbarzadeh and Mohammad Sadeghi”Parameter Study in Plastic Injection Molding
Process using Statistical Methods and IWO Algorithm” International Journal of Modeling and
Optimization, Vol. 1, No. 2, June 2011 pp-141 Dimensional changes because of shrinkage is one
of the most important problems in production of plastic parts using injection molding. In this study,
effect of injection molding parameters on the shrinkage in polypropylene (PP) and polystyrene
(PS) is investigated. The relationship between input and output of the process is studied using
regression method and Analysis of Variance (ANOVA) technique. To do this, existing data is used.
The selected input parameters are melting temperature, injection pressure, packing pressure and
packing time. Effect of these parameters on the shrinkage of above mentioned materials is studied
using mathematical modelling. For modelling the process, different types of regression equations
including linear polynomial, Quadratic polynomial and logarithmic function, are used to
interpolate experiment data
[2]Prof. S. B. Khedkar1, Prof. R. D. Thakre2, Prof. Y. V. Mahantare3, Mr. Ravi Gondne4 “Study
of Implementing 5S Techniques in Plastic Moulding” International Journal of Modern
Engineering Research (IJMER) Vol.2, Issue.5, Sep.-Oct. 2012 pp- 3653-3656.It will impact the
instructors and workman of Industry that work within the selected place. By following the 5S
methodology, this research effort may show significant improvements to safety, productivity,
efficiency, and housekeeping. The research documents improvements by using before and after
pictures. It also intends to build a stronger work ethic within the workman and engineer who would
be expected to continue the good practices.
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20th century, it was impossible to obtain sufficient quantities of the necessary raw materials to
make chemicals for the new products.
It was in 1862 that the first synthetic plastic material was introduced to the public. It was shown
at the Great International Exhibition, London, by Alexander Parkes. The new product was then
called "Parkesine" and had been made by mixing camphor (the chemical used in mothballs) with
nitrocellulose (used in many modern lacquers for motor car bodies).
However, the same discovery was made some years later by an American, John Hyatt who
christened the new material "celluloid". His incentive was a prize from a billiard ball maker to find
a substitute for ivory. What he discovered, celluloid, made lousy billiard balls, but great table
tennis balls. He did not win the prize. Celluloid enabled the movie industry to boom, for it was the
first material which could be imprinted with an image, and yet be flexible enough to feed through
a movie projector. It had a serious drawback however, and that was its flammability, the reason
many old theatres went up in flames. Along with other cellulose nitrates, celluloid was also used
to make, denture plates, shirt collars and cuffs, and car windows.
Gradually, appreciation of the uses of the results of scientific research increased as did people's
need for more goods, and of course more chemicals, steel and power to make them. Laboratories,
regarded for so long as eccentric curiosities, were at last recognized as being useful to society. It
was also realized that many new chemicals could be produced from what was merely waste residue
from other industrial processes.
It was this change in people's attitudes towards science and manufacturing that really paved the
way for the development of plastics on a commercial scale.
In 1909 came the next major advance with the introduction of phenol-formaldehyde, more
commonly known as "Bakelite" after its discoverer, Dr. Leo Henrik Baekeland, a Belgian working
in the United States.
The tempo of plastics development accelerated rapidly from this time onwards. Each decade saw
the introduction of several new varieties of plastics:
1920-21 urea-formaldehyde and the vinyl, polyvinyl chloride (PVC);
1931-40 the acrylics, polyvinyl acetate (PVA), nylon, polystyrene, melamine formaldehyde;
1941-50 polyesters, polyethylene (polythene), silicones, epoxy, acrylonitrile butadiene, styrene
(ABS);
1951-60 polyurethane, polypropylene.
Since 1960 many new and more specialized plastics have been developed and the list continues to
grow, until today there are many different "families" of plastics, each with numerous members.
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CHAPTER THREE
PRODUCT PLANNING
3.1. Products of the Recycling Process
The three machines have different mechanisms, hence different outputs. Some of the products of
this recycling processes are:
Handles
Plant buckets
Fruit bowls
Drawing boards
Hats
Lamp sheds
Boxes
Filaments
Raw materials for 3D printing machines.
Plates and different materials based on the molds in use.
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Power supply
Hopper
Shredder part
Frame work
Shredding part: shreds the plastic waste and turn into tiny flakes. It can rotate in both directions
if plastic get stuck it can be turned the other way around.
Power supply: the power supply consists of motor and gear train mechanism for speed and
direction control. The motor should be slow and powerful.
Frame work: the frame work provide support for the entire shredding machine. It also has space
for the placement of bucket under the shredding part.
Hopper: it is where the plastic waste goes into the machine. It provides guide for the plastic
waste and also as a protective body to cover the shredding blades.
Bucket: it is used to store the plastic flakes coming out of the shredder.
Filter mesh: the mesh determines the size of the output flakes. Do know that the smaller the
output wanted to be the more energy and time it takes.
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(Labelled plastic
flakes)
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Hopper
Barrel
Barrel holder
Nozzle
Frame work
Electronic unit
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Barrel: this is where the shredded plastic flakes get heated and compressed.
Nozzle: this is where the output of the process can be controlled. It is screwed on the barrel and
should be screwed tight. It is where the plastic gets injected in the mold.
Electronic unit: used to control the temperature of injection inside the barrel based on the
desired output.
Handle
Electronic unit
Hopper
Barrel
Frame work
Nozzle
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Handles
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Oven
Electronic unit
Car jack
Frame work
Drawing boards
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Trash cans
Solid blocks
Fruit bowls
Step one: Sorting the plastic waste materials according to their types.
Step Three: Washing shredded plastic wastes to remove remaining products and contaminants.
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Step Five: Feeding the shredded plastic wastes to one of the three machines (injection, extrusion,
or compression) based on the desired output.
Drawing boards
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The angled teeth engage more gradually than do spur gear teeth causing them to run more
smoothly and quietly
Helical gears are highly durable and are ideal for high load applications.
At any given time their load is distributed over several teeth, resulting in less wear
Efficiency of helical gear is less because helical gear trains have sliding contacts between the
teeth which in turns produce axial thrust of gear shafts and generate more heat.
The characteristics of Bevel Gear
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Design criteria Weight Spur gear Helical gear Bevel gear Worm gear
Score Weight Score weight Score weight Score Weight
Rank 1 2 3 4
Therefore, according to the solution principle computed on the above table spur gear type is
selected.
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Therefore, according to the solution principle computed on the above table solid with stepped
type is selected.
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Rank 1 2
Therefore, according to the solution principle computed on the above table rolling contact bearing type is
selected
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Nitro Alloy
Design Cast iron Aluminum
Weight Steel
criteria
Score Weight Score Weight Score Weight
Strength 0.2 9 1.8 10 2 6 1.3
Availability 0.15 9 1.35 8 1.2 10 1.5
Reliability 0.35 10 3.5 9 3.15 5 1.75
Power
0.15 9 1.35 9 1.35 7 1.05
transmission
Cost 0.15 8 1.2 6 0.9 10 1.5
Total 9.2 8.6 7.1
Rank 1 2 3
Therefore, according to the above table Nitro alloy steel is better, so it is selected.
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Therefore, the most widely used material AISI 52100 steel is selected.
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𝑇𝑃 = 13
𝑇𝐺 = 𝐺 × 𝑇𝑃 = 13 4 = 52
𝐷𝑃+𝐷𝐺 𝐷𝑃+4𝐷𝑃
L= = = 2.5𝐷𝑃 ,
2 2
105mm = 2.5𝐷𝑃
𝐷𝑃 = 42mm = 1.65in and 𝐷𝐺 = 4 𝐷𝑃 168mm = 6.61in
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Since the nearest standard value of the module is 3mm, therefore we shall take it.
𝐵
𝐴+√𝑉
𝐾𝑉 = ( )
𝐴
2⁄ 2⁄
A = 50+56(1-B), B = 0.25(12 − 𝑄𝑉 ) 3 = 0.25(12 − 6) 3 0.8255
A = 50+56(1-0.8255) = 59.77
𝐵 0.8255
𝐴+√𝑉 59.77+√51.84
𝐾𝑉 = ( ) =( ) = 1.098
𝐴 59.77
Reliability Factor: 𝑲𝑹
Assume: reliability R = 95%
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q=1
Ncp = 60 L 𝑁𝑃
𝑁𝑐𝑝 2.16×108
𝐺 4
(𝑌𝑁 )P = 1.3558Ncp-0.0178 = 1.3558( -0.0178
= 0.963
(𝑌𝑁 )G = 1.3558Ncg-0.0178 = 1.3558( -0.0178
= 0.988
(𝑍𝑁 )P = 1.4488Ncp-0.023 = 1.4488 ( -0.023
= 0.932
(𝑌𝑁 )G = 1.4488Ncg-0.023 = 1.4488( -0.023
= 0.962
Size Factor: 𝑲𝑺
SC = 170000psi, CP = 2300√𝑝𝑠𝑖
KmKb KtKr
(F)bend = n𝑊𝑡 K o K v K s 𝑃 × S ×Y
Jp t N
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1.236×1 1×0.885
= 2× 318.4 × 1 × 1.098 × 1.12 × 4 × 40314×0.963 = 0.36in
0.24
CP ZN 2 KmCf Np 14
(F)wear = (S ) nWt K o K v K s , dp = 𝑃 = 1.86 = 8.1
C KT KR dp 𝐼 𝑑
2300×0.932 2 1.236×1
= (170000×1×0.885) 2× 318.4 × 1 × 1.098 × 1.12 × 8.1×0.141 = 0.172in
Therefore, the thickness of the gear: F = 0.5in (13mm) from the standard of gear face width.
We know the normal load acting between the tooth surface, and find the normal load (WN), acting
between the tooth surfaces. It is given by
WN = WT / cos φ where
φ = Pressure angle.
𝑊𝑇 = 318.4𝑙𝑏𝑓=1416.3N
A thrust parallel and equal to WN will act at the gear center as shown in Fig.
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𝑊𝑇 = 318.4𝑙𝑏𝑓=1416.3N
A thrust parallel and equal to 𝑊𝑁 will act at the gear center as shown in Fig.
Since the shaft is under the combined effect of torsion and bending, therefore we shall
determine the equivalent torque. We know that equivalent torque,
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𝑊𝑅 =1534N
Assuming that the gear is overhung on the shaft and taking the overhang as 50mm, therefore
bending moment on the shaft due to the resultant load.
Let 𝑑𝑝 = diameter of pinion shaft. We know the equivalent twisting moment (𝑇𝑒 )
𝜋
𝑇𝑒 = 𝜏𝑑𝑝3 = 82265Nmm
16
16∗82265
dp3 = = 7986
𝜋∗30
dp = 19.98mm
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m = Module in mm.
Since the shaft is under the combined effect of torsion and bending, therefore we shall
determine the equivalent torque. We know that equivalent torque,
𝑊𝑅 =1534N
Assuming that the gear is overhung on the shaft and taking the overhang as 60 mm, therefore
bending moment on the shaft due to the resultant load.
Let 𝑑𝐺 = diameter of gear shaft. We know the equivalent twisting moment (𝑇𝑒 )
𝜋
𝑇𝑒 = 𝜏𝑑𝐺 3 = 141550Nmm
16
16∗141550
dG3 = = 24030
𝜋∗30
dG = 29.5mm = 30mm
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Assuming the gear operates 36hr per weak for 10 years then; Desired life, 𝑙𝑑 is
𝑙𝑑 = 10*52*36*60 = 1,123,200hr
Desired rotation speed, 𝑛𝑑 = 30𝑟𝑝𝑚.
The Weibull parameters are usually provided in the manufacturer’s catalog as follow
θ=4.459
b=1.483
The radial force acting on the bearing is calculated from the pinion force analysis
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𝑊𝑇 =1416.2N
𝜙=22.5⁰
tan𝜙=𝑊𝑁 /𝑊𝑇 where 𝑊𝑁 is the radial load
𝑊𝑁 =𝑊𝑇 * tan𝜙 =1416.3N*tan(22.5⁰)=586.5N
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And torsional shearing strength (or torque transmitted) of the shaft, of the key
𝜋
T=16 𝜏𝑑3
𝜋
1600l = 16 × 20 × (20)3 ,
l = 19.6mm= 20mm
𝑡 𝑑 𝜋
T = 𝑙 × 2 × 𝜎𝑐 × 2 = 16 𝜏𝑑 3
𝜋
𝑙 × 3.5 × 28 × 10 = 16 20 × 203 , 𝑙 = 32.5mm
Taking larger of the two values for safety, we have length of key, l = 35mm
For a shaft of 22mm diameter,
Width of key, w = 10mm and thickness of key, t = 8mm
Considering shearing of the key.
The shearing strength (or torque transmitted)
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𝑑 30
T= 𝑙 × 𝑤 × 𝜏 × 2 =𝑙 × 10 × 20 × = 3000𝑙
2
And torsional shearing strength (or torque transmitted) of the shaft, of the key
𝜋 𝜋
T=16 𝜏𝑑3 =3000l = 16 × 20 × 303 , l=35mm
𝑡 𝑑 𝜋
T=𝑙 × 2 × 𝜎𝑐 × 2 = 16 𝜏𝑑 3
𝜋
𝑙 × 4 × 28 × 15 = 16 20 × 303 , 𝑙 = 60mm
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CHAPTER FIVE
CONCLUSION
Waste materials are usually found littering all over the places in our urban cities and villages.
A Plastic Recycling Machine is therefore designed using locally sourced and available materials.
This design project is found to be very useful in absorbing the huge waste materials in our country.
This project is the Design, Analysis and Simulation with Solid Work 2016 of Plastic Recycling
Machine. All the studies in this project shows that the maximum stress occurs at the carrier
member. From the analysis of the design it is obtained that all the design of the components are
safe. And the design was a complete success.
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References
(1) AlirezaAkbarzadeh and Mohammad Sadeghi”Parameter Study in Plastic Injection
Molding Process using Statistical Methods and IWO Algorithm” International Journal of
Modeling and Optimization, Vol. 1, No. 2, June 2011 pp-141
(2) Prof. S. B. Khedkar1, Prof. R. D. Thakre2, Prof. Y. V. Mahantare3, Mr. Ravi Gondne4
“Study of Implementing 5S Techniques in Plastic Moulding” International Journal of
Modern Engineering Research (IJMER) Vol.2, Issue.5, Sep.-Oct. 2012 pp-3653-3656
(3) Poonam G. Shukla, Gaurav P. Shukla”Design& Fabrication of Pneumatically Operated
Plastic Injection Molding Machine” International Journal of Engineering and Innovative
Technology (IJEIT) Volume 2, Issue 7, January 2013 pp-98
(4) Madan Mohan Reddy .K*, Ajitha .B** and Bhavani .R”Melt-DensifiedPost Consumer
Recycled Plastic Bags Used as Light Weight Aggregate in Concrete”Madan Mohan Reddy
.K, Ajitha .B, Bhavani .R / International Journal of Engineering Research and Applications
(IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue4, July-August 2012, pp.1097-
1101.
(5) C.C. Ugoamadi, O.K. Ihesiulor,(Department of Mechanical Engineering, Michael Okpara,
University of Agriculture, Umudike, Nigeria.), Optimization of The Development of
Plastic Recycling Machine. Nigerian Journal of Technology, Vol.30, No. 3. October 2011.
(6) Prof. Kusekar S. K, Morajikar C. E, Kashid S. N, Hipparkar K. S, Deshpande V. S,
(Assistant Professor Department of Mechanical Engineering, A.G.P.I.T. Solapur,
Maharashtra, India. Student of Mechanical Engineering Department A.G.P.I.T. Solapur,
Maharashtra, India.). “Design and Development of Plastic Recycling Machine by Using
Finite Element Analysis.” International Research Journal Of Engineering and
Technology (IRJET), Volume: 2 Issue Date:02/May/2015.
(7) Esha Shah, Rajaram.“Plastic Recycling In Bangalore, India.” Waste Advisers on Urban
Environment and Development. Date: Dec 1997
BOOK REFERENCES:
- “The Finite ElementAnalysisTheory and Programming”,Krishnamoorthy C.S, Tata
McGraw-Hill, 2nd edition, 2001.
- “Design of MachineElement”,V.B..Bhandari, Tata McGraw-Hill, 3nd edition, 2007.
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