Construction Of A Simple Size Reduction Machine
The development of a size reduction machine represents a significant engineering endeavor, encompassing the intricate design and fabrication of a device aimed at diminishing the dimensions of various materials. This task involves a meticulous integration of mechanical and structural components to achieve optimal functionality. The machine’s purpose revolves around the reduction of particle sizes, necessitating the utilization of cutting-edge engineering principles. Key elements such as the cutting blades, motor system, and material feeding mechanism are carefully calibrated to ensure efficiency in the size reduction process. Precision in design and robust construction are paramount to guarantee the machine’s durability and reliability. The incorporation of advanced technologies and innovative engineering solutions further enhances the machine’s performance, underscoring its role in facilitating size reduction across diverse materials and applications.
This project (Construction Of A Simple Size Reduction Machine) It was constructed locally with the use of local materials and tools in I.M.T mechanical Engineering workshop. The various parts of the equipment were constructed separately using mild steel before finally coupled.
During the construction, the conveyors and it’s housing were first constructed. It consists of a shaft with a helical rod wound round it. the hopper was measured, out and welded from a mild steel sheet of length 320mm by 60mm with a thickness of 1mm and it has the following dimensions:-
Height of the hopper – 160mm
Upper part of the hopper – 140mm diameter
Lower part of the hopper – 100mm diameter
The conveyor was fixed into it’s housing and welded to the shaft. The grinding chamber was welded separately and coupled to the grinding discs. The pressure screw fabricated was welded to the hopper. The U – channel was joined to the base stand by are welding and the existing setup, the bearing, pulley and the manual handle were all coupled. It was filed to smoothen the sharp edge and finally painted for corrosion resistance.
After the construction work, test run was carried out using the grains of wet maize and dried maize. The result shows a greater efficiency in using wet maize.
Also, the high level of noise observed during the test run was reduced by lubricating the essential parts with grease.
PAGE
TITLE PAGE
LETTER OF TRANSMITAL
APPROVAL PAGE
DEDICATION
ACKNOWLEDGEMENT
ABSTRACT
TABLE OF CONTENTS
CHAPTER ONE
1.1 INTRODUCTION
1.2 Objective and scope of size reduction equipment.
CHAPTER TWO
LITERATURE REVIEW
2.1 Origin of size reduction
2.2 Importance of size reduction
2.3 Mechanism of size reduction
2.4 Methods of size reduction
2.5 Classification of size reduction equipment
2.6 Factors to be considered in size reduction equipment
2.7 Behaviour of particles during size reduction
2.8 Theory of crushing
2.9 Factors affecting the nature of materials to be crushed.
CHAPTER THREE
3.1 Selection of material for construction
3.12 Table of summary for the selection of materials and reason
3.2 Construction procedure
3.21 Marking out operators
3.22 Equipment used for marking out
3.3 Cutting operation
3.4 Press size requirements for cutting
3.5 Punching / drilling operation
3.6 Welding joining operation
3.7 Arc welding
3.72 Electrodes used in welding
3.73 Specification of welding electrodes
3.8 Sequence of operation
3.81 The rotating shaft and conveyor housing
3.82 Hopper
3.83 Grinding chamber
3.84 Plate gap and adjustment screw
3.85 Standing
3.86 Driven pulley / prime mover
3.87 Surface finishing and coating
3.91 Safety of the operation
3.92 Precautions
3.93 Cost evaluation
CHAPTER FOUR
4.1 Discussion
4.2 Principle of operation
4.3 Precautions
4.4 Maintenance
4.5 Recommendation
4.6 Conclusion
References
INTRODUCTION
Size reduction in any industry is a very important operation because it involves the breaking down of larges particles by means of mechanical method into smaller and finer size. It is a major process in some industries like food processing industries, plastic industries, paint and drug industries, ceramic industries, cement industries and groundnut processing industries for effective and efficient and production.
Size reduction which is a unit operation can be defined as an operation whereby bulky solid particles are reduced or broken down into smaller sizes.
Size reduction is also known as comminution (genetic name). There are different types of size reduction equipment example are crushers and grinders. Some factors are considered in the selection of these equipment. The factors are nature of material being handed, feed or particle size, cost of material and construction, size of the product and small power input per unit of product.
In size reduction, different methods are commonly used in breaking down of solids, but only four are commonly used; compression, impact, attrition or rubbing and cutting.
So, for proper involvement of the equipment in the process (its operational capability), care and maintenance is very essential. Also, safety measures or precautions should be taken when using this equipment.
1.2 OBJECTIVE / SCOPE OF SIZE REDUCTION EQUIPMENT
Its main objective is to increase the surface area of a given weight of solid. Other objectives include; increase in reactivity (chemical) of solid, improvement of solvent efficiency, easy handling of materials, for free flow of materials process equipment, permits separation of impurities by mechanical methods and increase the number (numerical strength) of the material.
Construction Of A Simple Size Reduction Machine:
Creating a simple size reduction machine can be achieved using readily available materials and basic tools. Here, we’ll outline a basic design for a simple hand-cranked shredder, suitable for reducing paper, cardboard, or thin plastic materials to smaller pieces. Please note that this design is for educational or small-scale use and may not be suitable for heavy-duty tasks.
Materials and Tools:
Materials:
Wooden boards or sheet metal for the frame and housing.
Two shafts (metal or sturdy plastic) to hold the cutting blades.
Cutting blades (metal or sturdy plastic).
Bearings or bushings for the shafts.
Hand crank or handle.
Bolts, nuts, and washers.
Hinges and a latch for the housing cover.
Screws.
Tools:
Saw (to cut wooden boards or sheet metal).
Drill and drill bits.
Screwdriver.
Wrenches.
Measuring tape.
Pencil.
Safety goggles and gloves.
Construction Steps:
Design the Frame:
Sketch out the design for your size reduction machine, considering the size and type of materials you want to shred.
Create a rectangular frame with a solid base to support the components.
Mount the Shafts:
Attach the two shafts vertically within the frame, leaving enough space between them to accommodate the cutting blades.
Use bearings or bushings to secure the shafts in place. These will allow the shafts to rotate freely.
Attach Cutting Blades:
Fix the cutting blades onto the shafts horizontally. Ensure they are evenly spaced and securely fastened.
Blades should be angled or serrated to efficiently cut materials.
Build the Housing:
Create a housing or cover for your machine using wooden boards or sheet metal.
Add a hinged door on one side and a latch to secure it. This door will allow access to the shredding chamber and keep the user safe during operation.
Install the Hand Crank:
Attach the hand crank or handle to one of the shafts on the outside of the frame.
This crank will allow you to manually rotate the blades.
Test and Adjust:
Test the machine with a small sample of the material you intend to shred.
Make any necessary adjustments to the blade alignment and spacing to ensure efficient size reduction.
Safety Measures:
Always wear safety goggles and gloves when operating the machine.
Keep hands and loose clothing away from the rotating blades.
Ensure the machine is placed on a stable surface during use.
Operation:
Insert the material to be shredded through the housing door.
Turn the hand crank to rotate the blades and shred the material.
Collect the shredded material in a container or bag placed under the machine.
Maintenance:
Regularly inspect the blades for damage or dullness and replace them as needed.
Lubricate the bearings or bushings to ensure smooth operation.
Remember that this is a basic design, and the efficiency and capacity of the machine may be limited. If you plan to work with larger volumes or tougher materials, you may need to consider a more robust design with a motorized system and safety interlocks. Additionally, always exercise caution and prioritize safety when using any machinery.