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We members of the jury and the head of department of Mechanical Engineering of Higher
Technical Teacher Traning College (HTTTC) Bambili of the University of Bamenda certify that
the DIPET I project titled: “DESIGN AND REALIZATION OF AN HDPE PLASTIC
BOTTLES CRUSHING MACHINE” has been corrected in accordance with the
recommendations of the jury.
Date………………………
Signature………………
i
ATTESTATION
We hereby declare that we are the sole author of this project. We authorize the Higher
Technical Teacher Training College (H.T.T.T.C) Bambili to lend this project to others
Institutions or to individuals for the purpose of scholarly research. We understand the nature of
plagiarism, and we are aware of the University’s policy on this. We certify this project is the fruit
of original work carried out within the HTTTC of Bambili under the supervision of
Mr.NGONGANG Ludovic.
ii
DEDICATION
To DONKENG’s family
To MEKONTSO’s family
iii
PREFACE
The goal of the Higher Technical Teachers’ Training College “HTTTC” Bambili is to
train DIPET I and DIPET II teachers for technical education. The end of this training is marked
by a written examination, a practical pedagogic examination and a research work constituting a
written project and practical realization of the prototype. The topic is proposed or chosen and
guided by the lecturer of the department concerned. The word “project” in education has
acquired a meaning which is rather different from its meaning on other fields. Perhaps one
should say that it has a family of meanings. Unless the word is being abused it will refer to a
method of learning based on problem solving and involving a great deal of participation on the
part of those carrying it out.
A project is intended to reflect “Real life” processes more closely than traditional formal
teaching. In a project as in life, a problem is encountered and recognized, after some thought
and possible discussion information is collected, organized and selected; the knowledge now
available enables solutions to be devised and tried out, after which the possible solutions can be
evaluated and a best one is selected and implemented. At this stage, a great deal may well have
been learned as a result of the “need-to-know” created by the problem, but the learning process is
not yet exhausted. The implementation of the selected solution gives the opportunity to review
alternatives, to reconsider decisions made and to think what should be done in similar situations
in the future.
iv
ACKNOWLEDGEMENTS
ACKNOWLEDGEMENT I
To GOD ALMIGHTY who guides and protects us every day. My personal effort could
not have been sufficient to achieve this study without the gathering of efforts on both sides of
various actors, who far or near have participated academically, professionally, financially, and
materially than purely moral and even spiritual.
I extend my gratitude to:
Professor AKUME Daniel AKUME Director of HTTTC, for accepting me in this
precious institution whose he is in charge.
My supervisor Mr. NGONGANG Ludovic, for his assistance and orientations that had a
capital contribution on the accomplishment of this dissertation.
Prof. KANAA Thomas, head of department of mechanical engineering for his advices
The lecturers of the department Mr. WOUMO Jean-Marie , Mr. BECHING ORU Roland,
Engr.YISAAlbert and the entire staff members of HTTTC Bambili for the supervision
and the teaching that had a capital contribution to my training.
My classmates for the interaction, peace, and the search of knowledge that was at the
center of our preoccupation within the years spent in HTTTC of Bambili.
My mother Mme DEMANOU ELISE who supported me morally and materially.
My father Mr DONKENG EMILE who supported me morally and materially.
My brothers and my my brothers and sisters who put me up during this study and
supported me morally.
v
ACKNOWLEDGEMENT II
The achievement of my training until now and this project has been done successfully by the
participation of many people; I heartily express my gratitude to:
Professor AKUME Daniel AKUME Director of HTTTC, for accepting me in this
precious institution whose he is in charge.
My supervisor Mr. NGONGANG Ludovic, for his assistance and orientations that had a
capital contribution on the accomplishment of this dissertation.
Prof. KANAA Thomas, head of department of mechanical engineering for his advices
The lecturers of the department Mr. WOUMO Jean-Marie , Mr. BECHING ORU Roland,
Engr.YISA Albert and the entire staff members of HTTTC Bambili for the supervision
and the teaching that had a capital contribution to my training.
My parents BOGNE Gabriel and DJUIDJE Elodie for their moral and financial support.
My brothers and sisters for their supports.
My husband MEKONSTO Romeo Bovarice for his love, endurance, morality and
financial support.
Babies MEKONTSO Hilda and MEKONTSO Priscille for their endurance.
Mother MEWABO Marthe for her advices
My grand mother MEDJOM Marie for her support
Family MENO specially MENO Edmond, MENO Carlos and MENO Horace
My classmates for the interaction, peace, and the search of knowledge that was at the
center of our preoccupation within the years spent in HTTTC of Bambili.
vi
ACKNOWLEDGEMENT III
This project could not have been successfully carried out without the cooperation and
Assistance of many people,it is for me an honor to thank:
vii
ABSTRACT
The project of end of study for the first cycle entitled ‘‘DESIGN AND REALIZATION
OF THE HDPE PLASTIC BOTTLES CRUSHED MACHINE” is not a new invention in the
sense that it already exists in Europe. Being given that we do not find any in our country and
local communities, considering the degree of pollution of plastic wastes in environment, we
thought of a partial innovation which is that to manufacture this machine usable in our
surrounding. We cannot destroy those plastic wastes because the combustion of these plastics
releases environment while destroying the atmosphere and by throwing them, they flee in the
ground creating losses in vegetation thus due to their very long lifespan. The only means of
avoiding all these harmful consequences on our environment is to recycle this plastic wastes; this
is why we decided conceive a machine which will be able to crush this waste in granulated form.
These plastic granules could be used in other field such as extrusion, the injection, etc; which
will allow to limit the loads of pollution, to avoid too much importation, to make economy. Thus
while taking account of the factors time, mobility, cost, maintenance, quality of the product, we
decided to do an crushing machine with one shaft and this machine has and reducing motor of
adjustable velocity; the machine function well with an angular velocity between 50 to 60 rpm,
having this datas we had calculated the power of the motor which is 2259.544 W. The machine is
capable to bring out 10 L of granules in 15 minutes.
viii
RESUME
Le projet de fin d'étude du premier cycle ``CONCEPTION ET REALISATION D’UNE
MACHINE A BROYER LES BOUTEILLES PLASTICS PEHD" n'est pas une nouvelle
invention dans le sens qu'il existe déjà en Europe. Étant donné que nous n'en trouvons pas dans
notre pays et communautés locales, vu le degré de pollution des pertes en plastique dans
l'environnement, nous avons pensé à une innovation partielle qui est celle de fabriquer cette
machine utilisable dans notre entourage. Nous ne pouvons pas détruire ces déchets en plastique
parce que la combustion de ces plastiques pollue l'environnement tout en détruisant
l'atmosphère et en les jetant, ils s’enfuient dans le sol créant ainsi des pertes en végétation dû à
leur durée de vie très longue. Les seuls moyens d'éviter toutes ces conséquences nocives sur
notre environnement est de réutiliser ces déchets; c'est pourquoi nous avons décidé de réaliser
une machine capable de broyer ces déchets sous forme granulée. Ces granules de plastique
pourraient être employés dans d'autre domaine tel que l'extrusion, l'injection, etc... Ce qui
permettra de limiter les charges de la pollution, d’éviter trop d'importation et d’augmenter
l'économie financière du pays. Ainsi en tenant compte des facteurs temps, mobilité, coût,
maintenance, qualité du produit, nous sommes parvenu à une broyeuse comportant un arbre;
cette machine possède un moteur reducteur de vitesse réglable; la machine fonctionne bien avec
une vitesse angulaire comprise entre 50 et 60 rpm, ayant ces données, nous avons calculé la
puissance du moteur qui est 2259.544 W. Cette machine est capable de produit 10 l de granules
en 15 minutes.
ix
TABLE OF CONTENTS
CERTIFICATION ............................................................................................................................................................... i
ATTESTATION ................................................................................................................................................................ ii
PREFACE ....................................................................................................................................................................... iv
ACKNOWLEDGEMENTS ................................................................................................................................................. v
ACKNOWLEDGEMENT I ................................................................................................................................................. v
ACKNOWLEDGEMENT II ............................................................................................................................................... vi
ABSTRACT ....................................................................................................................................................................viii
RESUME ........................................................................................................................................................................ ix
LIST OF ABBREVIATIONS...............................................................................................................................................xv
I.1.1-Definition...................................................................................................................................... 1
I.1.2-History and origins of plastics ...................................................................................................... 1
I.2-ORIGIN OF PLASTICS ............................................................................................................................................ 1
I.5.1-Production .................................................................................................................................... 5
x
I.5.2-Use of plastics .............................................................................................................................. 6
I.6-POLLUTION BY PLASTICS ...................................................................................................................................... 6
II.1.1-Functioning.................................................................................................................................. 9
CHAPTER II: PROPOSED SOLUTIONS AND CRITICAL ANALYSIS ...................................................................................... 9
II.2.1-Functioning................................................................................................................................ 10
II.2.2- Critical analysis ......................................................................................................................... 11
II.3-SOLUTION3: CRUSHING MACHINE WITH ONE SHAFT ...................................................................................... 11
II.3.1-Functioning................................................................................................................................ 11
II.3.2- Critical analysis ......................................................................................................................... 12
II.4-SOLUTION4: CRUSHING MACHINE WITH BLADE ON ITS SHAFT ....................................................................... 13
II.4.1-Functioning................................................................................................................................ 13
II.4.2- Critical analysis ......................................................................................................................... 14
II.5- PRESENTATION AND USE OF THE DATA OBTAINED ......................................................................................... 14
IV.1- INTRODUCTION............................................................................................................................................... 27
The manufacturing analysis will be presented following the steps below: ....................................... 27
xi
CHAPTER IV: MANUFACTURING ANALYSIS ................................................................................................................. 27
IV.5-CONCLUSION ................................................................................................................................................... 43
CHAPTER V: USER MANUAL, COST ESTIMATE OF THE MACHINE, SUMAMARY AND GENERAL CONCLUSION ........... 44
REFERENCES ................................................................................................................................................................ 46
APPENDICES ................................................................................................................................................................ 48
xii
LIST OF FIGURES
Figure 1: Clothe button................................................................................................................................................. 1
Figure 2: celluloid ........................................................................................................................................................ 2
Figure 3: wheel (rubber)............................................................................................................................................... 2
Figure 4: polypropylene................................................................................................................................................ 2
Figure 5: Diagram of the production of plastic ............................................................................................................ 3
Figure 6 : A)pollution of water with plastics b)plastic is eating by an aquatic animal c)location of the Plastic Vortex
...................................................................................................................................................................................... 7
Figure 7: pollution of the environment by plastic bottles in Douala ............................................................................ 8
Figure 8: Kinematic diagram of the crushing machine with three shafts ..................................................................... 9
Figure 9: Kinematic diagram of the crushing machine with two shafts ..................................................................... 10
Figure 10: Kinematic diagram of the crushing machine with one shaft ..................................................................... 12
Figure 11: Kinematic diagram of the crushing machine with blade........................................................................... 13
Figure 12: Free body diagram.................................................................................................................................... 16
Figure 13: Free body diagram.................................................................................................................................... 18
xiii
LIST OF TABLES
Tableau 1 : Some thermosetting plastics....................................................................................................................... 4
Tableau 2: Some thermoplastic ..................................................................................................................................... 5
Tableau 3: level of the production of plastics in the world [8] ..................................................................................... 6
Tableau 4: level of the production of plastics in Cameroon [10] ................................................................................. 6
Tableau 5: Nomenclature of the kinematic diagram of the crushing machine with three shafts .................................. 9
Tableau 6: Nomenclature of the kinematic diagram of the crushing machine with two shafts ................................... 11
Tableau 7: Nomenclature of the kinematic diagram of the crushing machine with one shaft .................................... 12
Tableau 8: Nomenclature of the kinematic diagram of the crushing machine with blade .......................................... 13
Tableau 9: Table of elementary surfaces .................................................................................................................... 30
Tableau 10: TABLE OF ELEMENTARY OPERATIONS ............................................................................................ 31
Tableau 11: TABLE OF ASSOCIATION OF SURFACES .......................................................................................... 32
Tableau 12: TABLE OF MACHINING RESTRICTIONS ............................................................................................ 33
Tableau 13: TABLE OF MACHINING LEVELS ..................................................................................................... 34
Tableau 14: TABLE FOR GROUPING OF PHASES ................................................................................................. 35
Tableau 15: DRAFT OF MACHINING SEQUENCE ................................................................................................. 36
Tableau 16: TABLE OF PHASE 10 ............................................................................................................................ 37
Tableau 17: TABLE OF PHASE 20 ............................................................................................................................ 38
Tableau 18: TABLE OF PHASE 30 ............................................................................................................................ 39
Tableau 19: TABLE OF PHASE 40 ............................................................................................................................ 40
Tableau 20: TABLE OF PHASE 50 ............................................................................................................................ 41
Tableau 21: TABLE OF PHASE 60 ............................................................................................................................ 42
xiv
LIST OF ABBREVIATIONS
Ref: reference
σmax: maximum normal stress
HDPE: high density polyethylene
Fc: cutting force
S: Cross section of the HDPE bottle plastic
MPa: Mega Pascal
⃗ : Linear acceleration
Ӫ : Angular acceleration
:Shear strain
: Bending moment
: Practical elastic resistance
: Quadratic moment
: Elastic resistance
: The side of the square part on the shaft
N: Newton
Nbr: Number
C: safety factor
Hm: average height of the bottle
Lm: average length of the bottle
l: width of the bottle
t: thickness of HDPE plastic bottle
rpm: revolution per minute
m: metter
ρ: density of HDPE bottle
υ: poisson ratio
HYSACAM: Hygiène et Salubrité du Cameroon
xv
CHAPTER I: GENERALITIES ON PLASTICS
I.2-ORIGIN OF PLASTICS
I.2.1-Animal origin
Casein which is a protein from milk is hardening to obtain galalithe which is a
thermosetting plastic; it was used to manufacture clothe button…
1
I.2.2-Vegetal origin
In the past, plastic was form using artisanal method:
-Celluloid was the first artificial plastic it is constituted of Cellulose which is a principal vegetal
component; it was used to produce billiard and tennis balls…
FIGURE 2: CELLULOID
-Latex from hevea and dandelion was used to produce rubber which is an elastic plastic; this
rubber was used to manufacture wheel…
-Maize was used to produce polypropylene which permits to manufacture yogurt cups, margarine
tubes…
FIGURE 4: POLYPROPYLENE
I.2.3-Natural origin
It represents 90% in the production of plastic. Nowadays with the industrialization,
Petroleum, charcoal and natural gas which are all natural, they are used to produce plastic such
as PVC, polypropylene, polystyrene, polyethylene… We can then say that petroleum (55%),
charcoal (35%) and natural gas (10%) are the essential origin of plastics [2].
2
I.3-OBTENTION MODE OF PLASTICS
Most modern plastics are derived from natural materials such as petroleum, charcoal and
natural gas. Starting from the process of petroleum refining (separating process by distillation of
its different components) from which we can obtain gas, naphta, super etc; Using naphtha which
is a liquid composed of hydrocarbon, we then transform it by cracking process (thermal process
which permit to split hydrocarbons in different molecules of lower sizes) to obtain monomers
such as: ethylene, propylene, benzene, styrene and others. Those molecules in certain conditions
of temperature and pressure by chemical reaction called polymerization will form the polymers
(molecules of highest sizes) such as polyethylene, polypropylene polystyrene….; a whole of
polymers must then form a plastic. To improve the chemical and physical properties (elasticity,
hardness…), we add an additive or adjuvant [3]. We can simplify all these stages by this
diagram:
POLYMERISATION
PLASTICS ADDITIVES POLYMERS
I.4-FAMILIES OF PLASTICS
The nature of polymers and the way in which they will be arranged will control the
properties of the plastic. We can then classify plastic into three families: thermosetting,
thermoplastics and elastomers.
I.4.1-Thermosetting plastics
These are plastics that soften when heated, and can be moulded when soft, and when cool
they will set into the moulded shape. But if heat is reapplied they will not soften again, they are
permanently in the shape that they have been moulded into. They are characterized by: their
resistance to heat, their non potentiality of recycling, and their destruction without melting when
raising the temperature [4]. Examples of thermosetting plastics are:
3
T ABLEAU 1 : S OME THERMOSETTING PLASTICS
I.4.2-Thermoplastics
These are plastics that can be softened and formed using heat, and when cool, they will take up
the shape that they have been formed into. But if heat is reapplied they will soften again. They are
characterized by: they become soft when they are heated and become back hard while cooling, they can
be melted again after use and reorganized several time, they are potentially recyclable [5]. Some
examples of thermoplastics are shown in table 2.
I.4.3-Elastomers
Elastomers are plastics which are deformed and tend to take their initial positions and
support high deformation before break. From latex of hevea, the natural rubber is stay the sole
elastomer known but the modern method of manufacturing permit to obtain high diversity of
materials by adding additives, accelerator,… [6]
4
T ABLEAU 2: S OME THERMOPLASTIC
5
T ABLEAU 3: LEVEL OF THE PRODUCTION OF PLASTICS IN THE WORLD [8]
Years Quantities ( millions of tons)
2009 250
2011 280
2012 288
2013 299
2014 311
2009 83358
2010 94171.59
2011 92333.46
2012 97836.46
2013 105132.08
I.5.2-Use of plastics
When we compare two photographs of classes at approximately hundred years of
interval, we see that actually, our classrooms are composed mainly of plastic: computer, cases,
pens, bags… Plastics are everywhere; our life will not exist without them.
Billion packing are distributed each year, representing more than 15000 tons of wastes
which are not recycled according to a study undertaken by TerraEco in France. In Cameroon the
figures are less known. But the scale of the wastes observed in the drains, the household refuse
and in certain large axis, lets us to note the simply immensity of the utilization. A true wasting to
which each individual takes share! A pollution on the scale of planet, ground to oceans [11].
I.6-POLLUTION BY PLASTICS
I.6.1- In the world
Every year in Europe, approximately 100 kilos of plastics are thrown per capita. These
plastics are everywhere: teeth brush, bags, packing, and bottles. The problem of the plastics is
often their single use; it is the case for example of a packing of cake which is open then at once
thrown. Once in nature, the plastic can put until 600 years for decomposition [12].
6
The plastics come from the store of trade where they are used to pack everything including
food. The specialists in environment estimate that there is more than 15000 tons of non recycled
waste, that is to say an average from 500 to 1000 millions of plastic parking per year in the world
[13]. If the plastic is not reused, it often finishes rejected in the ocean.
A) B)
C)
I.6.2- In Cameroon
In Cameroon, the annual production of the plastic wastes in the industrial sector would be
15 250 tons, In Douala, its economic capital, it would be 4000 tons [17].
HYSACAM estimates that, on 700 tons of collected wastes every day, 14 tons are non-
biodegradable wastes. Dr. JULES MARIE KEMAJOU, geographer declares that of the
14 tons of the non-biodegradable waste collected by HYSACAM per day, 05 are empty
plastic bottles [18].
An environmentalist affirms also that: 20 milliard of tons of every type of waste are
flown into the ocean every year [19].
Assuming that the plastics take more than 400 years for decomposition whereas their
utilization period is extremely short of about 20 minutes, the statistics are showing that
more than 200 000 ha of ground lost each year it is caused by the plastics because the
hundreds of millions of the plastic waste flood our cities and villages by failing their
way in water and under the ground which pollute our environment. Those plastic wastes
have many disastrous consequences such as: obstruction of the hydraulic channels, total
reduction of the effort of cleaning out of gutters while causing floods...; in spite of those
consequences, the destruction of plastic wastes is not without incidence on the
environment: the combustion produces greenhouse gases which can make disappear the
vegetation, produces acidification of the atmosphere and the photochemical oxidations
[20].
7
FIGURE 7: POLLUTION OF THE ENVIRONMENT BY PLASTIC BOTTLES IN DOUALA
This pollution has many consequences on us and on the environment such as:
Because of the rejection of waste plastics in ocean, the marine fauna and flora are
destroyed
Plastic being not biodegradable, it cause a durable pollution. Between 60% and 85% of
the collected wastes on the littoral are plastics [14].
One of the many examples illustrating pollution due to the plastic is the continent of
wastes “Trash Vortex” which covers 3.5 million of kilometer square in the Northern
Pacific Ocean. It is constituted of 100 million tons of waste plastic floating, which make
the largest rubbish dump. It is destroyed marine fauna and flora of the Pacific. Indeed, it
is estimated that more than one million of marine birds and more than 100.000 marine
mammals die every year because of indigestion of plastic wastes, for example the
tortoises which confuse the jellyfish and plastic bags. It upsets alimentary chain [15].
The effects in cascade can extend via the alimentary chain and touch human being by
example of the chemical substances in particular present in plastics would be at first rank
on the reduction of the quantity of spermatozoids at 50% and diseases bound to the
genital apparatus. Among the additives more debated, appears the bisphenol A, mostly
present in food plastics and in particular in 90% of feeding-bottles thus can reach baby
[16].
8
CHAPTER II: PROPOSED SOLUTIONS AND
CRITICAL ANALYSIS
The aim of this chapter is to present different machines suitable for our study, examine
the advantages and disadvantages so as to choose the one which presents the best result.
8 1 Sieve
7 1 Motor
6 1 Belt
5 2 Pulley
4 3 Gear
9
3 1 Frame
2 3 Shaft
1 1 Hopper
10
T ABLEAU 6: NOMENCLATURE OF THE KINEMATIC DIAGRAM OF THE CRUSHING MACHINE
WITH TWO SHAFTS
8 1 Sieve
7 1 Motor
6 1 Belt
5 2 Pulley
4 2 Gear
3 1 Frame
2 2 Shaft
1 1 Hopper
11
FIGURE 10: KINEMATIC DIAGRAM OF THE CRUSHING MACHINE WITH ONE SHAFT
T ABLEAU 7: NOMENCLATURE OF THE KINEMATIC DIAGRAM OF THE CRUSHING MACHINE
WITH ONE SHAFT
7 1 Sieve
6 1 Motor
5 1 Belt
4 2 Pulley
3 1 Frame
2 1 Shaft
1 1 Hopper
7 1 Shaft
6 1 Belt
5 1 Motor
4 2 Pulley
3 1 Door
2 3 Blade
1 1 Frame
13
II.4.2- Critical analysis
II.4.2.1- Advantages
easy to transport
Easy to manipulate
Cost of maintenance
Cost of manufacturing
II.4.2.2- Disadvantages
Low rate of production
Time consuming
Quality of the product
Solution 3 gives very good result for the five (5) characteristics
Solution 1 also has fairly good results for the five characteristics but the quality of the
product is bad.
Based on these, it is clear that the solution 3 (crushing machine with one shaft) presents the
best characteristics as it has very good grade for the different characteristics and has a medium
(accessible) manufacturing cost.
14
CHAPTER III: CONCEPTUAL STUDY
As our machine is to crush HDPE (high density polyethylene) plastics bottles in granule
form, there are some elements which need a special study such as the rotating shaft: it
dimensions have to be properly defined based on the cutting effort admissible and the different
constraints in the machine, the electric motor: since it is the one who transmit motion to the
system, and the sieve: it is the one who give the size of the granule. So during this chapter, we
will study these three elements of our machine.
III.1.2- HYPOTHESIS
In order to easily approach the computation in our works, we decided to consider the
hypothesis concerning the density, the elastic modulus, the poission ratio, the yield stress and the
safety coefficient present below see appendix 1:
The mass of the bottle is negligible
The density of HDPE is ρ= 839 kg.m-3
The elastic modulus of HDPE is E= 636.49 MPa
The poission ratio υ is υ= 0.38
The yield stress Re is Re = 16.45 MPa
The safety coefficient of HDPE is C = 1.6
S = L×l
= 70×50 = 3 500mm2
So FC = σmax×S = 10.28×3500
= 35 980 N
FC = 35 980 N
Hypothesis
The displacement is considered to be at constant velocity
The parts are rigid bodies
The gravity acceleration is g=10m/s2
16
Where Fc1 = Fc2 = Fc3 = Fc4 = Fc5 = Fc6=Fc7=Fc8=35.980 × 103 N
III.3.1-DETERMINATION OF RA and RB
Using the fundamental principle of Dynamic, we have:
Ʃ F ⃗ ext = m a⃗ (1)
(1) 0 (o,x) –
-Fc1 – Fc2 – Fc3 – Fc4 – Fc5 – Fc6 – fc7 – Fc8 + RA+ RB = 0 (o,y)
RA + RB = 8Fc1
RA = 8Fc1 – RB (3)
(2) RA× 0 - Fc1×0 - Fc2 × AC - Fc3 × AD - Fc4 × AE - Fc5 × AF - Fc6× AG - fc7× AH – Fc8 × AB +
RB × AB = 0
( )
RB =
= 143.918× 103 N
RA = 143.918× 103 N
17
FIGURE 13: FREE BODY DIAGRAM
X 0 0.0285
Ty -10.7941×104 N -10.7941×104 N
Mfz 0 3084 Nm
18
SECTION CD: 28.57 ≤ x ≤ 57.14 mm
X 0.0285 0.0571
Ty -7.1961×104 N -7.1961×104 N
19
X 0.0571 0.0857
Ty -3.5981×104N -3.5981×104N
Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) =0
↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71)
X 0.0857 0.1142
Ty -1,62N -1,62N
20
SECTION FG: 114.28 ≤ x ≤ 142.85 mm
Ty + RA – Fc1 - Fc2 - Fc3 - Fc4- Fc5 = 0 ↔ Ty = Fc1 + Fc2 + Fc3 + Fc4 + Fc5 - RA = 3.5978×104N
Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) + Fc5 (x –114,28) =0
↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71) - Fc5 (x –114,28)
X 0.1142 0.1422
Ty 3.5978×104N 3.5978×104N
21
Ty + RA – Fc1 - Fc2 - Fc3 - Fc4- Fc5 - Fc6 = 0
Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) + Fc5 (x –114,28)
+ Fc6(x –142,28) =0
↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71) - Fc5 (x –114,28) -
Fc6(x –142,28)
X 142,285 171,426
Ty 7.1958×104N 7.1958×104N
Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) + Fc5 (x –114,28)
+ Fc6(x –142,28) + Fc7(x –171,426) =0
↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71) - Fc5 (x –114,28) -
Fc6(x –142,28) -Fc7(x –171,426)
X 0.0758 0.114
Ty 10,7938×104N 10,7938×104N
Mfz 3084.231Nm 0
22
C - SHEAR FORCE AND BENDING MOMENT DIAGRAMS
We plot the force and bending moments diagram with the aim of determining the most
solicited sections of the driven shaft. The most solicited section will be used to determine the
dimensions of the shaft that can overcome the shear force and bending moment.
CONDITION OF RESISTANCE
In order to easily approach the computation in our works, we decided to consider the
hypothesis concerning the density the yield stress Re and the safety coefficient c of a quenched
steel present below see appendix 2.
σmax ≤ Rpe ↔ ≤
23
≤ ↔ × × ≤
↔ 6 Mfz max c ≤ Re a3
↔a ≥
× , × .
↔a ≥ ↔ a ≥ 4.26 mm
As the dimension of the shaft is greater than or equal to 13.687 (a = 4.26 mm),
any value which fulfill this condition can be chosen for the well-functioning of our machine;
therefore the value chosen as dimension of the shaft is a= 30 .
P= Fc×R×ω
= 35980×0,02×60×3,14 P =2259,544 W
ASSEMBLY
DRAWING
2016-2017 MM 3
III.6-CALCULATION OF CHAIN OF DIMENSIONS Ja AND Jb
The play Ja is located between the driven shaft 12 and the rolling bearing 6 and the play
Ja is located between the blade 2 and the frame 1
=270.5
= 269.5
Jb = b11 – b1
Jbmax = b11max – b1min
= 20.1 – 9.9
=10.2
= 9.8
26
CHAPTER IV: MANUFACTURING ANALYSIS
IV.1- INTRODUCTION
The main objective of this chapter is to present a plan of manufacturing for the
production of the components of the machine, it entails giving a chronological process of
realizing a part from the level of rough piece to finished piece. This is to minimize the cost of
production. It is necessary to do the manufacturing analysis of all the parts involved in the
machine but to avoid making this document unnecessarily bulky, we will limit the manufacturing
analysis to one part: The driving shaft. It embodies the various phase contracts and the
manufacturing charts.
27
Phase contract. It is a document which shows detail information on the manufacturing
process carried out on the piece at each phase. It shows the operation to be carried out
and the means of setting up the isostatic position, Clamping, choice of the manufacturing
equipment and cutting parameters.
The various manufacturing analysis will be presented on the preceding pages. Below are the
various sheets for the manufacturing analysis.
IV.3-MANUFACTURING DRAWING
IV.4-DETAILS DRAWING
28
IV.5-DIMENSION LINK GRAPH
Ox Direction
Oy Direction
Oz Direction
29
IV.6- ELEMENTRY SURFACES
30
TABLEAU 10: TABLE OF ELEMENTARY OPERATIONS
F1
F2 3.2 0.4 02 F2E, F2F
F3 3.2 0.4 02 F3E, F3F
F4 3.2 0.4 02 F4E, F4F
F5 3.2 0.4 02 F5E, F5F
F6 3.2 0.4 02 F6E, F6F
F7 3.2 0.4 02 F7E, F7F
F8 3.2 02 F8E, F8F
F9 3.2 0.4 02 F9E, F9F
F10 3.2 02 F10E, F10F
F11 3.2 02 F11E, F11F
F12 3.2 02 F12E, F12F
F13 3.2 0.4 02 F13E, F13F
D1 3.2 0.4 02 D1E, D1F
D2 3.2 0.4 02 D2E,D2F
C1 1.6 01 C1F
C2 1.6 01 C2F
31
TABLEAU 11: TABLE OF ASSOCIATION OF SURFACES
G0
32
TABLEAU 12: TABLE OF MACHINING RESTRICTIONS
RESTRICTIONS (CONTRAINTS)
Surfaces
F1
F10E
F10F F7E
G1E
G1F G1E
G2E
G2F G3E
G3E
G3F
F4E
F4F G3E
F7E
F7F
F12E
F12F
F13E
F13F
33
TABLEAU 13: TABLE OF MACHINING LEVELS
PREVIOUS T LEVELS
O
T
A
L
G1E 1 1 0
G1F 1 1 1 0
G2E 1 1 1 1 0
G2F 1 1 1 1 1 0
G3E 1 1 1 1 1 0
G3F 1 1 1 1 1 1 1 0
F4E 1 1 1 1 1 0
PRESENT
F4F 1 1 1 1 1 1 1 1 0
F7E 1 1 1 1 1 0
F7F 1 1 1 1 1 1 1 1 1 1 0
F10E 1 1 1 1 1 1 1 1 1 1
F10F 1 1 1 1 1 1 1 1 1 1 1 1 0
F12E 0
1 1 1 1 1 1 1 1 1 1 1 1 1 1 0
F12F
1 1 1 1 1 1 1 1 1 1 1 1 1 0
F13E
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0
F13F
C1F 1 1 0
C2F 1 1 1 1 1 1 1 1 1 0
34
TABLEAU 14: TABLE FOR GROUPING OF PHASES
(GANTT GRAPH)
1 C1F G1E
2 G1F
3 G2E
4 G2F
5 F7E G3E
6 G3F
7 F4F
8 C2F
9 F7F
10 F10F
11 F13E
12 F12F
13 F13F
14
35
TABLEAU 15: DRAFT OF MACHINING SEQUENCE
20 Turning 1 G1F
21 chamfering 1 C1F
30 Turning 2 G2F
31 Facing F4F
32 Chamfering 2 C2F
40 Milling 1 G3F
50 Milling 2 F7F,F10F,F12F,F13F
36
TABLEAU 16: TABLE OF PHASE 10
Control
Phase Sub-phase Operation tool
Initial control
of dimensions
-Vernier callipers L=300+-0.2
10
-Ruler Ø= 43+-0.1
37
TABLEAU 17: TABLE OF PHASE 20
Control
Phase Sub-phase Operation Tool
-Vernier callipers
L=270+-0.2
Turning -Lathe machine
20 21 Ø= 20+-0.1
chamfering -turning tool
l=30+-0.2
-ruler
38
TABLEAU 18: TABLE OF PHASE 30
Control
Phase Sub-phase Operation Tool
-Vernier callipers
Turning L=200+-0.2
-Lathe machine
30 31, 32 facing Ø= 20+-0.1
-turning tool
chamfering l=70+-0.2
-ruler
39
TABLEAU 19: TABLE OF PHASE 40
Control
Phase Sub-phase Operation Tool
-Vernier callipers
-Milling machine l=17+-0.2
40 Milling
-milling tool (Ø10) L=38+-0.2
-ruler
40
TABLEAU 20: TABLE OF PHASE 50
control
Phase Sub-phase Operation Tool
-Vernier callipers
-Milling machine
-milling tool (Ø 30) c=30+-0.2
50 Milling -ruler
41
TABLEAU 21: TABLE OF PHASE 60
control
Phase Sub-phase Operation Tool
-Vernier callipers
60 Final control All dimensions
-ruler
42
IV.5-CONCLUSION
After choosing the machine which is suitable for the work required, we then calculated
the efforts applied to and from the machine in order to dimension the machine. With these efforts
calculated, the machine dimensioned, and the manufacturing analysis which have been studied,
this now enables us to realize our machine which will be able to crush 10l of granule in 15 min.
We will now move on to the last chapter which points out the uses of the machine, how the
machine can be maintained, the cost estimate and short comings encountered during the
realization of the machine. The HDPE plastics crushing machine studied and analysed here is
produced on the dimensions as seen in this project, unless otherwise due to some practical
constraints.
43
CHAPTER V: USER MANUAL, COST ESTIMATE OF THE
MACHINE, SUMAMARY AND GENERAL CONCLUSION
Operational incidents:
If the machine does not start, check whether the machine is well connected
If the noise is abnormal, do the following
- Stop the machine
- Check if the revolving equipment functions well
V.2- MAINTENANCE
Always grease the bearings after every three months.
V.4- RECOMMENDATIONS
Because of the difficulties encountered during the study and the manufacturing of the
machine, we recommend to the government to:
44
V.5- GENERAL CONCLUSION
The theme "DESIGN AND REALIZATION OF AN HDPE PLASTIC BOTTLES
CRUSHING MACHINE" has as principal aim the crushing those plastic wastes in order to
facilitate their recycling.
Such machine has to be highly sensitive, allowing a control of the applied load and providing
good quality of final product; that is why some existing machines of that kind have been first
studied and then four machines have been proposed among which the one with the best
characteristics has been selected, designed and realized.
Many difficulties have been encountered during the design and the manufacturing processes: The
design of the machine has been complicated by the fact that the software AutoCAD was not well
memorized.
During the manufacturing process, the difficulties found on the field were the lack of materials
and their high cost. In addition to that, we did not have the free accesses to the workshops which
did not favoured to follow evolution of the work.
However, much of improvements on the machine can be made to increase its effectiveness like
the manufacture of the crushing blades with material that is able to crush all the types of plastics
considering that our own is crushing only the waste of the HDPE.
Keeping up with the imperfection of all human works, our work remains imperfect, that's why
we stay with an open heart to comments, criticisms and suggestions for corrections.
45
REFERENCES
[1] LES PLASTIQUES DANS NOTRE VIE, pp8, 2012
[3]STRID ; Gestion des déchets dans le Nord Vaudois : Les Différents Types de Plastiques
[4]STRID ; Gestion des déchets dans le Nord Vaudois : Les Différents Types de Plastiques
[5]STRID ; Gestion des déchets dans le Nord Vaudois : Les Différents Types de Plastiques
[10] cameroon.africadata.org
[11] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04
[13] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04
[14] L’impact du plastique sur l’environnement et la santé : Classe de 3eB du Collège Mendès-
France de Lillebonne, Seine-Maritime
[15] L’impact du plastique sur l’environnement et la santé : Classe de 3eB du Collège Mendès-
France de Lillebonne, Seine-Maritime
[18] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04
46
[19] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04
47
APPENDICES
APPENDICES 1
48
APPENDICE 2
49