IJOER-JUN-2016-7

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Published on June 30, 2016

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slide 1: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 34 Exploring the Possibility of using E-glass /Epoxy in the design of single toggle jaw crusher Sankar.M 1 Balaji.K 2 1 Department of Mechanical Engineering Post Graduate studies VEMU INSTITUTE OF TECHNOLOGY ANDHRAPRADESH INDIA 2 Assistant Professor Department of Mechanical Engineering VEMU INSTITUTE OF TECHNOLOGY ANDHRAPRADESH INDIA Abstract — Jaw crusher is a kind of size reduction machine that is wide utilized in mineral aggregates and metallurgy fields. The interaction between jaw plates and material particles brings the inevitable and high wear to the jaw plates throughout the jaw crusher operation that not only decreases the efficiency however also will increase the price and also the energy consumption of the jaw crusher. Obtained results from the kinematic analysis of the moving jaw and also the crushing force distribution analysis the jaw plates wear is analyzed on a macroscopical level. It’s useful to design the crusher for improved performance. Efforts to decrease energy consumed in crushing have cause thought of decreasing the weight of the swing plate of jaw crushers. Design of lighter weight jaw crusher would require a lot of precise accounting of the stress and deflections within the crushing plates than is available with ancient technique. The objective of this project is to present modeling and analysis of single toggle jaw crusher and comparison of deformation and stress load and weight savings results between manganese steel single toggle jaw crusher and composite single toggle jaw crusher under same conditions. This study gives information about the replacement of manganese steel jaw crusher with composite jaw crusher made of E glass/epoxy. The single toggle jaw crusher is to be solid modeled in proE and analysis is to be carried out by using ANSYS workbench13 for effective comparison. Keywords — single toggle jaw crusher manganese steel E glass/Epoxy stiffeners Auto CAD ANSYS 13.0 I. INTRODUCTION Crushing is that the process of reducing the dimensions of the lump of ore or over size rock into definite smaller sizes. Based on the mechanism used devices are of three types particularly Cone crusher Jaw crusher and Impact crusher. The first stage of size reduction of hard and huge lumps of run of mine ROM ore is to crush and reduce their size. The mechanism of crushing is either by applying impact force pressure or a combination of each. Jaw crushers are usually used as primary crushers or the primary step within the method of reducing rock. They typically crush using compression. The rock is dropped between two rigid pieces of metal one in all that then move inwards towards the rock and therefore the rock is crushed as a result of its a lower breaking point than the opposing metal piece. Jaw device movement is obtained by employing a pivot point located at one end of the “swing jaw” and an eccentric motion located at the opposite finish. FIG 1: SINGLE TOGGLE JAW CRUSHER. slide 2: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 35 TABLE 1 SPECIFICATIONS OF SINGLE TOGGLE JAW CRUSHER WITHOUT STIFFENERS S.NO PARAMETER VALUE 1 LENGTH OF THE JAW 1200MM 2 WIDTH OF THE JAW 900MM 3 THICKNESS OF THE JAW 215MM 4 LOAD 8700N TABLE 2 SPECIFICATIONS OF SINGLE TOGGLE JAW CRUSHER WITH STIFFENERS S.NO PARAMETER VALUE 1 Length of the jaw 1200MM 2 Width of the jaw 900MM 3 Thickness of the jaw 215MM 4 Height of stiffeners 50 MM 5 Width of stiffeners 50 MM Load 8700N II. DESIGN OF JAW PLATES Recently concern for energy consumption in crushing has led to the consideration of decreasing the weight and consequently the stiffness of the swing plate of jaw crushers to match the strength of the rock being crushed. An investigation of the energy saving of plate rock interaction when point load deformability and failure relationships of the rock are employed to calculate plate stresses. In order to conduct this investigation a model has been created in the modeling software PROE and then with the help of finite element analysis software ANSYS analysis it. The model is made firstly without stiffeners and analyzed then for further analysis numbers of stiffeners are added in the model and again it analyzed. 2.1 2D Model of Single Toggle Jaw Crusher FIG 2: CORRUGATED JAW CRUSHER 2D MODEL slide 3: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 36 2.2 Solid Modeling of Corrugated Swing Jaw Plate Using proe FIG 3: BOTTOM SUPPORT FOR THE JAW CRUSHER FIG 4: CORRUGATED JAW CRUSHER WITHOUT STIFFENERS FIG 5: CORRUGATED JAW CRUSHER WITH ONE STIFFENERS FIG 6: CORRUGATED JAW CRUSHER WITH TWO STIFFENERS FIG 7: CORRUGATED JAW CRUSHER WITH THREE STIFFENERS FIG 8: CORRUGATED JAW CRUSHER WITH FOUR STIFFENERS slide 4: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 37 2.3 Solid Modeling of Curved Swing Jaw Plate Using Proe FIG 9: CURVED JAW CRUSHER WITHOUT STIFFENERS FIG 10: CURVED JAW CRUSHER WITH ONE STIFFENER FIG 11: CURVED JAW CRUSHER WITH TWO STIFFENERS FIG 12: CURVED JAW CRUSHER WITH THREE STIFFENERS FIG 13: CURVED JAW CRUSHER WITH FOUR STIFFENERS slide 5: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 38 III. SWING JAW PLATES STATIC STRUCTURAL ANALYSIS USING ANSYS MANGANESE STEEL 3.1 Assumptions Analysis was undertaken based on the assumption that the point load strength of the disk and irregularly shaped particles to be equal and tensile point loads of different particle sizes are acting normal to the plate. For the analysis of the of swing jaw plate the model of the swing jaw plate is converted into STEP file and then this file is called for the analysis 3.2 Applying Material Before the Structural Analysis module used for the FEA model it must have material assigned to it. Each material in ANSYS has mechanical properties for computing the analysis for different materials but it has a facility to edits and add some material properties for other parts. TABLE 3 PROPERTIES OF MANGANESE STEEL PROPERTIES VALUE Density 7838 KG/MM 3 Elastic modulus 21010 3 MPA Shear modulus 80.7610 3 MPA Poisons ratio 0.3 Yield strength 550 MPA 3.3 Apply Boundary Conditions Boundary condition for Swing jaw plate is simply supported i.e. the support at bearing location hinge support and at the free end toggle force acting. Due to which this plate is acts as a simply supported figure shows the fixed point of plate. Fig showing Swing Jaw Plate Model Boundary Condition. 3.3.1 Applying Meshing FIG 14: SHOWING JAW CRUSHER MESHING 3.3.2 Applying Supports FIG 15: SHOWING JAW CRUSHER FIXED SUPPORT slide 6: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 39 3.3.3 Applying Loads FIG 15: SHOWING APPLYING LOADS ON JAW CRUSHER 3.3.4 Linear Static Stress Analysis FIG 16: SHOWING SWING JAW PLATE STRESS ANALYSIS FIG 17: SHOWING SWING JAW PLATE DISPLACEMENT 3.4 Swing Jaw Plates Static Structural Analysis Using ANSYS E Glass/ Epoxy 3.4.1 Applying Material TABLE 4 PROPERTIES OF E GLASS/EPOXY slide 7: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 40 3.4.2 Applying Meshing FIG 18: JAW CRUSHER MESHING 3.4.3 Applying Supports FIG 17: SHOWING JAW CRUSHER SUPPORT 3.4.4 Applying Loads FIG 18: SHOWING SWING JAW PLATE LOAD slide 8: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 41 3.4.5 Linear Static Stress Analysis FIG 19: SHOWING SWING JAW PLATE STRESS ANALYSIS FIG 20: SHOWING SWING JAW PLATE DISPLACEMENT IV. RESULTS FEA models using ANSYS are employed to calculate maximum tensile stresses for the jaw crusher. By using E-glass/Epoxy we can reduce weight of the jaw crusher up to 66.82. TABLE 5 CORRUGATED JAW MANGANESE STEEL STATIC STRUCTURAL ANALYSIS No Of Stiffer Von mess stress MPA TOTAL DEFORMATION mm Weight of jaw KG 0 2.0742 0.026908 1580.1 1 2.8917 0.082075 1024.6 2 2.2182 0.053149 1121.6 3 2.2151 0.052376 1174.5 4 2.2415 0.051505 1227.4 TABLE 6 CORRUGATED JAW E GLASS/EPOXY STRUCTURAL ANALYSIS No Of Stiffer Von mess stress MPA TOTAL DEFORMATION mm Weight of jaw KG 0 2.1151 0.51669 524.16 1 2.8533 1.5304 339.88 2 2.2329 0.69842 372.06 3 2.255 0.69489 389.61 4 2.2651 0.69226 407.16 TABLE 7 CURVED JAW MANGANESE STEEL STATIC STRUCTURAL ANALYSIS No Of stiffer Von mess stress MPA TOTAL DEFORMATION mm Weight of jaw KG 0 2.1335 0.028723 1614.4 1 3.7328 0.080046 1088.1 2 2.2869 0.051472 1163.9 3 2.2779 0.050716 1231 slide 9: International Journal of Engineering Research Science IJOER ISSN: 2395-6992 Vol-2 Issue-6 June- 2016 Page | 42 TABLE8 CURVED JAW E GLASS/EPOXY STATIC STRUCTURAL ANALYSIS No Of Stiffer Von mess stress MPA Total deformation mm Weight of jaw KG 0 2.0979 0.58084 535.86 1 3.59392 1.533 360.95 2 2.1695 0.73357 386.1 3 2.1669 0.73421 408.33 4 2.0121 0.71836 425.88 V. CONCLUSION From this we concluded that single toggle jaw crusher made by composite material will give better results regarding deformation and weight savings and stress and life the component compared to manganese steel. This is proved by analytically and FEA at 8700N for manganese steel and E glass/Epoxy composite material and also we made attempt for optimizing single toggle jaw crusher with multiple stiffeners and that FEA results are also included in results. REFERENCES 1 Pollitz H C “Crusher Jaw Plates” United States Patent Patent Number 3140057 Issued on July 1982 2 Bharule Ajay Suresh “M.Tech Thesis Computer Aided Design and Analysis of Swing Jaw Plate of Jaw Crusher” NIT Rourkela June 2009. 3 Cao Jinxi Qin Zhiyu Wang Guopeng “Investigation on Kinetic Features of Multi- Liners in Coupler Plane of Single Toggle Jaw Crusher” Journal of Taiyuan Heavy Machinery Institute July200. 4 Lytwynyshyn G. R. “MS Thesis-Jaw Crusher Design” Northwestern University Evanston August1990. 5 Cao Jinxi RongXingfu Yang Shichun “Jaw Plate Kinematical Analysis For Single Toggle Jaw crusher Design” Journal of Taiyuan Heavy Machinery Institute 2006. 6 Tickoo Sham “Catia for Engineers and Designers V5R20” DreamTech Press Germany 2000 7 Dowding Charles H Molling R Ruhl C" Application of point load-deformation relationships and design of jaw crusher plates” International Journal of Rock Mechanics and Mining Sciences Geo mechanics Volume 20 Issue 2 April 1983Pages 277-286. 8 M.Enamul Hossain… Journal of Composite Materials 4520 2133–2144. 9 William D. Callister “Material science and engineering”. 10 International Journal of Innovative Research in Science Engineering and Technology An ISO 3297: 2007 Certified Organization Vol. 4 Issue 1 January 2015

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