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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.

1.2. Problem Statement

In recent years, the production of plastic wastes has gained considerable importance within modern
societies as a result of the change in the consumption habits and lifestyles of consumers. The
evolution of societies worldwide has led to phenomena of mass consumption, thus resulting in
increasing amounts of plastic wastes produced and increased environmental impact generated by
these wastes.
Since the effect of global evolution has an effect on every corner of the world, AASTU is also
suffering from these impacts. Students in AASTU use different plastic products including water
bottles, juice bottles, soft drinks, cosmetics products, packaged foods, etc. All these products, after
consumption, become litter resulting in increasing amount of plastic wastes.
There are several problems caused by these plastic wastes. These including:
 Waste management problems
 Health problems
 Environmental pollution
 Loss of environmental hygiene and aesthetic

Fig. 1 Plastic wastes in AASTU

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1.3. Objective of the project

1.3.1. General objectives
The main objective of this project is designing analysis and simulation of Plastic Recycling
Machine.
1.3.2. Specific objectives
 To recycle a thermoplastic and reduce the solid plastic waste.
 Select a material with desired properties for the design of Plastic Recycling Machine.
 To design a Plastic Recycling Machine that is safe and reliable.
 To reduce the cost of the Plastic Recycling Machine.
 To contribute for the environmental hygiene.

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.

1.5. Significance of the project

Plastics are durable, lightweight and inexpensive materials that can readily be molded into various
products which find uses in a wide assortment of applications. As a result, the production and uses
of plastics have increased in last few decades. Every year, more than 100 million tons of plastics
are manufactured across the globe. Around 200 billion pounds of new plastic material is
thermoformed, foamed, laminated and extruded into millions of packages and products.
Consequently, the need for reuse, recovery and the recycling of plastics takes on an enormous
importance. The current worldwide plastic recycling industry is vast in scope. It presents both
opportunities and challenges.

1.6. Scope of the project

We can produce different types of domestic and industrial products by recycling the west plastic.
Using compound dies we can produce components on scale and avoid the time consumption. By
using automation and multi stage heating coils we can increase the production rate. The results
above counter exactly that showing that by recycling, companies can further reduce these cheap
production costs.
The scopes of this project cover conceptual design of plastic recycling machine by using total
design approach. Design method including market product design specification, conceptual and
detail design are used in this project. For conceptual and detail design, drawing and simulation will
be done by using AutoCAD and solid work software respectively.

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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.

[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.The use of plastic is increased now
days in many industries like automobile, packaging, medical, etc. The reason behind this is that
the plastic made things are quiet easier to manufacture, handle and reliable to use. So the plastic
goods manufacturing industries are striving hard to produce good quality products at large scale
and cheaper cost. The hydraulically operated machines solve the problem, but they are too costlier
for small scale and medium scale industries. This paper deals with design and fabrication of
pneumatically operated injection plastic molding machine. The manually operated machine is
converted into pneumatically operated machine by applying proper design procedure.
One of the very first experiments with synthetic plastics took place about 1835 when the French
chemist, Regnault, caused a chemical called vinyl chloride to turn into white powder. This was the
very earliest form of polyvinyl chloride, which we know as PVC, but it was not commercially
developed for almost another century. There were many other plastics, the development of which
was delayed for equally long periods. The main reason for this delay was that until well into the

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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.

3.2. Plastic Waste Recycling Machines

The recycling process basically consist shredding as a main component and other processes like
injection process, extrusion process, and compression process for obtaining the desired products.
The shredding process is input for the remaining processes and is mandatory. But other processes
are independent to each other.

3.2.1. The Shredding Machine

This machine chops the plastic waste into a smaller plastic flakes. These flakes are used in the
other machines to create new plastic products.
The size of this machine is based on a plastic bottle, and any plastic smaller than a plastic bottle
can be thrown in and if it is bigger, a bigger shredder can be built or it can be pre-cut to maintain
a smaller size.
The shredder basically consists of four different parts. These are:
 Shredding part
 Power supply
 Frame work
 Hopper
Other parts include the bucket and filter mesh.

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Power supply

Hopper
Shredder part

Frame work

Fig.2: Parts of the shredding machine

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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Shredded plastic flakes

(Labelled plastic
flakes)

Fig.3: Products of shredding process

3.2.2 The Extrusion Machine

This machine has a specific output like cables, 3D printer filament, or other raw materials. The
process is continuous which means shredded plastic is put in and it just keeps on extruding. The
down side of this machine is it is a little bit difficult to build as it needs precision. Buts once it is
done it can work perfectly.
The machine consists six different components. Namely:
 Hopper
 Barrel
 Nozzle
 Barrel holder
 Frame work and
 Electronics part

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Hopper

Barrel

Barrel holder

Nozzle

Frame work
Electronic unit

Fig.4: Parts of the extrusion machine

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.
Barrel holder: needed to hold the barrel and hopper together on the frame work.
Electronic unit: used to control the temperature of compression inside the barrel based on the
desired output.

3D printer filaments and lamp sheds

Fig.5: Products of extrusion process

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3.2.3 The Injection Machine

This machine injects plastics into molds. It is best suited to make small plastic objects. Products
can easily be replicated. The machine has different parts. The hopper is smaller from the one on
the other machines. The components include:
 Hopper
 Barrel
 Nozzle
 Frame work
 Electronics unit

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

Fig.6: Parts of the injection machine

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Handles

Fig.7: Products of injection process

3.2.4 The Compression Machine

It is like baking the plastic. The plastic goes in the molds and the molds go to the oven. It is
relatively slow but easy process, and the machine is easy to build.
It consists of four different components. These are:
 The oven
 Frame work
 Electronic unit
 Scissor jack press
The oven: this is where the mold, containing shredded plastic, goes inside and gets heated. It is
relatively expensive but quite helpful.
Frame work: supports the overall machine and provides a standing unit.
Electronic unit: provides temperature control inside the oven. The oven’s built in temperature
control is not accurate enough. That is why an external temperature unit is needed.
Scissor jack press: used to apply force to press the mold inside the oven.

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Oven

Electronic unit

Car jack

Frame work

Fig.8: Parts of the compression machine

Drawing boards

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Trash cans

Solid blocks

Fruit bowls

Fig.9: Products of compression process

3.3. The Plastic Recycling Process

The simplest of plastic recycling process involve collecting, sorting, shredding, washing, melting,
and pelletizing. In fact, the actual processes vary based on plastic resin or type of plastic product.

This plastic recycling process use the following steps:

Step one: Sorting the plastic waste materials according to their types.

Step Two: Shredding the sorted plastic waste materials.

Step Three: Washing shredded plastic wastes to remove remaining products and contaminants.

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Step Four: Drying washed plastic wastes.

Step Five: Feeding the shredded plastic wastes to one of the three machines (injection, extrusion,
or compression) based on the desired output.

Fruit bowls and buckets

Drawing boards

Fig.10: Products of the plastic recycling process

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4.2. Solution principle

A. Solution principle for gear
As we know gears are most often used in transmissions to convert an electric motor’s high speed and
low torque to a shaft’s requirements for low speed high torque: so the different type of gear are with their
characteristics are: -

The characteristics of Spur Gear

 Spur gears are highly reliable

 Spur gears are simplest, hence easiest to design and manufacture
 A spur gear is more efficient if you compare it with helical gear of same size
 Spur gears produce a lot of noise when operating at high speeds.
 when compared with other types of gears, they are not as strong as them

The characteristics of Helical Gear

 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

 This gear makes it possible to change the operating angle.

 One wheel of such gear is designed to work with its complementary wheel and no other.
 Must be precisely mounted.
 The shafts' bearings must be capable of supporting significant forces.

The characteristics of worm Gear

 Worm gear drives operate silently and smoothly

 They are self-locking
 They occupy less space
 They have good meshing effectiveness
 They can be used for reducing speed and increasing torque
 Worm gear materials are expensive

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For more information it is presented as fellow

Design criteria Weight Spur gear Helical gear Bevel gear Worm gear
Score Weight Score weight Score weight Score Weight

Efficiency 0.1 10 1 9 0.9 8 0.8 6 0.6

Ease to 0.1 9 0.9 7 0.7 6 0.6 7 0.7
Manufacturability
Design 0.1 9 0.9 8 0.8 6 0.6 7 0.7

Availability 0.1 9 0.9 7 0.7 7 0.7 5 0.5

Reliability 0.1 10 1.0 9 0.8 8 0.8 6 0.6
Strength 0.1 8 0.8 9 0.9 9 0.9 8 0.8
Power 0.1 10 1.0 8 0.8 9 0.9 7 0.7
transmissivity
Noise 0.05 7 0.35 8 0.4 7 0.35 9 0.45

Cost 0.15 9 1.35 8 1.2 7 1.05 6 0.9

Time to 0.1 10 1 8 0.8 8 0.8 7 0.7
manufacturability
Total 9.2 8 7.5 6.65

Rank 1 2 3 4

Table 4.1 gear selection

Therefore, according to the solution principle computed on the above table spur gear type is
selected.

B. Solution principle for Shaft

The characteristics of Solid stepped shaft
 It has rotational motion.
 It has good machinability.
 It has low notch sensitivity factor.
 It should have high wear resistant properties.
 easy to manufacture

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criteria weight Solid stepped shaft Hallow

Score weight Score weight
Ease to 0.15 9 1.35 8 1.2
Manufacturability
Design 0.1 9 0.9 8 0.8
Availability 0.1 9 0.9 7 0.7
Reliability 0.1 10 1 8 0.8
Strength 0.15 10 1.5 9 1.35
Noise 0.1 9 0.9 9 0.9
Cost 0.15 8 1.2 9 1.35
Time to 0.15 8 1.2 9 1.35
manufacturability
Total 8.95 8.45
Rank 1 2

Therefore, according to the solution principle computed on the above table solid with stepped
type is selected.

C. Solution principle for bearing

The characteristics of bearing
 More initial cost.
 Design of bearing housing complicated
 Low starting and running friction except at very high speeds.
 Ability to withstand momentary shock loads.
 Accuracy of shaft alignment.
 Low cost of maintenance, as no lubrication is required while in service.
 Small overall dimensions.
 Reliability of service.
 Easy to mount and erect.
 Cleanliness.
 More noisy at very high speeds.
 Low resistance to shock loading

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criteria weight Rolling contact bearing Sliding contact bearing

Score weight Score weight
Efficiency 0.1 9 0.9 8 0.8

Shock loads resist 0.1 9 1.35 8 1.2

Design 0.1 8 0.8 9 0.9

Availability 0.1 9 0.9 7 0.7

Reliability 0.1 10 1 8 0.8

No lubrication 0.15 10 1.5 8 1.2

Noise 0.1 8 0.8 9 0.9

Cost 0.1 9 0.9 8 1.2

Time to 0.15 8 1.2 9 1.35

manufacturability

Total 9.35 9.05

Rank 1 2

Therefore, according to the solution principle computed on the above table rolling contact bearing type is
selected

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4.3. Material Selection

4.3.1. Material selection for gear
The materials used for gear should have the following properties:
 It needs to have good strength
 It should have compact layout.
 It is required to have high efficiency.
 It should have reliable service.
 It should transmit exact velocity ratio.
 It may be used to transmit large power.
 It may be used for small center distances of shafts.

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.

4.3.2. Material Used for Shafts

The material used for shafts should have the following properties:
 It should have high strength
 It should have good machinability.
 It should have low notch sensitivity factor.
 It should have good heat treatment properties.
 It should have high wear resistant properties.
 It should have high rust resistant properties.

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Mild Steel Stainless steel Aluminum

Design criteria Weight
Score Weight Score Weight Score Weight
Availability 0.15 9 1.35 8 1.2 10 1.5
Strength 0.2 9 1.8 10 2 6 1.3
Cost 0.15 8 1.2 6 0.9 10 1.5
Rust resistance 0.35 10 3.5 9 3.15 5 1.75
wear resistant 0.15 9 1.35 9 1.35 7 1.05
Total 9.2 8.6 7.1
Rank 1 2 3

Therefore, according to the above table mild steel is selected.

4.3.3. Material Used for bearing

The material used for bearing should have the following properties:
 Low starting and running friction except at very high speeds.
 Ability to withstand momentary shock loads.
 Accuracy of shaft alignment.
 Low cost of maintenance, as no lubrication is required while in service.
 Small overall dimensions.
 Reliability of service.
 Easy to mount and erect.
 Cleanliness

Therefore, the most widely used material AISI 52100 steel is selected.

4.3.4. Material Used for key

The material used for key should have the following properties:
 It should have good crushing stress.
 It should have good shear stress.
 It should have high strength.

Therefore, based on the above properties mild steel is selected.

4.3.5. Material Used for shredding knife
The material used for shredding knife should have the following properties:

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 It should have high strength

 It should have good machinability.
 It should have good resistance to torsional effect.
 It should have good resistance to bending effect.
 It should have high wear resistant properties.
 It should have high rust resistant properties.

Therefore, based on the above properties stainless steel is selected.

4.4. Detail design

Assumption
 gear ratio 𝐺 = 4:1
 addendum = module = 1
 gear RPM 𝑁𝐺 = 30RPM
 gear center to center distance L = 105mm
 factor of safety 𝐹𝑆 = 2
 pressure angle full depth 𝜙 = 22.5O

4.4.1 Design of Spur Gear

Selection of Motor
Here, the speed of the gear 𝑁𝐺 is 30RPM and 𝐺 is 4, therefore the speed of the pinion is:
𝑁𝑃 = 𝐺. 𝑁𝐺 = 4 30RPM = 120RPM
The speed of the pinion is 120RPM, so we select the appropriate motor from motor
specification. We get a motor with 0.5hp power for 120RPM.
A motor having 0.5hp and 120Rpm is selected based on the above parameters.
We know that the minimum number of teeth on the pinion in order to avoid interference,
2×𝐴𝑊 2×1
𝑇𝑃 = 1 1
= 1 1
= 12.4
𝐺[√1+ ( +2)(sin 𝜙)2 −1] 4[√1+ ( +2)(sin 22.5)2 −1]
𝐺 𝐺 4 4

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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From these values:

𝐷 42
m = 𝑇𝑃 = = 3.23mm
𝑃 13

Since the nearest standard value of the module is 3mm, therefore we shall take it.

Number of teeth on the pinion:

𝐷𝑃 42
𝑇𝑃 = = = 14
𝑚 3

Number of teeth on the gear:

𝑇𝐺 = 𝐺 × 𝑇𝑃 = 4 14 = 56
Force Analysis on Gear:
𝜋𝐷𝑃𝑁𝑃 𝜋×1.65×120
Pitch Line Velocity; 𝑉= = = 51.84ft/min
12 12
33000𝐻
Transmitted Load; 𝑊𝑡 = where H = 0.5hp
𝑉
33000×0.5
𝑊𝑡 = = 318.4lbf
51.84

Material selection for gear:

In such design the material needs to have good strength and the compacted size.
To attain such requirements Nitro alloy grade 1 steel is selected.
Design Factors:
Dynamic Factor: 𝑲𝑽
Assume: 𝑄𝑉 = 6

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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𝐾𝑅 = 0.658-0.0759ln (1-R) = 0.885

Load Cycle Factor: 𝒀𝑵 , 𝒁𝑵

Assume: life hour L = 30000hr

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

From the recommendation 3p ≤ F ≤ 5p. Take F = 3𝜋⁄4 = 2.36in

From Luis Factor Table: YP = 0.277 and YG = 0.415

0.0535 0.0535
𝐹√𝑌 2.36√0.277
K S = 1.192( ) = 1.192( ) = 1.12
𝑃 4

Load Distribution Factor: 𝐾𝑚 = 1.236

Geometry Factor: I,J

cos ∅ sin ∅ 𝐺 cos 22.5 sin 22.5 4
I= = × 4+1 = 0.141
2 𝐺+1 2

JP = 0.24 and JG = 0.37

Allowable Bending Stress: 𝐒𝐭

Assume Brinell Hardness, B = 320. For Nitro alloy grade 1 steel

St = 86.2 B + 12730psi = 40314

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.

For safety purpose F = 15mm.

4.4.2 Design of shaft for spur Gears

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

WT = Tangential load, and

φ = Pressure angle.

𝑊𝑇 = 318.4𝑙𝑏𝑓=1416.3N

𝑊𝑁 = 318.4/cos22.5 = 344.6lbf = 1533N

A thrust parallel and equal to WN will act at the gear center as shown in Fig.

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Fig. 4.7 Load acting on the gear

4.4.3 Design for the pinion shaft

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

𝑊𝑇 = 318.4𝑙𝑏𝑓=1416.3N

𝑊𝑁 = 318.4/cos22.5 = 344.6lbf = 1533N

A thrust parallel and equal to 𝑊𝑁 will act at the gear center as shown in Fig.

The weight of the gear is given by

Wp = 0.001 18 Np.F.m2 (in N) where

Np = No. of teeth on the pinion,

F = Face width in mm, and m = Module in mm.

Wp = 0.00118 ∗14*15*32 = 2.23N

Since the shaft is under the combined effect of torsion and bending, therefore we shall
determine the equivalent torque. We know that equivalent torque,

Now the resultant load acting on the gear,

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𝑊𝑅 = √(𝑊𝑁2 + 𝑊𝑝2 + 2𝑊𝑁 + 𝑊𝑝 cos ∅ )

=√(15332 + 2.232 + 2 × 1533 + 2.23 × cos 22.5 )

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.

M = WR *x = 1534N * 50mm = 76700Nmm

And twisting moment on the shaft,

T = 𝑊𝑇 𝑥𝐷𝑝 /2 =1.4163kN x 42mm/2 = 29742Nmm

Equivalent twisting moment,

𝑇𝑒 = √𝑀2 + 𝑇 2 = = √767002 + 297422 = 82265Nmm

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

The diameter of the pinion shaft (𝑑𝑃 ) is 20mm.

4.4.4 Design for gear shaft

The weight of the gear is given by

WG = 0.001 18 NG.F.m2 (in N) where

NG = No. of teeth on the gear

F = Face width in mm, and

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`

m = Module in mm.

WG = 0.00118 ∗52*15*32 = 8.28N

Since the shaft is under the combined effect of torsion and bending, therefore we shall
determine the equivalent torque. We know that equivalent torque,

Now the resultant load acting on the gear,

𝑊𝑅 = √(𝑊𝑁2 + 𝑊𝐺2 + 2𝑊𝑁 + 𝑊𝐺 cos ∅ )

=√(15332 + 8.282 + 2 × 1533 + 8.28 × cos 22.5 )

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.

M = WR *x = 1534 * 60mm = 76700Nmm

And twisting moment on the shaft,

T = 𝑊𝑇 𝑥𝐷𝐺 /2 =1.4163kN x 168mm/2 = 118969 Nmm

Equivalent twisting moment,

𝑇𝑒 = √𝑀2 + 𝑇 2 = = √767002 + 1189692 = 141550Nmm

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

The diameter of the gear shaft (𝑑𝐺 ) is 30mm.

Then the length of this shaft is 318mm simply it is selected.

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4.4.5 Design of Bearing

Assumption for bearing

 Select ball bearing,a=3
 application factor, af=1.2
 Rating life revolution, LR=106rev
 02 series, Xo=0.02
 Reliability RD=0.98

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.

We know the normal (𝑊𝑁 ) and tangential load (𝑊𝑇 )

 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

So the desired load acting on the bearing, ‘FD’ is equal to 𝑊𝑁 so

 FD=𝑊𝑁 =586.5N
 the design life, XD= (lD*nD*60)/106= (1,123,200*30*60)/106=2021
 C10=af*FD[𝑋𝐷/(𝑋𝑜 + (𝜃 − 𝑋𝑜)(𝑙𝑛1/𝑅𝐷)^(1/𝑏))]1/𝑎
 C10=1.2*586.65[2021/(0.02 + (4.459 − 0.02)(𝑙𝑛1/0.98)^(1/1.483))]1/3 =12kN
 C10=12kN which is available in the table from the Deep Groove
 Bore=20mm, OD=47mm, Width=14mm, Fillet Radius=1mm, shoulder Diameter,
dS=25mm, dH=41mm
 Bore diameter in mm of bearing is the diameter of the shaft. From table 11-2 (02 series
deep groove ball bearing). The corresponding minimum bore diameter is 20mm.

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`

 For the shaft of pinion 20mm bore diameter bearing is selected.

 For the shaft of gear 30mm bore diameter bearing is selected.

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4.4.6 Design for Key

 Material selected is mild steel

 Shear strength 50MPa
 Crushing strength 70MPa
 Factor of safety 2.5
For a shaft of 20 mm diameter,
Thickness t = 7mm and w = 8mm. …from table for key standard.
τ = 50/2.5 = 20Mpa
 Considering shearing of the key.
The shearing strength (or torque transmitted)
𝑑 20
T= 𝑙 × 𝑤 × 𝜏 × 2 =𝑙 × 8 × 20 × = 1600𝑙
2

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

 Now considering crushing of the key.

The shearing strength (or torque transmitted) of the key,

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)
32
`

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

 Now considering crushing of the key.

The shearing strength (or torque transmitted) of the key,

𝑡 𝑑 𝜋
T=𝑙 × 2 × 𝜎𝑐 × 2 = 16 𝜏𝑑 3

𝜋
𝑙 × 4 × 28 × 15 = 16 20 × 303 , 𝑙 = 60mm

 Taking larger of the two values, we have length of key, l = 60mm

4.4.7 Design for shredding knife

It can be selected based on larger shaft diameter from standard with d=120mm and thickness=5mm
since material stainless steel is selected from the above.

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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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