Project Seminar on

Optimum Design and Analysis of Swing Jaw Plate of a Single Toggle Jaw CrusherUnder the id U d th guidance of f

Prof. N. Kavi

Presented by B B V L DEEPAK Roll No:208ME103 M/c Design & Analysis

Mechanical Engineering DepartmentNational Institute of Technology Technology,

Rourkela

Outline of Present Work1. Introduction and Scope for Study2. Literature R i 2 Li Review 3. Theoretical Analysis heo etical nalysis 4. Computational Study 5. Results, Discussion and Conclusion References R f

INTRODUCTION TO JAW CRUSHERSPrimary Crushers Mechanism: Compression. Size: Rectangular/Square Opening For instance 24 x 36 opening of 24" by 36 instance, Two jaws,Stationary Movable

DIFFERENT TYPES OF JAW CRUSHER1) Blake Type Jaw C CrusherLarger, rough, blocky as well as sticky rock or ore lumps can be y p crushed. Reinforcement of the crusher is possible with the help of high strength crusher frame to crush very hard rock or ore lumps. It is very simple to adjust to prevent much of wear and also t h f d l very easy to repair, Maintenance of the crusher is very easy easy.

Single-Toggle Jaw Crusher

Double-Toggle Jaw Crusher

2) Dodge Type Jaw CrusherThey are comparatively lower in capacity y p y p y than the Blake crushers and are more commonly used in laboratories.

Dodge Type Jaw Crusher

COMPONENTS OF JAW CRUSHER

JAW CRUSHER WORKING PRINCIPLE

A fixed jaw, mounted in a "V" alignment is the stationary breaking surface, while the movable jaw exerts force on the rock by forcing it against the stationary plate The space at plate. the bottom of the "V" aligned jaw plates is the crusher product size gap, or the size of the crushed product from the jaw crusher. The rock remains in the jaws until it is small enough to pass through the gap at the bottom of the jaws.

OBJECTIVE OF PRESENT WORKThe force distribution is analyzed with the kinematic analysis of the swinging jaw plate. Obtained results from the kinematic analysis of the moving jaw y gj and the crushing force distribution analysis, the jaw plates wear is analyzed on a macroscopic level. Design and Analysis of Swing Jaw Plates for Jaw Crusher.Top opening=304 mm Bottom opening=51 mm B i 51

FEM is applied to the analysis of the swing jaw plate& lever. To T improve the strength/weight ratio using stiffener elements. h h h ff l

LITERATURE REVIEWThe jaw crushers are used commercially to crush material at first in 1616 as cited by Anon [1].It is used to simplify the complex engineering. An important experimental contribution was made in 1913 when Taggart [2] showed that if the hourly tonnage to be crushed divided by Square of the gape expressed i i h yields a quotient l th 0 115 uses a j crusher. d in inches i ld ti t less than 0.115 jaw h Lindqvist M.and Evertsson C. M. [3] worked on the wear in rock of crushers which causes great costs in the mining and aggregates industry industry.DeDiemar R.B. [4] gives new ideas in primary jaw crusher design and manufacture of Jaw crusher utilizing open feed throat concept power savings and automation features Jaw concept, features. crushers with two jaw openings can be considered to be a completely new design.

Gupta Ashok and Yan D S [6] worked in design of jaw crushers which impart D.S. an impact on a rock particle placed between a fixed and a moving plate.

Dowding Charles H. [7] designed jaw plates to reduce efforts to decrease energy consumed in crushing have lead to consideration of decreasing the weight of the swing plate of jaw crushers for easily crushed material. Cao Jinxi [9] worked on the certain domain, called the liner domain, of the coupler plane is chosen to discuss the kinetic characteristic of a liner or a crushing interface in the domain. Based on the computation and the analysis of the practical ki ti characteristic of th points along a li ti l kinetic h t i ti f the i t l liner paralleling t th ll li to the direction of coupler line Qin Zhiyu [10] studied different positions of liners in the coupler plane have different moving features, the motion of points along the liners in the computing domain is quite different from that of them in the straight-line coupler .

THEORETICAL ANALYSIS

KINEMATIC ANALYSIS OF SWINGJAW PLATEDimensions and operating parameters When considering the jaw crusher of Figurer, there are variables of the feed that define the important machine dimensions.

The feed particle sizes of interest are:1. The size of particle that enters the crusher. 2. The size of particle that can be nipped. 3. The i 3 Th size of particle th t can f ll th f ti l that fall through th chamber at any ti h the h b t time. 4. The size of particle that can fall through the chamber when the j jaws are open as wide as possible. p p

The dimensions defined by those particle sizes are:1. The gape - the distance between the jaws at the feed opening 2. The closed side set (CSS) - the minimum opening between the jaws during the crushing cycle (minimum discharge aperture) 3. The 3 Th open side set (OSS) th maximum di h id t the i discharge aperture t 4. The throw the stroke of the swing jaw and the difference between OSS and CSS.

Y V a B bM (90) K

A(a,b)K

xN

L

P

y Jawcrushersketch

O

X C

U

r 12.0

l 1085

k 455.0

a 45.3

b 815.4

n(rpm) 300

mn + (mn) (n +1)(m 1) sin = n +12 2 2 2

cos = m + nsina + b + r + l k 2r(asin + bcos) m= n +12 2 2 2 2 2

a r sin i n= b r cos 0 36 72 108 144 180

=Crankanglemadeby vertical g / p =Angleb/wtwoplates216 252 288 324 360

18.89766 19.47334

19.994 20.24856 20.14637 19.74163

19.1922 18.69555 18.42959 18.50073 18.89766

Points on liner Pointsonliner900 450 750 400 600

Horizontal Horizontal Displacements

Vertical Displacements VerticalDisplacements900

700

350 500

450

300

y(mm)

mm

300 mm

250

300

200 150 100 150 0 100 100 150 50 300 0 150 300 450 300 300 0 120 240 360 0 120 240 360 (degrees)

0 x(mm) (Degrees)

x = u cos + (l v)sin + a r sin y = u sin (l v)co s + b rco s 6thpointtrack320 310 y(m mm)mm m

d h h i l d xandyarethehorizontaland verticaldisplacementsinglobal coordinatesVertical displacementat6th point320 310 mm m 300 290 280

Horizontal displacementat6th point232 228

300 290 280 210 220 230 240 x(mm)

224 220 216 0 120 240 360 6 (Degrees)

0

120

240

360 6

(Degrees)

d r (a + l sin ) cos + (l cos b) sin = d l a r sin + (b r cos ) d d v = (l v ) cos r cos u sin i d d X

vx=VelocityinXdirection HorizontalVelocities450 300 150 mm/s 0 150 300 450 0 120 (Degrees) 240 360 1 2 3 4 5 6 7 8 9 10 11

d d v = (l v) sin + r sin + u sin d d Y

Vy =VelocityinYdirection y VerticalVelocities600 1 400 2 3 200 mm/s 4 5 0 6 7 200 8 9 400 10 11 0 120 (Degrees) 240 360

600

d r cos( + ) v = (l v) d U

d + r sin( + ) v = u d V

VU =VelocityinUdirection VV =VelocityinVdirection VelocitisinUDirection600 400 200 mm/s 0 200 400 600 0 120 (Degrees) 240 360 1 2 3 mm/s 4 5 6 7 8 9 10 11 450 0 120 (Degrees) 240 360 300 150 0 150 150 450 300 1 2 3 4 5 6 7 8 9 10 11

VelocitiesinVDirection

d d a X = [ (l v)cos u sin ] 2 [ (l v)sin + u cos ] + r sin d d 2

2

d d aY = [ (l v)sin + uco s ] 2 + [ (l v)co s u sin ] + rco s d d 2

2

HorizontalAccelerations1.5E+04 1 1.0E+04 1 0E+04 5.0E+03 mm/s2 0.0E+00 5 0E 03 5.0E+03 1.0E+04 1.5E+04 0 120 240 360 (Degrees) 2 3 mm/s2 4 5 6 7 8 9 10 11 2.0E+04 1.5E+04 1.0E+04 5.0E+03 0.0E+00 5.0E+03 5.0E+03 1.0E+04 1.5E+04 2.0E+04 0

VerticalAccelerations1 2 3 4 5 6 7 8 9 120 0 (Degrees) 240 40 360 10 11

Velocity&Acceleration16

8 HorizontalVelocity 0 VerticalVelocity HorizontalAcceleration 8 VerticalAcceleration V ti l A l ti

mm/s;mm m/s2

16 0 120 (Degrees) 240 360

Due to the connection between the moving jaw velocity and the eccentric shaft rotational speed, the velocity and the acceleration parameters are relative to angle , rather than time t.

d 2 d 2 aU = (l v) + r sin( + ) 1 + d d

d 2 d 2 aV = u + rco s( + ) 1 + d d

au istheaccelerationinUDirection Andav istheaccelerationinVDirection AccelerationsinUdirection1.5E+04 1.0E+04 5.0E+03 mm/s2 0.0E+00 5.0E+03 1.0E+04 1.5E+04 0 60 120 180 (Degrees) 240 300 360 1 2 3 mm/s2 4 5 6 7 8 9 10 11 1.5E+04 0 120 240 360 (Degrees)

AcceleratiosinVDirection1.5E+04 1.0E+04 5.0E+03 0.0E+00 5.0E+03 1.0E+04 1 2 3 4 5 6 7 8 9 10 11

SQUEEZINGPROCESS:

The force on the particle during the squeezing process is shown in the Fig.

Since the horizon and the vertical velocities of the moving jaw are variable during the squeezing process, the forces on the particle are also variable in different stage.

When the component of the vertical velocity in the moving jaw plate direction is bigger than that of the horizontal velocity in the same direction, the forces on the particle are shown in Fig (a). When the component of the vertical velocity in the jaw plate direction is smaller than that of the p f y j p f horizon velocity, the forces on the particle are shown in Fig (b). Because the gravitational force is much smaller than others, it can be ignored.

EquilibriumunderFig.(a)conditionfortheparticlewillrequire Horizontaldirection:

Verticaldirection:

GiventhattheslidefirsttakesplacebetweentheParticleand themovingjawplate.Thefrictioncoefficientis

Thefrictioncoefficientbetweentheparticleandthefixedjawplate willbe

Bysolvingtheaboveequationswecanobtain

and

Itisinconsistenttotheassumption

Giventhattheslidefirsttakesplacebetweentheparticleandthe fixedjawplateandthefrictioncoefficientis

Thefrictioncoefficientbetweentheparticleandthemovingjaw platewillbe Bysolvingtheaboveequationswecanobtain

And

Itisrational.

COMPUTATIONALSTUDYFOR SWINGINGJAW PLATEANDSWINGINGLEVER

Design of Swing Jaw PlatesHeight of jaw plate 4.0 x Gape Width of jaw plate > 1.3 x Gape < 3.0 x Gape Throw(T) = 0.0502(Gape)0.85 Height of jaw plate(L) = 1200mm Width of jaw Throw (w) = 900mm ( ) (T) = 50mm

Model 300X400 300600 300X750 300900

A 400 600 750 900

B 300 300 300 300

C 1050 1750 2050 1850

D 1180 1680 1930 2490

E 1300 1680 1850 2350

F 700 950 1150 1500

Weight(Ton) 2.8 6.5 12 17.5

Dimensional Chart for Jaw Crusher

Solid Modeling of Swing Jaw Plates & Pitman

Fig. Swinging jaw plate with one stiffeners

Fig. swinging jaw plate with three stiffeners ee s e e s

Fig. swinging jaw plate with two stiffeners Fig. swinging lever of the single toggle jaw crusher

Swing Jaw Plates & Pitman Static Stress Analysis Using CATIA Assumptions A static analysis calculates the effects of steady loading conditions on a structure, while ignoring inertia and damping effects, such as those caused by time-varying loads. Here analysis is based on the assumption that the point load strength of the disk and irregularly shaped particles to be equal and t il point l d of diff d tensile i t loads f different particle sizes are acting normal t ti l i ti l to the plate.

Features of Generative Structural Analysis as FEA ToolUsing CATIA V5 the overall process for FEA can be subdivided into g p f smaller steps shown in Fig.4.7. These steps are explained below.1. Pre - processing i 3. P t Processing 3 Post- P i

2. computation

4. Mesh Refinement

5. Report Generation

1. Pre-Processing :This will involve the complex physical structure to be converted into an equivalent Finite Element model. This ill be followed b applying th material properties t th model. Th Thi will b f ll d by l i the t i l ti to the d l There are fi structural properties, Y five t t l ti Youngs Modulus, Poisson Ratio, Density and Yield Strength. Youngs Structure Swinging jaw plate Lever Material used modulus(GPa) Martensitic steel (C-1.1%, Mn-13%) Austenite steel (C-0.04%, Mn-0.7%, Cr-13%, Ni-4%,Mo-0.8% ) 200 300 0.266 7860 210 strength(MPa) 550 ratio 0.266 Yield Poisions Density (Kg/m3) 7860

Next step within pre-processing applying the boundary conditions and restraining to the FE model. And finally conversion of actual loads to equivalent FE Loads. one end of the pitman is hinged to the eccentric shaft and other end is connected is to the toggle plate.

Fig.3.29 Tetrahedron Element in Global xyz- System Fig. Boundary conditions to the pitman

2. Computation p In computation step the standard FE solutions procedures uses data provided by pre-processing step and then solves the FE model to find out the unknown displacement values. 3. Post-Processing Using the values of displacement computed in pervious step strain and stresses are calculated for the whole structure. 4. Mesh Refinement Iteration In order to get a more accurate solution, the mesh needs to be refined and the computation is to be done. 5. Report G 5 R t Generation ti Once the required accuracy level is achieved, various plots such as sp ace e t, c pa st ess, o sses St ess ca obta ed Displacement, Principal stress, Von-Misses Stress can be obtained.

Analysis for Optimizing the Toggle Plate Width y p g ggAnalysis is performed for assembled structure of swinging jaw plate with swinging lever for a conventional single toggle jaw crusher with constant toggle plate thickness and length.

Fig. Toggle Plate of the jaw crusher

Analysis has been carried out at the width of the toggle plate is considered at 100, 200, 400, 600, 800 and 900mm.

Fig. Von Misses Stress and Displacement for the Toggle plate width of 200mm

Fig. Von Misses Stress and Displacement for the Toggle plate width of 800mm

Table. Von Misses stress and displacements at various sizes of the Toggle Plate widths. Width of the Toggle Plate(mm) Von Misses Stress(N/mm2) Displacement (mm) 447 0.311 246 0.262 188 0.212 137 0.18 98.6 0.164 97.7 0.16 100 200 400 600 800 900

500 400 N/ /mm2

200 100 0100 200 400 600 800 900

mm

300

0.35 0.3 03 0.25 0.2 0.15 0 15 0.1 0.05 0100 200 400 600 800 900

mmFig. Von Misses stresses vs toggle plate width

mmFig. displacements vs toggle plate width

Analysis for Optimizing the Toggle Plate LocationA l i h f d l ti l l t t iti f Analysis has b been performed ,locating th t the toggle plate at position of 0, 50, 100, 150, 200, 250, 300mm form bottom surface of the pitman.125 100 0.18 0.15 0.12

m mm

75

N/mm2

0.09 0.06 0.03 0 0 50 100 150 200 250 300

50 25 00 50 100 150 200 250 300

mmTOGGLEPLATE TOGGLE PLATE LOCATION DISPLACEMENT VONMISSES STRESS 0 0.0842 90.8 50 0.0776 79.5 100 0.0765 54 150 0.102 73 200 0.128 65.2

mm250 0.14 89.1 300 0.164 98.6

Fig. Von Misses Stress and Displacement ,Toggle plate located at bottom

Fig. Von Misses Stress and Displacement ,Toggle plate located at 100mm from bottom

Analysis by Considering Stiffeners to the Swinging Jaw Plate

Fig. swinging jaw plate with one stiffener, two stiffeners, three stiffenersNumber of stiffeners 1 2 3 Von Misses stress(N/mm2) 158 68.3 53.9 Displacement(deformation)(mm) 0.836 0 836 0.145 0.0883

Fig. Von Misses Stress and Displacement ,using two stiffeners

Validation of ResultsTable. represents the comparison of results for deformations produced by Chrlesh H. Dowding model and present model, without considering stiffeners.Thickness of the plate (mm) 140 152 Deformation by Chrlesh H. Dowding (mm) 0.292 0.226 0.311 0.238 6.1% 5.04% Deformation by Present model (mm) % of Error

RESULTS , DISCUSSION & CONCLUSION

1. Force Distribution along the Liner:The distribution of the forces along the liner can be calculated by the product of mass of the swinging jaw plate and the resultant acceleration produced by the jaw plate at various points on the liner . F=M(ax2 +ay2) Whereax=horizontalacceleration&ay=verticalacceleration

2.0E+04 1.6E+04 1 6E+04

ResultantAcceleration

1 2 3 4 5 6

m mm/s2

1.2E+04 8.0E+03 8 0E+03 4.0E+03 0.0E+00 0 0E+00

0

120 240 (Degrees)

360

2. Wear Analysis: y

Jaw plates wear is determined by the close process. Two key factors

in this process affecting the jaw plates wear are squeezing and sliding. At present, the high manganese steel is widely used as the jaw plate

material, which has the outstanding work hardening character. By scanning the worn jaw plates, it is found that the sliding is the main factor to the jaw plates wear and the sufficient squeezing can even relieve the jaw plate wear. For the same jaw crusher, the slide between the particle and the

fixed jaw plate is more than that between the particle and the moving jaw plate, so the wear of the fixed jaw plate is more serious relative to the moving jaw plate wear.

3. Optimization of Width and Location of Toggle Plate:

While the material is nipping in the crushing chamber toggle supports the swinging lever at bottom end it means toggle plate is more affected during the crushing. By performing finite element analysis on the assembled system of swinging j p jaw plate and pitman for a typical PE 300x900 series type jaw crusher, it is found p f yp yp j f that the optimal value of the toggle width is 800mm at which the Von Misses stresses are approaching to asymptotic value at 98.6 N/mm2 and the deformation is 0.164mm. For a conventional PE 300x900 series type jaw crusher, toggle plate is located approximately at 300mm from the bottom of the pitman. But analysis gives the optimal value of toggle plate location is 100mm above form the bottom of the pitman and the Von Misses and deformation obtained are 54N/mm2 and 0.0765mm.

4. Optimization of Mass of the Swinging Jaw Plate Using stiffeners, strength to weight ratio of the jaw plate can be increased. Analysis has been performed on the assembled structure when swinging jaw plate is having without stiffener, one stiffener, two stiffeners and g gj p g ff ff ff three stiffeners.

No of stiffeners 0 1 2 3

Von Misses stress (N/mm2) 54 158 68.3 53.9

Deformation (mm) 0.0765 0.836 0.145 0.0883

Mass of the jaw plate (kg) 1018.314 701.882 739.683 776.683

% of mass reduced= (mass of jaw plate without stiffeners- mass of jaw p plate with three stiffeners) *100/ mass of jaw plate ) j p without stiffeners = (1081.314-776.683)*100/1018.314 = 23.73%

Conclusion1. A certain domain of the coupler plane and some points are chosen on the crushing interface or the liner. Based on the computation and the analysis of the practical kinematic characteristic of the points along the liner domain some traditional motion parameters are calculated domain, calculated. According to the requirement for the squeezing motion of different zone in the crushing chamber, the chamber geometry can be improved. 2. The movement of the moving jaw crusher is described in detail. The force distribution is analyzed with the different operational parameters, so the distribution feature of the force on the liner is obtained. The job is helpful for a design of new prototype of this kind of machine on optimizing the frame, designing the chamber and recognizing the crushing character. 3. Results obtained from the movement analyses of the moving jaw and the crushing force distribution analysis, the jaw plates wear is analyzed. The relationship between the slide and the wear is reasonable and some results of the wear analysis are validated in practice. Predicting the jaw plates wear on a macroscopic level will be helpful to the jaw crusher design for better performance.

4. 4

Finite element analysis of swing jaw plates is carried out using four - noded tetrahedral out, element to predict the optimized width and the location of the toggle plate, when it is subjected to point loading under simply supported boundary conditions.

5.

The stiffened plate models which leads to reductions in plate weight and indicates that design of new energy-efficient systems of the crushed material.

6.

In case stiffened jaw plates as the number of stiffener increases the strength/weight ratio of the jaw plate increases making it stronger than that of without stiffener.

7.

The stiffened plate models which leads to 25% saving in energy, of course this 25% is an estimate for a typical 600*900 series jaw crusher.

8.

Rock strength has only been of interest because of the need to know the maximum force exerted by the toggle for energy considerations. Thus a swing plate, stiff enough to crush taconite, taconite may be overdesigned for crushing a softer fragmental limestone limestone.

REFERENCES1. Anon Design of Jaw Crusher Avoids Toggles, Minerals Engineering, Volume3, Issue 6, March 1999 Pages571-580. 2. Taggart, Arthur F Hand Book of Ore Dressing, John Willey & Sons Inc, 1998, Pages 255-280. 3. Lindqvist M., Evertsson C. M. Liner wear in jaw crushers, Minerals Engineering, Volume 16, Issue 1, January 2003, Pages 1-12. 4. DeDiemar R B 4 D Di R.B. New concepts i J N t in Jaw C h Crusher t h l Mi technology, Minerals l Engineering,Volume 3, Issues 1-2, 1990, Pages 67-74. 5. Russell A.R., Wood D. M. Point load tests and strength measurements f brittle g for Spheres, International Journal of Rock Mechanics and Mining Sciences, Volume 46, Issue 2, February 2009,Pages272-280. 6. 6 Gupta Ashok, Yan D S Mineral Processing Design and Operation An introduction , Ashok D.S. Mineral Operation-An introduction Published by Elsevier, 2006, Pages 99-127.

7. Dowding Charles H, Molling R, Ruhl C," Application of point load-deformation relationships and d i l ti hi d design of j f jaw crusher plates, I t h l t International J ti l Journal of R k l f Rock Mechanics and Mining Sciences & Geomechanics, Volume 20, Issue 2, April 1983,Pages 277-286. 8. Zhiyu Qin, Ximin Xu, A Method of Optimization of the Mechanism of Compound Swing Jaw Crusher, Journal of Taiyuan Heavy Machinery Institute, July1992. Pages 255-263. 9. Cao Jinxi, Qin Zhiyu, Wang Guopeng, Investigation on Kinetic Features of MultiLiners in Coupler Plane of Single Toggle Jaw Crusher, Journal of Taiyuan Heavy Machinery Institute, July200.Pages 210-219. 10. Cao Jinxi, Rong Xingfu, Yang Shichun, Jaw Plate Kinematical Analysis For Single Toggle Jaw crusher Design, Journal of Taiyuan Heavy Machinery Institute, 2006.Pages 2006 Pages 62-66

Thank You