11 VI June 2023

https://doi.org/10.22214/ijraset.2023.53653
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue VI Jun 2023- Available at www.ijraset.com

Design and Fabrication of Plastic Shredder

Mr. Pratik A. Surgude1, Mr. Abhishek R. Sawant2, Mr. Tushar A. Nirwan3, Mr. Prem R. Vhatkar4, Prof. Girish S.
Modak5
BE Mechanical Engineering, P. E. S. Modern College of Engineering

Abstract: Prior to being transformed into useful items, plastic trash is first shredded into little pieces using a plastic shredder
machine. The shredder machine that is currently on the market has a concept design that is quite similar. The performance of
the shredding machine is mostly dependent on the shaft and blades. It was discovered that the geometry and orientation of the
blades installed in the double-shafts had a direct impact on the shredding efficiency. The feeding unit, shredding unit, power
transmission unit, and machine frame make up the shredder.
Keywords: Plastic, blade, shaft, shredder, recycling.

I. INTRODUCTION
Plastic shredders are being an emerging solution for turning the waste plastic into reusable resources. Plastic shredders are quite
useful in the process of plastic waste management by shredding the plastic waste into fine pieces which can be recycled and can be
reused again thereby helping the environment. This low-cost plastic shredder is surely an effective solution meanwhile keeping the
cost low and with hampering the overall process of shredding. It is a robust machine which is used to shred the plastic bottles into
small pieces, it has a set of cutting blades mounted on double shaft arrangement which will be further connected to the chain
coupling arrangement; the worm and worm wheel gearbox has been used to reduce the rpm and increase the torque required to cut
the plastic. The whole setup will be powered with the help of a 1 HP induction motor having 1440 rpm.

A. Objectives
1) To build a functioning plastic shredding machine for shredding plastic waste, hence reducing the plastic waste.
2) To study and apply the design procedure for shredder machine parts such as shaft, cutting blade, bearing and hopper
respectively.
3) To analyze the performance of cutting blade by using finite element analysis.
4) To shred the plastic waste into small pieces by using set of cutting blades so as to help in the process of plastic waste
management.

B. Analytical Calculations of Components

1) Cutting Blade: We are using a shredder blade with three cutting edges for plastic shredding. The calculate the cutting force
required for the cutting, we have studied the Mechanical properties of the PET (Polyethylene Terephthalate) material which are
given below.

TABLE 1
Mechanical Properties of PET material
Coefficient of friction (µ) From 0.2 to 0.4
Hardness (RC) From 94 to 101
Poisson’s ratio (υ) From 0.37 to 0.44
Tensile modulus (GPa) From 2 to 4
Tensile strength (Mpa) 80
Yield strength (Mpa) 64

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue VI Jun 2023- Available at www.ijraset.com

 τ(breaking)Plastic = 80 MPa
We have considered 90 MPa for safety.

 Cutting Force Required:

= τ(br)*(Area of blade)
= 90*5
Fc = 450 N.

 Torque exerting on the blade:

T = Force*Perpendicular distance (r)
= 450*40
= 18000 N.mm
T = 18 N.m.
 Power transmitted or required:
P = 2*π*N*T*(No. of blades)/(60*1000)
= 2*π*(50)*(18)*(7)/(60000)
= 659.73 W
P = 0.659 KW.

2) Shredder Shaft
Material Selected for Shaft – Mild Steel
Properties:
Syt = 320 MPa. Sut = 400 MPa.
µ = 0.31.
Young’s modulus = 200 GPa.
 Design of Shaft (By using Maximum Shear Stress Theory)
τmax = Ssy/Fs
= 0.5 Syt/1.5
= 0.5(320)/1.5
τmax = 106.67 N/mm2.

Shaft 1:

450 450 450 450

40 40 40

C D E F

A B

75
270

RA + RB = 1800 N
RA = 900 N.
mA = 0
mC = (900*75) = 67500 N.mm.
mD = (900*115) – (450*40) = 85500 N.mm.
mE = (900*155) – (450*80) – (450*40) = 85500 N.mm.
mF = (900*195) – (450*120) – (450*80) – (450*40) = 67500 N.mm.
mB = (900*270) – (450*195) – (450*115) – (450*155) – (450*75) =0

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue VI Jun 2023- Available at www.ijraset.com

Maximum bending moment (mb) = 85500 Nmm

Maximum torque (mt) = 18000 N.mm
τmax = 16/πd3 * (√(kb*mb)2 + (kt*mt)2)
106.67 = 16/πd3 * (√(1.5*85500)2 + (1*18000)2)
d = 18.35 mm.

Shaft 2:

450 450 450

40 40

C D E

A B
95
270

RA + RB = 1350 N
RA = 675 N.
mA = 0
mC = (95*675) = 45125 N.mm
mD = (675*135) – (450*40) = 73125 N.mm
mE = (675*175) – (450*80) – (450*40) = 64125 N.mm
mB = (675*270) – (675*175) – (450*135) – (450*95) = 0

Maximum bending moment (mb) = 73125 N.mm

Maximum torque (mt) = 18000 N.mm

τmax = 16/πd3 * (√(kb*mb)2 + (kt*mt)2)

106.67 = 16/πd3 * (√(1.5*73125)2 + (1*18000)2)
d = 17.44 mm

3) Bearing Selection
Fr (Radial load) = 1800 N.
Fa (Axial load) = 0
V (Rotation factor) = 1.0 Ka = 1.5
Lh10 = 8000
d = 20 mm
n = 50 rpm

Bearing selected is 6204

Co = 6.55 kN and C = 13.55 kN

Pe = V*Fr*Ka
= 1*1800*1.5
= 2700 N.

L10 = (Lh10*60*n)/106
= (8000*60*50)/106
L10 = 24 million rev.

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue VI Jun 2023- Available at www.ijraset.com

L10 = (C/Pe)a 24 = (C/2700)3

C = 7788.15 N
C = 7.78 kN
Selected bearing is 6204 with dimensions 20mm*47mm*14mm, Co = 6.55 kN and
C = 13.55 kN is Safe

4) Volume of the Hopper

= 1/3[ A1 +A2 + √ ]* h
Where,
A1 = Area of top base
A1 = 275 * 205
= 56375 mm2
A2 = Area of Bottom Base
A2 = 185*205
= 37925 mm2
h = Height of Hopper
= 145 mm
Volume of Hopper (V)
V = 1/3 [ 56375 + 37925 + √ 1+2] * 145
= 455*106 mm3
= 0.004 m3

5) Area of PET (Coca cola bottle)

= 7.7*10-4 m2
Therefore No. of bottle to fill the Hopper
= Volume of hopper / volume of PET bottle
= 0.004 / 7.7*10-4
= 5.19 = 5 Bottles.

C. Solid Modelling, Analysis and Manufacturing of Parts

Fig. 1. Modelling of Cutting Blade Fig. 2. Drafting of Cutting Blade

Fig. 3. Modelling of Shredder Shaft Fig. 4. Drafting of Shredder Shaft

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue VI Jun 2023- Available at www.ijraset.com

Fig. 5. Modelling of Hopper Fig. 6. Drafting of Hopper

Fig. 7. Total deformation analysis of blade Fig. 8. Von-mises stress analysis of blade

Fig. 9. Shaft Fig. 10. Blade

Fig. 11. Assembly of Shredder

D. Details Of Auxiliary Equipments Required For Operation

1) 1 HP Induction Motor
As per the calculations, the power required is 659.73 W, hence we have chosen 1 HP motor with 1440 rpm for powering the
shredder.

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue VI Jun 2023- Available at www.ijraset.com

2) Worm and Worm Wheel Speed Reduction Gearbox

The working or required rpm for the plastic shredder is 50 rpm, to achieve this, we have used worm and worm wheel gearbox with a
reduction ratio of 30:1.

3) Chain Coupling
To enhance better transmission between two connecting shafts and to cater any misalignment, we have used Chain couplings to
ensure smooth flow. It has an outer diameter 50 mm and bore diameter 15 mm respectively.

4) Transmission Gears
The power or drive has been given to one shaft, as there are two shafts rotating in opposite direction, we have used Spur gears to
transmit the drive from one shaft to another. They have outer diameter 60 mm with number of teeth 40 respectively.

E. Assembly And Results

All parts have been assembled and the overall structure look like this, the assembly of shaft and blade has been enclosed in a
shredder cover which is made of Mild steel plates with holes for shafts.

As the plastic bottle is fed into the shredder, it falls as a shredded plastic, which will be further used for recycling purpose.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 186
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue VI Jun 2023- Available at www.ijraset.com

II. CONCLUSION
1) The plastic bottle has been successfully shredded with the help of set of blades, the Fig. 26 shows the shredded pieces of plastic
bottle.
2) The Cutting blade selected is having three cutting edges with cutting force of 450N per blade.
3) The material selected for cutting blade is EN8 steel.
4) The shaft material selected is 40C8 with diameter of 18.35 mm, rounded off to 25 mm with a span of 270 mm.
5) There are 4 blades mounted on one shaft with a distance of 40 mm in between them, and there are 3 blades on second shaft with
a distance of 40 mm between each other.
6) There are two shafts with blades on each rotating in opposite direction with the help of gears.
7) The shredder is powered with the help of 1 HP Induction motor having 1440 rpm, the speed has been reduced with the help of
Worm and worm wheel gearbox with reduction ratio 30:1. The required rpm for working of the shredder is 50 rpm.
8) A hopper has been designed to feed the plastic bottles into the shredder with a decreasing cross-sectional area.
9) The whole setup is mounted on a fabricated stand with appropriate dimensions.

III. ACKNOWLEDGEMENT
I take this opportunity to thank all those who have contributed in successful completion of Project work. I would like to express my
sincere thank you to my guide
Prof. Dr. G. S. Modak who has encouraged me to work on this topic and valuable guidance wherever required. I also extend my
gratitude to Prof. Dr. S. Y. Bhosale (H.O.D. Mechanical Engineering Dept.) who has provided me opportunity to explore the subject
with more enthusiasm.
I express my immense pleasure and thankfulness to all the teachers and staff of the Department of Mechanical Engineering, PES’s
Modern College of Engineering, Pune for their co-operation and support.

REFERENCES
[1] M. F. Nasr and K. A. Yehia, Stress analysis of a Shredder Blade for cutting waste plastics (Journal of International Society for Science and Engineering issued
Dec 2019).
[2] N. B. V. Lakshmi Kumari, Yousuf Ahmed Faraz, Yousuf Khan and Anas Farzan, Design and Fabrication of Shredding Machine used for Plastics (IOSR
Journal of Mechanical and Civil Engineering issued Mar-Apr 2021).
[3] Prof. Dhiresh Desale and Neha A. Joshi, A review paper of design and fabrication of plastic shredding machine (International Journal of Advance Research and
Innovative Ideas in Education issued Apr 2021).
[4] S. VijayAnanth, T. N. Sureshkumar, Dhanasekaran C and Arvinth Kumar A, Design and Fabrication of Plastic Shredder Machine for Clean Environment
(International Journal of Management, Technology and Engineering issued Dec 2018).
[5] Atadious David and Oyejide Oluwayomi Joel, Design and Construction of a Plastic Shredder Machine for Recycling and Management of Plastic Wastes
(International Journal of Scientific and Engineering Research issued May 2018).

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