Deepak PROJECT SLIDE (Jaw Crusher)
Deepak PROJECT SLIDE (Jaw Crusher)
Deepak PROJECT SLIDE (Jaw Crusher)
on
Optimum Design and Analysis
of Swing Jaw Plate of a Single Toggle
Jaw Crusher
U d th
Under the guidance
id off
Prof. N. Kavi
Presented by
B B V L DEEPAK
Roll No:208ME103
M/c Design & Analysis
Primary Crushers
Mechanism: Compression.
Size: Rectangular/Square Opening
For instance,
instance 24 x 36 opening of 24" by 36”
Two jaws,
¾ Stationary
¾ Movable
DIFFERENT TYPES OF JAW CRUSHER
1) Blake Type Jaw Crusher
C
¾ Larger, rough, blocky as well as
sticky
y rock or ore lumpsp can be
crushed.
¾ Reinforcement of the crusher is
possible with the help of high
strength crusher frame to crush
very hard rock or ore lumps.
¾ It is very simple to adjust to Single-Toggle Jaw Crusher Double-Toggle Jaw Crusher
preventt much h off wear andd also
l
very easy to repair,
¾ Maintenance of the crusher is
very easy.
easy
2) Dodge Type Jaw Crusher
Theyy are comparatively
p y lower in capacity
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
¾An 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
d in
i inches
i h yields
i ld a quotient
ti t less
l than
th 0.115
0 115 uses a jaw
j crusher.
h
¾DeDiemar R.B. [4] gives new ideas in primary jaw crusher design and manufacture of
Jaw crusher utilizing open feed throat concept,
concept power savings and automation features.
features Jaw
crushers with two jaw openings can be considered to be a completely new design.
¾Cao 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
ti l kinetic
ki ti characteristic
h t i ti off the
th points
i t along
l a liner
li paralleling
ll li t the
to th
direction of coupler line
¾Qin 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 PLATE
Dimensions and operating parameters When considering the jaw crusher of Figurer,
there are variables of the feed that define the important machine dimensions.
¾ 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
3. Th size
i off particle
ti l that
th t can fall
f ll through
th h the
th chamber
h b att any time.
ti
4. The size of particle that can fall through the chamber when the
jjaws are open
p as wide as p
possible.
¾ 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
id sett (OSS) – the
th maximum
i di h
discharge aperture
t
4. The throw – the stroke of the swing jaw and the difference between OSS and CSS.
Y
V
A(a,b)
a
(90‐Ø) K’
B K
Ø
x
b θ
M N L θ P’
Jaw crusher sketch
O X
U
C
r l k a b n(rpm)
12.0 1085 455.0 45.3 815.4 300
−mn + (mn) − (n +1)(m −1)
2 2 2
sinθ =
n +1 2
cosθ = m + nsinθ
a + b + r + l − k − 2r(asinφ + bcosφ)
2 2 2 2 2
m=
n +1 2
i φ
a − r sin ∅= Crank angle made by
n= vertical
b − r cos φ θ= Angle b/w two plates
g / p
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
Points on liner Horizontal
Horizontal Vertical Displacements
Vertical Displacements
900 Displacements 900
450
750
400 700
600
350
500
450 300
y(mm)
250
mm
300 300
mm
200
150
100
150
0
100
‐100
‐150
50
‐300 300
‐300
0
0 150 300 450 0 120 240 360
0 120 240 360
x(mm) ∅(degrees)
∅(Degrees)
x = u cos θ + (l − v)sin θ + a − r sin φ d h h i l d
x and y are the horizontal and
vertical displacements in global
y = u sin θ − (l − v)co s θ + b − rco s φ
co‐ordinates
6 th point track Horizontal Vertical
displacement at 6th displacement at 6th
320
point point
232 320
310
228 310
mm)
mm
m
mm
m
300
y(m
224 300
220 290
290
216 280
0 120 240 360
6 0 120 240 360
6
280 ∅(Degrees) ∅(Degrees)
vx= Velocity in X direction
Horizontal Velocities
450
300 1
2
150 3
4
mm/s
0 5
6
‐150
7
8
‐300
9
‐450 10
∅(Degrees)
⎡ dθ dθ ⎤
v = ⎢(l − v) sin θ + r sin φ + u sin θ ⎥ ω
⎣ dφ dφ ⎦
Y
Vy = Velocity in Y direction
y
Vertical Velocities
600
1
400 2
200 4
5
mm/s
0 6
7
‐200
8
9
‐400
10
11
‐600
0 120 240 360
∅(Degrees)
⎡ dθ ⎤ ⎡ dθ ⎤
v = ⎢(l − v) − r cos(φ + θ ) ⎥ ω v = ⎢u + r sin(φ + θ ) ⎥ ω
dφ ⎣ dφ ⎦
V
⎣ ⎦
U
VU = Velocity in U direction
VV = Velocity in V direction
Velocitis in U‐Direction Velocities inV‐Direction
600 450
1 1
400 300
2 2
200 3 150 3
4 4
mm/s
mm/s
0 0 5
5
6 6
‐200 150
‐150
7 7
8 ‐300 8
‐400
9 9
10 ‐450 10
‐600
0 120 240 360 11
0 120 240 360 11
∅(Degrees)
∅(Degrees)
2
d θ ⎛ dθ ⎞ 2
2
d θ ⎛ dθ ⎞2
Horizontal Accelerations Vertical Accelerations
1.5E+04 2.0E+04
1 1
1.5E+04
1 0E+04
1.0E+04 2 2
1.0E+04
3 3
5.0E+03
4 5.0E+03
4
mm/s2
mm/s2
0.0E+00 5 0.0E+00 5
5 0E 03
‐5.0E+03 6 ‐5.0E+03
5.0E+03 6
7 ‐1.0E+04 7
‐1.0E+04 8 ‐1.5E+04 8
‐1.5E+04 9 9
‐2.0E+04
0 120 240 360 10 0 120
0 240
40 360 10
∅(Degrees) 11 11
∅(Degrees)
Velocity & Acceleration
16
Horizontal Velocity
m/s2
mm/s; mm
0 VerticalVelocity
Horizontal Acceleration
‐8
V ti l A l ti
Vertical Acceleration
‐16
0 120 240 360
∅(Degrees)
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 2θ ⎧ dθ ⎫ ⎤ 2 ⎡ d 2θ ⎧ dθ ⎫⎤ 2
∴ aU = ⎢ (l − v) + r sin(θ + φ ) ⎨1 + ⎬⎥ ω ∴ aV = ⎢u + rco s(θ + φ ) ⎨1 + ⎬⎥ ω
⎢⎣ d φ ⎩ d φ ⎭ ⎥⎦ ⎣⎢ dφ ⎩ dφ ⎭⎥⎦
au is the acceleration in U‐Direction
And av is the acceleration in V‐Direction
Accelerations in U‐direction Acceleratios in V‐Direction
1.5E+04 1.5E+04
1 1
1.0E+04 1.0E+04
2 2
5.0E+03 3 5.0E+03 3
4 4
mm/s2
mm/s2
0.0E+00 5 0.0E+00 5
6 6
‐5.0E+03 ‐5.0E+03
7 7
‐1.0E+04 8 ‐1.0E+04 8
9 9
‐1.5E+04 10 ‐1.5E+04 10
0 60 120 180 240 300 360 0 120 240 360
11 11
∅(Degrees) ∅(Degrees)
SQUEEZING PROCESS:
• 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).
Horizontal direction:
Vertical direction:
Given that the slide first takes place between the Particle and
the moving jaw plate. The friction coefficient is μ
The friction coefficient between the particle and the fixed jaw plate
will be μ’
By solving the above equations we can obtain
and
It is inconsistent to the assumption
Given that the slide first takes place between the particle and the
fixed jaw plate and the friction coefficient is μ
The friction coefficient between the particle and the moving jaw
plate will be μ’
By solving the above equations we can obtain
And
It is rational.
COMPUTATIONAL STUDY FOR
SWINGING JAW
PLATE AND SWINGING LEVER
Design of Swing Jaw Plates
Height of jaw plate ≈ 4.0 x Gape
Height of jaw plate(L) = 1200mm
Width of jaw plate > 1.3 x Gape
Width of jaw (w) = 900mm
< 3.0 x Gape
Throw ((T)) = 50mm
Throw(T) = 0.0502(Gape)0.85
Model A B C D E F Weight(Ton)
Fig. Swinging jaw plate with one Fig. swinging jaw plate with
stiffeners three
ee stiffeners
s e es
Assumptions
1. Pre - processing
i 3 Post-
3. P t Processing
P i
5. Report Generation
1. Pre-Processing :
This will involve the complex physical structure to be converted into an equivalent Finite Element model.
Thi will
This ill be
b followed
f ll d by
b applying
l i the
th material
t i l properties
ti tot the
th model.
d l There
Th are five
fi structural
t t l properties,ti Young’s
Y ’
Modulus, Poisson Ratio, Density and Yield Strength.
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.
500
0.35
400 0.3
03
0.25
/mm2
300
mm
0.2
200 0 15
0.15
N/
0.1
100 0.05
0 0
100 200 400 600 800 900 100 200 400 600 800 900
mm mm
Fig. Von Misses stresses vs toggle plate width Fig. displacements vs toggle plate width
Analysis for Optimizing the Toggle Plate Location
A l i h
Analysis has b f d ,locating
been performed l ti th
the ttoggle
l plate
l t att position
iti off
0, 50, 100, 150, 200, 250, 300mm form bottom surface of the pitman.
125 0.18
100 0.15
0.12
75
mm
0.09
m
N/mm2
50 0.06
25 0.03
0
0 0 50 100 150 200 250 300
0 50 100 150 200 250 300
mm mm
TOGGLE PLATE
TOGGLE PLATE
LOCATION 0 50 100 150 200 250 300
Fig. swinging jaw plate with one stiffener, two stiffeners, three stiffeners
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 )
Where ax=horizontal acceleration & ay=vertical acceleration
Resultant Acceleration 1
2.0E+04
1 6E+04
1.6E+04 2
3
mm/s2
1.2E+04
m
8 0E+03
8.0E+03 4
4.0E+03
5
0 0E+00
0.0E+00
6
0 120 240 360
∅(Degrees)
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
jjaw pplate and p
pitman ffor a typical
yp PE 300x900 series type
yp jjaw crusher, it is ffound
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
g g jjaw p
plate is having
g without stiffener,
ff one stiffener,
ff two stiffeners
ff and
three stiffeners.
No of stiffeners Von Misses stress Deformation Mass of the jaw plate
(N/mm2) (mm) (kg)
0 54 0.0765 1018.314
1 158 0.836 701.882
2 68.3 0.145 739.683
3 53.9 0.0883 776.683
= 23.73%
Conclusion
1. 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,
domain some traditional motion parameters are calculated.
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,
out using four - noded tetrahedral
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 may be overdesigned for crushing a softer fragmental limestone.
taconite, limestone
REFERENCES
1. 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.
4 D
4. DeDiemar
Di RB
R.B. “N
“New concepts
t ini Jaw
J C h
Crusher t h l ” Minerals
technology”, Mi l
Engineering,Volume 3, Issues 1-2, 1990, Pages 67-74.
6 Gupta Ashok,
6. Ashok Yan D D.S.
S “Mineral
Mineral Processing Design and Operation
Operation-An
An introduction
introduction”,
Published by Elsevier, 2006, Pages 99-127.
7. Dowding Charles H, Molling R, Ruhl C," Application of point load-deformation
relationships
l ti hi andd design
d i off jaw
j crusher
h plates”,
l t ” International
I t ti l Journal
J l off Rock
R k
Mechanics and Mining Sciences & Geomechanics, Volume 20, Issue 2, April 1983,Pages
277-286.
9. 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.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 62-66
2006.Pages
Thank You