This presentation contains various aspects of metal cutting like mechanics of chip formation, single point cutting tool, chip breakers, types of chips,etc
This cone crusher is suitable for crushing various kinds of ores and rocks with medium over hardness and it has the features of reliable structure, high production efficiency, convenient adjustment and economic use. The spring safety system is the overload protection device which is able to make the iron go through the crushing chamber without damaging machine.
This presentation contains various aspects of metal cutting like mechanics of chip formation, single point cutting tool, chip breakers, types of chips,etc
This cone crusher is suitable for crushing various kinds of ores and rocks with medium over hardness and it has the features of reliable structure, high production efficiency, convenient adjustment and economic use. The spring safety system is the overload protection device which is able to make the iron go through the crushing chamber without damaging machine.
Casting Process and different types of casting defectsSheetalUdgave1
Foundry casting processes can be categorized into several types, each suited for different applications, materials, and production volumes. Here are some common types of foundry casting processes:
Sand Casting:
Sand casting is one of the most versatile and widely used casting processes. It involves creating a mold using a mixture of sand and a binder around a pattern. Sand casting is suitable for both ferrous and non-ferrous metals.
Investment Casting:
Also known as precision or lost-wax casting, investment casting involves creating a wax pattern, coating it with a ceramic shell, and then melting the wax out to leave a hollow mold. This process is capable of producing intricate and high-precision parts.
Die Casting:
Die casting involves forcing molten metal into a reusable steel mold or die under high pressure. It is commonly used for producing high-precision parts with a smooth surface finish. Common metals used in die casting include aluminum, zinc, and magnesium.
Permanent Mold Casting:
Permanent mold casting, or gravity die casting, uses a reusable mold made of metal (usually steel or cast iron). Molten metal is poured into the mold, and gravity is used to fill the cavity. This process is suitable for high-volume production.
Centrifugal Casting:
In centrifugal casting, molten metal is poured into a spinning mold. Centrifugal force distributes the metal along the mold's interior, creating cylindrical or disk-shaped parts. This method is often used for producing pipes, tubes, and cylindrical components.
Shell Molding:
Shell molding is a type of sand casting that uses resin-coated sand to create thin, shell-like molds. It provides a good surface finish and dimensional accuracy, making it suitable for medium to high production volumes.
Continuous Casting:
Continuous casting is primarily used for producing metal sheets, strips, and rods. It involves continuously pouring molten metal into a mold that is open at the top and bottom. As the metal solidifies, it is continuously withdrawn from the bottom.
Squeeze Casting:
Squeeze casting combines elements of die casting and forging. Molten metal is injected into a mold under high pressure while a mechanical force, or squeeze, is applied to enhance the filling of the mold and reduce porosity.
V-Process Casting:
V-Process casting, or vacuum molding, uses a vacuum to create a mold without the need for a traditional flask. It involves the use of a thin plastic film as the mold surface and is known for producing fine details and complex shapes.
Slush Casting:
Slush casting is a low-pressure casting method used for hollow or semi-hollow parts. Molten metal is poured into a mold, and after a short period, the excess metal is poured out, leaving a solidified shell.The choice of casting process depends on factors such as the type of metal, the complexity of the part, production volume, and required precision. Each casting method has its advantages and limitations,
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
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Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
2. Introduction to Crushing
Types of Crushing
Jaw Crushers : (a) Blake Crusher
(b)Dodge Crusher
Blake versus Dodge crushers –advantages and disadvantages
Factors affecting efficiency of crushers
Gyratory Crushers
Comparision between jaw and gyratory crushers
Cone Crushers
Hammer Mill or Pulverator
Stamps
Spring Rolls
Sledging Rolls
Manual Crushing
Conclusion
Bibliography
3. A crusher is a multi dimensional machine which is designed to
reduce large size materials into smaller size materials .
Crushers may be used to reduce the size, or change the form of
waste materials so they can be more easily disposed of or
recycled, or to reduce the size of a solid mix of raw materials .
Crushers are normally low speed machines that are designed
for breaking large lumps of ores and stones, even aving a size
with a diameter of over one and half meter. The purpose of
crusher is to reduce the size of the materials for making them
usable in construction or industrial use, or for extraction of
valuable minerals trapped within a ore matrix.
4. Crushing is the process of transferring a force amplified by
mechanical advantage through a material made of molecules
that bond together more strongly ,and resist deformation more,
than those in the material being crushed do.
Crushing devices hold material between two parallel or tangent
solid surface, and apply sufficient force to bring the surface
together to generate enough energy within the material being
crushed so that its molecules separate from or change alignment
in relation to (deformation), each other .
There are four basis ways to reduce material.
1. Impact
2. Attrition
3. Shear
4. Compression
7. • The jaw crushers mainly divides into 2 types :Blake Crushers, Dodge
Crushers .
A. Blake Crushers: The essential parts comprise-
1. Fixed jaw (Mn steel)
2. Jaws (Swing jaw ) Mn steel
3. Eccentric
4. Flywheel
5. Pitman
6. Toggle
7. Fixed support for toggle
8. Exit
9. Feed
8. The fly wheel is actuated by a prime mover.
The pitamen attached to the eccentric also moves up and down
carrying the toggle with it .
Since one end of the toggle is fixed, the movable jaw, attached to the
other end, moves back and forth from the fixed jaw.
Thus any material lodge in the throat of the crusher is broken up.
11. The dodge type of crusher is also similar but the swing jaw is
pivoted at the bottom.
The important parts are :
1. Fixed jaw (Mn steel)
2. Mouth of crusher
3. Movable jaw
4. Axle for jaw
5. Fly wheel
6. Pitman
7. Eccentric
12. • When the fly wheel(5) rotates, the
pitman(6) moves up and down, on the
eccentric.
• This causes the lever arm(8), attached to
the moveable jaw(3), to move up and down
,while the upper portion of the jaw, which
is pivotted at its lower end, swings forward
and backward.
• The feed, dropped into the throat, is
delivered at X .
• Jaw plates, for crushers, are made of
chilled iron, white iron, high carbon .
13. 1. The Blake crusher delivers a product in which the sizes are
variable; as the lower portion of the jaw opens and closes. The
Dodge crusher delivers a more uniform size of product as the
opening at lower end is fixed.
2. The capacity is less for the Dodge crusher as compared to the Blake
of same size.
3. Nipping(holding material at the mouth) is less effective in the
Dodge and larger lumps jump out by slipping.
4. Sticky ore tends to clog in the Dodge crusher.
14. a) Width of discharge opening-this is varied by adjusting the toggles in the
Blake, or by inserting wedges in the Mn steel cheek plate of the Dodge
crusher .
b) The throw varies from 3/8 in. in the small crushers to 1 in. in the larger
machines, but the maximum throw is about three times. Brittle rocks,
like quartzite, and granite, require minimum throw, whereas tough rocks
like ,trap, limestone and rocks which resist compression like shale, etc,
require larger throw .
c) Speed has no market effect on the efficiency, but at higher speeds, the
efficiency drops.
d) Size of feed depends on the gape, nip angle, and the angle, of the mouth
opening which is about 24 degree. Taking these into consideration, the
largest size of the individual piece of rock ,should not exceed 80 to 90 %
of the gape .Larger fragments tend to clog the mouth.
15. • Gyratory crushers were developed after jaw crushers to supply the
crushing machines of higher capacities.
• The crushing action of gyratory crushers is similar to that of jaw
crushers ,since in this case also the moving crushing element
approaches and recedes from a fixed crushing element.
• But the relative motion of the crushing faces is due to the gyration of
the eccentrically mounted cone.
• Some tangential force and simple squeeze are also incorporated.
• Interaction between particles takes place and as a result the ore
crushed against.
• These are 3 types of gyratory crushers: Suspended spindle,
Supported spindle, Fixed spindle .
18. • Cost of the gyratory crusher is only 29 to 72% of that of the jaw
crusher of the same capacity.
• Cost of installation of the gyratory machine is less.
• The housing ,for the gyratory machines, costs more as it occupies
more space.
• Feed arrangements for the gyratory crusher are simpler than for the
jaw crusher.
• The gyratory machines are more efficient than the jaw machines and
more so, when working on full load .
• Maintenance costs are more for the gyratory machines.
• The gyratory crusher can work more efficiently where the material
tends to break in slabs. The general rule or thumb rule is that if
tonnage per hour is less than 0.115,then a jaw crusher is to be
preferred.
20. • Cone crusher was developed in 1920’s and since then it has gained
wide acceptance and now it is regarded as the standard crushing
appliance in the intermediate range.
• This is very much like a coffee grinder in principle, and the essential
parts are-
1. Feed hopper
2. Feed distributor tray
3. Fixed jaw
4. Breaking head
5. Spindle axle
6. Bevel gear drive for the breaking head
7. Pulley drive
21. • The cone crushers are made in two types, i.e. (a) standard
(b)short head
• These differ mainly in the shape of the crushing cavities.
• The standard crushers are used for the reduction of coarser feeds,
and the product is usually in the range of 6 and 60 mm.
23. • The machine comprises a
rotor(1),which consists of two
circular discs(2),to which the
hammers(3) are pivoted.
• The rotor is rotated about the axle.
• A grate or grizzly(4) is placed at
the lowest position and the
discharge passes swing out, under
the action of centrifugal forces and
the material lying on the breaker
plate(6), is stuck and it
disintegrates.
25. • Stamps are in principle large size pestle
and mortar.
• The pestle is acruated mechanically-
either by steam or compressed air
directly.
• When stamp is lifted by a cam and
drops down by gravity, it is called a
gravity stamp.
• In the gravity stamp the cam(3),on
rotation ,lifts the pestle.
26. While lifting, a rotary motion is
also imparted, to the pestle by the
cam.
The mortar is provided with
screen(6),on one side so that only
the undersize material flows out,
while the coarser fraction is
retained for further breaking &
crushing.
27. Stamp Mill, Murphy Park, Sunnyvale, CA
Image Source:
https://commons.wikimedia.org/wiki/File:Stamp_mill_ore_crusher_(Orphan_Girl_Mine,_Butte,_Montana,_USA).jpg
28. • The roll essentially comprises two rollers(1)
and (2) steel cased (x) mounted on a
common frame (7).
• The roller (2) is rigidly fixed by bolts, while
the roller (1) is mounted on a sliding block,
which moves on the frame (7).
• The moveable roll (1), is kept in contact with
roll (2) by the pull of a tension bar (3),
provided with springs.
• Both the rollers are driven by pulleys but the
pulley for roller (1)is smaller than that of
roller (2) (fixed roller).
• Thus, the speed, of the moveable roller ,is
greater than that of the fixed roller .
• A feed hopper is attached at the median
position between the rollers.
29. The angle of nip generally is about 25 degree, and the diameter of rolls
required, may be got from the formula
t=d+D/40
where t=the maximum thickness of feed,
d=the setting of the rollers, i.e, space between them,
D=diameter of rollers
The reduction ratio varies from 1 to 2, in general , but it is slightly
more for heavy duty rolls .
Capacity of a roll, T=R
31. • Single roll crusher is like a roll and also like a
crusher in its functions. This type is the sledging
roll(2) is a breaking plate and hinged at (1).
• It is held in position by a tension bolt (5)
tightened with springs(6).
• A roller (4), provided with hard teeth , is rotated
by gearing through pulley and belt arrangement.
• Material which is dropped into the mouth (3), is
pulverised as it gets between the breaking plate
(2) and the roller (4).
• The roller speed is 200 to 300 ft per Min .
• This type of crusher is used for fairly soft rocks
e.g- Limestone, shale ,clays .
32. • Breaking or crushing is also carried out manually.
1. Sledging is the process of breaking rocks with sledge hammers which are
10-16 lbs ,in weight.
2. Spalling is reducing 6-8 in lumps to 2 0r 3 in. sizes with the help of 2 to 3
lb. hammers .
3. Cobbing is further reduction of sizes from 2 to 3 in to less .
4. Explosives are also used in breaking up large boulders.
5. Pile driver type of breakers were used earlier ,but these are not popular
now .In pile driver type of breakers ,a heavy solid iron cylinder was lifted
up, by a pulley block, and dropped suddenly on the rock .Shattering was
produced in this manner .
6. Heating and quenching is one of the earliest methods of breaking rock,
used by man, for mining. This method was also practised, by the miners,
in India .This methods is reported to be efficient in liberating and
breaking quartz of high purity.
34. The modern crusher range is ideal for shaping
applications including making chips, sands, concrete
manufacture and glass recycling.
The range includes both horizontal and vertical impact
crushers.
They are used as primary, secondary or tertiary crushers
depending on the Producers final –product-size needs.