This document provides a project report on the design of a can and plastic bottle crusher. It includes sections on the design synthesis, evaluation, analysis, manufacturing process, rapid prototyping, cost calculation, and conclusion. The project aims to design a portable crusher that can reduce the volume of used cans and bottles. The design utilizes a single slider crank mechanism powered by an electric motor and microcontroller to automatically crush items placed in the machine.

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Project Report
On
Can & Plastic Bottle Crusher
MSE 508 CAD/CAM (Solid Works)
Project Guide
Prof. Richard Walker
Group Members
Luis Javier Castellanos
Nikhil Kumar Mistry
Suryakiran Pamudurthy
Tulasiram Arza
Viral Kumar Jayswal
Vijayendrasinh Rathod

2. Page | 2
Table of contents:
Sr No Topic Page no
1 Abstract 3
2 Introduction 4
3 Design Synthesis 5
4 Design Evaluation 13
5 Design Analysis 30
6 Manufacturing process 31
7 Rapid Prototyping 32
8 NDT Methods 32
9 Cost Calculation 35
10 Conclusion 36
11 Appendix 37
12 Project management 37
13 Gantt Chart 38

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Abstract:
This Project describes about the design of various components of can or plastic bottle crusher
machine which would help to crush the used can or plastic bottles and would thereby help in waste
management and disposal. At initial stage we team members searched well for a good project on
can or plastic bottle crusher and we got such six different ideas from each team members and
diagrams of that given below. Finally we decided a Single slider crank mechanism based can or
plastic bottle crusher as project. This project aims to design a portable can or plastic bottle crusher
that could be installed anywhere and would aid crush of used can or bottles. This machine is widely
used in beverage industries or in scrap dealers shop to reduce the volume of the cans/bottles.
Hence in this design of various parts are necessary, and design of various parts due to which the
design quality of those parts will be improved. This project is semi-automatic by using electronics
equipment like sensors, microcontroller, IC’s etc. along with mechanical components due to which
crushed cans or bottles are need not to segregate from bin and also machine will not run idle.
After all process has been done, this crusher may help us to understand the fabrication and
designing process as well as electronics equipment that involved in this project. After the design
has complete, it was transformed to its real product where the design is used for guideline.
Crushers are major size reduction equipment used in mechanical and allied industries which
crushes different types of soft and hard materials. The can or bottle crusher machine is widely
used in beverage industries or in scrap dealers shop to reduce the volume of the cans/bottles.
Hence in this design and analysis of various parts are necessary. The Electric Motor and a
microcontroller make up the backbone for this project. Overall, this project involves processes like
design, fabrication and assembling procedures. This project is mainly about generating a new
concept of can or plastic bottle crusher that would make easier to bring anywhere and easier to
crush the can or bottle.
Keywords: Design consideration, Design process, Single slider crank Mechanism, Can or Plastic
bottles, Electric motor, PLC, Sensors, IC’s,

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Introduction:
The sole purpose of this project is to understand the fundamental knowledge of design and
mechanism. A can crusher can be defined as “A device used for crushing aluminum cans or plastic
bottle for easier storage in recycling bins thereby giving you extra space by flattening of cans”. This
project consists of designing and fabrication of a semi-automatic can/bottle crusher machine. In
order to reduce the waste, we planned to create a can/bottle crusher that will reduce the volume
of aluminum cans/plastic bottles by approximately seventy percent by which transportation
volume will increase and transportation cost will reduce. Can crushers are primarily used to save
space and for recycling. Also the purpose of this project is to understand the fundamental
knowledge of design and single slider crank mechanism a simple mechanism property. A
mechanical can/bottle crusher machine is basically one of the most aid able machines. It helps to
reduce the pollution of the environment. Thus helps to create a better place to live in, apart from
that, this can/bottle crusher can actually be the future mode of recycles apart from the recycle
bins. It can be placed everywhere, in the park, houses, restaurants, malls, canteens even in cars.
Using a similar type of a design from the diagram below, but with an added bin below the can
crusher concept of recycling can be applied. In this project, development of a recycle bin
can/bottle crusher so the cans might crush as flat and look as symmetrically as possible and
inserted the bin. The designs are an environment friendly and use simple mechanism properties.
The design is so done that the knowledge of designing, mechanism and forces. The study of
manufacturing was very important in order to carry out this project to ensure that what are needs
to do. This project is about designing and fabricating the Recycle Bin Can/Bottle Crusher Machine
to help people easy to crush the can as well as bottle and bring anywhere. This project involves
the process of designing the different parts of this crusher machine considering forces and
ergonomic factor for people to use. After the design has completed, it was transformed to its real
product where the design is used for guideline. This project is mainly about generating a new
concept of can/bottle crusher that would make easier to bring anywhere and easier to crush the
can or bottle. This machine is developed solely for the purpose of recycling as plastic bottles are
harmful to environment and aluminum to plants growth. Many people recycles items like paper,
glass, and aluminum, While these efforts are a vital part of the process, the true recycling path
continues long after recyclables are collected from household bins or community drop-off centers
etc. Collecting, processing, manufacturing, and purchasing recycled products create a closed circle
or loop that ensures the value of recycling. Recycling is a series of activities that includes the
collection of used, reused, or unused items that would otherwise be considered waste, sorting
and processing the recyclable products into raw materials, and remanufacturing the recycled raw
materials into new products.
At initial stage we team members searched well for a good project on can or plastic bottle crusher
and we got such six different ideas from each team members and diagrams of that given below.
Finally we decided a Single slider crank mechanism based can or plastic bottle crusher as project.

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DESIGN PROCESS
Design Synthesis:
This is about designing and fabricating the Recycle Bin Can/Bottle Crusher Machine to help people
easy to crush the can as well as bottle and bring anywhere. This project involves the process of
designing the different parts of this crusher machine considering forces and ergonomic factor for
people to use. While developing this design we have considered several attributes like
manufacturing ease, cost of manufacturing, maintenance, portability and conventional way of
using it.
Design Representation:
We have six preliminary ideas about the project
Design 1: Slider Crank bearing bottle crusher mechanism
Slider crank bearing bottle crusher
In this mechanism rotary motion generated from motor which transmits into the reciprocating
motion of the slider through different sizes of pulleys. From slider a piston may be connected
which will crush the bottle or can.
The major components used in this mechanism are
 Motor
 Pulleys
 Shafts
 Bearings
 Connecting rod
 Crank
 Slider

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Constraints in this mechanism:
 Complicated design
 High maintenance
 High cost
 Not conventional
Design 2: Pulley and V belt drive mechanism
Pulley and V belt drive mechanism
In this mechanism rotary motion generated from the motor through the V belt and pulley is been
converted to reciprocating motion of the slider. We will have two sliders, one slider is fixed and
another slider is operated by pulleys. Bottle or can is placed between two sliders in a holder and
will get crushed by sliders.
The components used in this mechanism are:
 Motor
 Pulleys
 Belts
 Sliders
 Holder
Constraints in this mechanism are:
 High maintenance
 Not portable friendly
 High cost

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Design 3: Bottle crusher by pressing
Bottle crusher by pressing
This mechanism involves pressing operation. Place the bottle in the V block (bottom) in a holder
slot and apply an external pressure from the press block (top). Bottle gets crushed and to be
removed manually. This is to be operated manually.
Components used in this mechanism are:
 Machined and Galvanized Mild Steel blocks
Constraints in this mechanism are:
 Manufacturing time
 Manually operated
Design 4: Bevel gear bottle crusher
Bevel gear bottle crusher

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In this mechanism motor is connected to bevel gears and generates a reciprocating motion. Bevel
gear is connected to shaft which is connected to spur gears and with a connecting shaft it is
connected to pulleys which will makes the slider in a linear motion (back and forth). Bottle is placed
in between slider and a crushing hood which is placed in between slider and gear mechanism.
The components used in this mechanism are:
 Bevel gears
 Spur gears
 Connecting shafts
 Pulleys
 Slider
 Crushing hood
Constraints in this mechanism are:
 Complexity in manufacturing
 Highly dependent in gear mechanism
 High cost
Design 5: Spur gear bottle crusher
Spur gear bottle crusher
In this mechanism spurs gears are used and are connected to a hand operated wheel. By using
connecting shafts rotary motion from bevel gears generated by a hand wheel gets converted to a
reciprocating motion. Bottle or can is placed in between the slider and bottle holder and will get
crushed by the slider.

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The components used in this mechanism are:
 Handle operated wheel
 Spur gears
 Sliders
 Connecting shafts
 Pulleys
Constraints in this mechanism are:
 Complexity in manufacturing
 High maintenance required
Finalized Idea
Design 6: Can or plastic bottle crusher with a single slider mechanism
The aim of this is to give the complete design information about the Can Crusher machine. In this,
the explanations and some other parameters related to the project are included. This machine is
basically works on the principle of Single Slider Crank Mechanism which is the heart of this machine
and it converts rotary motion into a reciprocating machine to crush the Cans/Plastic bottles. In
this, link 1 is fixed and link 2 which is a crank is rotating about fixed link 1 and converts this rotary
motion into the reciprocating motion of slider (corresponds to the link 4) by means of connecting
rod which corresponds to the link 3. This is the inversion of single slider crank which is obtained
by fixing link 1.
Single slider crank mechanism
This mechanism consist of mechanical components:
Sr no Name of component Material
1 Base plates MS & HDG
2 Side plates MS & HDG

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3 Flange for both sec MS & HDG
4 Connecting rod both
section
MS & HDG
5 Piston for both sec MS & HDG
6 Cylinder MS & HDG
7 Bolt for CR MS & HDG
8 Nuts for CR MS & HDG
9 Piston fixture for linear
movement
MS & HDG
10 Motor shaft MS & HDG
11 Plate cover MS & HDG
This mechanism also consists of electrical components and they are:
a. PLC
b. Sensor IR
c. Connecting wires
d. D.C motor
e. Relay
f. Power cables
Final assembly of slider crank mechanism

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Solid works role:
Here the procedure steps of solid works tools are simply described to design major components
of the project as below
a) Plate:
 Select plane
 Use central rectangle method
 Extrude it till required limit
 Make holes according to screw
Plate and Plate Cover
b) Pulley:
 Select plane
 Sketch circle
 Extrude base
 Draw sketch construction circle on it
 Draw circular pattern on it
 Extrude cut on all circle
 Make it holes according to screw pattern
 Draw small circle on same center
 Extrude cut through all
 Hole dimensioning to connecting rod
Pulley / Flange

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c) Connecting rod:
 Sketch a circle, draw a profile
 Swift base the profile
Connecting rod
d) Piston:
 Select a plane
 Draw rectangle by central method
 Draw center line
 Offset entities
 Draw circle on extra edge of rectangle center line
 Draw large circle on same center
 Make a big circle on other side
 Trip extra portion from center line
 Extrude base
 Extrude whole circle part
 Draw plane on a large circle (side plane)
 Extrude base till end point of the rod
 Draw small circle on same point center
 Extrude cut till end
 Mirror on both end up & down
 Boss extrude on both end of circle
 Draw central rectangle on top view
 Extrude cut on both side using mirror
 Use fillet

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Piston
Design Analysis:
Connecting rod:
Model Information
Model name: Connecting rod - Second section
Current Configuration: Default
Solid Bodies
Document Name
and Reference
Treated As
Volumetric
Properties
Document
Path/Date
Modified
Boss-Extrude1
Solid Body
Mass:0.326586 kg
Volume:4.14976e-
005 m^3
Density:7870
kg/m^3
Weight:3.20055 N
C:UsersVJRDes
ktopNew
folderConnectin
g rod - Second
section.SLDPRT
Dec 09 19:25:32
2015
Study name Static 1
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On

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Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from
SOLIDWORKS Flow Simulation
Off
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document
(C:UsersGaurangDesktopNew folder)
Units:
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2
Material properties:
Model Reference Properties Components
Name: Galvanized Steel
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises
Stress
Yield strength: 2.03943e+008
N/m^2
Tensile
strength:
3.56901e+008
N/m^2
Elastic modulus: 2e+011 N/m^2
Poisson's ratio: 0.29
Mass density: 7870 kg/m^3
SolidBody 1(Boss-
Extrude1)(Connecting
rod - Second section)
Curve Data:N/A

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Loads and fixtures:
Fixture name Fixture Image Fixture Details
Fixed-2
Entities: 2 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(N) -1.99995 -5.2188e-006 1.5173e-006 1.99995
Reaction
Moment(N.m)
0 0 0 0
Load name Load Image Load Details
Force-1
Entities: 2 face(s)
Reference: Edge< 1 >
Type: Apply force
Values: ---, ---, 1 N
Resultant Forces:
Reaction Forces:
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N -1.99995 -5.2188e-
006
1.5173e-006 1.99995
Reaction Moments:
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 0

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Study results:
Name Type Min Max
Stress1 VON: von Mises Stress 0.0369403 N/m^2
Node: 66928
4367.91 N/m^2
Node: 2077
Connecting rod - Second section-Static 1-Stress-Stress1
Name Type Min Max
Displacement1 URES: Resultant
Displacement
0 mm
Node: 1
2.52049e-007 mm
Node: 58956
Connecting rod - Second section-Static 1-Displacement-Displacement1

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Name Type Min Max
Strain1 ESTRN: Equivalent Strain 1.81357e-013
Element: 20791
1.7343e-008
Element: 11516
Connecting rod - Second section-Static 1-Strain-Strain1

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Plate:
Model Information:
Model name: Part3-Plate between two section
Current Configuration: Default
Solid Bodies
Document Name
and Reference
Treated As Volumetric Properties
Document
Path/Date Modified
Mirror2
Solid Body
Mass:11.1416 kg
Volume:0.00141571
m^3
Density:7870 kg/m^3
Weight:109.188 N
C:UsersGaurangD
esktopNew
folderPart3-Plate
between two
section.SLDPRT
Dec 09 19:25:32
2015

19. Page | 19
Study Properties:
Study name Static 1
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from
SOLIDWORKS Flow Simulation
Off
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document
(C:UsersGaurangDesktopNew folder)
Units:
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2

20. Page | 20
Material Properties:
Model Reference Properties Components
Name: Galvanized Steel
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises
Stress
Yield strength: 2.03943e+008
N/m^2
Tensile strength: 3.56901e+008
N/m^2
Elastic modulus: 2e+011 N/m^2
Poisson's ratio: 0.29
Mass density: 7870 kg/m^3
SolidBody
1(Mirror2)(Part3-Plate
between two section)
Curve Data:N/A
Loads and Fixtures
Fixture name Fixture Image Fixture Details
Fixed-1
Entities: 1 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(N) -3.04235e-005 -6.14689e-005 666.788 666.788
Reaction
Moment(N.m)
0 0 0 0
Load name Load Image Load Details
Force-1
Entities: 1 face(s)
Type: Apply normal force
Value: 150 lbf

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Mesh Information:
Mesh type Solid Mesh
Mesher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Element Size 0.221083 in
Tolerance 0.0110542 in
Mesh Quality High
Mesh Information details:
Total Nodes 118826
Total Elements 73943
Maximum Aspect Ratio 7.4934
% of elements with Aspect Ratio < 3 97.2
% of elements with Aspect Ratio > 10 0
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:12
Computer name: OHM

22. Page | 22
Resultant Forces
Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire
Model
N -3.04235e-
005
-6.14689e-
005
666.788 666.788
Reaction Moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire
Model
N.m 0 0 0 0
Study Results:
Name Type Min Max
Stress1 VON: von Mises Stress 305.796 N/m^2
Node: 109357
17084.8 N/m^2
Node: 116059
Part3-Plate between two section-Static 1-Stress-Stress1

23. Page | 23
Name Type Min Max
Displacement1 URES: Resultant
Displacement
0 mm
Node: 441
6.02297e-007
mm
Node: 2870
Part3-Plate between two section-Static 1-Displacement-Displacement1
Name Type Min Max
Strain1 ESTRN: Equivalent
Strain
1.67681e-009
Element: 29204
5.74077e-008
Element: 17527
Part3-Plate between two section-Static 1-Strain-Strain1

24. Page | 24
Flange:
Model Information
Model name: Part1-Flange - second section
Current Configuration: Default
Solid Bodies
Document Name and
Reference
Treated
As
Volumetric
Properties
Document Path/Date Modified
Boss-Extrude2
Solid
Body
Mass:0.503049 kg
Volume:6.39198e-
005 m^3
Density:7870
kg/m^3
Weight:4.92988 N
C:UsersGaurangDesktopNew
folderPart1-Flange - second
section.SLDPRT
Dec 09 19:25:32 2015

25. Page | 25
Study Properties:
Study name Static 1
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from
SOLIDWORKS Flow Simulation
Off
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document
(C:UsersGaurangDesktopNew folder)
Units:
Unit system: SI (MKS)
Length/Displacement Mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2

26. Page | 26
Material Properties:
Model Reference Properties Components
Name: Galvanized Steel
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises
Stress
Yield strength: 2.03943e+008
N/m^2
Tensile strength: 3.56901e+008
N/m^2
Elastic modulus: 2e+011 N/m^2
Poisson's ratio: 0.29
Mass density: 7870 kg/m^3
SolidBody 1(Boss-
Extrude2)(Part1-Flange
- second section)
Curve Data:N/A

27. Page | 27
Loads and Fixtures:
Fixture name Fixture Image Fixture Details
Fixed-1
Entities: 1 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(N) 2.40966e-008 1.26893e-008 1.55032e-008 3.13371e-008
Reaction
Moment(N.m)
0 0 0 0
Load name Load Image Load Details
Force-1
Entities: 1 face(s)
Type: Apply normal force
Value: 1 N
Mesh Information:
Mesh type Solid Mesh
Mesher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Element Size 0.0787326 in
Tolerance 0.00393663 in
Mesh Quality High

28. Page | 28
Mesh information – Details
Total Nodes 84810
Total Elements 56686
Maximum Aspect Ratio 3.8734
% of elements with Aspect Ratio < 3 99.9
% of elements with Aspect Ratio > 10 0
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:02
Computer name: OHM
Resultant Forces
Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N 2.40966e-
008
1.26893e-
008
1.55032e-
008
3.13371e-008
Reaction Moments
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N.m 0 0 0 0

29. Page | 29
Study results:
Name Type Min Max
Stress1 VON: von Mises Stress 0.453725 N/m^2
Node: 79200
4608.69 N/m^2
Node: 83498
Part1-Flange - second section-Static 1-Stress-Stress1
Name Type Min Max
Displacement1 URES: Resultant
Displacement
0 mm
Node: 757
1.93097e-007
mm
Node: 83575
Part1-Flange - second section-Static 1-Displacement-Displacement1

30. Page | 30
Name Type Min Max
Strain1 ESTRN: Equivalent Strain 9.51876e-012
Element: 11688
1.79416e-008
Element: 16056
Part1-Flange - second section-Static 1-Strain-Strain1
Simulation Conclusion:
For crushing the bottle you might not need that much of pressure from the external force, it
may be 50 IPS could be enough but we had applied thrice of that force so we could get Idea
about deflection, and as shown in figure after got report of simulation the component got
bended out of reach of acceptance force.so we can strongly conclude about stress analysis that
if product does not bear the external force of desired value then should stop processing and try
to find out missing input which can accept that value.
Design Evaluation:
We have made decision matrix of design evaluation and below is the matrix.
Decision Matrix
Designs/Ideas Manufacturing Coventional Cost Portability Maintenance Score
Slider crank bearing
Mechanism 5 5 5 7 5 5
Pulley and V belt
mechanism 6 6 6 7 6 6
Pressing mechanism 6 6 8 8 8 7
Bevel gear Mechanism 2 5 9 6 4 5
Spur gear Mechanism 2 5 9 5 4 5
Slider Crank
Mechanism 9 8 9 9 9 9

31. Page | 31
First row consists of the designs and all the other rows are attributes we have added to finalize
our design. Attributes we have used are manufacturing ease, conventional use, cost to
manufacture the mechanism, portability of the mechanism and finally maintenance. By the
decision matrix we moved forward with Slider crank mechanism and starting designing all the
parts.
PDR and CDR:
We have 6 preliminary designs before proceeding with the finalized design, we had a several brain
storming sessions before generating a decision matrix. We have looked into every aspect right
from the raw material to final cost of producing an equipment. The finalized design is easy to
operate and have less maintenance. By the decision matrix we have reviewed every design and
finally we went ahead with slider crank mechanism.
MANUFACTURING PROCESS:
The design and manufacturing are an environment friendly and uses simple mechanism
properties such as fulcrum system, single slider crank mechanism and automation properties etc.
In this, some crushing force is needed to crush the cans/bottles to reduce its volume by large
extent. The design is so done that the knowledge of designing, mechanism and forces are
increased. This project consists of designing and fabrication of an automatic can crusher machine
considering various important parameters. In this project, development of a recycle bin can/bottle
crusher so the Can/bottle might crush as flat and look as symmetrically as possible and inserted
the bin. As well as the study of manufacturing was very important in order to carry out this project
to ensure that what are needs to do. This project involves the process of designing the different
parts of this crusher machine considering forces and ergonomic factor for people to use. This
project is mainly about generating a new concept of can/bottle crusher that would make easier to
bring anywhere and easier to crush the can or bottle. After the design has completed, it was
transformed to its real product where the design is used for guideline.
The 1st stage the design of base plate was done. The basic idea behind this project is to
manufacture such a machine crusher that could be placed on recycle cans and crushing operation
could be carried out easily. Also the crusher should be portable for transport replacement and
maintenance.
In the 2nd stage the crushing mechanism was designed. Experimentally it was found that
the bottom and top portions of bottle are hard and thus it is difficult to crush the bottle along its
axis. Crushing a bottle latterly would require greater force and produce more vibration. Also
crushing the bottle latterly would not produce a optimally compressed waste i.e. the force
required is more and the area the crushed product occupies is also greater than the axially
compressed waste. Considering all these factors a reciprocating mechanism was incorporated to
crush bottle along its axis. The Crushing operation that is the desired action is carried out in only
one stroke of cycle. A flywheel is connected between the reciprocating ram and driving mechanism
to store the energy in idle stroke and deliver it in the operational stroke of crushing. Thus the
flywheel is incorporated in design. In this way the mechanism is made more efficient. Also the

32. Page | 32
flywheel acts as an intermediate link to connect the driving mechanism and the ram. The end of
the link connected to ram is attached to flywheel and thus motion is transmitted.
In the further stage of design driving mechanism for the flywheel and reciprocating parts
where designed. The design of driving mechanism should be such that maximum torque should
be transmitted. However the speed can be compensated to increase the torque.
Rapid Prototyping:
Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical
part or assembly using three-dimensional computer aided design (CAD) data. Construction of the
part or assembly is usually done using 3D printing or "additive layer manufacturing" technology.
Non Destructive Testing (NDT):
Nondestructive testing (NDT) is the process of inspecting, testing, or evaluating materials,
components or assemblies for discontinuities, or differences in characteristics without destroying
the serviceability of the part or system. In other words, when the inspection or test is completed
the part can still be used.
In contrast to NDT, other tests are destructive in nature and are therefore done on a limited
number of samples ("lot sampling"), rather than on the materials, components or assemblies
actually being put into service.
These destructive tests are often used to determine the physical properties of materials such as
impact resistance, ductility, yield and ultimate tensile strength, fracture toughness and fatigue
strength, but discontinuities and differences in material characteristics are more effectively found
by NDT.
Today modern nondestructive tests are used in manufacturing, fabrication and in-service
inspections to ensure product integrity and reliability, to control manufacturing processes, lower
production costs and to maintain a uniform quality level. During construction, NDT is used to
ensure the quality of materials and joining processes during the fabrication and erection phases,
and in-service NDT inspections are used to ensure that the products in use continue to have the
integrity necessary to ensure their usefulness and the safety of the public.
Non Destructive Test Methods:
Test method names often refer to the type of penetrating medium or the equipment used to
perform that test. Current NDT methods are:
1) Acoustic Emission Testing (AE) 2) Electromagnetic Testing (ET)
3) Guided Wave Testing (GW) 4) Ground Penetrating Radar (GPR)

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5) Laser Testing Methods (LM) 6) Leak Testing (LT)
7) Magnetic Flux Leakage (MFL) 8) Magnetic Particle Testing (MT)
9) Neutron Radiographic Testing (NR) 10) Radiographic Testing (RT)
11) Thermal/Infrared Testing (IR) 12) Ultrasonic Testing (UT)
13) Vibration Analysis (VA) 14) Visual Testing (VT).
15) Microwave Testing, Liquid Penetrant Testing (PT)
As our project detail components list, we can apply many NDT test methods to identify atomic
structure or internal component cavities. Here we can apply very popular NDT test method
‘Radiographic Testing (RT)’ to each project detail component as below.
NDT- Radiographic Testing (RT):
Fig.
Industrial radiography involves exposing a test object to penetrating radiation so that the radiation
passes through the object being inspected and a recording medium placed against the opposite
side of that object. For thinner or less dense materials such as aluminum, electrically generated
x-radiation (X-rays) are commonly used, and for thicker or denser materials, gamma radiation is
generally used.
Gamma radiation is given off by decaying radioactive materials, with the two most commonly used
sources of gamma radiation being Iridium-192 (Ir-192) and Cobalt-60 (Co-60). IR-192 is generally

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used for steel up to 2-1/2 - 3 inches, depending on the Curie strength of the source, and Co-60 is
usually used for thicker materials due to its greater penetrating ability.
The recording media can be industrial x-ray film or one of several types of digital radiation
detectors. With both, the radiation passing through the test object exposes the media, causing an
end effect of having darker areas where more radiation has passed through the part and lighter
areas where less radiation has penetrated. If there is a void or defect in the part, more radiation
passes through, causing a darker image on the film or detector, as shown in Figure.
Radiographic Testing (RT) Techniques:
Film Radiography:
Film radiography uses a film made up of a thin transparent plastic coated with a fine layer of silver
bromide on one or both sides of the plastic. When exposed to radiation these crystals undergo a
reaction that allows them, when developed, to convert to black metallic silver. That silver is then
"fixed" to the plastic during the developing process, and when dried, becomes a finished
radiographic film.
To be a usable film, the area of interest (weld area, etc.) on the film must be within a certain
density (darkness) range and must show enough contrast and sensitivity so that discontinuities of
interest can be seen. These items are a function of the strength of the radiation, the distance of
the source from the film and the thickness of the part being inspected. If any of these parameters
are not met, another exposure ("shot") must be made for that area of the part.
Computed Radiography:
Computed radiography (CR) is a transitional technology between film and direct digital
radiography. This technique uses a reusable, flexible, photo-stimulated phosphor (PSP) plate
which is loaded into a cassette and is exposed in a manner similar to traditional film radiography.
The cassette is then placed in a laser reader where it is scanned and translated into a digital image,
which take from one to five minutes. The image can then be uploaded to a computer or other
electronic media for interpretation and storage.
Computed Tomography:
Computed tomography (CT) uses a computer to reconstruct an image of a cross sectional plane of
an object as opposed to a conventional radiograph, as shown in Figure 9. The CT image is
developed from multiple views taken at different viewing angles that are reconstructed using a
computer. With traditional radiography, the position of internal discontinuities cannot be
accurately determined without making exposures from several angles to locate the item by
triangulation. With computed tomography, the computer triangulates using every point in the
plane as viewed from many different directions.

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Digital Radiography:
Digital radiography (DR) digitizes the radiation that passes through an object directly into an image
that can be displayed on a computer monitor. The three principle technologies used in direct
digital imaging are amorphous silicon, charge coupled devices (CCDs), and complementary metal
oxide semiconductors (CMOSs). These images are available for viewing and analysis in seconds
compared to the time needed to scan in computed radiography images. The increased processing
speed is a result of the unique construction of the pixels; an arrangement that also allows a
superior resolution than is found in computed radiography and most film applications.
Cost Calculation:
Considering steel, fabrication and galvanizing process as per Indian rupees (INR)
Part
Weight in
Kg
Fabrication
price
Galvanizing
Price
Flange 1 14 18
Plate 45.4 635.6 817.2
Rod 0.652 9.128 11.736
Piston 1 14 18
Hardware 0.25 3.5 4.5
Total
Cost
48.302 676.228 869.436
Final Cost 4443.784

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CONCLUSION:
From the above study, it is observed that by arranging different mechanical components along
with electronic components machine can be made automatic one to crush the Cans as well as
plastic bottles solely to reduce the volume. Thus human efforts can be reduced as well as time
also, because sorting system is installed there to separate the bottles and cans to reduce the
human fatigue. As above results shows that the volume can be reduced to a large extent i.e. near
about seventy percent volume can easily be reduced, thus transportation volume can be increased
and transportation cost can be reduced to a large extent and these can be reuse.

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APPENDIX:
Project Management:
Group Structure:
CSUN Manufacturing Inc.
Design Team Analysis Team
Documentation
Team
Final Product
Decision Making
Product Review

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Gantt Chart:
0 5 10 15
Group disscussion
Idea collection
Finalized Idea
Components drawings
Assembly
Disscussion
Working piece
Reports
Gantt Chart