Analysis

The Analysis used in the project will largely be related to statics and mechanics of materials. The analysis of the loads on the wheels relates to mechanics of materials with max sheer in the carbon fiber. Additionally, FBD’s and force sum equations will be used to determine the loadings on the housing and bolts that hold the system together.

Analysis 1

The Analysis of the force exerted on the crushing wheel was needed to perform further calculations on the deflection of the wheels for requirements 8 and 10 listed in 1d. In the analysis, the moment of inertia was found and then imputed into the transverse shear equation to calculate the load on the wheels. This resulted in a 9,000 lb force being exerted on the wheels. This is shown in Appendix A-1 and there is no drawing associated.

Figure 3 Crushing Force

Analysis 2

The analysis for the shaft deflection was used to see if the 2-inch shaft selected would maintain the section 1d requirement of no deflection on the wheels of more than .05 inches. In the analysis beam deflection analysis was used to calculate the shafts displacement while under load which came out to be .0005 inches. When combined with eh deflection if the other wheel the total deflection for each set of wheels is only .001 inches under normal loading. This is all shown in appendix A-2 and there is no drawing associated.

Figure 4 Shaft Deflection

Analysis 3

This analysis is for the true force applied at each wheel with a wheel diameter of 8 inches. This will provide numbers for further calculation of housing deflection which addresses requirement 11 in section 1d. The analysis performed involved calculating the tangential and radial forces on the crusher teeth. It was found that each wheel provided 8,000 pounds of force which total for 2 wheels is 16,000 pounds. This is much greater than the required 9,000 pounds for delamination. All calculations can be found in Appendix A-3 and there is no current drawing associated.

Figure 5 True Crushing Force

Analysis 10

Analysis 10 was to determine if the threads in the bearing block bolts will hold the applied load. This pertains to requirement 12 in section 1d that says the bearing blocks must support 4500 lbs. The analysis performed was thread stripping strength, which produces a number for length of engagement. This length gives the threads the same strength as the bolt does in tension. Being that the dimension produced which was .2035 inches was less than the designed .5 inches this means that the threads will hold the applied load. From this, the bolt to be used was selected. The associated work for the analysis is in Appendix A-10 and the resultant design drawing and part are in Appendix B007.

Figure 7 Crusher Housing Assembly

Figure 8 eq(9-10)

Figure 6 Stripping Strength

Requirments

All moving components and nonmoving parts shall meet OSHA standards for safety.
Crusher shall delaminate more than 90 percent of the carbon fiber fed into the machine.
Drivetrain must have no more than 1.5” of slack in the chain operating the crusher.
Crusher wheels shall not deflect more than .05”.
Crusher will not stall while running.
Crusher will not deflect more than .5”
Housing shall not deflect more than 1/16 of an inch
Bearing Blocks must support 4500 lb’s each without yielding
All support bolts must hold an external load of 4500 lbs without yielding.
Crusher wheels shall be .35 inches apart.