International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

DESIGN AND ANALYSIS OF TWIN SHAFT SHREADER USING

PRO-E AND HYPERWORKS SOFTWARE

First Author : M. Sakthivel - II nd Year ME-Engineering Design

Second Author : G. Rajeshkannan- Asst. Professor
Third Author : M. Naveenkumar- Asst. Professor
Fourth Author : Dr. M. Muralimanokar–Head of the Department
Department of Mechanical Engineering
Maharaja Engineering College, Avinashi, Coimbatore
Anna University, Chennai, TN

ABSTRACT - This project deals with design and waste materials has observed in various operations of
analysis of twin shaft shredder blades. The model of machining, fabrication and etc. The twin shaft shredder
the twin shaft shredder is designed using PRO E is accommodate this waste scraps into small blocks of
CREO software, and the systematic analysis of the steel cubes in small portable chambers.
designed model is done using The mechanical shredding of waste is a tough
job, so electrical drive systems for shredders must be
HYPERWORKS/ANSYS software.
especially sturdy and reliable. This also applies to the
The model selected is twin shaft shredder gearedmotors from WEG‟s subsidiary Watt Drive,
from heavy machinery equipments manufacturing which the recycling machinery manufacturer uses
industries. In this model 16 blades are been used and todrive its new twin-shaft shredder.In the twin shaft
material is used commonly for the blades is heat shredder the material to be shredded is pulled between
threatened alloy steels-20MnCr5 steel. Now we are two shafts rotating slowly in opposite directions, each
replacing the material to EN8, EN31, EN19& EN36. fitted with cutter discs.
Then the model is analysis for the deflection, max The process is monitored by a PLC controller. If
stress induced and shear stress for both all materials the machine is overloaded or foreign objects get into the
under same load. cutting mechanism, the controller reverses the rotation.
The gap between the cutter discs is precisely defined to
I.INTRODUCTION
reduce the shredding force. A top-mounted stripping
The twin shaft shredder is commonly used for comb holds down the shredded material and prevents it
various kinds of shredding operations in heavy from winding around the shafts. The size of the output
machinery & high level products manufacturing material is determined by the cutter width or the number
industries. In those types of applications their scrap and of blades.

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

1.1 NEED FOR ANALYSIS limits based on the materials shredding in the
twin shaft shredder.
Recently, manufacturing industry
requires higher level of design and calculation The method developed, especially
almost in every part in both fabrication and nonlinear analysis, makes it possible to
testing which can make it possible to improve accurately design of blades. A research using
and develop products. So the twin shaft shredder nonlinear analysis to solve blades problem was
blades life need to increase for the heavy load & discussed by heavy machinery equipments,
mass production of shredding the various kinds however, only single blades model was
of parts like can be used for cost-effective considered. The purpose of design development
shredding of all sorts of industrial waste, rubber for the shredding blades are not only to reduce
metal and plastic waste, special waste, metal weight, quality and reliability, improve
swarf, electronic scrap ,etc durability when subjected to cyclic loading, or
improve quality of blades material and
processing, but also to reduce time and
manufacturing cost in the design process to gain
the highest economic benefit.

Computer technology in terms of

CAD/CAE (Computer-Aided Design and
Engineering) has been applied to solve
engineering problems for several decades.

Finite element method is an effective

part of CAD/CAE applied in design and analysis
to solve complicated problems.

Twin shaft Shredder blades simulation

using commercial code such as
HYPERWORKS, ANSYS, MSC/NASTRAN
and MDI/ADAMS by employed beam elements
Fig.1.1.Twin shaft shredder machine
to model leaf spring showed accurate behavior
prediction. Currently, the design of multi-leaf
In this method of twin shaft shredder has
springs and the prediction of behaviors are more
contains the blades in the action on the line of 16
efficient using finite element methods as
nos. the blades havethe life of maximum of the
presented in Ref.

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

1.2 MATERIALS ANALYSIS CHAPTER 2

In the state generally the alloy steels has
LITERATURE REVIEW
used of 20MnCr5 for manufacture the twin shaft
shredder blades.Theblade hastaken in the D. A. Fadare, T. G. Fadara and O. Y.
process of laser cutting and hardening process. Akanbi , Effect of Heat Treatment on
Then after the hardening the blades has under Mechanical Properties and Microstructure of
the controls of tool or bench grinding operations NST 37-2 Steel , Journal of Minerals &
in bench grinding. Generally the alloy steels has Materials Characterization & Engineering,
under heat treatment process up to 900̊ C to 960̊ C. 10(3), 2011, 299-308. This Study is based upon
We are going to change the materials of the empirical study which means it is derived
EN8, EN19, EN36&EN41instead of 20MnCr5 from experiment and observation rather than
alloy steels to improve the production cost of theory.
this material.And to improve the durability of
Main Objective is to Study the Effect on the
twin shaft shredder blades.
Hardness of three Sample Grades of Tool Steel
After the analysis which one of the i.e. EN-36, EN-8, EN19 and EN41after Heat
materials has cost effective & process effective Treatment Processes Such As Annealing,
and easy availability. That material has going to Normalizing, and Hardening & Tempering.[1]
take instead of Blades manufacturing. The
Nirav M. Kamdar, Prof. Vipul K. Patel
blades has design in the view of PRO E CREO
(2012),“Experimental investigation of
and analysis with the help of
machining parameters of EN36 steel using
Hyperworks/ANSYS.
tungsten carbide cutting tool during hot
machining”, International Journal Of
Engineering Research And Application, Vol.2
(3), pp.1833-1838.

This survey helps to find out the place of the

work to be carried out i.e. availability of setup,
techniques used for such, estimated time,
various cutting parameters, surface roughness&
Fig.1.2 Twin blade shredding unit
cost requires for such study carried out for such
industrial survey to be carried out we designed a
Survey questioner and selects various places

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

who offers heat treatment services Ludhiana Cutting speeds and Feed rates. Cutting force,
based. feed force and surface roughness were studied
under the influence of machining parameter at
After literature review and industrial survey
200 °C, 300 °C, 400 °C, 500 °C and 600 °C at
indicate for optimal cutting parameter, minimum
constant depth of cut 0.8 mm.
surface roughness (Ra) and maximum material
removal rate were obtained and developed The optimum result was achieved in the
model can be used to increase the machine experimental study by employing Design of
utilization at low production cost in experiments with Taguchi. . In present study,
manufacturing environment.[2] Analysis found that varying parameters are
affected in different way for different response.
A.S.Dhavale, V.R.Muttagi, (2012) Study of
The ANOVA analysis was used to obtain
Modeling and Fracture Analysis of Camshaft,
optimum cutting parameters.[4]
International Journal of Engineering Research
and Applications, Vol. 2, Issue 6.After selection Nirav M. Kamdar, Prof. Vipul K. Patel
of material & heat treatment processes further (2012),“Experimental investigation of
aims to perform mechanical & chemical analysis machining parameters of EN36 steel using
i.e. composition testing of the two tool steel tungsten carbide cutting tool during hot
EN-41, EN-19, before treatment. After machining”,
composition testing aims to do heat treatment International Journal Of Engineering
processes i.e. Annealing, Normalizing, and Research And Application, Vol.2 (3), pp.1833-
Hardening & Tempering to be carried on such 1838.In this research work, L18 orthogonal
material & after treatment aims to perform array based Taguchi optimization technique is
harness testing on the treated and untreated work used to optimize the effect of various cutting
samples.[3] parameter for surface roughness and Material
Removal Rate (MRR) of EN 36 work material in
S. Ranganathan and T. Senthivelan (2010),
turning operation.
“Optimizing the process parameters on tool wear
The orthogonal array, the signal to noise
of WC inert when hot turning of AISI 316
ratio and analysis of variance are employed to
Stainless steel,“Asian Research Publishing
study the performance characteristics in both dry
Network (ARPN), Vol. 5, No.7, pp. 24-35.In
and wet machining conditions of cylindrical
this work, the EN 36 Steel specimens heated
work pieces using Tin coated tungsten carbide
with gas flame were machined on a lathe under
cutting tool on CNC lathe. Five machining
different cutting conditions of Surface
parameter such as spindle speed, feed rate, depth
temperatures,
of cut, nose radius and the cutting environment

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

(wet & dry) are optimized with consideration of obtained and developed model can be used to
surface roughness. increase the machine utilization at low
Results of this study indicate for optimal production cost in manufacturing
cutting parameter, minimum surface roughness environment.[5]
(Ra) and maximum material removal rate were

CHAPTER 3

METHODOLOGY

Feasibility study of twin

shaft shredder

Study of various types of high

alloy steel

Study Performance analysis of high alloy

Steel material (Literature Review)

Modification in material properties

Performance Analysis of modified materials and

performance calculation

Design for twin shaft shredder

And load calculation

Conclusion and Future work

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

CHAPTER 4 interaction between metallic materials and their

EXPERIMENTAL PROCEDURES surroundings, thus affecting their stability in
aggressive environments.
Selection of the materials to
The incorporation of nitrogen imparts
manufacture the twin shaft shredder blades is to
better mechanical properties (friction and wear
basically identify the mechanical and chemical
resistance), but the dissolution kinetics
composition of the each different alloy steel
(corrosion resistance) remains closely related to
materials. The mechanical properties expose the
the composition of the corrosive medium. In this
values of maximum shear stress and strain,
context, the 20MnCr5 steel is largely employed
Ultimate tensile load, Elongation, yield strength
in industrial processes that take place in
and maximum temperature withstand limit.
aggressive environments. Hard iron nitrides are
4.1 PROPERTIES OF 20MnCr5 originated during the plasma treatment owing to
Plasma nitriding is a thermo chemical nitrogen diffusion in the near surface region at
process extensively applied in metallic materials temperatures below the eutectic point (593 °C).
science and surface engineering due to its Usually, two different phases
well‒known potential for improving properties corresponding to the ε-Fe2-3N and γ‟- Fe4N
such as hardness, wear and corrosion resistance nitrides are obtained, whose high hardness
of metallic parts. This surface treatment improves the strength, friction and wear
technique consists of the implantation of resistance. However, the highest wear resistance
nitrogen species at low energy into the steel is normally achieved when the close-packed
substrate and their subsequent diffusion into the hexagonal ε-Fe2-3N phase is primarily at the
bulk at temperatures above 300 °C. surface of the specimens. This is so because the
The interaction of nitrogen and steel mixed nitride layer of the ε- Fe2-3N and γ‟-
surface leads to the formation of different types Fe4N phases is, in fact, stressed due to a crystal
of metallic nitrides, which form the so-called lattice mismatch. Recent work have shown that
„„nitride layer”. Starting from the solid surface, the pitting corrosion resistance of the steel can
such a modified layer usually comprises an be significantly improved by nitride layers
oxide layer, a compound zone and a diffusion consisting of ε-Fe2-3N and γ‟-Fe4N phases.
zone. The resulting structure of these zones However, the effect of the nitride layer
depends on several processing parameters such microstructure on the pitting corrosion behavior
as the concentration of alloying elements, of steel is still not fully understood.
exposure time, substrate temperature and In this study, we address this question
gaseous mixture. The presence of a nitride layer by analyzing the influence of plasma processing
obviously changes the mechanisms of at optimal parameters (temperature 500 °C,

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

exposure time 4h and gaseous mixture 20 % H2, Chemical Composition is Important

80 % N2) on the corrosion, wear behavior and Testing for making sure that the Chemical
microstructure of plasma-nitrided 20MnCr5 Composition of the Purchased Material Matches
steel. with that of the International Standards of
4.2 COMPOSITION OF STEEL Materials. This Testing is done By Using the
MATERIALSEN41, EN8,EN19 AND EN36 Glow Discharge Spectrometer. Surface finishing
Selection of the materials to of Single Sample of Each material is done on the
manufacture the twin shaft shredder blades is to Belt Grinding Machine of 100Grit Belt. After
basically identify the mechanical and chemical Grinding and giving the material a good Surface
composition of the each different alloy steel finish Sample EN-8 is inserted in the Machine.
materials. The mechanical properties expose the The Machine Holds the Material by Vacuum
values of maximum shear stress and strain, Holder of the machine .
Ultimate tensile load, Elongation, yield strength
and maximum temperature withstand limit.

Table No.4.1 Composition of Tool Steel as per AISI Standard

MATERIAL COMPOSITION
*MARK C% Si% Mn% P% S% Cr% Mo% AL% Ni%

EN-8 0.45 0.30 0.50 0.024 0.025 1.40 _ _ _

EN-19 0.38 0.21 0.91 0.01 0.01 1.04 0.23 4.21 0.23

EN-36 0.70 0.25 0.42 0.012 0.01 1.05 0.14 _ 3.2

EN-41 0.40 0.30 0.60 _ _ 1.60 0.35 1.20 _

Then the Door is closed for

Industrial survey conduction are found to be
further Operation to be performed on the
very useful approach for selection of tool steel
material and command is given to the Specific
grade which will more beneficial for industrial
Software on the Computer.
point of view. From the literature review,
This is done by using the glow discharge
It is observed that less research work has
method, sample material is uniformly sputtered
been seen for Tool Steel i.e. EN19, EN8, EN36,
Spit up in an explosive manner] from the
and EN41 after Heat Treatment Processes Such
surface.

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

As Annealing, Normalizing, and Hardening & were performed at room temperature (≈20 °C)
Tempering. with a relative humidity of about 25%, a rotation
speed of 60 rpm, a normal load of 5 N and a
4.3EXPERIMENTAL PROCEDURE
wear track diameter of 3 mm. The wear rate is
20MnCr5 steel samples with nominal determined using the Archard equation
composition of 96.995% Fe, 0.20% C; 0.40 %
Ku= Vu/FN.D
Si; 1.25 % Mn; 1.09% Cr; 0.005 % Mo; 0.025%
P; and 0.035 % S. (In wt. %) were used in this Ku: the wear rate (m3N-1m-1); Vu: the
study. Before plasma nitriding, samples were wear volume (m3); FN: the applied normal force
polished with diamond powder and (N); D: the sliding distance (m). The wear
ultrasonically cleaned in ethanol and during the volume was calculated by measuring the mass
heating step to reach the processing temperature; lost. After the wear tests, the worn regions were
the specimens were ion-bombarded for 4 h in examined using a Jeol 5900 SEM.
Ar/H2 80/20 v/v plasma for cleaning purposes.
Analysis has been collected by referring
Specimens were nitrided in a vacuum various journals, books, papers etc. for the
furnace pumped down to low pressure (3 mbar) purpose of the Selection of tool steels grades
to minimize the oxygen contamination. The material on and work piece material on which
temperature of the samples is measured with the lesser study will be carried out. Another
use of a thermocouple. The nitriding parameters objective selection of Place where to Perform
were fixed similar to previous works. After Experiment, Market availability of the
processing, the samples were left to cool down recommended tool steel & their Cost Analysis,
slowly (during 8h) inside a vacuum chamber. Time Analysis to complete the experiment etc.
The morphology of the samples surfaces was The purpose of Selecting Tool Steel is
observed by Jeol 5900 Scanning Electron that they are Mostly Used in the Manufacturing
Microscope (SEM). The samples for SEM Industry. Tool Steel Grades like EN-8, EN19,
analyses were mirror-polished with colloidal EN41 and EN36 is selected for project. These
silica (mesh size = 0.05 μm). The nitrided layers steel grades were suggested to be the best during
were revealed at room temperature by chemical Surveying Various Industries for that objective
etching with Nital (2% v/v nitric acid in absolute we designed an industrial based questioner. The
ethanol). Carbon Composition is different from each other
in these materials. So we can easily differentiate
Wear tests were carried out with a pin-
between selected Parameters after Heat
on-disk tester, using a 5 mm diameter 100C6
Treatment. These three Materials are purchased
steel ball as the pin. Unlubricated wear tests

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From Material Shop of C.T.R Ludhiana. For Below shows the three Material undergoing
defining the objective of study to be carried out Spark testing.
more effectively and specific we designed Heat
Treatment Performance Index HTPI 2012. Chemical Composition is Important
Testing for making sure that the Chemical
There was a Requirement for 6 Samples Composition of the Purchased Material Matches
of Each Material for the Treatment and Testing with that of the International Standards of
Purpose. So we cut the Samples Using Power Materials. This Testing is done By Using the
Hack-Saw .All the Samples are 20mm in Glow Discharge Spectrometer. Surface finishing
Diameter and 2.5" to 3.5" in length. Chamfering of Single Sample of Each material is done on the
was done using Bench Grinder. During Belt Grinding Machine of 100Grit Belt. After
Chamfering we also Performed Spark Testing of Grinding and giving the material a good Surface
the material which is commonly used in the finish Sample EN-8 is inserted in the Machine.
Industries to analyze Different Material on the The Machine Holds the Material by Vacuum
basis of the Intensity of Spark Produced and Hold.
Flowers evolved during Spark Testing. Figure

EN8 EN19 EN41

Fig.4.1Pictorial View of Spark Testing for the Computer. This is done by using the glow
Various Materials discharge method, sample material is uniformly
sputtered Spit up in an explosive manner] from
Then the Door is closed for further the surface.
Operation to be performed on the material and It takes about 5-6 minutes for the chemical
command is given to the Specific Software on composition testing of a single material. The

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readings of the test are shown on the Display of the values Compared with that of Values as per
Computer in Tabulated Form. It Shows the International Standards.
Percentage Composition of Each Element .After
Testing Chemical Composition of the material,

Fig.4.2 Marks of Argon Gas after Composition Testing

The Testing of a Single Sample is done Annealing: After annealing value of hardness of
2-4 times from Different point on the smooth specimen is 55 HRA as compared to untreated
surface of the sample. The same Procedure for specimen annealed specimen becomes softer.
chemical testing is also done for EN-31 and D-3 So machine-ability properties of
also. The figure below show the Specimen specimen increase due to annealing we used
where the Chemical Composition Testing is HRA scale because after annealing EN-8
done leaving behind the impact of Argon Gas becomes soft and below 20 HRC. Value HRC
used at the time of testing. We can see three scale is not gives the accurate value and also
marks which states that Testing is Performed 3 value is not valid.
times on the Material.
Normalizing: After normalizing hardness is 25
4.4 MATERIAL PROCESS HRC given on Rockwell testing machine.It
METHODOLOGY shows after the normalizing the specimen
Before treatment EN8 hardness value becomes harder then annealing specimen .this is
is 10 HRC .Hardness of untreated material is due to formation of pearlite is more as compared
less due to low carbon % in EN8. After done to ferrite.
three treatments.

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Fig.4.3 Hardness Comparison of EN-8 Treated & Untreated

Hardening and Tempering: After H&T

improved the ductility, toughness, strength,
treatment specimen hardness is 48 HRC it shows
hardness and relive internal stress in the
H&T treatment makes hardest then other two
material. X-ray diffraction (XRD) method is
treatments. This means material has more wear
used to analyze the composition and the phase of
and tear as compared two other two heat
the alloy material.
treatments.
The experimental results of hardness
Comparison: After annealing specimen and microstructure are done to get idea about
becomes more softer then untreated specimen as heat treated EN36 steel. It is found that the
hardness value shown. After normalizing hardness of the EN36 steel is improved after the
hardness is more as compared to untreated heat treatment and the microstructure is changed
specimen. After hardening and tempering from ferrite to martensite.
specimen are hardest then other three specimens
En 36 steel has carbon content of 0.17%
due to formation of fine tempered martensite.
and the most common form of steel as it‟s
provides material properties that are acceptable
EN36 steel is an easily available and
for many automobile applications such as heavy
cheap material that is acceptable for heavy duty
duty gear, shaft, pinion, cam shafts, gudgeon
applications. Heat treatment on EN36 steel is

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

pins [1,8]. It is neither externally brittle nor examine the hardness, XRD and effect of
ductile due to its lower carbon content and lower microstructure of before and after heat treatment
hardness. As the carbon content increases, the on EN36 steel. In heat treatment, the machined
metal becomes harder and stronger. specimens are loaded in the chamber at below
800°C. Carburizing takes places at 920°C for
The process of heat treatment is carried
120 minutes then it is cooled by air and relaxing
out first by heating the metal and then cooling it
time is 75 minutes.
in water or oil or air. The purpose of heat
treatment is, to enhances the transformation of The purpose of the relaxing time is to arrest the
austenite to martensite i.e. (soft material to hard in and out of the carbon and it is followed by oil
material), to change the grain size, to modify the quenching at 820°C for 30 minutes, oil
structure of the material and relive the stress set temperature is below 80°C then by tempering at
up in the material. It is a one-time permanent 250°C for 90 minutes. In general, the untemper
treatment process and it is change the entire material structure has the high hardness and also
cross section of the material [5, 7]. The more brittle. Hence the tempering process
martensitic phase transformation is usually used should be done to reduce the brittleness, to
to increase the hardness of the steels. relieve the internal stress and to increase the
toughness and ductility of the material.
The various heat treatment processes are
annealing, normalizing, hardening, quenching
4.5 MATERIAL COMPARISON
and tempering. According to this work basically
After annealing specimen becomes more
focus on carburizing; it is a process of
harder then untreated specimen. After annealing
improving carbon on case. These are done by
hardness is more as compared to untreated
exposing the part to carbon rich atmosphere at
specimen. But specimen has not obtained good
the high temperature (close to melting point) and
microstructure. After hardening and tempering
allow diffusion to transfer the carbon atoms into
specimen are hardest then other three specimens
the steel. So, these work concentrations go
also having a good corrosion resistance.
through pack carburizing which can easily do in
Industrial survey conduction are found to
experimental setup. The carburizing process
be very useful approach for selection of tool
does not harden the steel it only increases the
steel grade which will more beneficial for
carbon content.
industrial point of view. From the literature
In heat treatments, both chemical review, it is observed that less research work has
composition and microstructure properties of a been seen for Tool Steel i.e. EN19, EN8, EN36,
case can be changed. The aim of this paper is to and EN41 after Heat Treatment Processes Such

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

As Annealing, Normalizing, and Hardening & review, it is observed that less research work has
Tempering. been seen for Tool Steel i.e. EN19, EN8, EN36,
Industrial survey conduction are and EN41 after Heat Treatment Processes Such
found to be very useful approach for selection of As Annealing, Normalizing, and Hardening &
tool steel grade which will more beneficial for Tempering.
industrial point of view. From the literature

Fig.4.4 Overview of all specimens related with project

Also very less work has been reported for AISI hardness is more as compared to untreated
EN19 Die Steel. It is observed that the effect of specimen. After hardening and tempering
hardness of work piece material after treatment specimen are hardest then other three specimens.
of Tool Steel i.e. EN41, EN8, and EN36 have After annealing specimen of EN-8 becomes
not been explored yet, so it„s interesting to Study more softer then untreated specimen as hardness
the Effect on the Hardness of three Sample value shown.
Grades of Tool Steel i.e. EN19, EN8, and EN36 After normalizing hardness is more as
after Heat Treatment Processes Such As compared to untreated specimen. After
Annealing, Normalizing, and Hardening & hardening and tempering specimen are hardest
Tempering. then other three specimens due to formation of
All these aspects will be addressed in fine tempered martensite. After annealing
research work. Indexing of HTPI 2012 is found specimen of EN41 becomes more harder then
to be very effective to defined objective untreated specimen. After annealing hardness is
function. After annealing specimen of EN19 more as compared to untreated specimen. But
becomes more softer then untreated specimen as specimen has not obtained good microstructure.
hardness value shown. After normalizing

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After hardening and tempering similar study EN41, mild steel, HC HCR cold
specimen are hardest then other three specimens working tool steel grades as so many.
also having a good corrosion resistance. Future HSS found to be very tool steel grade
Aspects of this study to carry out further is very difficult for such study as per investigation form
wide. Selecting of different tool steel material industrial survey. Using Different analytical
and compare them the effects on their approaches is also making an effective outcome
mechanical properties. Recommended material which is also recommended.
for further work done to be carried out for

CHAPTER 5
MODELLING AND ANALYZING PROCEDURE

5.1 MODELING THE TWIN SHAFT SHREDDER– COMMANDS USED IN THE PRO E CREO
2.0 SOFTWARE.

 CIRCLE- This command is used to create the circle.

 Sketch – select the plane or flat surface on the graphical window – click circle icon on the side
tool bar- select the center point of the circle- extend it to the required size-ok.

Fig.5.1 Twin blade shredding unit-CAD View

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

 LINE- This command is used to create the line.

 Sketch-select the plane or flat surface on the graphical window – click the line icon on the side
tool bar – select the start point and the endpoint of the circle-ok.

 TRIM- This command is used to break the two or more intersecting or crossed entities. The
entities may be a circle, line, arc or elipse in the window.

 Select the trim icon on the side tool bar- select the entities want to trim – ok.

 MIRROR- This command is used to create the symmetrical object of lines, circles or any
drawings in the sketch

 Select the mirror icon on the side tool bar- select the entities want to mirror – click the horizontal
axis or vertical axis or any axis created by manual on the graphical window – ok.

 DIMENSION CONSTRAINS- This command is used to create and modify the dimension
between two entities.

 Select the dimension constrain icon on the side tool bar- select the entities want to dimension it –
double click on the dimensioned line – change the dimension - ok.

 GEOMETRICAL CONSTRAIN – This command is used to constrain the two entities in

perpendicular, parallel, vertical, concentric or coincide, etc,..

 Select the geometrical constrain icon on the side tool bar – select the entities want to constrain -
select the required constrain – ok.

 EXIT WORKBENCH- This command is used to exit the sketcher workbench

 Select the exit workbench icon on the side tool bar – ok.

 PAD- This command is used to extrude or make the 3D object from the sketched 2D profiles in a
sketcher workbench

 Click the pad icon on the part design workbench – select the profile want to pad – enter the
dimension on the window - ok

 POCKET – This command is used to remove the material from the padded object

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 Click the pocket icon on the part design workbench – select the profile want to pocket – enter the
dimension on the window - ok

 RIB – This command is used to create the extruded object through the different shape of the
curve or complex profiles (ex. Springs)

 Click the rib icon on the part design workbench – select the profile – select the center curve – ok
 Rib is created only the two profiles are created into a two separate sketches

 THREAD- This command is used to define the thread on the circular surface inside and outside
(ex. used in bolts & nuts)

 Click the insert in the utility menu – dress-up features – select the thread/tap – select the lateral
surface and limit surface – enter the thread diameter, thread depth and pitch value on the window
– ok.

 CHAMFER – This command is used to chamfer the selected 3D object in the part design window

 Click the chamfer icon on the part design workbench – select the elements to chamfer – enter the
chamfer length and angle – ok.

 INSERT-EXISTING COMPONENT- This command is used to create the assembly from the
created parts in the part design

 Click the insert in the utility menu – existing component – select the component – open –ok.

 CONTACT CONSTRAIN – This command is used to mate the two flat surfaces or two circular
surfaces. This project we are using this command to mate the every leafs.

Fig.5.2 Twin blade shredding unit

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

 Click the insert in the utility menu – contact – select the components– click ok.

 OFFSET CONSTRAIN – This command is used to constrain the two objects between the
required dimensional intervals on it.

Fig.5.3 Twin blade shredder top view

 Click the insert in the utility menu – offset – select the components– enter the offset value - click
ok.

 ANGLE CONSTRAIN – This command is used to constrain the object in a required angle of our
need.

 Click the insert in the utility menu – angle – select the components– enter the angle value - click
ok.

 UPDATE – This command is used to update the every changes in the assembly workbench

 Click the update icon on the tool

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

Fig.5.4 Twin blade shredding unit-CAD View-1

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

BILL OF MATERIALS

S.NO. DESCRIPTION QTY

1 WASTE FOOD SHREDDER 1
2 PLATE AND BRG ASSEMBLY 2
3 BRG HSG PLATE 1
4 BALL BEARING-61904-2RS1 (SKF) 2
5 BLADE ASSEMBLY 1
6 SHAFT-RH & LH 1
7 BLADE-N1 8
8 SPACER-1& 2 2
9 HEX ROD SPACER 16
10 BLADE-N 8
11 SHAFT SUPPORT PLATE 16
12 BLADE SIDE COVER 2
13 BRG COVER PLATE 2
14 SPACER-GEAR 2
15 KEY-SHAFT LH & RH 1
16 NOMINAL SIZE M6 SPRING LOCK WASHER 36
17 M6X1.0X10 Hex Head Bolt 12
18 GEAR-36T 2
19 SPEACER-KEY 1
20 SPROCKET ASSEMBLY 1
SOROCKET CD
21 12.7 INCH CHAIN 1 =450mm(APPROX)
22 CHAIN_SPROCKET-36T 1 SPROCKET RATIO=3
23 CHAIN_SPROCKET-12T 1
24 SPEACER_SHAFT 2
25 M8X1.25X22 Hex Head Bolt 2
26 HSG ASSEMBLY 1
27 HSG_PLATE & PLATE-2 2
28 M6X1.0X18 Hex Head Bolt 24
29 M6X1.0 Hex Nut 8
30 V-BELT-(A -TYPE) 1
31 V-BELT-PULLEY-OD200 1
32 V-BELT-PULLEY-OD50 1

Table No.5.1 Twin shaft shredder bill of materials

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

MOTOR LOAD CALCULATION

TWIN SHAFT SHREDDER LOAD CALCULATION

PARAMETERS DATA UNITS

RADIUS OF THE BLADE 56 Mm

APPLIED LOAD 2 Kgs

NO OF BLADES 16 -

TORQUE 896 -

OUTPUT TORQUE 17920 N-mm

TORQUE 17.92 N-m

FACTOR OF SAFETY 1.3 -

TORQUE 23 N-m

MOTOR TORQUE FIND -

POWER (1 hp) 745 Kw

MOTOR POWER (2 Hp) 1490 Kw

MOTOR RPM 600 Rpm

FORMULA P=2*3.14*N*T/60 -

TORQUE T=(60*P)/2*3.14*N -

TORQUE 24 N-m

Table No.5.2 Twin shaft shredder motor torque calculation

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

BLADE RPM CALCULATION

TWIN SHAFT SHREDDER SPEED CALCULATION

PARAMETERS DATA UNITS

MOTOR INPUT RPM (N1) 600 Rpm

DRIVING PULLEY DIAMETER (D1) 180 Mm

DRIVEN PULLEY DIAMETER (D2) 30 Mm

FORMULA (R1) R1=DRIVEN PULLEY/DRIVING PULLEY -

RATIO (R1) 0.17 -

DRIVEN PULLEY MOTOR OUTPUT

N2=R1*N1 -
RPM

OUTPUT RPM 100 Rpm

DRIVING GEAR TEETH (T1) 12 -

DRIVEN GEAR TEETH (T2) 36 -

FORMULA (R2) R2=DRIVEN GEAR/DRIVING GEAR -

RATIO (R2) 3 -

N2=N3 RPM 100 Rpm

DRIVEN GEAR RPM (N4) N4=R2*N3 -

N4 300 Rpm

ROTOR IDEAL RPM 300 Rpm

Table No.5.3 Twin shaft shredder blade rpm calculation

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International Journal of Advanced Research in Basic Engineering Sciences and Technology (IJARBEST)

6.CONCLUSION AND FEATURE WORKS

CONCLUSION
In this study of project the twin shaft shredder blades has generally used of 20MnCr5 material for
blade manufacturing . It is capable to do the special process of heat treatment and annealing and
quenching in the temperature of 910̊ C-960̊ C.
But the 20 MnCr5material Quality of Life is maximum 30,000 cycles of rotation in shredding of
materials and rubbers. The process cost and service capability of this material is quite difficult on as soon
as possible.So in this project we are using the EN8, EN19, EN36 &EN41 materials for manufacture the
blades and reduce the process cost of this blade in shredding machine.
We have conduct the cutting, grinding, machining, hardening of major three tests hand overfeed
in these materials successfully. In these test we conclude and select the materials of EN36. Cause the cost
and availability of this material is simple in society. And this material is capable to our required process.

FUTURE WORKS
Design of the Twin Shaft Shredder machine & Blades has successfully completed with required
design calculation. The Required level RPM of Motor also analyzed and find out as per the project of
Twin Shaft Shredding Machine. In this project Design of twin Shaft Shredding Machine and Blades is
completed with Creo software and the blades and shredding machine is analyzed in future with the use of
Hyperworks/ANSYSsoftware. And calculate the stack up calculation of the blades assembly.
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