Project Seminar on
Optimum Design and Analysis of Swing Jaw Plate of a Single
Toggle Jaw CrusherUnder the id U d th guidance of f
Prof. N. Kavi
Presented by B B V L DEEPAK Roll No:208ME103 M/c Design &
Analysis
Mechanical Engineering DepartmentNational Institute of
Technology Technology,
Rourkela
Outline of Present Work1. Introduction and Scope for Study2.
Literature R i 2 Li Review 3. Theoretical Analysis heo etical
nalysis 4. Computational Study 5. Results, Discussion and
Conclusion References R f
INTRODUCTION TO JAW CRUSHERSPrimary Crushers Mechanism:
Compression. Size: Rectangular/Square Opening For instance 24 x 36
opening of 24" by 36 instance, Two jaws,Stationary Movable
DIFFERENT TYPES OF JAW CRUSHER1) Blake Type Jaw C CrusherLarger,
rough, blocky as well as sticky rock or ore lumps can be y p
crushed. Reinforcement of the crusher is possible with the help of
high strength crusher frame to crush very hard rock or ore lumps.
It is very simple to adjust to prevent much of wear and also t h f
d l very easy to repair, Maintenance of the crusher is very easy
easy.
Single-Toggle Jaw Crusher
Double-Toggle Jaw Crusher
2) Dodge Type Jaw CrusherThey are comparatively lower in
capacity y p y p y than the Blake crushers and are more commonly
used in laboratories.
Dodge Type Jaw Crusher
COMPONENTS OF JAW CRUSHER
JAW CRUSHER WORKING PRINCIPLE
A fixed jaw, mounted in a "V" alignment is the stationary
breaking surface, while the movable jaw exerts force on the rock by
forcing it against the stationary plate The space at plate. the
bottom of the "V" aligned jaw plates is the crusher product size
gap, or the size of the crushed product from the jaw crusher. The
rock remains in the jaws until it is small enough to pass through
the gap at the bottom of the jaws.
OBJECTIVE OF PRESENT WORKThe force distribution is analyzed with
the kinematic analysis of the swinging jaw plate. Obtained results
from the kinematic analysis of the moving jaw y gj and the crushing
force distribution analysis, the jaw plates wear is analyzed on a
macroscopic level. Design and Analysis of Swing Jaw Plates for Jaw
Crusher.Top opening=304 mm Bottom opening=51 mm B i 51
FEM is applied to the analysis of the swing jaw plate&
lever. To T improve the strength/weight ratio using stiffener
elements. h h h ff l
LITERATURE REVIEWThe jaw crushers are used commercially to crush
material at first in 1616 as cited by Anon [1].It is used to
simplify the complex engineering. An important experimental
contribution was made in 1913 when Taggart [2] showed that if the
hourly tonnage to be crushed divided by Square of the gape
expressed i i h yields a quotient l th 0 115 uses a j crusher. d in
inches i ld ti t less than 0.115 jaw h Lindqvist M.and Evertsson C.
M. [3] worked on the wear in rock of crushers which causes great
costs in the mining and aggregates industry industry.DeDiemar R.B.
[4] gives new ideas in primary jaw crusher design and manufacture
of Jaw crusher utilizing open feed throat concept power savings and
automation features Jaw concept, features. crushers with two jaw
openings can be considered to be a completely new design.
Gupta Ashok and Yan D S [6] worked in design of jaw crushers
which impart D.S. an impact on a rock particle placed between a
fixed and a moving plate.
Dowding Charles H. [7] designed jaw plates to reduce efforts to
decrease energy consumed in crushing have lead to consideration of
decreasing the weight of the swing plate of jaw crushers for easily
crushed material. Cao Jinxi [9] worked on the certain domain,
called the liner domain, of the coupler plane is chosen to discuss
the kinetic characteristic of a liner or a crushing interface in
the domain. Based on the computation and the analysis of the
practical ki ti characteristic of th points along a li ti l kinetic
h t i ti f the i t l liner paralleling t th ll li to the direction
of coupler line Qin Zhiyu [10] studied different positions of
liners in the coupler plane have different moving features, the
motion of points along the liners in the computing domain is quite
different from that of them in the straight-line coupler .
THEORETICAL ANALYSIS
KINEMATIC ANALYSIS OF SWINGJAW PLATEDimensions and operating
parameters When considering the jaw crusher of Figurer, there are
variables of the feed that define the important machine
dimensions.
The feed particle sizes of interest are:1. The size of particle
that enters the crusher. 2. The size of particle that can be
nipped. 3. The i 3 Th size of particle th t can f ll th f ti l that
fall through th chamber at any ti h the h b t time. 4. The size of
particle that can fall through the chamber when the j jaws are open
as wide as possible. p p
The dimensions defined by those particle sizes are:1. The gape -
the distance between the jaws at the feed opening 2. The closed
side set (CSS) - the minimum opening between the jaws during the
crushing cycle (minimum discharge aperture) 3. The 3 Th open side
set (OSS) th maximum di h id t the i discharge aperture t 4. The
throw the stroke of the swing jaw and the difference between OSS
and CSS.
Y V a B bM (90) K
A(a,b)K
xN
L
P
y Jawcrushersketch
O
X C
U
r 12.0
l 1085
k 455.0
a 45.3
b 815.4
n(rpm) 300
mn + (mn) (n +1)(m 1) sin = n +12 2 2 2
cos = m + nsina + b + r + l k 2r(asin + bcos) m= n +12 2 2 2 2
2
a r sin i n= b r cos 0 36 72 108 144 180
=Crankanglemadeby vertical g / p =Angleb/wtwoplates216 252 288
324 360
18.89766 19.47334
19.994 20.24856 20.14637 19.74163
19.1922 18.69555 18.42959 18.50073 18.89766
Points on liner Pointsonliner900 450 750 400 600
Horizontal Horizontal Displacements
Vertical Displacements VerticalDisplacements900
700
350 500
450
300
y(mm)
mm
300 mm
250
300
200 150 100 150 0 100 100 150 50 300 0 150 300 450 300 300 0 120
240 360 0 120 240 360 (degrees)
0 x(mm) (Degrees)
x = u cos + (l v)sin + a r sin y = u sin (l v)co s + b rco s
6thpointtrack320 310 y(m mm)mm m
d h h i l d xandyarethehorizontaland
verticaldisplacementsinglobal coordinatesVertical displacementat6th
point320 310 mm m 300 290 280
Horizontal displacementat6th point232 228
300 290 280 210 220 230 240 x(mm)
224 220 216 0 120 240 360 6 (Degrees)
0
120
240
360 6
(Degrees)
d r (a + l sin ) cos + (l cos b) sin = d l a r sin + (b r cos )
d d v = (l v ) cos r cos u sin i d d X
vx=VelocityinXdirection HorizontalVelocities450 300 150 mm/s 0
150 300 450 0 120 (Degrees) 240 360 1 2 3 4 5 6 7 8 9 10 11
d d v = (l v) sin + r sin + u sin d d Y
Vy =VelocityinYdirection y VerticalVelocities600 1 400 2 3 200
mm/s 4 5 0 6 7 200 8 9 400 10 11 0 120 (Degrees) 240 360
600
d r cos( + ) v = (l v) d U
d + r sin( + ) v = u d V
VU =VelocityinUdirection VV =VelocityinVdirection
VelocitisinUDirection600 400 200 mm/s 0 200 400 600 0 120 (Degrees)
240 360 1 2 3 mm/s 4 5 6 7 8 9 10 11 450 0 120 (Degrees) 240 360
300 150 0 150 150 450 300 1 2 3 4 5 6 7 8 9 10 11
VelocitiesinVDirection
d d a X = [ (l v)cos u sin ] 2 [ (l v)sin + u cos ] + r sin d d
2
2
d d aY = [ (l v)sin + uco s ] 2 + [ (l v)co s u sin ] + rco s d
d 2
2
HorizontalAccelerations1.5E+04 1 1.0E+04 1 0E+04 5.0E+03 mm/s2
0.0E+00 5 0E 03 5.0E+03 1.0E+04 1.5E+04 0 120 240 360 (Degrees) 2 3
mm/s2 4 5 6 7 8 9 10 11 2.0E+04 1.5E+04 1.0E+04 5.0E+03 0.0E+00
5.0E+03 5.0E+03 1.0E+04 1.5E+04 2.0E+04 0
VerticalAccelerations1 2 3 4 5 6 7 8 9 120 0 (Degrees) 240 40
360 10 11
Velocity&Acceleration16
8 HorizontalVelocity 0 VerticalVelocity HorizontalAcceleration 8
VerticalAcceleration V ti l A l ti
mm/s;mm m/s2
16 0 120 (Degrees) 240 360
Due to the connection between the moving jaw velocity and the
eccentric shaft rotational speed, the velocity and the acceleration
parameters are relative to angle , rather than time t.
d 2 d 2 aU = (l v) + r sin( + ) 1 + d d
d 2 d 2 aV = u + rco s( + ) 1 + d d
au istheaccelerationinUDirection Andav
istheaccelerationinVDirection AccelerationsinUdirection1.5E+04
1.0E+04 5.0E+03 mm/s2 0.0E+00 5.0E+03 1.0E+04 1.5E+04 0 60 120 180
(Degrees) 240 300 360 1 2 3 mm/s2 4 5 6 7 8 9 10 11 1.5E+04 0 120
240 360 (Degrees)
AcceleratiosinVDirection1.5E+04 1.0E+04 5.0E+03 0.0E+00 5.0E+03
1.0E+04 1 2 3 4 5 6 7 8 9 10 11
SQUEEZINGPROCESS:
The force on the particle during the squeezing process is shown
in the Fig.
Since the horizon and the vertical velocities of the moving jaw
are variable during the squeezing process, the forces on the
particle are also variable in different stage.
When the component of the vertical velocity in the moving jaw
plate direction is bigger than that of the horizontal velocity in
the same direction, the forces on the particle are shown in Fig
(a). When the component of the vertical velocity in the jaw plate
direction is smaller than that of the p f y j p f horizon velocity,
the forces on the particle are shown in Fig (b). Because the
gravitational force is much smaller than others, it can be
ignored.
EquilibriumunderFig.(a)conditionfortheparticlewillrequire
Horizontaldirection:
Verticaldirection:
GiventhattheslidefirsttakesplacebetweentheParticleand
themovingjawplate.Thefrictioncoefficientis
Thefrictioncoefficientbetweentheparticleandthefixedjawplate
willbe
Bysolvingtheaboveequationswecanobtain
and
Itisinconsistenttotheassumption
Giventhattheslidefirsttakesplacebetweentheparticleandthe
fixedjawplateandthefrictioncoefficientis
Thefrictioncoefficientbetweentheparticleandthemovingjaw
platewillbe Bysolvingtheaboveequationswecanobtain
And
Itisrational.
COMPUTATIONALSTUDYFOR SWINGINGJAW PLATEANDSWINGINGLEVER
Design of Swing Jaw PlatesHeight of jaw plate 4.0 x Gape Width
of jaw plate > 1.3 x Gape < 3.0 x Gape Throw(T) =
0.0502(Gape)0.85 Height of jaw plate(L) = 1200mm Width of jaw Throw
(w) = 900mm ( ) (T) = 50mm
Model 300X400 300600 300X750 300900
A 400 600 750 900
B 300 300 300 300
C 1050 1750 2050 1850
D 1180 1680 1930 2490
E 1300 1680 1850 2350
F 700 950 1150 1500
Weight(Ton) 2.8 6.5 12 17.5
Dimensional Chart for Jaw Crusher
Solid Modeling of Swing Jaw Plates & Pitman
Fig. Swinging jaw plate with one stiffeners
Fig. swinging jaw plate with three stiffeners ee s e e s
Fig. swinging jaw plate with two stiffeners Fig. swinging lever
of the single toggle jaw crusher
Swing Jaw Plates & Pitman Static Stress Analysis Using CATIA
Assumptions A static analysis calculates the effects of steady
loading conditions on a structure, while ignoring inertia and
damping effects, such as those caused by time-varying loads. Here
analysis is based on the assumption that the point load strength of
the disk and irregularly shaped particles to be equal and t il
point l d of diff d tensile i t loads f different particle sizes
are acting normal t ti l i ti l to the plate.
Features of Generative Structural Analysis as FEA ToolUsing
CATIA V5 the overall process for FEA can be subdivided into g p f
smaller steps shown in Fig.4.7. These steps are explained below.1.
Pre - processing i 3. P t Processing 3 Post- P i
2. computation
4. Mesh Refinement
5. Report Generation
1. Pre-Processing :This will involve the complex physical
structure to be converted into an equivalent Finite Element model.
This ill be followed b applying th material properties t th model.
Th Thi will b f ll d by l i the t i l ti to the d l There are fi
structural properties, Y five t t l ti Youngs Modulus, Poisson
Ratio, Density and Yield Strength. Youngs Structure Swinging jaw
plate Lever Material used modulus(GPa) Martensitic steel (C-1.1%,
Mn-13%) Austenite steel (C-0.04%, Mn-0.7%, Cr-13%, Ni-4%,Mo-0.8% )
200 300 0.266 7860 210 strength(MPa) 550 ratio 0.266 Yield Poisions
Density (Kg/m3) 7860
Next step within pre-processing applying the boundary conditions
and restraining to the FE model. And finally conversion of actual
loads to equivalent FE Loads. one end of the pitman is hinged to
the eccentric shaft and other end is connected is to the toggle
plate.
Fig.3.29 Tetrahedron Element in Global xyz- System Fig. Boundary
conditions to the pitman
2. Computation p In computation step the standard FE solutions
procedures uses data provided by pre-processing step and then
solves the FE model to find out the unknown displacement values. 3.
Post-Processing Using the values of displacement computed in
pervious step strain and stresses are calculated for the whole
structure. 4. Mesh Refinement Iteration In order to get a more
accurate solution, the mesh needs to be refined and the computation
is to be done. 5. Report G 5 R t Generation ti Once the required
accuracy level is achieved, various plots such as sp ace e t, c pa
st ess, o sses St ess ca obta ed Displacement, Principal stress,
Von-Misses Stress can be obtained.
Analysis for Optimizing the Toggle Plate Width y p g ggAnalysis
is performed for assembled structure of swinging jaw plate with
swinging lever for a conventional single toggle jaw crusher with
constant toggle plate thickness and length.
Fig. Toggle Plate of the jaw crusher
Analysis has been carried out at the width of the toggle plate
is considered at 100, 200, 400, 600, 800 and 900mm.
Fig. Von Misses Stress and Displacement for the Toggle plate
width of 200mm
Fig. Von Misses Stress and Displacement for the Toggle plate
width of 800mm
Table. Von Misses stress and displacements at various sizes of
the Toggle Plate widths. Width of the Toggle Plate(mm) Von Misses
Stress(N/mm2) Displacement (mm) 447 0.311 246 0.262 188 0.212 137
0.18 98.6 0.164 97.7 0.16 100 200 400 600 800 900
500 400 N/ /mm2
200 100 0100 200 400 600 800 900
mm
300
0.35 0.3 03 0.25 0.2 0.15 0 15 0.1 0.05 0100 200 400 600 800
900
mmFig. Von Misses stresses vs toggle plate width
mmFig. displacements vs toggle plate width
Analysis for Optimizing the Toggle Plate LocationA l i h f d l
ti l l t t iti f Analysis has b been performed ,locating th t the
toggle plate at position of 0, 50, 100, 150, 200, 250, 300mm form
bottom surface of the pitman.125 100 0.18 0.15 0.12
m mm
75
N/mm2
0.09 0.06 0.03 0 0 50 100 150 200 250 300
50 25 00 50 100 150 200 250 300
mmTOGGLEPLATE TOGGLE PLATE LOCATION DISPLACEMENT VONMISSES
STRESS 0 0.0842 90.8 50 0.0776 79.5 100 0.0765 54 150 0.102 73 200
0.128 65.2
mm250 0.14 89.1 300 0.164 98.6
Fig. Von Misses Stress and Displacement ,Toggle plate located at
bottom
Fig. Von Misses Stress and Displacement ,Toggle plate located at
100mm from bottom
Analysis by Considering Stiffeners to the Swinging Jaw Plate
Fig. swinging jaw plate with one stiffener, two stiffeners,
three stiffenersNumber of stiffeners 1 2 3 Von Misses stress(N/mm2)
158 68.3 53.9 Displacement(deformation)(mm) 0.836 0 836 0.145
0.0883
Fig. Von Misses Stress and Displacement ,using two
stiffeners
Validation of ResultsTable. represents the comparison of results
for deformations produced by Chrlesh H. Dowding model and present
model, without considering stiffeners.Thickness of the plate (mm)
140 152 Deformation by Chrlesh H. Dowding (mm) 0.292 0.226 0.311
0.238 6.1% 5.04% Deformation by Present model (mm) % of Error
RESULTS , DISCUSSION & CONCLUSION
1. Force Distribution along the Liner:The distribution of the
forces along the liner can be calculated by the product of mass of
the swinging jaw plate and the resultant acceleration produced by
the jaw plate at various points on the liner . F=M(ax2 +ay2)
Whereax=horizontalacceleration&ay=verticalacceleration
2.0E+04 1.6E+04 1 6E+04
ResultantAcceleration
1 2 3 4 5 6
m mm/s2
1.2E+04 8.0E+03 8 0E+03 4.0E+03 0.0E+00 0 0E+00
0
120 240 (Degrees)
360
2. Wear Analysis: y
Jaw plates wear is determined by the close process. Two key
factors
in this process affecting the jaw plates wear are squeezing and
sliding. At present, the high manganese steel is widely used as the
jaw plate
material, which has the outstanding work hardening character. By
scanning the worn jaw plates, it is found that the sliding is the
main factor to the jaw plates wear and the sufficient squeezing can
even relieve the jaw plate wear. For the same jaw crusher, the
slide between the particle and the
fixed jaw plate is more than that between the particle and the
moving jaw plate, so the wear of the fixed jaw plate is more
serious relative to the moving jaw plate wear.
3. Optimization of Width and Location of Toggle Plate:
While the material is nipping in the crushing chamber toggle
supports the swinging lever at bottom end it means toggle plate is
more affected during the crushing. By performing finite element
analysis on the assembled system of swinging j p jaw plate and
pitman for a typical PE 300x900 series type jaw crusher, it is
found p f yp yp j f that the optimal value of the toggle width is
800mm at which the Von Misses stresses are approaching to
asymptotic value at 98.6 N/mm2 and the deformation is 0.164mm. For
a conventional PE 300x900 series type jaw crusher, toggle plate is
located approximately at 300mm from the bottom of the pitman. But
analysis gives the optimal value of toggle plate location is 100mm
above form the bottom of the pitman and the Von Misses and
deformation obtained are 54N/mm2 and 0.0765mm.
4. Optimization of Mass of the Swinging Jaw Plate Using
stiffeners, strength to weight ratio of the jaw plate can be
increased. Analysis has been performed on the assembled structure
when swinging jaw plate is having without stiffener, one stiffener,
two stiffeners and g gj p g ff ff ff three stiffeners.
No of stiffeners 0 1 2 3
Von Misses stress (N/mm2) 54 158 68.3 53.9
Deformation (mm) 0.0765 0.836 0.145 0.0883
Mass of the jaw plate (kg) 1018.314 701.882 739.683 776.683
% of mass reduced= (mass of jaw plate without stiffeners- mass
of jaw p plate with three stiffeners) *100/ mass of jaw plate ) j p
without stiffeners = (1081.314-776.683)*100/1018.314 = 23.73%
Conclusion1. A certain domain of the coupler plane and some
points are chosen on the crushing interface or the liner. Based on
the computation and the analysis of the practical kinematic
characteristic of the points along the liner domain some
traditional motion parameters are calculated domain, calculated.
According to the requirement for the squeezing motion of different
zone in the crushing chamber, the chamber geometry can be improved.
2. The movement of the moving jaw crusher is described in detail.
The force distribution is analyzed with the different operational
parameters, so the distribution feature of the force on the liner
is obtained. The job is helpful for a design of new prototype of
this kind of machine on optimizing the frame, designing the chamber
and recognizing the crushing character. 3. Results obtained from
the movement analyses of the moving jaw and the crushing force
distribution analysis, the jaw plates wear is analyzed. The
relationship between the slide and the wear is reasonable and some
results of the wear analysis are validated in practice. Predicting
the jaw plates wear on a macroscopic level will be helpful to the
jaw crusher design for better performance.
4. 4
Finite element analysis of swing jaw plates is carried out using
four - noded tetrahedral out, element to predict the optimized
width and the location of the toggle plate, when it is subjected to
point loading under simply supported boundary conditions.
5.
The stiffened plate models which leads to reductions in plate
weight and indicates that design of new energy-efficient systems of
the crushed material.
6.
In case stiffened jaw plates as the number of stiffener
increases the strength/weight ratio of the jaw plate increases
making it stronger than that of without stiffener.
7.
The stiffened plate models which leads to 25% saving in energy,
of course this 25% is an estimate for a typical 600*900 series jaw
crusher.
8.
Rock strength has only been of interest because of the need to
know the maximum force exerted by the toggle for energy
considerations. Thus a swing plate, stiff enough to crush taconite,
taconite may be overdesigned for crushing a softer fragmental
limestone limestone.
REFERENCES1. Anon Design of Jaw Crusher Avoids Toggles, Minerals
Engineering, Volume3, Issue 6, March 1999 Pages571-580. 2. Taggart,
Arthur F Hand Book of Ore Dressing, John Willey & Sons Inc,
1998, Pages 255-280. 3. Lindqvist M., Evertsson C. M. Liner wear in
jaw crushers, Minerals Engineering, Volume 16, Issue 1, January
2003, Pages 1-12. 4. DeDiemar R B 4 D Di R.B. New concepts i J N t
in Jaw C h Crusher t h l Mi technology, Minerals l
Engineering,Volume 3, Issues 1-2, 1990, Pages 67-74. 5. Russell
A.R., Wood D. M. Point load tests and strength measurements f
brittle g for Spheres, International Journal of Rock Mechanics and
Mining Sciences, Volume 46, Issue 2, February 2009,Pages272-280. 6.
6 Gupta Ashok, Yan D S Mineral Processing Design and Operation An
introduction , Ashok D.S. Mineral Operation-An introduction
Published by Elsevier, 2006, Pages 99-127.
7. Dowding Charles H, Molling R, Ruhl C," Application of point
load-deformation relationships and d i l ti hi d design of j f jaw
crusher plates, I t h l t International J ti l Journal of R k l f
Rock Mechanics and Mining Sciences & Geomechanics, Volume 20,
Issue 2, April 1983,Pages 277-286. 8. Zhiyu Qin, Ximin Xu, A Method
of Optimization of the Mechanism of Compound Swing Jaw Crusher,
Journal of Taiyuan Heavy Machinery Institute, July1992. Pages
255-263. 9. Cao Jinxi, Qin Zhiyu, Wang Guopeng, Investigation on
Kinetic Features of MultiLiners in Coupler Plane of Single Toggle
Jaw Crusher, Journal of Taiyuan Heavy Machinery Institute,
July200.Pages 210-219. 10. Cao Jinxi, Rong Xingfu, Yang Shichun,
Jaw Plate Kinematical Analysis For Single Toggle Jaw crusher
Design, Journal of Taiyuan Heavy Machinery Institute, 2006.Pages
2006 Pages 62-66
Thank You