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INTRODUCTION

A double roll crusher consists of two adjacent rolls placed parallel to each other and
rotated in opposite directions. These are typically used in situations in which fines are to be
minimized.

As the two rolls rotate toward each other, the material is pulled down into the crushing
zone where it is grabbed and compressed by the rolls.

Product size is determined by the size of the gap between the rolls, and this gap can be
changed to vary product size or to compensate for wear.

Since both rolls rotate at the same speed, there is no relative motion between the two roll
surfaces, and crushing is primarily accomplished by compression.

Compression crushing is extremely efficient, as energy is only used to crush those

particles larger than the gap between the rolls. Fines are reduced because already sized material
passes freely through the crusher with no further reduction.

Protection from uncrushables is provided by means of a retractable roll assembly. It

retracts instantly when an uncrushable is encountered, then reverts to its original position once
the uncrushable has cleared the crushing chamber with no stoppage of the crusher.

Rock crusher is a machine designed to reduce large rocks into smaller rocks, gravel, or
rock dust. Mining operations use rock crushers, commonly classified by the degree to which they
fragment the starting material, with primary and secondary crushers handling coarse materials,
and tertiary and quarternary crushers reducing ore particles to finer gradations.

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REVIEW OF RELATED LITERATURE

OTHER TYPES OF CRUSHER

Single Roll Crusher

The crushing is done between the roll and the

back plate or anvils which are pivoted at the
top edge and adjustable at the point of
discharge. The adjusting bolts can be spring
loaded if the roll is fixed so as to permit the
passing of tramp metal. It is an effective
breaker of soft to medium hard limestone and
shale, but is not suited to blocky feeds unless
of a friable nature. During the crushing
process material will ride on the roll and there
will be considerable
able slip between the material and the top of the teeth. This will lead to excessive
wear if the material has other than low percentage silica. The machine will turn out a product
with less percentage fines than either the jaw or gyratory crushers. Size of product is governed
by the distance between the roll and the tip of the lower end of the anvil. This machine is
essentially a primary crusher and works most efficiently when set for a medium or coarse
product. Single roll crusher crushes by shearing action.
actio

Hammer Crusher

The hammer crusher is suitable for

semi-hard and erosive materials
lightweight, the strength of the pressure
resistance is not greater than 150MPa
and less than 15% moisture, such as
coal, salts, chalk, gypsum blocks,
limestone, etc.
The hammer crusher is a kind of
crushing machine, which is made of a
frame, rotors, grate bar, impact plate,
and adjustment device. Our hammer crusher can be used to crush various materials, such as
limestone, coal, gypsum, alum, bricks, tiles, etc.. The compressive strength of the material
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should not be more than 150 MPa. It is widely used in the cement industry, coal separation
process, power generation, construction industry, and other fields.
This kind of crusher also can be used for crushing chips andand paper with fiber structure
and strong elasticity and ductility, or recycling asbestos fiber by crushing wastes of asbestos
cement, etc.It is applicable for both dry and wet grinding. Hammer crusher is widely used for
crushing medium or high for medium hard hard and brittle materials by departments of mine, cement,
coal, building materials, metallurgy, chemical industry, road construction, chemical, gas and
thermal power generation, etc. coal gangue, coke, slag, limestone, phosphate rock, salt, whiting,
gypsum stains, alum, brick and tile, etc. can be crushed by this equipment. The compressive
strength of the material not exceeding 150MPa, whereas the moisture content must be below
15%.

Jaw crusher

A jaw crusher uses compressive

force for breaking of particle.
particle
This mechanical pressure is
achieved by the two jaws of the
crusher of which one is fixed
while the other reciprocates. A
jaw or toggle crusher consists
of a set of vertical jaws, one
jaw is kept stationary and is
called as fixed jaw while the
other jaw, called as swing jaw,
moves back and forth relative
to it, by a cam or pitman mechanism, acting like a class II lever or a nutcracker.. The volume or
cavity between the two jaws is called as the crushing chamber
chamber.. The movement of the swing jaw ja
can be quite small, since complete crushing is not performed in one stroke. The inertia required
to crush the material is provided by a weighted flywheel that moves a shaft creating an eccentric
motion that causes the closing of the gap.

Jaw crushers are classified on the basis of the position of the pivoting of the swing jaw

1. Blake crusher-the
the swing jaw is fixed at the upper position
2. Dodge crusher-the
the swing jaw is fixed at the lower position
3. Universal crusher-the
the swing jaw is fixed at an intermediate posi
position
The Blake crusher was patented by Eli Whitney Blake in 1858. The Blake type jaw crusher has a
fixed feed area and a variable discharge area. Blake crushers are of two types-
types single toggle and
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double toggle jaw crushers. In the single toggle jaw crushe

crushers,
rs, the swing jaw is suspended on the
eccentric shaft which leads to a much more compact design than that of the double toggle jaw
crusher.In the double toggle jaw crushers, the oscillating motion of the swing jaw is caused by
the vertical motion of the pitman.
tman. In the Dodge type jaw crushers, the jaws are farther apart at the
top than at the bottom, forming a tapered chute so that the material is crushed progressively
smaller and smaller as it travels downward until it is small enough to escape from the bottom
bot
opening.

Gyratory crusher

A gyratory crusher isconsists of a concave surface and a

conical head; both surfaces are typically lined with manganese
steel surfaces. The inner cone has a slight circular movement,
but does not rotate; the movement is generated by an
eccentric arrangement. As the same with the jaw crusher,
material travels downward between the two surfaces being
progressively crushed until it is small enough to fall out
through the gap between the two surfaces.

Gyratory crushers are designated in size either by the gape and

mantle diameter or by the size of the receiving opening.
Gyratory crushers can be used for primary or secondary
crushing.
The crushing action is caused by the closing of the gap between the mantle
mantle line (movable)
mounted on the central vertical spindle and the concave liners (fixed) mounted on the main
frame of the crusher. The gap is opened and closed by an eccentric on the bottom of the spindle
that causes the central vertical spindle to gyrate.
gyrate. The vertical spindle is free to rotate around its
own axis. The crusher illustrated is a short-shaft
short shaft suspended spindle type, meaning that the main
shaft is suspended at the top and that the eccentric is mounted above the gear. The short-shaft
short
design has superseded the long-shaft
shaft design in which the eccentric is mounted below the gear.

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Cone crusher
A cone crusher is similar in operation to a gyratory
crusher, with less steepness in the crushing chamber
and more of a parallel zone between crushing
crushin zones.
A cone crusher breaks rock by squeezing the rock
between an eccentrically gyrating spindle, which is
covered by a wear resistant mantle, and the
enclosing concave hopper, covered by a manganese
concave or a bowl liner. As rock enters the top of
thee cone crusher, it becomes wedged and squeezed
between the mantle and the bowl liner or concave.
Large pieces of ore are broken once, and then fall to
a lower position (because they are now smaller)
where they are broken again. This process continues
until the pieces are small enough to fall through the
narrow opening at the bottom of the crusher.
A cone crusher is suitable for crushing a variety of
mid-hard and above mid-hard
hard ores and rocks. It has the advantage of reliable construction, high
productivity, easy adjustment and lower operational costs. The spring release system of a cone
crusher acts an overload protection that allows tramp to pass through the crushing chamber
without damage to the crusher.

Impact crusher
Impact crushers involve the use
of impact rather than pressure to crush
material. The material is contained within a
cage, with openings on the bottom, end, or side
of the desired size to allow pulverized material
to escape.. There are two types of impact
crushers: horizontal shaft impactor and vertical
shaft impactor.

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DRAWING

Perspective Views

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Orthographic Views

Top View

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Front View

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Right Side View

Left Side View

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DESIGN CONSIDERATION:

Rock Crusher Type: Double Roll Crusher

Material to be crushed: Limestone

Maximum Feed Size: 6 in.

Distance Between rolls: 0.5 in.

Operating Condition: dry condition

Further specifications and design considerations were made along the design process.

DESIGN CALCULATION:

Solving for Radius of the Rolls:

To solve for the radius of the rolls, it is convenient to assume that the particle to be
crushed is spherical and roll surfaces are smooth. The figure below shows a spherical particle
about to enter the crushing zone of a roll crusher. The nip angle is defined as the angle that is
tangent to the roll surfaces at the points of contact between the rolls and the particle. Usually the
nip angle is between 20˚ and 30˚ but in some large roll crushers it is up to 40˚.

For the design I choose 40˚ nip angle.

R=
( )

Where:
R= radius of the roll
L= distance between rolls, 0.5 in
d= diameter of the feed, 6 in
ϴ= Nip angle, 40˚ ᶿ

0.5 − [6 cos 40]

R=
2(cos 40 − 1)

R = 8.754369234 in

D = 17.50873847 in

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For the roll diameter, the calculated diameter is not available in the market so I use D = 18”,
available at http://www.hajq.net/server/peijian_718.html.

Solving for nip angle:

R+
cos ϴ =
R+

.
9+
cos ϴ =
9+

ϴ = 39.57121946°

Solving for Feedrate:

Q= π60DWωLρB (t/h)

Where:

Q= crusher capacity
D= diameter of roll, m (18 in= 0.4572 m)
W= width of the roll, m (32 in = 0.8128 m)
ω= roll speed, 150 rpm
L= distance between rolls, m (0.5 in= 0.0127 m)
ρB= bulk density of feed material, t/m3(2.8248 t/m3)

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For the ρB of limestone, refer to http://www.natural-stone.com/limestone.html

Q= π (60) (0.4572) (0.8128) (150) (0.0127)( 2.8248)

Q= 376.9413002 t/h

Solving for the Crusher Power

From http://www.hajq.net/server/peijian_718.html. , I can get the power required for the roll.

For roller Model 2PG450x500

 Motor Power, 22 kw ( 29.48 Hp)
 Capacity up to 400 t/h
 18” diameter rolls (457.2 mm)

From the Design Hp Formula:

Where:

Nsf = 1.4+0.2 (Table 17.7 by Faires, p. 460)

Design Hp = 29.48 Hp

Transmitted Hp = 29.48 / 1.6

= 18.425 Hp

Comparing the power and the feedrate for commercial crusher

P1/C1 = P2/C2

Where:

P1 and C1 = Power and Capacity for the crusher to be designed

P2 and C2 = Power and Capacity for a commercial crusher

.
. /
= /

P1 = 17.36285864 hp

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Solving for Torque

P= 2πTN

Where:

P= 0.2749390443 hp
N= 900 rpm

17.36285864 hp 33,000ft − lb/min

T=
2π(150) 1 Hp

T = 607.9446513 lb − ft

Solving for the Force Required

F=T/r

.
F=

F= 810.5928684 lbs.

Design horsepower to drive mechanism including losses

According to Morse, p.452, losses in V-belt is 5%.

Transmitted power on V-belt

Transmitted power on V-Belt= Required power to drive the crusher/0.95

= 17.36285864 / 0.95
Transmitted power on V-Belt = 18.27669331 hp

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DRIVING SYSTEM DESIGN

V-Belt Design
Design Consideration:
Motor type: squirrel cage motor
Type of service: continuous (16hr/day) service
V-belt material: Rubber

From IEC MOTORS

Nearest capable of driving is:

Motor Power = 20 hp
RPM= 750 rpm

Solving for Design Hp

Design Hp =Transmitted Hp x Nsf

Where:
Nsf = 1.4+0.2 (Table 17.7 by Faires, p. 460)

Transmitted Hp = 18.27669331 Hp
Design Hp = 18.27669331 Hp x (1.4+0.2)
= 29.2427093 Hp

(From figure 17.14 Belt Selection from Horsepower and Speed by Faires, p.457, I choose
section C)

Solving for the diameter of the drive and driven sheave

N1D1 = N2D2

Where:
N1= Motor speed, 750 rpm
N2= Crusher speed, 150 rpm
D2= diameter of the driven sheave
D1= diameter of the drive sheave

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From Table 17.3, Standard V-belt Lengths; Horsepower Constants (Faires, p. 458)

If D2= 44 in. and D1= 9 in.

N2= (9x750)/44
N2=153.4090909 rpm

If D2=50 in. and D1= 11 in.

N2= (11x750)/50
N2= 165 rpm

If D2= 50 in and D1= 9 in.

N2= (9x750)/ 50
N2 = 135 rpm

If D2= 50 in. and D1= 10 in.

N2= (10x750)/50
N2= 150 rpm

I choose D2=50 in. and D1= 10 in. which is exactly 180 rpm.

Solving for minimum center distance

(Eq. by Faires, p, 457)

C= [(D2+D1)/2]+D1 ] or C =D2 whichever is longer
C= [(50+10)/2]+10 ]
C= 40 in.

I choose C = 50 in. which is longer

Note: The center distance is made adjustable so that the belts can be mounted into the grooves
without harmful stretching and so that initial tension can be maintained (Faires, p. 457).

Solving for belt length

(Eq. by Faires, p. 446 )

L = [(π/2)(D2 +D1)] + 2C + [(D2 - D1)2 / 4C]

L = [(π/2)(50 + 10)] + 2(50) + [(50 – 10)2 / 4(50)]
L=202.2477796 in.

From table 17.3, Standard V-belt length (by Faires p. 458) at section C, select C210 with pitch
length equal to 212.9 in.

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Solving for actual center distance

B = 4L − 6.28(D2 + D1)
B = 4(212.9) − 6.28(50 + 10)
B = 474.8 in.
B + B − 32(D2 − D1)
C=
16

474.8 + 474.8 − 32(50 − 10)

C=
16
C= 55.76341937 in

50<55.76341937 in., It is satisfactory because it is greater than the minimum center distance.

Solving for V-belt speed

Vm= πD1N1 / 12
= π(10)(750)/12
Vm= 1963.495408 ft/min

Solving for kd (small diameter factor)

From Table 17.4, by Faires, p.459

D2/D1 = (50/10)
=5

Kd = 1.14

Solving for Rated Hp

From equation by Faires, p.456
.
10 c Vm Vm
Rated Hp = a − −e
Vm KdD1 10 10

Where :
Vm= belt speed, 1963.495408 ft/min
Kd = 1.14
Rated hp constants:
a= 8.792
c= 38.819

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e= 0.0416

Rated hp constants (from table 17.3, by Faires, p. 458)

.
10 38.819 1963.495408 1963.495408
Rated Hp = 8.792 − − 0.0416
1963.495408 1.14(10) 10 10

Rated Hp = 9.244987449 Hp

Solving for Adjusted Hp

Horsepower rating must be corrected for length of belt (Kl) and arc of contact (K ).
(Faires, p.457)

Adjusted Hp = kϴ x kl (Rated Hp)

Where:
kl= Length correction factor, 0.92 from table 17.6 Length Correction Factors by Faires, (p.459)

kϴ= arc of contact factor

From table 17.5, Arc of Contact factors (Faires, p.459)

(D2 – D1) / C = (50 – 10) / 55.76341937
= 0.7173161268

By interpolation,

0.70 0.89
0.7173161268 kθ
0.80 0.87

kθ =0.8865367746
kl = 1.08

Therefore,
Adjusted Hp = 0.8865367746 x 1.08 x 9.244987449 Hp

= 8.851703063 Hp

Solving for Number of Belts

Number of Belts = Design Hp/ Adjusted Hp

= 29.2427093 Hp / 8.851703063 Hp
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= 3.3036252
Say 4 belt

Use 4 C210 leather V-belts with pitch length equal to 212.9 in. from section C, b x t = 7/8 in. x
17/32 in., figure 17.14, Belt Section from Horsepower and Speed by Faires, p. 457.

Solving for the Tension

F1

F2

F1 / F2 = efθ → Eq. 1

Where:
F1= total tension on the tight side, lb
F2 = total tension on the slack side, lb
f = coefficient of friction, 0.30 from Table 16-15 Coefficient of Friction for Belts,
for rubber on cast iron pulley
θ = arc of contact, rad

Computing the arc of contact

θ = {180 – 2sin-1 [(D2 – D1) / 2C]}(π / 180)

= {180 – 2sin-1 [(50– 10) / 2(55.76341937)]}(π / 180)
=2.407932823 rad

From eq.1
F1 / F2 = efθ
F1 = e(0.30) (2.407932823) F2
F1= 2.05932827 F2 → Eq.2

Power Transmitted on V-belt

From equation 16.7 (Daughtie and Vallance, p.383)

Hp = [ (F1 – F2) / 550 ] x Vm

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Where:
Hp= transmitted Hp, 18.27669331 hp
F1 =total tension on the tight side, lb
F2= total tension on the slack side, lb
Vm = belt speed, 1963.495408 ft/min

(F1-F2)= 550(18.27669331)(60) / 1963.495408

(F1-F2)= 307.1720345 → Eq. 3

Equating equation 2 and 3

2.05932827 F2 – F2 = 307.1720345
F2 = 289.9686936 lbs
F1 = 2.05932827 (289.9686936 lbs)
F1 = 597.1407281 lbs

Solving for thickness of the sheave

T =width of the belt x number of belt

=7/8(4) + 1
T = 4.5 in.

Computing the weight of the motor sheave

W1 = (π/4) D12tρ

Where:
D1 = diameter of the small sheave, 10 in.
t = thickness of small sheave, 4.5 in.
ρ = density of pulley material used, 0.256 lb/in³ for ordinary cast iron from Table 2-1,
General Properties of commonly used materials (Doughtie and Vallance, p.11)

W1 = (π/4)(10)2(4.5)(0.256)
W1= 90.47786842 lbs

Computing the weight of the Driven sheave

W2 = (π/4) D22tρ

Where:
D2= diameter of the driven sheave, 50 in.
t = thickness of sheave, 4.5 in.
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ρ = density of pulley material used, 0.256 lb/in³ for ordinary cast iron from Table 2-1,
General Properties of commonly used materials (Doughtie and Vallance, p.11)

W2 = (π/4)(50)2(4.5)(0.256)
W2 = 2261.946711 lbs

SHAFT DESIGN

Shaft 1
Design Consideration:
Material Used: SAE 1095
Maximum shear: 120000 psi

6” 27” 27”
Fx1
F1 Fy1
F1

F2 Fy2 Fr
Fx2

Ft

Computing the Angle of Wrap

Cos α = (D2-D1)/2C from eq. by Spotts, p.293

Where:
D₂= diameter of big sheave, 50 in
D₁= diameter of small sheave, 10 in
C = center distance, 55.76341937 in

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Therefore,

α= cos-1 ( . )

α = 68.98219404˚

Solving for Forces on Belt at Section A

F1 = 597.1407281 lbs
F2 = 289.9686936 lbs

Fx1 = F1sinα = 597.1407281 (sin 68.98219404˚)

Fx1 = 557.4123646 lbs

Fy1 = F1cosα = 597.1407281 (cos 68.98219404˚)

Fy1= 214.1693372 lbs (downward)

Fx2 = F2sinα = 289.9686936 (sin 68.98219404˚)

Fx2= 270.6767895 lbs

Fy2 = F2cosα= 289.9686936 (cos 68.98219404˚)

Fy2= 103.9996101 lbs (upward)

Horizontal Component, Fx = Fx1 + Fx2

Fx = 557.4123646 + 270.6767895) lbs
Fx = 828.0891541 lbs (to the right)

Vertical Component, Fy= Fy1 - Fy2

Fy = (214.1693372 - 103.9996101) lbs
Fy = 110.1697271 lbs (downward)

Forces at Section A Due to Weight of the Sheave, W2

W2 = 2261.946711 lbs

Total Load at section A

FHA = 828.0891541 lbs
FVA = (110.1697271 + 2261.946711) lbs
FVA = 2372.116438 lbs

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Solving for the weight of the roll

Roll material: high carbon steel
W = ρV

where:
ρ = density of the roll, 0.283244983 lb/in3(Material Science and Engineering 4th Edition,
V. Raghavan, p.396)
V = roll volume
V = (π/4)(D)2w

where:
D= diameter of the roll, 18 in.
W = roll width, 32 in.
V = (π/4)(18)2(32)
V = 8143.008158 in3

Therefore,
W = (8143.008158)) (.283244983)
W = 2306.466207 lbs

Solving for the Force Required Crushing the Limestone (Fr)

ς = F/A

where:

ς = compressive strength of limestone, 28 MPa = 4061.056829 psi,

A= area of the limestone to be crushed

Solving for the area:

e= effective length of the roll, 60%

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X = √(3)2 – (0.25)2
X = 2.989565186

w = 2(2.989565186)
w = 5.979130372

Therefore:
A = (5.979130372)(32)(0.6)
A = 114.7993031 in2

Fr=
= (4061.056829)(114.7993031)
Fr= 466206.4938 lbs.
Ft= force required to
o drive the crusher, 810.5928684 lbs

Total Roll Load

FVC = W - Ft
FVC = 2306.466207 – 810.5928684
FVC = 1495.873339 lbs (downward)
FHC = Fr = 466206.4938 lbs

Solving for Vertical Component of the Bearing

FVA= 2372.116438 lbs

FVC = 1495.873339 lbs

ΣMB = 0
54RVD = -6(2372.116438)
6(2372.116438) + 27(1495.873339)
RVD = 484.3681764 lbs

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ΣY=0
RVB = FVA + FVC - RVD
= 2372.116438 + 1495.873339 – 484.3681764
RVB = 3383.621601 lbs

Shear Diagram

Moment Diagram

MB = -2372.116438 x 6 = -14232.69863
14232.69863 in-lb
in
MC = -14232.69863
14232.69863 + (1011.505163)(11) = -3106.141837 in-lb
MF = [-3106.141837
3106.141837 + ½(1011.505163)(21.63830612)] = 7837.48734 in-lb
in
MD = 7837.48734 – ½(484.3681764)(10.36169388) = 5328.049955 in-lb
in
ME = 5328.049955 – (484.3681764)(11) = 0

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Solving for Horizontal

ntal Component of the Bearing

FHC = 466206.4938 lbs

FHA = 828.0891541 lbs

ΣMB = 0
54RHD = 27(466206.4938) + 6(828.0891541)
RHD = 233195.2568 lbs

ΣY = 0
RHB = FHA – FHC + RHD
= 828.0891541 – 466206.4938 + 233195.2568
RHB = 232183.1478 lbs

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Shear Diagram

Moment Diagram

MB = 828.0891541 x 6 = 4968.534925 in-lb

in
MC = 4968.534925 + (233011.237)(11)
(233011.237 = 2568092.142 in-lb
MF = [2568092.142 + ½(233011.237)(15.99368452)]
233011.237)(15.99368452)] = 4431446.249 in-lb
MD = 4431446.249 – ½(233195.2568)(16.00631548
233195.2568)(16.00631548) = 2565147.825 in-lb
ME = 2565147.825 – (233195.2568
233195.2568)(11) = 0

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Data for the Loading at Shaft 1

Section Load Resultant
Vertical Horizontal
A 2372.116438 lbs. 828.0891541lbs. 2512.502347 lbs.
B 3383.621601 lbs. 232183.1478 lbs 232207.8014 lbs.
C 1495.873339 lbs. 466206.4938 lbs. 466206.8936 lbs.
E 484.3681764 lbs. 233195.2568 lbs. 233195.7598 lbs.

Data for the Moment at Shaft 1

Section Load Resultant
Vertical Horizontal
B -14232.69863
14232.69863 in-lb 4968.534925 in-lb 15075.01408 in
in-lb
C -3106.141837
3106.141837 in-lb 2568092.142 in-lb 2568094.02 in
in-lb
D 7837.48734 in-lb 2565147.825 in-lb 2565159.798 in
in-lb
F 5328.049955 in-lb 4431446.249 in-lb 4431449.452 in
in-lb

Computing for the Required Shaft diameter

τ max= (CmM) + ( )
π ^

Where:
τ max = maximum shearing stress
d = diameter of the shaft
M = maximum bending moment,
Resultant Moment
M= (5328.049955
049955 ) + (4431446.249)
M = 4431449.452 in-lb

MACHINE DESIGN 2 29
2016 [ROCK CRUSHER]

T = maximum torque,

. , /
T= π( )

T = 639.9417384 ft − lb or 7679.300861 in − lb

Cm = shock and fatigue factor due to be applied for the computed bending moment, 1.5
from Table 3-1 constants for ASME Code or rotating shafts with suddenly applied
loads, steady load
Ct = shock and fatigue factor due to be applied for the computed torque, 1 from Table 3-1
constants for ASME Code or rotating shafts with suddenly applied loads, steady load

τ max = (1.5 x 4431449.452) + (1.0 x 7679.300861)

π ^

120000 = (6647178.164)
π ^

d = 6.558563648 in

From Machinery Shafting diameter, Art. 9.5, p.269, Faires, I select 6 3/4 in. diameter shaft to be
reduced equal to the diameter of the bearing.

Bearing Selection for Shaft 1

The maximum actual radial load of the bearing is at section D

Fr = 233195.7598 lbs

From eq. 9-17 by Doughtie and Vallance, p.209

Fc = (KaKl) KoKpKsKtFr

When rolling bearing turns while receiving a load, a lot of stress is repeatedly placed on the
small contact surface of the bearing rings and rolling elements, and the bearing must maintain
high precision while rotating. That means bearing materials must satisfy the following demands.

 Must be hard.
 Rolling fatigue life must be long.
 Wear must be slight.
 Must be shock-resistant.
 Dimensions must not vary largely with the passing of time.
 Must be economical and easy to machine.

MACHINE DESIGN 2 30
2016 [ROCK CRUSHER]

Design Consideration:
Material Used for the bearing: High Carbon Chrome Bearing Steel

The expected life of operation for the bearings is 5 years for 16hrs/day operation.
Shaft diameter may be reduced to accommodate the bearing.

Where:

Fc = catalog rating of bearing, lb (Table 9-7 & 9-8)

Ka = application factor taking into account the amount of shock (Table 9-4), 1.7 for heavy
shock load

Kl = , life factor

Ha = desired life of bearing, hours of use

Hc = catalog rated life, 10,000 hrs.

Krel = reliability factor (Table 9-3), 1.0

Ha= 5(365)(16)
Ha= 29, 200 hrs
Hc=10,000 hrs
Kl = = 1.134447194
( )( . )

Ko= oscillation factor, 1.0 for constant rotational speeds of the races

Kp= preloading factor, 1.0 for non-preloaded ball bearings

Ks = , speed factor

Na = rotational speed of bearing, 150 rpm

Nc = catalog rated rotational speed, 500 rpm

Kr = rotational factor, 1.0 for bearing with fixed outer races and rotating inner races

( . )( )
Ks = = 0.6694329501

Kt= thrust factor, 1.0 for no thrust-load component

MACHINE DESIGN 2 31
2016 [ROCK CRUSHER]

Therefore,

FC= (1.7 x1.134447194) x 1.0 x 1.0 x 0.6694329501 x 1.0 x 233195.7598

FC = 301065.4651 lbs

From Timken Roller Bearing, for the shaft diameter 6.75 in., I select 24034CJ Spherical Roller
Bearing with FC= 322000 lbs and bearing bore 6.6929 in. with OD= 10.2362 in. and Width=
3.5433 in.

Actual Shaft Diameter=6.6929 x 1.0025

= 6.70963225 in.

Design for Key for the Pulley on Shaft 1

Design consideration of Key:

Material used: AISI C1117(Normalized Carbon Steel)

Su = 63,700 psi
Sy = 35,000 psi

From Table 3, Standard Key Stock-Taperlock

For shaft diameter of 6.75 in.

b=1 ¾” t=1 ½”

Shearing Stress, Ss
.
Ss=

Where:
Sy = yield stress, 35,000 psi
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one direction,
gradual mild shock (Faires, p.20)

Therefore,

( . )( )
Ss= = 5833.333333 psi

MACHINE DESIGN 2 32
2016 [ROCK CRUSHER]

Compressive Stress, Sc

Sc =

Where:
Sy = yield stress, 35,000 psi
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one direction,
gradual mild shock (Faires, p.20)

Therefore,

Sc = = 11,666.66667

Solving for the Maximum Torque, T

Hp =

Where:
Hp= transmitted power, 18.27669331 Hp
T = maximum torque
N = rpm of the shaft, 187.5 rpm

Therefore,

18.27669331 hp 33,000ft − lb/min

T=
2π(150) 1 Hp

T = 639.9417384 ft − lb or 7679.300861 in − lb

Then,
F=

.
F= .

F = 2289.037782 lbs

MACHINE DESIGN 2 33
2016 [ROCK CRUSHER]

Solving for the Length of the Key

a. Based on the bearing stress of the key.

Sc =
.
11,666.66667 =
( )
L = 0.2616043179 in

b. Based on the shearing stress of the key

Ss =
.
5833.333333 =
L = 0.2242322725 in

Since L = 0.2616043179 in is longer, this will be the minimum length for a key. Since the
thickness of the key is 1 ½ in, therefore, I choose L= 0.75 in for the key length.

Bolt Design for the Bearings on Shaft 1

Bearing housing design is a four bolt flange housing design.

Design Condition:
Material Used: AISI C1045(WQT 1000 Carbon Steel)
Sy = 110,000 psi
Su = 130,700 psi

No. of bolts = 4 bolts

Fs = 3.0, from Table 1.1 Factors of Safety, based on yield strength of steel, ductile metals
(Faires, p.20)

To compute for the size of bolt I will use the resultant force that will cause shearing (F =
466206.8936 lbs) divided by the number of bolts.

Solving the Size of the Bolt

Based on Shearing stress

.
Ss =

MACHINE DESIGN 2 34
2016 [ROCK CRUSHER]

Where:
Sy= yield stress, 110,000 psi
Fs= factor of safety, 3.0

Ss =
Where:
F = maximum shear force, 466206.8936 lbs
A= cross sectional area of the bolt

Therefore,

. . ( , )
= .
( )

d = 2.845074818 in2

From Table 6-1 Unified & American National threads, coarse, fine, and extra-fine series
(Doughtie and Vallance, p.130) I select 3 in-4 UNC bolt with Ar = 5.97 in2 and minor diameter
of 2.6933 in. The bolt being screwed into the post is the threaded part.

Shaft 2

Design Consideration:
Material Used: SAE 1095
Maximum shear: 120000 psi
Shaft diameter: 6.75 in.

27” 27”

Fr

w = 2306.466207 lbs
Fr = 466206.4938 lbs
MACHINE DESIGN 2 35
2016 [ROCK
ROCK CRUSHER]
CRUSHER

Total Load

FVB = w = 2306.466207 lbs

FHB = Fr = 466206.4938 lbs

Solving for the Vertical Component of the Bearin

MACHINE DESIGN 2 36
2016 [ROCK
ROCK CRUSHER]
CRUSHER

Shear Diagram

Moment Diagram

MB =1153.233104 x 11= 12685.56414 in-lb

in
MF =12685.56414 + ½(1153.233104)(16)= 21911.42898 in
in-lb
MC =21911.42898 – ½(1153.233104)(16)= 12685.56414 in
in-lb
MD =12685.56414 – (1153.233104 x 11) = 0

MACHINE DESIGN 2 37
2016 [ROCK
ROCK CRUSHER]
CRUSHER

Solving for the Horizontal Component of the bearing

Shear Diagram

MACHINE DESIGN 2 38
2016 [ROCK CRUSHER]

Moment Diagram

MB =233103.2469 x 11= 2564135.716 in-lb

MF =2564135.716 + ½(233103.2469)(16)= 4428961.691 in-lb
MC =4428961.691 – ½(233103.2469)(16)= 2564135.716 in-lb
MD =2564135.716 – (233103.2469 x 11) = 0

Data for the Loading at Shaft 2

Loading
Section Resultant
Vertical Horizontal
A 1153.233104 lbs 233103.2469 lbs 233106.0996 lbs
B 2306.466107 lbs 466206.4938 lbs 466212.1992 lbs
D 1153.233104 lbs 233103.2469 lbs 233106.0996 lbs

Data for the Moment at Shaft 2

Moment
Section Resultant
Vertical Horizontal
E 21911.42898 lb-in. 4428961.691 lb-in. 4429015.892 lb-in.

B or C 12685.56414 lb-in. 2564135.716 lb-in. 2564167.095 lb-in.

MACHINE DESIGN 2 39
2016 [ROCK CRUSHER]

Bearing Selection for Shaft 2

The maximum actual radial load of the bearing is at section A or D

Fr = 233106.0996 lbs

From eq. 9-17 by Doughtie and Vallance, p.209

Fc = (KaKl) KoKpKsKtFr

When rolling bearing turns while receiving a load, a lot of stress is repeatedly placed on the
small contact surface of the bearing rings and rolling elements, and the bearing must maintain
high precision while rotating. That means bearing materials must satisfy the following demands.

 Must be hard.
 Rolling fatigue life must be long.
 Wear must be slight.
 Must be shock-resistant.
 Dimensions must not vary largely with the passing of time.
 Must be economical and easy to machine.

Design Consideration:
Material Used for the bearing: High Carbon Chrome Bearing Steel

The expected life of operation for the bearings is 5 years for 16hrs/day operation.
Shaft diameter may be reduced to accommodate the bearing.

Where:

Fc = catalog rating of bearing, lb (Table 9-7 & 9-8)

Ka = application factor taking into account the amount of shock (Table 9-4), 1.7 for heavy
shock load

Kl = , life factor

Ha = desired life of bearing, hours of use

Hc = catalog rated life, 10,000 hrs.

Krel = reliability factor (Table 9-3), 1.0

Ha= 5(365)(16)
Ha= 29, 200 hrs
Hc=10,000 hrs

MACHINE DESIGN 2 40
2016 [ROCK CRUSHER]

Kl = = 1.134447194
( )( . )

Ko= oscillation factor, 1.0 for constant rotational speeds of the races

Kp= preloading factor, 1.0 for non-preloaded ball bearings

Ks = , speed factor

Na = rotational speed of bearing, 150 rpm

Nc = catalog rated rotational speed, 500 rpm

Kr = rotational factor, 1.0 for bearing with fixed outer races and rotating inner races

( . )( )
Ks = = 0.6694329501

Kt= thrust factor, 1.0 for no thrust-load component

Therefore,

FC= (1.7 x1.134447194) x 1.0 x 1.0 x 0.6694329501 x 1.0 x 233195.7598

FC = 301065.4651 lbs

From Timken Roller Bearing, for the shaft diameter 6.75 in., I select 24034CJ Spherical Roller
Bearing with FC= 322000 lbs and bearing bore 6.6929 in. with OD= 10.2362 in. and Width=
3.5433 in.

Actual Shaft Diameter=6.6929 x 1.0025

= 6.70963225 in.

MACHINE DESIGN 2 41
2016 [ROCK CRUSHER]

SPRING DESIGN

Design Consideration:

Load: F =466206.4938 lbs (based on horizontal reaction of shearing)

Number of Spring: 133

Load = 466206.4938/133
Load = 3505.311983 lbs

Spring material: Oil Tempered Wire, squared and ground ends

Type of service: average service

From Table of Century Spring Catalog, I use 4053 spring with diameter, Dw = 1.00 in. with
maximum suggested load = 4200 lbs

Free length=20 in.

(OD + ID)
Dm =
2
(3.5 − 2.5)
=
2

Dm = 3 in.

Deflection = 1.0 in

MACHINE DESIGN 2 42
2016 [ROCK CRUSHER]

Solving for Spring Index

C=

C=

C=3

Solving for Stress Factor

.
k= +

( ) .
k= ( )
+

k=1.58

Stress due to load

Ss = k

( )( . )( )
Ss = (1.58) ( )

Ss = 42.31020538 ksi

Design Stress

Ssd= 0.324 Su

Where:

Ssd = 0.324(146/ Dw0.19)

.
Ssd=
( ) .

Ssd= 47.304 ksi

MACHINE DESIGN 2 43
2016 [ROCK CRUSHER]

Therefore,

Ssd>Ss(Appllicable)

Solving the Number of Active Coils

8
=

( . × )( )( )
NC = ( )( . )( )

NC = 15.18858835 or 15 active coils

Solving for Solid Height

At Table At 16 Approximate Free Length and Solid Heights (Faires, p.589)
Solid Height = DwNc + 2Dw
= (1)(15) + 2(1)
Solid Height= 17 in

Scale of Spring (k)

k= F/δ

k= 3505.311983/1

k= 3505.311983lb/in

Force to Compress the Spring to Solid Height

Fc = k (free length – solid height)

Fc = (3505.311983)(20 – 17) in

Fc = 10515.93595 lbs

Solving For Solid Stress

Ssolid stress = (Ss/F)(Fc)

Ssolid stress = (42.31020538/3505.311983)(10515.93595)

MACHINE DESIGN 2 44
2016 [ROCK CRUSHER]

Ssolid stress = 126.9306162 ksi

Solving For Permissible Solid Stress

Ss =

Where:
Q = 87.5
X= 0.19
.
Ss = .

Ss =77.28204675 ksi

The spring would take a permanent set if compressed to solid height.

Solving for Pitch

At Table At 16 Approximate Free Length and Solid Heights (Faires, p.589)

Free length = PNc + 2Dw

20 = P (15) + 2(1)
P =1.2 in

Solving for Pitch Angle

Pitch Angle, λ = tan-1 (P/3 )
Pitch Angle, λ = tan-1(1.2 /3π)
Pitch Angle,λ = 7.256082911°

MACHINE DESIGN 2 45
2016 [ROCK CRUSHER]

Spring Mounting

MACHINE DESIGN 2 46
2016 [ROCK CRUSHER]

DESIGN SUMMARY
Elements Specifications Loadings
Motor IEC MOTORS

8-pole

Power: 20 Hp 18.27669331 hp

Speed: 750 rpm

Model: 1LA5 207-8AB

400 V

V-belt V-belt: Rubber at Section C

Belt No: C210

C= 55.76341937 in
HpTrans.=18.27669331 hp
L = 212.9 in.

Vm= 1963.495408 ft/min

No. of Belts= 4

b x t = 7/8 x 17/32 in.

Sheave of V-belt Ordinary Cast Iron

ρ=0.256 lb/ in2

D1 = 10 in

D2 = 50 in

T = 4.5 in

N1 = 750 rpm

N2 = 150 rpm

W1 = 90.47786842 lbs

W2 = 2261.946711 lbs

MACHINE DESIGN 2 47
2016 [ROCK CRUSHER]

Shaft 1 SAE 1095

@ section F, Mmax resultant=
D = 6.75 in, selected diameter 4431449.452 in-lb
and to be machined to
6.70963225 in to fit the bore Tmax = 7679.300861 in-lb
bearing

L = 60 in
Bearing on Shaft 1 High Carbon Chrome Bearing
Steel

Spherical Roller Bearings

24034CJ
Fr= 233195.7598 lbs
Ha= 29, 200 hrs

Bearing Bore=6.6929 in

Fc=301065.4651 lbs

Key @ Shaft 1 AISI C1117 (Normalized

Carbon Steel)

b = 1 ¾ in
= 11,666.66667 psi
t = 1 ½ in (Bearing Stress)

Minimum
Length=0.2616043179 in

I will use L = 0.75 in

Bolt on Bearing @ Shaft 1 AISI C1045(WQT Carbon
Steel)

3 in-4 UNC bolt = 5833.3333 psi

(Shearing Stress)
Ar= 5.97 in2

N= 4 bolts

MACHINE DESIGN 2 48
2016 [ROCK CRUSHER]

Shaft 2 SAE 1095

D = 6.75 in, selected diameter @ section E, Mmax resultant =

and to be machined to 4429015.892 in-lb
6.70963225 in to fit the bore
bearing

L = 54 in
Bearing on Shaft 2 High Carbon Chrome Bearing
Steel

Spherical Roller Bearings

24034CJ
Fr=233106.0996 lbs
Ha= 29, 200 hrs

Bearing Bore=6.6929 in

Fc= 300949.71 lbs

Spring Oil Tempered Wire

Squared and Ground ends

No. of Spring: 133 Springs

Dw = 1 in Ss = 42.31020538 ksi

Free length = 20 in

Dm =3 in

Deflection = 1 in

Nc= 15 active coils

P = 1.2 in

λ = 7.256082911°, C = 3

Solid height = 17 in

k = 3505.311983 lb/in
MACHINE DESIGN 2 49
2016 [ROCK CRUSHER]

REFERENCES

Books :

Doughtie, V.L., &Vallance, A. (1978).Design of Machine Members(4thed.).New York:

McGraw- Hill, INC.

Faires, V.M. (1969). Design of Machine Elements (4thed.). New York: MacMillan Company.

Morse, F. (1953).Power Plant Engineering. Philippines: Litton Educational Pubishing, INC.

Spotts, M.F. (1991). Design of Machine Elements (6thed.). Singapore: Simon & Schuster (Asia)
Pte Ltd.

Internet:

IEC Squirrel Cage Motors - Dimensions. Retrieved 2008 from

http://www.siemens.com/IECSquirrelcagemotor_1503.html

Fine Roller Specifications. Retrieved May 25, 2014 from

http://www.hajq.net/server/peijian_718.html

Bulk Density of limestone. Retrieved May 31, 2014 from http://www.natural-

stone.com/limestone.html

Bearing Housing. Retrieved June 6, 2014 from http://www.alibaba.com/product-detail/new-

products-four-bolt-bearing-asahi_902799172.html

Chapter-6-Roll-Crushers.Retrieved May 26, 2014 fromhttp://www.scribd.com/doc/30156582/

Chapter-6-Roll-Crushers

Some Useful Numbers on the Engineering Properties of Materials.Retrieved June 2, 2014 from
http://www.stanford.edu/~tyzhu/Documents/Some%20Useful%20Numbers.pdf

MACHINE DESIGN 2 50
2016 [ROCK CRUSHER]

APPENDIX

Table 1 IEC MOTORS

Material Compressive Strength

Limestone 12-28 MPa

Table 2 Compressive Strenght of Limestone

MACHINE DESIGN 2 51
2016 [ROCK CRUSHER]

Table 3 Motor Dimension

MACHINE DESIGN 2 52
2016 [ROCK CRUSHER]

Figure 17.14 Belt Selections from Horsepower and Speed

Table 17.5 Arc-of contact factors Table 17.4 Small diameter factor

MACHINE DESIGN 2 53
2016 [ROCK CRUSHER]

Table 17.7 Service Factors

MACHINE DESIGN 2 54
2016 [ROCK CRUSHER]

Table 17.3 Standard V-belt Lengths;

Horsepower Constants

MACHINE DESIGN 2 55
2016 [ROCK CRUSHER]

Table 17.6 Length Correction Factors

Table AT8 Typical Properties of Steel-Various Sizes and Conditions

MACHINE DESIGN 2 56
2016 [ROCK CRUSHER]

Table 16-5 Coefficient of Friction For Belts

Table 9-3 Typical Reliability Factors for rolling element bearings

MACHINE DESIGN 2 57
2016 [ROCK CRUSHER]

Table 9-4 Typical Values of application factor for roller and ball bearings

Table 9-5 Typical trust factors Kt for ball bearing

MACHINE DESIGN 2 58
2016 [ROCK CRUSHER]

Table 4 Standard Key Stock

MACHINE DESIGN 2 59
2016 [ROCK CRUSHER]

Table 6-1 Uniform and American National Threads, coarse, fine and extra-fine

MACHINE DESIGN 2 60
2016 [ROCK CRUSHER]

Table 1.1 Factors of safety

Figure AF 15 Stress Factor

MACHINE DESIGN 2 61
2016 [ROCK CRUSHER]

Table 5 Timken Roller Bearing Catalog

MACHINE DESIGN 2 62
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Table AT 17 Mechanical Properties of Wire for Coil Springs

MACHINE DESIGN 2 63
2016 [ROCK CRUSHER]

Table AT 16 Approximate Free Lengths and Solid Heights

Table 9 Century Spring Catalog

MACHINE DESIGN 2 64