Design and Analysis of a Horizontal Shaft Impact Crusher

Abstract

Crusher is one of the major size reduction equipment that is used in metallurgical, mechanical, and other similar industries. They exist in various sizes and capacities which range from 0.1 ton/hr. to 50 ton/hr. They can be classified based on the degree to which they can fragment the starting material and the way they apply forces. Based on the mechanism used crushers are basically of three types namely Cone crusher, Jaw crusher and Impact crusher. Our objective is to design various components of an Impact crusher like drive mechanism, shaft, rotor, hammers, casing, and discharge mechanism which will be useful in minimizing weight, cost and maximizing the capacity and also do their analysis. Impact crushers involve the use of impact rather than pressure to crush materials. Here the material is held within a cage, with openings of the desired size at the bottom, end or at sides to allow crushed material to escape through them. This type of crusher is generally used with soft materials like coal, seeds or soft metallic ores. The mechanism applied here is of Impact loading where the time of application of force is less than the natural frequency of vibration of the body. Since the hammers/blow bars are rotating at a very high speed, the time for which the particles come in contact with the hammers is very small, hence here impact loading is applied. The shaft is considered to be subjected to torsion and bending. The grinding screen is also designed for optimal output from the crusher A performance model is also considered for the horizontal shaft impact crusher so as to find out the relation between the feed, the crusher parameters and the output parameters.