CERTIFICATION FOR CORRECTION

We members of the jury and the head of department of Mechanical Engineering of Higher
Technical Teacher Traning College (HTTTC) Bambili of the University of Bamenda certify that
the DIPET I project titled: “DESIGN AND REALIZATION OF AN HDPE PLASTIC
BOTTLES CRUSHING MACHINE” has been corrected in accordance with the
recommendations of the jury.

Date……………………… Date………………… Date………………………

President of jury Rapporteur Member

Prof. ANYI Eintien Mr. NGONGANG Ludovic Mr TSAGUE P. Youri

Signature……………… Signature……………........ Signature……………..

Date………………………

Head of the Department

Prof. KANA’A Thomas

Signature………………

i
 ATTESTATION
We hereby declare that we are the sole author of this project. We authorize the Higher
Technical Teacher Training College (H.T.T.T.C) Bambili to lend this project to others
Institutions or to individuals for the purpose of scholarly research. We understand the nature of
plagiarism, and we are aware of the University’s policy on this. We certify this project is the fruit
of original work carried out within the HTTTC of Bambili under the supervision of
Mr.NGONGANG Ludovic.

Signature of the authors Date…………………

 DONKENG KENFACK D. NAURA……………………….

 KAMGNO BOGNE CHANCELINE………………………….

 MEGUEMTUE BOGNE MINOLIE………………………….

ii
 DEDICATION

DONKENG KENGFACK D. NAURA

To DONKENG’s family

KAMGNO BOGNE CHANCELINE

To MEKONTSO’s family

MEGUEMTUE BOGNE MINOLIE

To my father BOGNE Gabriel

iii
 PREFACE
The goal of the Higher Technical Teachers’ Training College “HTTTC” Bambili is to
train DIPET I and DIPET II teachers for technical education. The end of this training is marked
by a written examination, a practical pedagogic examination and a research work constituting a
written project and practical realization of the prototype. The topic is proposed or chosen and
guided by the lecturer of the department concerned. The word “project” in education has
acquired a meaning which is rather different from its meaning on other fields. Perhaps one
should say that it has a family of meanings. Unless the word is being abused it will refer to a
method of learning based on problem solving and involving a great deal of participation on the
part of those carrying it out.

A project is intended to reflect “Real life” processes more closely than traditional formal
teaching. In a project as in life, a problem is encountered and recognized, after some thought
and possible discussion information is collected, organized and selected; the knowledge now
available enables solutions to be devised and tried out, after which the possible solutions can be
evaluated and a best one is selected and implemented. At this stage, a great deal may well have
been learned as a result of the “need-to-know” created by the problem, but the learning process is
not yet exhausted. The implementation of the selected solution gives the opportunity to review
alternatives, to reconsider decisions made and to think what should be done in similar situations
in the future.

iv
 ACKNOWLEDGEMENTS

ACKNOWLEDGEMENT I
To GOD ALMIGHTY who guides and protects us every day. My personal effort could
not have been sufficient to achieve this study without the gathering of efforts on both sides of
various actors, who far or near have participated academically, professionally, financially, and
materially than purely moral and even spiritual.
I extend my gratitude to:
 Professor AKUME Daniel AKUME Director of HTTTC, for accepting me in this
precious institution whose he is in charge.
 My supervisor Mr. NGONGANG Ludovic, for his assistance and orientations that had a
capital contribution on the accomplishment of this dissertation.
 Prof. KANAA Thomas, head of department of mechanical engineering for his advices
 The lecturers of the department Mr. WOUMO Jean-Marie , Mr. BECHING ORU Roland,
Engr.YISAAlbert and the entire staff members of HTTTC Bambili for the supervision
and the teaching that had a capital contribution to my training.
 My classmates for the interaction, peace, and the search of knowledge that was at the
center of our preoccupation within the years spent in HTTTC of Bambili.
 My mother Mme DEMANOU ELISE who supported me morally and materially.
 My father Mr DONKENG EMILE who supported me morally and materially.
 My brothers and my my brothers and sisters who put me up during this study and
supported me morally.

DONKENG KENFACK D. NAURA

v
 ACKNOWLEDGEMENT II
The achievement of my training until now and this project has been done successfully by the
participation of many people; I heartily express my gratitude to:
 Professor AKUME Daniel AKUME Director of HTTTC, for accepting me in this
precious institution whose he is in charge.
 My supervisor Mr. NGONGANG Ludovic, for his assistance and orientations that had a
capital contribution on the accomplishment of this dissertation.
 Prof. KANAA Thomas, head of department of mechanical engineering for his advices
 The lecturers of the department Mr. WOUMO Jean-Marie , Mr. BECHING ORU Roland,
Engr.YISA Albert and the entire staff members of HTTTC Bambili for the supervision
and the teaching that had a capital contribution to my training.
 My parents BOGNE Gabriel and DJUIDJE Elodie for their moral and financial support.
 My brothers and sisters for their supports.
 My husband MEKONSTO Romeo Bovarice for his love, endurance, morality and
financial support.
 Babies MEKONTSO Hilda and MEKONTSO Priscille for their endurance.
 Mother MEWABO Marthe for her advices
 My grand mother MEDJOM Marie for her support
 Family MENO specially MENO Edmond, MENO Carlos and MENO Horace
 My classmates for the interaction, peace, and the search of knowledge that was at the
center of our preoccupation within the years spent in HTTTC of Bambili.

KAMGNO BOGNE CHANCELINE

vi
 ACKNOWLEDGEMENT III

This project could not have been successfully carried out without the cooperation and
Assistance of many people,it is for me an honor to thank:

 Professor AKUME Daniel AKUME Director of HTTTC, for accepting me in this

precious institution whose he is in charge.
 My supervisor Mr. NGONGANG Ludovic, for his assistance and orientations that had a
capital contribution on the accomplishment of this dissertation.
 Prof. KANAA Thomas, head of department of mechanical engineering for his advices
 The lecturers of the department Mr. WOUMO Jean-Marie , Mr. BECHING ORU Roland,
Engr.YISA Albert and the entire staff members of HTTTC Bambili for the supervision
and the teaching that had a capital contribution to my training.
 My betroth MBOULANG CEDRIC for his love, his moral and financial supports.
 My sister in lord NONKI Sorelle for his moral and financial supports
 My parents BOGNE Gabriel and DJUIDJE Elodie for their moral and financial support.
 My classmates for the interaction, peace, and the search of knowledge that was at the
center of our preoccupation within the years spent in HTTTC of Bambili.
 My brothers and sisters for their supports specialy TOTOUM Armel and WADEM Gaby
 To all those who from near or far have participated to the realization of this work.

MEGUEMTUE BOGNE MINOLIE

vii
 ABSTRACT
The project of end of study for the first cycle entitled ‘‘DESIGN AND REALIZATION
OF THE HDPE PLASTIC BOTTLES CRUSHED MACHINE” is not a new invention in the
sense that it already exists in Europe. Being given that we do not find any in our country and
local communities, considering the degree of pollution of plastic wastes in environment, we
thought of a partial innovation which is that to manufacture this machine usable in our
surrounding. We cannot destroy those plastic wastes because the combustion of these plastics
releases environment while destroying the atmosphere and by throwing them, they flee in the
ground creating losses in vegetation thus due to their very long lifespan. The only means of
avoiding all these harmful consequences on our environment is to recycle this plastic wastes; this
is why we decided conceive a machine which will be able to crush this waste in granulated form.
These plastic granules could be used in other field such as extrusion, the injection, etc; which
will allow to limit the loads of pollution, to avoid too much importation, to make economy. Thus
while taking account of the factors time, mobility, cost, maintenance, quality of the product, we
decided to do an crushing machine with one shaft and this machine has and reducing motor of
adjustable velocity; the machine function well with an angular velocity between 50 to 60 rpm,
having this datas we had calculated the power of the motor which is 2259.544 W. The machine is
capable to bring out 10 L of granules in 15 minutes.

viii
 RESUME
Le projet de fin d'étude du premier cycle ``CONCEPTION ET REALISATION D’UNE
MACHINE A BROYER LES BOUTEILLES PLASTICS PEHD" n'est pas une nouvelle
invention dans le sens qu'il existe déjà en Europe. Étant donné que nous n'en trouvons pas dans
notre pays et communautés locales, vu le degré de pollution des pertes en plastique dans
l'environnement, nous avons pensé à une innovation partielle qui est celle de fabriquer cette
machine utilisable dans notre entourage. Nous ne pouvons pas détruire ces déchets en plastique
parce que la combustion de ces plastiques pollue l'environnement tout en détruisant
l'atmosphère et en les jetant, ils s’enfuient dans le sol créant ainsi des pertes en végétation dû à
leur durée de vie très longue. Les seuls moyens d'éviter toutes ces conséquences nocives sur
notre environnement est de réutiliser ces déchets; c'est pourquoi nous avons décidé de réaliser
une machine capable de broyer ces déchets sous forme granulée. Ces granules de plastique
pourraient être employés dans d'autre domaine tel que l'extrusion, l'injection, etc... Ce qui
permettra de limiter les charges de la pollution, d’éviter trop d'importation et d’augmenter
l'économie financière du pays. Ainsi en tenant compte des facteurs temps, mobilité, coût,
maintenance, qualité du produit, nous sommes parvenu à une broyeuse comportant un arbre;
cette machine possède un moteur reducteur de vitesse réglable; la machine fonctionne bien avec
une vitesse angulaire comprise entre 50 et 60 rpm, ayant ces données, nous avons calculé la
puissance du moteur qui est 2259.544 W. Cette machine est capable de produit 10 l de granules
en 15 minutes.

ix
 TABLE OF CONTENTS

CERTIFICATION ............................................................................................................................................................... i

ATTESTATION ................................................................................................................................................................ ii

DEDICATION ................................................................................................................................................................. iii

PREFACE ....................................................................................................................................................................... iv

ACKNOWLEDGEMENTS ................................................................................................................................................. v

ACKNOWLEDGEMENT I ................................................................................................................................................. v

ACKNOWLEDGEMENT II ............................................................................................................................................... vi

ACKNOWLEDGEMENT III ............................................................................................................................................. vii

ABSTRACT ....................................................................................................................................................................viii

RESUME ........................................................................................................................................................................ ix

TABLE OF CONTENTS ..................................................................................................................................................... x

LIST OF FIGURES ..........................................................................................................................................................xiii

LIST OF TABLES ............................................................................................................................................................xiv

LIST OF ABBREVIATIONS...............................................................................................................................................xv

I.1-PLASTICS: DEFINITION AND HISTORY ................................................................................................................... 1

I.1.1-Definition...................................................................................................................................... 1
I.1.2-History and origins of plastics ...................................................................................................... 1
I.2-ORIGIN OF PLASTICS ............................................................................................................................................ 1

I.2.1-Animal origin ................................................................................................................................ 1

CHAPTER I: GENERALITIES ON PLASTICS ....................................................................................................................... 1

I.2.2-Vegetal origin ............................................................................................................................... 2

I.2.3-Natural origin ............................................................................................................................... 2
I.3-OBTENTION MODE OF PLASTICS.......................................................................................................................... 3

I.4-FAMILIES OF PLASTICS ......................................................................................................................................... 3

I.4.1-Thermosetting plastics ................................................................................................................. 3

I.4.2-Thermoplastics ............................................................................................................................. 4
I.4.3-Elastomers .................................................................................................................................... 4
I.5- PRODUCTION AND USE OF PLASTICS .................................................................................................................. 5

I.5.1-Production .................................................................................................................................... 5

x
 I.5.2-Use of plastics .............................................................................................................................. 6
I.6-POLLUTION BY PLASTICS ...................................................................................................................................... 6

I.6.2- In Cameroon ................................................................................................................................ 7

I.7-SIGNIFICANCE OF THE STUDY .............................................................................................................................. 8

II.1-SOLUTION1: CRUSHING MACHINE WITH THREE SHAFTS ................................................................................... 9

II.1.1-Functioning.................................................................................................................................. 9
CHAPTER II: PROPOSED SOLUTIONS AND CRITICAL ANALYSIS ...................................................................................... 9

II.1.2- Critical analysis ......................................................................................................................... 10

II.2-SOLUTION2: CRUSHING MACHINE WITH TWO SHAFTS .................................................................................... 10

II.2.1-Functioning................................................................................................................................ 10
II.2.2- Critical analysis ......................................................................................................................... 11
II.3-SOLUTION3: CRUSHING MACHINE WITH ONE SHAFT ...................................................................................... 11

II.3.1-Functioning................................................................................................................................ 11
II.3.2- Critical analysis ......................................................................................................................... 12
II.4-SOLUTION4: CRUSHING MACHINE WITH BLADE ON ITS SHAFT ....................................................................... 13

II.4.1-Functioning................................................................................................................................ 13
II.4.2- Critical analysis ......................................................................................................................... 14
II.5- PRESENTATION AND USE OF THE DATA OBTAINED ......................................................................................... 14

III.1- CONSTRAINTS AND HYPOTHESIS .................................................................................................................... 15

III.1.1- CONSTRAINTS .......................................................................................................................... 15

III.1.2- HYPOTHESIS............................................................................................................................. 15
III.2- CUTTING EFFORT Fc ......................................................................................................................................... 15

CHAPTER III: CONCEPTUAL STUDY .............................................................................................................................. 15

III.3- DETERMINATION OF THE DIMENSION OF THE SHAFT .................................................................................... 16

III.3.1-DETERMINATION OF RA and RB ................................................................................................ 17

III.3.2- STUDY OF SOLICITATIONS ....................................................................................................... 17
III.4- OTHER COMPONENTS OF THE MACHINE ....................................................................................................... 24

III.4.1- THE ELECTRIC MOTOR ............................................................................................................. 24

III.4.2- THE SIEVE ................................................................................................................................ 24
III.5- ASSEMBLY DRAWING ...................................................................................................................................... 24

III.6-CALCULATION OF CHAIN OF DIMENSIONS Ja AND Jb ...................................................................................... 26

IV.1- INTRODUCTION............................................................................................................................................... 27

IV.2-MANUFACTURING ANALYSIS OF THE PARTS OF THE MACHINE ...................................................................... 27

The manufacturing analysis will be presented following the steps below: ....................................... 27
xi
CHAPTER IV: MANUFACTURING ANALYSIS ................................................................................................................. 27

IV.3-MANUFACTURING DRAWING .......................................................................................................................... 28

IV.4-DETAILS DRAWING .......................................................................................................................................... 28

IV.5-DIMENSION LINK GRAPH ................................................................................................................................. 29

IV.6- ELEMENTRY SURFACES ................................................................................................................................... 30

IV.5-CONCLUSION ................................................................................................................................................... 43

V.1- USER MANUAL FOR THE POTATOES PEELING MACHINE ................................................................................. 44

Operational incidents: ........................................................................................................................ 44

V.2- MAINTENANCE ................................................................................................................................................ 44

V.3- COST ESTIMATE OF THE MACHINE .................................................................................................................. 44

V.4- RECOMMENDATIONS ...................................................................................................................................... 44

CHAPTER V: USER MANUAL, COST ESTIMATE OF THE MACHINE, SUMAMARY AND GENERAL CONCLUSION ........... 44

V.5- GENERAL CONCLUSION ................................................................................................................................... 45

REFERENCES ................................................................................................................................................................ 46

APPENDICES ................................................................................................................................................................ 48

xii
 LIST OF FIGURES
Figure 1: Clothe button................................................................................................................................................. 1
Figure 2: celluloid ........................................................................................................................................................ 2
Figure 3: wheel (rubber)............................................................................................................................................... 2
Figure 4: polypropylene................................................................................................................................................ 2
Figure 5: Diagram of the production of plastic ............................................................................................................ 3
Figure 6 : A)pollution of water with plastics b)plastic is eating by an aquatic animal c)location of the Plastic Vortex
...................................................................................................................................................................................... 7
Figure 7: pollution of the environment by plastic bottles in Douala ............................................................................ 8
Figure 8: Kinematic diagram of the crushing machine with three shafts ..................................................................... 9
Figure 9: Kinematic diagram of the crushing machine with two shafts ..................................................................... 10
Figure 10: Kinematic diagram of the crushing machine with one shaft ..................................................................... 12
Figure 11: Kinematic diagram of the crushing machine with blade........................................................................... 13
Figure 12: Free body diagram.................................................................................................................................... 16
Figure 13: Free body diagram.................................................................................................................................... 18

xiii
 LIST OF TABLES
Tableau 1 : Some thermosetting plastics....................................................................................................................... 4
Tableau 2: Some thermoplastic ..................................................................................................................................... 5
Tableau 3: level of the production of plastics in the world [8] ..................................................................................... 6
Tableau 4: level of the production of plastics in Cameroon [10] ................................................................................. 6
Tableau 5: Nomenclature of the kinematic diagram of the crushing machine with three shafts .................................. 9
Tableau 6: Nomenclature of the kinematic diagram of the crushing machine with two shafts ................................... 11
Tableau 7: Nomenclature of the kinematic diagram of the crushing machine with one shaft .................................... 12
Tableau 8: Nomenclature of the kinematic diagram of the crushing machine with blade .......................................... 13
Tableau 9: Table of elementary surfaces .................................................................................................................... 30
Tableau 10: TABLE OF ELEMENTARY OPERATIONS ............................................................................................ 31
Tableau 11: TABLE OF ASSOCIATION OF SURFACES .......................................................................................... 32
Tableau 12: TABLE OF MACHINING RESTRICTIONS ............................................................................................ 33
Tableau 13: TABLE OF MACHINING LEVELS ..................................................................................................... 34
Tableau 14: TABLE FOR GROUPING OF PHASES ................................................................................................. 35
Tableau 15: DRAFT OF MACHINING SEQUENCE ................................................................................................. 36
Tableau 16: TABLE OF PHASE 10 ............................................................................................................................ 37
Tableau 17: TABLE OF PHASE 20 ............................................................................................................................ 38
Tableau 18: TABLE OF PHASE 30 ............................................................................................................................ 39
Tableau 19: TABLE OF PHASE 40 ............................................................................................................................ 40
Tableau 20: TABLE OF PHASE 50 ............................................................................................................................ 41
Tableau 21: TABLE OF PHASE 60 ............................................................................................................................ 42

xiv
 LIST OF ABBREVIATIONS
Ref: reference
σmax: maximum normal stress
HDPE: high density polyethylene
Fc: cutting force
S: Cross section of the HDPE bottle plastic
MPa: Mega Pascal
⃗ : Linear acceleration
Ӫ : Angular acceleration
:Shear strain
: Bending moment
: Practical elastic resistance
: Quadratic moment
: Elastic resistance
: The side of the square part on the shaft
N: Newton
Nbr: Number
C: safety factor
Hm: average height of the bottle
Lm: average length of the bottle
l: width of the bottle
t: thickness of HDPE plastic bottle
rpm: revolution per minute
m: metter
ρ: density of HDPE bottle
υ: poisson ratio
HYSACAM: Hygiène et Salubrité du Cameroon

xv
 CHAPTER I: GENERALITIES ON PLASTICS

I.1-PLASTICS: DEFINITION AND HISTORY

I.1.1-Definition
A plastic is a mixture containing a primary product which is likely to be mounded,
worked generally hot and under pressure, in order to lead to a semi-product or an object.

I.1.2-History and origins of plastics

The plastics were practically born with the 20th century. The history of the plastics goes
up however in Egypt Antique, because the Egyptians employed adhesives from gelatin, casein
and albumin. The history of the plastic started in 1838 when Henri Regnault synthesized PVC
(polyvinyl chloride) for first time, but this discovery remained without continuation. It is in 1869
that the Hyatt brothers developed the celluloid which is regarded as first artificial plastic.
The PVC is invented in 1880. In 1889, the French chemist Jean-Jacques Trillat obtains
galalithe while hardening casein of milk. This matter, harder than the horn, will be then used to
manufacture the billiard balls as well as other current articles (buttons, jewels, pens).In 1930,
Wallace Carothers invents Polystyrene and polyamide, which was the first technical plastic of
high performance. In 2000, the polyethylene and the polypropylene were the most produced
plastics [1].
These plastics are not from the same origins; they are from animal, vegetation and nature.

I.2-ORIGIN OF PLASTICS
I.2.1-Animal origin
Casein which is a protein from milk is hardening to obtain galalithe which is a
thermosetting plastic; it was used to manufacture clothe button…

FIGURE 1: CLOTHE BUTTON

1
I.2.2-Vegetal origin
In the past, plastic was form using artisanal method:

-Celluloid was the first artificial plastic it is constituted of Cellulose which is a principal vegetal
component; it was used to produce billiard and tennis balls…

FIGURE 2: CELLULOID
-Latex from hevea and dandelion was used to produce rubber which is an elastic plastic; this
rubber was used to manufacture wheel…

FIGURE 3: WHEEL (RUBBER )

-Alcohol from sugar cane was used to obtain polyvinyl of chloride and polyethylene which were
used to manufacture water, shampooing, detergent bottles, tube…

-Maize was used to produce polypropylene which permits to manufacture yogurt cups, margarine
tubes…

FIGURE 4: POLYPROPYLENE
I.2.3-Natural origin
It represents 90% in the production of plastic. Nowadays with the industrialization,
Petroleum, charcoal and natural gas which are all natural, they are used to produce plastic such
as PVC, polypropylene, polystyrene, polyethylene… We can then say that petroleum (55%),
charcoal (35%) and natural gas (10%) are the essential origin of plastics [2].

2
I.3-OBTENTION MODE OF PLASTICS
Most modern plastics are derived from natural materials such as petroleum, charcoal and
natural gas. Starting from the process of petroleum refining (separating process by distillation of
its different components) from which we can obtain gas, naphta, super etc; Using naphtha which
is a liquid composed of hydrocarbon, we then transform it by cracking process (thermal process
which permit to split hydrocarbons in different molecules of lower sizes) to obtain monomers
such as: ethylene, propylene, benzene, styrene and others. Those molecules in certain conditions
of temperature and pressure by chemical reaction called polymerization will form the polymers
(molecules of highest sizes) such as polyethylene, polypropylene polystyrene….; a whole of
polymers must then form a plastic. To improve the chemical and physical properties (elasticity,
hardness…), we add an additive or adjuvant [3]. We can simplify all these stages by this
diagram:

PETROLEUM DISTILLATION NAPHTA CRACKING PROCESS MONOMERS

POLYMERISATION
PLASTICS ADDITIVES POLYMERS

FIGURE 5: DIAGRAM OF THE PRODUCTION OF PLASTIC

I.4-FAMILIES OF PLASTICS
The nature of polymers and the way in which they will be arranged will control the
properties of the plastic. We can then classify plastic into three families: thermosetting,
thermoplastics and elastomers.

I.4.1-Thermosetting plastics
These are plastics that soften when heated, and can be moulded when soft, and when cool
they will set into the moulded shape. But if heat is reapplied they will not soften again, they are
permanently in the shape that they have been moulded into. They are characterized by: their
resistance to heat, their non potentiality of recycling, and their destruction without melting when
raising the temperature [4]. Examples of thermosetting plastics are:

3
 T ABLEAU 1 : S OME THERMOSETTING PLASTICS

NAMES USES Illustrations

Polyurethane (PUR) Dashboard, coil roller

skates…

Phenoplaste (PF) Domestic iron, radio, phone…

Aminoplaste (MF) Plates, switch…

Unsaturated polystyrene Blades of windmill, hulls and

cabin of boats…

I.4.2-Thermoplastics
These are plastics that can be softened and formed using heat, and when cool, they will take up
the shape that they have been formed into. But if heat is reapplied they will soften again. They are
characterized by: they become soft when they are heated and become back hard while cooling, they can
be melted again after use and reorganized several time, they are potentially recyclable [5]. Some
examples of thermoplastics are shown in table 2.

I.4.3-Elastomers
Elastomers are plastics which are deformed and tend to take their initial positions and
support high deformation before break. From latex of hevea, the natural rubber is stay the sole
elastomer known but the modern method of manufacturing permit to obtain high diversity of
materials by adding additives, accelerator,… [6]

4
 T ABLEAU 2: S OME THERMOPLASTIC

NAMES USES Illustrations

Polyethylene terephtalate Soda, water and juice bottle

(PET)

High density polyethylene Milk and water jugs, detergent bottles…

(HDPE)

Polyvinyl chloride (PVC) Fidelity cart, some detergent bottles…

Low density polyethylene Thicker bags, plastic wrap

(LDPE)

Polypropylene (PP) Yogurt cups, magarine tubes…

Polystyrene (PS) Egg cartons, non expended plastic picnic

cups…

Other It is the mixture of one of the above whit

another

I.5- PRODUCTION AND USE OF PLASTICS

I.5.1-Production
I.5.1.1-Global production
In Asia, China is the big producer of plastics with 26% from the total production in the
world; Europe comes after with 20%. On the other hand, in the totality of Africa and Middle-
East, 7% is produced and 5% in Latin America [7].
The production rate of plastic increases year by year as shown in table 3.

I.5.1.2- Production in Cameroon

The statistics of the ministry of environment and of the protection of Nature show that
600000 tons of plastics are produced in Cameroun each year without being eliminated after use
[9]. Production of plastic in Cameroon is as shown in table 4.

5
 T ABLEAU 3: LEVEL OF THE PRODUCTION OF PLASTICS IN THE WORLD [8]
Years Quantities ( millions of tons)

2009 250

2011 280

2012 288

2013 299

2014 311

T ABLEAU 4: LEVEL OF THE PRODUCTION OF PLASTICS IN CAMEROON [10]

Years Quantities (millions of tons)

2009 83358

2010 94171.59

2011 92333.46

2012 97836.46

2013 105132.08

I.5.2-Use of plastics
When we compare two photographs of classes at approximately hundred years of
interval, we see that actually, our classrooms are composed mainly of plastic: computer, cases,
pens, bags… Plastics are everywhere; our life will not exist without them.

Billion packing are distributed each year, representing more than 15000 tons of wastes
which are not recycled according to a study undertaken by TerraEco in France. In Cameroon the
figures are less known. But the scale of the wastes observed in the drains, the household refuse
and in certain large axis, lets us to note the simply immensity of the utilization. A true wasting to
which each individual takes share! A pollution on the scale of planet, ground to oceans [11].

I.6-POLLUTION BY PLASTICS
I.6.1- In the world
Every year in Europe, approximately 100 kilos of plastics are thrown per capita. These
plastics are everywhere: teeth brush, bags, packing, and bottles. The problem of the plastics is
often their single use; it is the case for example of a packing of cake which is open then at once
thrown. Once in nature, the plastic can put until 600 years for decomposition [12].

6
 The plastics come from the store of trade where they are used to pack everything including
food. The specialists in environment estimate that there is more than 15000 tons of non recycled
waste, that is to say an average from 500 to 1000 millions of plastic parking per year in the world
[13]. If the plastic is not reused, it often finishes rejected in the ocean.

A) B)

C)

FIGURE 6 : A)POLLUTION OF WATER WITH PLASTICS B)PLASTIC IS EATING BY AN AQUATIC

ANIMAL C )LOCATION OF THE PLASTIC V ORTEX

I.6.2- In Cameroon
 In Cameroon, the annual production of the plastic wastes in the industrial sector would be
15 250 tons, In Douala, its economic capital, it would be 4000 tons [17].
 HYSACAM estimates that, on 700 tons of collected wastes every day, 14 tons are non-
biodegradable wastes. Dr. JULES MARIE KEMAJOU, geographer declares that of the
14 tons of the non-biodegradable waste collected by HYSACAM per day, 05 are empty
plastic bottles [18].
 An environmentalist affirms also that: 20 milliard of tons of every type of waste are
flown into the ocean every year [19].
 Assuming that the plastics take more than 400 years for decomposition whereas their
utilization period is extremely short of about 20 minutes, the statistics are showing that
more than 200 000 ha of ground lost each year it is caused by the plastics because the
hundreds of millions of the plastic waste flood our cities and villages by failing their
way in water and under the ground which pollute our environment. Those plastic wastes
have many disastrous consequences such as: obstruction of the hydraulic channels, total
reduction of the effort of cleaning out of gutters while causing floods...; in spite of those
consequences, the destruction of plastic wastes is not without incidence on the
environment: the combustion produces greenhouse gases which can make disappear the
vegetation, produces acidification of the atmosphere and the photochemical oxidations
[20].

7
 FIGURE 7: POLLUTION OF THE ENVIRONMENT BY PLASTIC BOTTLES IN DOUALA
This pollution has many consequences on us and on the environment such as:

 Because of the rejection of waste plastics in ocean, the marine fauna and flora are
destroyed
 Plastic being not biodegradable, it cause a durable pollution. Between 60% and 85% of
the collected wastes on the littoral are plastics [14].
 One of the many examples illustrating pollution due to the plastic is the continent of
wastes “Trash Vortex” which covers 3.5 million of kilometer square in the Northern
Pacific Ocean. It is constituted of 100 million tons of waste plastic floating, which make
the largest rubbish dump. It is destroyed marine fauna and flora of the Pacific. Indeed, it
is estimated that more than one million of marine birds and more than 100.000 marine
mammals die every year because of indigestion of plastic wastes, for example the
tortoises which confuse the jellyfish and plastic bags. It upsets alimentary chain [15].
 The effects in cascade can extend via the alimentary chain and touch human being by
example of the chemical substances in particular present in plastics would be at first rank
on the reduction of the quantity of spermatozoids at 50% and diseases bound to the
genital apparatus. Among the additives more debated, appears the bisphenol A, mostly
present in food plastics and in particular in 90% of feeding-bottles thus can reach baby
[16].

I.7-SIGNIFICANCE OF THE STUDY

As we can see the major plastic waste which pollutes our environment and which can be
recycled are thermoplastics because of their single use, certain thermoplastics are reused in
certain households to carry and keep water but, after some time, they finish in the dustbin and
then pollute our environment; with their fatal consequences on the environment. It is why we
decided to reduce this pollution of plastic bottles by crushing then in granule form which will be
used in other domains (molding). The aim of our study is to design and realize a HDPE plastic
bottles crushing machine

8
 CHAPTER II: PROPOSED SOLUTIONS AND
CRITICAL ANALYSIS

The aim of this chapter is to present different machines suitable for our study, examine
the advantages and disadvantages so as to choose the one which presents the best result.

II.1-SOLUTION1: CRUSHING MACHINE WITH THREE SHAFTS

II.1.1-Functioning
Plastic bottles are thrown inside the hopper 1 and fall in the frame 3 which are then
crushed in granule form by the three rotating shafts 2; those three shafts are trained by an electric
motor 7. The plastics which are crushed pass through the sieve 8.

FIGURE 8: KINEMATIC DIAGRAM OF THE CRUSHING MACHINE WITH THREE SHAFTS

T ABLEAU 5: NOMENCLATURE OF THE KINEMATIC DIAGRAM OF THE CRUSHING MACHINE
WITH THREE SHAFTS

Ref Nber Designation

8 1 Sieve

7 1 Motor

6 1 Belt

5 2 Pulley

4 3 Gear

9
 3 1 Frame

2 3 Shaft

1 1 Hopper

II.1.2- Critical analysis

II.1.2.1- Advantages
 High rate of production
 Easy to manipulate
 Time consuming
 Quality of the product
II.1.2.2- Disadvantages
 very difficult to transport
 high cost of manufacturing
 high cost of maintenance

II.2-SOLUTION2: CRUSHING MACHINE WITH TWO SHAFTS

II.2.1-Functioning
Plastic bottles are thrown inside the hopper 1 and fall in the frame 3 which are then
crushed in granule form by the two rotating shafts 2; those three shafts are trained by an electric
motor 7. The plastics which are crushed pass through the sieve 8.

FIGURE 9: KINEMATIC DIAGRAM OF THE CRUSHING MACHINE WITH TWO SHAFTS

10
 T ABLEAU 6: NOMENCLATURE OF THE KINEMATIC DIAGRAM OF THE CRUSHING MACHINE
WITH TWO SHAFTS

Ref Nber Designation

8 1 Sieve

7 1 Motor

6 1 Belt

5 2 Pulley

4 2 Gear

3 1 Frame

2 2 Shaft

1 1 Hopper

II.2.2- Critical analysis

II.2.2.1- Advantages
 High rate of production
 Easy to manipulate
 Time consuming
 Quality of the product
II.2.2.2- Disadvantages
 difficulty in transportation
 high cost of manufacturing
 high cost of maintenance

II.3-SOLUTION3: CRUSHING MACHINE WITH ONE SHAFT

II.3.1-Functioning
Plastic bottles are thrown inside the hopper 1 and fall in the frame 3 which are then
crushed in granule form by the rotating shaft 2; the shaft 2 is trained by an electric motor 6. The
plastics which are crushed pass through the sieve 7.

11
FIGURE 10: KINEMATIC DIAGRAM OF THE CRUSHING MACHINE WITH ONE SHAFT
T ABLEAU 7: NOMENCLATURE OF THE KINEMATIC DIAGRAM OF THE CRUSHING MACHINE
WITH ONE SHAFT

Ref Nber Designation

7 1 Sieve

6 1 Motor

5 1 Belt

4 2 Pulley

3 1 Frame

2 1 Shaft

1 1 Hopper

II.3.2- Critical analysis

II.3.2.1- Advantages
 easy to transport
 Easy to manipulate
 Time consuming
 Quality of the product
12
II.3.2.2- Disadvantages
 Low rate of production
 high cost of maintenance
 cost of manufacturing

II.4-SOLUTION4: CRUSHING MACHINE WITH BLADE ON ITS SHAFT

II.4.1-Functioning
Plastic bottles are thrown inside the frame 1, which are then crushed in granule form by
the blade 2 on the rotating shaft 7; the shaft 7 is trained by an electric motor 5. The plastics
which are crushed pass through the door 3.

FIGURE 11: KINEMATIC DIAGRAM OF THE CRUSHING MACHINE WITH BLADE

T ABLEAU 8: NOMENCLATURE OF THE KINEMATIC DIAGRAM OF THE CRUSHING MACHINE
WITH BLADE

Ref Nber Designation

7 1 Shaft

6 1 Belt

5 1 Motor

4 2 Pulley

3 1 Door

2 3 Blade

1 1 Frame

13
II.4.2- Critical analysis
II.4.2.1- Advantages
 easy to transport
 Easy to manipulate
 Cost of maintenance
 Cost of manufacturing
II.4.2.2- Disadvantages
 Low rate of production
 Time consuming
 Quality of the product

II.5- PRESENTATION AND USE OF THE DATA OBTAINED

9
8
7
6
5 time consuming
4 manufacturing cost
3
mobility
2
1 maintenance cost
0 quality of the product
crushing crushing crushing crushing
machine with machine with machine with machine with
three shafts two shafts one shaft blades on its
shaft

As shown on the chart above:

 Solution 1 and 2 present the worst characteristics due to his high manufacturing cost, his
difficulty in transportation, the high cost of maintenance.

 Solution 3 gives very good result for the five (5) characteristics

 Solution 1 also has fairly good results for the five characteristics but the quality of the
product is bad.
Based on these, it is clear that the solution 3 (crushing machine with one shaft) presents the
best characteristics as it has very good grade for the different characteristics and has a medium
(accessible) manufacturing cost.

14
 CHAPTER III: CONCEPTUAL STUDY

As our machine is to crush HDPE (high density polyethylene) plastics bottles in granule
form, there are some elements which need a special study such as the rotating shaft: it
dimensions have to be properly defined based on the cutting effort admissible and the different
constraints in the machine, the electric motor: since it is the one who transmit motion to the
system, and the sieve: it is the one who give the size of the granule. So during this chapter, we
will study these three elements of our machine.

III.1- CONSTRAINTS AND HYPOTHESIS

III.1.1- CONSTRAINTS
Since bottles have cylindrical form, conical, parallelepiped form, the shape of the bottles
not being fixed, we decided to study on the particular case in which the bottles are cut into small
scale form before putting in the machine; for us to study on this form, we impose the following
dimensions according to the machine:
 The length L= 70 mm
 The width l= 50 mm
 Thickness t= 5 mm
 Concerning the size of granule, it will be between 4mm to 6.mm

III.1.2- HYPOTHESIS
In order to easily approach the computation in our works, we decided to consider the
hypothesis concerning the density, the elastic modulus, the poission ratio, the yield stress and the
safety coefficient present below see appendix 1:
 The mass of the bottle is negligible
 The density of HDPE is ρ= 839 kg.m-3
 The elastic modulus of HDPE is E= 636.49 MPa
 The poission ratio υ is υ= 0.38
 The yield stress Re is Re = 16.45 MPa
 The safety coefficient of HDPE is C = 1.6

III.2- CUTTING EFFORT Fc

Calculation of the necessary force which will permit to tear the HDPE bottle:
The appropriate stress used to tear HDPE bottle being:
15
 .
σmax = MPa = .
= 10.28 MPa

σmax = where S is the cross section of the bottle (L×l)

S = L×l

= 70×50 = 3 500mm2

So FC = σmax×S = 10.28×3500

= 35 980 N

FC = 35 980 N

III.3- DETERMINATION OF THE DIMENSION OF THE SHAFT

The shaft is the most important part in the machine; its two end are circular of radius R=
20 mm and its middle has a square form of side a=?? mm and of length 100mm, the total length
is 400 mm. it receives the rotational effort from the motor and drives the system by rotating
together with the blades which are mounted on it. For this shaft to rotate, it is guided in rotation
by two ball bearings, a provision is made on the shaft to mount the bearings; on the shaft there
are provision for the mounting of circlips to block the bearing. We can see that the shaft is the
center of functioning of the machine, so it is the backbone of the machine. In this part, we want
to determine the value of a.

Hypothesis
 The displacement is considered to be at constant velocity
 The parts are rigid bodies
 The gravity acceleration is g=10m/s2

FIGURE 12: FREE BODY DIAGRAM

16
Where Fc1 = Fc2 = Fc3 = Fc4 = Fc5 = Fc6=Fc7=Fc8=35.980 × 103 N

III.3.1-DETERMINATION OF RA and RB
Using the fundamental principle of Dynamic, we have:

Ʃ F ⃗ ext = m a⃗ (1)

ƩMA(F ⃗ ext) = JΔ ӫ (2) But for displacement at constant velocity a⃗ = 0 ; ӫ = 0

Ʃ F ⃗ ext = 0 ⃗ (1)
ƩMA(F ⃗ ext) = 0 (2)

(1) 0 (o,x) –

-Fc1 – Fc2 – Fc3 – Fc4 – Fc5 – Fc6 – fc7 – Fc8 + RA+ RB = 0 (o,y)

RA + RB = 8Fc1

RA = 8Fc1 – RB (3)

(2) RA× 0 - Fc1×0 - Fc2 × AC - Fc3 × AD - Fc4 × AE - Fc5 × AF - Fc6× AG - fc7× AH – Fc8 × AB +
RB × AB = 0

RB × AB = Fc1 (AC + AD + AE + AF +AG + AH + AB)

( )
RB =

= 143.918× 103 N

(3) RA = 8FC1 –RB

RA = 143.918× 103 N

RA = 143.918× 103 N and RB = 143.918× 103 N

III.3.2- STUDY OF SOLICITATIONS

According to the load distribution on the axis, it result that the axis is subjected to a simple
flexion.
a) Study of simple flexion

17
 FIGURE 13: FREE BODY DIAGRAM

b) Study of internal forces and moments

 SECTION AC: 0 ≤ x ≤ 28.57 mm

Ty + RA – Fc1 = 0 ↔ Ty = Fc1 - RA = -10.7941×104 N

Mfz - RA x + Fc1 x =0 ↔ Mfz = RA x - Fc1 x

X 0 0.0285

Ty -10.7941×104 N -10.7941×104 N

Mfz 0 3084 Nm

18
 SECTION CD: 28.57 ≤ x ≤ 57.14 mm

Ty + RA – Fc1 - Fc2 = 0 ↔ Ty = Fc1 + Fc2 - RA = -7.1961×104 N

Mfz - RA x + Fc1 x + Fc2 (x – 28,57 ) =0 ↔ Mfz = RA x - Fc1 x - Fc2 (x – 25)

X 0.0285 0.0571

Ty -7.1961×104 N -7.1961×104 N

Mfz 3084 Nm 5140,015Nm

 SECTION DE: 57.14 ≤ x ≤ 85.71 mm

Ty + RA – Fc1 - Fc2 - Fc3 = 0 ↔ Ty = Fc1 + Fc2 + Fc3 - RA = -3.5981×104N

Mfz - RA x + Fc1 x + Fc2 (x – 28,57 ) + Fc3 (x –57,14) =0

↔ Mfz = RA x - Fc1 x - Fc2 (x – 28,57) - Fc3 (x – 57,14)

19
 X 0.0571 0.0857

Ty -3.5981×104N -3.5981×104N

Mfz 5140,015Nm 6168,837Nm

 SECTION EF: 85.71 ≤ x ≤ 114.28 mm

Ty + RA – Fc1 - Fc2 - Fc3 - Fc4 = 0 ↔ Ty = Fc1 + Fc2 + Fc3 + Fc4 - RA = -1,62N

Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) =0

↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71)

X 0.0857 0.1142

Ty -1,62N -1,62N

Mfz 6168,83 Nm 6168,82 Nm

20
  SECTION FG: 114.28 ≤ x ≤ 142.85 mm

Ty + RA – Fc1 - Fc2 - Fc3 - Fc4- Fc5 = 0 ↔ Ty = Fc1 + Fc2 + Fc3 + Fc4 + Fc5 - RA = 3.5978×104N

Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) + Fc5 (x –114,28) =0

↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71) - Fc5 (x –114,28)

X 0.1142 0.1422

Ty 3.5978×104N 3.5978×104N

Mfz 6168,83 Nm 5140,154 Nm

 SECTION GH: 142.85 ≤ x ≤ 171.42 mm

21
Ty + RA – Fc1 - Fc2 - Fc3 - Fc4- Fc5 - Fc6 = 0

↔ Ty = Fc1 + Fc2 + Fc3 + Fc4 + Fc5 + Fc6 - RA = 7.1958×104N

Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) + Fc5 (x –114,28)
+ Fc6(x –142,28) =0

↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71) - Fc5 (x –114,28) -
Fc6(x –142,28)

X 142,285 171,426

Ty 7.1958×104N 7.1958×104N

Mfz 5140,154 Nm 3084.231Nm

 SECTION HB: 171.42 ≤ x ≤ 200 mm

Ty + RA – Fc1 - Fc2 - Fc3 - Fc4- Fc5 - Fc6- Fc7 = 0

↔ Ty = Fc1 + Fc2 + Fc3 + Fc4 + Fc5 + Fc6 + Fc7 - RA = 10,7938×104N

Mfz - RA x + Fc1 x + Fc2 (x – 28, 57) + Fc3 (x –57, 14) + Fc4 (x –85, 71) + Fc5 (x –114,28)
+ Fc6(x –142,28) + Fc7(x –171,426) =0

↔ Mfz = RA x - Fc1 x - Fc2 (x – 28, 57) - Fc3 (x –57, 14) - Fc4 (x –85, 71) - Fc5 (x –114,28) -
Fc6(x –142,28) -Fc7(x –171,426)

X 0.0758 0.114

Ty 10,7938×104N 10,7938×104N

Mfz 3084.231Nm 0

22
C - SHEAR FORCE AND BENDING MOMENT DIAGRAMS

We plot the force and bending moments diagram with the aim of determining the most
solicited sections of the driven shaft. The most solicited section will be used to determine the
dimensions of the shaft that can overcome the shear force and bending moment.

Figure 3.4: Shear forces and Bending moment diagram

CONDITION OF RESISTANCE

In order to easily approach the computation in our works, we decided to consider the
hypothesis concerning the density the yield stress Re and the safety coefficient c of a quenched
steel present below see appendix 2.

σmax ≤ Rpe ↔ ≤

where IGz = Re = 500 Mpa and c = 1.05

23

≤ ↔ × × ≤

↔ 6 Mfz max c ≤ Re a3

↔a ≥

× , × .
↔a ≥ ↔ a ≥ 4.26 mm

As the dimension of the shaft is greater than or equal to 13.687 (a = 4.26 mm),
any value which fulfill this condition can be chosen for the well-functioning of our machine;
therefore the value chosen as dimension of the shaft is a= 30 .

III.4- OTHER COMPONENTS OF THE MACHINE

III.4.1- THE ELECTRIC MOTOR
An electric motor transmits electrical energy to mechanical energy, so that it can be used
to do work. When an electric motor is fed with current, it rotates because of the way coils and
magnets are prepared and positioned. Power is being transmitted from motor to the system with
the help of the key. Motors are characterized by the type and amount of current they can take and
the output power they can produce. According to our machine, we decided to use a reducing
motor to reduce the angular velocity to be between 50 and 60 rpm.

CALCULATION OF THE POWER OF THE MOTOR (P)

P= Cω where C= Fc×R is the coupling force and ω= angular velocity

P= Fc×R×ω
= 35980×0,02×60×3,14 P =2259,544 W

III.4.2- THE SIEVE

The sieve in the machine permits to have the size of granule between a range of 3 and 5 mm; so
the diameter of the holes which are on the sieve is d= 5 mm.

III.5- ASSEMBLY DRAWING

After a conceptual study of the principal elements of the machine, it is imperative to
come out with the assembly drawing which will present the machine in a better way as a whole;
three views have been selected for the presentation of the machine:
The front view in section C-C
The left view A-A
The top view in section B-B
24
14 8 washer comm
13 1 Motor comm
12 1 Shaft S235 mach
11 2 ring S235 comm
10 2 Bearing comm
9 1 Coupling comm
8 12 Screw comm
7 2 Screw comm
6 2 Rolling bearing comm
5 1 Sieve S235 mach
4 8 Bolts comm
3 7 Ring comm
2 8 Blades S235 mach
1 1 Frame S235 mach
Ref Nber Designations Materials Obser
HTTTC- BAMBILI
Scale : 1/1

ASSEMBLY
DRAWING
2016-2017 MM 3
III.6-CALCULATION OF CHAIN OF DIMENSIONS Ja AND Jb
The play Ja is located between the driven shaft 12 and the rolling bearing 6 and the play
Ja is located between the blade 2 and the frame 1

Datas: a12= 300+_0.2 a6= 20+_0.2 a11= 10+_0.1

b1= 10+_0.1 b11= 10+_0.1
CALCULATION OF Ja

Ja = a12 – (a6 +a11)

Jamax = a12max – (a6 +a11)min
= 300.2 – (19.8 + 9.8)

=270.5

Jamin = a12min – (a6 +a11)max

= 299.8 – (20.2 + 10.1)

= 269.5

ITJa = Jamax – Jamin = 270.5 - 269.5 = 1 Ja = 30+-0.1

CALCULATION OF Jb

Jb = b11 – b1
Jbmax = b11max – b1min
= 20.1 – 9.9

=10.2

Jbmin = b11min – b1max

= 19.9 – 10.1

= 9.8

ITJb = Jbmax – Jbmin = 10.2 – 9.8 = 0.4 Jb = 10+-0.4

26
 CHAPTER IV: MANUFACTURING ANALYSIS

IV.1- INTRODUCTION
The main objective of this chapter is to present a plan of manufacturing for the
production of the components of the machine, it entails giving a chronological process of
realizing a part from the level of rough piece to finished piece. This is to minimize the cost of
production. It is necessary to do the manufacturing analysis of all the parts involved in the
machine but to avoid making this document unnecessarily bulky, we will limit the manufacturing
analysis to one part: The driving shaft. It embodies the various phase contracts and the
manufacturing charts.

IV.2-MANUFACTURING ANALYSIS OF THE PARTS OF THE MACHINE

In this part, we are going to see the various specifications and machining operations
involved in preparation of the driving shaft from the rough piece to the finished piece.
 The machining phases are denoted by numbers 10, 20, 30…;
 The various operations carried out on the parts are indicated.

The manufacturing analysis will be presented following the steps below:

 Manufacturing drawing of the driven shaft;

 Linking graph: It gives a chronological order of operations carried out on the shaft in the
Various axes
 Inventory of the elementary operations and association of surfaces:
It considers the tolerances, thickness and roughness of to determine the number of elementary
operations for each surface and possible associations.
 Analysis of the previous constraint: It enables us to establish the order of realization at
each level.
 Level of realization table.
 Phase grouping table: It enables us determine the chronological order of realization
consigned in the document (sheet of studies of manufacture).
 Fabrication sheet: It shows the general operations to be carried out on the piece; it
indicates the type of operation, tool to be used, the type of machine used, and tools for
observation.

27
  Phase contract. It is a document which shows detail information on the manufacturing
process carried out on the piece at each phase. It shows the operation to be carried out
and the means of setting up the isostatic position, Clamping, choice of the manufacturing
equipment and cutting parameters.
The various manufacturing analysis will be presented on the preceding pages. Below are the
various sheets for the manufacturing analysis.

IV.3-MANUFACTURING DRAWING

IV.4-DETAILS DRAWING

28
IV.5-DIMENSION LINK GRAPH
Ox Direction

Oy Direction

Oz Direction

29
IV.6- ELEMENTRY SURFACES

T ABLEAU 9: TABLE OF ELEMENTARY SURFACES

Surfaces Operations
F1
F2 Turning
F3 Turning
F4 Turning
F5 Turning
F6 Milling
F7 Milling
F8 Milling
F9 Milling
F10 Milling
F11 Milling
F12 Milling
F13 Milling
D1 Turning
D2 Turning
C1 Turning (chanfreining)
C2 Turning (chantreining)

30
 TABLEAU 10: TABLE OF ELEMENTARY OPERATIONS

REFERENCE FUNCTIONAL EXIGENCES TECHNOLOGICAL EXIGENCES FUNCTIONAL OPERATIONS

SURFACE
√ IT OTHERS NBR SYMBOLISATION

F1
F2 3.2 0.4 02 F2E, F2F
F3 3.2 0.4 02 F3E, F3F
F4 3.2 0.4 02 F4E, F4F
F5 3.2 0.4 02 F5E, F5F
F6 3.2 0.4 02 F6E, F6F
F7 3.2 0.4 02 F7E, F7F
F8 3.2 02 F8E, F8F
F9 3.2 0.4 02 F9E, F9F
F10 3.2 02 F10E, F10F
F11 3.2 02 F11E, F11F
F12 3.2 02 F12E, F12F
F13 3.2 0.4 02 F13E, F13F
D1 3.2 0.4 02 D1E, D1F
D2 3.2 0.4 02 D2E,D2F
C1 1.6 01 C1F
C2 1.6 01 C2F

31
 TABLEAU 11: TABLE OF ASSOCIATION OF SURFACES

SURFACES TO JUSTIFICATION NEW

BE DESIGNATION
ASSOCIATED Cutting tool Tool holder Others

G0

F2, D1 Slide tool G1E, G1F

F3, D2 Slide tool G2E, G2F

F5, F6, F8, F9, Milling tool G3E, G3F

F11

32
 TABLEAU 12: TABLE OF MACHINING RESTRICTIONS

RESTRICTIONS (CONTRAINTS)
Surfaces

Geometrical Technological Economic

Dimensio
Minor Finishing
nal ∕∕ Forms Others Repeat Operation Burr
machining tool

F1
F10E
F10F F7E
G1E
G1F G1E
G2E
G2F G3E
G3E
G3F
F4E
F4F G3E
F7E
F7F
F12E
F12F
F13E
F13F

33
 TABLEAU 13: TABLE OF MACHINING LEVELS

PREVIOUS T LEVELS
O
T
A
L

F G G G G G G F12 F13 F13 C1 C2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1

F4E F4F F7E F7F F10E F10F F12E
1 1E 1F 2E 2F 3E 3F F E F F F 5
F1 0

G1E 1 1 0

G1F 1 1 1 0

G2E 1 1 1 1 0

G2F 1 1 1 1 1 0

G3E 1 1 1 1 1 0

G3F 1 1 1 1 1 1 1 0

F4E 1 1 1 1 1 0
PRESENT

F4F 1 1 1 1 1 1 1 1 0

F7E 1 1 1 1 1 0

F7F 1 1 1 1 1 1 1 1 1 1 0

F10E 1 1 1 1 1 1 1 1 1 1

F10F 1 1 1 1 1 1 1 1 1 1 1 1 0

F12E 0

1 1 1 1 1 1 1 1 1 1 1 1 1 1 0
F12F
1 1 1 1 1 1 1 1 1 1 1 1 1 0
F13E
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0
F13F

C1F 1 1 0

C2F 1 1 1 1 1 1 1 1 1 0

34
 TABLEAU 14: TABLE FOR GROUPING OF PHASES
(GANTT GRAPH)

LEVEL ELEMENTARY OPERATIONS

1 C1F G1E

2 G1F

3 G2E

4 G2F

5 F7E G3E

6 G3F

7 F4F

8 C2F

9 F7F

10 F10F

11 F13E

12 F12F

13 F13F

14

35
 TABLEAU 15: DRAFT OF MACHINING SEQUENCE

PHASE SUB-PHASE DESIGNATION SURFACES MACHINED

REF
10 Initial control of dimensions F1

20 Turning 1 G1F

21 chamfering 1 C1F

30 Turning 2 G2F

31 Facing F4F

32 Chamfering 2 C2F

40 Milling 1 G3F

50 Milling 2 F7F,F10F,F12F,F13F

60 Final control of the dimensions F4F, F7F,

F10F,F12F,F13F,G1F, G2F,
G3F, C1F, C2F

36
 TABLEAU 16: TABLE OF PHASE 10

Machine tool used:

Control
Phase Sub-phase Operation tool
Initial control
of dimensions
-Vernier callipers L=300+-0.2
10
-Ruler Ø= 43+-0.1

37
 TABLEAU 17: TABLE OF PHASE 20

Machine tool used: lathe machine

Control
Phase Sub-phase Operation Tool

-Vernier callipers
L=270+-0.2
Turning -Lathe machine
20 21 Ø= 20+-0.1
chamfering -turning tool
l=30+-0.2
-ruler

Cutting speed Cs Number of revolution N

25 m/min 185.06 tr/min

38
 TABLEAU 18: TABLE OF PHASE 30

Machine tool used: lathe machine

Control
Phase Sub-phase Operation Tool

-Vernier callipers
Turning L=200+-0.2
-Lathe machine
30 31, 32 facing Ø= 20+-0.1
-turning tool
chamfering l=70+-0.2
-ruler

Cutting speed Cs Number of revolution N

25m/min 185.06 tr/min

39
 TABLEAU 19: TABLE OF PHASE 40

Machine tool used: milling machine

Control
Phase Sub-phase Operation Tool

-Vernier callipers
-Milling machine l=17+-0.2
40 Milling
-milling tool (Ø10) L=38+-0.2
-ruler

Cutting speed Cs Spindle speed n

40m/min 127.32 tr/min

40
 TABLEAU 20: TABLE OF PHASE 50

Machine tool used: milling machine

control
Phase Sub-phase Operation Tool
-Vernier callipers
-Milling machine
-milling tool (Ø 30) c=30+-0.2
50 Milling -ruler

Cutting speed Cs Spindle speed n

40m/min 424.41 tr/min

41
 TABLEAU 21: TABLE OF PHASE 60

Machine tool used:

control
Phase Sub-phase Operation Tool

-Vernier callipers
60 Final control All dimensions
-ruler

42
IV.5-CONCLUSION
After choosing the machine which is suitable for the work required, we then calculated
the efforts applied to and from the machine in order to dimension the machine. With these efforts
calculated, the machine dimensioned, and the manufacturing analysis which have been studied,
this now enables us to realize our machine which will be able to crush 10l of granule in 15 min.
We will now move on to the last chapter which points out the uses of the machine, how the
machine can be maintained, the cost estimate and short comings encountered during the
realization of the machine. The HDPE plastics crushing machine studied and analysed here is
produced on the dimensions as seen in this project, unless otherwise due to some practical
constraints.

43
 CHAPTER V: USER MANUAL, COST ESTIMATE OF THE
MACHINE, SUMAMARY AND GENERAL CONCLUSION

V.1- USER MANUAL FOR THE POTATOES PEELING MACHINE

The instructional manual provides full basic information on how to operate the machine
perfectly with full safety; it gives information on how to operate the machine in carrying out the
crushing process, it also provides information on how to carry out basic repairs or maintenance
on the machine.

Operational incidents:
 If the machine does not start, check whether the machine is well connected
 If the noise is abnormal, do the following
- Stop the machine
- Check if the revolving equipment functions well

V.2- MAINTENANCE
Always grease the bearings after every three months.

V.3- COST ESTIMATE OF THE MACHINE

The cost estimated for the machine is approximately 750 000 FCFA with the good
materials; because of the high price of materials used; we spent 305 000 FCFA because we have
used a simple steel instead of quenched steel.

V.4- RECOMMENDATIONS
Because of the difficulties encountered during the study and the manufacturing of the
machine, we recommend to the government to:

 Equips the workshop of school to facilitate the manufacturing process.

 Creates account for the realization of this type of project which is too expensive.
 Employ people who will collect plastic wastes in our environment to facilitate the
recycling.

44
V.5- GENERAL CONCLUSION
The theme "DESIGN AND REALIZATION OF AN HDPE PLASTIC BOTTLES
CRUSHING MACHINE" has as principal aim the crushing those plastic wastes in order to
facilitate their recycling.
Such machine has to be highly sensitive, allowing a control of the applied load and providing
good quality of final product; that is why some existing machines of that kind have been first
studied and then four machines have been proposed among which the one with the best
characteristics has been selected, designed and realized.
Many difficulties have been encountered during the design and the manufacturing processes: The
design of the machine has been complicated by the fact that the software AutoCAD was not well
memorized.
During the manufacturing process, the difficulties found on the field were the lack of materials
and their high cost. In addition to that, we did not have the free accesses to the workshops which
did not favoured to follow evolution of the work.
However, much of improvements on the machine can be made to increase its effectiveness like
the manufacture of the crushing blades with material that is able to crush all the types of plastics
considering that our own is crushing only the waste of the HDPE.
Keeping up with the imperfection of all human works, our work remains imperfect, that's why
we stay with an open heart to comments, criticisms and suggestions for corrections.

45
 REFERENCES
[1] LES PLASTIQUES DANS NOTRE VIE, pp8, 2012

[2]JACKY AUBRY ; Technologie Les Matériaux : Les Matières plastiques, pp4

[3]STRID ; Gestion des déchets dans le Nord Vaudois : Les Différents Types de Plastiques

[4]STRID ; Gestion des déchets dans le Nord Vaudois : Les Différents Types de Plastiques

[5]STRID ; Gestion des déchets dans le Nord Vaudois : Les Différents Types de Plastiques

[6]MobiScience.Briand : Familles de plastiques et leurs usages

[7] http://www.planetoscope.com/petrole/989-production-mondiale-de-plastique.html le 05-

11-2016 à 8h00

[8] http://fr.statista.com/statistiques/571746/production-mondiale-de-plastiques-1990/ le 05-01-

2017 à 20h06

[9]http://www.mediaterre.org/afrique -centrale/actu,20150206092606.html le 20-03-2017

[10] cameroon.africadata.org

[11] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04

[12] LES PLASTIQUES DANS NOTRE VIE, pp15, 2012

[13] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04

[14] L’impact du plastique sur l’environnement et la santé : Classe de 3eB du Collège Mendès-
France de Lillebonne, Seine-Maritime

[15] L’impact du plastique sur l’environnement et la santé : Classe de 3eB du Collège Mendès-
France de Lillebonne, Seine-Maritime

[16] LES PLASTIQUES DANS NOTRE VIE, pp15, 2012

[17] http://www.mali-pense.net/cameroun-RED-PLAST-un-projet.html le 13-10-2016 à 22h45

[18] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04

46
[19] http://www.africa-info.org/environnement/1332-cameroun-des-emballages-plastiques-
menacent-gravement-lenvironnement.html le 13-10-2016 à 22h04

47
APPENDICES
APPENDICES 1

48
APPENDICE 2

49