CHAPTER I INTRODUCTION

Crushers are machines used to crush various materials, namely rocks, ore, and other aggregates for the purpose of rock-fill for landscaping, road building, erosion control, and mining ores. There are several different types of crushers, all suited for different construction and mining applications and used to crush rocks of various forms and sizes.

I.

History

a) Early Crushing Methods

The crushing of rocks and aggregates has been a progressively demanding industry for at least the last three centuries. Originally, mining materials such as gold, silver, and copper were crushed by hand. When it was not possible to use brute force, heavy rocks were raised, either by groups of men or with the help of animals, and dropped. When irrigation systems were invented, men used water to raise rocks for crushing. Other methods included the use of sledgehammers.[1] Before the use of steam machines, stone getters would get into groups of two to four to blast and break rocks, drilling small holes into rock and filling them with straw and explosives. With steam power going strong in the 19th century, methods of drilling and crushing changed drastically. Machines that ran on electric or gas diesel were produced.

b) The First Crushing Machines

The first hint of a crushing machine appeared in 1830. An idea was posited about a drop hammer, which later was used in stamp mills. In the 1840s, a second patent was issued: a wooden box and a wooden cylindrical drum that revolved at 350 revolutions per minute. Neither device was developed enough to have an impact on the crushing industry.

Although he never developed a line of manufactured crushers, Thomas Edison helped develop a primary crusher when he was trying to reduce magnetic iron ore. He discovered that crushing rocks would be more economical than using explosives. Eli Whitney Blake produced the first successful jaw crusher in 1858, a prototype that all subsequent crushers would follow. Philters W. Gates patented the gyratory crusher, another primary crusher machine, in 1883. Both Blake's and Gates' models were engaged in a contest to measure which machine was most successful and productive. Having to crush nine cubic yards (6.9 m3) of stone, the Gates model completed the task in just 20 minutes and the Blake model finished at 64 minutes.

II.

INDUSTRIAL USE

In industry, crushers are machines which use a metal surface to break or compress materials. Mining operations use crushers, commonly classified by the degree to which they fragment the starting material, with primary and secondary crushers handling coarse materials, and tertiary and quaternary crushers reducing ore particles to finer gradations. Each crusher is designed to work with a certain maximum size of raw material, and often delivers its output to a screening machine which sorts and directs the product for further processing. Typically, crushing stages are followed by milling stages if the materials need to be further reduced. Additionally rock breakers are typically located next to a crusher to reduce oversize material too large for a crusher. Crushers are used to reduce particle size enough so that the material can be processed into finer particles in a grinder. A typical circuit at a mine might consist of a crusher followed by a SAG mill followed by a ball mill. In this context, the SAG mill and ball mill are considered grinders rather than crushers. In operation, the raw material (of various sizes) is usually delivered to the primary crusher's hopper by dump trucks, excavators or wheeled front-end loaders. A feeder device such as an apron feeder , conveyor or vibrating grid controls the rate at which this material enters the crusher, and often contains a preliminary screening device which allows smaller material to

bypass the crusher itself, thus improving efficiency. Primary crushing reduces the large pieces to a size which can be handled by the downstream machinery. Some crushers are mobile and can crush rocks (as large as 60 inches). Primarily used in-pit at the mine face these units are able to move with the large in feed machines (mainly shovels) to increase the tonnage produced. In a mobile road operation, these crushed rocks are directly combined with concrete and asphalt which are then deposited on to a road surface. This removes the need for hauling over-sized material to a stationary crusher and then back to the road surface.

III.

Scope of Project work

Computer aided design is essential to design the given crusher such that the computer can be viewed before manufacturing any modifications can be made in the design if required and also we can have different sizes of crusher at a single time without going to the manual process. The load withstanding capacity of different component can be found out. Finally by checking the design and with standing capacity of the component is then manufactured manual.

CHAPTER II I. Impact Mill

a) Introduction
Impact Crusher became of prime importance for the mining of cement, granite, coal, limestone, marble, barite, talc, porcelain, barytes, rivel gravel and so on. Imapct crushers are suitable for materials whose compressive strength is under 360Mpa and side length is under 500mm. They are preferred to crush granite, marble, barite, coal, talc, porcelain, glass, carborundum, zirconite, limestone, barytes, rivel gravel, etc. With the introduction of vertical roller mills, which accept a raw material size of up to 80mm, theImpact Crusher became of prime importance for the cement, coal, iron and other industry. Modern Impact Crushers are equipped with heavy duty rotors in common rail design. Specially designed cast discs are combined on one main shaft, concentrating the main weight at the

circumference of the rotor. The result is a high moment of inertia and kinetic energy, which allows one-step crushing of the raw material down to the required product size. State-of-the-art Impact Crushers are equipped with hydraulically supported impact walls and grinding path, allowing a calibration of the crushing gap and the product size according to the requirements. Therefore one crusher can be sufficient to produce limestone with a grain size of 0/80mm for the raw mills and a grain size of 0/35 mm as additive for the cement mills. To meet the problem of having uncrushable material like e.g. tramp iron in the feed material, each Impact Crusher should be equipped with an effective overload protection. ThyssenKrupp Frdertechnik achieves this by a patented combination of the grinding path and the lower impact wall. As soon as an overload occurs at the lower impact wall, the supporting cylinder is released and the gap between impact wall, grinding path and rotor is being widened. This avoids any damages to the grinding path by opening the gap before the tramp iron passes through. After discharging the uncrushable material to the discharge conveyor, the hydraulic cylinders move the impact wall and the grinding path back to the former position. Maintenance-friendly details like interchangeable wear plates, quick release bolts for very fast opening of the housing, hydraulically fixed blow bars, blow bar lifting and rotor positioning devices are also standard items of recent impact crushers.

TYPES OF CRUSHERS

Type

Hardness

Abrasion limit

Moisture content

Reduction ratio

Main use

Vertical shaft impactors (autogenous)

Soft to very hard

No limit

Dry or wet, not sticky

2/1 to 5/1

Quarried materials, sand & gravel

Type

Hardness

Abrasion limit

Moisture content

Reduction ratio

Main use

Jaw crushers

Soft to very hard

No limit

Dry to slightly wet, not 3/1 to 5/1 sticky

Heavy mining, Quarried materials, sand & gravel, recycling

Gyratory crushers

Soft to very hard

Abrasive

Dry to slightly wet, not 4/1 to 7/1 sticky

Heavy mining, Quarried materials

Horizontal shaft Soft to impactors medium hard

Slightly abrasive

Dry or wet, not sticky

10/1 to 25/1

Quarried materials, sand & gravel, recycling

Compound crusher

Medium hard to very hard

Abrasive

Dry or wet, not sticky

3/1 to 5/1

Mine, Building Materials

Vertical shaft impactors (shoe and anvil)

Medium hard to very hard

Slightly abrasive

Dry or wet, not sticky

6/1 to 8/1

Sand & gravel, recycling

Cone crushers

Medium hard to very hard

Abrasive

Dry or wet, not sticky

3/1 to 5/1

Quarried materials,

Type

Hardness

Abrasion limit

Moisture content

Reduction ratio

Main use

Sand & gravel

Mineral sizers

Hard to soft

Abrasive

Dry or wet and sticky

2/1 to 5/1

Heavy mining