SUMMARY

This report documents the development of a Metallic Wastage Compressed Machine utilizing a
Hydraulic Bottle Jack mechanism. The project's primary objective was to design and construct an
efficient system for compressing metallic waste materials, thereby contributing to waste management
efforts.

Through comprehensive research, design iterations, testing, and analysis, the team aimed to
achieve a practical solution to address the challenges associated with metallic waste disposal. This
summary provides a concise overview of the project's scope, objectives, methodology, outcomes, and
the significance of the developed machine in advancing sustainable waste management practices.

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TABLE OF CONTENT

DECLARATION .................................................................................................................................................... 2
SUMMARY ............................................................................................................................................................ 2
ACKNOWLEDGEMENT........................................................................................ Error! Bookmark not defined.
LIST OF FIGURES ................................................................................................................................................. 4
NOMENCLATURES & ABBREVIATIONS ........................................................................................................ 5
NOMENCLATURES.......................................................................................................................................... 5
ABBREVIATIONS ............................................................................................................................................. 5
INTRODUCTION ................................................................................................................................................... 6
AIM ..................................................................................................................................................................... 6
OBJECTIVES ......................................................................................................................................................... 7
METHODOLOGY .................................................................................................................................................. 8
OUTCOMES ........................................................................................................................................................... 9
ACTIVITIES DUE TO UNDER THE PROJECT ................................................................................................ 10
OVERVIEW OF THE PROJECT ......................................................................................................................... 12
LITERATURE SURVEYS ................................................................................................................................... 14
FIELD SURVEYS ................................................................................................................................................ 16
DESIGN ................................................................................................................... Error! Bookmark not defined.
CALCULATION .................................................................................................................................................. 19
TESTING METHODS .......................................................................................................................................... 25
RESULTS................................................................................................................. Error! Bookmark not defined.
DISCUSSION ....................................................................................................................................................... 26
CONCLUSION ..................................................................................................................................................... 28
Frame Construction and Assembly ................................................................................................................... 28
Lower Frame and Movable Jack Holding Bar .................................................................................................. 28
Die and Bench Fabrication ................................................................................................................................ 28
Final Assembly and Testing .............................................................................................................................. 29
Challenges and Improvements .......................................................................................................................... 29
Conclusion and Future Outlook ........................................................................................................................ 29
ANNEXES ............................................................................................................................................................ 31
Annex A: List of Tools and Equipment Used ................................................................................................... 31
Annex B: Materials Used .................................................................................................................................. 33
Annex C: Detailed Steps of Construction ......................................................................................................... 33
Annex D: Observations and Improvements ...................................................................................................... 36

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 Annex E: Testing and Results ........................................................................................................................... 37
Annex F: Visual Documentation ....................................................................................................................... 37

LIST OF FIGURES
Figure 1 Stress- strain curve .................................................................................................................................. 15
Figure 2 Welding frame .......................................................................................... Error! Bookmark not defined.
Figure 3 Cutting L angles .......................................................................................... Error! Bookmark not defined.
Figure 4 upper frame drilling for mount hooks ........................................................ Error! Bookmark not defined.
Figure 5 Fixed hydraulic jack ................................................................................... Error! Bookmark not defined.
Figure 6 smoothing inner die ................................................................................... Error! Bookmark not defined.
Figure 7 Smoothing die hole .................................................................................... Error! Bookmark not defined.
Figure 8 Sliding door with die ................................................................................... Error! Bookmark not defined.
Figure 9 Hydraulic jack ............................................................................................. Error! Bookmark not defined.
Figure 10 Hydraulic compress machine ............................................................................................................... 18
Figure 11 Spring Calculation .................................................................................................................................. 20
Figure 12 Dividing Forces ...................................................................................................................................... 20
Figure 13 spring constant calculation...................................................................... Error! Bookmark not defined.
Figure 14 power hacksaw machine ....................................................................................................................... 31
Figure 15 Bench Grinder........................................................................................................................................ 31
Figure 16 Hand Grinder ......................................................................................................................................... 31
Figure 17 Arc welding ............................................................................................................................................ 32
Figure 18 Drilling machine ..................................................................................................................................... 32
Figure 19 Hand files ............................................................................................................................................... 32
Figure 20 Hydraulic bottle jack .............................................................................................................................. 32
Figure 21 L bars ..................................................................................................................................................... 33
Figure 22 Hooks ..................................................................................................................................................... 33
Figure 23 spring ..................................................................................................................................................... 33
Figure 24 Machine frame ...................................................................................................................................... 34
Figure 25 Movable jack holding part .................................................................................................................... 35
Figure 26 Die with Bench....................................................................................................................................... 35
Figure 27 sliding door ............................................................................................................................................ 35
Figure 28 pressure plate ........................................................................................................................................ 36
Figure 29 piston rod .............................................................................................................................................. 36
Figure 30 Machine painting ................................................................................................................................... 36
Figure 31 Die with chips ........................................................................................................................................ 36
Figure 32 Chips block............................................................................................................................................. 37
Figure 33 Machine parts........................................................................................................................................ 38
Figure 34 Hook drawing ....................................................................................................................................... 38
Figure 35 spring drawing ....................................................................................................................................... 38
Figure 36 Piston drawing ....................................................................................................................................... 38
Figure 37 Mold lid drawing.................................................................................................................................... 38
Figure 38 Machine frame Drawing ........................................................................................................................ 38
Figure 39 Moving flat iron Drawing ...................................................................................................................... 38
Figure 40 Sliding door Drawing ............................................................................................................................ 38
Figure 41 Bench frame Drawing .......................................................................................................................... 38

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NOMENCLATURES & ABBREVIATIONS

NOMENCLATURES
1. L-Bar: Metal bars shaped like the letter "L" used to form the frame.
2. C-Structure: The C-shaped frame formed by connecting two L-bars.
3. Jack Holding Bar: The bar that holds and moves the hydraulic jack up and down.
4. Hydraulic Bottle Jack: A device used to apply high pressure to compose the metal wastages as
blocks.
5. Shaft: Helped to move the pressure (Hydraulic Jack) to die part
6. Spring: Elastic component used to return the jack holding bar to its original position.
7. Hook: Device used to attach the spring to the frame and the jack holding bar.
8. Box Structure: The base structure below the shaft, providing support and housing the die.
9. Base: The bottom part of the machine that supports the entire structure.
10. Die: A specialized tool used to hold the wastage and helped to change it as blocks.
11. Sliding Door: A door that slides to allow access to the inside of the box structure for removing
metal blocks.
12. Metal Chip: Small pieces of metal waste produced during the composition process.
13. Metal Waste Composing Machine: The final assembly of all components designed to process
change the metal wastage to metal block.

ABBREVIATIONS
1. LB: L-Bar
2. CS: C-Structure
3. JHB: Jack Holding Bar
4. HBJ: Hydraulic Bottle Jack
5. SH: Shaft
6. SP: Spring
7. HK: Hook
8. BS: Box Structure
9. BA: Base
10. D: Die
11. SD: Sliding Door
12. MC: Metal Chips

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INTRODUCTION

In the contemporary workshop environment, managing metallic waste efficiently is a significant

challenge. Excessive metallic waste not only consumes valuable space but also requires considerable
effort and time for disposal. To address this problem, we developed a Metal Waste Composing Machine.
This innovative machine compresses metal waste into smaller, manageable chips, facilitating easier
stock and disposal and significantly reducing the space occupied by the waste.

AIM

The primary aim of the Metal Waste Composing Machine is to minimize the space occupied by metallic
waste in our workshop and to streamline the disposal process. By transforming large volumes of metallic
scrap into compact, easily disposable chips, we aim to enhance the overall efficiency and cleanliness of
our workspace.

The metallic waste compression machine using a hydraulic bottle jack tackles a specific
challenge in small to medium-scale waste management: reducing the volume of metallic waste. This
innovative machine achieves significant compression, leading to several advantages. By minimizing the
size of metallic waste like aluminum cans, steel scraps, and mixed metals, the machine allows for better
storage utilization within facilities and potentially lowers transportation costs due to reduced weight and
volume.

The key to this machine's affordability and effectiveness lies in its core component: a hydraulic
bottle jack. This readily available tool provides the necessary compression force, offering a cost-
effective alternative to complex industrial compactors. The machine itself prioritizes safety through
features like a pressure relief valve that prevents overloading and it help to change the waste as chips.
Operating the machine is straightforward. After loading the metallic waste into the die and put the shaft
base inside the die, operate the jack and it’ll start to give the pressure to shaft. Shaft push the wastage
and start to compose the wastage as chips. After this processes pull over the slide to out and get the chips
block from die.

Finally we got the chips block outside and same as this and reduce all wastage as small. Maintain
the workshop clean and give the small space to put the chips and chips can easily remove the workshop,
Time also save in this process.

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OBJECTIVES

The project objectives are to implement the use of a manual hydraulic bottle jack waste metal chip press
machine in our workshop to address several key areas. Primarily, this machine aids in clearing the
workshop area by efficiently compressing metal chips into compact blocks. This process not only helps
in maintaining a clean and organized workspace but also facilitates easy storage and transportation of
waste materials. The compressed metal chip blocks occupy significantly less space, making it simpler
to store them until they can be transported for recycling or disposal.

Additionally, the use of this machine contributes to reducing environmental pollution. By compressing
the metal chips, we minimize the volume of waste, thereby decreasing the number of trips needed for
transportation and reducing carbon emissions. Furthermore, the compact blocks are easier to handle,
ensuring that the waste management process is more efficient and less labor-intensive. Importantly, this
approach also prevents the negative impact caused by the release of waste metal chips into the
environment. Uncontrolled release of metal chips can lead to soil and water contamination, posing
significant risks to ecosystems and human health.

Overall, the manual hydraulic bottle jack waste metal chip press machine is an essential tool in our
workshop, enabling us to achieve a cleaner, more organized workspace while also promoting
environmentally responsible practices and preventing environmental contamination.

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METHODOLOGY

The project begins with conducting extensive research to understand existing technologies,
methodologies, and best practices in waste management and hydraulic systems. This is system created
by more people but we try to make an impact our workshop so we modify the system of the pressure
machine which compress the chips from metal wastages. Based on the identified requirements, design
concepts are generated, integrating a hydraulic bottle jack mechanism for efficient compression. The
selected design concepts are then translated into detailed engineering designs, taking into account factors
such as material selection, structural integrity, and hydraulic system specifications.

Once the designs are finalized, a prototype of the metallic wastage compressed machine is
constructed by us. Finished the machine check the mechanism work and get the chips block from the
machine. Drawbacks gathered and make some change in machines parts. It is used to identify areas for
improvement, leading to necessary refinements in the design and functionality of the machine.

All aspects of the design, construction, Checking, and refinement processes are meticulously
documented to create comprehensive records for future reference and replication. Finally, training and
support are provided to operators for the effective utilization and maintenance of the metallic wastage
compressed machine, followed by its deployment in relevant waste management facilities.

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OUTCOMES
The project aims to achieve efficient waste volume reduction by designing a machine that effectively
compresses metallic waste, significantly reducing its volume. This reduction contributes to more
efficient waste management practices by minimizing storage space and transportation costs. Utilizing a
hydraulic car jack as the primary force application mechanism offers a cost-effective solution, providing
an alternative to more complex and expensive industrial compactors. This approach allows small to
medium-scale waste management operations to achieve substantial waste volume reduction without
requiring significant investment in costly machinery.
Enhanced safety measures are integral to the machine's design, incorporating features such as
pressure relief valves, safety guards, and emergency stop mechanisms to ensure safe operation. These
safety enhancements minimize risks to operators and reduce the likelihood of accidents or injuries during
use. Additionally, the machine's user-friendly design, with intuitive controls and ergonomic features,
makes it accessible to operators with minimal training, enhancing usability and facilitating efficient
operation in various waste management settings.
This machine can handle varying types of metallic waste effectively. By reducing the volume of
metallic waste, the machine also contributes to more sustainable waste management practices, aligning
with environmental goals by minimizing the environmental footprint associated with waste disposal and
transportation.
Moreover, the successful development and check the machine lay the groundwork for potential
expansion and adaptation to other waste management applications. This achievement opens
opportunities for further innovation and customization, allowing the machine to address specific waste
management challenges in different industries or sectors.

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ACTIVITIES DUE TO UNDER THE PROJECT

Creating a Metal Waste Composing Machine involves several intricate steps that culminate in a
functional device designed to efficiently transform waste steel into manageable chips. The process
begins with the preparation of the machine’s frame. Initially, long L bars are cut into four equal-length
pieces using a cutting machine. The edges of these bars are then meticulously ground to ensure uniform
length and smoothness. These L bars are subsequently welded in pairs to form two C-shaped bars, which
will serve as the primary structural components of the machine frame. The welding process employs
welding rods and a welding plant to ensure strong, durable joints.

The next phase involves constructing the upper part of the frame. A steel plate is drilled to create
two holes for fixing hooks, using a drilling machine to ensure precision. In the center of this plate, a
small cylinder is welded to serve as a support for the hydraulic bottle jack, which will be mounted upside
down. This assembly is then welded to the previously made C bars, completing the upper frame structure.
The welded joints are finished with grinding to ensure smoothness and uniformity.

Subsequently, attention turns to the lower part of the frame. A box bar is fixed at the bottom of
the frame to provide stability. Additionally, two more L bars are attached at 90-degree angles to further
reinforce the frame's stability and support. Grinding is again employed to give a clean finish to these
welded parts. At this stage, the primary structure of the machine frame is complete, sturdy, and well-
finished.

The construction then shifts to the movable jack holding bar. This component is crafted from a
steel plate with its four corners cut into L shapes, enabling it to move vertically between the C bars. Two
holes are drilled into this plate to attach hooks, and a small cylinder is welded to its underside to hold
the piston of the hydraulic jack. The upper part of this bar is equipped with a C-shaped barrier to secure
the jack. Springs are used to fix this movable bar to the upper frame, ensuring that it can move up and
down smoothly, facilitating the pressure application mechanism.

In parallel, a die and a bench are fabricated. The die is made from a cylinder, which is shaped
and smoothed using hand files to ensure it fits perfectly into its intended housing. The bench is
constructed using six L bars and a square plate. A hole, matching the diameter of the die, is drilled in
the center of this plate. The L bars are then welded to the plate to form the legs of the bench, with
additional L bars connecting the legs for enhanced stability. This assembly creates a sturdy platform
where the die is fixed. A sliding door is added to the bench, allowing easy removal of the steel chips
produced by the machine.

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 Before final assembly, two critical components are prepared: the piston rod and the pressure
applying surface. The pressure applying surface is a circular plate with a diameter slightly smaller than
that of the die, allowing it to travel within the die without obstruction. The hydraulic bottle jack, with a
10-ton capacity, is employed to generate the necessary pressure to operate the machine.

With all components prepared, the final assembly begins. Each part is meticulously fitted
together, ensuring that all mechanisms operate smoothly and efficiently. The frame, jack holding bar,
die, and bench are integrated into a cohesive unit. The piston rod and pressure applying surface are
installed, and the hydraulic jack is mounted in its designated position. Once assembled, the machine is
tested to verify its functionality. The tests confirm that the machine effectively transforms waste steel
into chips, operating seamlessly as intended.

After confirming the machine’s operational success, final touches are added. The entire machine
is given a thorough finishing, ensuring all surfaces are smooth and any rough edges are eliminated. A
coat of paint is applied to protect the metal surfaces from corrosion and to provide an aesthetically
pleasing appearance.

This comprehensive process, from cutting and welding the frame components to assembling and
testing the final machine, highlights the detailed craftsmanship and precision engineering required to
create a functional Metal Waste Composing Machine. The machine's ability to efficiently convert waste
steel into chips block demonstrates its utility and effectiveness, marking the successful completion of
this intricate project.

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OVERVIEW OF THE PROJECT

The Metal Waste Composing Machine project is an innovative initiative undertaken to address the
challenge of recycling metal waste in a workshop setting. This project involves designing and fabricating
a machine capable of transforming metal waste into reusable chips, thereby reducing waste and
promoting sustainability. The following overview details the step-by-step process of creating this
machine, highlighting the key components and techniques used.

The initial step in the construction of the machine frame involved cutting a long L bar into four
equal pieces. This was achieved using a cutting machine, ensuring precision and uniformity in the
lengths of the bars. Following the cutting process, the edges of the bars were ground to maintain the
same length and to ensure smooth, burr-free edges. This preparation was crucial for the subsequent
welding process.

With the L bars prepared, the next step was to form the C bars, which are essential components
of the machine frame. This involved joining two L bars together by welding, using a welding rod and a
welding plant. The welding process was executed with precision to ensure strong and stable joints. The
result was two C bars, which would serve as the main structural elements of the machine frame.

The upper part of the frame was constructed using a steel plate. Two holes were drilled into the
plate using a drilling machine, and hooks were fixed into these holes. A small cylinder was then welded
to the middle of the plate to hold the jack upside. This assembly was subsequently fixed to the C bars by
welding, and the joints were given a good finishing by grinding to ensure smoothness and durability.

The lower part of the frame involved fixing a box bar to the frame's downside. Additionally, two
L bars were fixed at 90-degree angles to provide extra support to the frame. The welding was done with
precision, followed by thorough grinding to achieve a smooth finish. This step completed the
construction of the machine frame, providing a sturdy foundation for the other components.

The movable jack holding bar is a critical component that allows for the vertical movement of
the hydraulic jack. This process began with a steel plate, which was cut at the four corners to form an L
shape. This shaping was necessary to enable the plate to move up and down between the C bars. Two
holes were drilled into the plate, and hooks were fixed into these holes. A C shape barrier was created
on the upper side to hold the hydraulic bottle jack, and a small cylinder was fixed on the downside to
hold the piston. This movable bar was then attached to the upper part of the frame using two springs,
allowing for controlled vertical movement.

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 The die and bench were fabricated as integral parts of the machine. The die was created using a
cylinder, which was shaped and smoothed using hand files to ensure a precise and smooth surface. The
bench was constructed using six L bars and one square plate. A hole was made in the middle of the
square plate to accommodate the die. The four L bars were fixed as legs of the bench, and two additional
L bars were used to connect the legs, providing stability and support. The die was then fixed to the bench,
and a sliding door was installed to facilitate the easy removal of metal chips.

Before assembling the machine, the piston rod and pressure applying surface were fabricated.
The pressure applying surface had a slightly smaller diameter than the die, allowing it to travel smoothly
into the die. A 10-ton hydraulic bottle jack was used to apply pressure, ensuring sufficient force to
compress the metal waste into chips.

With all components ready, the final step was to assemble the machine. This involved integrating
the frame, the movable jack holding bar, the die, and the bench. Each part was meticulously aligned and
fixed in place to ensure optimal functionality. Once assembled, the machine was tested to check its
mechanism. The test was successful, demonstrating the machine’s capability to efficiently convert metal
waste into reusable chips.

The final step involved giving the machine a good finishing touch. All surfaces were thoroughly
ground to remove any rough edges or imperfections. The machine was then painted to protect it from
corrosion and to give it a professional appearance.

The Metal Waste Composing Machine project successfully culminated in the creation of a
functional and efficient machine capable of recycling metal waste into reusable chips. This project not
only showcased the technical skills involved in metalworking but also underscored the importance of
sustainable practices in a workshop setting. Through precise cutting, welding, drilling, and assembling,
the team was able to fabricate a machine that addresses a significant environmental issue, promoting
recycling and reducing waste. The successful completion of this project is a testament to the meticulous
planning, execution, and teamwork involved.

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LITERATURE SURVEYS

The Metal Waste Composing Machine addresses the challenges of managing metallic waste by
converting metal waste chips into reusable blocks through compression, promoting sustainable metal
recycling practices. This literature survey examines the design, optimization, and maintenance of
hydraulic pressing machines, emphasizing their environmental and economic benefits.
Hydraulic pressing machines transform metallic waste into valuable blocks through compression,
providing a more energy-efficient and environmentally friendly alternative to traditional melting
methods. The primary configurations of these machines include single-action and double-action presses.
The hydraulic pressing machine for compressing metallic waste is designed with key objectives
of ensuring a compact and robust design, reducing transportation and storage costs, minimizing
environmental harm, simplifying maintenance, and incorporating automation to enhance efficiency. The
machine operates using a hydraulic bottle jack to apply significant compressive force to the metal waste.
Key components include the hydraulic bottle jack, pump handle, pump piston, check valves, hydraulic
fluid reservoir, main cylinder and piston (ram), release valve, compression chamber (die), and sliding
door.
The operation involves loading the waste into the chamber, pumping the handle to create
pressure, compressing the waste with the ram, maintaining pressure, and releasing the pressure to remove
the compressed block. Safety considerations include overload protection, hand safety, and regular
maintenance of hydraulic components. Optimization techniques focus on balancing pressure, ensuring
proper material composition, and controlling particle size distribution.
The compressed part of the machine includes a hydraulic system, compression chamber, valve
mechanisms, and an automated control system to ensure effective and efficient compression.
Maintenance involves regular inspections, proper lubrication, cleaning, and operator training. Effective
waste management is emphasized, with materials such as low carbon steel, aluminum, cast iron, and
copper being processed to minimize environmental impact and maximize resource conservation.

o Elasticity Limit of Mild Steel:

The elasticity limit, or yield point, of mild steel is the maximum stress the material can withstand
while still returning to its original shape after the stress is removed. Before this point, mild steel deforms
elastically, following Hooke's Law, where stress is proportional to strain. The slope of this linear
relationship is the elastic modulus, or Young's modulus, indicating the material's stiffness.

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 Once the stress exceeds the elasticity limit, mild steel undergoes plastic deformation, resulting
in permanent changes to its shape. This irreversible deformation occurs due to the movement of
dislocations within the crystal lattice structure. The yield strength, the stress at the elasticity limit, is a
critical parameter in engineering design to ensure structures remain within their elastic range during
normal use, preventing excessive deformation and structural failure. Understanding the elasticity limit
is essential for determining safety margins and ensuring the integrity of engineering designs.

Figure 1 Stress- strain curve

o Chip Formation:
During machining, metal is removed in the form of chips. Types of chips include continuous,
discontinuous, and those with built-up edges. Proper chip formation is essential for achieving desired
machining outcomes.

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FIELD SURVEYS
During our field survey, we identified several types of waste metal chip press machines available on the
industrial, each employing different mechanisms. The main categories we examined include electrical
hydraulic press machines, manual hydraulic press machines, screw type press machines, and crank type
press machines. Each type has its own set of advantages and disadvantages, which we carefully
considered in relation to our workshop's specific needs.

The electrical hydraulic press machine emerged as an ideal choice due to its high accuracy and excellent
quality of output. This machine operates using a motor coupled with a hydraulic pump, providing
consistent and reliable performance. It is widely used in various industries for its efficiency and
precision. However, the primary drawback of this machine is its high cost, It was difficult for us,
especially for smaller workshops like ours. The investment required for purchasing and maintaining an
electrical hydraulic pump press machine would significantly impact our budget, making it an impractical
choice for our current financial situation.

On the other hand, screw type press machines, while more affordable, were found to be insufficient for
our needs. These machines rely on a screw mechanism to apply pressure, which often results in lower
compression force and reduced effectiveness in compacting metal chips. The output quality from screw
type presses did not meet our standards for efficiency and compactness, making them an unsuitable
option for our workshop.

Similarly, crank type press machines presented their own set of challenges. These machines operate
using a crankshaft mechanism to generate pressing force. Crank type presses suffer from energy loss
during operation. The mechanical nature of the crankshaft mechanism leads to inconsistencies in the
applied pressure, resulting in variable output quality. The loss of energy and the variability in
performance made crank type press machines a less desirable option for our specific requirements.

After thorough consideration of the available options, we determined that a manual hydraulic pump press
machine using a bottle jack is the most suitable choice for our workshop. This type of machine offers a
balance of cost-effectiveness and quality. The manual hydraulic press operates using a bottle jack to
generate the necessary pressure for compressing metal chips. While it requires manual effort, the bottle
jack mechanism ensures consistent and adequate pressure application, leading to high-quality
compression of metal waste.

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The manual hydraulic press machine is significantly more affordable compared to the electrical
hydraulic pump press machine. It does not require an electrical power source, which further reduces
operational costs and makes it an environmentally friendly option. The simplicity of the manual
hydraulic press design also means lower maintenance costs and ease of use, making it an ideal solution
for our workshop's needs.

In conclusion, our field survey highlighted the various options available for waste metal chip press
machines, each with distinct advantages and disadvantages. While electrical hydraulic press machines
offer superior quality and precision, their high cost makes them impractical for our workshop. Screw
type and crank type press machines, although more affordable, do not meet our requirements for
efficiency and output quality. The manual hydraulic pump press machine using a bottle jack emerged as
the most suitable option, offering a cost-effective and reliable solution for our waste management needs.
This choice ensures that we can maintain a clean and organized workshop while efficiently managing
our waste metal chips and contributing to environmental sustainability.

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 The assembly of the machine involved bringing together all these components into a cohesive
unit. The design required careful alignment and secure fastening to ensure that all parts worked together
seamlessly. The final assembly included testing the machine to verify its functionality and efficiency.
This step was crucial to identify any potential design flaws and make necessary adjustments. The
successful operation of the machine demonstrated the effectiveness of the design, producing high-quality
chips from waste steel.

Figure 2 Hydraulic compress machine

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CALCULATION

Calculate the Spring Constant

1st method,

 Used an Experimental method(Static Method) to calcite the Spring Constant,

Static Method: Suspend a known mass from the spring and measure the displacement. Use
Hooke's Law to calculate 𝑘.
 Attach a mass 𝑚1 to the spring.
 Measure the displacement 𝑥 from the equilibrium position.
 Calculate the force 𝐹 using 𝐹=𝑚𝑔, where 𝑔 is the acceleration due to gravity
(approximately 9.81 m/s2).
 Use 𝑘=𝐹/𝑥.

 The weight of the springs can affect the calculations for the spring constant, especially
if the spring has a significant mass compared to the attached weight. Here’s how you
can account for it:

o If the spring's own weight 𝑊𝑠 is not negligible, it can affect the displacement and thus the
calculation of the spring constant. Here's how you can account for it:
1. Effective Mass: The effective mass of the spring meff is a fraction of the spring's total mass 𝑚𝑠.
For a uniform spring, it is typically considered to be 1/3 of its mass.
1
𝑚𝑒𝑓𝑓 = 𝑚𝑠
3

2. Total Mass: The total mass causing the displacement of the spring is the sum of the attached
mass 𝑚1 and the effective mass of the spring 𝑚eff:
1
𝑚𝑡𝑜𝑡𝑎𝑙 = 𝑚1 + 𝑚𝑠
3

3. Total Force: The total force 𝐹total acting on the spring is:
1
𝐹𝑡𝑜𝑡𝑎𝑙 = (𝑚1 + 𝑚𝑠 )𝑔
3

4. Calculating the Spring Constant: Measure the displacement 𝑥1 caused by the total force and
then use Hooke's Law to calculate the spring constant:
1
𝐹𝑡𝑜𝑡𝑎𝑙 (𝑚1 + 3𝑚𝑠 )𝑔
𝑘= =
𝑥1 𝑥1

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 1
𝑚
3 𝑠

X1 = 0

X2 = x 2

m1

1
Figure 3 Spring Calculation F1 = (𝑚1 + 𝑚𝑠 )𝑔
3

2nd method,
 Or we can estimate the spring constant using the formula for the spring constant of an
extension spring:
Gd4
𝑘= 8D3 N
where:
 G is the shear modulus of the material (for spring steel, G≈79 GPa=79×109 Pa)
 d is the wire diameter
 D is the mean coil diameter
 N is the number of active coils

Calculate the Final Force and Pressure applying to the Metal Waste Block,
Assuming there is no any forces induce from the frame, because it is very hard and rigid.

ms – Spring mass
mh – Jack holder mass
Fst Fst mj – Jack mass
1 1
𝑚 𝑚
3 𝑠 3 𝑠 Fst – Spring tension force
mh mj
Fj
(Fhw+Fjw+Fsw) – Sum of the jack
Fhw+Fjw+Fsw
holder, jack and spring weights(forces)
Fm to the downwards
Fj – The force applying by the jack
Rm – Fm – Reactive force from the
mold area

Figure 4 Dividing Forces

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To deform(to reach to the yield point) the mild-steel chips, it should press between 250 and 350 MPa
pressure. So we assumed that the final pressure inside the mold is 250MPa. According to that,

1. Inside of the mold,

 Rm = Fm = Fjw+Fhw+Fsw+Fj-Fst = Reactive force from the mold (Eq.1)
𝑑
 Mold area = Am = 𝜋( 2𝑚 )2 (dm = 113mm)
0.113
= 𝜋( 2 )2
= 0.010028m2

According to the above details,

Fm Fjw +Fhw +Fsw +Fj −F st
Final pressure inside the mold = = = 250MPa
Am 0.010028
Final force inside the mold = Fm = 2.507×106N

2. Spring parameters,
By using 2nd method,
 G is the shear modulus of the material (for spring steel, G≈79 GPa=79×109 Pa)
 d = 3.5mm
 D = Douter – d = 20mm – 3.5mm = 16.5mm
 N = Total coils – Inactive coils
= 48 – 12 = 36

According to the above details,

The spring constant(k) is
79×109 Pa×(0.0035m)4
𝑘=
8×(0.0165m)3 ×36

k = 91,633.6424N/m
The spring tension force is
Springs maximum pulled value roughly(x2) = 120mm
Therefore total Fst = 2kx2 (For two springs)
= 2 × 91,633.6424N/m × 0.12
= 21,992.08N

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 3. Hydraulic bottle jack, jack holding flat iron and springs weights downward force,
 F = ma
1
Fjw+Fhw+Fsw = mj 𝑔 + mh 𝑔 + 2 × (3 ms )𝑔

1
ms ≈ 0.07823kg
3
mj ≈ 4.850kg
mh ≈ 1.4kg

 All the weights are measured by using a scale(or balance)

According to above details,

Total weight force(Fw) = (0.07823×2 + 4.850 + 1.4)kg × 9.81m/s2
= 62.08N
4. Hydraulic jack parameters,

By using the Eq.1

Fm = Fjw + Fhw + Fsw + Fj - Fst

Fj = Fm – (Fjw + Fhw + Fsw) + Fst

= 2.507×106N - 62.08N + 21,992.08N
= 2.528929×106N Jack force at the final limit

 Diameter of the hydraulic piston = 7cm

8
 Area of the jack piston = 𝜋( )2 ×10-4
2
= 0.0050265m2

Work-done by a man for a single cycle,

Foutput = Finput ×(Alarge / Asmall)

how much length that the stroke lifting in hydraulic bottle jack in a single push? The length of the stroke
lifting in a hydraulic bottle jack in a single push depends on the volume of hydraulic fluid displaced by
the small piston and the area of the larger lifting piston.
 Area of the Small Piston (Asmall): The cross-sectional area of the small piston.
 Area of the Large Piston (Alarge): The cross-sectional area of the large piston.
 Stroke Length of the Small Piston (dsmall): The distance the small piston moves in a single push.
 Stroke Length of the Large Piston (dlarge): The distance the large piston moves in a single push.
2 8
Asmall = 𝜋( )2 ×10-4 Alarge = 𝜋( )2 ×10-4 dsmall = 47.5mm
2 2
= 0.000314159m2 = 0.0050265m2 dlarge = ?

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Volume of Fluid Displaced (V1):
V1 = Asmall × dsmall
= 0.000314159 × 0.0475 = 1.49×10-5
The volume of fluid displaced by the small piston is equal to the volume of fluid displaced by the large
piston(V2):
V2 = Alarge × dlarge
V1 = V2,
Asmall × dsmall
Therefore dlarge =
Alarge
1.49×10−5
=
0.0050265
= 0.002944m = 2.944mm ≈ 3mm
Total piston stroke length which we want to make the chip block inside the mold is 120mm. So the
number of strokes we have to push by the hydraulic jack hand is,
Number of strokes(n) = 120/3 = 40

Calculate the distance moved by the handle per stroke (dhandle):

dhandle = dsmall × MAlever
 Stroke Length of the small piston (dsmall): = 47.5mm
Length of the Handle
 MAlever - Lever Mechanical Advantage =
Effort Arm Length
0.18
=
0.03
=6
dhandle = 0.0475 × 6
= 0.285m
According to above calculation, the handle moves 28.5 cm per stroke.

Calculate the Work Done by the Person:

Work done (W) is given by the product of the force applied and the total distance moved by the handle:
W = Finput × (dhandle × n)
Finput – This value is gradually increasing when we applying the pressure from the hand and we can feel
it. So we assumed it is not varying time to time.
So we can equal the force in one stroke from the hand into the spring tension force.
Therefore, Finput = Fst = 2kx =
= 2 × 91,633.6424N/m × 0.003m (x = dlarge: The distance the large piston moves
in a single push.)
= 549.80N (Assume its not varying time to time)
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 W = Finput × (dhandle × n)
= 549.80N × 0.285m × 40
= 6267.72J
According to above calculation, 6267.72J work must do for a one cycle.

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TESTING METHODS

Initial Setup:

1. Ensure all components are securely assembled.

2. Fill the hydraulic jack with hydraulic fluid.

Operational Testing:

1. Place waste steel pieces in the die.

2. Pump the hydraulic jack to apply pressure.

3. Ensure the jack holding bar moves smoothly.

Chip Production:

1. Verify the pressure surface produces steel chips.

2. Check the sliding door for easy chip removal.

Performance Evaluation:

1. Measure chip size and consistency.

2. Test with different steel sizes/types for versatility.

Safety and Durability Check:

1. Inspect welded joints and components for stress or damage.

2. Confirm all safety mechanisms function correctly.

Final Adjustments:

1. Adjust for efficiency and safety improvements.

2. Smooth rough edges and apply paint for protection.

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DISCUSSION

The Metal Waste Compress Machine project represents a significant step forward in waste management
and recycling technologies. This machine, designed and built to convert metal waste into manageable
chips, has shown promise despite several challenges encountered during its operation. Through this
discussion, we will examine the key observations, identify the drawbacks, and suggest improvements to
enhance the machine's efficiency, safety, and output quality.
The completion of the Metal Waste Composing Machine marks a milestone in our efforts to
develop a sustainable solution for metal waste processing. The machine's primary function is to compact
metal waste into cylindrical chips, facilitating easier handling, transportation, and recycling. However,
our initial tests revealed several critical issues that must be addressed to optimize the machine's
performance.
One of the primary challenges encountered was the bending of the sliding door under high
pressure. The sliding door, an integral component of the machine, is responsible for retaining the waste
material during the compaction process. During operation, we observed that the door bends in the
middle, particularly when subjected to high pressure. This deformation not only hinders the removal of
the compacted chips but also raises concerns about the machine's structural integrity. To mitigate this
issue, we propose the use of a thicker plate for the sliding door. A more robust material will enhance the
door's resistance to bending, ensuring smooth operation and easy removal of the compacted chips.
Another significant drawback was the inefficiency associated with the use of two pistons for the
compaction process. The pistons, in their current configuration, are not optimized for length adjustment,
resulting in time-consuming operations and suboptimal performance. The introduction of a length-
adjustable piston could revolutionize the machine's functionality. Telescopic hydraulic cylinders, known
for their variable length adjustments, could be a viable alternative. This modification would allow for
more precise control over the compaction process, reducing time and effort while improving overall
efficiency.
Safety concerns were also prominent during our observations. The current design requires
manual loading of waste into the die, posing a risk of hand injuries. The manual process necessitates
close interaction with the machine's moving parts, which can be hazardous. To address this issue, we
recommend the implementation of a dedicated path for loading waste. A chute or hopper system would
guide the waste material directly into the die, minimizing manual intervention and significantly reducing
the risk of injuries. This enhancement not only prioritizes operator safety but also streamlines the loading
process, contributing to the machine's overall efficiency.

26 | P a g e
 The manual operation of the hydraulic bottle jack, used to apply pressure during the compaction
process, was identified as another area for improvement. Manual operation is not only labor-intensive
but also limits the machine's potential for consistent and controlled pressure application. Converting the
manual hydraulic jack to an automated system could yield substantial benefits. Electric or pneumatic
actuators, integrated with the existing hydraulic system, would facilitate automated pressure application.
This modification would not only enhance the machine's ease of use but also ensure consistent and
optimal pressure, leading to more uniform and reliable compaction results.
Our machine currently produces cylindrical chips due to the use of a single piston. While
cylindrical chips are practical, they are not the most space-efficient form for storage and transportation.
To address this limitation, we propose a redesign of the compaction mechanism to produce box-shaped
chips. This can be achieved by incorporating three pistons positioned to apply pressure from the top,
right, and left. The multi-directional pressure would result in more compact, box-shaped chips that
maximize space utilization. This modification would enhance the practicality of the machine's output,
making it more suitable for various storage and transportation scenarios.
In addition to the specific improvements identified, it is crucial to consider the broader
implications of these modifications. Enhancing the structural integrity of the sliding door and optimizing
the piston configuration will directly improve the machine's reliability and performance. Implementing
safety features, such as a dedicated waste loading path, underscores our commitment to operator well-
being and workplace safety. The automation of the hydraulic system aligns with modern industrial
practices, emphasizing efficiency and ease of use. Finally, the transition from cylindrical to box-shaped
chips demonstrates a focus on practical outcomes and space efficiency.
The Metal Waste Composing Machine project, while successful in its initial implementation,
highlights the importance of iterative design and continuous improvement. Each identified drawback
presents an opportunity for innovation and enhancement. By addressing these challenges, we can
transform the machine into a more robust, efficient, and user-friendly solution for metal waste
management.

27 | P a g e
CONCLUSION

The construction of our metal waste compressing machine have been a significant endeavor, culminating
in a functional device capable of efficiently compressing metal waste into chips. This project involved
a series of precise steps, each critical to ensuring the machine's performance and reliability.

Frame Construction and Assembly

Initially, we meticulously cut four L-bars to identical lengths using a cutting machine, ensuring
uniformity by grinding the edges. Welding two L-bars together to form C-bars, we created the
foundational structure of our machine frame. This process involved using welding rods and a welding
plant, with careful attention to detail to ensure strong and precise joints. The upper part of the frame
required a steel plate, which we drilled to accommodate hooks and a small cylinder, welded in place to
hold the hydraulic jack. The plate was then securely attached to the C-bars and finished with grinding to
ensure smoothness and stability.

Lower Frame and Movable Jack Holding Bar

The lower part of the frame was reinforced with a box bar and additional L-bars fixed at 90-degree
angles, providing essential support. Grinding ensured a polished finish, completing the sturdy frame. For
the movable jack holding bar, we modified a steel plate, cutting its corners into L-shapes to allow smooth
vertical movement within the C-bars. Drilling holes and attaching hooks facilitated the attachment of a
C-shaped barrier for holding the hydraulic jack. A small cylinder was welded to the underside to
accommodate the piston, and this assembly was attached to the upper frame with springs, enabling
effective movement.

Die and Bench Fabrication

The die and bench required careful craftsmanship. We shaped a cylinder into a die, smoothing it with
hand files to ensure it met our specifications. The bench was constructed from six L-bars and a square
plate, with a central hole matching the die's diameter. The legs of the bench were reinforced with
additional L-bars, creating a stable platform. The die was fixed to the bench, and a sliding door was
added to facilitate the easy removal of compressed chips.

28 | P a g e
Final Assembly and Testing
Before final assembly, we prepared the piston rod and pressure plate, ensuring the pressure plate's
diameter was slightly smaller than the die to allow smooth travel within it. We used a 10-ton hydraulic
bottle jack to apply the necessary pressure. Assembling all components, we tested the machine and were
pleased to find it performed exceptionally well, producing high-quality metal chips from waste steel.
The final steps involved grinding and painting the machine, giving it a polished and professional finish.

Challenges and Improvements

Despite the machine's success, we encountered several challenges that highlighted areas for
improvement. One significant issue was the bending of the sliding door under high pressure, which
prevented us from easily removing the chips. This can be remedied by using a thicker plate for the sliding
door, enhancing its durability and functionality. Another challenge was the use of two pistons, which we
found could be optimized with a length-adjustable piston. This adjustment would save time and simplify
the process, making the machine more efficient.
A critical safety concern was the risk of hand injuries when loading waste into the die. To
mitigate this, we propose adding a path for loading waste, ensuring hands are kept clear of the operational
area. The manual operation of the hydraulic bottle jack also posed a challenge; automating this process
would significantly enhance efficiency and ease of use. Additionally, while our machine currently
produces cylindrical chips, we identified that using three pistons (up, right, and left) to produce box-
shaped chips would save space and further optimize the machine's output.

Conclusion and Future Outlook

In conclusion, the development of our metal waste compressing machine has been a comprehensive
project that combined engineering precision with practical problem-solving. The machine has proven
effective in converting metal waste into reusable chips, contributing to sustainable practices in metal
recycling. However, the identified challenges present opportunities for further refinement and
innovation. By addressing these issues, such as enhancing the sliding door, optimizing the piston
mechanism, improving safety features, automating the pressure application, and modifying the chip
shape, we can significantly improve the machine's functionality and efficiency.
This project not only demonstrated our technical skills and teamwork but also underscored the
importance of continuous improvement in engineering. As we move forward, we are committed to
implementing these enhancements, ensuring our machine meets the highest standards of safety,
efficiency, and effectiveness. Our successful construction and testing of the metal waste compressing
machine mark a significant milestone in our academic journey, and we look forward to applying the
lessons learned to future projects and innovations.

29 | P a g e
REFRENCES

1. Metalworking Processes:

 Groover, M. P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and

Systems. Wiley.
 Degarmo, E. P., Black, J. T., & Kohser, R. A. (2011). Materials and Processes in Manufacturing.
Wiley.

2. Hydraulic Systems:

 Parr, A. (2011). Hydraulics and Pneumatics: A Technician's and Engineer's Guide. Butterworth-
Heinemann.
 Chapple, J. W. (2008). Fluid Power: Hydraulics and Pneumatics. Cengage Learning.

3. Welding Techniques:

 Cary, H. B., & Helzer, S. C. (2005). Modern Welding Technology. Pearson.

 Jeffus, L. (2016). Welding: Principles and Applications. Cengage Learning.

4. Metal Fabrication:

 Scarr, D. (2005). Metal Fabrication Technology for Agriculture. Delmar Cengage Learning.
 Finn, R. (2018). Metal Fabrication Technology. Pearson.

5. Safety in Metalworking:

 Rossol, M. (2011). The Artist's Complete Health and Safety Guide. Allworth Press.
 American National Standards Institute (ANSI). (2012). ANSI Z49.1: Safety in Welding, Cutting,
and Allied Processes. American Welding Society.

6. Automation in Manufacturing:

 Groover, M. P. (2016). Automation, Production Systems, and Computer-Integrated

Manufacturing. Pearson.
 Mikell, P. G. (2020). Introduction to Manufacturing Processes. Wiley.

30 | P a g e
ANNEXES

Annex A: List of Tools and Equipment Used

1. Power Hacksaw Cutting Machine: Used to cut L-bars into equal lengths.

Figure 5 power hacksaw machine

2. Grinding Machine: Used for

grinding the edges of the bars and ensuring

uniformity.

Figure 7 Hand Grinder

Figure 6 Bench Grinder

3. Welding Plant and Welding Rods: Used for welding the L-bars to create C-bars and other

components.

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 Figure 8 Arc welding
4. Drilling Machine: Used to drill holes in the steel plates for hooks

and other attachments.

Figure 9 Drilling machine

5. Hand Files: Used for shaping and smoothing the surface of the die.

Figure 10 Hand files

6. Hydraulic Bottle Jack: A 10-ton jack used to apply pressure in the machine.

Figure 11 Hydraulic bottle jack

32 | P a g e
Annex B: Materials Used

1. L-Bars: Steel L-bars for the frame and bench construction.

Figure 12 L bars

2. Steel Plates: Various steel plates used for different parts of the machine, including the sliding

door and pressure plate.

3. Hooks: For attaching the hydraulic jack and other components.

Figure 13 Hooks
4. Small Cylinders: Used to hold the hydraulic jack and piston in place.

5. Springs: For the movable jack holding bar.

Figure 14 spring

6. Welding Rods: Used for welding various components together.

Annex C: Detailed Steps of Construction

1. Frame Construction:

33 | P a g e
 o Cut four L-bars to the same length.

o Grind the edges and ensure all bars are of uniform length.

o Weld two L-bars together to form C-bars, creating the machine frame.

2. Upper Frame Assembly:

o Drill two holes in a steel plate and fix hooks.

o Weld a small cylinder to the middle of the plate to hold the jack.

o Attach this assembly to the C-bars and finish with grinding.

3. Lower Frame Assembly:

o Attach a solid bar to the bottom of the frame.

o Fix two L-bars at 90-degree angles for additional support.

o Grind for a smooth finish.

Figure 15 Machine frame

4. Movable Jack Holding Bar:

o Cut a steel plate's corners into L-shapes for movement between C-bars.

34 | P a g e
 o Drill two holes and fix hooks.

o Create a C-shaped barrier to hold the hydraulic jack.

o Weld a small cylinder to hold the piston.

o Attach the movable bar to the upper frame with springs.

Figure 16 Movable jack holding part

5. Die and Bench Fabrication:

o Shape a cylinder into a die and smooth it with hand files.

o Construct a bench with six L-bars and a square plate, with a central hole matching the

die's diameter.

o Attach the die to the bench and add a sliding door for easy chip removal.

Figure 18 sliding door

Figure 17 Die with Bench

6. Final Assembly:

o Prepare the piston rod and pressure plate(Mold lid).

o Assemble all parts, ensuring the pressure plate's diameter is slightly smaller than the die.

o Use a 10-ton hydraulic bottle jack to apply pressure.

35 | P a g e
 o Finish with grinding and painting.

Figure 19 pressure plate

Figure 20 piston rod

Figure 22 Die with chips

Figure 21 Machine painting

Annex D: Observations and Improvements

1. Sliding Door Issue:

o Problem: The sliding door bends under high pressure, preventing chip removal.

o Solution: Use a thicker plate for the sliding door to enhance durability.

2. Piston Optimization:

o Problem: Using two pistons is inefficient.

o Solution: Find an alternative length-adjustable piston to save time

36 | P a g e
 3. Safety Concerns:

o Problem: Risk of hand injuries when loading waste into the die.

o Solution: Implement a path for loading waste to protect hands from injury.

4. Manual Operation of Hydraulic Jack:

o Problem: Manual operation is less efficient.

o Solution: Automate the hydraulic bottle jack for increased efficiency and ease of use.

5. Chip Shape:

o Problem: Producing cylindrical chips is not space-efficient.

o Solution: Use three pistons (up, right, and left) to produce box-shaped chips, saving

space.

Annex E: Testing and Results

1. Testing:

o Assembled all parts and tested the machine mechanism.

o Machine produced high-quality chips from waste steel.

2. Results: Figure 23 Chips block

o Machine functioned well, meeting initial design expectations.

o Identified areas for improvement based on performance and safety observations.

Annex F: Visual Documentation

1. Photos: Include photos of each step of the construction process, from initial cutting and welding

to final assembly and testing.

2. Diagrams: Detailed diagrams of the machine components and assembly process.

37 | P a g e
3. Final Machine: Photos of the completed machine with labels identifying key parts and features.

Hydraulic Bottle
Jack
Threaded Hook

Extension Coil
Spring
Press Machine
Frame
Up-Down Moving
Jack Guide Bar

Middle Hallow
Shaft

Mold

Sliding Door

Figure 24 Machine parts

Bench

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Figure 25 Hook drawing

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Figure 26 spring drawing

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Figure 27 Piston drawing

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Figure 28 Mold lid drawing

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Figure 29 Machine frame Drawing

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Figure 30 Moving flat iron Drawing

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 45 | P a g e
2 1
B B
240.00 mm

Figure 31 Sliding door Drawing

A NAME
Dinusha
DATE TITLE: A
Sliding door
DRAWN
CHECKED
ENG APPR.
MFG APPR.
Q.A.
SIZE DWG. NO. REV
COMMENTS:
A
SCALE: 1:3
WEIGHT: SHEET 1 OF 1
2 1
Figure 32 Bench frame Drawing

46 | P a g e