Optimizing Plastic Shredding Machine Blade Design with Ansys Workbench Simulation and Cutting Trial
Keywords:
Plastic recycling, Shredding machine, Cutting blade, Blade design, Stress analysisAbstract
Efficient plastic recycling depends on reliable size reduction. This study develops and evaluates cutting blades for a plastic shredding machine, integrating simulation, manufacturing, and performance testing. Finite-element analysis in ANSYS quantifies the effect of blade inner-radius on von Mises stress, equivalent strain, and tip deformation under operating loads. An intermediate inner-radius minimized stress concentration and deflection, indicating superior structural integrity. Manufacturing trials employed laser cutting; process parameters—cutting speed, lift height, nozzle standoff, and oxygen pressure—were tuned to minimize kerf defects and heat-affected zone, followed by finish grinding. The optimized blades delivered consistent comminution, yielding particles <30 mm with 62% size uniformity in shred tests. The results demonstrate that simultaneous optimization of geometry (inner-radius) and laser-cutting parameters enables durable, high-quality blades and improves downstream recycling efficiency. The study provides actionable guidance for blade design and fabrication and highlights the coupling between geometric stress control and manufacturability for sustainable plastic recycling systems.
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