This diploma thesis deals with construction design of a pendulum for the jaw crusher DCJ 700x300. The first part of the thesis is dedicated to treatment of mineral materials with focus on minimizing minerals. The second part deals with devices used for crushing minerals, jaw crushers and their variants in particular. The third part is devoted to specific design of the jaw crusher based on assigned input. The next part deals with construction design of the pendulum and technology of its production exploring weldments and casts. The aim of this thesis is to perform a strength analysis of the chosen version of pendulum production using the FEM method. The diploma thesis includes drawing documentation of the jaw crusher and the pendulum.

This master thesis deals with structural design of pendulum for single toggle jaw crusher DC 110x70 and consists of several main parts. The first part focuses on the processing of mineral materials, especially on the process of mechanical uncoupling. The second part compares main characteristics of single toggle and double toggle jaw crushers. The third part deals with the structural nodes for the crusher DC 110x70. Another part is consisted of two variants for the pendulum construction with a comparison of the advantages and disadvantages. For the selected variant is carried out the stress control using Finite element method (FEM) in the program I-DEAS. The last part focuses on the positioning an exit slit for designed pendulum.

During this master thesis a crushing material composite was developed in order to determine if a specific design consisting of a pointy hard phase with a ductile phase in between can reduce the load needed to crush stone and therefor decrease the energy consumption during stone crushing. The steel hard phase (ASP 2012) was printed using an additive manufacturing method called selective laser melting (SLM). A process parameter optimization was performed in order to achieve a dense material and a pre-heated building platform was used to prevent cracking. The hard phase designs were printed and then filled with bronze (JM3 and JM7). The composites and steel references were tested by placing a stone on each sample and applying pressure until the stone broke. After the tests, the loads and the deterioration of the samples was analyzed. The results showed that it was possible to print the hard phase, but some defects like micro cracking were hard to eliminate entirely. Several methods were tested to cast the bronze but the most suitable during this project was melting of the bronze in an induction furnace with vacuum atmosphere. The results from the crushing simulations showed that there was a small difference between the references and the developed macro composites. The composites began to crush stones at lower loads than the references. Nevertheless, due to a large dispersion of the results a statistical difference could not be established.

This diploma thesis is concerned with a construction design of single toggle jaw crusher DCJ 900x500. In the first part, the theoretical background and ways of material disintegration are discussed. The second chapter describes types of material crushers in general, especially jaw crushers and their parts. The third chapter is concerned with calculations and the design of the most important parts of the machine. The fourth part consists of the crusher power calculation, design of the pendulum and its production technology. The last part includes the result of FEM analysis for the particular variant of pendulum production. The thesis also includes drawing documentation of the crusher and the pendulum.

This thesis deals with the design of the construction of a pendulum of a single toggle jaw crusher. The first part of this thesis treats the mechanical raw minerals disintegration. In the second part the characteristics of a single toggle jaw crusher and double toggle jaw crusher are compared. The third part addresses the calculation and the construction of the main components of the jaw crusher. Next part of the thesis consists of the calculation of the crushing force, the pendulum design, and the method of manufacturing a pendulum. The strength analysis of the designed pendulum using the finite element method (FEM) in program NX-Ideas is made in the last part of this thesis.

A cominuição de amostras geológicas envolve etapas para reduzir seus grãos garantindo sua representatividade, com o auxílio de vários equipamentos de moagem de amostras. São duas as contaminações que podem ser causadas durante o uso desses equipamentos. A primeira é a contaminação primária, pelo contato face a face entre a amostra e os componentes do sistema de moagem, e a segunda é a contaminação cruzada, derivada do material de outras amostras, previamente tratadas, que esteja depositado na superfície dos equipamentos de moagem. São limitadas as informações encontradas na literatura acerca das contaminações primárias, a maioria dos autores presumindo que a mesma seja maior na etapa final dos processos de tratamento. Ainda assim, se faz necessário um estudo sistemático sobre as possibilidades de contaminação primária, durante as diversas etapas de tratamento das amostras. Para esta pesquisa foram utilizadas amostras de quartzo puro, coletado na Fazenda Batatal, em Diamantina, Minas Gerais, com o exame da contaminação primária causada pelo uso dos equipamentos de fragmentação (britador de mandíbulas primário de aço manganês, britador de mandíbulas secundário de carbeto de tungstênio e prensa hidráulica com acessórios de fragmentação em aço) e, a seguir, os de pulverização (moinho de anéis de ágata, carbeto de tungstênio e aço-Cr). O quartzo, um dos materiais mais puros encontrados na natureza, é o que apresenta dureza suficientemente alta para promover intensos processos de interação e contaminação mais extrema. Posteriormente, avaliou-se a possibilidade da contaminação cruzada em quartzo causada pelo tratamento prévio de amostras de basalto (o RS132, da Formação Serra Geral, Rio Grande do Sul) e de granito (o ITU-06.04A, da intrusão Salto, Salto, São Paulo), utilizadas como padrões nos laboratórios do Instituto de Geociências da Universidade de São Paulo, IGc-USP, com composições determinadas por fluorescência de raios X (FRX), no Laboratório de FRX do IGc-USP. As determinações químicas em soluções convenientemente preparadas de amostras de quartzo, utilizadas nas etapas de contaminação primária e cruzada, foram realizadas por espectrometria óptica com plasma indutivo acoplado (ICP-OES) e espectrometria de massa com plasma indutivo acoplado (ICP-MS) no Laboratório de Química e ICP-OES/MS do IGc-USP. Para estudos da contaminação primária foram geradas alíquotas Q1A, Q1B, Q1C, Q2A, Q2B, Q2C, Q3A, Q3B e Q3C (1 identifica tratamento por britador primário de ferro fundido, 2 o britador secundário de CW, 3 a prensa de aço-carbono; e A, B e C identificam os moinhos de anéis na moagem final: ágata, CW e aço-cromo). Nos estudos da contaminação cruzada foram geradas quatro alíquotas, Q4A-Gcc e Q4B-Gcc (quartzo pulverizado, respectivamente, em moinho de anéis de ágata e de CW, após pulverização do granito), e Q4A-Bcc e Q4B-Bcc (quartzo pulverizado nos mesmos moinhos, após tratamento do basalto). A única contaminação registrada foi causada pelos equipamentos durante cominuição primária do quartzo. A ambientação dos moinhos realizada após a moagem de granito ou basalto foi efetuada mediante limpeza rotineira, seguida de moagem com areia quartzosa (a seguir descartada), procedimento efetivo para evitar contaminação cruzada, por remover o material (basáltico ou granítico) aderido às superfícies dos equipamentos. O britador primário de aço manganês colabora com contaminações por Fe e Mn e elementos Cr, Mo, Cu, Sc e Nb, em teores menores. O britador de mandíbulas secundário de CW contaminou com W, provavelmente também com C (determinado por programa Total-Quant), e com algo de Al. A prensa em aço carbono contamina em níveis de 50 ppm de Fe, e teores menores de Cr e Mn. Moinhos pulverizadores de aço temperado contaminaram principalmente com Fe e Cr e, em teores menores, com Mn, W, Ni, Zn, Mo, e V. Cu e Sc aparecem também em níveis extremamente baixos nas amostras tratadas, e podem ser adicionados por estes moinhos. O moinho de anéis de CW contaminou com W (1000 ppm) e Co (70 ppm), aparecendo ainda C com teores apreciáveis; também contamina com Ta e Nb (em torno de 2 e 0,6 ppm, respectivamente). As determinações de vários elementos-traço no quartzo pulverizado em moinho de anéis de ágata ficaram muito próximas, ou abaixo, do limite de detecção das técnicas utilizadas, não se documentando nenhuma contaminação por efeito da utilização deste equipamento. / The grinding of geologic samples is performed to reduce grain size of the constituting minerals and to preserve a representative sample of the original material, with the help of several grinding and milling equipments. The primary and a secondary or crossed contamination are the possible effects that can be produced during these processes. The first is caused by the interaction between the components of the grinding equipments and the sample, the second derives from contamination by other geologic materials previously ground in those equipments. The information found in the previous literature on the subject is relatively limited, most authors assuming that the main contamination may be produced during the final stages of comminution, the one leading to the generation of fine powders. Thus, there is a need to conduct a systematic survey about extent and possibility of primary contaminations. The materials used are samples of pure quartz crystals from the Fazenda Batatal, city of Diamantina, Minas Gerais state, with research initially centered on the examination of primary contamination caused by the fragmentation equipment (manganese steel primary crusher, W carbide secondary crusher, hydraulic press with steel anvil) and then grinding to fine powder (ring grinders equipped with agate, W carbide or chrome-steel rings). Quartz, one of the purest substances found in nature, is a hard mineral that interacts vigorously with the grinding equipment, therefore causing more extreme contamination. A second round was performed testing crossed contamination in quartz caused by previous grinding of basalt (RS 132, Serra Geral Formation, Rio Grande do Sul state) and granite (ITU-06.04A, from the Salto intrusion, city of Salto, São Paulo state), used as standards at the chemistry laboratories of the Instituto de Geociências, Universidade de São Paulo (IGc-USP), with their compositions determined by XRF at Igc-USP. The other chemical determinations, performed on samples of quartz solutions, for checking primary as well as crossed contamination, were performed on ICP-OES and ICPMS equipments, at the Chemistry and ICP-OES/MS Laboratory of Igc-USP. For the testing of primary contamination, the quartz aliquots Q1A, Q1B, Q1C, Q2A, Q2B, Q2C, Q3A, Q3B, and Q3C were prepared (1, 2 and 3 identify, respectively, primary jaw crusher with iron jaws, the secondary crusher with W carbide jaws and the hydraulic press with carbon steel anvil; A, B and C stand for the three used ring grinders, respectively equipped with agate, W carbide and chrome steel rings). Crossed contamination was tested with the aliquots Q4A-Gcc and Q4B-Gcc (quartz samples powdered, respectively, in the agate ring grinder and the CW ring grinder, after grinding of granite), and Q4A-Bcc and Q4B-Bcc (the same procedures as before, now with previous grinding of basalt). The only contamination registered in this study was caused during primary crushing and grinding of the quartz samples. Cleansing of equipment performed after grinding of basalt or granite using conventional cleaning techniques followed by grinding of quartzose sand (later discarded), is a procedure that erases the previous (basaltic or granitic) material from the used equipment; no significant crossed contamination was registered. The primary manganese steel crusher adds principally Fe and Mn to quartz, and elements as Cr, Mo, Cu, Sc and Nb, in lesser amounts. The secondary W carbide jaw crusher contaminates with W, probably also with C (determined with the TotalQuant program), and also with some Al. The carbon steel press contributes with contamination of about 50 ppm Fe, and lesser amounts of Cr and Mn. Powdering mills with tempered steel add mainly Fe and Cr and, to lesser extents, also Mn, W, Ni, Zn, Mo, and V to the quartz; Cu and Sc are present as possible contaminants in very low levels. The W carbide ring mill contaminates quartz with W (around 1000 ppm) and Co (around 70 ppm), adding significant levels of C. This mill contributes also with Ta and Nb additions (2 and 0.6 ppm, respectively). The determination of trace elements in quartz powdered with the agate ring mills does not register significant increases in the analyzed amounts, with levels that remain close to, or below, the respective detection limits, thus possibly precluding any contamination with the use of these mills.

A cominuição de amostras geológicas envolve etapas para reduzir seus grãos garantindo sua representatividade, com o auxílio de vários equipamentos de moagem de amostras. São duas as contaminações que podem ser causadas durante o uso desses equipamentos. A primeira é a contaminação primária, pelo contato face a face entre a amostra e os componentes do sistema de moagem, e a segunda é a contaminação cruzada, derivada do material de outras amostras, previamente tratadas, que esteja depositado na superfície dos equipamentos de moagem. São limitadas as informações encontradas na literatura acerca das contaminações primárias, a maioria dos autores presumindo que a mesma seja maior na etapa final dos processos de tratamento. Ainda assim, se faz necessário um estudo sistemático sobre as possibilidades de contaminação primária, durante as diversas etapas de tratamento das amostras. Para esta pesquisa foram utilizadas amostras de quartzo puro, coletado na Fazenda Batatal, em Diamantina, Minas Gerais, com o exame da contaminação primária causada pelo uso dos equipamentos de fragmentação (britador de mandíbulas primário de aço manganês, britador de mandíbulas secundário de carbeto de tungstênio e prensa hidráulica com acessórios de fragmentação em aço) e, a seguir, os de pulverização (moinho de anéis de ágata, carbeto de tungstênio e aço-Cr). O quartzo, um dos materiais mais puros encontrados na natureza, é o que apresenta dureza suficientemente alta para promover intensos processos de interação e contaminação mais extrema. Posteriormente, avaliou-se a possibilidade da contaminação cruzada em quartzo causada pelo tratamento prévio de amostras de basalto (o RS132, da Formação Serra Geral, Rio Grande do Sul) e de granito (o ITU-06.04A, da intrusão Salto, Salto, São Paulo), utilizadas como padrões nos laboratórios do Instituto de Geociências da Universidade de São Paulo, IGc-USP, com composições determinadas por fluorescência de raios X (FRX), no Laboratório de FRX do IGc-USP. As determinações químicas em soluções convenientemente preparadas de amostras de quartzo, utilizadas nas etapas de contaminação primária e cruzada, foram realizadas por espectrometria óptica com plasma indutivo acoplado (ICP-OES) e espectrometria de massa com plasma indutivo acoplado (ICP-MS) no Laboratório de Química e ICP-OES/MS do IGc-USP. Para estudos da contaminação primária foram geradas alíquotas Q1A, Q1B, Q1C, Q2A, Q2B, Q2C, Q3A, Q3B e Q3C (1 identifica tratamento por britador primário de ferro fundido, 2 o britador secundário de CW, 3 a prensa de aço-carbono; e A, B e C identificam os moinhos de anéis na moagem final: ágata, CW e aço-cromo). Nos estudos da contaminação cruzada foram geradas quatro alíquotas, Q4A-Gcc e Q4B-Gcc (quartzo pulverizado, respectivamente, em moinho de anéis de ágata e de CW, após pulverização do granito), e Q4A-Bcc e Q4B-Bcc (quartzo pulverizado nos mesmos moinhos, após tratamento do basalto). A única contaminação registrada foi causada pelos equipamentos durante cominuição primária do quartzo. A ambientação dos moinhos realizada após a moagem de granito ou basalto foi efetuada mediante limpeza rotineira, seguida de moagem com areia quartzosa (a seguir descartada), procedimento efetivo para evitar contaminação cruzada, por remover o material (basáltico ou granítico) aderido às superfícies dos equipamentos. O britador primário de aço manganês colabora com contaminações por Fe e Mn e elementos Cr, Mo, Cu, Sc e Nb, em teores menores. O britador de mandíbulas secundário de CW contaminou com W, provavelmente também com C (determinado por programa Total-Quant), e com algo de Al. A prensa em aço carbono contamina em níveis de 50 ppm de Fe, e teores menores de Cr e Mn. Moinhos pulverizadores de aço temperado contaminaram principalmente com Fe e Cr e, em teores menores, com Mn, W, Ni, Zn, Mo, e V. Cu e Sc aparecem também em níveis extremamente baixos nas amostras tratadas, e podem ser adicionados por estes moinhos. O moinho de anéis de CW contaminou com W (1000 ppm) e Co (70 ppm), aparecendo ainda C com teores apreciáveis; também contamina com Ta e Nb (em torno de 2 e 0,6 ppm, respectivamente). As determinações de vários elementos-traço no quartzo pulverizado em moinho de anéis de ágata ficaram muito próximas, ou abaixo, do limite de detecção das técnicas utilizadas, não se documentando nenhuma contaminação por efeito da utilização deste equipamento. / The grinding of geologic samples is performed to reduce grain size of the constituting minerals and to preserve a representative sample of the original material, with the help of several grinding and milling equipments. The primary and a secondary or crossed contamination are the possible effects that can be produced during these processes. The first is caused by the interaction between the components of the grinding equipments and the sample, the second derives from contamination by other geologic materials previously ground in those equipments. The information found in the previous literature on the subject is relatively limited, most authors assuming that the main contamination may be produced during the final stages of comminution, the one leading to the generation of fine powders. Thus, there is a need to conduct a systematic survey about extent and possibility of primary contaminations. The materials used are samples of pure quartz crystals from the Fazenda Batatal, city of Diamantina, Minas Gerais state, with research initially centered on the examination of primary contamination caused by the fragmentation equipment (manganese steel primary crusher, W carbide secondary crusher, hydraulic press with steel anvil) and then grinding to fine powder (ring grinders equipped with agate, W carbide or chrome-steel rings). Quartz, one of the purest substances found in nature, is a hard mineral that interacts vigorously with the grinding equipment, therefore causing more extreme contamination. A second round was performed testing crossed contamination in quartz caused by previous grinding of basalt (RS 132, Serra Geral Formation, Rio Grande do Sul state) and granite (ITU-06.04A, from the Salto intrusion, city of Salto, São Paulo state), used as standards at the chemistry laboratories of the Instituto de Geociências, Universidade de São Paulo (IGc-USP), with their compositions determined by XRF at Igc-USP. The other chemical determinations, performed on samples of quartz solutions, for checking primary as well as crossed contamination, were performed on ICP-OES and ICPMS equipments, at the Chemistry and ICP-OES/MS Laboratory of Igc-USP. For the testing of primary contamination, the quartz aliquots Q1A, Q1B, Q1C, Q2A, Q2B, Q2C, Q3A, Q3B, and Q3C were prepared (1, 2 and 3 identify, respectively, primary jaw crusher with iron jaws, the secondary crusher with W carbide jaws and the hydraulic press with carbon steel anvil; A, B and C stand for the three used ring grinders, respectively equipped with agate, W carbide and chrome steel rings). Crossed contamination was tested with the aliquots Q4A-Gcc and Q4B-Gcc (quartz samples powdered, respectively, in the agate ring grinder and the CW ring grinder, after grinding of granite), and Q4A-Bcc and Q4B-Bcc (the same procedures as before, now with previous grinding of basalt). The only contamination registered in this study was caused during primary crushing and grinding of the quartz samples. Cleansing of equipment performed after grinding of basalt or granite using conventional cleaning techniques followed by grinding of quartzose sand (later discarded), is a procedure that erases the previous (basaltic or granitic) material from the used equipment; no significant crossed contamination was registered. The primary manganese steel crusher adds principally Fe and Mn to quartz, and elements as Cr, Mo, Cu, Sc and Nb, in lesser amounts. The secondary W carbide jaw crusher contaminates with W, probably also with C (determined with the TotalQuant program), and also with some Al. The carbon steel press contributes with contamination of about 50 ppm Fe, and lesser amounts of Cr and Mn. Powdering mills with tempered steel add mainly Fe and Cr and, to lesser extents, also Mn, W, Ni, Zn, Mo, and V to the quartz; Cu and Sc are present as possible contaminants in very low levels. The W carbide ring mill contaminates quartz with W (around 1000 ppm) and Co (around 70 ppm), adding significant levels of C. This mill contributes also with Ta and Nb additions (2 and 0.6 ppm, respectively). The determination of trace elements in quartz powdered with the agate ring mills does not register significant increases in the analyzed amounts, with levels that remain close to, or below, the respective detection limits, thus possibly precluding any contamination with the use of these mills.

Diploma thesis deals with design of a flywheel and a belt pulley of single toggle jaw crusher DCJ 900x600. The first part is dedicated to overview of the methods for calculation of a size of flywheels for working machines. The second part is focused on calculation of a size of the flywheel. The third part treats the constructional design of the flywheel. In the last two parts there is elaborated analysis of a changing size of the flywheel depended on increasing the working rotation speed and change of coefficient .