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Stream/Area:
-
Subject:
-
Paper ID:
IJSREM65546
Volume:
10 |
6 |
Jun 2026
Pages:
1-10
Publication Frequency:
Monthly (12 issues per year)
License:International Journal of Scientific Research in Engineering and Management follows the Creative Commons Attribution 4.0 (CC BY 4.0) License, allowing free use and distribution with proper attribution.
Mechanical Engineering
Department of Mechanical Engineering, JSPM's Narhe Technical Campus, Narhe, Pune
Mechanical Engineering
Department of Mechanical Engineering, JSPM's Narhe Technical Campus, Narhe, Pune
Mechanical Engineering
Department of Mechanical Engineering, JSPM's Narhe Technical Campus, Narhe, Pune
Mechanical Engineering
Department of Mechanical Engineering, JSPM's Narhe Technical Campus, Narhe, Pune
Mechanical Engineering
Department of Mechanical Engineering, JSPM's Narhe Technical Campus, Narhe, Pune
Metal machining operations generate a large amount of waste in the form of aluminium burrs, chips, and shavings, which are bulky in nature and difficult to handle, store, and recycle efficiently. Improper disposal of these burrs leads to workspace clutter, safety hazards, and reduced operational efficiency. To address this issue, this project focuses on the design and development of a pneumatic scrap compressing mechanism that converts loose aluminium burrs into compact and manageable forms. The system consists of a box-type compression chamber with a hopper for feeding scrap, a pneumatic cylinder, and a hand lever-operated valve for controlled operation. A 63 mm bore and 250 mm stroke pneumatic cylinder is used, which operates at a working pressure of 5 to 7 bar. At 5 bar pressure, the cylinder generates a force of approximately 1.56 KN, which is sufficient for compressing loose aluminium burrs. The compression process is carried out in a single stroke. The calculated minimum required stroke length is around 133 mm, while a 250 mm stroke is selected to ensure complete compression and proper clearance. The system can handle approximately 2.5 to 3.5 kg of aluminium burrs per cycle, depending on the bulk density of the scrap. The achieved compression results in a volume reduction of about 50%, making storage and transportation significantly easier. The entire structure is fabricated using 5 mm thick mild steel plates, ensuring sufficient strength to withstand repeated compression loads.
KEYWORDS
The design, fabrication, and testing of this pneumatic scrap compressing machine successfully demonstrates that highly efficient metal densification can be achieved using standard workshop air pressures. By utilizing a robust 63 mm bore cylinder and a rigid 5 mm mild steel plate frame, the system reliably delivers a volume reduction of over 50% for aluminum chips. This compact, low-cost solution effectively eliminates workspace clutter, enhances operational safety, and dramatically improves recycling profitability, making it an ideal waste management tool for small-to-medium scale machine shops.
The following peer-reviewed research papers, technical reports, and academic design standards provided the foundational theory and validation baselines for this project: [1] C. Rietdorf, "Environmental Assessment of Metal Chip Recycling and Volumetric Pre-Compaction Modeling Metrics," International Journal of Cleaner Production, vol. 412, pp. 112-125, 2024. [2] M. Carta, G. Attanasio, and F. Gagliardi, "Solid-State Recycling of AA6063 Aluminum Chips via Direct Hot Extrusion and Pre-Compaction Density Reviews," Metals, vol. 15, no. 2, p. 184, 2025. [3] M. ElMehtedi, A. Forcellese, and M. Simoncini, "Sustainability Study and Life Cycle Assessment of Decentralized Aluminum Chips Compaction Frameworks," Sustainability, vol. 15, no. 8, pp. 6432-6445, 2023. [4] IRJET Engineering Team, "Design, Development & Structural Fatigue Analysis of Desktop-Scale Scrap Compressing Mechanisms," IRJET Research Report, vol. 12, no. 1, pp. 450-458, 2025. [5] A. Ulus and M. Demir, "Optimization of Material Recovery Efficiency for Briquetted High-Purity Aluminum Machining Chips," ResearchGate Mechanical Publication, ID 34125, 2017. [6] S. Baruah, "An activity-based parametric cost analysis and payback optimization framework for upcycling machining chips using localized compactors," ScienceDirect: Journal of Materials Processing, vol. 289, p. 116904, 2025. [7] R. Paul, S. Anand, and K. J. George, "Ergonomic Design and Safety Frameworks of localized Compactor Units for Small-Scale Tooling Workshops," SciSpace Academic Forum, vol. 8, pp. 22-31, 2013.
Publication Date
6/26/2026
Peer Review Type
Double-Blind Peer Review
Review Rounds: 2
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Conflict of Interest
The authors declare no conflict of interest related to this research work.
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No funding information available for this research.
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