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I would advise against shredding this material as as you have realized it is ridiculously light. I would recommend trying ball Milling a small batch to see if that process would give you better results. the other benefit for Bowl Milling in the circumstances you can ball mill this material wet, that would also allow you to keep it together and prevent dust from getting kicked up.
Regarding the the gearing, I’m suggesting you use the gearing off a 15 speed bicycle and the chain from the same to give you a solid range of gears to work from and means of power transmission that won’t slip. The gearing and associated bits, I would think, can be pulled off. I can’t see to locate a good example on youtube for you to take a look at.
For the flywheel I’m suggesting you place it on the motor output shaft before your gearbox to act as a kinetic energy reservoir. That way when you do have those unexpected high load moments on the shredder there will be a greater amount of kinetic energy when high friction happens. It’s a similar method of storing kinetic energy that you’d find in a mechanical press:
Fair ideas all around.
I would suggest ball milling rather than a kitchen blender though. You can get much finer particulate that way than you can hope to with a blender or such.
Melting polystyrene gets a bit trickier as it has to be done in an inert atmosphere (very shaky memory on that, so you should fact check). As such it doesn’t recycle easily. If it could be processed back into the precursor, which doubles as an ok solvent, it would reduce the stuff as a problem.
I also have to wonder how stable the stuff would be after getting powdered. Could it be used in clay heavy soil to help loosen it?
Anyway, I’ve had a long day and I’m rambling a bit. Try your ideas, take notes and pictures and share with us.
In the US from a professional shop those numbers sound close to reasonable.
I expect you can, but LDPE sin’t going to have the same rigidity as HDPE
Other thought(s), if you are working with a low RPM output and torque issues, you need a more aggressive means of power transmission than a belt, swapping over to a chain drive system would be fairly cheap and would work neatly as you can pull it off a bicycle.
If you’re clever about it you can even keep the derailer system and have a range of gears to get more torque for the shredding or higher speed.
@giago page 77-79 of that catalog have jaw couplers and the information for calculating which one you should select.
A further consideration I’ve had recently is to used a dual output gearbox to drive a shredder and extruder off one motor, you’d only be able to use one side at a time, but both would rotate when the unit was turned on.
I’m curious, is there any reason you’re not using mild steel or A36 hex bar? It’s cheap and pretty available.
There actually is a coupler that is already available that should work for what you want, they are what I have known as spiders or jaw couplers. The nice thing is they are an intentional weak point that will fail before damage occurs to either the power side or the work side.
Generally I use these in higher speed (1000-3000RPM), but they should translate over to what you need for low speed high torque applications.
If that doesn’t suit, I can probably provide you a different solution.