Optimizing plastic shredder rotor design through structural finite element analysis: A comprehensive approach using experimental design and response surface methodology

Shredder machines are essential for recycling plastic waste. They are used to shred plastic materials into smaller pieces, which can then be processed into new products. The shaft and rotary blades of the plastic shredder are its most crucial parts since they directly influence how effectively the machine shreds or recycles material. The shredder's rotor is optimized based on the design of experiments and the response surface method. The natural frequencies and mode shapes are identified by modal analysis, and the critical natural frequencies that must be avoided during operation are identified through harmonic response analysis. The shredder's rotor is optimized by determining its critical areas through a transient structural analysis. The optimization goals are attained by using the response surface method and experiment design in the ANSYS WORKBENCH DESIGN EXPLORATION module. The rotor of the optimized shredder is investigated, and its results are contrasted with the nominal design. The study of the optimum structure leads to a slight increase in mass of 2.43% in addition to reductions in equivalent stress and total deformation by about 9.84% and 42.86% respectively, as well as a 21.4%, 4.35%, and 4.48% increase in the first three natural frequencies, respectively.