RECYLCLED ALUMINIUM MINATURE GEAR (RAMG)

Abstract

Recycled Aluminium Miniature Gear (RAMG). Fabrication of Recycled Aluminium miniature gear (RAMG) from food packaging waste involves a series of sequential processes including collection, cleaning, drying, pressing, melting, casting, finishing, gear cutting, testing and inspection.

Specification

Description:RECYLCLED ALUMINIUM MINATURE GEAR (RAMG)
TECHNICAL FIELD
[0001] The present invention relates to recycling of waste materials. The present invention also relates to food packaging aluminium foil waste recycling. The present invention additionally related to miniature gears from waste materials. Further, the present invention specifically relates to recycled aluminium miniature gear (RAMG).
BACKGROUND OF THE INVENTION
[0002] Aluminium (Al) is used as a food packaging material as it is mechanically strong and at the same time has low weight. Waste management of food packaging aluminum foil is a big challenge due to the growing online food ordering culture; most people order food online. The Al foil reaches the environment without proper recycling, and it starts to pollute the environment in no time. Therefore, this work provides a unique waste management solution through recycling process of Aluminium foil using melting of Aluminium foil and casting of Aluminium ingots to produce recyclable miniature gear. Thus, giving it a second life and turning waste into wealth.
[0003] Problem statement of the present invention: Inadequate waste management is one of the biggest challenges that the entire globe is facing right now. Tons of wastes are generated every single day that ultimately reaches the landfills without proper treatment. Earlier the food packaging industries used plastics for food packaging. However, due to the growing plastic pollution problem, it has been replaced with Al foil. The current practices involve throwing the Al food packaging foil without much thought of recycling it. Inadequate collection and recycling facilities are ultimately resulting in waste accumulation in the environment, thus seriously polluting it.
[0001] Conventionally, several attempts were made for recycling food packaging foil can be given a second life through proper strategies. In one embodiment of prior art, brick that has excellent fire resistance- "a non-burning brick" was developed from the waste Aluminium lime ash. Another prior art attempt for to produce sodium Aluminate from the waste aluminum scrap in order to reduce the secondary pollution. The sodium aluminate has found its application in water purification, steel testament and etc.
[0002] No prior art teaches Recycled Aluminium Miniature Gear (RAMG) from the discarded waste Al food packaging foil. Al is known to have a great strength-to-weight ratio. It has high corrosion resistance and quickly dissipates heat due to high thermal conductivity. Such gear can be used for small, geared motors, high precision applications in automobiles, Robotics, aerospace, defence sector, marine environment and other machine components, etc. Based on the foregoing a need therefore exists for recycled aluminium miniature gear (RAMG), as discussed in greater detail herein.
SUMMARY OF THE INVENTION
[0003] The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiment and is not intended to be a full description.
[0004] It is, therefore, one aspect of the disclosed embodiments to provide for an improved recycling process for processing aluminium foil waste.
[0005] It is another aspect of the disclosed embodiments to provide for a Recycled Aluminium Miniature Gear (RAMG) from the discarded waste Al food packaging foil.
[0006] It is further aspect of the disclosed embodiments to provide recycled aluminium miniature gear (RAMG) used for small, geared motors, high precision applications in automobiles, Robotics, aerospace, defence sector, marine environment and other machine components.
[0007] Recycled Aluminium Miniature Gear (RAMG). Fabrication of Recycled Aluminium miniature gear (RAMG) from food packaging waste involves a series of sequential processes including collection, cleaning, drying, pressing, melting, casting, finishing, gear cutting, testing and inspection.
[0008] Initially, the Aluminium foil is collected and cleaned using an appropriate proportion of [1 litre] of water and [30 ml of] liquid detergent to remove hydrophobic food residues and other impurities on its surface. Further, hot drying process is carried out with heated air stream (40-50°C) to remove unbounded water and moisture on the given amount of cleaned aluminium foils. Further, cleaned, and dried aluminium foil is pressed using pneumatic hydraulic pressing machine into a small bale of 40 mm x 40 mm size for ease of storage, transportation, and recycling. A tilting furnace is used to melt the aluminium bales of 500 grams at a temperature of 6400 C for 10 minutes. A sand casting process is followed for developing cubical shape of size 5 cm x 1 cm for a specified time duration of 150 sec. A grinding finishing machining process is followed to remove the surface irregularities and achieve the required surface finish in the solidified cast aluminium block. Computer aided geometric model of a miniature spur gear is built with desired intricate shape and dimensions of the miniature spur gear. Wire Cut Electro Discharge machining operation is carried out using brass diameter is 0.20 mm with optimal process parameters of pulse on [25µs], pulse off time [6 µs], current [1 Amp], wire feed rate [80 mm/s], to cut the aluminium surface with a surface finish of 4µm. Finally, the dimensional and geometric accuracy of the fabricated Recycled Aluminium miniature gear (RAMG) is inspected using machine vision inspection system.
DETAILED DESCRIPTION
[0009] The values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
[0010] The embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. The embodiments disclosed herein can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. As used herein, the term "and/or" includes all combinations of one or more of the associated listed items.
[0011] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0012] Invention: Al is known for its low weight and excellent mechanical properties. Primary production of Al consumes a lot of energy and resources. By recycling the Al we can cut off the CO2 emission up to a great extent that is otherwise emitted during the primary production of Al (mining operation). Proposed Recycled Al Miniature Gear (RAMG) can also find its application in automobile, aerospace, defence and other sectors where low load high-speed application is required. End-of life management of waste Al food packaging foil can cut off the use of natural resources needed for the production of primary Al. Therefore, such an innovative way of managing waste needs to be protected for humanity and mankind.
[0013] Gears are one of the most important components of any mechanical system for power transmission applications. Producing gears from secondary Al can cut off costs that are generated during the primary production of the Al. Due to its low weight, high mechanical strength, and good machinability. It has high wear and corrosion resistance. It can find its application in sectors like Aerospace, Défense, robots, small, geared motors, and other machines. Due to high thermal conductivity, it can disperse heat quickly. RAMG can help in making lighter construction, thus saving fuel which in turn can also help in reducing the pollution. The discarded Al foils can be given a second life this way.
[0014] Fabrication of Recycled Aluminium miniature gear (RAMG) from food packaging waste involves a series of sequential processes including collection, cleaning, drying, pressing, melting, casting, finishing, gear cutting, testing and inspection. Initially, the Aluminium foil is collected and cleaned using an appropriate proportion of [1 litre] of water and [30 ml of] liquid detergent to remove hydrophobic food residues and other impurities on its surface. Further, hot drying process is carried out with heated air stream (40-50°C) to remove unbounded water and moisture on the given amount of cleaned aluminium foils. Further, cleaned, and dried aluminium foil is pressed using pneumatic hydraulic pressing machine into a small bale of 40 mm x 40 mm size for ease of storage, transportation, and recycling. A tilting furnace is used to melt the aluminium bales of 500 grams at a temperature of 6400 C for 10 minutes. A sand casting process is followed for developing cubical shape of size 5 cm x 1 cm for a specified time duration of 150 sec. A grinding finishing machining process is followed to remove the surface irregularities and achieve the required surface finish in the solidified cast aluminium block. Computer aided geometric model of a miniature spur gear is built with desired intricate shape and dimensions of the miniature spur gear. Wire Cut Electro Discharge machining operation is carried out using brass diameter is 0.20 mm with optimal process parameters of pulse on [25µs], pulse off time [6 µs], current [1 Amp], wire feed rate [80 mm/s], to cut the aluminium surface with a surface finish of 4µm. Finally, the dimensional and geometric accuracy of the fabricated Recycled Aluminium miniature gear (RAMG) is inspected using machine vision inspection system.
Currently most of the Al foils are simply discarded after the very first use. The remnants of the food particles are attached to the foil. Without proper treatment, the foil starts to get contaminated and pollutes the environment. An important metal like Al can be given a second life. Aluminium has a wide range of applications due to its low weight and good mechanical strength. The development of a Recycled Aluminium Miniature Gear (RAMG) from the discarded aluminum foils gives it a second life. It is a sustainable approach to mitigate environmental pollution due to improper waste management. FIG. 2 illustrates the transformation of the waste Al food packaging foil into RAMG. The waste foil has gone through all the steps as mentioned in Fig.1.This way we may save an important metal like Aluminium from reaching the landfills. RAMG is a sustainable product and has the potential to be used for several mechanical power transmission applications. Thus, in this way, the invention establishes a circular economic model for waste Al foil.
[0015] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
, Claims:I/We Claim
1. A method for obtaining a Recycled Aluminium Miniature Gear (RAMG), comprising steps of:
collecting and cleaning Aluminium foil using 1 litre of water and 30 ml of liquid detergent to remove hydrophobic food residues and other impurities on its surface;
hot drying process is carried out with heated air stream (40-50°C) to remove unbounded water and moisture on the given amount of cleaned aluminium foils wherein cleaned, and dried aluminium foil is pressed using pneumatic hydraulic pressing machine into a small bale of 40 mm x 40 mm size for ease of storage, transportation, and recycling;
melting aluminium bales of 500 grams at a temperature of 6400 C for 10 minutes wherein a sand-casting process is followed for developing cubical shape of size 5 cm x 1 cm for a specified time duration of 150 sec; and
grinding finishing machining process is followed to remove the surface irregularities and achieve the required surface finish in the solidified cast aluminium block.
2. The method as claimed in claim 1 wherein the computer aided geometric model of a miniature spur gear is built with intricate shape and dimensions of the miniature spur gear by Wire Cut Electro Discharge machining operation is carried out using brass diameter is 0.20 mm with optimal process parameters of pulse on [25µs], pulse off time [6 µs], current [1 Amp], wire feed rate [80 mm/s], to cut the aluminium surface with a surface finish of 4µm.

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