High-torque twin-shaft metal chip shredder engineered with hardened-steel cutters, an optimized gearbox system, and an FEA-verified frame for continuous industrial recycling operations.

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Project Description

KS Projects engineered a heavy-duty twin-shaft metal chip shredder designed to process tangled machining swarf into smaller, manageable chips for recycling, briquetting, and material handling.

Using SolidWorks, mechanical calculations, and FEA, the complete machine was developed around a high-torque counter-rotating cutting system capable of processing aluminum, brass, stainless steel, and other machining waste.

A 55 kW motor paired with an 18:1 helical gearbox was selected to provide the torque required for demanding startup and operating conditions. The drive system was engineered to deliver approximately 25,000 N·m peak torque with a 3× service factor.

Structural FEA was performed on the box-section frame under cutter loads of up to 120 kN, maintaining calculated frame deflection below 0.4 mm.

The machine also incorporates replaceable hardened-steel cutters and bolt-in combs to simplify maintenance and extend service life.

Standardized bearings, seals, fasteners, and weld-ready plate components were used to reduce manufacturing complexity and long-term maintenance costs.

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Engineering Capabilities

• 3D CAD Modeling – SolidWorks – Shafts, cutters, combs, hopper, frame, and gearbox mounting

• FEA Structural Analysis – Frame loading, deformation, and stiffener optimization

• Gearbox & Motor Selection – 55 kW motor and 18:1 helical reducer

• Mechanical Calculations – Shear force, cutter speed, torque, and bearing life

• DfMA – Standardized components and fabrication-ready steel assemblies

• Technical Documentation – Manufacturing drawings, GD&T, weld maps, and BOM

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Project Results

✅ 30% increase in throughput compared with the previous single-shaft design at the same motor power

✅ Engineered for approximately 25,000 N·m peak torque

✅ Frame deflection maintained below 0.4 mm at 120 kN cutter load

✅ Optimized stiffener layout reduced structural weight by 12%

✅ Cutter service life increased approximately 2×

✅ Standardized components reduced manufacturing costs by approximately 15%

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Technologies & Expertise

Industrial Shredder Design | Metal Recycling Equipment | SolidWorks | FEA | Gearbox Design | High-Torque Machinery | Mechanical Engineering | DfMA | Custom Machinery Design