Design and Fabrication of An Automated Glass Bottle Cutter for Reuse and Recycling Bottle Glass Products
At a Glance
Section titled āAt a Glanceā| Metadata | Details |
|---|---|
| Publication Date | 2025-03-16 |
| Journal | Journal of Engineering Technology and Applied Physics |
| Authors | Anuar Ishak, Ainaa Maya Munira Ismail, Ahmad Idzwan Yusuf, Ab Aziz Mohd Yusof |
| Institutions | Universiti Teknologi MARA |
| Analysis | Full AI Review Included |
Executive Summary
Section titled āExecutive SummaryāThe following points summarize the design, fabrication, and validation of an automated glass bottle cutter prototype intended for reuse and recycling applications:
- Automated Efficiency: The prototype replaces traditional manual scoring and thermal shock methods with a DC motor-driven diamond blade, drastically accelerating the cutting process to 30-60 seconds per bottle.
- Structural Integrity: Finite Element Analysis (FEA) confirmed the durability of the critical plain carbon steel (AISI 1013) blade holder. The maximum Von Mises stress (7.94 x 107 N/m2) is safely below the materialās yield strength (2.21 x 108 N/m2).
- Versatile Design: The machine accommodates a wide range of bottle sizes, handling diameters from 3 cm to 10 cm and lengths up to 35 cm, facilitated by adjustable bottle holders and speed controls (3000 RPM to 5000 RPM).
- Enhanced Safety: The automated system significantly improves user safety by minimizing direct contact with sharp glass edges and incorporating a high base wall to contain glass dust dispersion.
- Material and Construction: The machine is fabricated primarily from plain carbon steel (AISI 1013), selected for its high ductility, weldability, and cost-effectiveness, ensuring suitability for prolonged, intensive use.
- Environmental Impact: The device promotes the circular economy by enabling communities and businesses to upcycle waste glass into valuable products (drinking glasses, vases, ashtrays), contributing to substantial reductions in carbon emissions associated with new glass production.
Technical Specifications
Section titled āTechnical Specificationsā| Parameter | Value | Unit | Context |
|---|---|---|---|
| Construction Material | Plain Carbon Steel (AISI 1013) | N/A | Primary structural material |
| Prototype Dimensions (L x W x H) | 305 x 250 x 230 | mm | Final fabricated size |
| Prototype Weight | 25 | kg | Overall mass |
| Operating Voltage | 240/220 | V | Power requirement |
| Motor 1 Power Output | 1.51 | kW | Primary cutting motor |
| Motor 2 Power Output | 20 | W | Rotation motor |
| High Speed Range | 5000 | RPM | Recommended for thicker glass |
| Low Speed Range | 3000 | RPM | Recommended for thinner glass |
| Max Tool Diameter (Motor) | 100 | mm | Maximum tool size accommodated |
| Max Cutting Diameter (Blade) | 120 | mm | Diamond blade capability |
| Bottle Diameter Range | 3 to 10 | cm | Accommodated bottle size |
| Bottle Length Range | Up to 35 | cm | Accommodated bottle size |
| Typical Cutting Time | 30-60 | seconds | Time per bottle cut |
| Max Von Mises Stress (FEA) | 7.94 x 107 | N/m2 | Calculated stress on blade holder |
| Material Yield Strength (AISI 1013) | 2.21 x 108 | N/m2 | Safety margin confirmed |
Key Methodologies
Section titled āKey MethodologiesāThe development and fabrication process followed an iterative engineering workflow, focusing on design optimization, structural analysis, and material selection:
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Design and Modeling:
- Three distinct concept designs were generated and evaluated based on complexity, cost, and functionality (e.g., adjustable holders, base wall height).
- The final prototype design was modeled and detailed using SOLIDWORKS 2017 3D CAD software.
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Material Selection and Preparation:
- Plain carbon steel (AISI 1013) was chosen for its high ductility, ease of machining, and cost-effectiveness, ensuring the machineās robustness for intensive use.
- Raw materials (25 mm and 32 mm square hollow steel, plate, and rod) were measured and cut precisely using a cut-off saw and angle grinder.
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Structural Analysis (FEA):
- Stress simulation was performed on the critical blade holder component using SolidWorks.
- A load of 72 N was applied to the blade holder to determine the maximum Von Mises stress (7.94 x 107 N/m2), confirming that the structure would not fail or fracture under operational loads.
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Fabrication and Assembly:
- Components were welded using Gas Metal Arc Welding (GMAW) and arc welding techniques.
- Holes were drilled using a bench drill for bolt and nut attachments.
- A DC motor and a diamond cutting blade were integrated, replacing conventional wheel cutters and manual scoring methods.
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Testing and Validation:
- The machineās performance was tested using various bottle diameters (e.g., 70 mm soy sauce bottle, 50 mm Vsoy bottle).
- Tests confirmed the machineās ability to cut through glass efficiently and to smooth the cut surface, meeting all design specifications.
Commercial Applications
Section titled āCommercial ApplicationsāThe automated glass bottle cutter provides significant value across several sectors focused on waste management and sustainable product creation:
- Hospitality and Food Service:
- Allows restaurants, bars, and hotels to immediately upcycle high volumes of glass waste into functional or decorative items (e.g., custom drinking glasses, candle holders), reducing waste disposal costs.
- Recycling and Waste Management:
- Provides recycling facilities with a robust, automated tool for processing glass bottles into usable raw materials or semi-finished products more efficiently than manual methods.
- Sustainable Product Manufacturing:
- Supports small-scale commercial ventures and craft industries focused on creating eco-friendly products from repurposed glass, such as vases, ashtrays, and lamps.
- Environmental Conservation:
- Directly contributes to the circular economy by diverting glass from landfills, thereby reducing the environmental pollution associated with non-biodegradable waste and saving energy compared to manufacturing new glass.
- Educational and DIY Markets:
- Offers a safe and precise tool for educational settings and hobbyists interested in glass repurposing, promoting awareness of recycling importance.
View Original Abstract
The glass bottle cutter has a substantial commercialisation potential, as present trends indicate a growing interest in repurposing waste materials. This apparatus enables communities to manufacture new items from discarded glass bottles, including drinking glasses, ashtrays, and vases. Disposal at recycling centres or craft stores is essential for businesses such as restaurants and bars that often produce excess glass waste. Hence, this apparatus is resilient and long-lasting, designed to handle significantly larger amounts more efficiently than manual glass bottle cutters, which require scoring the bottle and alternating between hot and cold water. The main goals of this project are to develop a prototype for a glass bottle-cutting machine and to manufacture the machine according to the designed prototype. The manufacturing process encompasses measuring, cutting, welding, and drilling, with the machine predominantly constructed from metals. It employs a DC motor to facilitate the rotation of the diamond blade, substituting conventional wheel cutters. This design markedly diminishes the necessity for physical labour and enables bottles to be severed in under one minute. The cutter accelerates the procedure, yielding a superior finish with reduced physical exertion. The design and analysis of the prototype have been successful. Potential enhancements may involve the integration of a safety button, applying a coolant to inhibit the dispersion of glass dust, and including a polishing mechanism for smoother edges. These upgrades would boost the machineās efficiency and desirability.