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This paper sets out to perform a static force analysis of the single toggle jaw crusher mechanism and to obtain the force transmission characteristics of the mechanism. In order to obtain force transmission metrics that are characteristic of the structure of the mechanism, such influences as friction, dead weight, and inertia are considered to be extraneous and neglected. Equations are obtained by considering the balance of forces at the moving joints and appropriately relating these to the input torque and the output torque. A mechanical advantage, the corresponding transmitted torque, and the variations thereof, during the cycle of motion of the mechanism, are obtained. The mechanical advantage that characterizes the mechanism is calculated as the mean value over the active crushing stroke of the mechanism. The force transmission characteristics can be used as criteria for the comparison of different jaw crusher mechanism designs in order to select the most suitable design for a given application. The equations obtained can also be used in estimating the forces sustained by the components of the mechanism.

The inaccessibility of commercial software has necessitated the development of low-cost, general-purpose finite element method (FEM) computer programs for structural analysis. Using the FEM program, the elastic, elastic-plastic, residual and service stresses and displacements in a closed ended, thick-walled cylinder under internal pressure were established. The displacement formulation was implemented and eight-noded brick isoparametric elements chosen. The frontal solution technique and the incremental theory of plasticity were used, as only limited computing facilities were available. The results were found to be in very good agreement with the through-thickness analytical values. The benefits of autofrettage were demonstrated and an optimum overstrain of 16% established for a cylinder with a thickness ratio of 2. The material economy achieved through autofrettage and the limitations imposed are illustrated. The FEM program could therefore be reliably used for other complex geometries and load conditions.