310896254-Elbow-Mechanism.pdf

A PROJECT REPORT ON

“ELBOW MECHANISM” SUBMITED TO THE GOVERNMENT POLYTECHNIC PUNE, (An Autonomous Institute of Government of Maharashtra)

IN THE PARTIAL FULFILLMENT OF THE FINAL YEAR DIPLOMA COURSE IN MECHANICAL ENGINEERING SUBMITED BY. 1. Tanuja Vijaykumar Kashid 2. Sourav Siddheshwar Kotgund 3. Sanket Virbhadra Kothale 4. Sheryas Prakash Misale 5. Pagar Jagdish Dharma 6. Pasalkar Aditya Laxman

En.No. 1324222 En. No. 1324226 En. No. 1324227 En. No. 1324228 En. No. 1324230 En. No. 1324231

GUIDED BY

Mr . P. U. Garge DEPARTMENT OF MECHANICAL ENGINEERING PUNE-411 016 (AN AUTONOMOUS INSTITUTE OF GOVT. OF MAHARASHTRA) 2015-16

GOVERNMENT POLYTECHNIC PUNE (AN AUTONOMOUS INSTITUTE OF GOVT. OF MAHARASHTRA) PUNE-411 016

CERTIFICATE This is to certified that the project work entitled “ELBOW MECHANISM” is a benefited work carried out by the below mentioned students in partial fulfilment for the award of Diploma in MECHANICAL ENGINEERING of GOVERNMENT POLYTECHNIC, PUNE during the year 2015-2016. It is certified that all corrections/ suggestions indicated for Internal Assessment have been incorporated in this report. The project report has been approved as it satisfies the Academic requirements in respect of project work prescribed for Diploma in MECHANICAL ENGINEERING. NAME OF STUDENT

1. Tanuja Vijaykumar Kashid 2. Sourav Siddheshwar Kotgund 3. Sanket Virbhadra Kothale 4. Sheryas Prakash Misale 5. Pagar Jagdish Dharma 6. Pasalkar Aditya Laxman

Prof. P.U. Garge Project Guide

Dr. M. Giridhar Head of Department

ENROLLMENT NO.

En.No. 1324222 En. No. 1324226 En. No. 1324227 En. No. 1324228 En. No. 1324230 En. No. 1324231

Dr. D. R. Nandanwar Principle

External Examiner

ELBOW MECHANISM

ACKNOWLEDGEMENT

We take this momentous opportunity to express our heartfelt gratitude, ineptness & regards to vulnerable and highly esteemed guide, Mr. P.U.Garge, for providing us an opportunity to present our project on “ELBOW MECHANISM”.

We with full pleasure converge our heartiest thanks to Our project guide Mr. P.U.Garge,

Lecturer,

Department

of

Mechanical

Engineering,

Government

Polytechnic Pune, for their invaluable advice and wholehearted cooperation without which this project would not have seen the light of day.

We attribute hearties thanks to all the faculty of the department of mechanical and friends for their valuable advice and encouragement

Thanking.

GOVERNMENT POLYTECHNIC PUNE 1

ELBOW MECHANISM

INDEX OF CHAPTERS

Sr.No. 1.

Chapter Name

Pg.No. 6

Introduction 1.1. Function of transmission. 1.2. Types of transmission. 1.3. Need for project. 1.4. Solution.

2.

Construction & Working.

11

2.1. Construction. 2.2. Working. 2.3. Advantages & Disadvantages. 2.4. Simple gear train. 3.

Design

17

3.1. System Design. 3.2. Mechanical Design. 3.3. Input Data. 3.4. Design of Propeller Shaft. 3.5. Design of Gears. 3.6. Design of Input Shaft. 3.7. Design of Output Shaft. GOVERNMENT POLYTECHNIC PUNE 2

ELBOW MECHANISM 3.8. Design of Bearing Bush. 3.9. Design of Bent Pins. 4.

33

Process Sheet 4.1. Process Sheet For Pulley. 4.2. Process Sheet For L-H Output Shaft. 4.3. Process Sheet For R-H Output Shaft. 4.4. Process Sheet For R-H Input Shaft. 4.5. Process Sheet For L-H Input Shaft. 4.6. Process Sheet For L-H_BRG_HSG. 4.7. Process Sheet For R-H_BRG_HSG. 4.8. Process Sheet For Central_BRG_HSG. 4.9. Process Sheet For Cover Ring.

5.

Test & Trial on ELBOW MECHANISM.

46

6.

Operation Table.

48

6.1. Sample Calculation. 7.

Result Table.

52

8.

Cost Analysis.

54

9.

Conclusion & Future Scope

58

10.

Bibliography

60

GOVERNMENT POLYTECHNIC PUNE 3

ELBOW MECHANISM

--------DEFINATION OF PROJECT--------

P-

Planning before carrying out the work

R- row material required for the work

O- Organization of the work

J- joint effort put in to the work

E- estimation of material required in the work

C- Costing of the work

T- techniques used in performing

GOVERNMENT POLYTECHNIC PUNE 4

ELBOW MECHANISM

Project Abstract / Summary : ABSTRACT

This project “EL-BOW TRANSMISSION” being compact and portable equipment, which is skilful and is having practice in transmitting power at right angle without any gears being manufactured. The El-bow Mechanism transmits the input power towards the output side such a way that the angular forces produced in the slacks are transmitted with the help of rods which takes up the input power and the right angle drive is transferred towards the output slack and rod assembly. Hence very little friction plays while the power is being transmitted. Hunting and back lash errors are absent. Therefore, it is appreciated that efficiency as high as 90-92% are possible in gear less transmission mechanism.

Why did you choose to work on this project topic : Here is a wonderful mechanism that carries force through a 90ºbent rod. Transmitting rotational motion around an axis usually involves gears, which can quickly become complicated, inflexible and clumsy-looking, often ugly. So, instead of using gears, this technology elegantly converts rotational motion using a set of cylindrical bars, bent to 90º, in a clever, simple and smooth process that translates strong rotational force even in restricted spaces.A gearless transmission is provided for transmitting rotational velocity from an input connected to three bent links. Both the input shaft and the housing have rotational axes. The rotational axis of the input shaft is disposed at an angle of 90 degree with respect to the rotational axis of the housing. As a result, rotation of the input shaft results in a processional motion of the axis of the bent link. The rotary and reciprocating motion of bent link transmit rotation of prime mover to 90 degree without any gear system to an output shaft. GOVERNMENT POLYTECHNIC PUNE 5

ELBOW MECHANISM

CHAPTER NO.1

INTRODUCTION

GOVERNMENT POLYTECHNIC PUNE 6

ELBOW MECHANISM PROJECT TITLE : ELBOW MECHANISM

INTRODUCTION

The word ‘TRANSMISSION’ on which the project is based upon means the whole of the mechanism that transmits the power from the engine crankshaft to the rear wheels. However the ‘transmission’ is also being used very commonly in the literature for a mechanism, which provides us with suitable variation of the engine torque at the road wheels, whenever required. This may be a gearbox (also called manual transmission) or an automatic transmission.

FUNCTIONS OF TRANSMISSION

The main functions that are performed by the transmission are:

1)The torque or the tractive effort produced by the engine varies with speed only within narrow limits. But the practical consideration for the running of automobile under different conditions demands a large variation of torque available at the wheels. The main purpose of the transmission is to provide means to vary the leverage or the torque ratio between the engine and the road wheels as required. 2)The transmission also provides a neutral position so that the engine and the road wheels are disconnected even with the clutch in the engaged position. 3)A mean to back the car by reversing the direction of rotation of the drive is also provided by the transmission.

GOVERNMENT POLYTECHNIC PUNE 7

ELBOW MECHANISM TYPES OF TRANSMISSION The transmissions may be classified into the manual and the automatic types. The manual transmissions are conventionally called gearboxes. Their mechanical efficiency in direct drive is about 98%, whereas in reduction gears, it is slightly greater than 90%. As most of the time the driving is done in direct drive, friction losses in manual transmissions are very small. That coupled with simplicity and lower initial cost, is the reason these are still popular particularly in fuel-efficient automobiles. On the other hand the operation of engaging and disengaging the clutch along with changing gears while driving over a crowded highway means a lot of fatigue to the driver. Therefore, in luxury vehicles automatic transmissions are employed which simplify the driving operation considerably. NEED FOR PROJECT: The conventional transmission system used in auto rickshaw is as shown in the figure. The transmission train comprises of the engine as the power plant , and the clutch –gear box and differential arrangement as the traction device. The power is available at the differential end as two outputs , which is supplied to the wheels individually by means of double hooke’s joint as the engine is at a higher level as compared to the wheels. The double hooke’s joint has certain disadvantages that, it does not transmit constant angular velocity, so also the efficiency of transmission is low(65%).More over this efficiency further drops with the increase in angular velocity ie speed output from the engine. The drive is subjected to inherent vibrations and considerable axial and radial forces are encountered during power transmission. Actually the situation is simple that the power from the differential has to be transmitted at right angles to the wheels, and even if the wheels move over a bump on the road this right angle is not disturbed.

GOVERNMENT POLYTECHNIC PUNE 8

ELBOW MECHANISM

Universal System Used in 3-Wheeler

GOVERNMENT POLYTECHNIC PUNE 9

ELBOW MECHANISM SOLUTION

ELBOW MECHANISM (ORBITAL TRANSMISSION SYSTEM.) The orbital transmission system is an adaptation of the original mechanism named Elbow mechanism developed by LEO -NARDO-DAVINCI. This Elbow mechanism is capable of transmitting heavy torque at high speeds between two shafts at right angles. This mechanism comprises of two shafts drilled with three holes each on the same pitch circle diameter on each shaft and a set of three bent pins that are made of steel and bent at exactly 900. This mechanism is capable of transmitting high speeds (12000 rpm). The drive is compact and can be made into hermetically sealed units filled with lubricating oil in order to increase the life of the drive. This drive has an efficiency as high as 93%. In the project we are getting the two inputs to the transmission system from the one shaft through simple gear train . gears used over here are of same diameter and having same number of teeth on its periphery. One variable speed motor drives the main propeller shaft through belt and pully. Pully is fitted rigidly on it. The single shaft can be driven by both manually as well as using motor drive. This transmission system is extremely compact and will improve the efficiency of power transmission of the vehicle and thereby the mileage of the vehicle.

GOVERNMENT POLYTECHNIC PUNE 10

ELBOW MECHANISM

Chapter No.:- 2

CONSTRUCTION AND WORKING

GOVERNMENT POLYTECHNIC PUNE 11

ELBOW MECHANISM

CONSTRUCTION

1. ELECTRIC MOTOR:Electric motor of following specifications is used Single phase Ac Motor 230 volt,0.5 AMP. 50 Hz Power = 100 watt Speed = 0 to 6000 rpm TEFC CONSTRUCTION COMMUTATOR MOTOR 2. PULLEY:pulley is v-belt pulley of 40 degree groove angle and 6mm ‘A’ section .This reduction pulley gives an speed reduction ratio of 4.68 .This reduction pulley is mounted at the bearing end of the propeller shaft. 3. LH&RH INPUT SHAFT:Input shaft is an steel construction where in main shaft is an high grade steel (EN 24) Input shaft supports the reduction pulley at lower end and the horizontal places at the upper end .The horizontal plates are drilled with three holes of equal pitch, these holes receive the bent pins. 4. BENT PINS:Pins are made form high carbon steel; in three sets of 90 ,120,140 degree respectively pins are bent to the desired angle in a special fixture such that the bend is not sharp but slightly filleted to avoid stress concentration.

GOVERNMENT POLYTECHNIC PUNE 12

ELBOW MECHANISM

5.

CENTRAL BEARING HOUSING:The central bearing housing houses two ball bearings 6201 zz in which the input shafts are mounted .The central bearing housing is welded to the base fame. 5. LH BEARING HOUSING:The LH bearing housing houses ball bearing 6201 zz in which the LH_ output shafts are mounted .The LH bearing housing is welded to the base fame. 6. RH BEARING HOUSING:The RH bearing housing houses ball bearing 6201 zz in which the RH_ output shafts are mounted .The LH bearing housing is welded to the base fame 7. PROPELLER SHAFT Pulley is mounted on propeller shaft. Pulley is driven by motor shaft and then it drives propeller shaft. Propeller shaft is also manually driven by hand wheel which is located at other end of shaft, which is fixed. 8. GEARS 4 Gears are used for power transmission from propeller shaft to the both wheels through Input and output shaft mechanism. 9. WHEELS The wheels are of nylon that are fitted at the output shaft ends

GOVERNMENT POLYTECHNIC PUNE 13

ELBOW MECHANISM WORKING: Electric motors supply power to the Propeller shafts of the orbital transmission system by means of belt and pulley arrangement. Then, drive is given to the two input shaft through simple gear train mechanism. Gear used over here are spur type and of same diameter. Therefore, there will be no variation in speed of two wheels. The input shaft rotate to move the pins about the central axis, this motion causes the pins to slide to and fro inside the output shaft holes which in turn results into rotary motion of the output shaft. Thus the rotary input from the motors is transferred to the output wheel shafts that cause the wheels to rotate.

ADVATAGES OF ELBOW MECHANISM 1. Better transmission efficiency (90%) as compared to conventional double hook e’s joint ( 60 to 65 %) 2. Better efficiency of system results in better fuel economy. 3. Radial speed of input and output shaft is same , hence no phase shift. 4. No vibrations in drive. 5. Efficiency remains almost constant even with increase in transmission speed. 6. Compact as compared to double hooke’s joint. 7. Lower manufacturing cost. 8. Lower maintenance required. DISADVANTAGES : 1. Slightly high cost of manufacture. 2. Special machines like jig boring is required for manufacture. 3. Conventional Transmission system needs to be modified to incorporate the above system/.

GOVERNMENT POLYTECHNIC PUNE 14

ELBOW MECHANISM Simple Gear TrainIn simple gear train, each shaft carries one wheel only and there no relative motion between the axis of the shafts. Gear used over here are of same diameter and having same number of teeth. one gear is driving and two gears are driven type. One idler gear is used in intermediate to one driving and driven shaft. Let, N1 and T1 is speed and no. of teeth of Driving gear which is fixed on propeller shaft and rotated. N2,T2 and N3 T3 are speed and no. of teeth of driven gear 1 and driven gear 2 respectively. And let say, N4 and T4 is the speed and No. of teeth of Idler gear which is intermediate between driving shaft and driven gear 1. Since the driving wheel drives driven gear 2, N3 x T3 = N1 x T1 ......(1) As well as driving gear drives Idler gear, N4 x T4 = N1 x T1 ........(2) Since Idler gear drives Driven gear 1, N2 x T2 = N4 x T4 ........(3) Gear used are of same diameter and same no. of teeth so there is no speed reduction take place. NO OF TEETH OF ALL GEARS = T1 = T1 = T3 = T4 ................. (4) From Equation 1,2,3,4, N1 = N2 = N3 = N4........................( hence proved) So we can say that same power is given to driven shafts without any speed reduction. If the input and output gears are exactly the same size, they will turn at the same speed. In many simple gear trains there are several gears between the input gear and the output gear. These middle gears are called idler gears. Idler gears do not affect the speed of the output gear.

GOVERNMENT POLYTECHNIC PUNE 15

ELBOW MECHANISM

Chapter No.:-3

Design

GOVERNMENT POLYTECHNIC PUNE 16

ELBOW MECHANISM

DESIGN Design consists of application of scientific principles , technical information and imagination for development of new or improvised machine or mechanism to perform a specific function with maximum economy and efficiency.

Hence an careful design approach has to be adopted. The total design work, has been split up into two parts;

SYSTEM DESIGN

MECHANICAL DESIGN

GOVERNMENT POLYTECHNIC PUNE 17

ELBOW MECHANISM SYSTEM DESIGN

System design mainly concerns with various physical constrains, deciding basic working principle, space requirements, arrangements of various components etc.

Following parameters are looked upon in system design. a) Selection of system based on physical constraints. The mechanical design has direct norms with the system design hence system is designed such that distinctions and dimensions thus obtained in mechanical design can be well fitted in to it. b) Arrangement of various components made simple to utilize every possible space. c) Ease of maintenance and servicing achieved by means of simplified layout that enables quick decision assembly of components. d) Scope of future improvement.

GOVERNMENT POLYTECHNIC PUNE 18

ELBOW MECHANISM MECHANICAL DESIGN In mechanical design the components are listed down and stored on the basis of their procurement in two categories, Design parts Parts to be purchased.

For designed parts detailed design is done and dimensions there obtained are compared to next dimensions which are already available in market. This simplifies the assembly as well as the post production and maintenance work. The various tolerances on work are specified .The process charts are prepared and passed to manufacturing stage. The parts to be purchased directly are selected from various catalogues and are specified so as to have case of procurement . In mechanical design at the first stage selection of appropriate material for the part to be designed for specific application is done. This selection is based on standard catalogues or data books; eg:- (PSG DESIGN DATA BOOKS ) (SKF BEARING CATALOGUE ) etc.

APPROACH TO MECHANICAL DESIGN OF ‘PLANETARY SPEED REDUCER’ In design the parts of ‘planetary speed reducer’ we shall adopt the following approach ; a) Selection of appropriate material . b) Assuming an appropriate dimension as per system design. c) Design check for failure of component under any possible system of

forces.

GOVERNMENT POLYTECHNIC PUNE 19

ELBOW MECHANISM INPUT DATA 1) MOTOR DETAILS: SINGLE PHASE AC MOTOR 230 VOLT, 50Hz , 0.5 Amp POWER = 100 WATT SPEED = 200 TO 4500 rpm TEFC CONSTRUCTION MOTOR. 2) DIAMETER OF PLATES =45mm 3) PCD OF HOLES ON DISC = 32mm 4) THICKNESS OF PLATES =8mm 5) DIAMETER OF PINS (3No’s)=4mm 6) DIAMETER OF INPUT SHAFT=10mm 7) DIAMETER OF OUTPUT SHAFT=10mm 8) DIAMETER OF DRIVER PULLEY = 16mm 9) DIAMETER OF DRIVEN PULLEY = 75mm 10)SPEED REDUCTION RATIO = 75/16 =4.688 11)SPEED OF MECHANISM (MAX)=1200rpm (MIN)=0 rpm 12)MAX OUTPUT TORQUE AT 850 rpm = 0.08 kg.m 13) DIAMETER OF PROPELLER SHAFT = 14) NO. OF GEARS = 4 15) PCD OF ALL GEARS = 26mm

GOVERNMENT POLYTECHNIC PUNE 20

ELBOW MECHANISM DESIGN OF INPUT SHAFT:-

Torque calculation:Max Input Power = 100 watt at 6000 rpm. At motor shaft 9 60

I/P power =

2∏NT 60

2 x ∏ x 6000 x T 60

=

60 x 100 ⇒

T=

= 0.1592 N-m

2 x ∏ x 6000

Assuming 100 % efficiency of transmission between motor shaft & Mechanism I/P shaft .

⇒

2 ∏ N T motor O/p

=

⇒

60 T mech i/p = 4.688 x 0.1592

2 ∏ NT mech i/p 60

= 0.7463 N-m

Assuming 100% overload; ⇒ factor of safety

=2

⇒ Tdesign

= 2 Tmech i/p

⇒ Tdesign

=2x0.7463 =1.4926 N.m

⇒ Tdesign

= 1.4926 x 103 N.m

MATERIAL SELECTION Designation

EN 24

Ultimate Tensile strength

Yield strength

N/mm2

N/mm2

800

600

GOVERNMENT POLYTECHNIC PUNE 21

ELBOW MECHANISM ASME CODE OR DESIGN OF PROPELLER SHAFT:Since the shaft is subjected to variable load at different speed condition sit is necessary to make proper allowance for harmful effects of load fluctuation Propeller shaft is supported between two bearings and pulley is rigidly mounted on it and the weight of pulley is neglected and cyclic fluctuations occurs while rotating. According to ASME code permissible value of shear stress may be calculated for various relations. fs max = 0.18 fult =0.18 x 800 = 144 N/mm2 or fs max = 0.3 x 600 = 180 N/ mm2

Considering minimum of the above values. ⇒ fs max = 144 N/mm2

This is allowable valves of shear stress induced in input shaft of or safe operation . Shaft is provided a hole for rivet which reduces its strength ; ⇒ Reducing above value by 25%

⇒ fs max = 0.75 x 144 = 100 N/mm2 Diameter of input shaft =6mm Check for torsional failure of shaft:-

T= Π /16 fs act

d

3

GOVERNMENT POLYTECHNIC PUNE 22

ELBOW MECHANISM ⇒ fs ac t =

16 x T Πd 3

16 x 1.4926 x 103 =

Π x 10 3

fs act = 35.19 N/mm2

⇒ As fs act < fs all

⇒ Shaft is safe under torsional load.

GOVERNMENT POLYTECHNIC PUNE 23

ELBOW MECHANISM

Spur Gear Design :1. Outside Diameter = 22mm 2. No. Of Teeth = 19 3. Root Diameter = 18mm 4. Addendum = A = 1mm 5. Dedendum = D = 1mm 6. Pressure Angle = ϕ = 20 degree ( Standard ) 7. Base Circle Diameter = 18mm 8. Pitch Circle Diameter = 20mm 9. Circular Pitch = πM = 4mm 10. Module = 1.05mm 11. Circular Tooth Thickness = πM = 2mm 2 12. Whole Depth Of Teeth = 2mm

GOVERNMENT POLYTECHNIC PUNE 24

ELBOW MECHANISM

DESIGN OF INPUT SHAFT:Power and Torque is transmitted to both input shaft through simple gear train mechanism and subjected to twisting moment only. According to ASME code permissible value of shear stress may be calculated for various relations. fs max = 0.18 fult =0.18 x 800 = 144 N/mm2 or fs max = 0.3 x 600 = 180 N/ mm2

Considering minimum of the above values. ⇒ fs max = 144 N/mm2

This is allowable valves of shear stress induced in input shaft of or safe operation . Shaft is provided a hole for rivet which reduces its strength ; ⇒ Reducing above value by 25%

⇒ fs max = 0.75 x 144 = 100 N/mm2 Diameter of input shaft =6mm Check for torsional failure of shaft:-

T= Π /16 fs act

d

3

GOVERNMENT POLYTECHNIC PUNE 25

ELBOW MECHANISM

⇒ fs ac t =

16 x T Πd 3

16 x 1.4926 x 103 =

Π x 10 3

fs act = 35.19 N/mm2

⇒ As fs act < fs all

⇒ Shaft is safe under torsional load.

GOVERNMENT POLYTECHNIC PUNE 26

ELBOW MECHANISM

Design of out put shaft:Material selection Designation

Ultimate Tensile strength N/mm

EN24

2

800

Yield strength N/mm2 600

Design check for Torsional Failure T=Π/16 fs act d3

Diameter of output shaft = 6mm fs act =

16 x T Π x 63

fs act

= 35.19 N.mmd

3

⇒ shaft is safe under torsional load.

GOVERNMENT POLYTECHNIC PUNE 27

ELBOW MECHANISM

Design check for bending failure of o/p shaft:O/p shaft supports the weight of the bent pins ,discs etc and is held at one end in bush bearing which weigh approx. 0.75 kg Assuming factor of safety = 2 Bending Load =2 x 0.75 =1.5kg =15N fb act = M Z

fb act =

32 M ∏ d3 32 x15 x 130

⇒fb act =

∏ x (10)

3

= 19.86 N/mm2

As fb act < fb all

⇒ shaft is safe in bending .

GOVERNMENT POLYTECHNIC PUNE 28

ELBOW MECHANISM

Design of Bearing bush Material selection Designation

Ultimate Tensile strength N/mm

C30/EN8K

Bearing pressure

2

N/mm2

620

pb

Yield strength

400

load

=

Project area (Pb)

=

W lxd

Where ; pb = Average bearing pressure N/mm2 P= Radial load on journal (N) l = Length of journal in contact(mm) d= Diameter of journal (mm) Here ; d= 10mm l = 22 mm & Average bearing pressure for steel combination 12.6 N/mm2 Pb act = 12.6 N/mm2 Radial load Torque = w x r ⇒ W = 1.4926 x 10 3 =497.53 N PB = 497.53/22 x 10 =2.26 ⇒ As Pb act < Pb all ⇒Bearing brush is safe.

GOVERNMENT POLYTECHNIC PUNE 29

ELBOW MECHANISM

Design of Bent Pins:Bent pins are torque transmitting elements similar to bolts in ease of flange coupling . Material Selection

Designation

Tensile strength

Yield strength

N/mm2

N/mm2

520

350

EN9

a) Design check for shear failure of Pins. d= diameter of pins = 4 n = no . of pins =3

T=

∏ x d 2 x fs b x n x

4

1.4926 x 103 = ∏ 4

dP 2

x (4)2 x fsb act x 3 x 36 2

⇒ fsb act = 2.199 N/mm2 As ; fsb act < fsb all ⇒Pins are safe in shear (Torsional)

b) Design check for crushing failure:-

T = n x d x t f x f c b act x dp 2 3

1.4926 x 10 = 3 x 4 x 7 x f cb act x 36 2 ⇒ fcb act = 0.98716 N/mm2

As fcb act < fcb all

GOVERNMENT POLYTECHNIC PUNE 30

ELBOW MECHANISM

Chapter No: 4

Process Sheet

GOVERNMENT POLYTECHNIC PUNE 31

ELBOW MECHANISM

PART NO : OTS - 03 PART NAME : PULLEY

MATERIAL SPECIFICATION : EN 9 RAW MATERIAL SIZE: φ80X 30 QUANTITY :- 01 NO’S. Tools

Sr. No

Description of Operation

Jigs & Fixture

Time in minutes

M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

1. Clamp stock

3 Jaw chuck

Lathe

-

-

20

-

20

2. Facing one sides

--”--

--”--

Facing tool

Vernier

-

5

5

3. Turning diameter 75 through 23.5 mm length 4. Turning φ 30 through 14.5 mm length

--“--

--“--

Turning tool

--“--

5

10

15

--“--

--“--

--“--

--“--

-

30

30

5. Turning groove φ 50 mm ;3mm deep

--“--

--“--

Grooving tool

--“--

5

10

15

6. Chamfer 6 x 45 degree on face

--”--

--”--

Crank facing tool

--”--

10

3

13

7. Roughing V groove

--”--

--”--

Parting tool

--”--

10

10

20

8. Finish V groove

--“--

--“--

V- tool

15

25

40

9. Centre drill

--“--

--“--

Centre drill

Angle protractor --“--

5

2

7

10. Drilling φ 14.5 hole through 40 mm

--“--

--“--

Twist drill φ 6mm

--“--

5

2

7

11. Reaming φ 15 hole through 40 mm

--“--

--“--

Reaming φ 6

--“--

5

3

8

12. Parting off to 24mm Length

--“--

--“--

Parting tool

--“--

5

7

12

13. Facing other side to 23.5 mm length

--“--

--“--

Facing tool

--“--

5

2

7

GOVERNMENT POLYTECHNIC PUNE 32

ELBOW MECHANISM

PART NO : OTS - 07 PART NAME :LH_ OUTPUT SHAFT

MATERIAL SPECIFICATION : EN24 RAW MATERIAL SIZE: φ55 x 145 QUANTITY :- 0 4 NO’S. Tools

Sr. No

Description of Operation

Jigs & Fixture

Time in minutes

M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

1. Clamp stock

3 Jaw chuck

Lathe

-

-

10

-

10

2. Facing one sides

--”--

--”--

Facing tool

Vernier

5

2

7

3. Turning outer diameter to φ 48mm through length 4. Center drilling

--“--

--“--

Turning tool

--“--

5

13

18

--“--

--“--

Center drill

--“--

5

2

7

--“--

--“--

Twist drill

--“--

5

3

8

--“--

--“--

Turning tool

--“--

5

3

8

--”--

--”--

Turning tool

--”--

5

12

17

--”--

--”--

Turning tool

--”--

5

12

17

--”--

--”--

Turning tool

--”--

5

10

15

--”--

--”--

--”--

5

12

17

--”--

--”--

Threading tool Reamer

--”--

5

12

17

--”--

--”--

Parting tool

--”--

5

2

7

13. Facing other side

--“--

--“--

Facing tool

--“--

5

2

7

14. Clam job on m/c vice

3jaw chuck

-

--“--

30

-

30

15. Drilling φ 3.85 holes through thickness 3 No’s

--“--

DRO milling m/c --“--

Twist drill

--“--

5

3

8

5. Turning φ 15mmthrough 101 length 6. Turning φ 15mmthrough 86 length 7. Turning φ 12mmthrough 57 length 8. Turning φ 10mmthrough 45 length 9. Turning φ 8mmthrough 15 length 10. Threading M8 threads 11. Turning φ 12mmthrough length 12. Grooving as per profile

GOVERNMENT POLYTECHNIC PUNE 33

ELBOW MECHANISM 16. Reaming φ 4 holes thro thickness 3 No’s 17. Chamfer 0.5 x 45 degree B/s of each hole

--“--

--“--

Reamer

--“--

5

5

10

--“--

--“--

Twist drill

--“--

5

12

17

GOVERNMENT POLYTECHNIC PUNE 34

ELBOW MECHANISM

PART NO : OTS - 08 PART NAME :RH_ OUTPUT SHAFT

MATERIAL SPECIFICATION : EN24 RAW MATERIAL SIZE: φ55 x 145 QUANTITY :- 0 4 NO’S. Tools

Sr. No

Description of Operation

Jigs & Fixture

Time in minutes

M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

1. Clamp stock

3 Jaw chuck

Lathe

-

-

10

-

10

2. Facing one sides

--”--

--”--

Facing tool

Vernier

5

2

7

3. Turning outer diameter to φ 48mm through length 4. Center drilling

--“--

--“--

Turning tool

--“--

5

13

18

--“--

--“--

Center drill

--“--

5

2

7

--“--

--“--

Twist drill

--“--

5

3

8

--“--

--“--

Turning tool

--“--

5

3

8

--”--

--”--

Turning tool

--”--

5

12

17

--”--

--”--

Turning tool

--”--

5

12

17

--”--

--”--

Turning tool

--”--

5

10

15

--”--

--”--

Threading tool

--”--

5

12

17

11. Turning φ 12mmthrough length 12. Grooving as per profile

--”--

--”--

Reamer

--”--

5

12

17

--”--

--”--

Parting tool

--”--

5

2

7

13. Facing other side

--“--

--“--

Facing tool

--“--

5

2

7

14. Clam job on m/c vice

3jaw chuck

-

--“--

30

-

30

15. Drilling φ 3.85 holes through thickness 3 No’s

--“--

DRO milling m/c --“--

Twist drill

--“--

5

3

8

5. Turning φ 15mmthrough 101 length 6. Turning φ 15mmthrough 86 length 7. Turning φ 12mmthrough 57 length 8. Turning φ 10mmthrough 45 length 9. Turning φ 8mmthrough 15 length 10. Threading M8 threads

GOVERNMENT POLYTECHNIC PUNE 35

ELBOW MECHANISM 16. Reaming φ 4 holes thro thickness 3 No’s 17. Chamfer 0.5 x 45 degree B/s of each hole

--“--

--“--

Reamer

--“--

5

5

10

--“--

--“--

Twist drill

--“--

5

12

17

GOVERNMENT POLYTECHNIC PUNE 36

ELBOW MECHANISM

PART NO : OTS - 06 PART NAME :RH_ INPUT SHAFT

MATERIAL SPECIFICATION : EN24 RAW MATERIAL SIZE: φ55 x 120 QUANTITY :- 0 4 NO’S. Tools

Sr. No

Description of Operation

Jigs & Fixture

Time in minutes

M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

1. Clamp stock

3 Jaw chuck

Lathe

-

-

10

-

10

2. Facing one sides

--”--

--”--

Facing tool

Vernier

5

2

7

3. Turning outer diameter to φ 48mm through length 4. Center drilling

--“--

--“--

Turning tool

--“--

5

13

18

--“--

--“--

Center drill

--“--

5

2

7

5. Turning φ 15mmthrough 76 length 6. Turning φ 12mmthrough 12length 7. Grooving as per profile

--“--

--“--

Twist drill

--“--

5

3

8

--”--

--”--

Turning tool

--”--

5

12

17

--”--

--”--

Parting tool

--”--

5

2

7

8. Facing other side

--“--

--“--

Facing tool

--“--

5

2

7

9. Clam job on m/c vice

3jaw chuck

-

--“--

30

-

30

10. Drilling φ 3.85 holes through thickness 3 No’s 11. Reaming φ 4 holes thro thickness 3 No’s 12. Chamfer 0.5 x 45 degree B/s of each hole

--“--

DRO milling m/c --“--

Twist drill

--“--

5

3

8

--“--

--“--

Reamer

--“--

5

5

10

--“--

--“--

Twist drill

--“--

5

12

17

GOVERNMENT POLYTECHNIC PUNE 37

ELBOW MECHANISM

PART NO : OTS - 05 PART NAME :LH_ INPUT SHAFT

MATERIAL SPECIFICATION : EN24 RAW MATERIAL SIZE: φ55 x 120 QUANTITY :- 0 4 NO’S. Tools

Sr. No

Description of Operation

Jigs & Fixture

Time in minutes

M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

1. Clamp stock

3 Jaw chuck

Lathe

-

-

10

-

10

2. Facing one sides

--”--

--”--

Facing tool

Vernier

5

2

7

3. Turning outer diameter to φ 48mm through length 4. Center drilling

--“--

--“--

Turning tool

--“--

5

13

18

--“--

--“--

Center drill

--“--

5

2

7

5. Turning φ 15mmthrough 76 length 6. Turning φ 12mmthrough 12length 7. Grooving as per profile

--“--

--“--

Twist drill

--“--

5

3

8

--”--

--”--

Turning tool

--”--

5

12

17

--”--

--”--

Parting tool

--”--

5

2

7

8. Facing other side

--“--

--“--

Facing tool

--“--

5

2

7

9. Clam job on m/c vice

3jaw chuck

-

--“--

30

-

30

10. Drilling φ 3.85 holes through thickness 3 No’s 11. Reaming φ 4 holes thro thickness 3 No’s 12. Chamfer 0.5 x 45 degree B/s of each hole

--“--

DRO milling m/c --“--

Twist drill

--“--

5

3

8

--“--

--“--

Reamer

--“--

5

5

10

--“--

--“--

Twist drill

--“--

5

12

17

GOVERNMENT POLYTECHNIC PUNE 38

ELBOW MECHANISM

PART NO : OTS - 10 PART NAME : LH_BRG_HSG

Sr. No

MATERIAL SPECIFICATION: EN 9 RAWMATERIAL SIZE: 50X20X60 QUANTITY: - 01 NO’S.

Description of Operation

Tools Jigs Fixture

& M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

Milling

-

-

15

-

15

14

19

1.

Clamp stock

2.

Facing All Sides --”-Sq. to total length 40x12x50 mm Clamp stock on 4 jaw chuck lathe

--”--

Facing cutter

Vernier

5

Lathe

-

-

25

Drilling Ø 18.5 --”-through thickness Boring Ø 25 --”-through thickness Counter Boring --”-Ø 32 through 10 thickness

--”--

Twist drill

Vernier

15

10

25

--”--

Boring tool

Vernier

15

10

25

--”--

Boring tool

Vernier

15

10

25

3. 4. 5. 6.

M/C Vice

Time in minutes

25

GOVERNMENT POLYTECHNIC PUNE 39

ELBOW MECHANISM PART NO : OTS - 11 PART NAME : RH_BRG_HSG

Sr. No

MATERIAL SPECIFICATION: EN 9 RAWMATERIAL SIZE: 50X20X60 QUANTITY: - 01 NO’S.

Description of Operation

Tools Jigs Fixture

& M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

Milling

-

-

15

-

15

14

19

1.

Clamp stock

2.

Facing All Sides --”-Sq. to total length 40x12x50 mm Clamp stock on 4 jaw chuck lathe

--”--

Facing cutter

Vernier

5

Lathe

-

-

25

Drilling Ø 18.5 --”-through thickness Boring Ø 25 --”-through thickness Counter Boring --”-Ø 32 through 10 thickness

--”--

Twist drill

Vernier

15

10

25

--”--

Boring tool

Vernier

15

10

25

--”--

Boring tool

Vernier

15

10

25

3. 4. 5. 6.

M/C Vice

Time in minutes

25

GOVERNMENT POLYTECHNIC PUNE 40

ELBOW MECHANISM PART NO : OTS - 9 PART NAME : CENTRAL_BRG_HSG

Sr. No

Description of Operation

MATERIAL SPECIFICATION: EN 9 RAWMATERIAL SIZE: 140X20X50 QUANTITY: - 01 NO’S. Tools

Jigs Fixture

& M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

Milling

-

-

15

-

15

14

19

1.

Clamp stock

2.

Facing All Sides --”-Sq. to total length 135x12x40 mm Clamp stock on 4 jaw chuck lathe

--”--

Facing cutter

Vernier

5

Lathe

-

-

25

Drilling Ø 18.5 through thickness Boring Ø 25 through thickness Counter Boring Ø 32 through 10 thickness Drilling Ø 18.5 through thickness Boring Ø 25 through thickness Counter Boring Ø 32 through 10 thickness

--”--

--”--

Twist drill

Vernier

15

10

25

--”--

--”--

Boring tool

Vernier

15

10

25

--”--

--”--

Boring tool

Vernier

15

10

25

--”--

--”--

Twist drill

Vernier

15

10

25

--”--

--”--

Boring tool

Vernier

15

10

25

--”--

--”--

Boring tool

Vernier

15

10

25

3. 4. 5. 6. 7. 8. 9.

M/C Vice

Time in minutes

25

GOVERNMENT POLYTECHNIC PUNE 41

ELBOW MECHANISM

PART NO : OTS - 17 PART NAME :COVER RING

MATERIAL SPECIFICATION : EN9 RAW MATERIAL SIZE: φ60 x 50 QUANTITY :- 0 4 NO’S. Tools

Sr. No

Description of Operation

Jigs & Fixture

Time in minutes

M/c Tools

Cutting Tools

Measuring Instrument

Setting Time

M/c Time

Total Time

1. Clamp stock

3 Jaw chuck

Lathe

-

-

10

-

10

2. Facing one sides

--”--

--”--

Facing tool

Vernier

5

2

7

3. Turning outer diameter to φ 54mm through length 4. Center drilling

--“--

--“--

Turning tool

--“--

5

13

18

--“--

--“--

Center drill

--“--

5

2

7

--”--

--”--

Twist drill

Vernier

15

10

25

--”--

--”--

Boring tool

Vernier

15

10

25

--”--

--”--

Boring tool

Vernier

15

10

25

--”--

--”--

Boring tool

Vernier

15

10

25

--“--

--“--

Facing tool

--“--

5

2

7

3jaw chuck

DRO milling m/c --“--

-

--“--

30

-

30

Twist drill

--“--

5

3

8

--“--

Reamer

--“--

5

5

10

5. Drilling Ø 18.5 through thickness 6. Boring Ø 41 through thickness 7. Counter Boring Ø 45 through 40 thickness 8. Counter Boring Ø 47 through 8 thickness 9. Threading M48 Threads through 8mm length 10. Facing other side 11. Clam job on m/c vice

12. Drilling φ 3.85 --“-holes through thickness 3 No’s 13. Reaming φ 4 --“-holes thro thickness 3 No’s

GOVERNMENT POLYTECHNIC PUNE 42

ELBOW MECHANISM 14. Chamfer 0.5 x 45 degree B/s of each hole

--“--

--“--

Twist drill

--“--

5

12

GOVERNMENT POLYTECHNIC PUNE 43

17

ELBOW MECHANISM

Chapter No.:-5

TEST & TRIAL ON ELBOW MECHANISM

GOVERNMENT POLYTECHNIC PUNE 44

ELBOW MECHANISM

TEST & TRIAL ON ELBOW MECHANISM AIM: To conduct trial on Orbital Mechanism to determine a) TORQUE Vs SPEED CHARACTERISTICS b) POWER Vs SPEED CHARACTERISTICS In order to conduct trial , an dynobrake pulley cord, weight pan are provided on the output shaft.

INPUT DATA:A) Drive Motor AC230 Volt 0.5 Amp, 100 watt 50 Hz, 200 to 4500 rpm TEFC COMMUTATOR MOTOR B) Diameter (Effective ) of Dynobrake pulley = 25 mm.

PROCEDURE:1) Start motor by turning electronic speed variator knob. 2) Let mechanism run & stabilize at certain speed (say 1300 rpm) 3) Place the pulley cord on dynobrake pulley and add 100 gm weight into , the pan , note down the out put speed for this load by means of tachometer. 4) Add another 100 gm cut & take reading . 5) Tabulate the readings in the observation table 6) Plot Torque Vs speed characteristic Power Vs speed characteristic

GOVERNMENT POLYTECHNIC PUNE 45

ELBOW MECHANISM

Chapter No.:-6

OBSERVATION TABLE

GOVERNMENT POLYTECHNIC PUNE 46

ELBOW MECHANISM

OBSERVATION TABLE SR NO

LOADING

UNLODING

WEIGHT (gm) 1. 100

SPEED rpm 1300

WEIGHT (gm)

2. 150

MEAN SPEED

100

SPEED rpm 1300

1300

1250

150

1240

1245

3. 200

1200

200

1100

1190

4. 250

1100

250

1080

1090

5. 300

1000

300

1040

1020

6. 350

970

350

930

950

7. 500

880

500

890

885

8. 600

850

600

850

850

9. 700

700

700

690

695

10. 800

650

800

640

645

11. 1000

600

1000

610

605

GOVERNMENT POLYTECHNIC PUNE 47

ELBOW MECHANISM SAMPLE CALCULATIONS:- (AT 0.6 kg Load) 1) Average Speed :N=

( N1 + N2 )

( 650 + 650 ) =

2

= 650 rpm 2

2) Output Torque:Tdp = Weight in pan x Radius of Dynobrake Pulley = (0.6 x 9.81) x 12.5 =73.575 N.mm =0.0737575 N.mm

Tdp

3) Input Power:- (Pi/p) Pi/p

= =

2 Π N Ti/p 60 2 x Π x 650 x 0.08 60

Pi/p =5.44 watt

4)OutPut Power:-(Po/p) Po/p =

2 Π NTo/p 60 =

2 x Π x 650 x 0.0737575 60

Po/p = 5.02 watt

4) Efficiency:η = Out put power GOVERNMENT POLYTECHNIC PUNE 48

ELBOW MECHANISM Input power =

5.02 x 100 5.44

η

= 92.28 %

⇒ Efficiency of transmission of orbital mechanism at 90 degree = 92.28%

GOVERNMENT POLYTECHNIC PUNE 49

ELBOW MECHANISM

Chapter No.:- 7

Result Table

GOVERNMENT POLYTECHNIC PUNE 50

ELBOW MECHANISM RESULT TABLE

LOAD (gms)

SPEED (rpm)

TORQUE (N.M)

POWER (watt)

1.

100

1300

0.01226

1.66

2.

150

1245

0.01839

2.39

3.

200

1190

0.0245

3.053

4.

250

1090

0.0306

3.49

5.

300

1020

0.0368

0.93

6.

350

950

0.0429

4.26

7.

500

885

0.0613

5.68

8.

600

850

0.073575

6.54

9.

700

695

0.086

6.25

10. 800

560

0.098

5.75

11. 1000

440

0.1226

5.52

SR NO

GOVERNMENT POLYTECHNIC PUNE 51

ELBOW MECHANISM

Chapter No.:- 8

Cost Analysis

GOVERNMENT POLYTECHNIC PUNE 52

ELBOW MECHANISM BILL OF MATERIALS SR

PART

NO.

CODE

1.

EM-1

2.

DESCRIPTION

QTY

MATERIAL

MOTOR

01

STD

EM -2

PULLEY

01

EN9

3.

EM -3

MAIN SHAFT

01

EN24

4.

EM -4

MAIN SHAFT BRG HSG

01

EN9

5.

EM -5

LH_ IP_SHAFT

01

EN24

6.

EM -6

RH_ IP_SHAFT

01

EN24

7.

EM -7

LH_ OP_SHAFT

01

EN24

8.

EM -8

RH_ OP_SHAFT

01

EN24

9.

EM -9

CENTRAL BRG HSG

01

EN9

10.

EM –10

LH_BRG_HSG

01

EN9

11.

EM –11

RH_BRG_HSG

01

EN9

12.

EM –12

BASE FRAME

01

MS

13.

EM -13

BRG6201ZZ

04

STD

14.

EM -14

WHEELS

03

STD

15.

EM -15

BENT PINS

03

EN9

16.

EM -16

JACK BOLTS

03

STD

17.

EM-17

COVER RING

04

EN9

18.

EM-18

PROPELLER SHAFT

1

EN24

19.

EM-19

GEAR

04

N8

RAW MATERIAL COST GOVERNMENT POLYTECHNIC PUNE 53

ELBOW MECHANISM The total raw material cost as per the individual materials and their corresponding rates per kg is as follows,

Total raw material cost = Rs 4450/-

MACHINING COST OPERATION

RATE

TOTAL TIME

TOTAL

Rs /HR

HRS

LATHE

80

16

1280

MILLING

95

9

855

DRILLING

50

3.6

180

TAPPING

Rs 3 /- per hole

16

48

TOTAL

COST Rs/-

2363

TOTAL MACHINING COST = Rs 2363 /MISCELLANEOUS COSTS OPERATION

COST(Rs)

Sawing

160

Gas cutting

80

Bench Work

40

Total

280

GOVERNMENT POLYTECHNIC PUNE 54

ELBOW MECHANISM

COST OF PURCHASED PARTS SR

DESCRIPTION

QTY

COST

1.

Vee Belt

01

75

2.

Bolts

-

35

3.

Electric Motor

01

1200

4.

Wheels

03

360

5.

Electronic Speed Variater

01

180

6.

Bearings

07

400

NO.

The cost of purchase parts = Rs 2180 /TOTAL COST TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost

+ cost of Purchased Parts +Overheads = Rs 9273/Hence the total cost of machine = Rs 9273/-

GOVERNMENT POLYTECHNIC PUNE 55

ELBOW MECHANISM

Chapter No: 09

Conclusion and Future scope

GOVERNMENT POLYTECHNIC PUNE 56

ELBOW MECHANISM

CONCLUSION AND FUTURE SCOPE Some successful mechanical devices function smoothly however poor fly they Are made while other does this only by virtue of a accurate construction & fitting of their moving parts. This projects which looks very simple & easy to construct was actually Very difficult to conceive & imagine without seeing an actual one in practice. It is an event a fact in the creative mental process nit the forces, which predominate among the schemes of the active tinkers. Motions demands to be studied first &we have done that very thing. We find that while acceptable analysis for existing mechanism can often be Made quite easily we cannot without insight & imagination make effective synthesis of new mechanism hence we are mould to present this our project gear less transmission at 90*(El-bow mechanism) which we have managed to successfully device after long & hard input in conceiving its working principle.

GOVERNMENT POLYTECHNIC PUNE 57

ELBOW MECHANISM

Chapter No.:-10

BIBLIOGRAPHY

GOVERNMENT POLYTECHNIC PUNE 58

ELBOW MECHANISM

BIBLIOGRAPHY

A.G.Erdman& G.N. Sandor -“Mechanism Design ”,

Newell Harton -“Ingenious Mechanism For Designers & Inventors”

PSG - “DESIGN DATA HAND BOOK”(1998)

V.B.BHANDARI

“Design of Machine Elements”, Tata Mc – Graw Hill Publication (1999)

R.S.KHURMI & J.K.GUPTA

-

“A Text Book of Machine Design”. Eurasia Publication (1990)

GOVERNMENT POLYTECHNIC PUNE 59