Gearless Transmission.docx

7/26/2019 Gearless Transmission.docx

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INDEX

S. no Name of the topic Pageno

1 Introduction

2 Working

3 Concept drawing of machine

4 Application

5 Comparision

6 Selection of material

!aw material and and standard material

" #achine design

$ Concept in m%d%p

1& Cost estimation

11 !aw material and and standard material

12 Specification ' manufacturing of parts

13 (ossi)le impro*ements and ad*ances

14 Conclusion


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15 +i)liograph,

INTRODUCTION

-o da,s world re.uires speed on each and e*er, field% /ence repidness and

.uick working is the most important% 0ow a da,s for achie*ing repidness

*arious machines and e.uipments are manufactured ), man% ngineer is

contantl, conformed to the challanges of )ringing ideas and design in to realit,%

0ew machine and technigues are )eing de*eloped continuousl, to manufacture

*arious products at cheaper rates and high .ualit,% -he proect A!SS

-!A0S#ISSI708 )eing compact and porta)le e.uipment which is skilful

and is ha*ing something practise in the transmitting power at right angle with

out an, gears )eing manufactured% #ost of the material is made a*aila)le ),

our college% -he parts can )e easil, made in our college9shop its price is also

less% this proect gi*es us knowledge e:perienceskill and new ideas of the

manufacturing% It is a working proect and ha*ing guarantee of the success% -his

proect is the e.uipment useful to impro*e the .ualit, of the gear )eing

manufactured and can )e made in less time hence we ha*e selected this proect

el9)ow mechanism is an ingenious link mechanism of slider and kinematic

chain principle% -his is also called as gearless transmission mechanism8

this mechanism is *er, useful for transmitting motion at right angles% /owe*er

in certain industrial application gearless transmission at right angle8 can also

work at o)tuse or accurate angle plane can )e compared to worm and worm

gear or )e*el and pinion gear which are in*aria)l, used in the industr, for

numerous application% -he main feature for mechanism comparati*el, high


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efficienc, )etween the input and the output power shafts with regards to the

gear efficiencies%

It has ela)oratel, discussed in detail in the entire )ooks o engineering that the

gear dri*es ha*e *er, low mechanical efficiencies% Since ;actor relating to

under frictional ;orces )etween the mating gear teeth the erratic hunting of the gears the

)ack lash )etween the teeth can not )e o*er come and hence the efficienc, can

not )e more than 55< 7f recent gears of warm )e*el t,pe are )eing manufactured

in pol, prop.leneand epo:, material where the ;rictional ;orces are

comparati*el, eliminated%*en though such gears are used for relati*el, small

applications the efficienc,is not more than 42 the

/untingand )ack lash one a)sent% -herefore it is appreciated that efficienc, as

high as$&9$2< are possi)le in gear less transmission mechanism%

/ere we are going to show two applications of l9)ow mechanism% /ow it

will)ecome work which we are showing ), cutting the wood ), attaching

thewood cutter at the output shaft as well as we are also making it as

compressor%It will suct the air from atmosphere compressor it ' deli*ers it at

high pressure%As we were calculate the result o)tained is we can get the

compressed air at pressure2 )ar%

-he first application of this mechanism was made use of the

Big Ben


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Clockha*ing four dials on the tower of ondon% -his clock was installed

some

-ime )etween 163& to 1635 A?% And still it is functioning in good condition%

WORKING

/ere is a wonderful mechanism that carries force through a $&@)end%-ranslating

rotational motion around an a:is usuall, in*ol*es gears which can .uickl,

)ecome complicated infle:i)le and clums,9looking often ugl,% Soinstead of

using gears this technolog, elegantl, con*erts rotational motionusing a set of

c,lindrical )ars )ent to $&@ in a cle*er simple and smoothprocess that

translates strong rotational force e*en in restricted spaces%

A gearless transmission is pro*ided for transmitting rotational *elocit, from

aninput connected to three )ent links% +oth the input shaft and the housing ha*erotational

a:es% -he rotational a:is of the input shaft is disposed at an angle of $& degree

with respect to the rotational a:is of the housing% As a result rotationof the

input shaft results in a processional motion of the a:is of the )ent link%-he

rotar, and reciprocating motion of )ent link transmit rotation of primemo*er to

$& degree with out an, gear s,stem to an output shaft without gears%-he transmission

includes an input shaft%


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CONCEPT DRAWING OF AC!INE


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WORKING


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-he earless transmission or l9)ow mechanism is a de*ice for transmitting

#otions at an, fi:ed angle )etween the dri*ing and dri*en shaft%

-he s,nthesis of this mechanism would re*eal that it comprises of a num)er of

pins would )e )etween 3 to " the more the pins the smoother the operation%

-hese pins slide inside hollow c,linders thus formatting a sliding pair%

7ur mechanism has 3 such sliding pairs% -hese c,linders are placed in a

/ollow pipe and are fastened at 12& to each other% -his whole assem)l, is

mountedon )rackets wooden ta)le% (ower is supplied ), an electric motor%

-he working of the mechanism is understood ), the diagram% An unused form

of transmission of power on shaft located at an angle%

#otion is transmitted from dri*ing to the dri*en shaft through the roads which

are )ent to conform to the angles )etween the shafts% -hese roads are located at

in the holes e.uall, spaced around a circle and the, are free to slide in ' out as

the shaft re*ol*es% -his t,pe of dri*e is especiall, suita)le where .uite operation

at high speed is essential )ut onl, recommended for high dut,%

-he operation of this transmission will )e apparent ), the action of one

rod%?uring a re*olution% If we assume that dri*ing shaft A8 is re*ol*ing

as indicated ), arrow the dri*en shaft + will rotate counter clockwise% As shaft

A turns through half re*olution C shown in the inner and most effecti*e dri*ing

position slides out of )oth shafts A ' +%

-he first half re*olution and rod C8 then will )e at the top then during

-he remaining half this rod C8 slide in wards until it again reaches to inner


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most position shown in ;ig% in the meanwhile the other roads ha*e of

course passed through the same c,cle of mo*ements all rods are successi*el,

sliding inwards and outwards%

Although this transmission is an old one man, mechanics are skeptical a)out its

operation howe*er it is not onl, practica)le )ut has pro*ed satisfactor, for

*arious applications when the dri*e is for shafts which are permanentl, located

at gi*en angle% Although this illustration shows a right angle transmission this

dri*e can )e applied also to shafts located at intermediate angle )etween & and

$&%In making this transmission it is essential to ha*e the holes for a gi*en rod located

accuratel, in the same holes must )e e.uall, spaced in radial and

circumferential directions )e parallel to each rod should )e )ent to at angle at

which the shaft are to )e located% If the holes drilled in the ends of the shafts

ha*e )lind8 or closed ends there ought to )e a small *ent at the )ottom of each

rod hole for the escape of air compressed ), the pumping action of the rods%

-hese holes are useful for oiling to a*oid )lind holes shafts ma, ha*e enlarged

port or shoulder% -his transmission ma, )e pro*ided centrall, and in line with

the a:is of each shaft and pro*ided with a circular groo*e at each rod or a

cross9pin to permit rotation of the shaft a)out the rodsimpl, acti*e as a

retaining de*ice for shipping and handling purposed%

As mentioned in first chapter that we are showing two applications of

-his mechanism at a time%


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1B As a wood cutting machine -he cutter is attached on the output shaft

2B when motion is transmittedthrough mechanism to output shaft the shaft

will start to rotate at adusted speed%

-he speed is adusted ), means of pulle, i%e%%!(#B% -he cutters

Will also start to rotate along with the shaft the )ecause of cutter is

25&mm%the through slot introduces in the ta)le for free rotation of cutter

edges in ta)le% 0ow the feed gi*en to wooden rods or pl,wood to cut in

desire shape and siDe%-he speed is adusted ), means of pulle,

i%e%%%!(#B% -hecutters will also start to rotate along with the shaft the

)ecause of cutter is 25&mm% the through slot is introduced in the ta)le%

0ow feedgi*en to wooden rods or pl,wood to cut in desired shape and

siDe%

3B As a air compressor or air pump 9E the compressor or and pump also

introduced in our proect when the pins inside the drilled holes

are reciprocates as well as re*ol*es along the a:is of c,linder it gi*es the

compressor effect% Among the three pins when first pin goes at innerdead

center it sucts the air then it start to mo*e at outer dead center ),

re*ol*ing it compresses the air against seal and c,linder head discand

does simultaneousl, ), three pins and we can get continue discharge of

air the .uantit,%

3B#echanical seal is defined as a de*ise which seals ), *irtue of a:ial

contact pressure )etween two relati*el, flat surfaces in a plane right angle to


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the a:is of the shaft%-he seal used in 9+7W m=c compressor is stationar,

t,pe% It is place)etween c,linder and c,linder head%

APP"ICATION


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-he featured product has its widest application as an e:tension for a socket

wrench% /ere the design makes it eas, to reach fasteners in the automoti*e and other

mechanical industries where direct access to )olts and screws is often limited%

/owe*er the possi)le applications for this technolog, e:tend into numerous

fields% Fust think of the possi)ilities for power transmission in push )ikes to,s

and hand9cranked e.uipment or for mo*ement transmission in store and

outdoor signage%

1% ?ri*ing for all kinds four faced tower clocks% -he el)ow mechanism wasfirst use in the ,ear 16"5 for the famous ondon tower clocknamed )ig)en%

2% -he mechanism is in*aria)le used for multiple spindle drilling operation

called the gang drilling

3% Gsed for angular drilling )etween & to $& degree position%

4% u)rication pump for C%0%C% lathe machines%

5% -he mechanism is *er, useful for a reaching a dri*e at a clums,location%

6% Air )lower for electronic and computer machine%

% -he mechanism has found a *er, usefull, use in electronic and computer

technolog, for multiple%

"% -he el)ow mechanism is used for mo*ement of periscope in su)marines

$% the ,ear 16"5 for the famous ondon tower clock%

COPRATION


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COPARISON OF GEARED DRI#E WIT! GEAR"ESS DRI#E

-he gearless dri*e is capa)le of transmitting motion at an, fi:ed angle )etween

& to $&% -his desired effect is also possi)le with help of )e*el gearless differ

to a great e:tent not onl, in their manufacturing method or working principle

)ut also in other aspects etc% the aspects ha*e )een discussed )elowH

$%ANUFACTURING ET!ODS

+e*el gears which are straight teeth or spiral teeth are manufactured on special

purposes machines like earless machines% -hese re.uired large amount of

calculation and e*er, pair or set of gear are made together and there is no

interchangea)ilit,%

-he gearless dri*e has this ad*antage that it can )e machined and manufactured on

con*entional machines an it pro*ide complete freedom of interchangea)ilit,%

II% WORKING PRINCIP"E&'

A gear comprises of a frustum of a cone with teeth out on its peripher,%-he dri*ing gear

mounted on the input shaft meshes with the dri*en gear and thus pro*ides motion at right

angle to the input shaft %-he working of the gearless dri*e has )een e:plained in the

earlier chapter and it o)*iousl, *er, different from the a)o*e9J

III% CAUSE OF FAI"URE&'

Starting with the principle that failure id the result of the stress I%e%condition more

se*ere then the material can with stand% -he *arious t,pe of failures such as pitting

corrosion erosion fatigue etc% Cause the wearing of the gear tooth resulting in


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the tooth leads to the replacement of the entire gear set which is *er, e:pensi*e%

-he effect of pitting erosion corrosion etc% will )e present in the gearless dri*e

also )ut the effect of these will )e not )e as se*ere as inthe case of geareddri*e

failure will take place in the pi s ton e%g%%%ither )ending or crack% 7f the pins

)ut the main ad*antage is thatonl, particular pin will ha*e to )e replaced

instead

of case of failure%

#I% ATERIA"&'

-he material chosen for an, component must

aB )e easil, a*aila)le

)B )e capa)le of )eing processed in the desired eaminations and

cB ha*e the necessar, ph,sical properties% -he gears generall, fail due to

)ending fatigue and impact and the gears are also responsi)le for

the failure of the components in the gears ha*e to *er, carefull,

determined since it ma, lead to pitting%

#% "U(RICATION AND COO"ING&'

A few open gears dri*es are lu)ricated ), grease )ut gear units are usuall, totall,

enclosed and oil lu)ricated% -he arrangement for lu)rication is simple and eas,

since it re.uires onl, a leak proof housingin which the gears are placed and oil is

filled% -his lu)ricating also acts as cooling medium% -he heat generated and it then spreads

to other areas% In the gearless dri*e lu)rication and cooling pla,s a*er, maor


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role%

-he efficienc, of the mechanism is affected ),lu)rication% Although the s,stem

of lu)rication and cooling comple: as discussed in the ne:t chapter )ut gi*es

good result% ?ue to sliding contract )etween pins and c,linders heat generated

is more and thus effecti*e cooling is a must%

#I% TOR)UE TRANSITTUNG CAPACIT*&'

-he gear dri*e is capa)le of transmitting *er, high tor.ue ascompared to the gearless dri*e

which is ment onl, for low tor.ue applications%

#II% "IFE AND EFFICIENC*&'

?esigned life represents the total period of operation regardless of an,

*ariations of tor.ue or speed which ma, occur during that the time industrial

-he geared dri*e is capa)le of gi*ing an efficienc, of a)out 4&


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1B-ool life

2B(roducti*el,

3Bnerg, sa*ing%

LB -he different speed at eight angle & to $&B is possi)le which is not

asil, possi)le in gear dri*e

LIB fficienc, can )e increased ), increasing no of pins ), precise

machiningselecting suita)le material and proper lu)rication%


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SE"ECTION OF ATERIA"

-he proper selection of material for the different part of a machine is the main

o)ecti*e in the fa)rication of machine% ;or a design engineer it is must that he )e

familiar with the effect which the manufacturing process and heat treatment

ha*e on the properties of materials% -he Choice of material for engineering

purposes depends upon the following factorsH

1%A*aila)ilit, of the materials%

2% Suita)ilit, of materials for the working condition in ser*ice%

3%-he cost of materials%

4%(h,sical and chemical properties of material%

5%#echanical properties of material%

-he mechanical properties of the metals are those which are associated with the

a)ilit, of the material to resist mechanical forces and load% We shall now

discuss these properties as followsH

1%Strength H It is the a)ilit, of a material to resist the e:ternall, applied forces

2%StressH Without )reaking or ,ielding% -he internal resistance offered ), apart

to an e:ternall, applied force is called stress%

3%StiffnessH It is the a)ilit, of material to resist deformation under stresses%-he

modules of elasticit, of the measure of stiffness%

4%lasticit,H It is the propert, of a material to regain its original shape

after deformation when the e:ternal forces are remo*ed% -his propert,

is desira)le for material used in tools and machines% It ma, )e noted that steel is


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more elastic than ru))er%

5%(lasticit,H It is the propert, of a material which retain the deformation

produced under load permanentl,% -his propert, of material is necessar, for

forging in stamping images on coins and in ornamental work%

6%?uctilit,H It is the propert, of a material ena)ling it to )e drawn intowire with

the application of a tensile force% A ductile material must )e )oth strong and

plastic% -he ductilit, is usuall, measured ), the termspercentage elongation

and percent reduction in area% -he ductile materials commonl, used in

engineering practice are mild steel copperaluminum nickel Dinc tin and lead%

%+rittlenessH It is the propert, of material opposite to ductile% It is the propert,

of )reaking of a material with little permanent distortion% +rittle materials when

su)ected to tensile loads snap off without gi*ing an,sensi)le elongation% Cast

iron is a )rittle material%

"%#allea)ilit,H It is a special case of ductilit, which permits material to

+e rolled or hammered into thin sheets a mallea)le material should )e plastic

)ut it is not essential to )e so strong% -he mallea)le materials commonl, used

in engineering practice are lead soft steel wrought ironcopper and aluminum%

-oughnessH It is the propert, of a material to resist the fracture due to high

impact loads like hammer )lows% -he toughness of the material decreaseswhen it

is heated% It is measured ), the amount of a)sor)ed after )eing

$%stressed up to the point of fracture% -his propert, is desira)le in parts su)ected


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to shock an impact loads%

1&%!esilienceH It is the propert, of a material to a)sor) energ, and to resist rock

and impact loads% It is measured ), amount of energ, a)sor)ed per unit *olume

with in elastic limit% -his propert, is essential for spring material%

11% CreepH When a part is su)ected to a constant stress at high temperature

for long period of time it will undergo a slow and permanent deformation

called creep% -his propert, is considered in designing internal com)ustion

engines )oilers and tur)ines%

12%/ardnessH It is a *er, important propert, of the metals and has a wide*erit, of

meanings%It em)races man, different properties such as resistance to wear

scratching deformation and mach ina)ilit, etc% It also means the a)ilit, of the

metal to cut another metal% -he hardness is usuall, e:pressedin num)ers which

are dependent on the method of making the test% -he hardness of a metal ma, )e

determined ), the following test

%aB+rinell hardness test

)B!ockwell hardness test

cBKickers hardness also called diamond p,ramidB test and

dB Share scaleroscope%

-he science of the metal is a specialiDed and although it o*er flows in to

!eal ms of knowledge it tends to shut awa, from the general reader% -he

knowledge of materials and their properties is of great significance for a design

engineer% -he machine elements should )e made of such a material which has


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properties suita)le for the conditions of operations% In addition to this a design

engineer must )e familiar with the manufacturing processes and the heat

treatment sha*e on the properties of the materials% In designing the *arious part

of the machine it is necessar, to know how the material will function in ser*ice%

;or this certain characteristics or mechanical properties mostl, used in

mechanical engineering practice are commonl, determined from standard

tensile tests% In engineering practice the machine parts are su)ected to *arious

forces which ma, )e due to either one or more of the following%

1%nerg, transmitted

2%Weight of machine

3%;rictional resistance

4%Inertia of reciprocating parts

5%Change of temperature

6%ack of )alance of mo*ing parts

-he selection of the materials depends upon the *arious t,pes of stresses that

are set up during operation% -he material selected should with stand it%

Another criteria for selection of metal depend upon the t,pe of load )ecause a

#achine part resist load more easil, than a li*e load and li*e load more easil,

than a shock load%

Selection of the material depends upon factor of safet, which in turn

?epends upon the following factors%


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1%!elia)ilities of properties

2%!elia)ilit, of applied load

3%-he certaint, as to e:act mode of failure

4%-he e:tent of simplif,ing assumptions

5%-he e:tent of localiDed

6%-he e:tent of initial stresses set up during manufacturing

%-he e:tent loss of life if failure occurs

"%-he e:tent of loss of propert, if failure occurs

#aterials selected in m=c

+ase plate motor support slee*e and shaft

#aterial used

#ild steel

!easonsH

1%#ild steel is readil, a*aila)le in market

2%It is economical to use

3%It is a*aila)le in standard siDes

4%It has good mechanical properties i%e% it is easil, machina)le

5%It has moderate factor of safet, )ecause factor of safet, results in

unnecessar, wastage of material and hea*, selection% ow factor of safet,

results in unnecessar, risk of failure

6%It has high tensile strength


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%ow co9efficient of thermal e:pansion

(roperties of #ild SteelH

#%S% has a car)on content from & % 15 < to &%3&


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RAW ATERIA" AND STANDARD ATERIA"

SR NO PART NAE AT )T* DECREPTION1 ;!A# #s 1 C section 5: 4&: 4 mm

2 #7-! S-? 1 &%25 hp 144& rpm

3

S/A;-

#s 2 ?ia 2&mm : 35&mm

4

/7GSI0

#s 2 ?ia $5 mm : 62 mm

5

+0- I0M

#s 3 ?ia 1& mm : 24& mm

6 (GN CI 2 ?ia 45 ' 25& mm

(?S-A

+A!I0

CI 4 (2&4

" +- eather 1 a956

$

A0

#S 1 35 : 35 : 5 mm

1&

0G- +7-

WAS/!

#S 1& #1&

11 W?I0 !7? 9

12 C77G! 9


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AC!INE DESIGN

-he su)ect of #AC/I0 ?SI0 deals with the art of designing machine of

structure% A machine is a com)ination of resistance )odies with successfull,

constrained relati*e motions which is used for transforming other forms of

energ, into mechanical energ, or transmitting and modif,ing a*aila)le design is

to create new and )etter machines or structures and impro*ing the e:isting ones

such that it will con*ert and control motions either with or without transmitting

power% It is the practical application of machiner, to the design and construction

of machine and structure% In order to design simple component satisfactoril,

a sound knowledge of appliedscience is essential% In addition strength and

properties of materials includingsome metrological are of prime importance%

knowledge of theor, of machine and other )ranch of applied mechanics is also

re.uired in order to know the *elocit,% Acceleration and inertia force of the

*arious links in motionmechanics of machiner, in*ol*e the design%


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CONCEPT IN .D.P.

Consideration in #achine ?esign When a machine is to )e designed the

following points to )e consideredH 9

iB-,pes of load and stresses caused ), the load%

iiB#otion of the parts and kinematics of machine% -his deals with the

iiiB t,pe of motion i%e% reciprocating % !otar, and oscillator,%

i*B Selection of material ' factors like strength dura)ilit, weightcorrosion

resistant weld a)ilit, machine a)ilit, are considered%

*B ;orm and siDe of the components%

*iB ;rictional resistances and ease of lu)rication%

*iiB Con*ience and economical in operation%

*iiiB use of standard parts%

i:B ;acilities a*aila)le for manufacturing%

:B Cost of making the machine%

:iB 0um)er of machine or product are manufactured


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GENERA" PROCEDURE IN AC!INE DESIGN

-he general steps to )e followed in designing the machine are asfollowed%

iB(reparation of a statement of the pro)lem indicating the

iiB purpose of the machine%

iiiB Selection of groups of mechanism for the desire motion%

i*B Calculation of the force and energ, on each machine mem)er%

*B Selection of material%

*iB ?etermining the siDe of component drawing and sending for manufacture%

*iiB (reparation of component drawing and sending for manufacture%

*iiiB #anufacturing and assem)ling the machine%

-esting of the machine and for functioning

(ower of motor O P /%( O 46 : %25 O 1"6%5 09 m =s

!pm of motor O 144& rpm

(ower of motor O ( O 1"6%5 watt%

( O 2 Q0 -( =6&

Where 0 O !pm of motor O 144&

- O -or.ue transmitted

1"6%5 O 2QR14&R-=6&


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- O 1%23 09m

- O 123" 09mm

DESIGNING OF S!AFT

(ENDINGH

-he material forces that are de*eloped on an, cross section of the shaft gi*e rise

to stresses at e*er, point% -he internal or resisting moment gi*es rise to so called )ending

stresses%

TORSION&

When the shaft is twisted ), the couple such that the a:is of the shaft and the

a:is of the couple coincides the shaft is su)ected to pure torsion and thestresses at an,

point of cross section is torsion or shear stresses%

CO(INED (ENDING AND TORSION&

In practice the shaft in general are su)ected to com)ination of the a)o*e

-wo t,pes of stresses% -he )ending stresses ma, )e due to following

1%Weight of )elt

2%(ull of )elts

3%ccentric #ounting

4% #isalignment -he torsional mo*ement on the other hand ma, )e due to

direct

or indirect twisting% -hus an, cross9section of the shaft is su)ected

simultaneousl, of )oth )ending stresses and torsional stresses%


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;ollowing stresses are normall, adopted in shaft design

#a: tensile stress O 6& 0=mm2

#a:m shear stress O 4& 0=mm2

Shaft design on )asic of stud,

Considering 25 < o*erload

-ma:O 123" : 1%25O 1%525 : 1& 309mm

-he shaft is su)ect to pure torsional stress

We know -O 3% 14=16 : fs : d3

1525& O 3% 14= 16 : &: d3

? O1&%2&mm

-aking factor of safet, O 2

? O 1& : 2 O 2&mm

Same tor.ue is transmitted to )ent link shaft

So tor.ue on each shaft O - =3 O 1525& =3 O 5&"3 0 mm

-O 3% 14=16 : fs : d3

5&"3 O 3% 14= 16 : &: d3

? O %1 mm

-aking factor of safet, O1%4

? O : 1 %4 O $%" O1&mm

DESIGN OF C'SECTION

#aterialH 9 #%S%


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-he *ertical column channel is su)ected to )ending stress

Stress gi*en ), OE #=I O f ) = ,

In a)o*e e.uation first we will find the moment of inertia a)out : and ,A:is

and take the minimum moment of inertia considering the channel of

ISC 5 : 4& siDe%

We know the channel is su)ect to a:ial compressi*e loadIn

column section the ma:imum )ending moment occurs at channel of section

# O !a : =2

# O 5& : 15&&=2

# O 5625&& 09mm

We know

; ) O #=

O t l : ) T )2=6BB

O 5 4&: 65 T 652=6BB

O 33&4 mm3

0ow check )ending stress induced in CSection

; ) induced O #=

; ) induced O 5625&& =33&4 O 1&%25 0 = mm2

As induced stress *alue is less than allowa)le stress *alue design is safe%

; ) O (ermiss)le )ending stress O 32& 0 = mmU

; ) induced V f ) allowa)le

/ence our design is safe%


29/48

DESIGN OF WE"DED +OINT OF C!ANNE"H

-he welded oint is su)ected to pure )ending moment % so it should )e design

for )ending stress% We know minimum area of weld or throat area

A O &%& : s : l

Where s O siDe of weld

l O length of weld

A O &%& : 5 : 5 T 4& T 35 T 5" T35 B

A O &%& : 5 : 243

A O "5$ mm2

+ending strength of parallel fillet weld ( O A : f )

; ) O "& 0 = mm2

As load applied at the end of le*er is 25& 0 % So moment generated at the

welded oint is

# O( : O 25&: 45&O 1125&& 0 mm

we know f ) O # =

+/3 9 )h3

O 99999999999999999999999999999999

6/

4&R53 935 : 5"3


30/48

O 9999999999999999999999999999999999

6 : 5

O 2&$"24

Calculating induce stress de*eloped in welded oint

; ) induced O 1125&& = 2&$"24O &%536 0 =mm2

As induce stress is less then allowa)le stress the design is safe%

DESIGN FOR WE"DED +OINTS&

?iameter of shaft O ? O 2& mm%

SiDe of weld O s O 4 mm

; s O load=shear area

O6&&=Q %? : t

O6&&=Q : 2& : t

now t O s%cos 45 O &%& s

f s O $%55=&%&R4 0=mm2

f s O 3%3 0=mm2

As induced stress *alue is less than allowa)le *alue which is 56 0=mm2

So design is safe%


31/48

COST ESTIATION

Cost estimation ma, )e defined as the process of forecasting the e:penses that

must )e incurred to manufacture a product% -hese e:penses take into a

consideration all e:penditure in*ol*ed in a design andmanufacturing with all

related ser*ices facilities such as pattern making toolmaking as well as a

portion of the general administrati*e and selling costs%

PURPOSE OFCOST ESTIATINGH

1%-o determine the selling price of a product for a .uotation or contract so as to

ensure a reasona)le profit to the compan,%

2%Check the .uotation supplied ), *endors%

3%?etermine the most economical process or material to manufacture the

product%

4%-o determine standards of production performance that ma, )e used to control

the cost%

+ASICAN

T!E (UDGET ESTIATION IS OF TWO T*RES&

1%material cost

2%#achining cost


32/48

ATERIA"COST ESTIATIONH

#aterial cost estimation gi*es the total amount re.uired to collect the raw material which

has to )e processed or fa)ricated to desired siDe and functioning of the

components%

-hese materials are di*ided into two categories%

1%#aterial for fa)ricationH

In this the material in o)tained in raw condition and is manufactured

or processed to finished siDe for proper functioning of the component%

2%Standard purchased partsH

-his includes the parts which was readil, a*aila)le in the market like

Allen screws etc% A list is forecast ), the estimation stating the .ualit, siDe and

standard parts the weight of raw material and cost per kg% ;or the fa)ricated

parts%

AC!INING COST ESTIATION&

-his cost estimation is an attempt to forecast the total e:penses that ma, include to

manufacture apart from material cost% Cost estimation of manufactured parts

can

)e considered as udgment on and after careful consideration which includes

la)our material and factor, ser*ices re.uired to produce the re.uired part%


33/48

PROCEDURE FOR CA"CU"ATION OF ATERIA" COST&

-he general procedure for calculation of material cost estimation is

1%After designing a proect a )ill of material is prepared which is di*ided into

two categories%

a%;a)ricated components

)%Standard purchased components

2%-he rates of all standard items are taken and added up%

3% Cost of raw material purchased taken and added up%

"A(OUR COST&

It is the cost of remuneration wages salaries commission )onus etc%B of

-he emplo,ees of a concern or enterprise%

a)our cost is classifies asH

1B?irect la)our cost

2 BIndirect la)our cost

DIRECT "A(OUR COSTH

-he direct la)our cost is the cost of la)our that can )e identified directl, with

the manufacture of the product and allocated to cost centers or cost units% -he

direct la)our is one who counters the direct material into sale a)le product> the

wages etc% of such emplo,ees constitute direct la)our cost%?irect la)our cost


34/48

ma, )e apportioned to the unit cost of o) or either on the)asis of time spend ), a

worker on the o) or as a price for some ph,sical measurement of product%

INDIRECT "A(OUR COSTH

It is that la)our cost which can not )e allocated )ut which can )e apportioned

to

or a)sor)ed ), cost centers or cost units% -his is the cost of la)our that does not

alters the construction confirmation composition or condition of direct material

)ut is necessar, for the progressi*e mo*ement and handling of product to the

point of dispatch e%g% maintenance men helpers machine setterssuper*isors

and foremen etc%

-he total la)our cost is calculated on the )asis of wages paid to the la)our for"

hours per da,%

Cost estimation is done as under

Cost of proect O AB material cost T +B #achining cost T CB la) our cost

AB #aterial cost is calculated as under H9

1B!aw material cost

iiB ;inished product cost

RAW ATERIA" COST&

It includes the material in the form of the #aterial supplied ), the

XSteel authorit, of India limited and YIndian aluminum co%Z as the round

)arsangles s.uare rods plates along with the strip material form% We ha*e


35/48

to search for the suita)le a*aila)le material as per the re.uirement of

designed safe *alues% We ha*e searched the material as followsH9

SPECIFICATION , ANUFACTURING OF PARTS

ANUFACTURING PROCESS &

-he following are the *arious manufacturing process used in mechanical

engineering%

$% PRIAR* S!APING PROCESS&

-he process used for the preliminar, shaping of the machine component

is known as primar, shaping process%

-% AC!INE PROCESS &

-he process used for gi*ing final shape to the machine componentaccording to

planned dimensions is known as machining process% -he common operation

drilling )oring etc%

% SURFACE FINIS!ING PROCESS&

-he process used to pro*ide a good shape surface finish for the

#achine components are known as surface finishing processes% -he common

operation used for the process are polishing )uffing lapping etc%

/% +OINING PROCESS &

-he process used for oining machine components are known as oining

process%


36/48

-he common operation used for this process are soldering )raDingwelding etc%

0% PROCESS AFFECTING C!ANGE IN PROPERTIES&

-hese are intended to import specific properties to material e%g% heat treatment

hot working cold rolling etc%

WE"DED +OINTS &

[ DEFINITIONH

A welded oint is a permanent oint which is o)tained ), the fusion of the edges

of the two parts to )e oined together with or without the application of

pressure and a filler material%

Welding is intensi*el, used in fa)rication as an alternati*e method for casting

or forging and as a replacement for )olted and re*erted oints% It is also used as

a

repair medium%

ADNANTAGES&

1B -he welded structures are usuall, lighter than ri*eted structures%

2B-he welded oints pro*ide ma:imum efficienc, which to impossi)le

inner*ated oints

3B Alteration and addition can )e easil, made%

4B As the welded structure is smooth in appearance it is good looking%


37/48

5B In welded structures tension mem)ers are not weakened%

6B In a welded oint has high strength often more than parent metal%

DISAD#ANTAGES&

1B Since there is une*en heating and cooling during fa)rication therefore the

mem)ers ma, get distorted as additional stresses ma, de*elop%

2B It re.uires a highl, skilled la)our and super*ision%

3B0o pro*ision for e:pansion and contraction in the frame therefore there is

possi)ilit, of cracks%

4B -he inspection of welding work is difficult than ri*eting work%

# ' (E"T AND ROPE DRI#ERS &

K 9 )elt is mostl, used in factories and workshops where a great amount of

power is to )e transmitted from one pulle, to another then the two pulle, sare

*er, near to each other%

-he K 9 )elt are made of fa)ric and cords moulded in ru))er and co*ered in fa)ric and

ru))er% -he power is transmitted ), the wedging action )etween the )elt and the *

groo*e in the pulle, as shea*e%

AD#ANTAGES&

1B -he dri*e is positi*e%

2BSince the * 9 )elts are made endless and there is no oint ca)le therefore


38/48

the dri*e is smooth%

3B It pro*ides larger life 3 to 5 ,ears%

4B It can )e easil, installed and remo*ed%

5B -he operation of the )elt and pulle, is .uiet%

6B -he )elt ha*e the a)ilit, to cushion the shack when the machines are started%

B -he wedging action gi*es high *alue of limiting friction therefore power transmitted ),

* 9 )elts is more than flat )elts for the same coefficient of friction are of

contact and allowa)le tension%

DISAD#ANTAGES&

1B-he * 9 )elt dri*e connect )e used with large centre distances )ecause

of larger weight for unit length%

2B-he * 9 )elt are not so dura)le as flat%

3B-he construction of pulle,s for * 9 )elts is more complicated than pulle,s

of flat )elt%

4BSince the * 9 )elts are su)ected to certain amount of creep therefore not

suita)le for constant speed applications%

5B-he )elt life is greatl, influenced with temperature change improper )elt

tension and mismatching of )elt lengths%

COPONENT& FRAE C!ANNE"

ATERIA"&' .S. C!ANNE"

ATERIA" SPECIFICATION&' I.S.".C./1X.20X0


39/48

S!

07

?ISC!I(-I70

7;7(!A-I70

#AC/I0

GS?

CG--I0 #ASG!#0

-

-I#

1 Cutting the

channel in to

length of 1&&&

mm long

as cutting

machine

as cutter Steel rule 15 min%

2 Cutting the

channel in to

length of 4"&mm long

as cutting

machine

as cutter Steel rule 15 min%

3 ;illing

operation can

)e performed

on cutting side

and )ring it in

perpendicular

c%s%

+ench *ice ;ile -r, s.uare 15 min%

4 Weld the

channels to the

re.uired siDe as

per the

drawing

lectric arc

welding

machine

%%%%%%%%%%%%%%%%% -r, s.uare 2& min

5 ?rilling the

frame at

re.uired points

as per the

!adial drill

machine

-wist drill Kernier calliper 1& min


40/48

drawing

Name of pa3t& pin

ate3ia4 & 53ight 6tee4

)7antit8&

Sr% no% ?etail

operation

m=c used -ool used accs #ea%inst

1 #arking on

shaft

9 9 9 Scale

2 Cutting as per

dwg

(ower

hack saw

/ock saw

)lade

Fig '

fi:tures

Scale

3 ;acing )oth

side of shaft

athe

machine

Single

point

cuttingtool

chuck Kernier

calliper

4 -urning as per

dwg siDe

9 9 9 9

5 +ending as

cutting

!ight

angle

Kice 9


41/48

6 ;illing on )oth

end

;late file Kice 9

Name of pa3t& ho76ing

ate3ia4 & 53ight 6tee4

)7antit8& -

Sr% no% ?etail

operation

m=c used -ool used accs #ea%inst

1 #arking on

shaft

9 9 9 Scale

2 Cutting as per

dwg

(ower

hack saw

/ock saw

)lade

Fig '

fi:tures

Scale

3 ;acing )oth

side of shaft

athe

machine

Single

point

cutting

tool

chuck Kernier

caliper

4 -urning as per

dwg siDe

9 9 9 9

5 ?rilling 3 hole ?rilling

machine

?rill Kernier

caliper

6 ;illing on )oth ;late file Kice 9


42/48

end

Name of pa3t& p7448

ate3ia4 & C.I

)7antit8& -

S!

07

?ISC!I(-I7

0 7;

7(!A-I70

#AC/I0

GS?

CG--I0 #ASG!#0

-

-I#

1 -ake standardpull, as per

design

%%%%%%%%%%%%% %%%%%%%%%%%%%%%% %%%%%%%%%%%%%%%%%%%% %%%%%%%%%%%%

2 ;ace )oth side

of hu) portion

athe m=c Single

point

cutting

tool

Kernier calliper 15 min%

3 /old it in

three ack

chuck ' )ore

inner dia as per

shaft siDe

athe m=c Single

point

cutting

tool

Kernier calliper 2& min%


43/48

4 ?rilling the

hu) at re.uired

point as per the

drawing

!adial drill

m=c

-wist drill Kernier calliper 1& min

5 -ap the hu) at

drill area

/and tap

set

tap Kernier calliper 1& min

POSSI("E IPRO#EENTS

AND

AD#ANCES

-he proect designed and manufactured ), us although is onl, model and has not

undergone an, e:tensi*e research or stud, )ut we are .uite confident that it is

possi)le to impro*e itZs efficienc, to a considera)le e:tent ), impro*ing the

manufacturing techni.ues and also ), corporati*e certain modifications%

-his de*ice can also )e used for *arious other applications )esides ust

transmitting motion at desired angle those applications ha*e discussed

indetailing

the followingH 9

ET!OD OF IPRO#ING EFFICIENC*& '


44/48

#anufacturing of impro*ing efficienc,H 9

-he main motion is transmitted with the help of a sliding pair which formed )etween pin '

the c,linder% -hese pins ha*e to )e lapped and cleaned and itshould )e capa)le of

pro*iding complete interchangea)ilit, similarl, with the c,linder the, too ha*e to

)e hone or lapped so a to pro*ide smooth surfacefinish% -his will result in less frictional loss

and loss heat generation%

"I(RICATION AND COO"ING ET!ODS& '

u)rication and cooling are a must in sliding mem)ers% 7ne of the simple

techni.ues applied for lu)rication can )e to drill oil holes in the c,linder )od,

for fill than up with oil% +ut this techni.ue will not )e *er, effecti*e since the

weight and use of c,linders will increase%

ODIFICATION& '

7ne of the methods ), which efficienc, or performance can )e enhanced is ),

increasing the num)er of pins% ;rom the working of the mechanism we know that the pin

at the inner most position is the drawing pin the pins the mechanism% -hus if the no%

re.uired for the ne:t pin to attain the inner most position is considera)le reduced and

thus the performance of the mechanism 'its life increases%

POSSI("E AD#ANCE&

We can also use this transmission s,stem as

1%As lu)ricating pump while transmitting power%

2%Steam engine eliminating the crank of shaft ' complicated *al*e s,stemB%


45/48

"U(RICATING PUP &

-he small change which ha*e to incorporate for this purpose is to place

stationar, disc at the rear and it so fits with the c,linder that it a*oids leak ages%

WORKING&

-he slot position and length is so that adusted that when pin is at inner most position

c,linder meshes with the suction port ' suction of oil is started the slotre mains

open till pin gi*en ma:imum outward stroke after that c,linder end isclosed ),

the dics% 0ow the pin starts mo*ing inwards and thus compression stroke

commences% -he deli*er, slot location is so adusted that after the completion

of "& to "5< of compression stroke the c,linder meshes with the deli*er,

stroke ' thus the compressed fluid is discharged at high pressure% -he deli*er,

slot length was such adusted that remains in mesh with c,linder for 15to 2&

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Gearless Transmission.docx