Professional Documents
Culture Documents
Department of Mechanical Engineering Bharath University Chennai-600073 October 2010 Bonafide Certificate
Department of Mechanical Engineering Bharath University Chennai-600073 October 2010 Bonafide Certificate
Certified that this project report SIX BAR SLIDER CRANK POWER
HAMMER MECHANISM is the bonafide work of YEMMINA
MADHUSUDHAN who carried out the project work under my
supervision.
GUIDE
Mechanical Department
PROFESSOR
BHARATH UNIVERSITY
Mechanical Department
BHARATH UNIVERSITY
173, Agaram road, Selaiyur, Chennai 73
AIM:
To design and fabricate a simple mechanical operated power hammer by
applying the principle of kinematic arrangement and machine design concepts.
1.
1.1
INTRODUCTION TO MECHANISMS
In the design or analysis of a mechanism, one of the most important concern is the
number of degrees of freedom (also called movability) of the mechanism. It is defined
as the number of input parameters (usually pair variables) which must be
independently controlled in order to bring the mechanism into a useful engineering
purpose.
Fig 1.2
fig 1.3
one of the links is to be fixed, therefore the number of movable links will be ( -1)
and thus the total number of degrees of freedom will be 3(n-1) before they are
connected to any other link. In general, a mechanism with number of links
connected by j number of binary joints or lower pairs (i.e. single degree of freedom
pairs) and h number of higher pairs (i.e. two degree of freedom pairs), then the
number of degrees of freedom of a mechanism is given by
n = 3( -1)-2j-h
This equation is called Kutzbach criterion for the movability of a mechanism
having plane motion.
If there are no two degree of freedom pairs (i.e. higher pairs), then h= 0,
substituting h= 0 in equation 1, we have
n=3( -1)-2j
1.5
cycle chain, as shown in below fig. It consists of four links p, q, l and s, each of them
forms a turning pair. The four links may be of different lengths. According to
Grasshofs law for a four bar mechanism, the sum of the shortest and longest link
lengths should not be greater than the sum of the remaining two link lengths if there is
to be continuous relative motion between the two links.
According to Grasshofs law for a four bar mechanism, the sum of the shortest
and longest link lengths should not be greater than the sum of the remaining two link
lengths if there is to be continuous relative motion between the two links.
A very important consideration in designing a mechanism is to ensure that the
input crank makes a complete revolution relative to the other links. The mechanism in
which no link makes a complete revolution will not be useful. In a four bar chain, one
of the links, in particular the shortest link, will make a complete revolution relative to
the other three links, if it satisfies the Grasshofs law. Such a link is known as crank
or driver.
1.6
consists of one sliding pair and three turning pair. It is, usually, found in reciprocating
steam engine mechanism. This type of mechanism converts rotary motion into
reciprocating motion and vice versa.
In single slider crank chain, as shown in below fig the links 1 and 2, links 2
and 3, and links 3 and 4 form three turning pairs while the links 4 and 1 form a sliding
pair.
The link 1 corresponds to the frame of the engine, which is fixed. The link 2
corresponds to the crank; link 3 corresponds to the connecting rod and link 4
corresponds to cross- head. As the crank rotates the cross-head reciprocates in the
guides and thus the piston reciprocates in the cylinder.
2.
Until now we have confined ourselves to study of hand tools used in smithy
work. They certainly perform very well so far as the hand- forging is concerned, but
their use for satisfactory production is limited to small forging only. It would not be
difficult to understand that the intensity of blows, however great one may try to
achieve through hand hammering, will not be sufficient enough to effect the proper
plastic flow in a medium sized or heavy forging. For this, a power hammer is usually
employed. The capacity of these hammers is given by the total weight of their falling
parts i.e., tup or ram and die. A 200 kg hammer will be one of which the falling parts
weigh 200 kg. The heavier these parts and greater the height from which they fall.
The higher will be intensity of blow the hammer will provide. Power hammers in
common use are of different types e.g. spring power hammers, pneumatic power
hammers, Steam hammers and Drop or Forge hammers and six bar slider crank power
hammers. These hammers are named partly after their construction, partly according
to their way of operation. Apart from these, a large number of forging presses and
machines are used in forging work. In the following articles these hammers and
machines will be discussed in detail.
2.1
2.1.1
Helve hammer
Helve hammers are well adapted for general engineering work where the size
Trip Hammer
Trip hammers have a vertically reciprocating ram that is actuated by toggle
connection driven by a rotating shaft at the top of the hammer. Trip hammers are also
built in sizes from 5 to 200 kg. The stroke range of both helve and trip hammers
ranges from about 400 per minute for small sizes to about 175 for large size.
2.1.3
Lever-Spring Hammer
They are mechanical driven hammers with a practically constant lift and an
2.1.4
Pneumatic hammer
The hammer has two cylinders compressor cylinder and ram cylinder. Piston
of the compressor cylinder compresses air, and delivers it to the ram cylinder where it
actuates the piston which is integral with ram delivering the blows to the work. The
reciprocation of the compression piston is obtained from a crank drive which is
powered from a motor through a reducing gear. The air distribution device between
the two cylinders consists of rotary valves with ports through which air passes into
the ram cylinder, below and above the piston, alternately. This drives the ram up and
down respectively.
3.
3.1
Power hammers
Unfortunately, using presently available power hammers and formers can
Mechanism
In recent research the four bar linkage mechanism is used for the humanoid
robots for the free movement of their toe. Using this mechanism the major part of the
force acts on the non-movable portion of this link rather then on the toe tip. Because
of this it is possible to decrease the constraint on the joint. At the same time the
following multiple roles of the toe are expected. One it to generate a large kicking
force at the toe pad and another is to maintain multiple contact with the floor by the
toe joint control.
4.
10
4.1
Construction
As shown in above diagram it consists of 5 links, and one fixed link. The five
links are crank (link 1), link 3. Connecting rod (link 4), Crank (link 5) and Ram die
(link 2).Column can be considered as a fixed link. The link 1 rotates about a turning
pair F, it is rotated by a pin joint axis, the link 3 and link 1 is connected by a turning
pair E. The connecting rod (link 4) and link 3 are connected by a turning pair D. The
crank (link 5) is fixed at a turning pair A and oscillates about the pin joint axis. Crank
(link 5) and connecting rod (link 4) are connected by a turning pair B.
Ram Die (link 2) and connecting rod (link 4) are connected by a sliding pair
C. Ram Die and composite bush are connected by a sliding pair G.
Crank (link1) is joined at turning pair F to the column and also crank (link 5)
is joined at turning pair A. Column is welded to the base, vice (not shown in above
fig) is fitted to the column for holding the work piece. All the links, Column, Base
and Vice are made up of Mild Steel, they are rigid enough to absorb the vibrations
and shocks produced during work. Composite bush is made up of two materials outer
one is of Mild Steel and the liner is made up of Gun Metal to prevent from wear, tear
and corrosion resistance. A handle is provided at point E, with the help of the handle
the crank (link 1) is rotated.
4.2
Working Principle
The Crank (link 1) rotates at a fixed axis at F it is joined to link 3. As the link
1 is rotated the motion is transmitted to the link 3 which is connected at point E. The
motion is further transmitted to the connecting rod which is joined with the link 3 at
D. Finally the connecting rod transmits the motion to the Ram Die (link 2) which
reciprocates at a fixed path G. The Connecting rod (link 4) and Ram Die (link 2) are
connected at C, Where a slot is provided for getting a straight line motion of the ram
Die. The crank (link 5) is provided for oscillating the connecting rod at a fixed path.
11
4.3
Manufacturing Process
12
It was manufactured by two different materials one of Mild steel and other
was liner made up of Gun metal. The outer one is made up of Mild steel on which
facing and turning operations were done on a lathe and then the inner one was made
up of Gun metal on which facing and turning were carried out of the required size
then the liner was inserted in the outer bush by the application of a press fit.
4.3.5 Column
The Column is made up of Mild Steel of required dimension. First the
marking for the holes to fix the links were done on the column. The outer profile was
marked and then made to cut on a gas cutter, and then it was milled to the required
size and then finally chamfering was done to remove unnecessary sharp corners and
edges. Drills were drilled on the column for bearings, turning pairs F and A. Then the
composite bush was welded on the column. Vice was fitted on the column by the
application of welded joints for holding the work piece.
4.4
given below
n = 3( -1)-2j-h
Where,
n = Degree of freedom
= no of links
j = no of lower pairs
h = no of higher pairs
Links:
a)
Fixed link
b)
Crank (link 1)
c)
Crank (link 5)
d)
Link 3
13
e)
Connecting Rod
f)
Ram Die
Turning pair F
b)
Turning pair E
c)
Turning pair D
d)
Turning pair A
e)
Turning pair B
f)
Sliding pair C
g)
Sliding pair G
n = 3( -1)-2j-h
h=o
n = 3( -1) -2j
n = 3(6-1) -2 x 7
n=3x52x7
n = 15 14
n=1
4.5
Applications
4.5.1 Forging
Forging refers as the process of plastically deforming metals or alloys to a
specific shape by a compressive force exerted by some external agency like hammer,
Press, rolls, or by an upsetting machine of some kind. The portion of a work in which
forging is done is termed the forge and the work is mainly performed by means of
14
heavy hammers, forging machines, and presses. Forging processes are among the
most important manufacturing techniques since forging is used in small tools, railroad
equipment, automobile, and aviation industries.
A number of operations are used to change the shape of the raw material to the
finished form. The typical forging operations are:
1.
Upsetting.
2.
Fullering.
3.
Drawing down.
4.
Setting down.
5.
Punching.
6.
Bending.
7.
Welding.
8.
Cutting.
All these operations are carried out with the metal in a heated condition,
which must be maintained by taking a fresh heat when the work shows sign of
getting cold.
Forging Processes
The processes of reducing a metal billet between flat-dies or in a closedimpression die to obtain a part of predetermined size and shape are called smith
forging and impression-die forging respectively. Depending on the equipments
utilized they are further sub-divided as hand forging, hammer forging, press forging,
drop forging, mechanical press forging, upset or machine forging.
In general, the methods of forging may be classified as follows:
15
FORGING
PROCESS
IMPRESSION
DIE
SMITH
Hand
Drop
Power
Press
Machine
Hammer
Press
4.5.2 Press
Press working involves production of final component from sheet metal in
cold condition. The machine which is used to apply the required pressure of force in a
short duration is called press. The press consists of a frame, supporting bed and ram.
The ram is equipped with special punches and moves towards and into the die block
which is attached to a rigid body. The punch and die block assemble are generally
referred to as a die set or simply die.
A disadvantage of press working is that the operations are carried out at
room temperature and the metal is less deformable of strain hardening.
Classification of Presses
Presses are classified in various ways as listed below.
(i)
Mechanical press.
16
Blanking,
(ii)
Piercing
(iii)
Lancing,
(iv)
(v)
Notching,
(vi)
Shaving, and
(vii)
Trimming.
2. Shaping operations
(i)
(ii)
Drawing, and
(iii)
Bending.
II.
1.
DESIGN CALCULATIONS
is proportionally taken according to the diagram of the Six bar Slider crank Power
hammer mechanism. By checking the movability after more and more trails of link
lengths we finalized the dimensions as shown below
1.
crank (link 1)
120mm
2.
420mm
3.
link3
440mm
4.
connecting rod(link4) =
655mm
17
5.
2.
crank (link 5)
120mm
links
This mechanism is designed for applying a compressive force of 0.6 tonnes for
forging or press operation.
Minimum cross sectional area required to transmit is 0.6 tonnes load (A):
load
permisible shear stress
p
[]
mm 2
= 300 N / mm 2
permisible
shear stress []
= 300/4
p
=
[ ]
= 80mm
= 75 N/mm
=
6000/75
The formula for the minimum effective area is obtained as bt (dt) it can be
observed in the link as in the fig2.1
18
Fig 2.1
In fig 2.1 hatched portions indicates minimum effective cross sectional area in the
entire mechanism. We know that stress is inversely proportional to the area, so the
minimum area leads to increase the stress. So it is always preferred to design any
machine by taking minimum cross sectional area as effective area.
Effective
area (A)
bt - (d t) mm
where,
t
Effective
19
From the design of bolt we obtained diameter of pin as 6mm, by keeping the diameter
of pin constant and by trail and error method we obtained the breadth and thickness of
the link as 20mm and 6mm respectively.
3.
3.1
Maximum stress
Nominal stress
p
(w - a)h
The below diagram is for the finite width plate with a transverse hole.
p
(w - a)h
Where,
20
P = tensile force
= 0.6 tonne
= 0.6 1000 9.81
= 5886N
Therefore,
nom =
5886
(20 - a)6
Kt =
max
nom
nom =
max
kt
5886
150
=
( 20 a)6
2. 3
5886
= 65.22
(120 6a)
5886 = 65.22(120-6a)
5886 = 7826.5 391.32a
5886 7826.5 = - 391.32a
- 1940.5 = - 391.32a
Therefore
a=
1940 .5
391 .32
a = d (diameter) = 4.99mm
Due to dynamic characteristics of links the diameter of pin is selected as 6 mm.
3.2
y =
300 N/ mm 2
Factor of safety = 2
Permissible bearing of crushing stress = ( b ) =
21
y
n
= 300/2 = 150N/ mm 2
Bearing stress ( b )
p
d +n
81.75 N/ mm 2
The bearing stress is greater than 81.75 N/ mm 2 , so the design is satisfactory.
= 0.6
300
= 180 N/ mm 2
y
load
shear area
6000
shear area
Shear area for punching operation can be observed from above diagram is dt
Where,
22
Shear area = dt =
6000
180
dt = 33.3 mm 2
Therefore
t=
33 .3
7
t = 1.5mm
CRANK (LINK 1)
23
Description
: Crank 1
Part No
:1
Material
: Mild Steel.
Required size
SL. NO
MACHINE
OPERATION
TOOL
GAUGE
Vernier
1
Power saw
Cutting
Hacksaw
caliper, steel
rule
Grinding
Grinding
Fillet
Drilling
Drill 6 x 6
Drill bit
Drilling
Drill 6 x 6
Drill bit
Bench vice
Filing
Flat file
2.
Description
: Die
Part No
:2
wheel
RAM DIE
24
Vernier
caliper
Vernier
caliper
Material
: Mild Steel.
Required size
: 20mm x 420mm
SL. NO
MACHINE
OPERATION
Power saw
Cutting
Lathe
Facing
Lathe
Drilling
Drilling
Tapping
Milling
TOOL
Hacksaw
Vernier caliper,
blade
steel rule
Single point
cutting tool
Drilling 10x2
GAUGE
Vernier caliper
Drill 20
Vernier caliper
Drill 4.5 x 5
Drill 4.5
Vernier caliper
Drill 6 x 6
Drill 6
Vernier caliper
M6 internal
thread
End mill
Slot
3.
Description
: LINK 3
Part No
:3
Tap
cutter
LINK 3
25
Vernier caliper
Material
: Mild Steel.
Required size
SL. NO
MACHINE
OPERATION
TOOL
GAUGE
Vernier
1
Power saw
Cutting
Hacksaw
caliper, steel
rule
Grinding
Grinding
Fillet
Drilling
Drill 6 x 6
Drill bit
Drilling
Drill 6 x 6
Drill bit
Bench vice
Filing
Flat file
4.
wheel
CONNECTING ROD
Description
: Connecting Rod
Part No
:4
Material
: Mild Steel.
Required size
26
Vernier
caliper
Vernier
caliper
SL. NO
MACHINE
OPERATION
TOOL
GAUGE
Vernier
1
Power saw
Cutting
Hacksaw
caliper, steel
rule
Grinding
Grinding
Fillet
Drilling
Drill 6 x 6
Drill bit
Drilling
Drill 6 x 6
Drill bit
Milling
Slot
Bench vice
Filing
Flat file
5.
wheel
CRANK (LINK 5)
Description
: Crank (link 5)
Part No
:5
Material
: Mild Steel.
27
Vernier
caliper
Vernier
caliper
Vernier
caliper
Required size
SL. NO
MACHINE
OPERATION
TOOL
GAUGE
Vernier
1
Power saw
Cutting
Hacksaw
caliper, steel
rule
Grinding
Grinding
Fillet
Drilling
Drill 6 x 6
Drill bit
Drilling
Drill 6 x 6
Drill bit
Bench vice
Filing
Flat file
6.
wheel
COMPOSITE BUSH
Description
: composite bush
Part No
:6
28
Vernier
caliper
Vernier
caliper
Bush.
6.1
Material
: Mild steel
Required size
: 38mmx 100mm
SL. NO
1
6.2
MACHINE
Power saw
OPERATION
Cutting
TOOL
Hacksaw
caliper,
Single point
steel rule
Vernier
Lathe
Facing
Lathe
Drill 25
Drill bit
Lathe
Reaming
Reamer
cutting tool
Liner
Material
: Gun metal
Required size
: 25mm x 105mm
29
GAUGE
Vernier
caliper
Vernier
caliper
Vernier
caliper
SL. NO
1
MACHINE
Power saw
OPERATION
Cutting
Lathe
Facing
3
4
Lathe
Lathe
Drill 25
Reaming
Lathe
Step turning
7.
COST ESTIMATION
7.1
TOOL
GAUGE
Vernier
Hacksaw
caliper,
Single point
steel rule
Vernier
cutting tool
Drill bit
Reamer
Single point
caliper
Micrometer
Micrometer
Vernier
cutting tool
caliper
Name of component
Quantity
Cost/piece
Cost in Rupees
Bearing (6mm)
M6 bolt and nut
4
5
15
8
60
40
30
26
26
1.5
12
TOTAL COST
7.2
144
Material Cost
Name of component
Quantity
Cost in Rupees
150
100
2000
156
TOTAL COST
7.3
2406
Machining Cost
Machine
Lathe
Drilling
Gas Cutting
Welding
Milling
Total Cost
Cost in Rupees
500
300
170
200
660
1830
31
7.4
Particulars
Transportation and Allowances
Painting and Name Plate
Cost of Standard Components
Material Cost
Machining Cost
Total Cost
Cost in Rupees
1220
800
144
2406
1830
6400
32
33