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CHAPTER 3

DESIGN METHODOLOGY

In previous chapter , we discussed that the literature on the already existed stamping and
punching machines some patents on elliptical trammel mechanism in other than stamping
systems and patents on different stamping systems were discussed. In this chapter we are
going to discuss about the methodology to implement elliptical trammel mechanism to
stamping application.

3.1 ELLIPTICAL TRAMMEL MECHANISM IN STAMPING

The mechanism used in the multiple stamping machine for stamping is elliptical trammel
mechanism. The movement of sliders to four edges is used for stamp on product moving on
the conveyor.

3.1.1 SELECTION OF INPUT POINT IN THE MECHANISM

The input is given to the system at the midpoint of the connecting link through electric motor.
Since the midpoint of the connecting link will trace the circular path.

Fig3.1. Coupler curve to midpoint of elliptical trammel mechanism.
Fig3.2 Geometric diagram of elliptical trammel system.

From the Fig 3.2 let at any instant, the link 3(i.e. connecting link) make angle Ө with the

X-axis.

Considering the displacements of the sliders from the centre of the trammel,

x = BC cos Ө and y = AC sin Ө.
𝑥 𝑦
= 𝑐𝑜𝑠Ө And = 𝑠𝑖𝑛Ө.
𝐵𝐶 𝐴𝐶

Squaring and adding

𝑥2 𝑦2
+ = cos 2 Ө + sin2 Ө = 1
𝐵𝐶 2 𝐴𝐶 2

This is the equation of ellipse. The path traced by C is an ellipse with semi major and semi
minor axes being equal to AC and BC respectively.

When C is the midpoint of AB; AC = BC.

𝑥2 𝑦2
And + 𝐴𝐶 2 = 1 or x2 + y2 = (AC)2
𝐵𝐶 2

Which is the equation of a circle with AC (=BC) as the radius of the circle. Thus form the
above mathematical proof we can say that the midpoint of connecting link will trace circular
path.
3.2 DESIGNING OF MULTIPLE STAMPING MACHINE

3.2.1PARTS MODELLING

In this part modelling each part of the machine were modelled. By giving constraints for
perfect motion transfer assembled the total parts, motion was given to input to predict the
output properly.

Software Introduction

CATIA (Computer Aided Three-Dimensional Interactive Application) started as an in-

house development in 1977 by French aircraft manufacturer Avions Marcel Dassault, at

that time customer of the CAD/CAM CAD software to develop Dassault's Mirage fighter

jet. It was later adopted in the aerospace, automotive, shipbuilding, and other industries.

CATIA enables the creation of 3D parts, from 3D sketches, sheet metal, composites, and

moulded, forged or tooling parts up to the definition of mechanical assemblies. The

software provides advanced technologies for mechanical surfacing & BIW. It provides

tools to complete product definition, including functional tolerances as well

as kinematics definition. CATIA provides a wide range of applications for tooling design,

for both generic tooling and mould & die. CATIA offers a solution to shape design, styling,

surfacing workflow and visualization to create, modify, and validate complex innovative

shapes from industrial design to Class-A surfacing with the ICEM surfacing technologies.

CATIA supports multiple stages of product design whether started from scratch or from

2D sketches. CATIA v5 is able to read and produce STEP format files for reverse

engineering and surface reuse.

All the parts of Multiple stamping machine are design and modelled by using CATIA V5

software.
Modelling

It is very important to model each and every part to assemble a machine. To assemble a
machine each and every part should modelled carefully with forward view and should
have relative motion between parts. Multiple stamping machine consists of following
parts.

1. Base part.
2. Sliders.
3. Connecting link.
4. Crank wheel.
5. Connecting wheel.
6. Holding part.
7. Geneva wheel.
8. Belt and roller mechanism
9. Bevel gear mechanism.
10. Stamp support.

1. Base part

It is the base of the machine which is in bottom, the two sliders which are connected with
connecting link will move on this part in perpendicular directions. It has a slotted paths in
perpendicular directions for exact motion of sliders in their paths. The Fig 3.3 shows the
part model of Base part. It is the fixed part in assembly of multiple stamping machines.
Fig3.3. Modelled Base part

2. Slider

Slider is main part which is used for stamping. These two sliders will move on base part,
to the four edges of the slots with high acceleration and makes stamp on the product. The
width of the slider is given less than that of the slot provided on base part for clearance
and smooth movement. The Fig 3.4 shows the part model of the slider.

Fig3.4.Modelled Slider part.

3. Connecting link

It is the part which connects the two sliders at its ends. The two sliders are connected to
connecting link with revolute pairs. The midpoint of the connecting link will trace circular
path so it’s the suitable point to give input through crank wheel. So one projection is
provided at middle of the connecting link to have connection with crank wheel. The Fig
3.5 shows the part model of the connecting link.
Fig3.5.Modelled connecting link.

4. Crank wheel

Crank wheel is main driving part of the mechanism which is having connection with the
prime mover through shaft. The crank wheel transfer the motion to the sliders. The cranks
wheel consists of a pin hole to have connection with connecting link. The Fig 3.6 shows
the part model of the crank wheel.

Fig3.6.Modelled part of Crank wheel.

5. Connecting wheel

Connecting wheel is like a crank wheel and its place above the crank wheel on the same
prime mover shaft, used to transfer motion intermittently to the conveyor system through
Geneva wheel. It has a projection on the periphery which touches the Geneva wheel slots
Intermittently and transfers motion. The Fig3.7 shows the part model of the connecting
wheel.

Fig3.7.Modelled part of connecting wheel.

6. Holding part

The use of this part is to hold the Geneva wheel shaft to maintain correct parallel offset
with the main driving shaft. A pin joint is given between the Geneva shaft and the holding
part. The Fig 3.8 shows the part model of the holding part.

Fig3.8.Modelled part of Holding part

7. Geneva wheel

It is used to transmit motion intermittently between the driving shaft and the bevel gear
mechanism. The wheel will have slots, the pin on the periphery of the connecting wheel
will go inside to the slots and causes the Geneva wheel to move by transmitting the torque
and force. The Fig 3.9 shows the part model of the Geneva wheel.
Fig3.9. Modelled part of Geneva wheel.

8. Belt roller mechanism

The Fig3.10 shows the belt roller mechanism on which samples will come to exact
position to get stamp. The rollers will be in connection with bevel gear mechanism. The
intermittent motion transferred through the Geneva wheel will come to belt system. The
belt system will move with respect to the motion of the sliders to make the sample stamp
accurately.

Fig3.10.Modelled Belt roller mechanism.

9. Bevel gear mechanism

Bevel gears are used to transmit power between the two perpendicular shafts. The bevel
gear mechanism connects the Geneva wheel shaft and the belt roller mechanism to give
input to belt mechanism to move the samples. One bevel gear mechanism will be
connected to remaining three bevel gear mechanisms to transfer motion to remaining sides
of the belt mechanisms to move the samples. The 3.11 shows the bevel gear And 3.12
shows the differential mechanism and Bevel gear mechanism.
Fig3.11.Modelled of Bevel gear.

Fig3.12. Modelled of Bevel gear Mechanism and Differential system.

10. Stamp support

The main use of stamp support is to give support to the product while stamping. The
sample moving on the belt will not have sufficient strength to sustain the stamping force.
Stamp support is provided in between the Geneva wheel shaft and base. The Fig3.13
shows modelled of stamp support.
Fig3.13.modelled of Stamp support.

ASSEMBLY AND DESCRIPTION

The parts of the machine are created in part modelling of CATIA V5. The modelled parts
were assembled and simulated in assembly and mechanisms. The servo motor is chosen
for giving input. The outputs of forces to slider graphs and motion also simulated in the
CATIA V5. The Fig 3.14 and Fig3.15 shows the total assembly of the machine.

Fig3.14.Assembly of Multiple stamping machine.
Fig3.15.Assembly of Multiple stamping machine.

Description

The multiple stamping machine consists of many parts to transfer given input torque of
crank to output force of slider. The input torque was given to crank shaft through electrical
motor. The crank wheel on cranks shaft will have connection with the midpoint of the
connecting link with the projection with perfect rigid joint to transfer torque. The
connecting link will make the sliders to slide in the paths by transferring the force through
revolute pairs which are in between the slider and connecting link. Now the sliders will
move to the four edges of the base and make stamp on sample.

The movement of the conveyor also will have connection with the driving crank
shaft for accurate stamping on the sample. The driving shaft will have the connecting
wheel above the crank wheel, the connecting wheel will have projection pin on the
periphery of the connecting wheel. The connecting wheel will rotate when the driving
shaft rotates, the projection on the connecting wheel will go inside the slots of the Geneva
wheel to make the belt system in connection with the Geneva wheel to move. When the
Geneva wheel moves the shaft connected to the system make the bevel gears to move then
the total differential also will move makes the other remaining belts to move. Per one
cycle of crank each slider will stamp on the two samples, total four samples will come out
per one cycle to crank input.