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Analysis and Synthesis of Four bar Mechanism

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International Journal of Theoretical and Applied Mechanics
ISSN 0973-6085 Volume 3 Number 2 (2008) pp. 171–186
© Research India Publications
http://www.ripublication.com/ijtam.htm

Analysis and Synthesis of Fourbar Mechanism

L. Roy, A. Sen, R. P. Chetia and M. J. Borah

Department of Mechanical Engineering,

National Institute of Technology
Silchar-788010, India
*Corresponding Author e-mail: lintu_roy@yahoo.com

Abstract

Computer programme and Genetic algorithm is used in analysis and

synthesis of a planar four-bar mechanism. Link dimensions were varied to
obtain coupler path maps. Position, velocity, acceleration and the force at the
coupler point at various input angles were obtained and the designed path is
utilized in the working models. Plot of variation of the link angles, variation
of velocity and acceleration of the coupler point with the crank angle is
obtained. It is found that ratio of velocity of crank and coupler point varies
between 4.48 and 0.38, acceleration of the coupler point is maximum. The
four bar mechanism can be used to transfer small jobs at regular interval of
time. With addition of another four bar mechanism with this, a papad making
machine is shown as an useful application.

Keywords: coupler curves, coupler point, Grashof’s law, four bar mechanism.

Notation
OAPBC the complete four bar mechanism
P coupler point
a crank
d ground link
b coupler link
c rocker
e length of one of the sides of the ternary link
f length of the line joining A and C
θ angle between the a and d
β the coupler angle
172 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

γ angle made by the link b with the hz.line passes through the point A
RA,RP position vector of the point A, P
RPA the relative position of point P w.r.t point A
VA Velocity of point A
VP Velocity of point P
VPA Velocity of point P w.r.t point A
AA Acceleration of the point A
AP Acceleration of the point P
APA Acceleration of the point P w.r.t point A
1 Acceleration of the crank
2 Acceleration of the coupler
3 Acceleration of the rocker
φ angle made by the line joining point A and C with the horizontal line passes
through the point A.
F12 force acting on link 1 due to link 2.
F32 force acting on link 3 due to link 2.
F43 force acting on link 4 due to link 3.
F14 force acting on link 1 due to link 4.
T12 torque on link 1 due to link 2.
R12 relative position of link 2 w.r.t link 1
R32 relative position of link 3 w.r.t link 2.
R34 relative position of link 4 w.r.t link 3.
R14 relative position of link 4 w.r.t link 1.

Introduction
Mechanism, when lightly loaded and run at low speeds can be treated as kinematic
devices; i.e, they can be analyzed kinematically without regard to forces. A general
method for simulating the motion of planar mechanisms on an analogue computer [1]
was based on continuous solution of the loop equations describing instantaneous
mechanism configuration. Analysis and approximately synthesized slider crank
mechanism with a flexibly attached slider, considering constant speed of crank
rotation and less friction was given in [2]. Filemon [3] used a new diagram, with
Burmester curves which demonstrates design possibilities and offers solutions and
also describes a check of whether solution is available in the diagram or not.
Dimensionless equation describing the behavior of dc motor driven four-bar
mechanism was indicated in [4], it presents a new non-dimensional parameters to
describe the motor mechanism system. A geometrical approach [6] is presented to
obtain the system of equations for velocity that result from the modelization of
linkages using a FEM point of view. Feng [5] presents a genetic algorithm based
technique for mechanism dimensional synthesis. A population of optimum points is
Analysis and Synthesis of Fourbar Mechanism 173

obtained that allows the designer to select a design that satisfies all subjective
constraints. An approach of optimal synthesis of a fourbar linkage by method of
controlled deviation is made. This method allows controlled of motion of the coupler
in the four-bar linkage around the given path. Comparison of the calculated value of
the objective function is made individually in each iteration and the moving is done in
the direction of decreasing the value of the objective function.

Theory
Analysis of four Bar Mechanism
In the analysis typically based on calculation of position, path traversed velocity and
acceleration of the coupler point.

Position Analysis
Coupler curve is the path or locus of coupler point. It can be obtained geometrically
by calculating
the co-ordinates. From Figure 1, we get coordinates of A as (a *cosθ, a*sin θ), co-
ordinates of B as (a*cos θ +b*cos γ, a*sinθ +b*sin γ) and co-ordinates of P as (a*cos
θ +e*cos (γ+ β)), So f = (a2+d2-2*a*d*cos (θ))1/2 φ =arc tan((a*sin (θ))/ (d-a*cos (θ))
Considering Y-axis as the imaginary axis and X-axis as the real axis, we have
RA =a*cos (θ) +b*j*sin (θ). Thus the position of the coupler point P can is obtained.

Figure 1: Schematic diagram of four bar mechanism showing position vectors.

Velocity Analysis
Velocity of Coupler Point
Let ω1,ω2 and ω3 be the angular velocities of the links OB, AB and BC respectively
a*cos α+ b*cos β - c*cos φ - d = 0 (i)
Differentiating it w.r.t. time, we have
-a*ω1*sinθ -b*ω2*sin β +c* ω3*sin φ=0 (ii)
Similarly we can have
a*sin θ -b*sin β - c*sin φ=0 (iii)
174 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

We get by differentiating
a*ω1*cosθ -b*ω2 *cosβ -c*ω3* cosφ=0 (iv)
Multiplying (ii) by cos β and (iv) by sin φ and adding, we get
ω3=[(a*ω1 sin(β- θ))/(c* ω3* sin(β- φ))] (v)
Similarly, multiplying (ii) by cos φ and (iv) by sin φ and adding, we get
ω 2=-[(a*ω1 sin(φ -θ))/(b*ω3*sin(φ-β))] (vi)
Velocity of A can be obtained by differentiating equation (iv)
VA=b*ω1*(j*cos (θ)-sin (θ))
Similar to position analysis, velocity of P is obtained by addition of two vectors VA
and VPA.VPA is calculated by differentiating equation (v).Thus,
VPA = e*ω2*(j*cos (β + γ)-sin (β + γ))
From vector diagram, we get
VP = VA +VPA

Acceleration Analysis
Differentiating equations (ii) and (iv) w.r.t.time,
-a1*ω1*sinω1t-b*ω2*sin ω2t+c*ω3*sinω3t =0 (vii)
a*ω1*cos ω1t +b*ω 2*cos β 2t -c*ω3*cosφ =0 (viii)

Differentiating equations (vii) and (viii) w.r.t.time, we have

(-a* α1*sin θ -a*ω12cosθ)-(b*α 2*sin β --b*ω32*cos β )+(c*α3*sin φ+c*ω32cosφ) =0
and
(a*α1*cos θ -a*ω12 *sin θ)+( b*α 2*cos β -b*ω22 sin β-c* α 3 *cosφ +c*ω12 sin φ)=0
where α 1 = dω/dt, α 2= dω2/dt, α 3 =dω3/dt
2
α 1= (a *α 1*sin (φ -θ) – a *ω1 cos(φ -θ) – b *ω2 2 *cos (β - φ) + c* w32) / b*sin(β -φ)
2
α 3=a *α1 * sin (β - θ)–a *ω1 cos(β - θ) – b*ω22 + c* ω 32 cos (β - φ)) / c*sin(β - φ)
Acceleration of A ,acceleration of A w.r.t P can be obtained as
AA=a*α1(-sin θ+j*cos θ)- α* ω12*(cos θ+j sinθ)
APA=e*α2-sin(β + γ)+j*cos(β + γ)-p* ω22*cos(β + γ)+j*sin(β + γ) , Ap= AA+ APA

Dynamic Force Analysis

All dimensions of link lengths, link positions, location of the links' CG s, linear
acceleration of those CG s, and link angular accelerations and velocities have been
determined from kinematic analysis. The forces acting at all the pin joints of the
linkages are required to be found out. The linkage has three moving links. The
external force is F and external torque T. These external loads are due to some other
mechanism pushing or twisting against the motion of the linkage. Any link can have
any number of external loads and torques acting on it. Only one external force and
external torque are shown here as an example. To solve for the pin forces, it is
necessary that these applied external forces and torques be defined for all position of
interest.So, for one member of the pair of action-reaction forces at each joint and also
for the driving torque T12 needed to be supplied at link 2 in order to maintain the
kinematic state as defined. F12, F32 will also act due to link 2.The equal and opposite
forces at each of these points are designated F21 and F23 respectively. All the unknown
Analysis and Synthesis of Fourbar Mechanism 175

forces in the figure are shown at arbitrary angles and lengths as their true values are
still to be determined. The linkage kinematic parameters are defined with respect to a
global XY system whose origin are at the driver pivot O2 and whose X axis goes
through link 4 is fixed pivot O4.
For link 4,substituting the reaction force -F43 for F34 ,a similar set of equations can be
written:
F14x – F43x = m4aG4x (ix)
F14y – F43y = m4aG4y (x)
(R14x F14y – R14y F14x ) - ( R34x F43y – R34y F43x ) + T4 = IG4 α4 (xii)

T12, the source torque, only appears in the equation for link 2 as that is the driver
crank to which the motor is attached. Link 3 has no externally applied torque (though
it could have) but does have an external force Fp . Link 4 has no external force acting
on it(though it could have)but does have an external torque T4.(The driving link 2
could also have an external force acting on it though it usually does not).There are
nine unknowns present in these nine equations,F12X, F12Y, F32X, F32Y, F43X, F43Y, F14X,
F14Y and T12,so we can also solve them simultaneously. We rearrange terms, all
known constant terms on the right and then put in matrix form.

Synthesis
Using Maps of Coupler Curve
The use of mechanisms which could generate straight line. Going through the maps
generated (Figure 2), a few curves were identified to have a substantial path in a
straight line. Now, after a little consideration, it was decided that a mechanism can be
designed to transport small objects at regular interval of time. So, for the designed
motion, the maps of coupler curves were checked.The curve that satisfied the criteria
most was selected and the corresponding link dimensions were taken,then by trial and
error method, more accurate results were obtained. For the required path, the maps
developed were checked out and it was found that such a path (though not accurate) is
possible to obtain by taking the link dimensions as d/a =2 b/a =3 c/a=3 e/a = 3.By
taking dimensions in the above ratio and then changing the ratios a bit, by trial and
error the required curve was obtained. Accordingly the model was made. As a
176 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

probable use of the model, it may be used as papad making machine, after attaching
another four bar mechanism.( Figure 10)

Figure 2: Schematic diagram of fourbar mechanism for force analysis.

Figure 3: First and Second map of coupler curve generated.

Figure 4: Photographs of the model

Analysis and Synthesis of Fourbar Mechanism 177

[10 20 20 20 30 330]
[10 30 30 20 30 330]

[10 20 23 22 30 330]

[10 20 30 20 30 330]
Figure 5: Stages of development of the required path.

Figure 6: Graphs obtained by analyzing the synthesized model.

Figure 7: Flowchart of work of Genetic Algorithm

178 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

Figure 8: The graph showing iteration

This path almost This path is nearly straight but

coincides with a straight not as straight las the other one.
line. (After applying GA) (Before applying GA)

Figure 9: Comparison between paths generated after and before the application of
GA.

Figure 10: The new modified papad making machine

Analysis and Synthesis of Fourbar Mechanism 179

Figure 11: Graph between link angles and crank angle.

Figure 12: Graph between link angles and crank angle.

180 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

Figure 13: Result of the program that simulates motion of a fourbar mechanism

Figure 14: Graphs showing angular velocities of various links

Figure 15: Graphs showing velocity of coupler point.

Analysis and Synthesis of Fourbar Mechanism 181

Figure 16: Graphs showing angular accelerations of links.

Figure 17: Graphs showing acceleration of coupler point.

182 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

Figure 18: Comparison of forces on the links.

Figure 19: Inertia forces on different links

Analysis and Synthesis of Fourbar Mechanism 183

Figure 20: The pattern of shaking force acting on the system.

By Genetic Algorithm
With the help of Genetic Algorithm toolbox in MATLAB, synthesis process was
carried out.The goal function used here computes the position error as the sum of the
square of the Euclidean distances between Ci and ci.Where,Ci is the set of target
points indicated by the designer and ci is the set of coupler point positions of the
design. There the goal function is,∑{(xi-Xi)2+(yi -Yi)2} where (xi,yi) is the set of
coordinates from the desired path and (Xi,Yi) is the set of coordinates of the points
generated in the algorithm. When the distance between the points are minimum,
optimum results are obtained.Flow chart of work of Genetic algorithm is given in
Figure 7. Constraint used. is the Grashof condition. i.e S+L<=P+Q where S,L and
P,Q are the lengths of the shortest, longest and length of the other two links. Figure 8
shows the graph which was generated during iteration was on for synthesis of the
mechanism. The limit was given up to 1000 iterations, after which the best result was
obtained with an error of only 0.00048542 units of distance. The modification has
been done on the basis of results obtained after synthesis with the help of genetic
algorithm.

Discussion on Results
The maps (Figure 2) showing variation in coupler curve that is generated due to
change in link dimensions and coupler angle. The link length ratios b/a, e/a and c/a
vary from 1.5 to 5 and d/a has been kept at a constant value of 2. The second map was
generated for the purpose of synthesis. The link length ratio b/a, c/a, and e/a has been
kept at a constant 2.5 and d/a varies from 1.5 to 5.The link dimension ratios required
to obtain the path (shown in Figure 5) can be found from these two maps. It is
required to find out the motion path which matches the actual motion path. In the
184 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

obtained path, the coupler angle is very large i.e >3000. So, all the curves in the 3240
column .The process of trial and error was used (just comparison and a few steps of
trial and error) and the link dimensions are found out were a = 10 units,b=20
units,c=23 units d=22 units ,e=30 units and β = 330o.Analysis of mechanism is a
classical problem which has a number of solutions and attracts researchers worldwide
even today. The maps developed are of new type in comparison of that generated in
[7].Though, the process to design the linkage as said in this paper is lengthy and not
very accurate and it is an easy way. There were a few negligible errors in the analysis,
may be due to i).The mechanisms were assumed to be planar, ii). The links were
assumed rigid, which is not so. iii). Inaccuracies in links dimensions of the working
models. The mechanism thus designed was found to be working according to the
requirement. When the crank is rotated, coupler point traverses the path, which
attached to a plank also traverses the same path. First, it follows a horizontal path
during which it transports the object.After that it comes down vertically and then it
goes back to its original position where another object is waiting to be transported. In
the next part, mechanism was synthesized with the help of genetic algorithm. A set of
target points were given which are {(10,-23), (0,-21), (-5,-20), (-10,-19), (-15,-13)}.
After iterations the result was obtained (Figure 8).Using the obtained results, the
model was modified for better performance. The genetic algorithm results obtained
are a = 10 units, b = 20.6 units, c = 23.3 units, d=22 units, e= 30.6 units β = 329o.
Figure 9 shows the comparison between paths generated after and before the
application of GA. In the analysis of the mechanism the several observations is noted.
Figure 11 graph shows that the crank angle increases from 45o to 405o linearly, where
Theta2, theta3 and theta4 are the crank angle, angle of the coupler link and angle of
the rocker arm respectively with respect to the grounded link. The angle subtended by
the coupler shows a decrement initially up to 36o, after which there is an increment
upto 103 o ,then it decreases to its initial value. Similarly, the rocker arm rocks by and
angle of 58o. It does not complete full 360o and oscillates between 153o and 95o. The
Figure 12 shows variation of x- coordinate of the coupler point with crank angle,
variation of y- coordinate and the variation of distance from the crank pivot with
crank angle.Variation of distance from the crank pivot with crank angle,starts with
40.5 cm.then decreases to 20.6 cm, and then it increases again to 40.5 cm. This proves
that the coupler point completes a full path. It is assumed that the angular velocity of
the crank is constant, the angular acceleration of the crank to be zero It is justified as
constant velocity was assumed for the crank. The first plot shows invariant angular
velocity of the crank, in Figure 14 omega 2, omega 3, omega 4 are the angular
velocities of the crank, coupler and rocker link respectively .The angular velocity of
the coupler link varies from 4.96 rad/sec to -9.00 rad/sec. Initially it increases
gradually up to 4.96 rad/sec, and then the slope becomes steeper till it reaches -9.00
rad/sec. After this it shows a sharp increase. The angular velocity of the rocker arm
varies in between 4.33 rad/sec to -8.25 rad/sec. With an initial increase up to 4.33
rad/sec, it decreases slowly up to -8.25 rad/sec after which it increases at a sharper
rate. This continues till it reaches its original value once again. The ratio of angular
velocities of the crank and the rocker arm varies from 0.433 to -0.825(Figure 15). The
velocity goes maximum up to 207 cm/s. The minimum value is -96 cm/s. Initially it
gradually increases to its maximum value of 86 cm/s. After that the graph shows a
Analysis and Synthesis of Fourbar Mechanism 185

steep fall to its minimum of -115 cm/s. The velocity of the coupler point varies from
19 cm/s to 216 cm/s which is quite high. In between 315o and 405o of crank angle it
shows a faster increase in velocity, sudden increase in the angular velocity can be
seen as the crank angle crosses 395o. In Figure 16 Alpha2, alpha3, alpha4 are the
angular accelerations of the crank, coupler and rocker link respectively Acceleration
shows a decreasing trend then suddenly becomes steeper to reach its minimum value
of -146 rad/s2 again reaches a maximum value of 80 rad/s2 after which it starts to
increase gradually to reach its initial acceleration. The rocker arm acceleration
initially decreases steeply, then a little bit slowly and for a span it is almost constant,
then it decreases sharply till it reaches its minimum which is -83 rad/s2, then it shows
a sharp increase till it reaches its maximum of 125 rad/s2 after which it again gradually
decreases to reach its initial value. In Figure 17 the acceleration pattern of the coupler
point starting from negative zone, it gradually goes to the positive zone, and then a
sudden increment can be seen till it reaches its maximum after which it again
decreases sharply to reach its minimum .The next graph shows the y component of the
acceleration. Unlike the x component, it starts from the positive zone and gradually
comes near to the x axis and remains near without much variation for a span. After
this it shows a sudden decrease, it goes below the x axis to reach its minimum and
then the graph shows a sudden increase again. The third graph shows the magnitude
of the acceleration. As expected, it is above the x axis in the positive zone. Initially, it
shows a decrement till it almost touches the x axis i.e. the acceleration becomes nearly
zero. It remains near and above the axis for a span. After this, it increases and make
two short humps on its way to reach its starting point. The fourth graph shows the
angle of acceleration of the coupler curve as the crank angle changes. For a small span
it remains nearly constant above the x axis. Then, a sharp decrement is seen till it goes
below the x axis. Then it increases over a long span, gradually. Then it gradually
decreases till it touches the axis. After it intersects the axis for a small span it remains
nearly constant. Then it decreases gradually over a small span. Then it increases
sharply to reach its maximum value. After this, it gradually decreases to reach its
initial value. (Figure 11 to Figure 17) and also the force analysis figures (Figure 18 to
Figure 20) has been plotted with the students edition software available in [7].The
force analysis diagrammatic representation are given as (Figure 2) - link 2
corresponds to the crank, link 3 to the coupler and link 4 to the rocker arm. The input
data for the force analysis: mass of the links 2,3,4 are 34.9 gm, 106.39 gm,65.22 gm
respectively. Corresponding mass moment of inertia about the CG 872.5 gm-cm2,
46352.7 gm-cm2, 8108.3 gm-cm2 respectively. Distance to CG from the pivot 5 cm,
17 cm, 11.15 cm. Angle of CG in LRCS is 0.00 degrees,-18.00 degrees, and 0.00.
degree ,external forces on link 3 and 4 are 10 dynes each. Angle of force in GCS –330
degrees,-120 degrees. External force location: distance to force point from CG 17 cm,
11.5 cm. Angle of force point in LRCS is –120 degrees and -30 degrees .The external
torques on links 3 and 4 are 5 dyne-cm each. Friction forces on link 3 dyn is 2
dyn.The force pattern gradually increases, then falls sharply, then rises again (Figure
18).The velocity of the crank has been assumed to be constant, the acceleration is
zero. So, inertia force is also zero. The inertia force of the coupler link decreases
gradually, then for crank angle it remains almost constant, then it increases gradually
(Figure 19).The inertia force of the rocker arm much more prominent. The shaking
 186 L. Roy, A. Sen, R. P. Chetia and M. J. Borah

force acting on the system decreases sharply in the beginning, then it starts increasing
gradually after that it decreases sharply again till it reaches its minimum value
(Figure 20).

Conclusion
1) The new maps developed can be used for synthesis of four bar mechanism .It is
easier to follow the synthesis procedure.
2) In comparison with the crank velocity, the velocity attained by the coupler point
is 4.48 times the crank velocity and the minimum velocity is 0.38 times the
crank velocity.
3) The acceleration of the coupler point varies between 51 cm/s2 and 3758 cm/s2 in
spite of zero acceleration of the crank
4) The magnitude of force at the coupler point varies between 4.11099N and
0.7797 N
5) Total distance traveled by the coupler point is 19.9 cm
6) The results obtained from the programme matches with the model prepared.
7) The design developed can be used for transporting small objects at regular
interval of time. It can be also be used or papad making machine .

References
[1] Jones, J. Rees and Rooney, G.T Motion analysis of rigid link mechanisms by
gradient optimization on an analog computer. Journal of Mechanisms Vol.5,
pp.191-201.Pergamon press, 1970.
[2] Davidson, Joseph K. Analysis and Synthesis of slider crank mechanism with a
flexibly attached slider. Journal of Mechanisms Vol.5, pp. 239-247.Pergamon
press, 1970.
[3] Filemon, E. Useful ranges of centerpoint curves for design of crank-and-
rocker linkages. Mechanism and machine theory Vol.7, pp. 47-53. Pergamon
press, 1972.
[4] Sadler, J.P., Mayne, R.W. and Fan, K.C. Generalized study of crank rocker
mechanism driven by a dc motor. Mechanism and machine theory Vol.15, pp.
435-445. Pergamon press, 1980.
[5] Fang, W. E. (1994). ”Simultaneous Type and Dimensional Synthesis of
Mechanisms be Genetic Algorithm.” Proc. Of 23rd Biennial Mechanisms
Conference, Minneapolis, MN, p.239.
[6] Hernándezr, A., Altuzarra, O., Avilés, R ., and Petuya, V. Mechanism and
machine theory Vol.38:12, pp. 1413-1429. Pergamon press, 2003.
[7] Bulatovic, Radovan R. and Djordjevic, Stevan R, Optimal synthesis of a
fourbar linkage by method of controlled deviation. Theoret. Appl. Mech.
Vol.31, No.3-4, pp. 265-280. Belgrade, 2004.
[8] Norton, Robert L. Design of Machinery, Third edition. Tata McGraw-Hill,
New Delhi(2005).

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