1

CHAPTER 1
INTRODUCTION
Circular gears are widely used in design of wide range of mechanisms.
There are no practical limitations to the usage of gears but their versatilities can
be maximised when used as non-circular gears. Non-Circular gears are gears
with distorted shapes that are available mostly as elliptical gears, eccentric
circular gears, oval gears, or internal noncircular gears and of higher order.
Non-Circular gears are used to improve the function, versatility, and simplicity
of many mechanical processes. Noncircular gears have been considered a
curiosity and a product of niche applications for a long time because of their
design and manufacture complexity. Our paper tries to contemplate a better
inside by designing an application based on non-circular gears. Whitworth
Quick-Return Mechanism is second inversion of the slider crank mechanism
attained by fixing the crank instead of the ground link. The peculiar feature of
this mechanism is that its forward stroke takes a little longer and cuts the metal
whereas the return stroke takes a shorter period. The shaper machine used in
lathe workshops works on the principle of Whitworth quick return mechanism
Quick return mechanism consists of many linkages that rotates at high speeds.
The linkages tend to have dynamic effects. Balancing weight are to be added to
these linkages to avoid vibrations. This intern increases the overall weight of the
mechanism. The proposed mechanism intended to replace the conventional
mechanism with a compact, robust design.
A quick return mechanism is an apparatus to produce a reciprocating motion

in which the time taken for travel in one direction is less than in the other. It is
driven by a circular motion source (typically a motor of some sort) and uses a
system of links and sliding joints. Quick return is a common feature of tools in
which the action is performed in only one direction of the stroke, such as shapers
 2

and powered saws, because it allows less time to be spent on returning the tool to
its initial position.

The disc influences the force of the arm, which makes up the frame of
reference of the quick return mechanism. The frame continues to an attached
rod, which is connected to the circular disc. Powered by a motor, the disc
rotates and the arm follows in the same direction (linear and left-to-right,
typically) but at a different speed. When the disc nears a full revolution, the arm
reaches its furthest position and returns to its initial position at a quicker rate,
hence its name. Throughout the cut, the arm has a constant velocity. Upon
returning to its initial position after reaching its maximum horizontal
displacement, the arm reaches its highest velocity.

The quick return mechanism was modeled after the crank and slider
(arm), and this is present in its appearance and function; however, the crank is
usually hand powered and the arm has the same rate throughout an entire
revolution, whereas the arm of a quick return mechanism returns at a faster rate.
The "quick return" allows for the arm to function with less energy during the cut
than the initial cycle of the disc.

1.1 Specifications

When using a machine that involves this mechanism, it is very important

to not force the machine into reaching its maximum stress capacity; otherwise,
the machine will break. The durability of the machine is related to the size of
the arm and the velocity of the disc, where the arm might not be flexible enough
to handle a certain speed. Creating a graphical layout for a quick return
mechanism involves all inversions and motions, which is useful in determining
the dimensions for a functioning mechanism. A layout would specify the
dimensions of the mechanism by highlighting each part and its interaction
 3

among the system. These interactions would include torque, force, velocity, and
acceleration. By relating these concepts to their respective analyses (kinematics
and dynamics), one can comprehend the effect each part has on another.
1.2 Mechanics
In order to derive the force vectors of these mechanisms, one must approach a
mechanical design consisting of both kinematic and dynamic analyses .

1.3 Kinematic Analysis

Breaking the mechanism up into separate vectors and components allows

us to create a kinematic analysis that can solve for the maximum velocity,
acceleration, and force the mechanism is capable of in three-dimensional
space.[3] Most of the equations involved in the quick return mechanism setup
originate from Hamilton's principle. This substitution can solve for various radii
and components of the displacement of the arm at different values.
Trigonometry is needed for the complete understanding of the kinematic
analyses of the mechanism, where the entire design can be transcribed onto a
plane layout, highlighting all of the vector components. An important concept
for the analysis of the velocity of the disc relative to the arm is the angular
velocity of the disc. If one desires to calculate the velocity, one must derive the
angles of interaction at a single moment of time, making this equation useful.

1.4 DC Motor
1.4.1 Dc Motor

DC motor is any of a class of rotary electrical machines that converts

direct current electrical energy into mechanical energy. The most common types
rely on the forces produced by magnetic fields. Nearly all types of DC motors
have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor.
 4

DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's speed
can be controlled over a wide range, using either a variable supply voltage or by
changing the strength of current in its field windings. Small DC motors are used
in tools, toys, and appliances. The universal motor can operate on direct current
but is a lightweight brushed motor used for portable power tools and appliances.
Larger DC motors are used in propulsion of electric vehicles, elevator and
hoists, or in drives for steel rolling mills. The advent of power electronics has
made replacement of DC motors with AC motors possible in many applications.

1.4.2 Electromagnetic motors

A coil of wire with a current running through it generates an

electromagnetic field aligned with the center of the coil. The direction and
magnitude of the magnetic field produced by the coil can be changed with the
direction and magnitude of the current flowing through it. A simple DC motor
has a stationary set of magnets in the stator and an armature with one or more
windings of insulated wire wrapped around a soft iron core that concentrates the
magnetic field. The windings usually have multiple turns around the core, and
in large motors there can be several parallel current paths. The ends of the wire
winding are connected to a commutator. The commutator allows each armature
coil to be energized in turn and connects the rotating coils with the external
power supply through brushes. (Brushless DC motors have electronics that
switch the DC current to each coil on and off and have no brushes.)

The total amount of current sent to the coil, the coil's size and what it's
wrapped around dictate the strength of the electromagnetic field created. The
sequence of turning a particular coil on or off dictates what direction the
effective electromagnetic fields are pointed. By turning on and off coils in
sequence a rotating magnetic field can be created. These rotating magnetic
 5

fields interact with the magnetic fields of the magnets (permanent or

electromagnets) in the stationary part of the motor (stator) to create a torque on
the armature which causes it to rotate. In some DC motor designs the stator
fields use electromagnets to create their magnetic fields which allow greater
control over the motor.

At high power levels, DC motors are almost always cooled using forced
air. Different number of stator and armature fields as well as how they are
connected provide different inherent speed/torque regulation characteristics.
The speed of a DC motor can be controlled by changing the voltage applied to
the armature. The introduction of variable resistance in the armature circuit or
field circuit allowed speed control. Modern DC motors are often controlled by
power electronics systems which adjust the voltage by "chopping" the DC
current into on and off cycles which have an effective lower voltage.

1.4.3 Brushed

A brushed DC electric motor generating torque from DC power supply by

using an internal mechanical commutation. Stationary permanent magnets form
the stator field. Torque is produced by the principle that any current-carrying
conductor placed within an external magnetic field experiences a force, known
as Lorentz force. In a motor, the magnitude of this Lorentz force (a vector
represented by the green arrow), and thus the output torque,is a function for
rotor angle, leading to a phenomenon known as torque ripple) Since this is a
two-pole motor, the commutator consists of a split ring, so that the current
reverses each half turn ( 180 degrees). For brushes intended to carry more than
an ampere or two, a flying lead will be molded into the brush and connected to
the motor terminals. Very small brushes may rely on sliding contact with a
metal brush holder to carry current into the brush, or may rely on a contact
spring pressing on the end of the brush.
 6

1.4.4 Brushless

Typical brushless DC motors use one or more permanent magnets in the

rotor and electromagnets on the motor housing for the stator. A motor controller
converts DC to AC. This design is mechanically simpler than that of brushed
motors because it eliminates the complication of transferring power from
outside the motor to the spinning rotor. The motor controller can sense the
rotor's position via Hall effect sensors or similar devices and can precisely
control the timing, phase, etc., of the current in the rotor coils to optimize
torque, conserve power, regulate speed, and even apply some braking.
Advantages of brushless motors include long life span, little or no maintenance,
and high efficiency. Disadvantages include high initial cost, and more
complicated motor speed controllers. Some such brushless motors are
sometimes referred to as "synchronous motors" although they have no external
power supply to be synchronized with, as would be the case with normal AC
synchronous motors.

Other types of DC motors require no commutation.

 Homopolar motor – A homopolar motor has a magnetic field along the

axis of rotation and an electric current that at some point is not parallel to
the magnetic field. The name homopolar refers to the absence of polarity
change. Homopolar motors necessarily have a single-turn coil, which
limits them to very low voltages. This has restricted the practical
application of this type of motor.
 Ball bearing motor – A ball bearing motor is an unusual electric motor
that consists of two ball bearing-type bearings, with the inner races
mounted on a common conductive shaft, and the outer races connected to
a high current, low voltage power supply. An alternative construction fits
the outer races inside a metal tube, while the inner races are mounted on a
 7

shaft with a non-conductive section (e.g. two sleeves on an insulating

rod). This method has the advantage that the tube will act as a flywheel.
The direction of rotation is determined by the initial spin which is usually
required to get it going.

1.4.5 Permanent magnet stators

A PM motor does not have a field winding on the stator frame, instead
relying on PMs to provide the magnetic field against which the rotor field
interacts to produce torque. Compensating windings in series with the armature
may be used on large motors to improve commutation under load. Because this
field is fixed, it cannot be adjusted for speed control. PM fields (stators) are
convenient in miniature motors to eliminate the power consumption of the field
winding. Most larger DC motors are of the "dynamo" type, which have stator
windings. Historically, PMs could not be made to retain high flux if they were
disassembled; field windings were more practical to obtain the needed amount
of flux. However, large PMs are costly, as well as dangerous and difficult to
assemble; this favors wound fields for large machines.

To minimize overall weight and size, miniature PM motors may use high
energy magnets made with neodymium or other strategic elements; most such
are neodymium-iron-boron alloy. With their higher flux density, electric
machines with high-energy PMs are at least competitive with all optimally
designed singly fed synchronous and induction electric machines.

1.4.6 Wound stators

Fig 1.1 wound stators

 8

A field coil may be connected in shunt, in series, or in compound with the

armature of a DC machine (motor or generator)
Main article: universal motor
See also: Excitation (magnetic)

There are three types of electrical connections between the stator and rotor
possible for DC electric motors: series, shunt/parallel and compound (various
blends of series and shunt/parallel) and each has unique speed/torque
characteristics appropriate for different loading torque profiles/signatures.

1.5 Series connection

A series DC motor connects the armature and field windings in series

with a common D.C. power source. The motor speed varies as a non-linear
function of load torque and armature current; current is common to both the
stator and rotor yielding current squared (I^2) behavior. A series motor has very
high starting torque and is commonly used for starting high inertia loads, such
as trains, elevators or hoists.[2] This speed/torque characteristic is useful in
applications such as dragline excavators, where the digging tool moves rapidly
when unloaded but slowly when carrying a heavy load.

1.6 Shunt connection

A shunt DC motor connects the armature and field windings in parallel or

shunt with a common D.C. power source. This type of motor has good speed
regulation even as the load varies, but does not have the starting torque of a
series DC motor. It is typically used for industrial, adjustable speed
applications, such as machine tools, winding/unwinding machines and
tensioners.
 9

1.7 Compound connection

A compound DC motor connects the armature and fields windings in a

shunt and a series combination to give it characteristics of both a shunt and a
series DC motor. This motor is used when both a high starting torque and good
speed regulation is needed. The motor can be connected in two arrangements:
cumulatively or differentially. Cumulative compound motors connect the series
field to aid the shunt field, which provides higher starting torque but less speed
regulation. Differential compound DC motors have good speed regulation and
are typically operated at constant speed. A mechanical linkage is an assembly of
bodies connected to manage forces and movement. The movement of a body, or
link, is studied using geometry so the link is considered to be rigid.The
connections between links are modeled as providing ideal movement, pure
rotation or sliding for example, and are called joints. A linkage modeled as a
network of rigid links and ideal joints is called a kinematic chain.
1.8 Linkage mobility
Locking pliers exemplify a four-bar, one degree of freedom mechanical
linkage. The adjustable base pivot makes this a two degree-of-freedom five-bar
linkage. It is common practice to design the linkage system so that the
movement of all of the bodies are constrained to lie on parallel planes, to form
what is known as a planar linkage. It is also possible to construct the linkage
system so that all of the bodies move on concentric spheres, forming a spherical
linkage. In both cases, the degrees of freedom of the link is now three rather
than six, and the constraints imposed by joints are now c = 3 − f.

1.9 Joints

The most familiar joints for linkage systems are the revolute, or hinged,
joint denoted by an R, and the prismatic, or sliding, joint denoted by a P. Most
other joints used for spatial linkages are modeled as combinations of revolute
 10

and prismatic joints. Analysis and synthesis of linkages. The primary

mathematical tool for the analysis of a linkage is known as the kinematics
equations of the system. This is a sequence of rigid body transformation along a
serial chain within the linkage that locates a floating link relative to the ground
frame. Each serial chain within the linkage that connects this floating link to
ground provides a set of equations that must be satisfied by the configuration
parameters of the system. The result is a set of non-linear equations that define
the configuration parameters of the system for a set of values for the input
parameters.

Freudenstein introduced a method to use these equations for the design of

a planar four-bar linkage to achieve a specified relation between the input
parameters and the configuration of the linkage. Another approach to planar
four-bar linkage design was introduced by L. Burmester, and is called
Burmester theory.

1.9.1 Planar one degree-of-freedom linkages

The mobility formula provides a way to determine the number of links and
joints in a planar linkage that yields a one degree-of-freedom linkage. If we
require the mobility of a planar linkage to be M = 1 and fi = 1,

Fig 1.10.1 force and lever

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A lever is a beam connected to ground by a hinge, or pivot, called a

fulcrum. The ideal lever does not dissipate or store energy, which means there is
no friction in the hinge or bending in the beam. In this case, the power into the
lever equals the power out, and the ratio of output to input force is given by the
ratio of the distances from the fulcrum to the points of application of these
forces. This is known as the law of the lever. The mechanical advantage of a
lever can be determined by considering the balance of moments or torque, T,
about the fulcrum.

where F1 is the input force to the lever and F2 is the output force. The distances
a and b are the perpendicular distances between the forces and the fulcrum.
Since the moments of torque must be balanced, . So, The mechanical advantage
of the lever is the ratio of output force to input force, This relationship shows
that the mechanical advantage can be computed from ratio of the distances from
the fulcrum to where the input and output forces are applied to the lever,
assuming no losses due to friction, flexibility or wear. This remains true even
though the horizontal distance (perpendicular to the pull of gravity) of both a
and b change (diminish) as the lever changes to any position away from the
horizontal

1.10 Classes of levers

Fig 1.10.2 classes of lever

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CHAPTER 2

LITERATURE REVIEW

Sir Joseph Whitworth was born in Stockport, Cheshire, on the 21st of

December, 1803. His father was a schoolmaster and a dissenter, who later
became a Congregationalist minister. Sir Joseph Whitworth was taught by his
father until he was twelve years old, he then went on to become a pupil at
William Vint's Academy at Idle, near Leeds. The academy was run by
dissenters and used new teaching methods of a practical nature, which earned
the academy a very good reputation. At the age of fourteen Sir Joseph
Whitworth was indentured as an apprentice at his uncle's cotton spinning mill in
Derbyshire, with the view of becoming a partner. He was fascinated by the
machinery and soon mastered the techniques of the spinning industry. Even at
this young age he was critical of the rough standards of accuracy. This led to his
ambition to become a practical engineer making machines. His ambition was so
strong that in 1821 at the age of eighteen he left the mill, against the wishes of
his family, to join Crighton and Co. a leading machine making company in
Manchester. He went on to work in several other engineering establishments in
the same area as a mechanic working at a bench, until in 1825, in order to
further his career, he moved to London and secured job at Henry Maudslay's
works at Lambeth Marsh.
After leaving Maudslay's works Sir Joseph Whitworth went on to work at
Holtzapfell's and then on to Joseph Clement's works. In 1833 he returned to
Manchester and began his own company, proudly displaying the sign "Joseph
Whitworth, Tool-Maker from London". He was probably the first to specialise
in the manufacturing of machine parts, most other engineers made machines for
their own use which were not for sale. His first premises were a small room in a
mill, which he had rented, the following year he moved to larger premises in
 13

Corlton Street. His first wage bill in May 1833 was a mere £2 10s, this had
increased to almost £50, (double the average wage) by April 1834.

During the early years of the company he spent more than this on
equipping the workshop with tools, machinery and materials. His education at
Vint's Academy had given him a good understanding of business affairs and the
business prospered. There was a great demand for machine tools in the 1830's,
due to the rapid expansion of the railways. Manchester was the terminal point
for the first major public railway and the centre of the textile industry. Rapid
progress was being made in mechanisation and it was said to have been
'glorious times for the engineers'. In 1834 his workforce totalled fifteen, by
1854 this had increased to 368 and in 1874, when his works were made into a
limited company he was employing.

Determined to achieve high standards of accuracy he constructed a measuring

machine, based on Henry Maudslay's measuring machine accurate to 0.0001"
and another which could detect differences of less than one millionth of an inch.
The standard method of measurement at that time was by using callipers and a
graduated rule. Engineers were accustomed to working in 'bare' of 'full'
measures until the late 1830's. An article published in the Manchester City
News in 1865 commented that "Mr Whitworths foot rule, on which he had the
thirty-second parts of an inch marked, was regarded as a curiosity, and many
did not hesitate to affirm that to work to such a standard was an unnecessary
refinement". He was one of the first to point out the advantages of
decimalisation, the common fractional system was impossible for precision
work.
 14

In 1841 Sir Joseph Whitworth produced a paper on a universal system of screw

threads. He then collected a variety of screws and proposed a universal thread
using their average pitch and depth. The result was the 'Whitworth thread' with
the depth and pitch of constant proportion, giving the 'V' thread a mean angle of
55 degrees and the number of threads per inch was specified for various
diameters. The thread was first introduced in his own workshop and was in
universal use by 1858. It was not until 1880, when his standard gauges and
screw threads were in common use, that they were officially adopted by the
Board of Trade.
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CHAPTER 3

METHODOLOGY OF THE WORK

Collection of experimental data

Design the QR mechanism

Calculation of experiment

Collection of materials

Fabrication of QR mechanism

Analyses project

Constructed the result

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CHAPTER 4

DESIGN AND FABRICATION

4.1 Design and prototype

The prototype of gear based quick return mechanism is created by the

simple elements and mechanism. Its construction is simple & the design is
portable one. In order to cost effective product of the gear based quick return
mechanism is metals, connecting rod, and motors. three helpers are used for
design and fabrication.

4.2 Design parameters

The design parameter of a gear based quick return mechanism can be

classified as geometric and fuctional. The geometric parameters of a gear based
quick return mechanism is aperture width and length, diameter of the gear, size
of the motor ,power capcity of motor. the fuctional parameters are efficiency of
the machine, power carrying capacity of the machine.

4.3 Layout out of mechanism

Quick-return (QR) mechanisms feature different input durations for their

working and return strokes. The time ratio (TR) of a QR mechanism is the ratio
of the change in input displacement during the working stroke to its change
during the return stroke. QR mechanisms are used in shapers, power-driven
saws, and many other applications requiring a load-intensive working stroke in
comparison to a low-load return stroke [1–3]. Several basic types of mechanism
have a QR action. These include slider-crank mechanisms (e.g., see the offset
slider-crank mechanism in Fig. 1a and the inverted slider-crank mechanisms,
including the crank-shaper mechanism, in Fig. 1b and the Whitworth in Fig. 1c)
and four-bar mechanisms (e.g., see the crank-rocker-driven piston in).
 17

Mechanism analysis techniques taught in a first course on the theory of

mechanisms can be applied to evaluate the performance of QR mechanisms.
Design of a mechanism, on the other hand, requires determining a mechanism to
perform a desired task. For example, synthesis of a reciprocating QR device
requires determination of a mechanism to produce a desired TR and a necessary
stroke. Note that there is not necessarily a unique mechanism design for a
particular task: many mechanism types (e.g., offset slider-crank, Whitworth,
drag-link, etc.) may be capable of performing it. Even within one mechanism
type, many different link-length combinations (perhaps an infinity of several
dimensions [1]) may perform the required task. Choosing a type of mechanism
for a task is called type synthesis. Selecting link lengths for a chosen type is
referred to as dimensional synthesis [1–3].

When many Quick-return mechanisms 101 International Journal of

Mechanical Engineering Education 32/2 mechanisms of various types and/or
dimensions that satisfy the primary task exist, concerns such as mechanism size,
minimum transmission angles, maximum accelerations, etc., can be considered
to isolate a preferred design. The task of a QR mechanism is simple to
understand. Several concepts of design and analysis can be illustrated by a QR
mechanism project. For example, students can be exposed to concepts of
kinematic analysis, of minimum transmission angles, of type and dimensional
synthesis, and of computer-aided modelling programs. Several techniques can
be considered and developed by students to achieve the required synthesis task;
for example, physical modelling, graphical, iterative, and analytical techniques
can all be used to synthesize a desired mechanism.
 18

Having a laboratory manual that briefly outlines different possible

techniques, and leaves the Fig. 1 Slider-crank QR mechanisms:

(a) offset slider-crank,

(b) crank-shaper,

(c) Whitworth.

R. P. Podhorodeski et al. International Journal of Mechanical

Engineering Education 32/2 student-applied technique open, requires a creative
algorithm-design process. Over the past 10 years at the Department of
Mechanical Engineering, University of Victoria, a variety of projects featuring
different mechanism types have been used within a first course on the theory of
mechanisms. The QR project, along with similar technique-open projects on
inertia modelling and on cam design, has given the students a strong
appreciation of mechanism analysis and design issues, and has allowed the
assignment to the course of a significant percentage of accreditation units (AUs)
for Engineering design [4].1 The project described in this work is assigned to
and completed by the students within the first four weeks of a first course on
mechanism analysis. This course occurs in the first term of third year, of a
semester four-year academic programme that leads to an accredited bachelor of
engineering in mechanical engineering degree.
 19

Fig 4.1 quick return mechanism

4.4 Dynamic Analysis

In addition to the kinematic analysis of a quick return mechanism, there is

a dynamic analysis present. At certain lengths and attachments, the arm of the
mechanism can be evaluated and then adjusted to certain preferences. For
example, the differences in the forces acting upon the system at an instant can
be represented by D'Alembert's principle. Depending on the structural design of
the quick return mechanism, the law of cosines can be used to determine the
angles and displacements of the arm. The ratio between the working stroke
(engine) and the return stroke can be simplified through the manipulation of
these concepts. Despite similarities between quick return mechanisms, there are
many different possibilities for the outline of all forces, speeds, lengths,
motions, functions, and vectors in a mechanism
 20

Fig 4.2 dynamic analysis

4.5 Spur gear

Fig 4.3 spur gear

Spur gears are the most common type of gears. They have straight teeth, and
are mounted on parallel shafts. Sometimes, many spur gears are used at once to
create very large gear reductions. Spur gears are used in many devices that you
can see all over How Stuff Works, like the electric screwdriver, dancing
monster, oscillating sprinkler, windup alarm clock, washing
machine and clothes dryer. But you won't find many in your car.
 21

This is because the spur gear can be really loud. Each time a gear tooth engages
a tooth on the other gear, the teeth collide, and this impact makes a noise. It also
increases the stress on the gear teeth. To reduce the noise and stress in the gears,
most of the gears in your car are helical.

Spur gears are the most easily visualized common gears that transmit
motion between two parallel shafts. Because of their shape, they are classified
as a type of cylindrical gears. Since the tooth surfaces of the gears are parallel to
the axes of the mounted shafts, there is no thrust force generated in the axial
direction. Also, because of the ease of production, these gears can be made to a
high degree of precision. On the other hand, spur gears have a disadvantage in
that they easily make noise. Generally speaking, when two spur gears are in
mesh, the gear with more teeth is called the “gear” and the one with the smaller
number of teeth is called the “pinion”.

The unit to indicate the sizes of spur gears is commonly stated, as

specified by ISO, to be “module”. In recent years, it is usual to set the pressure
angle to 20 degrees. In commercial machinery, it is most common to use a
portion of an involute curve as the tooth.

4.6 Ram

The stroke length of a ram is the distance the ram moves forward or backward.
It depends upon the distance between the centre of the bull gear and the centre
of the sliding block. it is adjusted according to the length of the work.
 22

Fig 4.4 quick return mechanism of ram

4.7 Electronics connections with specifications

The major components of this apparatus are the Motor, quick return links
(crank, connecting rod, fixed link)
4.7.1 Motor

The motor is a constant speed type that derives power from the electrical source.
The motor has a provision to be driven at different constant speeds. The motor
is coupled with the rotating disc.

The main advantages or specification of using 12 V DC Motor is as follows:

 It is light in weight.
 30kg load carrying capacity.
 Input speed = 3000 rpm
 Output speed = 53 rpm
 Stealth looking.
 Cheap purchase price.
 23

4.7.3 Adaptor:
 Supply Voltage :- 230V AC
 Output Voltage :- 12V DC
 Current :- 7 Amp

It is used to drive the Motor.

It is used to convert AC voltage into DC voltage.
4.7.3 Quick Return Links

The various links are assembled and are driven by the motor at various speeds.
In this apparatus the crank radius can change for 4 different position of crank.
For this various crank radius the quick return ratio is calculated.

4.8 construction

Base table is made of rectangular shape and has proper support to base to
avoid vibration. It consist of a Connecting Rod, Slider, disc, Gear box Motor,
tachometer, spraying pump etc. Motor is attached to rotary disc. Motor uses
electricity and a magnetic field to produce torque, which cause it to turn.
Spraying pump is attached to the slider. Crank and lever reciprocating
Mechanism are used in machine tool such as Shapers and power driven saw.
4.9 working
In this mechanism, there is a input power supply of 230 V AC. This is
reduced to 12 V DC. This is achieving with the help of reduction transformer
(Adaptor). Once this power is giving to the DC motor it revolves to 53 rpm with
the help of reduction gear box. Therefore, Speed is reduced to 53 rpm. DC
motor is connected to gear box which is directly connected to the pillow block
bearing. This type of bearing is used in light duty applications. Then this
bearing is connected to the wheel with proper shaft. In this mechanism, there
are 2 links. 1st link is connected rod and 2nd link is slider.
 24

In 1st link, there are two holes. 1st hole is directly engaged with the wheel and
2nd hole is engaged with the slider (2nd link). Both the links are connected to
each other with the help of Rivet. The connecting rod converts the rotary motion
into reciprocating motion of slider which is directly connected to the ram of the
mechanism. End of ram is fixed with tool. So, finally the rotary motion is
converted in to reciprocating motion.
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CHAPTER 5
CALCULATIONS
5.1 BASED ON GEAR
Designing a spur gear drive required to transmit 2 kw at a pinion speed of 80
rpm. The velocity ratio is 1.5. the teeth are 20 full depth involute with 29 teeth
on pinion. Both the pinion and gear are made up of same material. Safe stress is
150 N/MM2 . assuming light shock condition. The dias are d1= 60mm & d2=
80mm.

Given data:

P=2kw

N1=80rpm

I=1.5

D1=60 mm

D2= 80mm

To find:

Design spur gear

Sol:

1.selection of material

Both the pinion 7 gears are made up of same material. so, we have to design
only pinion.

2. Selection of material

No of teeth on pinion = 29

No of teeth on pinion = 44
 26

3. Calculation of FT

Tangential load Ft=

V=

V=

V=.251 m/s

K0= 1 (for light shock)

Ft=2(10

Ft= 7957 N

4. Calculations of basic dimensions

Face width (b) = 10

=10(2)

b =20 mm

Module (m) = d/z =60/29= 2.06 mm

Velocity (v) = .251 mm

5. Calculation of Fd:

Dynamic load Fd=

Fd=
 27

Fd= 10549 N

6. Calculation of beam strength(fs)

FS=

=20616.31 N

7. Check for beam strength ( tooth breakage):

Fd<FS

10549<20616

So, the design is satisfactory.

8. Calculation of wear lode:

Fw =d1 w

Q= =2[2]/3 =1.33

w=.919 N

Fw =60 .919

Fw =12629 N.

9. check for wear:

Fw<Fd

1269<10549

Therefore the design is satisfactory.

10. basic dimensions of pinion and gear

 28

 Module (m) = 8mm

 No of teeth z1=29; z2=44
 Pitch circle dia : d1=60 mm ; d2=80 mm

 Centre distance: a=

 Face width : b= 20 mm
 Height factor f0= 1, for full depth 200 teeth
 Bottom clearance : c=.25 mm =.25
 Tip diameter da1= (z1+2f0)m
=(29+2)2=64 mm
da2 = (z2+2 f0)m
=(44+2)2=88 mm
 Root diameter : df1=(z1-2 f0) m=(29-2)2=50 mm
df2 = (z2-2 f0)m=(44-2)2

5.2 BASED ON OVER ALL MECHANISM

If the length of the slotted lever is 700 mm, what would be the length of
the assuming that the line of the stroke passes through the extreme
positions Of the free the slotted lever ?

Given Data : AB 300 mm •z 0.3 m ;

AE 150 mm c" 0.15 m ; BPI 700 mm 0.7 m.
Solution : (i) Inclination of the slotted bar with the Fixed link :
Let Z ABE = inclination of the slotted bar with the vertical

Figure shows the extreme positions of the crank.

We know that, sin Z ABE

= sin 900 –β/2

=AE/AB
 29

=.15/.3
=.5
< ABE = 900 –β/2

= sin-I (0.5)

= 300 Ans.

fig 5.1 quick return mechanism

(ii)Time ratio of cutting stroke to the return stroke :

We know that,
= sin 900 –β/2
 30

(iii) Length of the stroke :

Length of the stroke = P1P2

=2( P1P)
=2(BP1) sin 900- (β/2)
=2×0.7×

L = 450 mm
 31

CHAPTER-6
RESULT AND DISCUSSION

Retrieved from outdoor examination tests from the days chosen for
February and March -2019.the performance of gear based quick return
mechanism is calculated from the various types of analyses and tests. More
number of analysis and calculations performed during last 1 month. Finally the
input power of the motor to gear is increases up to 80% from the analysing of
first time. based on changing the bearing mechanism in connection of motor to
gear. During designing a spur gear drive required to transmit 2 Kw at a pinion
speed of 80 rpm. The velocity ratio is 1.5. The teeth are 200 full depth involute
with 29 teeth on pinion and gear of steel with maximum safe stress of 150
n/mm2 . light shock condition. The diameters are d1=60 mm & d2=80mm.

The input speed of the 500 rpm and this speed is to be transmitted to the
gear of pinion. That time the speed of the pinion is 80 rpm and then this energy
of pinion is transmitted to the gear by those of contacting one with each other.
So, the speed of the gear is reduced to 53 rpm by the speed ratio of the gear and
pinion.

Calculated dimensions of parts

ITEM VALUE
Diameter of the gear 80 mm
Diameter of the pinion 60 mm
Power of motor 10 kw
Length of stroke 700 mm

Table 6.1 dimensions of parts

 32

CHAPTER-7
CONCLUSION
As a conclusion, it is confirm that the quick return motion may increase
the efficiency of the machine. This is because; the time taken for the slider to
return to its initial position is less than the time taken for the slider to
accomplish the cutting operation with the same distance. From this experiment,
the purpose of this machine is to moves the ram into desired direction having
uniform deposition on this sub-straight. Finally, the aid of this project has
demonstrated to the difference of rotation angle for cutting and returning strokes
that may increase the efficiency of machine.
 33

CHAPTER-8
PHOTOCOPY
 34

CHAPTER 9
FUTURE SCOPE
Design and fabrication of gear based quick return mechanism is used for many
purpose in reciprocating mechanism. The future based quick return mechanism
is applied for many shaper mechanisms in cnc machine. And the construction
based works.
 35

CHAPTER-9
COST ESTIMATION

Table no 9.1 Cost Estimation

S.NO DESCRIPTION ITEMS (No) COST (Rs)

1 Gear 2 450
2 Bolts 10 60
3 Washers 20 50
4 Connecting rod 1 100
5 Metal rods 10 1000
6 Hollow tube 1 200
7 Motor 1 800
8 Welding ARC 1000
9 Transport & food allowances - 1000
TOTAL 4660
 36

CHAPTER-10
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