Elbow Mechanism PDF

A PROJECT REPORT ON
“ELBOW MECHANISM”
SUBMITED TO THE GOVERNMENT POLYTECHNIC PUNE,
(An Autonomous Institute of Government of Maharashtra)
IN THE PARTIAL FULFILLMENT OF THE FINAL YEAR

DIPLOMA COURSE IN MECHANICAL ENGINEERING
SUBMITED BY.
1. Tanuja Vijaykumar Kashid En.No. 1324222
2. Sourav Siddheshwar Kotgund En. No. 1324226
3. Sanket Virbhadra Kothale En. No. 1324227
4. Sheryas Prakash Misale En. No. 1324228
5. Pagar Jagdish Dharma En. No. 1324230
6. Pasalkar Aditya Laxman En. No. 1324231
GUIDED BY
Mr . P. U. Garge
DEPARTMENT OF MECHANICAL ENGINEERING

PUNE-411 016
(AN AUTONOMOUS INSTITUTE OF GOVT. OF MAHARASHTRA)
2015-16
GOVERNMENT POLYTECHNIC PUNE
(AN AUTONOMOUS INSTITUTE OF GOVT. OF MAHARASHTRA)
PUNE-411 016
CERTIFICATE
This is to certified that the project work entitled “ELBOW MECHANISM” is a benefited
work carried out by the below mentioned students in partial fulfilment for the award of
Diploma in MECHANICAL ENGINEERING of GOVERNMENT POLYTECHNIC,
PUNE during the year 2015-2016. It is certified that all corrections/ suggestions indicated for
Internal Assessment have been incorporated in this report. The project report has been
approved as it satisfies the Academic requirements in respect of project work prescribed for
Diploma in MECHANICAL ENGINEERING.
NAME OF STUDENT ENROLLMENT NO.
1. Tanuja Vijaykumar Kashid En.No. 1324222

2. Sourav Siddheshwar Kotgund En. No. 1324226
3. Sanket Virbhadra Kothale En. No. 1324227
4. Sheryas Prakash Misale En. No. 1324228
5. Pagar Jagdish Dharma En. No. 1324230
6. Pasalkar Aditya Laxman En. No. 1324231
Prof. P.U. Garge Dr. M. Giridhar Dr. D. R. Nandanwar
Project Guide Head of Department Principle External Examiner

ELBOW MECHANISM
ACKNOWLEDGEMENT
We take this momentous opportunity to express our heartfelt gratitude, ineptness &
regards to vulnerable and highly esteemed guide, Mr. P.U.Garge, for providing us an
opportunity to present our project on “ELBOW MECHANISM”.
We with full pleasure converge our heartiest thanks to Our project guide Mr.
P.U.Garge, Lecturer, Department of Mechanical Engineering, Government
Polytechnic Pune, for their invaluable advice and wholehearted cooperation without
which this project would not have seen the light of day.
We attribute hearties thanks to all the faculty of the department of mechanical and
friends for their valuable advice and encouragement
Thanking.
GOVERNMENT POLYTECHNIC PUNE 1

ELBOW MECHANISM
INDEX OF CHAPTERS
Sr.No. Chapter Name Pg.No.
1. Introduction 6
1.1. Function of transmission.
1.2. Types of transmission.
1.3. Need for project.
1.4. Solution.
2. Construction & Working. 11
2.1. Construction.
2.2. Working.
2.3. Advantages & Disadvantages.
2.4. Simple gear train.
3. Design 17
3.1. System Design.
3.2. Mechanical Design.
3.3. Input Data.
3.4. Design of Propeller Shaft.
3.5. Design of Gears.
3.6. Design of Input Shaft.
3.7. Design of Output Shaft.

ELBOW MECHANISM
3.8. Design of Bearing Bush.
3.9. Design of Bent Pins.
4. Process Sheet 33
4.1. Process Sheet For Pulley.
4.2. Process Sheet For L-H Output Shaft.
4.3. Process Sheet For R-H Output Shaft.
4.4. Process Sheet For R-H Input Shaft.
4.5. Process Sheet For L-H Input Shaft.
4.6. Process Sheet For L-H_BRG_HSG.
4.7. Process Sheet For R-H_BRG_HSG.
4.8. Process Sheet For Central_BRG_HSG.
4.9. Process Sheet For Cover Ring.
5. Test & Trial on ELBOW MECHANISM. 46
6. Operation Table. 48
6.1. Sample Calculation.
7. Result Table. 52
8. Cost Analysis. 54
9. Conclusion & Future Scope 58
10. Bibliography 60

ELBOW MECHANISM
--------DEFINATION OF PROJECT--------
P- Planning before carrying out the work
R- row material required for the work
O- Organization of the work
J- joint effort put in to the work
E- estimation of material required in the work
C- Costing of the work
T- techniques used in performing

ELBOW MECHANISM
Project Abstract / Summary : ABSTRACT
This project “EL-BOW TRANSMISSION” being compact and portable

equipment, which is skilful and is having practice in transmitting power at right
angle without any gears being manufactured. The El-bow Mechanism transmits
the input power towards the output side such a way that the angular forces
produced in the slacks are transmitted with the help of rods which takes up the
input power and the right angle drive is transferred towards the output slack
and rod assembly. Hence very little friction plays while the power is being
transmitted.
Hunting and back lash errors are absent. Therefore, it is appreciated
that efficiency as high as 90-92% are possible in gear less transmission
mechanism.
Why did you choose to work on this project topic :

Here is a
wonderful mechanism that carries force through a 90ºbent rod. Transmitting
rotational motion around an axis usually involves gears, which can quickly
become complicated, inflexible and clumsy-looking, often ugly. So, instead of
using gears, this technology elegantly converts rotational motion using a set of
cylindrical bars, bent to 90º, in a clever, simple and smooth process that
translates strong rotational force even in restricted spaces.A gearless
transmission is provided for transmitting rotational velocity from an input
connected to three bent links. Both the input shaft and the housing have
rotational axes. The rotational axis of the input shaft is disposed at an angle of
90 degree with respect to the rotational axis of the housing. As a result, rotation
of the input shaft results in a processional motion of the axis of the bent link.
The rotary and reciprocating motion of bent link transmit rotation of prime
mover to 90 degree without any gear system to an output shaft.

ELBOW MECHANISM
CHAPTER NO.1
INTRODUCTION

ELBOW MECHANISM
PROJECT TITLE : ELBOW MECHANISM
INTRODUCTION
The word ‘TRANSMISSION’ on which the project is based upon means the
whole of the mechanism that transmits the power from the engine crankshaft to
the rear wheels. However the ‘transmission’ is also being used very commonly
in the literature for a mechanism, which provides us with suitable variation of
the engine torque at the road wheels, whenever required. This may be a
gearbox (also called manual transmission) or an automatic transmission.
FUNCTIONS OF TRANSMISSION
The main functions that are performed by the transmission are:
1)The torque or the tractive effort produced by the engine varies with speed
only within narrow limits. But the practical consideration for the running of
automobile under different conditions demands a large variation of torque
available at the wheels. The main purpose of the transmission is to provide
means to vary the leverage or the torque ratio between the engine and the road
wheels as required.
2)The transmission also provides a neutral position so that the engine and the
road wheels are disconnected even with the clutch in the engaged position.
3)A mean to back the car by reversing the direction of rotation of the drive is
also provided by the transmission.

ELBOW MECHANISM
TYPES OF TRANSMISSION
The transmissions may be classified into the manual and the automatic
types. The manual transmissions are conventionally called gearboxes. Their
mechanical efficiency in direct drive is about 98%, whereas in reduction gears,
it is slightly greater than 90%. As most of the time the driving is done in direct
drive, friction losses in manual transmissions are very small. That coupled with
simplicity and lower initial cost, is the reason these are still popular particularly
in fuel-efficient automobiles. On the other hand the operation of engaging and
disengaging the clutch along with changing gears while driving over a crowded
highway means a lot of fatigue to the driver. Therefore, in luxury vehicles
automatic transmissions are employed which simplify the driving operation
considerably.
NEED FOR PROJECT:
The conventional transmission system used in auto rickshaw is as shown in the

figure. The transmission train comprises of the engine as the power plant , and
the clutch –gear box and differential arrangement as the traction device. The
power is available at the differential end as two outputs , which is supplied to
the wheels individually by means of double hooke’s joint as the engine is at a
higher level as compared to the wheels.
The double hooke’s joint has certain disadvantages that, it does not
transmit constant angular velocity, so also the efficiency of transmission is
low(65%).More over this efficiency further drops with the increase in angular
velocity ie speed output from the engine. The drive is subjected to inherent
vibrations and considerable axial and radial forces are encountered during
power transmission.
Actually the situation is simple that the power from the differential has
to be transmitted at right angles to the wheels, and even if the wheels move
over a bump on the road this right angle is not disturbed.

ELBOW MECHANISM
Universal System Used in 3-Wheeler

ELBOW MECHANISM
SOLUTION
ELBOW MECHANISM (ORBITAL TRANSMISSION SYSTEM.)
The orbital transmission system is an adaptation of the original

mechanism named Elbow mechanism developed by LEO -NARDO-DA-
VINCI. This Elbow mechanism is capable of transmitting heavy torque at high
speeds between two shafts at right angles. This mechanism comprises of two
shafts drilled with three holes each on the same pitch circle diameter on each
shaft and a set of three bent pins that are made of steel and bent at exactly 900.
This mechanism is capable of transmitting high speeds (12000 rpm).
The drive is compact and can be made into hermetically sealed units filled with
lubricating oil in order to increase the life of the drive. This drive has an
efficiency as high as 93%.
In the project we are getting the two inputs to the transmission system
from the one shaft through simple gear train . gears used over here are of same
diameter and having same number of teeth on its periphery. One variable speed
motor drives the main propeller shaft through belt and pully. Pully is fitted
rigidly on it. The single shaft can be driven by both manually as well as using
motor drive.
This transmission system is extremely compact and will improve the
efficiency of power transmission of the vehicle and thereby the mileage of the
vehicle.

ELBOW MECHANISM
Chapter No.:- 2
CONSTRUCTION AND
WORKING

ELBOW MECHANISM
CONSTRUCTION
1. ELECTRIC MOTOR:-
Electric motor of following specifications is used
Single phase Ac Motor
230 volt,0.5 AMP.
50 Hz
Power = 100 watt
Speed = 0 to 6000 rpm
TEFC CONSTRUCTION
COMMUTATOR MOTOR
2. PULLEY:-
pulley is v-belt pulley of 40 degree groove angle and 6mm ‘A’
section .This reduction pulley gives an speed reduction ratio of 4.68
.This reduction pulley is mounted at the bearing end of the propeller
shaft.
3. LH&RH INPUT SHAFT:-

Input shaft is an steel construction where in main shaft is an high
grade steel (EN 24) Input shaft supports the reduction pulley at
lower end and the horizontal places at the upper end .The horizontal
plates are drilled with three holes of equal pitch, these holes receive
the bent pins.
4. BENT PINS:-
Pins are made form high carbon steel; in three sets of 90 ,120,140
degree respectively pins are bent to the desired angle in a special
fixture such that the bend is not sharp but slightly filleted to avoid
stress concentration.

ELBOW MECHANISM
5. CENTRAL BEARING HOUSING:-

The central bearing housing houses two ball bearings 6201 zz in
which the input shafts are mounted .The central bearing housing is
welded to the base fame.
5. LH BEARING HOUSING:-
The LH bearing housing houses ball bearing 6201 zz in which the
LH_ output shafts are mounted .The LH bearing housing is welded
to the base fame.
6. RH BEARING HOUSING:-
The RH bearing housing houses ball bearing 6201 zz in which the
RH_ output shafts are mounted .The LH bearing housing is welded
to the base fame
7. PROPELLER SHAFT
Pulley is mounted on propeller shaft. Pulley is driven by motor shaft
and then it drives propeller shaft. Propeller shaft is also manually
driven by hand wheel which is located at other end of shaft, which is
fixed.
8. GEARS
4 Gears are used for power transmission from propeller shaft to the
both wheels through Input and output shaft mechanism.
9. WHEELS
The wheels are of nylon that are fitted at the output shaft ends

ELBOW MECHANISM
WORKING:
Electric motors supply power to the Propeller shafts of the orbital

transmission system by means of belt and pulley arrangement. Then, drive is
given to the two input shaft through simple gear train mechanism. Gear used
over here are spur type and of same diameter. Therefore, there will be no
variation in speed of two wheels. The input shaft rotate to move the pins about
the central axis, this motion causes the pins to slide to and fro inside the output
shaft holes which in turn results into rotary motion of the output shaft.
Thus the rotary input from the motors is transferred to the output wheel
shafts that cause the wheels to rotate.
ADVATAGES OF ELBOW MECHANISM
1. Better transmission efficiency (90%) as compared to conventional

double hook e’s joint ( 60 to 65 %)
2. Better efficiency of system results in better fuel economy.
3. Radial speed of input and output shaft is same , hence no phase shift.
4. No vibrations in drive.
5. Efficiency remains almost constant even with increase in transmission
speed.
6. Compact as compared to double hooke’s joint.
7. Lower manufacturing cost.
8. Lower maintenance required.
DISADVANTAGES :
1. Slightly high cost of manufacture.

2. Special machines like jig boring is required for manufacture.
3. Conventional Transmission system needs to be modified to
incorporate the above system/.

ELBOW MECHANISM
Simple Gear Train-

In simple gear train, each shaft carries one wheel only and there no relative
motion between the axis of the shafts.
Gear used over here are of same diameter and having same number of teeth.
one gear is driving and two gears are driven type. One idler gear is used in
intermediate to one driving and driven shaft.
Let,
N1 and T1 is speed and no. of teeth of Driving gear which is fixed on propeller
shaft and rotated.
N2,T2 and N3 T3 are speed and no. of teeth of driven gear 1 and driven gear 2
respectively.
And let say, N4 and T4 is the speed and No. of teeth of Idler gear which is
intermediate between driving shaft and driven gear 1.
Since the driving wheel drives driven gear 2,
N3 x T3 = N1 x T1 ......(1)
As well as driving gear drives Idler gear,
N4 x T4 = N1 x T1 ........(2)
Since Idler gear drives Driven gear 1,
N2 x T2 = N4 x T4 ........(3)
Gear used are of same diameter and same no. of teeth so there is no speed
reduction take place.
NO OF TEETH OF ALL GEARS = T1 = T1 = T3 = T4 ................. (4)
From Equation 1,2,3,4,
N1 = N2 = N3 = N4........................( hence proved)
So we can say that same power is given to driven shafts without any speed
reduction.
If the input and output gears are exactly the same size, they will turn at the
same speed.
In many simple gear trains there are several gears between the input gear and
the output gear.
These middle gears are called idler gears. Idler gears do not affect the speed
of the output gear.

ELBOW MECHANISM
Chapter No.:-3
Design

ELBOW MECHANISM
DESIGN
Design consists of application of scientific principles , technical

information and imagination for development of new or improvised machine or
mechanism to perform a specific function with maximum economy and
efficiency.
Hence an careful design approach has to be adopted. The total design

work, has been split up into two parts;
SYSTEM DESIGN
MECHANICAL DESIGN

ELBOW MECHANISM
SYSTEM DESIGN
System design mainly concerns with various physical constrains,

deciding basic working principle, space requirements, arrangements of various
components etc.
Following parameters are looked upon in system design.

a) Selection of system based on physical constraints. The mechanical
design has direct norms with the system design hence system is
designed such that distinctions and dimensions thus obtained in
mechanical design can be well fitted in to it.
b) Arrangement of various components made simple to utilize every
possible space.
c) Ease of maintenance and servicing achieved by means of simplified
layout that enables quick decision assembly of components.
d) Scope of future improvement.

ELBOW MECHANISM
MECHANICAL DESIGN
In mechanical design the components are listed down and stored on the
basis of their procurement in two categories,
Design parts
Parts to be purchased.
For designed parts detailed design is done and dimensions there

obtained are compared to next dimensions which are already available in
market. This simplifies the assembly as well as the post production and
maintenance work. The various tolerances on work are specified .The process
charts are prepared and passed to manufacturing stage.
The parts to be purchased directly are selected from various catalogues
and are specified so as to have case of procurement .
In mechanical design at the first stage selection of appropriate material
for the part to be designed for specific application is done.
This selection is based on standard catalogues or data books;
eg:- (PSG DESIGN DATA BOOKS )
(SKF BEARING CATALOGUE ) etc.
APPROACH TO MECHANICAL DESIGN OF ‘PLANETARY SPEED

REDUCER’
In design the parts of ‘planetary speed reducer’ we shall adopt the

following approach ;
a) Selection of appropriate material .
b) Assuming an appropriate dimension as per system design.
c) Design check for failure of component under any possible system of
forces.

ELBOW MECHANISM
INPUT DATA
1) MOTOR DETAILS:
SINGLE PHASE AC MOTOR
230 VOLT, 50Hz , 0.5 Amp
POWER = 100 WATT
SPEED = 200 TO 4500 rpm
TEFC CONSTRUCTION MOTOR.
2) DIAMETER OF PLATES =45mm
3) PCD OF HOLES ON DISC = 32mm
4) THICKNESS OF PLATES =8mm
5) DIAMETER OF PINS (3No’s)=4mm
6) DIAMETER OF INPUT SHAFT=10mm
7) DIAMETER OF OUTPUT SHAFT=10mm
8) DIAMETER OF DRIVER PULLEY = 16mm
9) DIAMETER OF DRIVEN PULLEY = 75mm
10)SPEED REDUCTION RATIO = 75/16 =4.688
11)SPEED OF MECHANISM (MAX)=1200rpm
(MIN)=0 rpm
12)MAX OUTPUT TORQUE AT 850 rpm = 0.08 kg.m
13) DIAMETER OF PROPELLER SHAFT =
14) NO. OF GEARS = 4
15) PCD OF ALL GEARS = 26mm

ELBOW MECHANISM
DESIGN OF INPUT SHAFT:-
Torque calculation:-
Max Input Power = 100 watt at 6000 rpm.

At motor shaft
9
60
2∏NT 2 x ∏ x 6000 x T
I/P power = 60 = 60
60 x 100
⇒ T= = 0.1592 N-m
2 x ∏ x 6000
Assuming 100 % efficiency of transmission between motor shaft & Mechanism I/P
shaft .
⇒ 2 ∏ N T motor O/p = 2 ∏ NT mech i/p
60 60
⇒ T mech i/p = 4.688 x 0.1592
= 0.7463 N-m
Assuming 100% overload;

⇒ factor of safety =2
⇒ Tdesign = 2 Tmech i/p
⇒ Tdesign =2x0.7463
=1.4926 N.m
⇒ Tdesign = 1.4926 x 103 N.m
MATERIAL SELECTION
Designation Ultimate Tensile strength Yield strength
N/mm2 N/mm2
EN 24 800 600

ELBOW MECHANISM
ASME CODE OR DESIGN OF PROPELLER SHAFT:-
Since the shaft is subjected to variable load at different speed condition sit is
necessary to make proper allowance for harmful effects of load fluctuation
Propeller shaft is supported between two bearings and pulley is rigidly
mounted on it and the weight of pulley is neglected and cyclic fluctuations occurs
while rotating.
According to ASME code permissible value of shear stress may be calculated
for various relations.
fs max = 0.18 fult
=0.18 x 800
= 144 N/mm2
or
fs max = 0.3 x 600
= 180 N/ mm2
Considering minimum of the above values.

⇒ fs max = 144 N/mm2
This is allowable valves of shear stress induced in input shaft of or safe operation .
Shaft is provided a hole for rivet which reduces its strength ;
⇒ Reducing above value by 25%
⇒ fs max = 0.75 x 144

= 100 N/mm2
Diameter of input shaft =6mm
Check for torsional failure of shaft:-
3
T= Π /16 fs act d

ELBOW MECHANISM
⇒ fs ac t = 16 x T
Πd 3
16 x 1.4926 x 103
= Π x 10 3
fs act = 35.19 N/mm2
⇒ As fs act < fs all
⇒ Shaft is safe under torsional load.

ELBOW MECHANISM
Spur Gear Design :-
1. Outside Diameter = 22mm
2. No. Of Teeth = 19
3. Root Diameter = 18mm
4. Addendum = A = 1mm
5. Dedendum = D = 1mm
6. Pressure Angle = ϕ = 20 degree ( Standard )
7. Base Circle Diameter = 18mm
8. Pitch Circle Diameter = 20mm
9. Circular Pitch = πM = 4mm
10. Module = 1.05mm
11. Circular Tooth Thickness = πM = 2mm
12. Whole Depth Of Teeth = 2mm

ELBOW MECHANISM
DESIGN OF INPUT SHAFT:-
Power and Torque is transmitted to both input shaft through simple gear train
mechanism and subjected to twisting moment only.
According to ASME code permissible value of shear stress may be calculated
for various relations.
fs max = 0.18 fult
=0.18 x 800
= 144 N/mm2
or
fs max = 0.3 x 600
= 180 N/ mm2
Considering minimum of the above values.

⇒ fs max = 144 N/mm2
This is allowable valves of shear stress induced in input shaft of or safe operation .
Shaft is provided a hole for rivet which reduces its strength ;
⇒ Reducing above value by 25%
⇒ fs max = 0.75 x 144

= 100 N/mm2
Diameter of input shaft =6mm
Check for torsional failure of shaft:-
3
T= Π /16 fs act d

ELBOW MECHANISM
⇒ fs ac t = 16 x T
Πd 3
16 x 1.4926 x 103
= Π x 10 3
fs act = 35.19 N/mm2
⇒ As fs act < fs all
⇒ Shaft is safe under torsional load.

ELBOW MECHANISM
Design of out put shaft:-
Material selection

2
N/mm N/mm2
EN24 800 600
Design check for Torsional Failure

T=Π/16 fs act d3
Diameter of output shaft = 6mm

fs act = 16 x T
Π x 63
3
fs act = 35.19 N.mmd
⇒ shaft is safe under torsional load.

ELBOW MECHANISM
Design check for bending failure of o/p shaft:-
O/p shaft supports the weight of the bent pins ,discs etc and is held at one end in bush
bearing which weigh approx. 0.75 kg
Assuming factor of safety = 2
Bending Load =2 x 0.75
=1.5kg
=15N
fb act = M
Z
fb act = 32 M
∏ d3
32 x15 x 130
⇒fb act = = 19.86 N/mm2
3
∏ x (10)
As fb act < fb all
⇒ shaft is safe in bending .

ELBOW MECHANISM
Design of Bearing bush
Material selection

2
N/mm N/mm2
C30/EN8K 620 400
Bearing pressure pb = load

Project area
(Pb) = W
lxd
Where ;
pb = Average bearing pressure N/mm2
P= Radial load on journal (N)
l = Length of journal in contact(mm)
d= Diameter of journal (mm)
Here ; d= 10mm
l = 22 mm & Average bearing pressure for steel combination 12.6 N/mm2
Pb act = 12.6 N/mm2
Radial load
Torque = w x r
⇒ W = 1.4926 x 10 3 =497.53 N
PB = 497.53/22 x 10 =2.26
⇒ As Pb act < Pb all
⇒Bearing brush is safe.

ELBOW MECHANISM
Design of Bent Pins:-

Bent pins are torque transmitting elements similar to bolts in ease of flange coupling .
Material Selection
Designation Tensile strength Yield strength

N/mm2 N/mm2
EN9 520 350
a) Design check for shear failure of Pins.

d= diameter of pins = 4
n = no . of pins =3
T= ∏ x d 2 x fs b x n x dP
4 2
1.4926 x 103 = ∏ x (4)2 x fsb act x 3 x 36

4 2
⇒ fsb act = 2.199 N/mm2

As ; fsb act < fsb all
⇒Pins are safe in shear (Torsional)
b) Design check for crushing failure:-

T = n x d x t f x f c b act x dp
2
3
1.4926 x 10 = 3 x 4 x 7 x f cb act x 36
2
⇒ fcb act = 0.98716 N/mm2 As fcb act < fcb all

ELBOW MECHANISM
Chapter No: 4
Process Sheet

ELBOW MECHANISM
PART NO : OTS - 03
PART NAME : PULLEY MATERIAL SPECIFICATION : EN 9
RAW MATERIAL SIZE: φ80X 30
QUANTITY :- 01 NO’S.
Tools Time in minutes

Sr. Description of Jigs &
No Operation Fixture M/c Cutting Measuring Setting M/c Total
Tools Tools Instrument Time Time Time
1. Clamp stock 3 Jaw chuck Lathe - - 20 - 20
2. Facing one sides --”-- --”-- Facing tool Vernier - 5 5
3. Turning diameter 75 --“-- --“-- Turning tool --“-- 5 10 15

through 23.5 mm
length
4. Turning φ 30 --“-- --“-- --“-- --“-- - 30 30
through 14.5 mm
length
5. Turning groove φ --“-- --“-- Grooving --“-- 5 10 15

50 mm ;3mm deep tool
6. Chamfer 6 x 45 --”-- --”-- Crank facing --”-- 10 3 13
degree on face tool
7. Roughing V groove --”-- --”-- Parting tool --”-- 10 10 20
8. Finish V groove --“-- --“-- V- tool Angle 15 25 40

protractor
9. Centre drill --“-- --“-- Centre drill --“-- 5 2 7
10. Drilling φ 14.5 hole --“-- --“-- Twist drill φ --“-- 5 2 7

through 40 mm 6mm
11. Reaming φ 15 hole --“-- --“-- Reaming φ 6 --“-- 5 3 8

through 40 mm
12. Parting off to 24mm --“-- --“-- Parting tool --“-- 5 7 12

Length
13. Facing other side to --“-- --“-- Facing tool --“-- 5 2 7

23.5 mm length

ELBOW MECHANISM
PART NO : OTS - 07
PART NAME :LH_ OUTPUT SHAFT MATERIAL SPECIFICATION : EN24
RAW MATERIAL SIZE: φ55 x 145
QUANTITY :- 0 4 NO’S.
2. Facing one sides --”-- --”-- Facing tool Vernier 5 2 7
3. Turning outer --“-- --“-- Turning tool --“-- 5 13 18

diameter to φ 48mm
through length
4. Center drilling --“-- --“-- Center drill --“-- 5 2 7
5. Turning φ --“-- --“-- Twist drill --“-- 5 3 8

15mmthrough 101
length
6. Turning φ --“-- --“-- Turning tool --“-- 5 3 8
15mmthrough 86
length
7. Turning φ --”-- --”-- Turning tool --”-- 5 12 17
12mmthrough 57
length
10mmthrough 45
length
8mmthrough 15
length
10. Threading M8 --”-- --”-- Threading --”-- 5 12 17
threads tool
11. Turning φ --”-- --”-- Reamer --”-- 5 12 17
12mmthrough
length
12. Grooving as per --”-- --”-- Parting tool --”-- 5 2 7
profile
13. Facing other side --“-- --“-- Facing tool --“-- 5 2 7
14. Clam job on m/c 3jaw chuck DRO - --“-- 30 - 30

vice milling
m/c
15. Drilling φ 3.85 holes --“-- --“-- Twist drill --“-- 5 3 8
through thickness 3
No’s

ELBOW MECHANISM
16. Reaming φ 4 holes --“-- --“-- Reamer --“-- 5 5 10
thro thickness 3
No’s
17. Chamfer 0.5 x 45 --“-- --“-- Twist drill --“-- 5 12 17
degree B/s of each
hole

ELBOW MECHANISM
PART NO : OTS - 08
PART NAME :RH_ OUTPUT SHAFT MATERIAL SPECIFICATION : EN24

diameter to φ 48mm
through length

15mmthrough 101
length
6. Turning φ --“-- --“-- Turning tool --“-- 5 3 8
15mmthrough 86
length
12mmthrough 57
length
10mmthrough 45
length
8mmthrough 15
length
10. Threading M8 --”-- --”-- Threading --”-- 5 12 17
threads tool
11. Turning φ --”-- --”-- Reamer --”-- 5 12 17
12mmthrough
length
profile

vice milling
m/c
through thickness 3
No’s

ELBOW MECHANISM
thro thickness 3
No’s
degree B/s of each
hole

ELBOW MECHANISM
PART NO : OTS - 06
PART NAME :RH_ INPUT SHAFT MATERIAL SPECIFICATION : EN24


diameter to φ 48mm
through length

15mmthrough 76
length
12mmthrough
12length
profile

vice milling
m/c
through thickness 3
No’s
thro thickness 3
No’s
degree B/s of each
hole

ELBOW MECHANISM
PART NO : OTS - 05
PART NAME :LH_ INPUT SHAFT MATERIAL SPECIFICATION : EN24


diameter to φ 48mm
through length

15mmthrough 76
length
12mmthrough
12length
profile

vice milling
m/c
through thickness 3
No’s
thro thickness 3
No’s
degree B/s of each
hole

ELBOW MECHANISM
PART NO : OTS - 10
PART NAME : LH_BRG_HSG
MATERIAL SPECIFICATION: EN 9
RAWMATERIAL SIZE: 50X20X60
QUANTITY: - 01 NO’S.
Sr. Description of Tools Time in minutes

No Operation
Jigs & M/c Cutting Measuring Setting M/c Total
Fixture Tools Tools Instrument Time Time Time
1. Clamp stock M/C Vice Milling - - 15 - 15
2. Facing All Sides --”-- --”-- Facing cutter Vernier 5 14 19

Sq. to total
length 40x12x50
mm
3. Clamp stock on 4 jaw chuck Lathe - - 25 25
lathe
4. Drilling Ø 18.5 --”-- --”-- Twist drill Vernier 15 10 25
through
thickness
5. Boring Ø 25 --”-- --”-- Boring tool Vernier 15 10 25
through
thickness
6. Counter Boring --”-- --”-- Boring tool Vernier 15 10 25
Ø 32 through
10 thickness

ELBOW MECHANISM
PART NO : OTS - 11
PART NAME : RH_BRG_HSG

No Operation

Sq. to total
length 40x12x50
mm
lathe
through
thickness
through
thickness
Ø 32 through
10 thickness

ELBOW MECHANISM
PART NO : OTS - 9
PART NAME : CENTRAL_BRG_HSG

No Operation

Sq. to total
length
135x12x40 mm
lathe
through
thickness
through
thickness
Ø 32 through
10 thickness
through
thickness
through
thickness
Ø 32 through
10 thickness

ELBOW MECHANISM
PART NO : OTS - 17
PART NAME :COVER RING MATERIAL SPECIFICATION : EN9


diameter to φ
54mm through
length

through
thickness
through
thickness
Ø 45 through
40 thickness
Ø 47 through 8
thickness
9. Threading M48
Threads
through 8mm
length
10. Facing other --“-- --“-- Facing tool --“-- 5 2 7
side
11. Clam job on 3jaw chuck DRO - --“-- 30 - 30
m/c vice milling
m/c
12. Drilling φ 3.85 --“-- --“-- Twist drill --“-- 5 3 8
holes through
thickness 3 No’s
13. Reaming φ 4 --“-- --“-- Reamer --“-- 5 5 10
holes thro
thickness 3 No’s

ELBOW MECHANISM
14. Chamfer 0.5 x --“-- --“-- Twist drill --“-- 5 12 17
45 degree B/s
of each hole

ELBOW MECHANISM
Chapter No.:-5
TEST & TRIAL ON ELBOW

MECHANISM

ELBOW MECHANISM
TEST & TRIAL ON ELBOW MECHANISM

AIM: -
To conduct trial on Orbital Mechanism to determine
a) TORQUE Vs SPEED CHARACTERISTICS
b) POWER Vs SPEED CHARACTERISTICS
In order to conduct trial , an dynobrake pulley cord, weight pan are provided
on the output shaft.
INPUT DATA:-
A) Drive Motor
AC230 Volt
0.5 Amp, 100 watt
50 Hz, 200 to 4500 rpm
TEFC COMMUTATOR MOTOR
B) Diameter (Effective ) of Dynobrake pulley = 25 mm.
PROCEDURE:-
1) Start motor by turning electronic speed variator knob.
2) Let mechanism run & stabilize at certain speed (say 1300 rpm)
3) Place the pulley cord on dynobrake pulley and add 100 gm weight
into , the pan , note down the out put speed for this load by means
of tachometer.
4) Add another 100 gm cut & take reading .
5) Tabulate the readings in the observation table
6) Plot Torque Vs speed characteristic
Power Vs speed characteristic

ELBOW MECHANISM
Chapter No.:-6
OBSERVATION TABLE

ELBOW MECHANISM
OBSERVATION TABLE
SR LOADING UNLODING MEAN

NO SPEED
WEIGHT SPEED WEIGHT (gm) SPEED
(gm) rpm rpm
1. 100 1300 100 1300 1300
2. 150 1250 150 1240 1245
3. 200 1200 200 1100 1190
4. 250 1100 250 1080 1090
5. 300 1000 300 1040 1020
6. 350 970 350 930 950
7. 500 880 500 890 885
8. 600 850 600 850 850
9. 700 700 700 690 695
10. 800 650 800 640 645
11. 1000 600 1000 610 605

ELBOW MECHANISM
SAMPLE CALCULATIONS:- (AT 0.6 kg Load)
1) Average Speed :-
N= ( N1 + N2 ) ( 650 + 650 )
= = 650 rpm
2 2
2) Output Torque:-
Tdp = Weight in pan x Radius of Dynobrake Pulley
= (0.6 x 9.81) x 12.5
=73.575 N.mm
Tdp =0.0737575 N.mm
3) Input Power:- (Pi/p)
Pi/p = 2 Π N Ti/p
60
= 2 x Π x 650 x 0.08
60
Pi/p =5.44 watt
4)OutPut Power:-(Po/p)
Po/p = 2 Π NTo/p
60
= 2 x Π x 650 x 0.0737575
60
Po/p = 5.02 watt
4) Efficiency:-
η = Out put power
ELBOW MECHANISM
Input power
= 5.02 x 100
5.44
η = 92.28 %
⇒ Efficiency of transmission of orbital mechanism at 90 degree =

92.28%

ELBOW MECHANISM
Chapter No.:- 7
Result Table

ELBOW MECHANISM
RESULT TABLE
SR LOAD (gms) SPEED TORQUE POWER

NO (rpm) (N.M) (watt)
1. 100 1300 0.01226 1.66
2. 150 1245 0.01839 2.39
3. 200 1190 0.0245 3.053
4. 250 1090 0.0306 3.49
5. 300 1020 0.0368 0.93
6. 350 950 0.0429 4.26
7. 500 885 0.0613 5.68
8. 600 850 0.073575 6.54
9. 700 695 0.086 6.25
10. 800 560 0.098 5.75
11. 1000 440 0.1226 5.52

ELBOW MECHANISM
Chapter No.:- 8
Cost Analysis

ELBOW MECHANISM
BILL OF MATERIALS
SR PART DESCRIPTION QTY MATERIAL
NO. CODE
1. EM-1 MOTOR 01 STD
2. EM -2 PULLEY 01 EN9
3. EM -3 MAIN SHAFT 01 EN24
4. EM -4 MAIN SHAFT BRG HSG 01 EN9
5. EM -5 LH_ IP_SHAFT 01 EN24
6. EM -6 RH_ IP_SHAFT 01 EN24
7. EM -7 LH_ OP_SHAFT 01 EN24
8. EM -8 RH_ OP_SHAFT 01 EN24
9. EM -9 CENTRAL BRG HSG 01 EN9
10. EM –10 LH_BRG_HSG 01 EN9
11. EM –11 RH_BRG_HSG 01 EN9
12. EM –12 BASE FRAME 01 MS
13. EM -13 BRG6201ZZ 04 STD
14. EM -14 WHEELS 03 STD
15. EM -15 BENT PINS 03 EN9
16. EM -16 JACK BOLTS 03 STD
17. EM-17 COVER RING 04 EN9
18. EM-18 PROPELLER SHAFT 1 EN24
19. EM-19 GEAR 04 N8
RAW MATERIAL COST

ELBOW MECHANISM
The total raw material cost as per the individual materials and their corresponding
rates per kg is as follows,
Total raw material cost = Rs 4450/-
MACHINING COST
OPERATION RATE TOTAL TIME TOTAL

Rs /HR HRS COST Rs/-
LATHE 80 16 1280
MILLING 95 9 855
DRILLING 50 3.6 180
TAPPING Rs 3 /- per hole 16 48
TOTAL 2363
TOTAL MACHINING COST = Rs 2363 /-

MISCELLANEOUS COSTS
OPERATION COST(Rs)
Sawing 160
Gas cutting 80
Bench Work 40
Total 280

ELBOW MECHANISM
COST OF PURCHASED PARTS

SR DESCRIPTION QTY COST
NO.
1. Vee Belt 01 75
2. Bolts - 35
3. Electric Motor 01 1200
4. Wheels 03 360
5. Electronic Speed Variater 01 180
6. Bearings 07 400
The cost of purchase parts = Rs 2180 /-

TOTAL COST
TOTAL COST = Raw Material Cost +Machine Cost + Miscellaneous Cost
+ cost of Purchased Parts +Overheads
= Rs 9273/-
Hence the total cost of machine = Rs 9273/-

ELBOW MECHANISM
Chapter No: 09
Conclusion and Future scope

ELBOW MECHANISM
CONCLUSION AND FUTURE SCOPE
Some successful mechanical devices function smoothly however poor fly they
Are made while other does this only by virtue of a accurate construction &
fitting of their moving parts.
This projects which looks very simple & easy to construct was actually
Very difficult to conceive & imagine without seeing an actual one in practice.
It
is an event a fact in the creative mental process nit the forces, which
predominate among the schemes of the active tinkers. Motions demands to be
studied first &we have done that very thing.
We find that while acceptable analysis for existing mechanism can often be
Made quite easily we cannot without insight & imagination make effective
synthesis of new mechanism hence we are mould to present this our project
gear
less transmission at 90*(El-bow mechanism) which we have managed to
successfully device after long & hard input in conceiving its working principle.

ELBOW MECHANISM
Chapter No.:-10
BIBLIOGRAPHY

ELBOW MECHANISM
BIBLIOGRAPHY
A.G.Erdman& G.N. Sandor

-“Mechanism Design ”,
Newell Harton
-“Ingenious Mechanism
For Designers & Inventors”
PSG - “DESIGN DATA HAND BOOK”(1998)
V.B.BHANDARI -
“Design of Machine Elements”,
Tata Mc – Graw Hill Publication (1999)
R.S.KHURMI & J.K.GUPTA -

“A Text Book of Machine Design”.
Eurasia Publication (1990)

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A PROJECT REPORT ON

IN THE PARTIAL FULFILLMENT OF THE FINAL YEAR

DEPARTMENT OF MECHANICAL ENGINEERING

NAME OF STUDENT ENROLLMENT NO.

1. Tanuja Vijaykumar Kashid En.No. 1324222

Prof. P.U. Garge Dr. M. Giridhar Dr. D. R. Nandanwar

Project Guide Head of Department Principle External Examiner

GOVERNMENT POLYTECHNIC PUNE 1

Sr.No. Chapter Name Pg.No.

1.1. Function of transmission.

1.2. Types of transmission.

1.3. Need for project.

2. Construction & Working. 11

2.3. Advantages & Disadvantages.

2.4. Simple gear train.

3.1. System Design.

3.2. Mechanical Design.

3.3. Input Data.

3.4. Design of Propeller Shaft.

3.5. Design of Gears.

3.6. Design of Input Shaft.

3.7. Design of Output Shaft.

GOVERNMENT POLYTECHNIC PUNE 2

3.8. Design of Bearing Bush.

3.9. Design of Bent Pins.

4.1. Process Sheet For Pulley.

4.2. Process Sheet For L-H Output Shaft.

4.3. Process Sheet For R-H Output Shaft.

4.4. Process Sheet For R-H Input Shaft.

4.5. Process Sheet For L-H Input Shaft.

4.6. Process Sheet For L-H_BRG_HSG.

4.7. Process Sheet For R-H_BRG_HSG.

4.8. Process Sheet For Central_BRG_HSG.

4.9. Process Sheet For Cover Ring.

5. Test & Trial on ELBOW MECHANISM. 46

6.1. Sample Calculation.

9. Conclusion & Future Scope 58

GOVERNMENT POLYTECHNIC PUNE 3

P- Planning before carrying out the work

R- row material required for the work

O- Organization of the work

J- joint effort put in to the work

E- estimation of material required in the work

C- Costing of the work

T- techniques used in performing

GOVERNMENT POLYTECHNIC PUNE 4

Project Abstract / Summary : ABSTRACT

This project “EL-BOW TRANSMISSION” being compact and portable

Why did you choose to work on this project topic :

GOVERNMENT POLYTECHNIC PUNE 5

GOVERNMENT POLYTECHNIC PUNE 6

PROJECT TITLE : ELBOW MECHANISM

The main functions that are performed by the transmission are:

GOVERNMENT POLYTECHNIC PUNE 7

NEED FOR PROJECT:

The conventional transmission system used in auto rickshaw is as shown in the

GOVERNMENT POLYTECHNIC PUNE 8

Universal System Used in 3-Wheeler

GOVERNMENT POLYTECHNIC PUNE 9

ELBOW MECHANISM (ORBITAL TRANSMISSION SYSTEM.)

The orbital transmission system is an adaptation of the original

GOVERNMENT POLYTECHNIC PUNE 10

GOVERNMENT POLYTECHNIC PUNE 11