DESIGN AND FABRICATION OF QUICK RETURN
METHOD USING GENEVA MECHANISM
A PROJECT REPORT
Submitted by
MOHANPRASANTH S (Reg No: 422516114038)
NEDUMARAN A (Reg No: 422516114042)
PRAVEEN KUMAAR V (Reg No: 422516114043)
In partial fulfilment for the award of the degree
Of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
UNIVERSITY COLLEGE OF ENGINEERING VILLUPURAM
(A Constituent College of Anna University Chennai)
Kakuppam, Villupuram-605 103
APRIL 2019
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ANNA UNIVERSITY, CHENNAI 600 025
BONAFIDE CERTIFICATE
Certified that this project report “DESIGN AND FABRICATION OF
QUICK RETURN METHOD USING GENEVA MECHANISM “is the
bonafide work of MOHANPRASANTH . S (422516114038),
NEDUMARAN. A (422516114042), PRAVEEN KUMAAR. V
(422516114043), who carried out the project work under my supervision
Dr.V.GNANAMOORTHI, M.E, Ph.D. Mr. S.V.SASIKARAN, M.TECH
HEAD OF THE DEPARTMENT, TEACHING FELLOW,
Dept. of Mechanical Engineering, Dept. of Mechanical Engineering,
UCEV, Kakuppam, UCEV, Kakuppam,
Villupuram - 605103. Villupuram - 605103.
Submitted for the University project viva voce examination held on……………
INTERNAL EXAMINER EXTERNAL EXAMINER
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ACKNOWLEDGEMENT
We thank ALMIGHTY GOD for giving us his blessings,
dedication and the motivation to fulfil our goals in completing the project.
It’s our pleasure in expressing our immense gratitude and heartfelt
thanks to our honourable DEAN Dr. R. Senthil M.E., Ph.D.,
We express our heartfelt thanks to our respected Head of the
Mechanical Department, Dr.V.Gnanamoorthi M.E., Ph.D., Who has
contributed his fruitful ideas and valuable suggestions in doing this project.
We are profoundly grateful to our project guide, teaching fellow
Mr. S.V.SASIKARAN M.TECH, guided us with his tremendous effort
towards the completion of the project.
We extend our gratitude to all the faculty members and technical
assistance of the Mechanical lab for their help in implementing our project
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ABSTRACT
The geneva mechanism or maltese
mechanism is a gear mechanism that translates continuous rotary
motion into reciprocating motion .In this project we use geneva
mechanism to achieve quick return method instead of using crank and
slotted lever mechanism & whitworth quick return mechanism.
In geneva mechanism we use gears to
achieve the quick return method. In this project there will be sun gear,
planet gear, and orbital gear. The sun and orbital gear have equal
number of tooth and those gears having teeth at certain degrees
present opposite to each other.
The planet gear is present between the
orbital gear and sun gear which is full toothed gear. The orbital gear
and sun gear is attached in a single round plate and it fixed in same
axis. The input is given through it. The output is taken from the planet
gear which is attached to the rack and pinion gear.
When it start to rotate due to change in
module and direction of teeth present in both orbital gear and sun gear
we get the output as reciprocating motion with variation of speed. The
forward stroke is slower when compared to the return stroke.
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TABLE OF CONTENTS
CHAPTER NO TITLE PAGE
NO
ABSTRACT 4
1. INTRODUCTION 7
2. CONCEPT 8
2.1 GEAR CONCEPT 8
2.2 GENEVA CONCEPT 9
3. CONSTRUCTION 10
4. WORKING 11
4.1 EXISTING MODEL 11
4.2 PROPOSED MODEL 20
5. ORBITAL GEAR 22
6. SUN GEAR 23
7. PLANET GEAR 23
8. RACK AND PINION 24
9. APPLICATION 27
10. ADVANTAGES 28
11. DISADVANTAGES 28
12 COST ESTIMATION 29
13 CONCLUSION 30
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LIST OF FIGURES
1. ORBITAL GEAR
2. SUN GEAR
3. PLANET GEAR
4. GENEVA SETUP
5. CRANK AND SLOTTED LEVER
6. WITHWORTH QUICK RETURN
LIST OF TABLES
1. COST ESTIMATION
2. DIMENSIONS OF GEAR
COMPONENTS USED
1. ORBITAL GEAR
2. SUN GEAR
3. PLANET GEAR
4. RACK AND PINION
5. SHAFT
6. BEARINGS
7. HANDLE
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INTRODUCTION
A quick return mechanism is a mechanism that
converts rotary motion into reciprocating motion at different rate for
its two strokes. When the time required for the working stroke is
greater than the return stroke, it is a quick return mechanism.
It yields the significant improvement in
machine productivity. Currently it is widely used in machine tools, for
instance, shaping machines, power-driven saws, and other
applications requiring a working stroke with intensive loading and
return stroke with non intensive loading.
Several quick return mechanisms can be found
in nowadays, including the offset crank- slider mechanism, the crank
shaper mechanism, the double crank mechanism and the whitworth
mechanism. All the above mechanisms are inexpensive but bulky and
difficult to balance. In situations, if compact space is essential to the
design, than the linkage is not a good choice. Therefore we find
al0074ernate way for this quick return mechanism.
This work aims to present a new design for the
quick return mechanism, and verify its feasibility by conducting
simulation and experimental studies by using gears.
In our mechanism we use gears instead of using
linkages. These gears convert the continuous rotary motion into
reciprocating motion with the help of rack and pinion at different
speed ratio. The orbital gear and sun gear is present. The planet gear
is slides between those two gears. Both the orbital gear and sun gear
have equal number of teeth at certain angles opposite to each other.
The planet rotates in between them and gives the reciprocating motion
at different speed ratio.
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CONCEPTS
GEAR CONCEPT:
A gear or cogwheel is a rotating machine
part having cut teeth, or in the case of a cogwheel, inserted teeth
(called cogs), which mesh with the another toothed part to transmit
torque. Geared device can change the speed, torque, and direction of
power source. Gears almost always produce a change in torque,
creating a mechanical advantage through their gear ratio, and thus
considered a simple machine. An advantage of gear is that the teeth of
a gear prevent slippage. When two gear mesh, if one gear is bigger
than the other, a mechanical advantage is produced, with the
rotational speed, and the torques, of the two gears differing in
proportion to their diameters.
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GENEVA CONCEPT:
The geneva mechanism or maltese mechanism
is a gear mechanism that translates continuous rotary motion into
reciprocating motion. The sun and orbital gear have equal number of
tooth and those gears having teeth at certain degrees present opposite
to each other. The planet gear is present between the orbital gear and
sun gear which is full toothed gear. These planet gear gives the output
as reciprocating motion through rack and pinion.
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CONSTRUCTION
The construction of geneva mechanism is quit
easy when compared to the other quick return mechanism like crank
and slotted lever mechanism & whitworth quick return mechanism.
There is orbital gear, sun gear, planet gear and finally rack and pinion
to get the output. The orbital gear and sun gear are attached at the
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same shaft with equal number of teeth is present, but those gears are
present at the certain angles and opposite to each other.
The planet gear is full toothed which rotates in between
those orbital and sun gears. The input is given through the other side
of shaft with the help of handle. When handle starts rotates in
clockwise direction the planet gear meshes with that sun gear and
starts rotate through anticlockwise direction for certain angles then it
meshes with the orbital gear and starts rotate in clockwise direction
due to variation module the planet gear rotates at different speed ratio.
The ouput is taken from planet gear with the help of rack and pinion.
The pinion is attached to the planet gear through the shaft.
The sun and orbital gear is constrained at the same place
with the help of a round plate. Bearings are present to rotate the shaft
freely. Totally four bearings are present, two bearings are present at
either side of the input shaft and other two bearings are present at the
output shaft to reduce friction and the shaft moves freely.
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CONSTRUCTION OF GENEVA MECHANISM
WORKING OF QUICK RETURN METHOD:
EXISTING MODEL
1. CRANK AND SLOTTED LEVER MECHANISM:
This mechanism is mostly used in shaping
machines, slotting machines and in rotary internal combustion
engines. In this mechanism, the link AC (i.e. link 3) forming the
turning pair is fixed, as shown in fig. The link 3 corresponds to
the connecting rod of a reciprocating steam engine. The driving
crank CB revolves with uniform angular speed about the fixed
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centre C. A sliding block attached to the crank pin at B slides
along the slotted bar AP and thus causes AP to oscillate about
the pivoted point A. A short link PR transmits the motion from
AP to the ram which carries the tool and reciprocates along the
line of stroke R1R2. The line of stroke of the ram (i.e. R1R2) is
perpendicular to AC produced.
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2. THE WITHWORTH QUICK RETURN
MECHANISM:
The withworth quick return mechanism is used to
increase the speed of a useless stoke in quick return mechanism. This
is basically converting a rotary motion into reciprocating motion. In
reciprocating motion, the forward stroke is the useful stroke where
work is done.
It is one of the inversion of the slider-crank shown in fig.
(a) obtained by fixing of the link 2.
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When the link 2 is fixed, the link 3 along with slider at
its end B becomes a crank. This makers the link 1 to rotate about O
along with the slider which also reciprocates on it [fig. (b)]
Slider 4 rotates in circle about A and slider on link 1. C
is a point on link 1 extended backwards where the link 5 is pivoted.
The other end of the link 5 is pivoted to the tool. The axis of the
motion of slider 6 (tool)passes through o and is perpendicular to OA,
the fixed link . the crank 3 rotates in counter clockwise direction.
Intially, let the slider 4 be at B so that C. cutting tool 6
will be at extreme left position. With the movement of crank, the
slider traverses the path B whereas the point C move through C.
cutting tool 6 will have forward of the slider 6 is proportional to the
obtuse angleB”AB at A.
Similarly, the slider 4 completes the rest of the circle
through the part B and passes through CC. there is backward stroke of
the tool 6. The time taken in this is proportional to the acute angle B
AB at A.
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3. DOUBLE SLIDER CRANK CHAIN
MECHANISM
A four bar chain having two turning and two
sliding pairs such that two pairs of the same kind are adjacent is
known as double slider crank chain.
Inversions of Double slider Crank chain:
It consists of two sliding pairs and two
turning pairs. They are three important inversions of double slider
crank chain. 1) Elliptical trammel. 2) Scotch yoke mechanism. 3)
Oldham‘s Coupling.
1. Elliptical Trammel:
This is an instrument for drawing ellipses.
Here the slotted link is fixed. The sliding block P and Q in
vertical and horizontal slots respectively. The end R generates an
ellipse with the displacement of sliders P and Q.
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The co-ordinates of the point R are x and y.
From the fig. cos θ = x. PR and Sin θ = y. QR Squaring and adding
(i) and (ii) we get x2 + y2 = cos2 θ + sin2 θ (PR) 2
(QR) 2
x2 + y2 = 1 (PR) 2 (QR) 2
The equation is that of an ellipse, Hence the
instrument traces an ellipse. Path traced by mid-point of PQ is a
circle. In this case, PR = PQ and so x 2 +y 2 =1 (PR) 2 (QR) 2
It is an equation of circle with PR = QR = radius of a circle. 2.
Scotch yoke mechanism: This mechanism, the slider P is fixed. When
PQ rotates above P, the slider Q reciprocates in the vertical slot. The
mechanism is used to convert rotary to reciprocating mechanism.
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2. Oldham’s coupling:
The third inversion of obtained by fixing the
link connecting the 2 blocks P & Q. If one block is turning
through an angle, the frame and the other block will also turn
through the same angle. It is shown in the figure below.
An application of the third inversion of the
double slider crank mechanism is Oldham‘s coupling shown in the
figure. This coupling is used for connecting two parallel shafts when
the distance between the shafts is small. The two shafts to be
connected have flanges at their ends, secured by forging. Slots are cut
in the flanges. These flanges form 1 and 3. An intermediate disc
having tongues at right angles and opposite sides is fitted in between
the flanges. The intermediate piece forms the link 4 which slides or
reciprocates in flanges 1 & 3. The link two is fixed as shown. When
flange 1 turns, the intermediate disc 4 must turn through the same
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angle and whatever angle 4 turns, the flange 3 must turn through the
same angle. Hence 1, 4 & 3 must have the same angular velocity at
every instant. If the distance between the axis of the shaft is x, it will
be the diameter if the circle traced by the centre of the intermediate
piece. The maximum sliding speed of each tongue along its slot is
given by v=xω where, ω = angular velocity of each shaft in rad/sec v
= linear velocity in m/sec
3. Scotch yoke mechanism:
This mechanism, the slider P is fixed.
When PQ rotates above P, the slider Q reciprocates in the vertical
slot. The mechanism is used to convert rotary to reciprocating
mechanism.
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4. Mechanical Advantage, Transmission angle:
The mechanical advantage (MA) is
defined as the ratio of output torque to the input torque. (or) ratio
of load to output. Transmission angle. The extreme values of the
transmission angle occur when the crank lies along the line of
frame.
PROPOSED MODEL
GENEVA MECHANISM:
The geneva mechanism or maltese
mechanism is a gear mechanism that translates continuous rotary
motion into reciprocating motion.
There is orbital gear, sun gear, planet gear
and finally rack and pinion to get the output. The orbital gear and sun
gear are attached at the same shaft with equal number of teeth is
present, but those gears are present at the certain angles and opposite
to each other.
The planet gear is full toothed which rotates in
between those orbital and sun gears. The input is given through the
other side of shaft with the help of handle. When handle starts rotates
in clockwise direction the planet gear meshes with that sun gear and
starts rotate through anticlockwise direction for certain angles then it
meshes with the orbital gear and starts rotate in clockwise direction
due to variation module the planet gear rotates at different speed ratio.
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The orbital gear has number of teeth which
present only at 230 degrees and the same number of teeth present in
sun gear at 110 degrees which is opposite to the orbital gear. The
remaining 20 degree gap is provided for the planet gear to reduce the
speed of gear in one direction and changes into another direction with
different velocity. The output is taken from the from the planet gear
with help of rack and pinion attached to through the shaft. These
shaft is supported by bearings to reduce the friction and moves freely.
When it start to rotate due to change in module
and direction of teeth present in both orbital gear and sun gear we get
the output as reciprocating motion with variation of speed. The
forward stroke is slower when compared to the return stroke.
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COMPONENTS DIMENSIONS
ORBITAL GEAR 300mm
SUN GEAR 45mm
PLANET GEAR 15mm
PINION 40mm
RACK 75mm
ORBITAL GEAR:
This is the outer internal gear which is used to
rotate the planet gear in clockwise direction due to this action we get
output return stroke with lesser time period. The number of teeth
present in the orbital gear is 28 at 230 degrees. The dimension of
outer gear is 30cm.
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SUN GEAR:
The sun gear is the gear present at the centre of the
system which is also has same number of gears present in orbital gear
at 110 degrees. The size of the sun gears is 45mm. Both the sun gear
and orbital gear fixed in the same shaft.
PLANET GEAR:
This is the gear which is rotates between the sun gear
and orbital gear. The dimension of the sun gears is 15mm. this gear
rotates both the direction when orbital and sun gear rotates in same
direction. This is due to the teeth present in the orbital gear and sun
gear. The planet gear is the full toothed gear present at 360 degrees.
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RACK AND PINION GEAR:
Rack and pinion gear is used to convert the rotary motion
into linear motion. The length of rack is 75mm and the diameter of
pinion is 40mm. In this mechanism the output from the planet gear is
converted in to linear reciprocating motion by means of rack and
pinion.
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SIDE VIEW OF QUICK RETURN METHOD
USING GENEVA MECHANISM
APPLICATIONS:
This mechanism is used in the shaper machine where
there is forward stroke is slower than the return stroke.
It is also used in planar machines, vertical drilling
machine, power-driven saws, mechanical actuators and
revolver mechanism.
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ADVANTAGES:
By using gears, large velocity ratio can be
obtained with minimum space.
Gears can be mechanically strong, so higher loads
can be lifted
Gears requires only less lubrication, hence less
maintenance is required.
They have long life, so the gear system is very
compact.
Using gear systems, we can transmit motion
between non intersecting shafts.
DISADVANTAGES:
They are not suitable for large velocities.
They have no flexibility.
Gear operation is noisy.
Due to the engagement of toothed wheel of
gears, some part may be permanently damaged
in case of excessive loading.
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COST ESTIMATION:
S.NO MATERIALS QUANTITY COST
1 Wood 7Sq.ft 500
2 Belt 3 300
3 bearings 4 400
4 Shaft 2 250
5 anabond 1 50
6 Nail 500g 100
7 fevicol 1 75
8 Wood cutting 1(3days) 2250
machine(rent)
9 handle 1 75
10 Emery sheet 5 50
TOTAL : 4050
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CONCLUSION:
Therefore from this project we conclude that the usage
of geneva mechanism will be alternative for other quick return
mechanisms with more efficient in some of the application. Due to
compact size of this mechanism, it will be useful for less space
requirement areas and useful in low velocity areas.
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