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
2. Sourav Siddheshwar Kotgund
3. Sanket Virbhadra Kothale
4. Sheryas Prakash Misale
5. Pagar Jagdish Dharma
6. Pasalkar Aditya Laxman
En.No. 1324222
En. No. 1324226
En. No. 1324227
En. No. 1324228
En. No. 1324230
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
1. Tanuja Vijaykumar Kashid

2. Sourav Siddheshwar Kotgund
3. Sanket Virbhadra Kothale
4. Sheryas Prakash Misale
5. Pagar Jagdish Dharma
6. Pasalkar Aditya Laxman
Prof. P.U. Garge

Project Guide
Dr. M. Giridhar
Head of Department
ENROLLMENT NO.
En.No. 1324222
En. No. 1324226
En. No. 1324227
En. No. 1324228
En. No. 1324230
En. No. 1324231
Dr. D. R. Nandanwar
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.
1.
Chapter Name
Pg.No.
6
Introduction
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.
33
Process Sheet
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 90bent 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 90, 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 hookes joint as the engine is at a
higher level as compared to the wheels.
The double hookes 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-DAVINCI. 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 es 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 hookes 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 TrainIn 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 (3Nos)=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
I/P power =
2NT
60
2 x x 6000 x T
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
60
T mech i/p = 4.688 x 0.1592
2 NT mech i/p
60
= 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
EN 24
Ultimate Tensile strength
Yield strength
N/mm2
N/mm2
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:-
T= /16 fs act
ELBOW MECHANISM
fs ac t =
16 x T
d 3
16 x 1.4926 x 103
=
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 = = 20 degree ( Standard )
7. Base Circle Diameter = 18mm
8. Pitch Circle Diameter = 20mm
9. Circular Pitch = M = 4mm
10. Module = 1.05mm
11. Circular Tooth Thickness = M = 2mm
2
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:-
T= /16 fs act
ELBOW MECHANISM
fs ac t =
16 x T
d 3
16 x 1.4926 x 103
=
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

Designation

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

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

fs act =
16 x T
x 63
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 =
x (10)
= 19.86 N/mm2
As fb act < fb all
shaft is safe in bending .
ELBOW MECHANISM
Design of Bearing bush

Material selection
Designation

N/mm
C30/EN8K
Bearing pressure
N/mm2
620
pb
Yield strength
400
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
520
350
EN9
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
1.4926 x 103 =
4
dP
2
x (4)2 x fsb act x 3 x 36

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: 80X 30
QUANTITY :- 01 NOS.
Tools
Sr.
No
Description of
Operation
Jigs &
Fixture
Time in minutes
M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
1. Clamp stock
3 Jaw chuck
Lathe
20
20
2. Facing one sides
----
----
Facing tool
Vernier
3. Turning diameter 75
through 23.5 mm
length
4. Turning 30
through 14.5 mm
length
----
----
Turning tool
----
10
15
----
----
----
----
30
30
5. Turning groove
50 mm ;3mm deep
----
----
Grooving
tool
----
10
15
6. Chamfer 6 x 45
degree on face
----
----
Crank facing
tool
----
10
13
7. Roughing V groove
----
----
Parting tool
----
10
10
20
8. Finish V groove
----
----
V- tool
15
25
40
9. Centre drill
----
----
Centre drill
Angle
protractor
----
10. Drilling 14.5 hole

through 40 mm
----
----
Twist drill
6mm
----
11. Reaming 15 hole

through 40 mm
----
----
Reaming 6
----
12. Parting off to 24mm

Length
----
----
Parting tool
----
12
13. Facing other side to

23.5 mm length
----
----
Facing tool
----
ELBOW MECHANISM
PART NO : OTS - 07
PART NAME :LH_ OUTPUT SHAFT
MATERIAL SPECIFICATION : EN24

RAW MATERIAL SIZE: 55 x 145
QUANTITY :- 0 4 NOS.
Tools
Sr.
No
Description of
Operation
Jigs &
Fixture
Time in minutes
M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
1. Clamp stock
3 Jaw chuck
Lathe
10
10
2. Facing one sides
----
----
Facing tool
Vernier
3. Turning outer
diameter to 48mm
through length
4. Center drilling
----
----
Turning tool
----
13
18
----
----
Center drill
----
----
----
Twist drill
----
----
----
Turning tool
----
----
----
Turning tool
----
12
17
----
----
Turning tool
----
12
17
----
----
Turning tool
----
10
15
----
----
----
12
17
----
----
Threading
tool
Reamer
----
12
17
----
----
Parting tool
----
13. Facing other side
----
----
Facing tool
----
14. Clam job on m/c

vice
3jaw chuck
----
30
30
15. Drilling 3.85 holes

through thickness 3
Nos
----
DRO
milling
m/c
----
Twist drill
----
5. Turning
15mmthrough 101
length
6. Turning
15mmthrough 86
length
7. Turning
12mmthrough 57
length
8. Turning
10mmthrough 45
length
9. Turning
8mmthrough 15
length
10. Threading M8
threads
11. Turning
12mmthrough
length
12. Grooving as per
profile
ELBOW MECHANISM
16. Reaming 4 holes
thro thickness 3
Nos
17. Chamfer 0.5 x 45
degree B/s of each
hole
----
----
Reamer
----
10
----
----
Twist drill
----
12
17
ELBOW MECHANISM
PART NO : OTS - 08
PART NAME :RH_ OUTPUT SHAFT

Tools
Sr.
No
Description of
Operation
Jigs &
Fixture
Time in minutes
M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
1. Clamp stock
3 Jaw chuck
Lathe
10
10
2. Facing one sides
----
----
Facing tool
Vernier
3. Turning outer
diameter to 48mm
through length
4. Center drilling
----
----
Turning tool
----
13
18
----
----
Center drill
----
----
----
Twist drill
----
----
----
Turning tool
----
----
----
Turning tool
----
12
17
----
----
Turning tool
----
12
17
----
----
Turning tool
----
10
15
----
----
Threading
tool
----
12
17
11. Turning
12mmthrough
length
12. Grooving as per
profile
----
----
Reamer
----
12
17
----
----
Parting tool
----
----
----
Facing tool
----
14. Clam job on m/c

vice
3jaw chuck
----
30
30

through thickness 3
Nos
----
DRO
milling
m/c
----
Twist drill
----
5. Turning
15mmthrough 101
length
6. Turning
15mmthrough 86
length
7. Turning
12mmthrough 57
length
8. Turning
10mmthrough 45
length
9. Turning
8mmthrough 15
length
10. Threading M8
threads
ELBOW MECHANISM
16. Reaming 4 holes
thro thickness 3
Nos
degree B/s of each
hole
----
----
Reamer
----
10
----
----
Twist drill
----
12
17
ELBOW MECHANISM
PART NO : OTS - 06
PART NAME :RH_ INPUT SHAFT

Tools
Sr.
No
Description of
Operation
Jigs &
Fixture
Time in minutes
M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
1. Clamp stock
3 Jaw chuck
Lathe
10
10
2. Facing one sides
----
----
Facing tool
Vernier
3. Turning outer
diameter to 48mm
through length
4. Center drilling
----
----
Turning tool
----
13
18
----
----
Center drill
----
5. Turning
15mmthrough 76
length
6. Turning
12mmthrough
12length
7. Grooving as per
profile
----
----
Twist drill
----
----
----
Turning tool
----
12
17
----
----
Parting tool
----
----
----
Facing tool
----
9. Clam job on m/c

vice
3jaw chuck
----
30
30

through thickness 3
Nos
11. Reaming 4 holes
thro thickness 3
Nos
degree B/s of each
hole
----
DRO
milling
m/c
----
Twist drill
----
----
----
Reamer
----
10
----
----
Twist drill
----
12
17
ELBOW MECHANISM
PART NO : OTS - 05
PART NAME :LH_ INPUT SHAFT

Tools
Sr.
No
Description of
Operation
Jigs &
Fixture
Time in minutes
M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
1. Clamp stock
3 Jaw chuck
Lathe
10
10
2. Facing one sides
----
----
Facing tool
Vernier
3. Turning outer
diameter to 48mm
through length
4. Center drilling
----
----
Turning tool
----
13
18
----
----
Center drill
----
5. Turning
15mmthrough 76
length
6. Turning
12mmthrough
12length
7. Grooving as per
profile
----
----
Twist drill
----
----
----
Turning tool
----
12
17
----
----
Parting tool
----
----
----
Facing tool
----
9. Clam job on m/c

vice
3jaw chuck
----
30
30

through thickness 3
Nos
11. Reaming 4 holes
thro thickness 3
Nos
degree B/s of each
hole
----
DRO
milling
m/c
----
Twist drill
----
----
----
Reamer
----
10
----
----
Twist drill
----
12
17
ELBOW MECHANISM
PART NO : OTS - 10
PART NAME : LH_BRG_HSG
Sr.
No
MATERIAL SPECIFICATION: EN 9
RAWMATERIAL SIZE: 50X20X60
QUANTITY: - 01 NOS.
Description of
Operation
Tools
Jigs
Fixture
& M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
Milling
15
15
14
19
1.
Clamp stock
2.
Facing All Sides ---Sq. to total

length 40x12x50
mm
Clamp stock on 4 jaw chuck
lathe
----
Facing cutter
Vernier
Lathe
25
Drilling 18.5 ---through

thickness
Boring 25 ---through
thickness
Counter Boring --- 32 through
10 thickness
----
Twist drill
Vernier
15
10
25
----
Boring tool
Vernier
15
10
25
----
Boring tool
Vernier
15
10
25
3.
4.
5.
6.
M/C Vice
Time in minutes
25
ELBOW MECHANISM
PART NO : OTS - 11
PART NAME : RH_BRG_HSG
Sr.
No
QUANTITY: - 01 NOS.
Description of
Operation
Tools
Jigs
Fixture
& M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
Milling
15
15
14
19
1.
Clamp stock
2.

length 40x12x50
mm
lathe
----
Facing cutter
Vernier
Lathe
25
Drilling 18.5 ---through

thickness
Boring 25 ---through
thickness
Counter Boring --- 32 through
10 thickness
----
Twist drill
Vernier
15
10
25
----
Boring tool
Vernier
15
10
25
----
Boring tool
Vernier
15
10
25
3.
4.
5.
6.
M/C Vice
Time in minutes
25
ELBOW MECHANISM
PART NO : OTS - 9
PART NAME : CENTRAL_BRG_HSG
Sr.
No
Description of
Operation
QUANTITY: - 01 NOS.
Tools
Jigs
Fixture
& M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
Milling
15
15
14
19
1.
Clamp stock
2.

length
135x12x40 mm
lathe
----
Facing cutter
Vernier
Lathe
25
Drilling 18.5
through
thickness
Boring 25
through
thickness
Counter Boring
32 through
10 thickness
Drilling 18.5
through
thickness
Boring 25
through
thickness
Counter Boring
32 through
10 thickness
----
----
Twist drill
Vernier
15
10
25
----
----
Boring tool
Vernier
15
10
25
----
----
Boring tool
Vernier
15
10
25
----
----
Twist drill
Vernier
15
10
25
----
----
Boring tool
Vernier
15
10
25
----
----
Boring tool
Vernier
15
10
25
3.
4.
5.
6.
7.
8.
9.
M/C Vice
Time in minutes
25
ELBOW MECHANISM
PART NO : OTS - 17
PART NAME :COVER RING

Tools
Sr.
No
Description of
Operation
Jigs &
Fixture
Time in minutes
M/c
Tools
Cutting
Tools
Measuring
Instrument
Setting
Time
M/c
Time
Total
Time
1. Clamp stock
3 Jaw chuck
Lathe
10
10
2. Facing one sides
----
----
Facing tool
Vernier
3. Turning outer
diameter to
54mm through
length
4. Center drilling
----
----
Turning tool
----
13
18
----
----
Center drill
----
----
----
Twist drill
Vernier
15
10
25
----
----
Boring tool
Vernier
15
10
25
----
----
Boring tool
Vernier
15
10
25
----
----
Boring tool
Vernier
15
10
25
----
----
Facing tool
----
3jaw chuck
DRO
milling
m/c
----
----
30
30
Twist drill
----
----
Reamer
----
10
5. Drilling 18.5
through
thickness
6. Boring 41
through
thickness
7. Counter Boring
45 through
40 thickness
8. Counter Boring
47 through 8
thickness
9. Threading M48
Threads
through 8mm
length
10. Facing other
side
11. Clam job on
m/c vice
12. Drilling 3.85

---holes through
thickness 3 Nos
13. Reaming 4
---holes thro
thickness 3 Nos
ELBOW MECHANISM
14. Chamfer 0.5 x
45 degree B/s
of each hole
----
----
Twist drill
----
12
17
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
NO
LOADING
UNLODING
WEIGHT
(gm)
1. 100
SPEED
rpm
1300
WEIGHT (gm)
2. 150
MEAN
SPEED
100
SPEED
rpm
1300
1300
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) Output Torque:Tdp = Weight in pan x Radius of Dynobrake Pulley

= (0.6 x 9.81) x 12.5
=73.575 N.mm
=0.0737575 N.mm
Tdp
3) Input Power:- (Pi/p)

Pi/p
=
=
2 N Ti/p
60
2 x x 650 x 0.08
60
Pi/p =5.44 watt
4)OutPut Power:-(Po/p)
Po/p =
2 NTo/p
60
=
2 x x 650 x 0.0737575
60
Po/p = 5.02 watt
4) Efficiency:
= Out put power
ELBOW MECHANISM
Input power
=
5.02 x 100
5.44
= 92.28 %
Efficiency of transmission of orbital mechanism at 90 degree =

92.28%
ELBOW MECHANISM
Chapter No.:- 7
Result Table
ELBOW MECHANISM
RESULT TABLE
LOAD (gms)
SPEED
(rpm)
TORQUE
(N.M)
POWER
(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
SR
NO
ELBOW MECHANISM
Chapter No.:- 8
Cost Analysis
ELBOW MECHANISM
BILL OF MATERIALS
SR
PART
NO.
CODE
1.
EM-1
2.
DESCRIPTION
QTY
MATERIAL
MOTOR
01
STD
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
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
LATHE
80
16
1280
MILLING
95
855
DRILLING
50
3.6
180
TAPPING
Rs 3 /- per hole
16
48
TOTAL
COST Rs/-
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
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
NO.
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

GOVERNMENT POLYTECHNIC PUNE

1. Tanuja Vijaykumar Kashid

Prof. P.U. Garge

GOVERNMENT POLYTECHNIC PUNE 1

Construction & Working.

3.1. System Design.

Test & Trial on ELBOW MECHANISM.

6.1. Sample Calculation.

Conclusion & Future Scope

GOVERNMENT POLYTECHNIC PUNE 3

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 6

The main functions that are performed by the transmission are:

GOVERNMENT POLYTECHNIC PUNE 7

GOVERNMENT POLYTECHNIC PUNE 8

Universal System Used in 3-Wheeler

GOVERNMENT POLYTECHNIC PUNE 9

ELBOW MECHANISM (ORBITAL TRANSMISSION SYSTEM.)

GOVERNMENT POLYTECHNIC PUNE 10

GOVERNMENT POLYTECHNIC PUNE 11

1. ELECTRIC MOTOR:Electric motor of following specifications is used

GOVERNMENT POLYTECHNIC PUNE 12

GOVERNMENT POLYTECHNIC PUNE 13

ADVATAGES OF ELBOW MECHANISM

GOVERNMENT POLYTECHNIC PUNE 14

GOVERNMENT POLYTECHNIC PUNE 15

GOVERNMENT POLYTECHNIC PUNE 16

Hence an careful design approach has to be adopted. The total design

GOVERNMENT POLYTECHNIC PUNE 17

System design mainly concerns with various physical constrains,

Following parameters are looked upon in system design.

GOVERNMENT POLYTECHNIC PUNE 18

For designed parts detailed design is done and dimensions there

APPROACH TO MECHANICAL DESIGN OF PLANETARY SPEED

GOVERNMENT POLYTECHNIC PUNE 19

GOVERNMENT POLYTECHNIC PUNE 20

Torque calculation:Max Input Power = 100 watt at 6000 rpm.

Assuming 100% overload;

= 1.4926 x 103 N.m

Ultimate Tensile strength

GOVERNMENT POLYTECHNIC PUNE 21

Considering minimum of the above values.

fs max = 0.75 x 144

GOVERNMENT POLYTECHNIC PUNE 22

fs act = 35.19 N/mm2

As fs act < fs all

Shaft is safe under torsional load.

GOVERNMENT POLYTECHNIC PUNE 23

Spur Gear Design :1. Outside Diameter = 22mm

GOVERNMENT POLYTECHNIC PUNE 24