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Power Hammer Mechanism Project Report
Power Hammer Mechanism Project Report
INTRODUCTION TO MECHANISMS
The degrees of freedom (DOF) of a rigid body are defined as the number of
independent movements it has. Figure 1.2 shows a rigid body in a plane. To determine
the DOF of this body we must consider how many distinct ways the bar can be
moved. In a two dimensional plane such as this computer screen, there are 3 DOF.
The bar can be translated along the x axis, translated along the y axis, and rotated
about its centroid.
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1.4 Kutzbach Criterion Equation
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According to Grasshof’s law for a four bar mechanism, the sum of the shortest
and longest link lengths should not be greater than the sum of the remaining two link
lengths if there is to be continuous relative motion between the two links.
A very important consideration in designing a mechanism is to ensure that the
input crank makes a complete revolution relative to the other links. The mechanism in
which no link makes a complete revolution will not be useful. In a four bar chain, one
of the links, in particular the shortest link, will make a complete revolution relative to
the other three links, if it satisfies the Grasshof’s law. Such a link is known as crank
or driver.
1.6 Single Slider Crank Mechanism
A single slider crank chain is a modification of the basic four bar chain. It
consists of one sliding pair and three turning pair. It is, usually, found in reciprocating
steam engine mechanism. This type of mechanism converts rotary motion into
reciprocating motion and vice versa.
In single slider crank chain, as shown in below fig the links 1 and 2, links 2
and 3, and links 3 and 4 form three turning pairs while the links 4 and 1 form a sliding
pair.
The link 1 corresponds to the frame of the engine, which is fixed. The link 2
corresponds to the crank; link 3 corresponds to the connecting rod and link 4
corresponds to cross- head. As the crank rotates the cross-head reciprocates in the
guides and thus the piston reciprocates in the cylinder.
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2. Study of Power Hammers
Until now we have confined ourselves to study of hand tools used in smithy
work. They certainly perform very well so far as the hand- forging is concerned, but
their use for satisfactory production is limited to small forging only. It would not be
difficult to understand that the intensity of blows, however great one may try to
achieve through hand hammering, will not be sufficient enough to effect the proper
plastic flow in a medium sized or heavy forging. For this, a power hammer is usually
employed. The capacity of these hammers is given by the total weight of their falling
parts i.e., tup or ram and die. A 200 kg hammer will be one of which the falling parts
weigh 200 kg. The heavier these parts and greater the height from which they fall.
The higher will be intensity of blow the hammer will provide. Power hammers in
common use are of different types e.g. spring power hammers, pneumatic power
hammers, Steam hammers and Drop or Forge hammers and six bar slider crank power
hammers. These hammers are named partly after their construction, partly according
to their way of operation. Apart from these, a large number of forging presses and
machines are used in forging work. In the following articles these hammers and
machines will be discussed in detail.
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built in sizes from 5 to 200 kg. The stroke range of both helve and trip hammers
ranges from about 400 per minute for small sizes to about 175 for large size.
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3. PRESENT SCENARIO OF POWER HAMMER AND
MECHANISMS
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some embodiments, the power hammer assembly can comprise a power assembly for
providing a single stroke speed and/or a single set stroke with respect to the striking
of die assemblies against a piece of metal. In some embodiments, the power hammer
assembly of the present invention can comprise a larger throat area and/or a larger die
gap than presently available power hammers to facilitate ease of use. In some
embodiments, the power hammer assembly of the present invention can comprise
adjustment features allowing for the use of die sets of varying configurations such as,
for example, shank size, shank length or alternatively, die sets fabricated for use with
other machinery. In some embodiments, the power hammer assembly of the present
invention can comprise a belt transmission assembly designed to slip in the event of
die interference during set-up or operation so as to avoid damaging the power
hammer assembly. In some embodiments the power hammer assembly of the present
invention includes fine adjustment means for spacing between the upper and lower
die.
3.2 Mechanism
Four bar parallel linkage mechanism for toe movement
In recent research the four bar linkage mechanism is used for the humanoid
robots for the free movement of their toe. Using this mechanism the major part of the
force acts on the non-movable portion of this link rather then on the toe tip. Because
of this it is possible to decrease the constraint on the joint. At the same time the
following multiple roles of the toe are expected. One it to generate a large kicking
force at the toe pad and another is to maintain multiple contact with the floor by the
toe joint control.
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4. SIX BAR SLIDER CRANK POWER HAMMER
MECHANISM
4.1 Construction
As shown in above diagram it consists of 5 links, and one fixed link. The five
links are crank (link 1), link 3. Connecting rod (link 4), Crank (link 5) and Ram die
(link 2).Column can be considered as a fixed link. The link 1 rotates about a turning
pair F, it is rotated by a pin joint axis, the link 3 and link 1 is connected by a turning
pair E. The connecting rod (link 4) and link 3 are connected by a turning pair D. The
crank (link 5) is fixed at a turning pair A and oscillates about the pin joint axis. Crank
(link 5) and connecting rod (link 4) are connected by a turning pair B.
Ram Die (link 2) and connecting rod (link 4) are connected by a sliding pair
C. Ram Die and composite bush are connected by a sliding pair G.
Crank (link1) is joined at turning pair F to the column and also crank (link 5)
is joined at turning pair A. Column is welded to the base, vice (not shown in above
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fig) is fitted to the column for holding the work piece. All the links, Column, Base
and Vice are made up of Mild Steel, they are rigid enough to absorb the vibrations
and shocks produced during work. Composite bush is made up of two materials outer
one is of Mild Steel and the liner is made up of Gun Metal to prevent from wear, tear
and corrosion resistance. A handle is provided at point E, with the help of the handle
the crank (link 1) is rotated.
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after completing this process now we proceed towards milling the slot of 65 x 8 x 6
mm3 by using an end mill cutter. Finally filing was done on bench vice to remove
unnecessary sharp corners.
4.3.5 Column
The Column is made up of Mild Steel of required dimension. First the
marking for the holes to fix the links were done on the column. The outer profile was
marked and then made to cut on a gas cutter, and then it was milled to the required
size and then finally chamfering was done to remove unnecessary sharp corners and
edges. Drills were drilled on the column for bearings, turning pairs F and A. Then the
composite bush was welded on the column. Vice was fitted on the column by the
application of welded joints for holding the work piece.
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4.4 Determination of Degrees of Freedom
The formula for finding the degree of freedom from the Kutzbach equation is
given below
n = 3( -1)-2j-h
Where,
n = Degree of freedom
= no of links
j = no of lower pairs
h = no of higher pairs
Links:
a) Fixed link
b) Crank (link 1)
c) Crank (link 5)
d) Link 3
e) Connecting Rod
f) Ram Die
Therefore, number of links = 6
Lower pairs:
a) Turning pair F
b) Turning pair E
c) Turning pair D
d) Turning pair A
e) Turning pair B
f) Sliding pair C
g) Sliding pair G
Therefore, number of lower pairs = 7
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Therefore, n = 3( -1)-2j-h
h=o
n = 3( -1) -2j
n = 3(6-1) -2 x 7
n=3x5–2x7
n = 15 – 14
n=1
Therefore, the mechanism has single degree of freedom.
4.5 Applications
4.5.1 Forging
Forging refers as the process of plastically deforming metals or alloys to a
specific shape by a compressive force exerted by some external agency like hammer,
Press, rolls, or by an upsetting machine of some kind. The portion of a work in which
forging is done is termed the forge and the work is mainly performed by means of
heavy hammers, forging machines, and presses. Forging processes are among the
most important manufacturing techniques since forging is used in small tools, railroad
equipment, automobile, and aviation industries.
A number of operations are used to change the shape of the raw material to the
finished form. The typical forging operations are:
1. Upsetting.
2. Fullering.
3. Drawing down.
4. Setting down.
5. Punching.
6. Bending.
7. Welding.
8. Cutting.
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All these operations are carried out with the metal in a heated condition,
which must be maintained by taking a ‘fresh’ heat when the work shows sign of
getting cold.
Forging Processes
The processes of reducing a metal billet between flat-dies or in a closed-
impression die to obtain a part of predetermined size and shape are called smith
forging and impression-die forging respectively. Depending on the equipments
utilized they are further sub-divided as hand forging, hammer forging, press forging,
drop forging, mechanical press forging, upset or machine forging.
In general, the methods of forging may be classified as follows:
FORGING
PROCESS
IMPRESSION
SMITH
DIE
Hammer
Press
4.5.2 Press
Press working involves production of final component from sheet metal in
cold condition. The machine which is used to apply the required pressure of force in a
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short duration is called press. The press consists of a frame, supporting bed and ram.
The ram is equipped with special punches and moves towards and into the die block
which is attached to a rigid body. The punch and die block assemble are generally
referred to as a die set or simply die.
A disadvantage of press working is that the operations are carried out at room
temperature and the metal is less deformable of strain hardening.
Classification of Presses
Presses are classified in various ways as listed below.
(i) Mechanical press.
(ii) Hydraulic press.
1. Cutting operations.
(i) Blanking,
(ii) Piercing
(iii) Lancing,
(iv) Cutting off and Parting,
(v) Notching,
(vi) Shaving, and
(vii) Trimming.
2. Shaping operations
(i) Forming (embossing, Beading and Cutting, Bulging etc.),
(ii) Drawing, and
(iii) Bending.
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II. DESIGN CALCULATIONS
Minimum cross sectional area required to transmit is 0.6 tonnes load (A):
load p
mm 2
permisible shear stress [ ]
taking M.S for link design yield sress ( y ) 300 N / mm 2
adopting factor of safety 4
permisible shear stress [ ] 300/4 75 N/mm 2
p
minimum area required 6000/75
[ ]
Effective area (A) 80mm 2
The formula for the minimum effective area is obtained as bt – (dt) it can be
observed in the link as in the fig2.1
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Fig 2.1
In fig 2.1 hatched portions indicates minimum effective cross sectional area in the
entire mechanism. We know that stress is inversely proportional to the area, so the
minimum area leads to increase the stress. So it is always preferred to design any
machine by taking minimum cross sectional area as effective area.
where,
b breadth of the link in mm
t thickness of the link in mm
d diameter of pin hole in mm
Effective area (A) 80mm 2
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From the design of bolt we obtained diameter of pin as 6mm, by keeping the diameter
of pin constant and by trail and error method we obtained the breadth and thickness of
the link as 20mm and 6mm respectively.
3. Design calculation for bolt diameter
The below diagram is for the finite width plate with a transverse hole.
Where,
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P = tensile force
= 0.6 tonne
= 0.6 1000 9.81
= 5886N
Therefore,
5886
nom
(20 - a)6
max
Kt =
nom
max
nom
kt
5886 150
=
(20 a)6 2.3
5886
= 65.22
(120 6a)
5886 = 65.22(120-6a)
5886 = 7826.5 – 391.32a
5886 – 7826.5 = - 391.32a
- 1940.5 = - 391.32a
1940.5
Therefore a=
391.32
a = d (diameter) = 4.99mm
Due to dynamic characteristics of links the diameter of pin is selected as 6 mm.
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= 300/2 = 150N/ mm 2
p
Bearing stress ( b )
dn
P = 0.6 + 1000 9.81N
d = 6mm
t = 6mm
n=2
0.6 1000 9.81
( b )
66 2
81.75 N/ mm 2
The bearing stress is greater than 81.75 N/ mm 2 , so the design is satisfactory.
= 0.6 300
= 180 N/ mm 2
load
y
shear area
6000
y
shear area
Shear area for punching operation can be observed from above diagram is dt
Where, d = diameter of blanking or piercing hole in mm.
t = the thickness of the blank in mm.
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6000
Shear area = dt =
180
dt = 33.3 mm 2
33.3
Therefore t=
7
t = 1.5mm
1. CRANK (LINK 1)
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Description : Crank 1
Part No :1
Material : Mild Steel.
Required size : 120mm x 20mm x 6mm
Vernier
1 Power saw Cutting Hacksaw caliper, steel
rule
Grinding
2 Grinding Fillet
wheel
Vernier
3 Drilling Drill 6 x 6 Drill bit
caliper
Vernier
4 Drilling Drill 6 x 6 Drill bit
caliper
2. RAM DIE
Description : Die
Part No :2
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Material : Mild Steel.
Required size : 20mm x 420mm
Single point
2 Lathe Facing Vernier caliper
cutting tool
Drilling 10x2
3 Lathe Drill 20 Vernier caliper
5
4 Drilling Drill 4.5 x 5 Drill 4.5 Vernier caliper
M6 internal
6 Tapping Tap
thread
End mill
7 Milling Slot Vernier caliper
cutter
3. LINK 3
Description : LINK 3
Part No :3
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Material : Mild Steel.
Required size : 440mm x 20mm x 6mm
Vernier
4 Drilling Drill 6 x 6 Drill bit
caliper
ROD
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SL. NO MACHINE OPERATION TOOL GAUGE
Vernier
1 Power saw Cutting Hacksaw caliper, steel
rule
Grinding
2 Grinding Fillet
wheel
Vernier
3 Drilling Drill 6 x 6 Drill bit
caliper
Vernier
4 Drilling Drill 6 x 6 Drill bit
caliper
Vernier
5 Milling Slot End mill cutter
caliper
5. CRANK (LINK 5)
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SL. NO MACHINE OPERATION TOOL GAUGE
Vernier
1 Power saw Cutting Hacksaw caliper, steel
rule
Grinding
2 Grinding Fillet
wheel
Vernier
3 Drilling Drill 6 x 6 Drill bit 6.
caliper
Vernier C
4 Drilling Drill 6 x 6 Drill bit
caliper O
5 Bench vice Filing Flat file M
P
OSITE BUSH
6.1 Bush.
7. COST ESTIMATION
Bearing (6mm) 4 15 60
M6 bolt and nut 5 8 40
½ inch bolt and nut 1 26 26
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M5 Countersunk bolt
8 1.5 12
and nut
M6 Countersunk bolt
2 3 6
and nut
TOTAL COST 144
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7.4 Total Cost of Six bar Slider Crank Power Hammer
Mechanism
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