Department of Mechanical Engineering SJBIT

INTRODUCTION TO 3-D PRINTING

3D printing refers to processes in which material is joined or solidified under
computer control to create a three dimensional object with material being added
together.3D printing is used in both rapid prototyping and additive manufacturing
(AM).Objects can be of almost any shape or geometry and typically are produced
using digital model data from a 3D model or another electronic data source such
as an Additive Manufacturing. Stereo lithography (STL) is one of the most
common file type that is used for 3D printing. Thus unlike material removed from
a stock in the conventional machining process,3D printing or AM builds a three-
dimensional object from computer-aided design(CAD)model or AMF file,
usually by successively adding material layer by layer. The term “3Dprinting"
originally referred to a process that deposits a binder material onto a powder bed
with inkjet printer heads layer by layer. More recently, the term is being used in
popular vernacular to encompass a wider variety of additive manufacturing
techniques .United States and global technical standards use the official term
additive manufacturing for this broader sense, since the final goal of additive
manufacturing is to achieve mass production, which greatly differs from 3D
printing for Rapid prototyping.
TERMINOLOGY
The umbrella term additive manufacturing (AM) gained wide currency in the
2000s, inspired by the theme of material being added together (in any of various
ways). In contrast, the term subtractive manufacturing appeared as
a heteronym for the large family of machining processes with
material removal as their common theme. The term 3D printing still referred only
to the polymer technologies in most minds, and the term AM was likelier to be
used in metalworking and end use part production contexts than among polymer,
inkjet, or stereo lithography enthusiasts. By the early 2010s, the terms 3D
printing and additive manufacturing evolved senses in which they were
alternate umbrella terms for AM technologies, one being used in popular
vernacular by consumer-maker communities and the media, and the other used
more formally by industrial AM end-use part producers, AM machine
manufacturers, and global technical standards organizations. Until recently, the
term 3D printing has been associated with machines low-end in price or in
capability. Both terms reflect that the technologies share the theme of material
addition or joining throughout a 3D work envelope under automated control.
Peter Zelinski, the editor-in-chief of Additive Manufacturing magazine, pointed
out in 2017 that the terms are still often synonymous in casual usage but that
some manufacturing industry experts are increasingly making a sense distinction
whereby AM comprises 3D printing plus other technologies or other aspects of
a manufacturing process. Other terms that have been used as AM synonyms
or hyponyms have included desktop manufacturing, rapid manufacturing (as the
logical production-level successor to rapid prototyping), and on-demand
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manufacturing (which echoes on-demand printing in the 2D sense of printing).

That such application of the adjectives rapid and on-demand to the
noun manufacturing was novel in the 2000s reveals the prevailing mental
model of the long industrial era in which almost all production manufacturing
involved long lead times for laborious tooling development. Today, the
term subtractive has not replaced the term machining, instead complementing it
when a term that covers any removal method is needed. Agile tooling is the use
of modular means to design tooling that is produced by additive manufacturing
or 3D printing methods, to enable quick prototyping and responses to tooling and
fixture needs. Agile tooling uses a cost effective and high quality method to
quickly respond to customer and market needs, and it can be used in hydro-
forming, stamping, injection moulding and other manufacturing processes.
BRIEF HISTORY
Early additive manufacturing equipment and materials were developed in the
1980s. In 1981, Hideo Kodama of Nagoya Municipal Industrial Research
Institute invented two additive methods for fabricating three-dimensional plastic
models with photo-hardening thermoset polymer, where the UV exposure area is
controlled by a mask pattern or a scanning fibre transmitter.
On 16 July 1984, Alain Le Méhauté, Olivier de Witte, and Jean Claude
André filed their patent for the stereo lithography process. The application of the
French inventors was abandoned by the French General Electric Company (now
Alcatel-Alsthom) and CILAS (The Laser Consortium). The claimed reason was
"for lack of business perspective".
Three weeks later in 1984, Chuck Hull of 3D Systems Corporation filed his own
patent for a stereo lithography fabrication system, in which layers are added by
curing photopolymers with ultraviolet light lasers. Hull defined the process as a
"system for generating three-dimensional objects by creating a cross-sectional
pattern of the object to be formed,". Hull's contribution was the STL
(Stereolithography) file format and the digital slicing and infill strategies
common to many processes today. The technology used by most 3D printers to
date—especially hobbyist and consumer-oriented models—is fused deposition
modelling, a special application of plastic extrusion, developed in 1988 by S.
Scott Crump and commercialized by his company Stratasys, which marketed its
first FDM machine in 1992.
The term 3D printing originally referred to a powder bed process employing
standard and custom inkjet print heads, developed at MIT in 1993 and
commercialized by Soligen Technologies, Extrude Hone Corporation, and Z
Corporation

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PRINCIPLE OF 3-D PRINTING

3D printing or additive manufacturing is a process of making three dimensional solid
objects from a digital file. The creation of a 3D printed object is achieved using
additive processes. In an additive process an object is created by laying down
successive layers of material until the object is created. Each of these layers can
be seen as a thinly sliced horizontal cross-section of the eventual object. 3D
printing is the opposite of subtractive manufacturing which is cutting out /
hollowing out a piece of metal or plastic with for instance a milling machine. 3D
printing enables you to produce complex (functional) shapes using less material
than traditional manufacturing methods. It all starts with the creation of a 3D model in
your computer. This digital design is for instance a CAD (Computer Aided Design) file. A 3D
model is either created from the ground up with 3D modelling software or based on data
generated with a 3D scanner. With a 3D scanner you’re able to create a digital copy of an
object. 3D printable models may be created with a computer aided design (CAD)
package, via a 3D scanner, or by a plain digital camera and photogrammetric
software .3D printed models created with CAD result in reduced errors and can
be corrected before printing, allowing verification in the design of the object
before it is printed. The manual modelling process of preparing geometric data
for 3D computer graphics is similar to plastic arts such as sculpting. 3D scanning
is a process of collecting digital data on the shape and appearance of a real object,
creating a digital model based on it. Before printing a 3D model from an STL file,
it must first be examined for errors. Most CAD applications produce errors in
output STL file. Generally STLs that have been produced from a model obtained
through 3D scanning often have more of these errors. This is due to how 3D
scanning works as it is often by point to point acquisition, reconstruction will
include errors in most cases. Once completed ,the STL file needs to be processed
by a piece of software called a "slicer," which converts the model into a series of
thin layers and produces a G code file containing instructions tailored to a specific
type of 3D printer. This G code file can then be printed with 3D printing client
software (which loads the G-code, and uses it to instruct the 3D printer during the
3D printing process). Printer resolution describes layer thickness and X-Y
resolution in dots per inch (dpi) or micrometres (μm). Typical layer thickness is
around 100 m (250DPI), although some machines can print layers as thin as 16
m (1,600DPI).X-Y resolution is comparable to that of laser printers .The particles
(3Ddots) are around 50 to 100m (510 to 250 DPI) in diameter. Higher resolution
creates larger files. For an STL file type, a mesh resolution of 0.01-0.03 mm and
a≤0.016mm chord length produce optimal results in the print of the part.
Construction of a model with contemporary methods can take anywhere from
several hours to several days, depending on the method used and the size and
complexity of the model. Additive systems can typically reduce this time to a few
hours, although it varies widely depending on the type of machine used and the
size and number of models being produced simultaneously. Traditional
techniques like injection moulding can be less expensive for manufacturing

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polymer products in high quantities, but additive manufacturing can be faster,

more flexible and less expensive when producing relatively small quantities of
parts.3D printers give designers and concept development teams the ability to
produce parts and concept models using a desktop size printer. Seemingly
paradoxical, more complex objects can be cheaper for 3D printing production
than less complex objects.
3D PRINTING PROCESSES
There are a variety of processes and equipment used in the synthesis of a three-
dimensional object. 3D printing is also known as additive manufacturing,
therefore the numerous available 3D printing processes tend to be additive in
nature with a few key differences. The main areas in which these processes differ
are the technologies used in the process and the materials.
Some of the different types of processes include extrusion, light polymerized,
continuous liquid interface production and powder bed. Each process and piece
of equipment has pros and cons associated with it. These usually involve aspects
such as speed, costs, as well as a material's properties and its available colours.
The variety of processes and equipment allows for numerous uses by amateurs
and professionals alike. Some lend themselves better toward industry use whilst
others make 3D printing accessible to the average consumer. Some printers are
large enough to fabricate buildings whilst others tend to micro and Nano scale
sized objects. Fused deposition modelling (FDM), derives from automatic
polymeric foil hot air welding system, hot-melt gluing and automatic gasket
deposition. Such principle has been further developed by S. Scott Crump in the
late 1980s and was commercialized in 1990 by Stratasys.After the patent on this
technology expired, a large open-source development community developed and
both commercial and DIY variants utilizing this type of 3D printer appeared. As
a result, the price of this technology has dropped by two orders of magnitude
since its creation, and it has become the most common form of 3D printing.
In fused deposition modelling, the model or part is produced by extruding small
beads or streams of material which harden immediately to form layers. A filament
of thermoplastic, metal wire, or other material is fed into an extrusion nozzle
head. The nozzle head heats the material and turns the flow on and off.
Typically stepper motors or servo motors are employed to move the extrusion
head and adjust the flow. The printer usually has 3 axes of motion. A computer-
aided manufacturing (CAM) software package is used to generate the G-Code
that is sent to a microcontroller which controls the motors.
Plastic is the most common material for such printing. Various polymers may be
used, including acrylonitrile butadiene styrene , polycarbonate , polylactic
acid high-density polyethylene PC/ABS, polyphenylsulfone and polystyrene In
general, the polymer is in the form of a filament fabricated from virgin resins.

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There are multiple projects in the open-sourced community aimed at processing

post-consumer plastic waste into filament. These involve machines used to shred
and extrude the plastic material into filament. Additionally, fluoropolymers such
as PTFE tubing are used in the process due to the material's ability to withstand
high temperatures. This ability is especially useful in transferring filaments.
Metal and glass may both be used as well, though they are much more expensive
and generally used for works of art.
FDM is somewhat restricted in the variation of shapes that may be fabricated. For
example, FDM usually cannot produce stalactite-like structures, since they would
be unsupported during the build. Otherwise, a thin support must be designed into
the structure, which can be broken away during finishing. Fused deposition
modelling is also referred to as fused filament fabrication (FFF) by companies
who do not hold the original patents like Stratasys does.
APPLICATIONS OF 3-D PRINTING
In the current scenario, 3D printing or AM has been used in manufacturing,
medical, industry and sociocultural sectors which facilitate 3D printing or AM to
become successful commercial technology. The earliest application of additive
manufacturing was on the tool room end of the manufacturing spectrum. For
example, rapid prototyping was one of the earliest additive variants, and its
mission was to reduce the lead time and cost of developing prototypes of new
parts and devices, which was earlier only done with subtractive tool room
methods such as CNC milling, turning, and precision grinding. In the 2010s,
additive manufacturing entered production to a much greater extent. Additive
manufacturing of food is being developed by squeezing out food, layer by layer,
into three-dimensional objects. A large variety of foods are appropriate
candidates, such as chocolate and candy, and flat foods such as crackers,
pasta, and pizza. 3D printing has entered the world of clothing, with fashion
designers experimenting with 3D-printed bikinis, shoes, and dresses. In
commercial production Nike is using 3D printing to prototype and manufacture
the 2012 Vapour Laser Talon football shoe for players of American football, and
New Balance is 3D manufacturing custom-fit shoes for athletes. 3D printing has
come to the point where companies are printing consumer grade eyewear with
on-demand custom fit and styling (although they cannot print the lenses). On-
demand customization of glasses is possible with rapid prototyping. Vanessa
Friedman, fashion director and chief fashion critic at The New York Times, says
3D printing will have a significant value for fashion companies down the road,
especially if it transforms into a print-it-yourself tool for shoppers. "There's real
sense that this is not going to happen anytime soon," she says, "but it will happen,
and it will create dramatic change in how we think both about intellectual
property and how things are in the supply chain." She adds: "Certainly some of
the fabrications that brands can use will be dramatically changed by technology."

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In cars, trucks, and aircraft, AM is beginning to transform both (1) unibody and
fuselage design and production and (2) power train design and production. For
example: In early 2014, Swedish super car manufacturer Koenigsegg announced
the One: 1 a super car that utilizes many components that were 3D printed. Urbee
is the name of the first car in the world car mounted using the technology 3D
printing (its body work and car windows were" printed"). In 2014, Local Motors
debuted Strati, a functioning vehicle that was entirely 3D Printed using ABS
plastic and carbon fibre, except the power train .In May 2015 Airbus announced
that its new Airbus A350XWB included over 1000 components manufactured by
3Dprinting. In 2015, a Royal Air Force Euro fighter Typhoon fighter jet flew with
printed parts. The United States Air Force has begun to work with 3D printers,
and the Israeli Air Force has also purchased a 3D printer to print spare part. In
2017, GE Aviation revealed that it had used design for additive manufacturing to
create a helicopter engine with 16 parts instead of 900, with great potential impact
on reducing the complexity of supply chains.
In 2005, academic journals had begun to report on the possible artistic
applications of 3D printing technology. As of 2017, domestic 3D printing was
reaching a consumer audience beyond hobbyists and enthusiasts. Off the shelf
machines were increasingly capable of producing practical household
applications, for example, ornamental objects. Some practical examples include
a working clock and gear sprinted for home woodworking machines among other
purposes. Web sites associated with home 3D printing tended to include
backscratchers, coat hooks, door knobs, etc.
3D printing, and open source 3D printers in particular, are the latest technology
making inroads into the classroom. Some authors have claimed that 3D printers
offer an unprecedented "revolution" in STEM education. The evidence for such
claims comes from both the low cost ability for rapid prototyping in the
classroom by students, but also the fabrication of low-cost high-quality scientific
equipment from open hardware designs forming open-source labs. Future
applications for 3D printing might include creating open-source scientific
equipment. In the last several years 3D printing has been intensively used by in
the cultural heritage field for preservation, restoration and dissemination
purposes. Many Europeans and North American Museums have purchased 3D
printers and actively recreate missing pieces of their relics. The Metropolitan
Museum of Art and the British Museum have started using their 3D printers to
create museum souvenirs that are available in the museum shops. Other
museums, like the National Museum of Military History and Varna Historical
Museum, have gone further and sell through the online
platform Threading digital models of their artefacts, created using Artec
3D scanners, in 3D printing friendly file format, which everyone can 3D print at
home.

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LIMITATIONS OF 3-D PRINTING

• Surface texture is generally too rough.

• Material save low heat deflection temperatures.
• Materials generally have low strengths.
• Material prices are far too high restricting the growth of the market.
• Parts are generally not as dense as parts made by CNC and other processes.
• Making complex parts or organic parts requires a lot of 3D modelling
training.
• 3D scanners are not good enough and create holes in final files.
• Re-meshing software is not good enough.
• Materials have low heat deflection temperatures.
• Material prices are far too high restricting the growth of the market.
• Remising software is not good enough.
• Printers are not fast enough.
• Industrial AM machines are too expensive.
• Machines are generally too slow.
• Very little R&D is done in 3D printing.
• Every process is different so silos are being developed not one
common development effort.
• The AMF file format has not been widely adopted by software tools
leaving us stuck with STL.
• Many desktop people are over-promising and using over claim to sell
their products.
• Many industrial 3D printing vendors are prisoners of their own patents,
developing only technologies that fit squarely into their portfolio.
• There is too much manual labour in manufacturing with 3D printing,
30% of costs.
• Certification of materials is taking too long and not enough materials
are certified for many uses.
• There is no closed loop control on machines. It is difficult to obtain
surface finishes and looks of parts that are comparable to mass
production parts.

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RAPID PROTOTYPING
Rapid prototyping is a group of techniques used to quickly fabricate a scale model
of a physical part or assembly using three-dimensional computer aided
design (CAD) data. Construction of the part or assembly is usually done using 3D
printing or "additive layer manufacturing" technology.
The first methods for rapid prototyping became available in the late 1980s and
were used to produce models and prototype parts. Today, they are used for a wide
range of applications and are used to manufacture production-quality parts in
relatively small numbers if desired without the typical unfavourable short-run
economics. This economy has encouraged online service bureaus. Historical
surveys of RP technology start with discussions of simulacra production
techniques used by 19th-century sculptors. Some modern sculptors use the
progeny technology to produce exhibitions. The ability to reproduce designs
from a dataset has given rise to issues of rights, as it is now possible to interpolate
volumetric data from one-dimensional images.
As with CNC subtractive methods, the computer-aided-design – computer-aided
manufacturing CAD -CAM workflow in the traditional Rapid Prototyping
process starts with the creation of geometric data, either as a 3D solid using a
CAD workstation, or 2D slices using a scanning device. For Rapid prototyping
this data must represent a valid geometric model; namely, one whose boundary
surfaces enclose a finite volume, contain no holes exposing the interior, and do
not fold back on themselves. In other words, the object must have an "inside".
The model is valid if for each point in 3D space the computer can determine
uniquely whether that point lies inside, on, or outside the boundary surface of the
model. CAD post-processors will approximate the application vendors' internal
CAD geometric forms (e.g., B-splines) with a simplified mathematical form,
which in turn is expressed in a specified data format which is a common feature
in additive manufacturing: STL (stereo lithography) a de facto standard for
transferring solid geometric models to SFF machines. To obtain the necessary
motion control trajectories to drive the actual SFF, rapid prototyping, 3D
printing or additive manufacturing mechanism, the prepared geometric model is
typically sliced into layers, and the slices are scanned into lines (producing a "2D
drawing" used to generate trajectory as in CNC's tool path), mimicking in reverse
the layer-to-layer physical building process.
The term rapid prototyping (RP) refers to a class of technologies that are used to
produce physical objects layer-by-layer directly from computer-aided design
(CAD) data. These techniques allow designers to produce tangible prototypes of
their designs quickly, rather than just two- dimensional checks. In addition
to the production of prototypes, rapid prototyping techniques can also
be used to produce moulds or mould inserts (rapid tooling) and even

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fully functional end use parts (rapid manufacturing). Because these are non-
prototyping applications, rapid prototyping is often referred to as solid free-form
fabrication or layered manufacturing. For small series and complex parts, these
techniques are often the best manufacturing processes available. They are not a
solution to every part fabrication problem. After all, CNC technology and
injection moulding are economical, widely understood, available, and offer wide
material selection. In rapid prototyping, the term “rapid” is relative; it aims at the
automated step from CAD data to machine, rather than at the speed of the
techniques. dimensional pictures. Besides visual aids for communicating ideas
with co-workers or customers, these prototypes can be used to test various aspects
of their design, such as wind tunnel tests and Depending on the dimensions of the
object, production times can be as long as a few days, especially with complex
parts or when long cooling times are required. This may seem slow, but it is still
much faster than the time required by traditional production techniques, such as
machining. This relatively fast production allows analysing parts in a very early
stage of designing, which decreases the resulting design cost. The costs can also
be reduced because rapid prototyping processes are fully automated and
therefore, need the skill of individual craftsmen for no more than finishing the
part.

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PEAUCELLIER-LIPKIN STRAIGHT LINE MECHANISM

The Peaucellier–Lipkin linkage or mechanism, invented in 1864, was
the first true planar straight line mechanism – the first planar linkage
capable of transforming rotary motion into perfect straight-line motion,
and vice versa. It is named after Charles-Nicolas Peaucellier (1832–
1913), a French army officer, and Yom Tov Lipman Lipkin (1846–
1876), a Lithuanian Jew and son of the famed Rabbi Israel Salanter.
Until this invention, no planar method existed of producing exact
straight-line motion without reference guideways, making the linkage
especially important as a machine component and for manufacturing.
In particular, a piston head needs to keep a good seal with the shaft in
order to retain the driving (or driven) medium.The mathematics of the
Peaucellier–Lipkin linkage is directly related to the inversion of a
circle.
From the construction of the Peaucellier linkage it is clear that this is a
much more complex mechanism than the mechanisms generating
approximate straight lines, which were simple four bar linkages. This
mechanism has eight members and six joints. Peaucellier linkage can
convert an input circular motion to the exact straight line motion. The
construction of this mechanism is such that the point which is
connected to the crank moves in a circular path and the point traversing
the straight line is selected as the output point. The linkage has a
rhombic loop formed of the equal length members, 5, 6, 7 and 8. Two
equal length links are connected to the opposite corners of the rhombus
at one end and to a common fixed point at the other ends. The point A
of the rhombus is connect to fixed point O2 through the link 2. The
length of the link 2 is equal to the distance between points O2 and O4.
By the constraints of the geometry point A moves in a circular path and
as the point A moves in a circle point P traverses an exact straight line
path normal to the line joining O2 and O4.

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Mathematical proof of concept

Collinearity
First, it must be proven that points O, B, D are collinear. This may be
easily seen by observing that the linkage is mirror-symmetric about
line OD, so point B must fall on that line.
More formally, triangles BAD and BCD are congruent because side
BD is congruent to itself, side BA is congruent to side BC, and side
AD is congruent to side CD. Therefore, angles ABD and CBD are
equal. Next, triangles OBA and OBC are congruent, since sides OA
and OC are congruent, side OB is congruent to itself, and sides BA
and BC are congruent. Therefore, angles OBA and OBC are equal.
Finally, because they form a complete circle, we have
∠OBA + ∠ABD + ∠DBC + ∠CBO = 360°

But, due to the congruence’s, angle OBA = angle OBC and angle
DBA = angle DBC, thus

2 × ∠OBA + 2 × ∠DBA = 360°

∠OBA + ∠DBA = 180°
Therefore points O, B, and D are collinear.

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Thus, by the properties of inversive geometry, since the figure traced

by point D is the inverse of the figure traced by point B, if B traces a
circle passing through the center of inversion O, then D is constrained
to trace a straight line. But if B traces a straight line not passing through
O, then D must trace an arc of a circle passing through O.

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WHITWORTH QUICK RETURN MECHANISM

The Whitworth quick return mechanism converts rotary motion into
reciprocating motion, but unlike the crank and slider, the forward
reciprocating motion is slower rate than the return stroke. This is why
it is called quick return mechanism. This mechanism is made of a
driving crank and of a driven slider crank. In the considered
configuration, the fixed pivot of the driven crank is located on the
outside of the circle on which the end of the driving crank moves. This
leads to an alternated motion of the slider crank. The angular speed of
the driven crank is variable. The duration of the motion for its part
corresponding to the blue arc is shorter than the one related to the red
arc. This is why this device is named quick return mechanism, which
was used in crank shapers, with the slow part or the stroke being used
for the working time of the tool and the quick part for the non-
productive time.
Design of Whitworth Quick Return Mechanism
The disc influences the force of the arm, which makes up the frame of
reference of the quick return mechanism. The frame continues to an
attached rod, which is connected to the circular disc. Powered by a
motor, the disc rotates and the arm follows in the same direction (linear
and left-to-right, typically) but at a different speed. When the disc nears
a full revolution, the arm reaches its furthest position and returns to its
initial position at a quicker rate, hence its name. Throughout the cut,
the arm has a constant velocity. Upon returning to its initial position
after reaching its maximum horizontal displacement, the arm reaches
its highest velocity.
The quick return mechanism was modeled after the crank and slider
(arm), and this is present in its appearance and function; however, the
crank is usually hand powered and the arm has the same rate throughout
an entire revolution, whereas the arm of a quick return mechanism
returns at a faster rate. The "quick return" allows for the arm to function
with less energy during the cut than the initial cycle of the disc.

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Specifications of Quick Return Mechanism

When using a machine that involves this mechanism, it is very
important to not force the machine into reaching its maximum stress
capacity; otherwise, the machine will break. The durability of the
machine is related to the size of the arm and the velocity of the disc,
where the arm might not be flexible enough to handle a certain speed.
Creating a graphical layout for a quick return mechanism involves all
inversions and motions, which is useful in determining the dimensions
for a functioning mechanism. A layout would specify the dimensions
of the mechanism by highlighting each part and its interaction among
the system. These interactions would include torque, force, velocity,
and acceleration. By relating these concepts to their respective analyses
(kinematics and dynamics), one can comprehend the effect each part
has on another.
Mechanics of Quick Return Mechanism
In order to derive the force vectors of these mechanisms, one must
approach a mechanical design consisting of both kinematic and
dynamic analyses.
Kinematic Analysis
Breaking the mechanism up into separate vectors and components
allows us to create a kinematic analysis that can solve for the maximum
velocity, acceleration, and force the mechanism is capable of in three-
dimensional space. Most of the equations involved in the quick return
mechanism setup originate from Hamilton's principle.
The position of the arm can be found at different times using the
substitution of Euler's formula:

Into the different components that have been pre-determined, according

to the setup.

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This substitution can solve for various radii and components of the
displacement of the arm at different values. Trigonometry is needed for
the complete understanding of the kinematic analyses of the
mechanism, where the entire design can be transcribed onto a plane
layout, highlighting all of the vector components.
An important concept for the analysis of the velocity of the disc relative
to the arm is the angular velocity of the disc:

If one desires to calculate the velocity, one must derive the angles of
interaction at a single moment of time, making this equation useful.
Dynamic Analysis
In addition to the kinematic analysis of a quick return mechanism, there
is a dynamic analysis present. At certain lengths and attachments, the
arm of the mechanism can be evaluated and then adjusted to certain
preferences. For example, the differences in the forces acting upon the
system at an instant can be represented by D'Alembert's principle.
Depending on the structural design of the quick return mechanism, the
law of cosines can be used to determine the angles and displacements
of the arm. The ratio between the working stroke (engine) and the
return stroke can be simplified through the manipulation of these
concepts. Despite similarities between quick return mechanisms, there
are many different possibilities for the outline of all forces, speeds,
lengths, motions, functions, and vectors in a mechanism.

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Application of Whitworth Quick Return Mechanism

Quick return mechanisms are found throughout the engineering industry in
different machines:

• Shaper
• Screw press
• Power-driven saw
• Mechanical actuator
• Revolver mechanisms
• Rotary Engines
• Water pumping system

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PEAUCELLIER-LIPKIN STRAIGHT LINE MECHANISM

Conclusion

In conclusion, it is confirmed that the quick return motion may increase

the efficiency of the machine tool because it can reduce the rotation
angle for the return stroke. This is because, the time taken for the slider
to return to its initial positon is less than the time taken for the slider to
accomplish the lifting operation with the same distance. Therefore the
occurrence of the cutting stroke can be done in many instances. This
study has delved into the analysis of the motion and the configuration
of the Peaucillier Mechanism as it travels through its entire range of
motion. Although the original goal was to create the maximum stroke
possible,it has resulted that this is not a practical application at all with
the exponentially increasing velocities at the limits of the motion.

Mech Mantra: E= I2 Education = Innovation X Implementation Page 17

Department of Mechanical Engineering SJBIT

References:

1. en.wikipedia.org
2. “Kinematics of Machine” by J.B.K Das
3. “Theory of Machines” by S.S Ratan
4. www.slideshare.net
5. www.instructables.com
6. www.grabcad.com
7. www.researchgate.com
8. ieeexplore.ieee.org
9. www.brighthubengineering.com
10. Archive.org

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