Machine Design and CAD Lab Manual-Revised 15 PDF

Universiti Tenaga Nasional, 2015
Mechanical Design and CAD Laboratory
Bachelor of Mechanical Engineering (Hons.)

Department of Mechanical Engineering
College of Engineering
Universiti Tenaga Nasional
MAY 2013
0
TABLE OF CONTENTS
ITEMS PAGES
============================================================================
Course Overview 2
Guidelines for Laboratory Report 3
Basic Laboratory Safety Rules 7
Lab Experiment Manual 8
Experiment # 1: Slider Crank Chain Experiment (Informal report 9
Experiment # 2: Slotted Link Mechanism Experiment (Short report) 16
Experiment # 3: Cam and Tappet Experiment (formal Report and open ended) 22
Experiment # 4: BELT Experiment (formal Report and open ended) 29
Experiment # 5: Crank and Slotted Lever QRM (Informal report) 35
Experiment # 6: Hookes Coupling Experiment (InFormal report) 43
CREO/SOLID WORK Manual

2D - CREO Simulation Tutorial
3D - CREO Simulation Tutorial
3D - SOLIDWORKS Simulation Tutorial
References
1
COURSE OVERVIEW
Course Description
This course provides the practical and laboratory basis for of the design of machines
based on kinematics and dynamic requirement. Introduction to basic concepts, mobility,
synthesis and machine elements such as linkages and cams is covered. Detailed analysis on
finding the position, velocity and acceleration of linkages is carried out. Introduction to
dynamic analysis of linkages is covered. Students will do a group work involving design
and analysis.
Course Objectives :
1) To introduce laboratory experiments on machine elements.
2) To expose to CAD /CAE software: CREO and SOLIDWORKS in the design of
machine components to students.
Transferrable Skills :
Ability to perform a practical laboratory and analyze the mechanism related
experiments. Students are also able to use commercially available simulation software to
analyze a structural behavior of a given part.
2
GUIDELINE FOR LABAROTARY REPORT
a. Short Report Format

General Instructions: prepared individually or in group and must manually written and submit towards end of the lab
session.
No Items Description
1. Cover page 1. Authors name SID no.

2. Title of experiment
(10%) 3. Day and date of experiment
4. Course and course code
5. Semester and Academic Year (e.g. Sem 1 2013/14)
6. Section and group number
2. Data , Observations and The data and observations obtained in the experiments should be presented in an orderly form
calculation of results in a data table if possible. Sample of calculation should be shown to confirm the calculation used
and understanding towards the theory and experiment.
(40%)
3. Analysis and Discussions The data obtained will be analyzed with a view towards fulfilling the purpose stated at the
beginning of the report. If there is an accepted or expected value for a quantity that is to be
(40%) obtained by the experiment, the percentage difference between the expected and experimental
value should be calculated. In many cases, complete with graph, which is often a very helpful
way of showing the relationship between two quantities. The graph must have a title, each exist
will show scale, units, and a label. All data points must have a marking to show that it is an
observed data point and all data points must be connected showing the trend of the data.
Discussion should tie the results of the experiments to the purpose. Sources or error, deviations
and uncertainty should be discussed and how they might affect the results. Any points that are
specifically asked for in experiment instructions should be discussed in this section
4. Overall report (10%) Neat, clear labels and titles. With references is given.
3
b. Informal Report Format
General Instructions: prepared individually or in group and must be printed properly.
1. Cover page 7. Authors name SID no.

(10%) 9. Day and date of experiment
2. Statement of Purpose / This should be a brief description of what the experiment is demonstrating. Be specific. It
Abstract / Objective (10%) should be consistent with the statement of the experiment instructions.
3. Data ,Observations and The data and observations obtained in the experiments should be presented in an orderly form
calculation of results (30%) in a data table if possible. Sample of calculation should be shown to confirm the calculation
used and understanding towards the theory and experiment.
4. Analysis and Discussions The data obtained will be analyzed with a view towards fulfilling the purpose stated at the
beginning of the report. If there is an accepted or expected value for a quantity that is to be
(30%) obtained by the experiment, the percentage difference between the expected and experimental
value should be calculated. In many cases, complete with graph, which is often a very helpful
way of showing the relationship between two quantities. The graph must have a title, each
exist will show scale, units, and a label. All data points must have a marking to show that it is
an observed data point and all data points must be connected showing the trend of the data.
Discussion should tie the results of the experiments to the purpose. Sources or error, deviations and
uncertainty should be discussed and how they might affect the results. Any points that are specifically
asked for in experiment instructions should be discussed in this section
5. Conclusions (10%) This section summarizes the lab report. Any conclusions drawn from the results should be
given in this section. Express the implication of the results. Examine the outcome in the light
of the stated objectives.
6. References (2%) A list of all references used in writing the report should be included in this section. Use the
following format:
1. Book :
(Note: Books and Journals a. Author (s). Year. Title. Edition. Place: Publisher. Page number. (example: L.H. van
are highly recommended) Vlack. 1989. Elements of Materials Science and Engineering. 6th Ed. Reading :Addison-
Wesely Publ. pp100-105.)
b. Title. Year. Book Title. Edition. Place: Publisher. Page number. (Example: Materials
Science Handbook. 1986. 20th Ed. Ohio: C.R.C. Press. pp. 1986)
2. Journals : Author (s), Year, Article Title; Journal Title, Volume, Page number. (Example:
Brandt, A. 1977. Multtilevel adaptive solution to boundary value problems. Math of
Computation. 31: 333-390)
3. Internet : Title. Year. URL. (Example: Selected encyclopedias and major reference works
in polymer science and technology at Stanford University. 1998. http://www-
sul.stanford.edu/depts/swain/polymer/encys.html
7 Appendices (2%)
8 Overall report (6%) Neat, clear labels and titles. With references is given.
4
c. Formal Report Structure
General Instructions:
* Formal Lab Report has to be prepared individually or in group and must be printed properly.
1. Title page (5 %) This page must include:
4. Day and date experiment was performed and due date
5. (a)* Individual reports: Authors name and matrix no; and Names and matrix no(s) of group
member
(b)* Group Reports: Names and matrix no(s) of group member
*Either (a) or (b)

7. Name of the lab instructor
2. Table of content This should be placed following the title page (for reports more than 10 pages). It should list up each
(3%) section of the report and corresponding page number.
3. Summary / Abstract This should encapsulate the major portion of the report and provides a concise overview of the
/Objectives work. The length should be no more than 200-300 words or 2-3 paragraphs. It should highlight the
objectives, results and conclusions of the experiment.
(6%)
4. Theory (10%) Any theory related to the experiment should be included. The theory must be clearly explained and
complete with diagrams where necessary. The relevant equations should be introduced. Each figure
should be labelled and numbered.
5. Equipment / A list of equipment and specimen used should be included. This may be the same as the list on the
Description of experiment instructions. Sketch of the equipment should also be included where necessary.
Experimental
Apparatus and
procedures (5%) Procedures are a step-by-step explanation of what was done in the lab and why each step was
performed. The procedure listed in the experiment instructions may be used as a guide. The
description does not have to be very lengthy, but should enough detail so that a reader
knowledgeable in the field would understand what was done. Sufficient information should be
provided to allow the reader to repeat the experiment in an identical manner.
6. Data ,Observations The data and observations obtained in the experiments should be presented in an orderly form in a
and calculation of data table if possible. A spreadsheet would be ideal, especially if there are many repetitive
results (30%) calculations in the analysis of the data. Each table, figure and graph should be labelled and
numbered. Sample of calculation should be shown to confirm the calculation used and
understanding towards the theory and experiment.
7. Analysis and The data obtained will be analysed with a view towards fulfilling the purpose stated at the beginning
discussion (24%) of the report. When possible, part of the analysis may be combined with the data table in a
spreadsheet. If there is an accepted or expected value for a quantity that is to be obtained by the
experiment, the percentage difference between the expected and experimental value should be
calculated. In many cases, another part of the analysis will be the construction of the graph, which is
5
often a very helpful way of showing the relationship between two quantities.
The graph must have a title, each exist will show scale, units, and a label. All data points must have
a marking to show that it is an observed data point and all data points must be connected showing
the trend of the data. If the student is using a computer software package to generate graphs, then
this package must convey the same information as would a hand generated graph.
Discussion section should tie the results of the experiments to the purpose. Sources or error,
deviations and uncertainty should be discussed and how they might affect the results. Any points
that are specifically asked for in experiment instructions should be discussed in this section.
8. Conclusions (10%) This section summarizes the lab report. Any conclusions drawn from the results should be given in
this section. Express the implication of the results. Examine the outcome in the light of the stated
objectives.
9. References (1%) A list of all references used in writing the report should be included in this section. Use the
following format:
Book :
1. Author (s). Year. Title. Edition. Place: Publisher. Page number. (example: L.H. van Vlack.
1989. Elements of Materials Science and Engineering. 6th Ed. Reading :Addison-Wesely
Publ. pp100-105.)
2. Title. Year. Book Title. Edition. Place: Publisher. Page number. (Example: Materials
Science Handbook. 1986. 20th Ed. Ohio: C.R.C. Press. pp. 1986)
Journals : Author (s), Year, Article Title; Journal Title, Volume, Page number. (Example: Brandt, A.
1977. Multtilevel adaptive solution to boundary value problems. Math of Computation. 31: 333-
390)
Internet : Title. Year. URL. (Example: Selected encyclopedias and major reference works in
polymer science and technology at Stanford University. 1998. http://www-
sul.stanford.edu/depts/swain/polymer/encys.html
Note: Books and Journals are highly recommended

10. Appendices (1%)
11. Overall report (5%) Neat, clear labels and titles. With references is given.
6
BASIC LABAROTARY SAFETY RULES
Each and every students taking MEMB331 (Machine Design and CAD Lab) are expected to follow
these requirements in order to ensure the safety throughout the semester:
GENERAL GUIDELINES
1. Do not enter laboratory until you are instructed to do so.

2. Conduct yourself and your experiment in a responsible manner at all times in the laboratory.
3. When first entering laboratory do not touch any equipment, chemicals, or other materials in
the laboratory area until you are instructed to do so.
4. All personal belonging, which you do not need during the experiments, must be placed in the
cupboard.
5. Perform only those experiments authorized by your instructor. Unauthorized experiments are
not allowed.
6. Follow all written and verbal instructions carefully.
7. Never work alone in the laboratory. No student may work in the laboratory without the
presence of the instructor or technician.
8. Do not eat sweets, drink beverages, or chew gum in the laboratory.
9. Be prepared for your work in the laboratory. Read all procedures thoroughly before entering
the laboratory remember you have to answer pre lab questions before performing the
experiments!
10. Never fool around in the laboratory.
11. Clean up all areas of the laboratory where you (and your group) worked.
12. Experiments must be monitored at all times. Do not wander around the room, distract other
students, startle other students or interfere with the laboratory experiments of others.
13. Dress properly and decently during a laboratory activity. Shoes must completely cover the
foot. No sandals and open toed shoes are allowed on lab days.
ACCIDENTS AND INJURIES
14. Report any accident (spill, breakage, etc.) or injury (cut, burn, etc.) to the instructor or
technician immediately.
7
UNIVERSITI TENAGA NASIONAL

Department of Mechanical Engineering
MEMB331
MACHINE DESIGN AND CAD LAB
LAB EXPERIMENT MANUAL
Prepared by
Eng Kian Hin, Ahmad Kamal Kadir
Edited by
Nolia Harudin
8
EXPERIMENT 1: SLIDER CRANK CHAIN EXPERIMENT
OBJECTIVES
The objectives of this experiment are to obtain a graph of piston velocity against crank
angle using the method of instantaneous centers, assuming that the crank rotates at a
constant angular velocity, to obtain the crank angles which correspond to the maximum
piston velocity, and to show that for a slider crank chain the piston motion tends to
approach simple harmonic motion with increasing values of connecting rod/crank ratio.
THEORY
The Slider Crank Chain is one of the two basic mechanisms which form the basic for
many more complicated motions. (The other one is the Four Bar Chain or Chebyshev
linkage of which over 800 forms are known.)
To find the velocities the method of Instantaneous Centers

Consider a rigid body moving relative to axes OX and OY, as in the figure below.
Suppose that the velocities va and vb of points A and B relative to OXY are known. As far
as A is concerned the body appears to be rotating about a point anywhere on the line
through A perpendicular to va. Similarly the velocity vb can only result from rotation
about a point somewhere on a line through B perpendicular to vb. If these two lines meet
9
at a point I, it is the point about which the body is rotating at the instant considered. I is
called the Instantaneous Centre.
If the two lines are co-linear the instantaneous centre may be anywhere on them. The two
velocities will be parallel but not necessarily equal. If the lines are parallel and not co-
linear, I is at infinity and the two velocities are parallel and equal. The body is therefore
moving translationally and every point has the same velocity.
An instantaneous centre is not the same thing as a fixed pivot; unless the body is
constrained so that its motion is always a rotation about the same point. Then the point of
rotation and the instantaneous centre are co-incident. Thus an instantaneous centre is at
different points at different instants. So whilst accelerations can be expressed relative to
the instantaneous centre, to do so is not usually helpful as the centre itself can have
acceleration.
Consider the mechanism, in the position shown below:-
The instantaneous centre of the connecting rod AB is at IAB. The linear velocity of A is:-
v a
= OA .
10
Assuming that the angular velocity is unity
v a
= OA
Since the connecting rod is instantaneously rotating about point IAB
v a
=
v b
I AB A
I AB B
So the piston velocity is given by:-

va
v b
= I AB B
I AB A
Triangles IAB and OAX are similar, thus:-
I AB B
=
OX
I AB A OA
OX
So v b
=
OA
OA = OX
11
APPARATUS
Slider Crank Chain with a variable connecting rod length.
12
PROCEDURES
1) Set the crank to zero on the circular scale.
2) Slacken both knurled nuts and adjust the position of the piston pivot so that the
connecting rod is 115mm long. Make sure that the spacer washer is between the
piston and the connecting rod. In normal use, the knurled nuts will be just slack.
However, the motion of the slider crank can be locked at any position by
tightening both knurled nuts.
3) For every 10 of crank rotation, record the piston displacement and the cross-scale
readings in the given tables. (Note: With the crank angle set to zero, note the
initial reading of the cross-scale. This will need subtracting from all subsequent
readings in order to obtain true reading.)
4) Repeat steps 1 to 3 for connecting rod lengths of 130, 140, 155 and 175mm.
RESULTS
1) Plot a graph of piston velocity versus crank angle for the five different connecting
rod length.
2) Plot a graph of the piston displacement against crank angle for the five different
connecting rod lengths.
3) Plot a graph of piston acceleration versus crank angle for the five different
connecting rod length.
DISCUSSION
1) Comment on the form of the graph.
2) Define Simple Harmonic Motion.
3) At what angles the maximum piston velocities occur? Are these 90 and 270 ? If
not, why not?
4) What is the effect of increasing ratio on the form of the graph?
5) From the graph of piston velocity versus crank angle or from the experimental
velocity data, at what crank angles does the maximum acceleration occur for the
five different connecting rod lengths?
13
6) What is the value of maximum acceleration for the five different connecting rod
lengths?
7) Do the maximum acceleration and velocity occur at the same angle? Is there a
relationship between the crank angles at which they occur, assuming that they do
not occur at the same angle? If yes, what is the relationship?
14
RESULT SHEET
Slinder Crank Experiment
Connecting rod length: mm
Crank Radius: mm Ratio: .
Crank Angle Piston Displacement (mm) Piston Velocity (mm/s)
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
15
EXPERIMENT 2: SLOTTED LINK MECHANISM EXPERIMENT
OBJECTIVE
The objective of this experiment is to investigate the motion of a slotted link and to see if
the piston rod moves with Simple Harmonics Motion
THEORY
Simple Harmonic Motion is defined as when a mass or point moves in such a way that its
accelerations is proportional to its displacement from a fixed point in its path and is
directed to that point, the motion is said to be simple harmonic.
The Simple Harmonic Circle enables us to establish a relationship between displacement

and accelerations. Consider the diagram below:
Q is a point which rotates at constant at constant velocity in a circle of a radius r. AB is

a diameter and O the center of the circle of rotation. Point P is the projection of Q upon
the diameter AB at any instant. The displacement of P from O is x. Clearly point P
oscillates between A and B as q moves around the circle. So P can only have velocities
along AB at any instant in time, similarly for accelerations. Now if we resolve the
centripetal accelerations into two components parallel and perpendicular to AB, then the
parallel components will represents the accelerations of P.
16
Acceleration parallel to AB given by this equation:

AB = 2 r. cos .t
Now displacement x is
x = r.cos .t
So the accelerations of P is
P =a
P = 2x
Thus the accelerations of P is proportional to its displacement, x, from O and is clearly
towards O. Therefore the motion is Simple Harmonic Motions.
Alternatively we may consider the following method:
But:
The minus sign indicates that the accelerations is to the left and thus the center of
rotations O.
17
What do you note about the displacement, velocity and accelerations? They v a r y
sinusoidally
Periodic Time
This is the time taken for a complete oscillation from B to A and back again. The time
taken is also that for a complete revolution of particle Q which is an angular distance is
2 radians, so:
2
=

However from previous analysis we know that:
Slotted Link Mechanism or Scotch Yoke

The apparatus is diagrammatically below:
It is clear that the driving pin which is fixed to the crank is similar to the point Q
on the SHM circle. The piston rod with a slotted link is constrained to move is a straight
line. The limits of the motions are either end of a diameter of the circle of the drive pin
rotations. So the motions of the slotted link and piston rod are identical to point P in the
foregone analysis. Thus the link and anything attached there to will move with SHM.
18
APPARATUS
Slotted link Mechanism
19
PROCEDURES
1 . Set the crank at zero degrees. Record the piston displacement.
2. Move the crank by 10 and record the displacement.
3. Repeat steps 1 and 2 for one complete revolution of the crank.
4. Tabulate your results in the table given.
5. Calculate the theoretical piston rod displacement in the table.
RESULTS
1. Plot a graph of the experimental piston rod displacement versus crack angle.
2. Plot on the same graph the theoretical piston rod displacement against crank angle
3. From the experimental piston rod displacement data plot a graph of experimental
velocity and accelerations versus crank angle.
4. From the theoretical Simple Harmonic Motion equations, plot a graphs of
theoretical velocity and accelerations versus crank angle.
DISCUSSION
1. Prove the theoretical displacement x = r (1 cos )
2. Compare the experimental and theoretical piston rod displacement, velocity and
accelerations. How well do your experimental results agree with theory?
3. What is the motion produced by the Slotted Link mechanism? Explain your
answer.
4. Where do maximum displacement, velocity and acceleration on the slide occur?
Explain your answer
20
RESULT SHEET
Slotted Link Mechanism Experiment
Crank Radius = 35 mm
Crank Angles, Experimental Piston Rod Theoretical,

displacement, x, (mm) x = r (1 cos ) (mm)
(degrees
0
)
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
21
EXPERIMENT 4: WHITWORTHS QUICK RETURN MOTION
EXPERIMENT
OBJECTIVES
The objectives of this experiment are to investigate the performance of a Whitworths

Quick Return Motion and to verify that the motion does have a quick stroke and a slow
cutting or forward stroke.
THEORY
Definition of a Mechanism
A mechanism is a simplified model, usually in the form of a line diagram which is used to
reproduce exactly the motion occurring in a machine. The purpose of this reproduction is to
enable the nature of the motion to be investigated without the encumbrance of the various
solid bodies which form the machine elements.
The various parts of the mechanism are called links or elements. Where two links are in
contact and relative motion is possible, then they are known as pair. An arbitrary set of links
which form a closed chain that is capable of relative motion, and that can be made into rigid
structure by the addition of a single link, is known as a kinematics chain. To form a
mechanism from a kinematics chain one of the links must be fixed. However as any of the
links can be fixed, it follows that there are as many mechanisms as there are links in the
chain. The technique of obtaining different mechanisms by fixing the various links in turn is
known as inversion.
22
Kinematics Pairs
The relative motion between two links of a pair can take different forms. Three types of
pairs are known as lower pairs and these are the frequently occurring ones:-
Sliding : such as occurs between a piston and cylinder

Turning : such as occurs with the wheel on axle
Screw motion : such as occurs between a nut and a bolt.
All other cases are considered to be combination of sliding and rolling and are called higher
pairs. Strictly screw motion is a higher pair as it combines turning and sliding.
Slider- Crank Mechanism
The slider-crank mechanism is well known as the basis of a reciprocating engine. As shown
in the diagram below it contains of three turning pairs and one sliding pair.
In the previous diagram the link1 is fixed. If we now fix link 2, that is consider an inversion
of the slider-crank mechanism we obtain the mechanism below. This is known as
Whitworths Quick return.
23
24
25
26
27
EXPERIMENT 5: CRANK AND SLOTTED LEVER QUICK

RETURN MOTION EXPERIMENT
OBJECTIVES
The objective of this experiment is to investigate the kinematics motion of a Crank and
Slotted Lever Quick Return mechanism. The investigation is to show that it is indeed a
quick return mechanism and to evaluate the increase in efficiency that this would offer if
applied to a machine tool.
THEORY
Definition of a Mechanism
A mechanism is a simplified model, usually in the form of a line diagram, which is used
to reproduce the motion occurring in a machine. The purpose of this reproduction is to
enable the nature of the machine. The purpose of this reproduction is to enable the nature
of the motion to be investigated without the encumbrance of the various solid bodies
which form the machine elements
The various parts of the mechanism are called links or elements. Where two links are in
contact and a relative motion is possible, then they are known as a pair. An arbitrary set
of a links which form a closed chain that is capable of relative motion, and that can be
made into a rigid structure by the addition of a single link, is known as a kinematics
chain. To form a mechanism from a kinematics chain one of the links must be fixed.
However as any of the links can be fixed, it follows that there are as many mechanism as
there are links in the chain. The technique obtaining different mechanism by fixing the
various links in turn is known as inversion.
28
Kinematics Pairs
The relative motion between two links of a pair can take different form. Three types of a
pairs are known as lower pairs and these are the frequently occurring ones:
Sliding : such as occurs between a piston and a cylinder
Turning : such as occurs with a wheel on an axle
Screw motion: such as occurs between a nut and a bolt
All other cases are considered to be combinations of sliding and rolling are called higher
pairs. Strictly screw motion is a higher pair as it combines turning and sliding.
Slider Crank Mechanism

The slider- crank mechanism is well known as the basis of a reciprocating engine. As
shown in the diagram below it consists of three turning pairs and one sliding pair
In the above diagram, the link 1 is fixed. If we now fix link 2, that is consider an
inversion of the mechanism, we obtain the mechanism shown below. This is known as
Whitworths Quick Return Mechanism.
29
Expansion of a Revolute Pairs

Consider the four bar linkage shown below:-
The revolute pair R3 can be expanded so that it becomes a block, 3. When the crank 2
form a complete revolution the block, 3, only transverses a small are from E1 to E2.
The motion of 3 is still described by means of an angle referred to B. The curved slider is
thus still a revolute form and 3 are described by an angle and not by linear distance.
The curved slider remains a revolute pair as long as its radius of curvature is finite. If the
radius of a curvature of a revolute pair becomes infinite, i.e. its center of rotation is at
30
infinity. Then the revolute pair becomes prismatic pair variable change from an angular
measurement to a linear distance measurement.
For Bar Chains:-
Thus a prismatic pair may be considered as a revolute pair whose center is at infinity in
the direction perpendicular to the generatrix.
31
Here we can see that a four bar mechanism when taken to the limit can be shown to
become slider-crank mechanism. This is very useful in the synthesis of a planar
mechanism as the properties of a four bar mechanism become the properties of the slider-
crank mechanism.
Now consider the crank and slotted lever quick return motion.
It is evident that we have a four bar chain with a prismatic pair as a limiting case of a
revolute pair. Superimposed upon this is an inversion of the slider-crank chain.
32
The crank radius, OB is 40 mm. The slotted lever length, AC, is 240 mm. It is a matter of
a trigonometry to develop an expression for x in terms of the crank angle, , and the
length of the links. On the apparatus x is 70 mm when is 0 and 180.
APPARATUS
Crank and Slotted Lever Quick Return Mechanism
33
PROCEDURES
1 . Set the crank so that the pointer is at zero on the scale. Note the crosshead
position, x.
2. Rotate the crank by 10 increments and for every increment, note the
corresponding crosshead position, x.
RESULTS
1. Find an expression for theoretical distance (x) in term of .
2. Plot a graph of experimental crosshead position, x, versus crank angle.
3. Plot on the same graph, a graph of theoretical crosshead position versus crank
angle.
4. On both graphs, show the return and cutting stroke.
5. Plot a graph of crosshead velocity versus crank angle. On the graph, show the
return and cutting stroke.
DISCUSSION
1. How well does the experimental result agree with the predictions from the theory?
2. What rotation angle is required for the cutting and return strokes?
3. Discuss the motion of the slider and verify that it is indeed a quick return
mechanism.
4. What is the increase in efficiency (in term of the time required for each stroke in
one revolution of crank) obtainable in the mechanism?
34
Universiti Tenaga Nasional , 2015
RESULT SHEET
Crank and Slotted Lever Quick Return Motion Experiment
Crank Angles, Experimental Slider Theoretical Slider

(degrees) position, x, (mm) position, x, (mm)
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
35
EXPERIMENT 6: HOOKES COUPLING EXPERIMENT
OBJECTIVES
The objective of this experiment is to investigate the variation in displacement for a
single joint at various angles and to show that when two joints are used together with the
same intermediate angle, the variation in displacement is cancelled out.
THEORY
A flexible coupling or universal joint is frequently used to link two shafts and transmit
circular motion from the other. Indeed continuous circular motion is perhaps the single
largest thing that mankind produces in the world with the available energy. A universal
joint is simply a combination of machine elements which transmit rotation from one axis
to another. A universal join can accommodate larger angles between the shafts. An
arbitrary and accepted lower limit is 3o. In general if the angularity between two shafts is
less than 3o a flexible coupling is used. A universal joint is used where the angularity
between the shafts is intentional. Kinematically universal joints may be divided into two
types the Hookes Cardan coupling ant the constant velocity joint. These name although
frequently used do not clarify the difference between them. A Hookes coupling is a fixed
arm coupling and a constant velocity joint is a variable arm coupling. We are concerned
here with a fixed arm coupling only.
The following analysis will show that the angle as the angle between the shafts increases
there is a periodic speed and hence torque fluctuation. Such fluctuation cannot be
tolerated in machinery so it is usual to have two coupling with small intermediate shaft.
The second coupling introduces equal and opposite fluctuations, thus the overall effect is
of smooth and uniform transmission. However both the input and the output shaft must
make the same angle with the intermediate shaft for this to work.
A Hookes coupling consists of a cruciform spider which pivots in two fork ends formed
in the end of the shafts. For practical manufacturing reasons the fork ends are made as
36
separate pieces to which the shafts are attached. Thus standard coupling can be simply
fixed to any length of shaft.
A Hookes coupling is shown schematically below
The driven shaft OB is inclined at an angle to the driving shaft in plan view. The axes of
the shafts are on the same horizontal plane. In the figure below the spider arm CD moves
through an angle to C1D1.
37
Mechanical Design And CAD Laboratory
P P is the plan view of the plane of rotation of CD and Q Q is the plan view of the plan
view of the plane rotation of EF. If we now draw RO at right- angles to C1D1 and project
R to R1 in the plan view we can take radius O R1 and draw an arc to cut Q Q at R2. We
may now project this point to meet RS at T1. Then angle TOS equals, the angle moved
through by the arm EF in the plane of rotation where P P is the plan view
Consider;
so;
The above equation gives the displacement. The velocity equation may be obtained by
differentiating equation (2)
Velocity;
The graph below shows the relationship between input and output angles from 0 to 90o
for displacement where the joint angle is 10o to 50o
38
The graph below gives the velocity variation for a single coupling for shaft angle from
10o to 50o.
39
APPARATUS
Hookes Coupling Apparatus
40
PROCEDURE
Part 1
1. Set the left hand Bracket over so that the angle 1 between the shaft is 45
2. Set the other joint to be straight, 2 = 0
3. Start the scale on the input shaft at zero. Rotate the shaft by 10 at each turn. Note
the reading on the input and output scales.
4. Repeat for 360 that is one complete rotation for the shaft input.
5. Tabulate results in the data sheet
6. Repeat procedures 1 through 5 for 1 = 15 and 30
Part 2
1. Set both 1 and 2 equal at 30, both bend at the same side.
2. For one revolution of the input shaft (at10 intervals), take readings of the scale of
the output shaft
3. Tabulate results on the data sheet.
4. Repeat the experiment with the input and output shaft parallel but still keep at the
same value of 30.
5. Tabulate results in the table given.
GRAPH AND RESULT

From the result in part 1:
1. Plot the output shaft angle versus the input shaft angle for 1 = 15, 30 and 45o
(all in one plot).
2. Plot tan (input shaft angle) versus tan (output shaft angle)1.
3. Plot the output shaft velocity (experimental and theoretical) versus input shaft
angle for 1 = 15, 30 and 45o.
From the result in part 2:

1. Plot the output shaft angle versus the input shaft angle for both readings, parallel
and same side readings in the same graph.
1
Only plot from 100o to 260o for both x and y-axis as Tan 90,270 = infinity.
41
DISCUSSION
1. Comment on the output shaft angle versus input shaft angle plot that you have
obtained2.
2. What is the significance of the tan (input shaft angle) versus tan (output shaft
angle) plot?3 In other words, what information can you obtain from the plot? Does
the plot show the validity of the analysis that was shown in the laboratory? 4
3. Comment on the output shaft velocity versus input shaft angle plot that you have
obtained. How well do the velocity variations you found compare with those
predicted in theory.
4. What is the purpose of the second part of the experiment? Does the result justify
the purpose?
5. What is the effect if 1 is not the same as 2
2
Minimum 3 comments, hint(1): what happen at 0o& 90o& 180o& 270o& 360o
3
Refer equation 2, recap order of the equation
4
Please recap the boundary of cos().
42
RESULT SHEET
Hookes Coupling Experiment Part 1
For alpha1, 1 = degrees
Input, Output, Tan Tan , Output Velocity

0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
43
Input, Output,
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
360
44

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Universiti Tenaga Nasional, 2015

Mechanical Design and CAD Laboratory

Bachelor of Mechanical Engineering (Hons.)

CREO/SOLID WORK Manual

1) To introduce laboratory experiments on machine elements.

2) To expose to CAD /CAE software: CREO and SOLIDWORKS in the design of

machine components to students.

GUIDELINE FOR LABAROTARY REPORT

a. Short Report Format

1. Cover page 1. Authors name SID no.

b. Informal Report Format

General Instructions: prepared individually or in group and must be printed properly.

1. Cover page 7. Authors name SID no.

c. Formal Report Structure

1. Title page (5 %) This page must include:

*Either (a) or (b)

6. Section and group number

Note: Books and Journals are highly recommended

BASIC LABAROTARY SAFETY RULES

1. Do not enter laboratory until you are instructed to do so.

ACCIDENTS AND INJURIES

UNIVERSITI TENAGA NASIONAL

LAB EXPERIMENT MANUAL

EXPERIMENT 1: SLIDER CRANK CHAIN EXPERIMENT

To find the velocities the method of Instantaneous Centers

Consider the mechanism, in the position shown below:-

Assuming that the angular velocity is unity

Since the connecting rod is instantaneously rotating about point IAB

So the piston velocity is given by:-

Triangles IAB and OAX are similar, thus:-

EXPERIMENT 2: SLOTTED LINK MECHANISM EXPERIMENT

The Simple Harmonic Circle enables us to establish a relationship between displacement

Q is a point which rotates at constant at constant velocity in a circle of a radius r. AB is

Acceleration parallel to AB given by this equation:

Alternatively we may consider the following method:

However from previous analysis we know that:

Slotted Link Mechanism or Scotch Yoke

Slotted link Mechanism

Crank Angles, Experimental Piston Rod Theoretical,

The objectives of this experiment are to investigate the performance of a Whitworths

Sliding : such as occurs between a piston and cylinder

Slider- Crank Mechanism

EXPERIMENT 5: CRANK AND SLOTTED LEVER QUICK

Slider Crank Mechanism

Expansion of a Revolute Pairs

Crank and Slotted Lever Quick Return Mechanism

Crank and Slotted Lever Quick Return Motion Experiment

Crank Angles, Experimental Slider Theoretical Slider

EXPERIMENT 6: HOOKES COUPLING EXPERIMENT

A Hookes coupling is shown schematically below

GRAPH AND RESULT

From the result in part 2:

For alpha1, 1 = degrees

Input, Output, Tan Tan , Output Velocity

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