EMT 2336 Dynamics of Planar Mechanisms Lecture notes compiled by Githu Njiri May 2011 Students are reminded not to treat these lecture notes as a comprehensive and solely sufficient material for their studies since the purpose of the notes is not meant to be a substitute for regularly attending classes, reading relevant textbooks and recoramended books. The notes are ‘aimed at providing a quick reference and a brief guidance for the students.Expected Outcomes ‘At the end of this course, you should be able to; + Carry out kinematic synthesis of planar mechanisms, * Write computer programs to design linkages (Computer Aided Design of Linkages - Simulation) * Determine static forces acting on a planar mechanism * Determine inertia forces acting on a planar mechanism Course Outline 1, Dynamics of mechanisms: Newtonian mechanics; static forces, dynamic forces, inertia forces in linkages, centre of percussion 2, Kinematic Synthesis of Linkages - Classification of synthesis; (function gen- eration, path generation and motion generation), Freudensteins Equation, Cheby- shev's theorem, Minimizing Structural Errors, Computer simulation in design of linkages, Practicals 1. Case study and computer simulation Prerequisites - EMT 2331: Kinematics of Planar Mechanisms ~ EMG 2207; Engineering Mechanics-Dynamics Reference Textbooks 1. Hannah, J. and Stephens, R.C., Mechanics of Machines -Elementary Theory and Examples, Arnold International Publishers. 2. Hannah, J. and Stephens, R.C, Mechanics of Machines Advanced Theory and Examples, Arnold International Publishers.3. Ryder, G.H. and Bennett, M.D., Mechanics of Machines, McMillan Education Ltd Publishers, 2nd Ed., 1990. 4. Hamilton, H.M and Charles F.R., Mechanics and Dynamics of Machinery, 5. Shigley J. and Uieker, Theory of Machines and Mechanisms, 6. Norton, R.L., Design of Machinery - An Introduction to the Synthesis and Analysis of Mechanisms and Machines, McGraw-Hill Publishers, 3rd Ed., 2004. 7. Grosjean, J., Kinematics and Dynamics of Mechanisms, McGraw-Hill Book Co. (UK) Led, 1991. 8. Mabie, H. H., Mechanisms and Dynamics of Machines. 9. Prentice, J. M., Dynamics of Mechanical Systems. Meeting times © Lectures: © Tutorials: Practical: Course Policies Assignments # Are part of course work and shall constitute 5%. © Shall be due a week after it is assigned unless otherwise specified. « The objective of the homework is to train you to use the principles we covered in class. Please feel free to solve homework in groups or individually. Solution to any assignment problem will be posted after homeworl collected. Continuous Assessment Tests (CATS) © There will be a total of three CATS which will be held at times scheduled on mutual agreement in class, but within the periods proposed by the Registrar AA. ‘© Are part of course work and shall constitute 10%. * Each CAT will be revised in class on the day the marked scripts are returned.Practicals © Are part of course work and constitute 15%. # They shall be done in groups which will be formed alphabetically unless there is a strong reason not to do so. Bach student shall submit a practical report two weeks after the practical is done. Collusion will not be accepted and both parties will be penalized. * Note that marks will be awarded for good conduct in the laboratories. This infor- mation will be obtained from the technician in charge. End Semester Exam ‘© University rules and regulations apply. © Shall constitute 70% ‘* The objective of exams is to test your understanding of material covered. Therefore, please do not expect to see one of the homework problems, slightly masked, in the test. You should not also expect to see something totally new in an exam, as you will not have enough time to consider it. ‘© My experience tells me that your chance of passing an exam is greatly enhanced if you solve assignments and tutorials regularly. ‘Therefore the exam constitutes of the Course work and End Semester Exam as; 30% Course work - Assignments (5%), CATS (10%) and Practicals (15%). 70% End Semester Exam. Notes © Lwill only provide approximately 70% in class. It is your duty therefore to go an. extra mile and cover the other 30% by reading the textbooks given as references herein, or any other material you think appropriate, The reference textbooks are available in the University's Main Library. My lectures will be based on the most important material in the reading assignment ‘and i won't repeat much of the material in the assigned readings. It is the duty of the students to read carefully and critically, identifying and bringing questions about the readings to class. © Feel free to consult me in my office at any time for elaborations and answers to questions on the subject. Remember, Aulizaye si mjinga iii‘© I believe you are all aware that, no student should be allowed to sit for an end semester exam without having attended at least two-thirds of the lectures. To this effect, nominal rolls will be provided during class times for each student present to sign as a proof of his/her presence. Regular counter-checks will be done to determine if anyone absent has been signed for. ivContents Expected Outcomes... Soe oee Sr Course Outline Practicals . . Prerequisites Reference Textbooks Meeting Times Course Policies 1 Forces in Mechanisms 1.1, Introduction LLL Force 1.1.2 Free Body Diagrams (FBD) . 1.2. Static forces in linkages 1.2.1 Static equilibrium . . 1.3. Tutorial 2 1.4 Inertia forces and torques 1.4.1 Inertia force and torque in a rigid body . 14.2 Inertia forces and torques in linkages . . 1.4.3 Four bar linkage as a typical case 1.4.4 Static forces in quick-return mechanism, 2 Kinematic Synthesis of Planar Linkages 2.1 Classification of kinematic synthesis problems 2.2 Input-output relationship of a standard four-bar linkage: Freudenstein's equation soos ii 10 15 18 18 192.3 Function generation 2.3.1 Structural error 24 Tutorial 1. 22 25 29Chapter 1 Forces in Mechanisms 1.1 Introduction A mechanism is a device that transforms motion and in so doing transmits power by means of forces and torques in its elements. Planar mechanisms I dealt with the geometry of the mechanism and the relationship between the displacement, velocity and acceleration with time. The forces which produce the motion and which result from motion of a mechanism were not considered. The knowledge of forces acting on a machine member is very important. These forces must be within the working limit of the material of the member to which they are acting. For example if the force acting on a piston in an internal combustion engine is too high, it might cause the gudgeon pin to shear. Also if the force operating on a journal bearing is too high, it will squeeze the oil film and cause metal to metal contact, and hence overheating and rapid failure of the bearing. ‘Therefore a designer of a mechanism should ensure that all the elements of the mechanism have been properly designed so that they will not fail during service. Hence the study of forces acting on a mechanism is of paramount importance in design of mechanisms, In this chapter, we shall investigate the static and dynamic forces and torques in mech- anisms 1.1.1 Force ‘This is the action of one body on another. Its a vector quantity and hence to completely define a force we must specify its magnitude, direction and place of application of the force. ‘The forces of action and reaction between any two of the connecting bodies are called constraint forces. They constrain the body to move in a specific manner. Forces external to these bodies are called applied forces.‘The ditection of a force includes the concept of the line along which the force is directed and sense. Thus a force is directed negatively or positively along the line of action 1.1.2 Free Body Diagrams (FBD) AFBD is a sketch of a body isolated from other bodies on which the forces and moments are shown in action. If the FBD is of the entire machine, then the forces and moments shown are the external applied forces and moments, whereas, if the FBD is of a portion of a machine part, then the forces shown should include the internal actions and reaction forces. - Free bond diagrams are very important in analysis of forces and moments in machines, since; «they assist in understanding of the problem © they make it easy for one to translate word thoughts into physical models © they make mathematical relations in static equilibrium easy to see and find. 1.2. Static forces in linkages In order to calculate the forces and torques in any mechanism, it is necessary to isolate each element of the mechanism as a free body and then apply the equilibrium conditions. 1.2.1 Static equilibrium Lets consider the transmission of forces in mechanisms neglecting inertia forces, in which ‘case the forces and torques will be in static equilibrium. Force and torque being vector quantities can be resolved into components, and for a body to be in static equilibrium, then, the summation of forces in any direction must be zero, and also the summation of torques about any axis must be also zero, that is, oM - For a body to be in equilibrium under the action of two forces Fy and Fy applied at points A and B as shown in figure 1.1(a), these two forces must be equal in magnitude, opposite in sense and must. be collinear.In the case of a body subjected to three forces F;, F, and F; applied at points A, B and C respectively as shown in figure 1.1(b), then for static equilibrium, the line of action of these forces must be concurrent and meet at the same point P. This is the principle of concurrence 5 @ © Figure 1: All the three forces can be represented in a triangle of forces, each side of which is parallel to the line action of a force. Example 1.1 ‘The figure below shows a slider-crank mechanism whose crank is 65 mm and connecting rod 200 mm long. At the instant when #, = 45°, the force on the slider is 500 N. Calculate the torque 7 which must be exerted on the crank A,A in order to maintain static equilibrium. Calculate also the corresponding forces in all the members. Neglect friction and inertia forces. Solution: First we draw free body diagrams for all the members of the mechanism. First method- Draw free body diagrams for all the members of the mechanism. The forces Fp acting in the connecting rod must be equal, opposite and collinear. The slider is subjected to three forces P which is known in both magnitude direction , Fay and Fy which are known in direction only.* Angle ¢ is, 6 = sin? FA sin 8 AB = sine ( 85m as” = ‘Go 13.29° Apply static equilibrium to each member. At the slider, Or P—Fypcosé = 0 P___ +500 ; Fan = ag ~ cals Se cA =0 Fy Fagsing = 0 A, = Fagsing = 513.76 sin 13.29° = 118.1 N At the crank A,A, Ma, = 0 T = AAP yp cosdsin§ + AAF ag sin $ cos Oy FAP ap sin($ +62) 0.65 x 513.76 sin 13.29° + 45°) 8.4 Nm ‘The torque required to maintain static equilibrium is T = direction. 8.4Nm in the clockwise Alternative method- Draw free body diagrams for all the joints in the mechanism, Apply static equilibrium to each miember.At the slider, Ro: = P=500N At the connecting rod, DMs =0 Ro:ABsin$ + RpjAB cos = 0 =Rozsing _ 500sin13.29° Roy = so cos gag NBIN CF =0 Raz Ros = 0 Ray = Ros = 500 N | -118.1N | At the crank, | DMs, = 0 | T = RaA,Asin 6, — RayA,A cos, = 500 x 0.065.sin 45 — (—118.1) x 0.065 cos 45° = 28.4 Nm1.3 Tutorial 2 1, For the double crank-slider mechanism shown in figure 1.2, calculate the force F on slider A, necessary to maintain static equilibrium at the instant shown. The dimension of the links are: AB = 152 mm, C,B = CD = 127 mm, and BC = 42 mm, Figure 1.2: 2. For the quick-return mechanism shown in figure 1.3, calculate the torque T required to overcome a load P = 200 N and the corresponding forces in all the members at the instant shown, The dimensions of the links are: A,B = 62.5 mm , B,C = 400 mm and DC = 200 mm. Neglect the inertia effects and the friction at the joints except at the slider D where coefficient of friction is = 0.3 \-?3. Figure 1.4 shows a dockside crane. Neglecting the mass of each member, calculate the static torque T required to overcome a load W of 300 kN when # = 60° and 135°, corresponding to initial and final positions. ‘The link dimensions are: AB = 14.7 m, BD = 6.5 m, DE = 19.3 m, BC = 22.3 m, and CD = 16 m c Figure 1.4: 1.4 Inertia forces and torques 1.4.1 Inertia force and torque in a rigid body Consider a moving rigid body of mass m acted upon by a system of forces. Figure 1:‘The resultant force vector is; In general, the line of action of this resultant force will not be through the center of mass G of the body, and its effect is to produce a linear and angular accelerations. ‘The linear and angular accelerations can be obtained using the Newton's second law of motion. Linear acceleration is obtained from equation, Fa = maz (1a) “ and the angular acceleration is obtained from equation, Tr = log (1.2) where Tj; is the resultant moment about the center of mass of the body produced by the resultant force. Hence, Tr = Feb ‘Thus if all forces and moments acting on a body are known, then equations 1.1 and 1.2 can be used to determine the linear and angular accelerations of the rigid body. 1.4.2 Inertia forces and torques in linkages In most cases the motion of a mechanism members is usually specified in advance by the machine requirements. Hence the problem now becomes; given the motion of a mechanism, determine which forces are required to produce this motion, that is, given the linear and angular accelerations of a body, use equations 1.1 and 1.2 to determine the inertia forces and torques acting on the various members of the mechanism. To determine the linear and angular accelerations of various members in a mechanism, acceleration analysis should be done using either of the methods discussed in Planar Mechanisms I (i.e, graphical or analytical methods of acceleration analysis) When a mechanism is accelerating the resulting forces and torques are referred to as inertia forces and inertia torques. ‘They are also known as dynamic forces and torques. ‘They can be very high particularly in high speed mechanisms such as, slider-crank mech- anism used in internal combustion engines, packaging machines, stitching machines etc. Ibis therefore important to be able to calculate them in order to take them into account in detailed designs of all the members of the mechanisms. When a body ia accelerating, there must a force F and a torque T acting on the body such that, (13) (4)Where m is the mass of the body, a is the acceleration of the center of mass of the body, Tis the moment of inertia of the body about an axis through the center of mass of the body, and a is the angular acceleration of the body. ‘The inertia force F = ma acts in the center of mass of a body and has the same line of action as the linear acceleration of the mass center but in the opposite direction. Similarly, the inertia torque T = Ja acts about the mass center of the body, and is in the opposite direction with the angular acceleration of the body. When calculating forces and torques in mechanisms graphically, it is necessary to replace a force a torque on a body by a single force. This is a well known principle in mechanics and is illustrated in figure 1.6. ‘Figure 1.6(a) shows a body subjected to inertia force F = ma and inertia torque T = Ia. @ ) Figure 1.6: In figure 1.6(b), two extra forces have been added, one at G opposite and equal to the applied force F, and another at O at a distance d from G. For the two forces in figure 1.6(a) and (b) to be dynamically equivalent, then the two forces at G should cancel out, and the single force at O should replace the original force and torque. The force F at O must therefore be applied at a distance d from center of mass G such that, Fa= & (15) ISS Ina mechanism, if we know the ma and Ja of a particular link as inertia force and inertia torque respectively, then, These equations are considered as equations of static equilibrium in which the © Forces includes the inertia forces, and 5>Torques include inertia torques. This implies that the dynamic problem is reduced to a static problem called d’Alembert’s principle.1.4.3. Four bar linkage as a typical case Consider a four bar linkage shown below whose crank rotates at a constant velocity w2. Oy, Cy and Cy are the mass centers of crank, coupler and follower links. mg, ms and mg are the masses of crank, coupler and follower links. J2, Js and I, are the moments of inertia of crank, coupler and follower links. We need to determine torque T,, which must be applied at the crank to produce motion. First, we draw an acceleration diagram of the linkage in order to determine the angular accelerations of all the links, and the linear accelerations of the mass centers of all the links, To draw an acceleration diagram, we need to determine all the angular velocities of the links. This can be achieved graphically through velocity diagram method or instant center method, v Acceleration diagram Figure 1.7: From the acceleration diagram, the accelerations of the center of masses of the links are, ‘© Acceleration for the mass center of crank is, aga = 73 © Acceleration for the mass center of coupler is, acs = O65 * Acceleration for the mass center of the follower is, aes = OG 10‘Also from the acceleration diagram, angular accelerations of the coupler and follower links are, Angular acceleration for the coupler link AB is, - The direction of these accelerations are obtained from the diagram. The angular accel- eration of the crank link is zero, since the link rotates with constant angular velocity. ‘The figure below shows the three links together with the inertia forces and torques shown dotted and opposite to the direction of accelerations. A=ma, Figure 18: We are now in a position to draw a free body diagram for each link. The inertia forces and torques are considered to be external and must be in equilibrium with the reactions at each joint, The vector sum of the inertia forces, that is, $= Fy + Fs + Fy commonly referred to as shaking force, will result in vibrations of the linkage. Such vibrations may sometimes be unacceptable and design efforts to balance the linkage will be necessary to avoid damage to the mechanism and to reduce the transmission of these vibrations to the surroundings. Example 1.2 ‘The figure 1.9 below shows a slider crank mechanism whose crank A,A is 65 mm long and connecting rod AB is 200 mm long. At the instant when 2 = 30°, the crank is urotating at a constant speed of 3000 rev/min in anticlockwise direction. ‘The masses of the crank, connecting tod and slider are 1.75 kg, 3.25 kg, and 1.25 kg, respectively. ‘The location of centers of mass for the crank and connecting rod are at 25 mm and 65 mm. from A, and A respectively. The moment of inertia of the crank and connecting rod is, 2.5x 10° kg/m? and 4.3 x 10-? kg/m? respectively. Calculate the torque T’at the crank which is required to overcome the inertia forces. A Figure 19: Solution: The first step is to calculate linear and angular accelerations of each member of the mechanism. To do this we require the angular velocities of the crank and connecting rod. ‘The angular velocity wa, of the crank is, 2nNaa _ 2m x 3000 00 oO Waa 314.2 rad/s ‘The angular velocity way of the connecting rod is obtained by drawing a velocity diagram for the linkage at the instant. Absolute velocity of point A, Va =wa,a x AA = 314.2 x 0.065 = 204 m/s From the velocity diagram, @ _ 18 a = SS = 90 ra, aw = Te = BM pg 70 ad/s ‘The next step is to draw the acceleration diagram to determine the accelerations of the center of masses and angular accelerations of the link. ‘+ Normal acceleration of the point A is, a% = w3,4 x AjA = 314.2? x 0.065 = 6417 m/s’ © The tangential acceleration of point A is zero since the crank rotates at a constant, speed. 2Velocity diagram Z Accln diagram ‘Space diagram Figure 1.10: * The normal acceleration of point B relative to A is aj, = why x AB = 90? x 0: 1620 m/s?. From the acceleration diagram, Linear acceleration of mass center of the crank is, aq = OG = 2466 m/s” Linear acceleration of mass center of the connecting rod is, Qg = Oy = 6300 m/s* Linear acceleration of the slider is, ag = 0b = 6672 m/s” Angular acceleration of the connecting rod is, at als! Inertia force at the crank is, Fy = My X ag = 1.75 x 2466 = 4315.5 N Inertia force at the connecting rod is, Fy = Mz X a = 3.25 x 6300 = 20475 N 1BInertia force at the slider is, Fy = Mg x ag = 1.25 x 6672 = 8340 N Inertia torque at the connecting rod, T = Is X agp = 4.3 x 107 x 14700 = 632.1 Nm Draw free-body diagrams for all the members as shown below, Figure 1.11: Applying static equilibrium to each link, At the slider, At the connecting rod. DM = Roy x HB 059.35" = Roy = ‘Taking moments at the connecting rod about point A, 0 Tz — Fasin 20.1° x AC} cos 9.35" — F, cos 20.1° x AC} sin 9.35" —RgzAB x cos 9.35" 632.1 — 20475 sin 20.1° x 0.065 cos 9.35" — 20475 cos 20.1° x 0.065 sin 9.35° —8340 x 0.2sin9.35° = -293.3 N = 293.3 TFeos9.550 ~ 486.2 N uYR =0 Roe + F00820.19 - Raz = 0 Raz = 8340 + 20475 cos 20.19 = 27568 N “cA=0 Roy + Fysin20.1" — Ray = 0 By w Ray = 1486.2 + 20475 sin 20.19 = -5550.2 N Taking moments at the crank about point A, to determine torque T. Note that the inertia force Fy has no moment about point A, since its line of action passes through this point. DMs, = 0 T = Ray x AAcos30” — Ra, x AAsin 30° = 5550.2 x 0.065 cos 30" — 27568 x 0.065 sin 30° = -583.5 Nm ‘Therefore the torque required at the crank to overcome inertia forces is T = 583.5Nm. in the an anticlockwise direction. 1.4.4 Static forces in quick-return mechanism Figure 1.12 shows the configuration of a quick-return mechanism. The cutting force P acting on the tool passes through the center of the slider. Its required to determine the necessary driving torque which is to be applied on link 2 to overcome the cutting force P, neglecting the friction and inertia forces. Figure 1.12: 6