ME444: Analysis and Design of Mechanisms

Lab 3

(Study of Quick Return Mechanism)

Group 8
Date: March 17, 2025

Sr. No Name Roll Number

1 Ayush Lonakadi 23B2253
2 Varun Inamdar 23B2203
3 Aagam Kasaliwal 23B2215
4 Lakshaditya Singh 23B2230
5 Anirudh Maindargikar 23B2219
1.​Introduction:
A quick return mechanism is a mechanical system used primarily in
shapers, slotters, and automation equipment. It is designed to make the
return stroke of a moving part faster than the forward stroke. This
mechanism helps increase the machine's efficiency by reducing the time
spent on the return motion, allowing for faster overall operation.

●​ Objectives:​
The primary objectives of this experiment are:
1.​ Understanding the Quick Return Mechanism: Analyze how a
four-bar quick return mechanism operates, where the rocker moves
faster during the return stroke than the forward stroke.​

2.​ Constructing the Mechanism: Build a physical model of the quick

return mechanism using cardboard and pins based on given
parameters.​

3.​ Analyzing Link Lengths and Angles: Derive key parameters such as
the angle α and link lengths l2​and l3​based on the given values of φ
(rocker angle) and Quick Return Ratio (QRR).​

4.​ Observing Toggle Positions: Identify and study the extreme

positions of the rocker where the crank reaches toggle points.​

5.​ Validating Theoretical Calculations: Compare experimental

observations with theoretical calculations of stroke time, link
positions, and angular movement.

●​ Background of Experiment:

The quick return mechanism is a fundamental kinematic system employed in

shaping machines, slotters, and other reciprocating motion applications. It is
designed to increase efficiency by making the return stroke faster than the
forward stroke, reducing idle time.
 This mechanism typically consists of a four-bar linkage, where a crank
(input link) drives a rocker (output link) through a series of linkages. The
defining characteristic of this system is that the crank rotates at a constant
speed but covers a larger angle during the forward stroke than the return
stroke. This results in an asymmetrical motion where the return stroke takes
less time, leading to a quick return ratio (QRR) greater than 1.

The mechanism's toggle positions correspond to the rocker's extreme

positions. Different quick return ratios can be achieved by adjusting the link
lengths and pivot positions to optimize machining or motion efficiency.

This experiment aims to construct and analyze a simple, quick return

mechanism using cardboard and pins, reinforcing the principles of
kinematics and mechanism design.

2.​Methodology:
The methodology involves several key steps:

1. Understanding Given Parameters

●​ The rocker angle (φ) values and quick return ratio (QRR) are
provided.​ ​ ​ ​ ​ ​ ​ ​

​ ​ Table 1: Given values of QRR and φ

QRR φ

2.7 77.5 degrees

●​ Using these values, calculate α (the crank rotation offset angle)

through the relation: QRR = (180 + α)/(180 - α).
 Figure 1: Construction of Quick Return Mechanism

2. Selecting Key Design Parameters

●​ Choose an arbitrary length for link 4 (l4) (the rocker).

●​ Select an appropriate location for the fixed pivot O4.

3. Constructing the Mechanism

●​ Draw the extreme positions of the rocker, ensuring they are

symmetric about a vertical reference line through O₄.
●​ Draw a reference line XX’ through position B1.
●​ Draw another reference line YY’ through B2, making an angle α with
XX’.
●​ Identify the intersection of XX’ and YY’ to determine the location of
the second fixed pivot O2.
4. Calculating Link Lengths

●​ Using the geometric relationships O2B1 = l2 + l3 and O2B2 = −l2 + l3

○​ Solve for l2 (crank length) and l3 (coupler length).

5. Constructing the Physical Model

●​ Cut cardboard pieces corresponding to l2, l3, and l4.

●​ Pins at O2 and O4 are used to fix the pivots and assemble the
mechanism.

Figure 2: The Quick return mechanism model

 3.​Results
The results include:

1.​ Crank rotation offset angle(α): Obtained by using the relation of

QRR and α.

Table 2: Value of Crank rotation offset angle

Sr. Angles Theoretical Value Experimental value

No
1 α 82.7° 88॰

2 φ 77.5॰(given) 74॰

2.​ Link Lengths: Calculated by analyzing the geometry of the

mechanism and a chosen value for l4.

Table 3: Value of link lengths l1, l2, l3 and l4

Sr. No Link Lengths

1 l1 6.8 cm
2 l2 4.0 cm
3 l3 7.7 cm
4 l4 10.0 cm

​ 3. Input angles vs Output angles

Table 4: Input angle (θ2) v/s Output angle (θ4)

Input angles: θ₂ (degrees) Output angles: θ₄ (degrees)

0 58
20 54
40 57
60 62
80 73
100 81
120 88
140 99
160 108
180 111
200 118
220 123
240 126
260 125
280 124
300 123
320 114
340 82
360 58
4.​Discussion
The quick return mechanism model was successfully built and
analyzed in this experiment. The primary goal was to understand its
working principle and comparing theoretical calculations with
experimental observations.

Accuracy of the Mechanism

The values obtained from the experiment closely matched the

theoretical predictions. The crank rotation offset angle (α) was
calculated using the quick return ratio (QRR) formula, giving a
theoretical value of 82.7°, while the experimental measurement was
88°. Similarly, the given rocker angle (φ) of 77.5° was experimentally
measured as 74°. These small differences (within 5.3°) indicate that
the model was constructed with reasonable accuracy.

Determining Link Dimensions

The link lengths were determined using the conditions O2B1 = l2 + l3

and O2B2 = -l2 + l3, allowing the required values for l2, l3, and l4 to be
calculated. A minor variation in link lengths due to manual cutting
introduced slight deviations, but the overall motion remained
consistent with expectations.

Comparison of Theoretical and Experimental Data

The expected quick return behavior was observed by plotting input

angles (θ2) vs. output angles (θ4). The forward stroke spanned
approximately 290° of crank rotation, while the return stroke was
completed in just 70°, confirming that the QRR was greater than 1.
The differences between theoretical and measured output angles were
minimal, further supporting the experiment's validity.

Some sources of error include:

●​ Measurement inaccuracies while marking angles and cutting

links.
●​ Due to an error in implementation, experimental φ came out to
be 74° instead of 77.5°.
●​ Friction at pivot points affects smooth motion.
●​ Slight misalignment in pin placements, which could alter link
behavior.

Effect of Link Length Variations

It was observed that small variations in link dimensions significantly

affected the mechanism’s behavior. A longer rocker length (l₄)
resulted in a different return stroke duration, reinforcing the
importance of precise fabrication in practical applications.
 Challenges and Observations

While the basic working of the mechanism was demonstrated

effectively, some practical challenges were noted:

●​ Minor deviations in stroke timing due to link flexibility and

assembly tolerances.
●​ Difficulties in achieving exact symmetry while setting up the
extreme positions of the rocker.
●​ Friction and slight looseness in joints, which introduced small
inconsistencies.

Despite these challenges, the mechanism performed as expected, with

the return stroke being noticeably faster than the forward stroke. The
experimental values were close to theoretical predictions, confirming
the model's validity.

5.​Conclusions:
A model demonstrating the quick return mechanism was successfully
created. The experimental data closely matched the theoretical predictions,
indicating the method’s reliability for studying the quick return mechanism.

Minor errors were observed, primarily due to fabrication and measurement

uncertainties. Further improvements in manufacturing precision and
measurement accuracy could help reduce these errors.

This lab helped us understand the working and synthesis of a quick return
mechanism, effectively bridging the gap between theoretical concepts and
real-world applications.
 6.​Contributions:

Name Roll Number Contributions

Varun Inamdar 23B2203 Model, Results
Aagam Kasaliwal 23B2215 Introduction, Methodology, Model
Ayush Lonakadi 23B2253 Results, Discussion
Lakshaditya Singh 23B2230 Plots, Tables
Anirudh Maindargikar 23B2219 Model, results, conclusion

7.​References:

●​ https://en.wikipedia.org/wiki/Quick_return_mechanism (Quick
Return Mechanism - 14/03/2025)
●​ https://moodle.iitb.ac.in/mod/assign/view.php?id=56695 (Lab 3
instructions - 14/03/2025)