BTM 3134

MANUFACTURING COMPONENT DESIGN

 Contact Hours

Lecture: 2 units (2 hours X 14 weeks)

Laboratory: 2 units (4 hours X 14 weeks)
Time Table
Lecture: Monday: 4 to 6 pm at T-BK-01
Laboratory: Tuesday: 2 to 6 pm
Lecturer: Associate Professor Dr Ratnakar Kulkarni
 Course Synopsis:
Design of motion components for the manufacturing industry, including
the study of components like gears, cams, and linkages, and their
applications. Course also includes introduction to finite-element
applications and the usage of common FEA programs. Students will
learn the basics behind the usage of ANSYS, and the common
applications. Students will learn modeling, constraints, loading,
limitations, using help and look-up menus, and various other topics.
Course Outcomes
CO1 Synthesize and analyse four bar mechanism, velocity and acceleration
diagrams for mechanisms, analyse gear trains, cams.
CO2 Use FEA for design of machine components and for analysis of the
results.
CO3 Obtain solutions based on the machine component design and
interpret the results.
CO4 Design manufacturing component based on the real world data
Learning References

1. Kevin Russel, Quing Shen & Raj Sodhi, ‘Kinematics and

Dynamics of Mechanical Systems’, CRC Press, 2016
Edition.
2. John Uicker & Gordon Pennock, ’Theory of Machines &
Mechanism’, Oxford University Press
3.Xiaolin Chen & Yijun Liu, ‘Finite Element Modelling and
Simulation with ANSYS Workbench’ CRC Press, 2014
Assessment Scheme
Assessment Method Marks %
Quiz 5
Test 15
Final Examination 40

Lab Assignments 10

Project Presentation 30

Total 100
Lesson Plan
Week Topics
Position Analysis
 Introduction to kinematics
1,2
 Kinematic analysis of planar mechanism
 Initial position problem, vector loop
Velocity Analysis
 Plane motion of a rigid body
3&4
 Relative velocity method
 Klien Construction method
Acceleration Analysis
 Using relative acceleration method
5&6
 General approach for acceleration analysis

Finite Element Analysis

 Basic components of FEA & Understanding the components
7 and elements
 Solid modeling, meshing, and solution
Week Topics
8 Mid Term Examination
Gear Trains
 Gear introduction & Classification
9 & 10
 Types of gear train
 Epicyclic gear train
Cams
 Introduction, classification of cams
 Types of followers
11 & 12
 Types of motion
 Construction of cam profile

Mechanical Synthesis
 Kinematic analysis versus synthesis
13 & 14
 Quantitative synthesis
 Applications of quantitative synthesis
 Introduction to Kinematics
The subject theory of machines may be defined as the branch of engineering
science, which deals with the study of relative motion between the various parts of
a machine, and forces which act them.
Kinematics: It is that branch of theory of machines which deals with the various
parts of theory of machines.
Dynamics: Deals with the forces and their effects while acting upon the machine
parts in motion.
Kinetics: Deals with inertia forces which arise from combined effects of mass and
motion of the machine parts.
Statics: Deals with the forces and their effects while machine parts at rest.
 Links or Elements
A mechanism is made of a number of resistant bodies out of which some may have motions
relative to the others. A resistant body or a group of resistant bodies with rigid connections
preventing their relative movement is known as a link. A link may also be defined as a member or a
combination of members of a mechanism, connecting other members and having motion relative to
them, thus a link may consist of one or more resistant bodies. A link is also known as Kinematic link
or an element.
Links can be classified into
Binary link: Link which is connected to
other links at two points. (Fig.1. a)
Ternary link: Link which is connected to
other links at three points. (Fig.1.b)
Quaternary link: Link which is connected
to other links at four points. (Fig1. c)
 Kinematic Pair
A Kinematic Pair or simply a pair is a joint of two links having relative motion
between them.
Types of kinematic pairs:
(i) Based on nature of contact between elements
(ii) Based on relative motion between pairing elements
(iii) Based on the nature of mechanical constraint

(i) Based on nature of contact between elements

(a) Lower pair. If the joint by which two members are connected has surface
contact, the pair is known as lower pair. Eg. pin joints, shaft rotating in bush
, slider in slider crank mechanism.

(b) Higher pair. If the contact between the pairing elements takes place at a
point or along a line, such as in a ball bearing or between two gear teeth
in contact, it is known as a higher pair.
(

(a) Siding pair. Sliding pair is constituted by two

elements so connected that one is constrained to
have a sliding motion relative to the other. DOF = 1
(b) Turning pair (revolute pair). When connections
of the two elements are such that only a constrained
motion of rotation of one element with respect to the
other is possible, the pair constitutes a turning pair.
DOF = 1
(c) Cylindrical pair. If the relative motion between the
pairing elements is the combination of turning and sliding,
then it is called as cylindrical pair. DOF = 2

(d) Spherical pair. A spherical pair will have surface contact

and three degrees of freedom. Eg. Ball and socket joint. DOF = 3
(e) Helical pair or screw pair. When the nature of contact between
the elements of a pair is such that one element can turn about the
other by screw threads, it is known as screw pair. Eg. Nut and bolt. DOF = 1
(iii) Based on the nature of mechanical constraint
(a) Closed pair. Elements of pairs held together
mechanically due to their geometry constitute
a closed pair. They are also called form-closed
or self-closed pair.

(b) Unclosed or force closed pair. Elements of pairs

held together by the action of external forces constitute
unclosed or force closed pair .Eg. Cam and follower.
 Degrees of Freedom
An unconstrained rigid body moving in space can describe the following
independent motions.
1. Translational Motions along any three mutually perpendicular axes x, y and z,
2. Rotational motions along these axes.
Thus a rigid body possesses six degrees of freedom. The connection of a link with
another imposes certain constraints on their relative motion. The number of
restraints can never be zero (joint is disconnected) or six (joint becomes solid).
Degrees of freedom of a pair is defined as the number of independent relative
motions, both translational and rotational, a pair can have.
Degrees of freedom = 6 – no. of restraints.
To find the number of degrees of freedom for a plane mechanism we have an
 Grubler’s Equation

F= 3 ( n– 1 ) – 2 j1-– j2
F= Mobility or number of degrees of freedom
n= Number of links including frame.
j1= Joints with single (one) degree of freedom.
j2= Joints with two degrees of freedom.
If F> 0, results a mechanism with ‘F’ degrees of freedom.
F= 0, results in a statically determinate structure.
F< 0, results in a statically indeterminate structure.
The degrees of freedom for various joints

Type of Joint Nature of Motion Degree of

Freedom
Hinges (Revolute) Pure rolling 1
Slider (prismatic) Pure sliding 1
Cylindrical, Cam, Gear, Ball Rolling and sliding 2
Bearings
Rolling Contact Pure rolling
Spherical 3
 Linkage, Mechanism and structure:
A linkage is obtained if one of the links of kinematic chain is fixed to the ground. If
motion of each link results in definite motion of the others, the linkage is known as
mechanism.
If one of the links of a redundant chain is fixed, it is known as a structure. To obtain
constrained or definite motions of some of the links of a linkage, it is necessary to
know how many inputs are needed. In some mechanisms, only one input is
necessary that determines the motion of other links and are said to have one
degree of freedom. In other mechanisms, two inputs may be necessary to get a
constrained motion of the other links and are said to have two degrees of freedom
and so on.
 Mechanism
When one of the links of a kinematic chain is fixed, the chain is known as
mechanism. It may be used for transmitting or transforming motion e.g. engine
indicators, typewriter etc
A mechanism with four links is known as simple mechanism, and the mechanism
with more than four links is known as compound mechanism. When a
mechanism is required to transmit power or to do some particular type of work,
it then becomes a machine. In such cases, the various links or elements have to
be designed to withstand the forces (both static and kinetic) safely.