DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE
Certified that this project report
SIX BAR SLIDER CRANK POWER HAMMER MECHANISM
I s t h e b o n a f i d e w o r k o f YEMMINAMADHUSUDHAN
w h o c a r r i e d o u t t h e p r o j e c t w o r k u n d e r m y sup
ervision

AIM:
To design and fabricate a simple mechanical operated power hammer byapplying
the principle of kinematic arrangement and machine design concepts

1.INTRODUCTION TO MECHANISMS
1.1
Concept of degrees of freedom
In the design or analysis of a mechanism, one of the most important
concern is thenumber of degrees of freedom (also called movability) of the
mechanism. It is
defineda s t h e n u m b e r o f i n p u t p a r a m e t e r s ( u s u a l l y p a i r
v a r i a b l e s ) w h i c h m u s t b e independently controlled in order to
bring the mechanism into a useful engineering purpose.

Degrees of Freedom of a Rigid Body in a Plane

The degrees of freedom (DOF) of a rigid body are defined as the
number
of i n d e p e n d e n t m o v e m e n t s i t h a s . F i g u r e 1 . 2 s h o w s a r i g i d
b o d y i n a p l a n e . T o determine the DOF of this body we must
consider how many distinct ways the bar can be moved. In a two
dimensional plane such as this computer screen, there are 3 D O F . T h e
bar can be translated along the x axis, translated along the
y a x i s , a n d rotated about its centroid.
Degrees of Freedom of a Rigid Body in Space
An unrestrained rigid body in space has six degrees o
f f r e e d o m : t h r e e translating motions along the
x
,
y
and
z
axes and three rotary motions around the
x
,
y
and
z
axes respectively in the as shown in the fig 1.3
1.4
Kutzbach Criterion Equation
Consider a plane mechanism with

number of links. Since in a mechanism,one of the links is to be fixed,

therefore the number of movable links will be (

-1)a n d t h u s t h e t o t a l n u m b e r o f d e g r e e s o f f r e e d o m w i l l b e 3 ( n -
1) before they
arec o n n e c t e d t o a n y o t h e r l i n k . I n g e n e r a l , a m e c h a n i s m w
ith

n u m b e r o f l i n k s connected by j number of binary joints or lower pairs

(i.e. single degree of freedom p a i r s ) a n d h n u m b e r o f h i g h e r p a i r s
( i . e . t w o d e g r e e o f f r e e d o m p a i r s ) , t h e n t h e number of degrees of
freedom of a mechanism is given by
n = 3(

-1)-2j-h
This equation is called Kutzbach criterion for the movability of a
mechanismhaving plane motion.I f t h e r e a r e n o t w o d e g r e e o f f r e e d o m
p a i r s ( i . e . h i g h e r p a i r s ) , t h e n h = 0 , substituting h= 0 in equation 1, we
have
n=3(
-1)-2j
1.5
Four bar chain mechanism
The simplest and the basic kinematic chain is a four bar chain or
quadraticcycle chain, as shown in below fig. It consists of four links p, q, l and s,
each of themf o r m s a t u r n i n g p a i r . T h e f o u r l i n k s m a y
b e o f d i f f e r e n t l e n g t h s . A c c o r d i n g t o Grasshofs law for a four bar
mechanism, the sum of the shortest and longest link lengths should not be
greater than the sum of the remaining two link lengths if there isto be continuous
relative motion between the two links.

According to Grasshofs law for a four bar mechanism, the sum of the shortestand
longest link lengths should not be greater than the sum of the remaining two
link lengths if there is to be continuous relative motion between the two links.A
very important consideration in designing a mechanism is to ensure that theinput
crank makes a complete revolution relative to the other links. The mechanism
inwhich no link makes a complete revolution will not be useful. In a four bar chain,
oneof the links, in particular the shortest link, will make a complete revolution
relative tothe other three links, if it satisfies the Grasshofs law. Such a link is
known as crank or driver.1.6
Single Slider Crank Mechanism

A single slider crank chain is a modification of the basic four bar chain.
Itconsists of one sliding pair and three turning pair. It is, usually, found
in reciprocatings t e a m e n g i n e m e c h a n i s m . T h i s t y p e o f m e c h a n i s m c
o n v e r t s r o t a r y m o t i o n i n t o reciprocating motion and vice versa.In single
slider crank chain, as shown in below fig

the links 1 and 2, links 2and 3, and links 3 and 4 form three turning pairs
while the links 4 and 1 form a sliding pair.

The link 1 corresponds to the frame of the engine, which is fixed. The link
2c o r r e s p o n d s t o t h e c r a n k ; l i n k 3 c o r r e s p o n d s t o t h e c o n n
e c t i n g r o d a n d l i n k 4 corresponds to cross- head. As the crank
rotates the cross-head reciprocates in theguides and thus the piston
reciprocates in the cylinder.
2 . S t u d y o f P o w e r H a m m e r s

Until now

we have confined ourselves to study of hand tools used in smithywork. They

certainly perform very well so far as the hand- forging is concerned, buttheir use
for satisfactory production is limited to small forging only. It would not
bed i f f i c u l t t o u n d e r s t a n d t h a t t h e i n t e n s i t y o f b l o w s , h o w e v e r
g r e a t o n e m a y t r y t o achieve through hand hammering, will not be
sufficient enough to effect the proper plastic flow in a medium sized or
heavy forging. For this, a power hammer is usuallyemployed. The capacity of these
hammers is given by the total weight of their falling parts i.e., tup or ram and die.
A 200 kg hammer will be one of which the falling partsweigh 200 kg. The
heavier these parts and greater the height from which they fall.The
higher will be intensity of blow the hammer will provide. Power
hammers inc o m m o n u s e a r e o f d i f f e r e n t t y p e s e . g . s p r i n g p o w e r
h a m m e r s , p n e u m a t i c p o w e r hammers, Steam hammers and Drop or Forge
hammers and six bar slider crank power hammers. These hammers are named
partly after their construction, partly accordingto their way of operation. Apart
from these, a large number of forging presses and 6

machines are used in forging work. In the following articles

t h e s e h a m m e r s a n d machines will be discussed in detail.2.1
Types of Power Hammers
2.1.1
Helve hammer
Helve hammers are well adapted for general engineering work where the
sizeo f t h e
stock is changed frequently. They consist of a horizontal woode
n h e l v e , pivoted at one end with a hammer at the other end. An adjustable
eccentric raises thehammer which when falls strikes a blow. They are made in
sizes from 5 to 200kg.2.1.2
Trip Hammer
Trip hammers have a vertically reciprocating ram that is actuated by
toggleconnection driven by a rotating shaft at the top of the hammer. Trip
hammers are also b u i l t i n s i z e s f r o m 5 t o 2 0 0 k g . T h e s t r o k e r a n g e
o f b o t h h e l v e a n d t r i p h a m m e r s ranges from about 400 per minute for
small sizes to about 175 for large size.2.1.3
Lever-Spring Hammer
They are mechanical driven hammers with a practically constant lift and
aninsignificantly variable striking power. It only increases with
increasing operatingspeed and thus has increases number of strokes per
minute. The ram is driven fromrocking lever acting on an elastic rod.
The rocking lever consists of a leaf spring so that an elastic drive is brought
about.They are suitable for drawing out and flattening small forgings
produced
inl a r g e n u m b e r s . T h e i r d i s a d v a n t a g e i s t h e f r e q u e n t b r e a k
i n g o f s p r i n g s d u e t o vibrations when in operations.Spring hammers are
built with rams weighing from 30 to 250 kg. The number of strokes varies from
200 to 40 blows per minute.2.1.4
Pneumatic hammer

The hammer has two cylinders compressor cylinder and ram cylinder. Pistonof the
compressor cylinder compresses air, and delivers it to the ram cylinder where
itactuates the piston which is integral with ram delivering the blows to
the work. Ther e c i p r o c a t i o n o f t h e c o m p r e s s i o n p i s t o n i s o b t a i n e d
f r o m a c r a n k d r i v e w h i c h i s powered from a motor through a
reducing gear. The air distribution device betweenthe two cylinders
consists of rotary valves with ports through which air passes into the ram
cylinder, below and above the piston, alternately. This drives the ram up anddown
respectively.
2.1.5Hydraulic hammer
In this hammers instead of air oil was used. The cost hydraulic hammer
is high as compared to the pneumatic hammers. Hydraulic hammer is used in high
force applications. These are noise less.
3. PRESENT SCENARIO OF POWER HAMMER ANDMECHANISMS
3 . 1 P o w e r h a m m e r s
Unfortunately, using presently available power
hammers and formers cansubject users to a number of inherent
disadvantages. Generally, presently available p o w e r h a m m e r s a n d
formers are expensive and may cost on the order of tens
o f thousands of dollars putting them out of reach of all but the largest
metalworking operators. Presently, available power hammers and
formers tend to be bulky
ando c c u p y l a r g e f o o t p r i n t s m a k i n g t h e m u n s u i t a b l e f o r s m a l l -
s c a l e o p e r a t i o n s . I n addition, presently available power hammers and formers
can require precise, customachined die sets, which may be unusable with other
machinery, in order to provide proper operational clearance. Finally, presently
available power hammers and former sc a n b e o p e r a t e d b y l i n k a g e d r i v e s
t h a t h a v e t h e c a p a c i t y t o l i t e r a l l y d e s t r o y t h e machines if proper die
set-ups and clearances are not maintained.8

Recent research of power hammer

The present disclosure addresses a power hammer assembly providing
user swith the metal forming advantages associated with power
machinery at a reduced expense and in a smaller footprint than presently
available power hammer systems.
Ing e n e r a l , t h e p o w e r h a m m e r a s s e m b l y o f t h e p r e s e n t i n v e n t i o n p
r o v i d e s t h r e e - dimensional shaping capabilities, which have application
in the forming of custommetal products such as, for example,
customized motorcycle and automotive
parts.T h e p o w e r h a m m e r a s s e m b l y o f t h e p r e s e n t d i s c l o s u r
e can be fabricated anda s s e m b l e d i n a k i t f a s h i o n w i t h
c o m m o n l y a v a i l a b l e t o o l s t o r e d u c e c o s t s . Alternatively,
the power hammer assembly of the present disclosure can be purchasedi n a n
assembled configuration. In one aspect, a power hammer
a s s e m b l y o f t h e present disclosure provides powered forming capabilities
while remaining economical with respect to performance, vibration, and
footprint size and acquisition costs. In some embodiments, the power
hammer assembly can comprise a power assembly for providing a single stroke
speed and/or a single set stroke with respect to the striking of die assemblies
against a piece of metal. In some embodiments, the power hammer assembly of the
present invention can comprise a larger throat area and/or a larger
dieg a p t h a n p r e s e n t l y a v a i l a b l e p o w e r h a m m e r s t o f a c i l i t a t e e a s e
o f u s e . I n s o m e embodiments, the power hammer assembly of the
present invention can comprise adjustment features allowing for the use of die
sets of varying configurations such as, for example, shank size, shank length or
alternatively, die sets fabricated for use with other machinery. In some
embodiments, the power hammer assembly of the presentingention can
comprise a belt transmission assembly designed to slip in the event
of d i e i n t e r f e r e n c e d u r i n g s e t -
u p o r o p e r a t i o n s o a s t o a v o i d d a m a g i n g t h e p o w e r hammer
assembly. In some embodiments the power hammer assembly of the
presentinvention includes fine adjustment means for spacin g between the
upper and lower die.
3.2 Mechanism
Four bar parallel linkage mechanism for toe movement
 In recent research the four bar linkage mechanism is used for the
humanoidrobots for the free movement of their toe. Using this mechanism the
major part of theforce acts on the non-movable portion of this link rather then on
the toe tip. Becauseo f t h i s i t i s p o s s i b l e t o d e c r e a s e t h e c o n s t r a i n t o n
t h e j o i n t . A t t h e s a m e t i m e t h e following multiple roles of the toe are
expected. One it to generate a large kickingforce at the toe pad and
another is to maintain multiple contact with the floor by the toe joint
control.
4. BAR SIX SLIDER CRANK POWER
H A M M E R MECHANISM

It was manufactured by two different materials one of Mild steel and

other was liner made up of Gun metal. The outer one is made up of Mild
steel on whichfacing and turning operations were done on a lathe and
then the inner one was madeup of Gun metal on w hich facing and
turning were carried out of the required size then the liner was inserted in
the outer bush by the application of a press fit.
4.3.5Column
The Column is made up of Mild Steel of required dimensi
o n . F i r s t t h e marking for the holes to fix the links were done on the column.
The outer profile wasmarked and then made to cut on a gas cutter, and then
it was milled to the requiredsize and then finally chamfering was done
to remove unnecessary sharp corners and edges. Drills were drilled on the
column for bearings, turning pairs F and A. Then thecomposite bush was
welded on the column. Vice was fitted on the column by the application of
welded joints for holding the work piece.
4.4Determination of Degrees of Freedom
The formula for finding the degree of freedom from the Kutzbach equation isgiven
below
n = 3(

-1)-2j-h
Where,n = Degree of freedom

=
no of linksj = no of lower pairsh = no of higher pairs
Links:
a ) F i x e d l i n k b ) C r a n k (
l i n k 1 ) c ) C r a n k ( l i n k 5 ) d
) L i n k 3 13

e ) C o n n e c t i n g R o d f ) R a m
D i e Therefore, number of links = 6
Lower pairs:
a ) T u r n i n g p a i r F b ) T u r n i n
g p a i r E c ) T u r n i n g p a i r D d
) T u r n i n g p a i r A e ) T u r n i n g
p a i r B f ) S l i d i n g p a i r C g )
S l i d i n g p a i r G Therefore, number of lower pairs =
7 Number of higher pairs = 0Therefore,
n = 3(

-1)-2j-h
h = on = 3(
-1) -2jn = 3(6-1) -2 x 7n = 3 x 5 2 x 7n = 15 14n = 1Therefore, the mechanism
has single degree of freedom.
4.5
Applications
4.5.1Forging
Forging refers as the process of plastically deforming metals or alloys to aspecific
shape by a compressive force exerted by some external agency like hammer,Press,
rolls, or by an upsetting machine of some kind. The portion of a work in
whichforging is done is termed the forge and the work is mainly
performed by means of 14

heavy hammers, forging machines, and presses. Forging processes are

among themost important manufacturing techniques since forging is used in small
tools, railroadequipment, automobile, and aviation industries.A number of
operations are used to change the shape of the raw material to thefinished form.
The typical forging operations are:
1.
Upsetting.
2.
Fullering.
3.
Drawing down.
4.
Setting down.
5.
Punching.
6.
Bending.
7.
Welding.
8.
Cutting.A l l t h e s e o p e r a t i o n s a r e c a r r i e d o u t w i t h t h e m e t a l i n a
heated condition,which must be maintained by taking a fresh
h e a t w h e n t h e w o r k s h o w s s i g n o f getting cold.
Forging Processes
The processes of reducing a metal billet between flat -dies or in a
closed-i m p r e s s i o n d i e t o o b t a i n a p a r t o f p r e d e t e r m i n e d s i z e a n d
shape are called s mithforging and impression -
d i e f o r g i n g r e s p e c t i v e l y . D e p e n d i n g o n t h e e q u i p m e n t s utilized they
are further sub-divided as hand forging, hammer forging, press forging,drop
forging, mechanical press forging, upset or machine forging.In general, the
methods of forging may be classified as follows

4.5.2Press

Press working involves production of final component from sheet metal incold
condition. The machine which is used to apply the required pressure of force in
ashort duration is called press. The press consists of a frame, supporting bed and
ram.The ram is equipped with special punches and moves towards and
into the die block which is attached to a rigid body. The punch and die
block assemble are generallyreferred to as a die set or simply die.A
disadvantage of press working is that the operations are carried out
atroom temperature and the metal is less deformable of strain hardening.
Classification of Presses
Presses are classified in various ways as listed
below.(i) Mechanical press.(ii) Hydraulic press.
FORGINGPROCESS
SMITHIMPRESSIONDIE
H a n d P o w e r D r
o p P r e s s M
a c h i n e Hammer Press
16
Press Tool Operations
A large number of operations can be performed by using press tools, and all press
tool operations can be broadly classified into two types. 1.
Cutting operations.(i)
Blanking,
(ii)
Piercing
(iii)
Lancing,
(iv)
Cutting off and Parting,
(v)
Notching,
(vi)
Shaving, and
(vii)
Trimming.2.
Shaping operations

(i
) Forming (embossing, Beading and Cutting, Bulging etc.),
(ii)
Drawing, and
(iii)
Bending.II.
DESIGN CALCULATIONS
1.Determination of length of the links
For evaluating the length of the links we made prototype, Length of the linksis
proportionally taken according to the diagram of the Six bar Slider
crank Power hammer mechanism. By checking the movability after more
and more trails of link lengths we finalized the dimensions as shown below
1.
c r a n k ( l i n k 1 )
= 1 2 0 m m
2.
R a m d i e l i n k 2 =
4 2 0 m m
3.
l i n k 3 =
4 4 0 m m
4.
c o n n e c t i n g r o d ( l i n k 4 ) = 6 5 5 m m 17

5.
c r a n k ( l i n k 5 )
= 1 2 0 m m
2.
Design calculation for finding the width and thickness of thelinks
This mechanism is designed for applying a compressive force of 0.6 tonnes
for forging or press operation.
Minimum cross sectional area required to transmit is 0.6 tonnes load (A):
80m
m(A)areaEfective60/75][ p requiredarem
inm
um
7530/4][streshpaermisble4 safetyof factoadropting/300)(sresyildesignlikfor M.Staking][ p strehpaermisbleoad
222y2
========

N/mmmm N mm
The formula for the minimum effective area is obtained as
bt (dt)
it can beobserved in the link as in the fig2.1

Fig 2.1
In fig 2.1 hatched portions indicates minimum effective cross sectional
area in theentire mechanism. We know that stress is inversely
proportional to the area, so theminimum area leads to increase the
stress. So it is always preferred to design anymachine by taking minimum
cross sectional area as effective area.
80m
(A)areaEfectivmminhopleinof d
iam
detr mminlinktheof thicknes mminlinktheof breadthb w
her,mm t)(d- bt(A)areaEfectiv
22
=====
For safe design
2
mm80t)(d- bt

19

From the design of bolt we obtained diameter of pin as 6mm, by keeping the
diameter of pin constant and by trail and error method we obtained the breadth and
thickness of the link as 20mm and 6mm respectively.
3 . D e s i g n c a l c u l a t i o n f o r b o l t d i a m e t e r 3.1
Calculation of Stress Concentration
Stress concentration factor is given by,Kt =
stresNominalstresM
axim
um
Nominal stress is given by,
a)h-(w p
nom
=

The below diagram is for the finite width plate with a transverse hole

We know that width of the plate W = 20mmThickness of the plate h =

6mm Nominal stress is given by,
a)h-(w p
nom
=

Where,20

P = tensile force= 0.6 tonne= 0.6

1000

9.81= 5886NTherefore,
a)6-(20586
nom
=

Kt =
nom

max

tmaxnom
k

=

a)620(56
8

=
3.2150

a)6120(586

= 65.225886 = 65.22(120-6a)5886 = 7826.5 391.32a5886 7826.5 = - 391.32a-

1940.5 = - 391.32aTherefore a =
32.3915.14 0
9
a = d (diameter) = 4.99mmDue to dynamic characteristics of links the diameter
of pin is selected as 6 mm.
3.2Calculation for bearing stress.
For M.S material

=
300 N/
2
mm
Factor of safety = 2
Permissible bearing of crushing stress =
n )(
y b

=
21

= 300/2 = 150N/
2
mm
Bearing stress
nd p )(
b
+

P = 0.6 + 1000

9.81Nd = 6mmt = 6mmn = 2

)(
b

2669
10.6
.8

81.75 N/
2
mm
The bearing stress is greater than 81.75 N/
2
mm
, so the design is satisfactory.
4 D e s i g n f o r p u n c h i n g o p e r a t i o n
Permissible shear stress is given by,
yy
6.0

=
= 0.6

300= 180 N/
2
mm

areashearload
y

areashear6000
y

Shear area for punching operation can be observed from above diagram is
dt

Where,
d
= diameter of blanking or piercing hole in mm.
t
= the thickness of the blank in mm.22

Shear area =
dt

=
18060
dt

= 33.3
2
mm
Therefore t =
73.33

t = 1.5mm
.IIIOPERATION SHEETS
1 . C R A N K ( L I N K 1 )
23

D e s c r i p t i o n : C r a n k
1 P a r t N
o : 1 M a t e r i
a l : M i l d S t e e l . R e
q u i r e d s i z e : 1 2 0 m m x 2 0 m m x
6 m m