Machining Process and Metrology

CARDAN GEAR MECHANISM

School of Mechanical and Building Sciences

Certificate

This is to certify that cardan gear mechanism was a genuine

Signature of the Examiner

Signature of the supervisor

Abstract
The goal of the project is to manufacture a cardan gear. Cardan gear promise large stroke
length . They however are not commercially used. The work initially aimed in manufacturing
gears of required dimensions but later due to logistical constraints the gears were procured
from outside.
Parts like handle, making of carriage, fixing of bearings were done using boring , turning and
gas cutting operation. The work helped us to improve our concepts of gear and helped us to
improve our machining skills.

ACKNOWLEDGEMENT

We would like to express deep gratitude towards my guide Prof.

Also special thanks and due regards extends to, Prof. C.P
Karthikeyan for his indispensable help and inspiration. In
appreciation, we offer them our sincere gratitude.
Suggestions for Improvement are invited and shall be gratefully
acknowledged. We would also like to thank the Department of
Mechanical Engineering, VIT University Chennai Campus.

Table of Contents
Page No
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ii

Abstract
Table of contents

1. Introduction
2. Parts
3. Working
4. Pictures
5. Applications
6. Acknowledgement
7. References

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2
3
4
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INTRODUCTION
The cardan-gear mechanisms invented by Girolamo Cardano in the 16th century is
used to convert rotation motion to reciprocating linear motion without using linkages
or slideways. In order to achieve this, the gear ratio of the large gear to the small
should be 2/1.
However it does give a rather long stroke at 4x the centre distance of the 2:1 gears.
For, say a 1-1/2" stroke that distance would have to be 3/8" resulting in some very
tiny gears indeed.
The intermediate gear is presumably an idler and could usefully have a prime number
tooth count in order to even out wear. Converts rotary motion into straightline motion . It eliminates need of drives or sideways .
It is simple in concept and easy to manufacture .

The length of the arm is equal to the distance between the center of the large gear and
the outer small gear. If this distance is equal to D, than the tip of the arm travels 4D
for each revolution of the triangle block.

PARTS

Input shaft

Fixed gear

Carriage

First gear (middle / idler gear)

Second gear

Lever

WORKING
Input shaft rotates a carriage around the fixed gear . On the carriage an idler
gear rolls on the periphery of the fixed gear. This idler gear rotates a second
gear (on the carriage) .

The end of a lever located on the second gear describes the straight line.
Girolamo Cardano, an Italian mathematician (1501-1576), is known for
Cardans formulas for solving cubic equations.
Let the large circle be C with center O and radius R, and let the rolling circle
by c with radius r _ 1 2 R and center S.

PICTURES

Manufacturing Information
Flame cutting

Gas, a suitable burner and a steady hand are all that is needed for cutting mild steel. Flame
cutting is a combustion process. It is not the heating flame itself that does the actual cutting
but an oxygen jet, which burns the material during heat formation and transports the
combustion products (slag) away from the cut. When cutting, the purity of the oxygen is of
huge importance to the cutting speed. The purer the gas, the higher the cutting speed and the
better the productivity and cut quality. he construction of the cutting nozzle and its
adjustment to various fuel gases with regard to the size of the gas channels, exact geometry,
tolerances and surface finish are of crucial importance to achieving a high quality cut. The
cutting speed can be increased by using a curtain nozzle, for example. This type of nozzle has
a special oxygen channel which protects the cutting oxygen jet from impurities, making
higher cutting speeds possible.
Oxyfuel cutting can be used for cutting mild and low-alloyed steel, up to thicknesses of just
over 1,000 mm. The cut quality also depends on the surface of the work piece, and can be
affected by different types of shop primer. Use of several burners for straight cutting, phase
cutting and joint preparation is an example of the cutting processs versatility
The metal plate was cut using gas cutting

Welding
Arc welding is a type of welding that uses a welding power supply to create an electric arc
between an electrode and the base material to melt the metals at the welding point. They can
use either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes. The welding region is usually protected by some type of shielding gas, vapor, or
slag. Arc welding processes may be manual, semi-automatic, or fully automated.
The gear base was attached using arc welding.

Drilling
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular crosssection in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is
pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions
per minute. This forces the cutting edge against the workpiece, cutting off chips from what
will become the hole being drilled.

Drilled holes are characterized by their sharp edge on the entrance side and the presence of
burrs on the exit side (unless they have been removed). Also, the inside of the hole usually
has helical feed marks.
Holes for bearing 25mm and 20 mm were done using drilling operation.
Boring
In machining, boring is the process of enlarging a hole that has already been drilled (or cast),
by means of a single-point cutting tool (or of a boring head containing several such tools), for
example as in boring a gun barrel or an engine cylinder. Boring is used to achieve greater
accuracy of the diameter of a hole, and can be used to cut a tapered hole. Boring can be
viewed as the internal-diameter counterpart to turning, which cuts external diameters.
There are various types of boring. The boring bar may be supported on both ends (which only
works if the existing hole is a through hole), or it may be supported at one end (which works
for both through holes and blind holes). Lineboring (line boring, line-boring) implies the
former. Backboring (back boring, back-boring) is the process of reaching through an existing
hole and then boring on the "back" side of the workpiece (relative to the machine headstock).
Because of the limitations on tooling design imposed by the fact that the workpiece mostly
surrounds the tool, boring is inherently somewhat more challenging than turning, in terms of
decreased toolholding rigidity, increased clearance angle requirements (limiting the amount
of support that can be given to the cutting edge), and difficulty of inspection of the resulting
surface .

The base for bearings was made using boring operations.

Cost and Dimensions

Size(mm)

Cost (Rs)

Big Gear

150 dia.

400

Small Gear-2

40 dia.

150*2=300

Handle

180 length

50

Carriage
Nuts

100
25 dia.

20

Nuts-4

20 dia.

20*4=80

Applications
1. Used to convert rotation motion to reciprocating linear motion without using linkages
or slideways.
2. The cardan gear machines can be more efficient than the slider-crank machines.
3. The smooth running, low mass inertia, high pressures and small frictional
power losses make the cardan gear machines clearly better than the slider-crank
machines.
4. The friction losses of the cardan gear machines are generally quite small.
5. The mechanical efficiencies are much higher in the cardan gear machines than in the
slider-crank machines in normal use.
6. Crankshaft torques and power needs are smaller in the cardan gear air pumps than in
the equal slider-crank air pumps.
7. Suitable applications of the cardan gear machines are three-cylinder half-radial
engines for motorcycles, six-cylinder radial engines for airplanes and six-cylinder
double half-radial engines for sport cars.

Conclusion
The project for manufacturing of cardan gear was achieved successfully. Stroke
of 4D was achieved and measured. The gear motion was observed exceptionally
smooth .
The work must be continued to find out the reason for failure of cardan gear.
Alternate applications of cardan gear also needs to be found out.

References
1. http://www.scribd.com
2. http://www.mekanizmalar.com/cardan_gear.html
3. http://www.mathworks.in/help/physmod/sm/examples_v2/using-thecommon-gear-block-cardan-gear-mechanism.html