STUDY AND ANALYSIS OF GEARLESS POWER

TRANSMISSION

A MINORPROJECT REPORT SUBMITTED IN THE PARTIAL FULFILLMENT OF

REQUIREMENT FOR THE AWARDOF DEGREE OF

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

SUBMITTED TO
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA
BHOPAL (M.P.)

SUBMITTED BY
ANAS PARVEZ KHAN (0103ME171028)
GAURAV KUMAR (0103ME171061)
GEETANSHU BHAGAT (0103ME171062)
ANURAG CHANDROL (0103ME171036)

UNDER THE GUIDANCE OF

Dr. Neeraj Dubey
(Professor)

DEPARTMENT OF MECHANICAL ENGINEERING

LAKSHMI NARAIN COLLEGE OF TECHNOLOGY
BHOPAL (M.P.)
 LAKSHMI NARAIN COLLEGE OF TECHNOLOGY BHOPAL
(M.P.)

CANDIDATE’S DECLARATION

I hereby declare that this Minor Project Reportentitled “STUDY AND

ANALYSIS OF GEARLESS POWER TRANSMISSION” is my own work
conducted under the supervision of Dr. Neeraj Dubey (Professor) ofMechanical
Engineering Department, Lakshmi Narain College of Technology, Bhopal, MP.

I further declare that to the best of my knowledge and belief that this report does
not contain any part of work that has been submitted for the award of any degree
either in this university or in any other university/Deemed university without
proper citation.

ANAS PARVEZ KHAN (0103ME171028)

GAURAV KUMAR (0103ME171061)
ANURAG CHANDROL (0103ME171036)
GEETANSHU BHAGAT (0103ME171062)

1
 LAKSHMI NARAIN COLLEGE OF TECHNOLOGY BHOPAL
(M.P.)

CERTIFICATE

This is to certify that the Minor Project Report entitled “STUDY AND
ANALYSIS OF GEARLESS POWER TRANSMISSION” is the bonafide
project work carried out independently by ANAS PARVEZ KHAN,GAURAV
KUMAR, ANURAG CHANDROL & GEETANSHU BHAGAT students of
Bachelor of Engineering in Mechanical Engineering from Rajiv Gandhi
Proudyogiki Vishwavidyalaya, Bhopal for the partial fulfillment of the requirement
for the award of the degree of Bachelor of Engineering and this report has not for,
med previously the basis for the award of any degree, diplomaor any other similar
title according to our knowledge.

Guided By: Approved By:

Dr. Neeraj Dubey Dr. Shailendra Dwivedi

(Professor) (Head of the Department)
Mechanical Engineering Department Mechanical Engineering Department
LNCT, Bhopal (MP) LNCT, Bhopal (MP)

Forwarded By:

Dr. Kailash Shrivastava

(Principal)
LNCT, Bhopal (MP)

2
 LAKSHMI NARAIN COLLEGE OF TECHNOLOGY BHOPAL
(M.P.)

APPROVAL CERTIFICATE

This MinorProject work entitled “STUDY AND ANALYSIS OF GEARLESS

POWER TRANSMISSION” being submitted by ANAS PARVEZ KHAN
(0103ME171028), GAURAV KUMAR (0103ME171061), ANURAG
CHANDROL (0103ME171036)& GEETANSHU BHAGAT
(0103ME171062)has been examined by us and is hereby approved for the award
of degree of Bachelor of Engineering in Mechanical Engineering which has been
submitted to Rajiv Gandhi Proudyogiki Vishwavidyalaya, Bhopal (M.P.).

Internal Examiner External Examiner

Date: Date:
 LAKSHMI NARAIN COLLEGE OF TECHNOLOGY BHOPAL
(M.P.)

ACKNOWLEDGEMENT

Completing a task is never a one-man effort. It is often the result of valuable contribution of a
number of individuals, in direct or indirect manner that help in shaping and achieving an
objective. This acknowledgement is nothing but a small token of gratitude in recognition of their
help in this endeavor.

It is my great pleasure to record profound gratitude to my supervisor, Dr. Neeraj Dubey

(Professor), Department of Mechanical Engineering, LNCT, Bhopal for his constant inspiration
and invaluable guidance throughout the course of investigation.

I am extremely thankful to Dr. A. N. Sinha, Director (Academics), Dr. Kailash Shrivastava,

Principal,Dr. Ashok Kumar Rai, Dean of Administration & OSD,Dr. Shailendra Dwivedi,
Professor & Head (Mechanical Engineering), and all the faculty members of Department of
Mechanical Engineering, LNCT Bhopal for providing all the facilities, help and encouragement
for carrying out the project work successfully.

Finally, I owe entire of my academic achievements to my parents who have tremendously

encouraged me throughout my academic career as well as whole life.

Before all and after all the man thanks should be to the Almighty God.

ANAS PARVEZ KHAN (0103ME171028)

GAURAV KUMAR (0103ME171061)
ANURAG CHANDROL (0103ME171036)
GEETANSHU BHAGAT (0103ME171062)

4
 CONTENTS

CANDIDATE’S DECLARATION I
CERTIFICATE II
APPROVAL CERTIFICATE III
ACKNOWLEDGEMENT IV
CONTENTS V
ABSTRACT VII

CHAPTER 1.INTRODUCTION
1.1 PROBLEM DEFINITION

1.2 PROJECT OVERVIEW/SPECIFICATION

1.3 WORKING PRINCIPLE.

1.4 NEED OF GEARLESS POWER TRANSMISSION

CHAPTER 2. LITERATURE REVIEW AND OBJECTIVES

2.1 R. SOMRAJ et al.
2.2 NEERAJ PATIL et al.
2.3 AASHISH KUMAR et al.
2.4 SOLANKI NEHAL et al.
2.5 SHIV PRAKASH YADAV et al.
2.6 BRIEFING OF GEARLESS POWER TRANSMISSIONM
2.7 SYSTEM STUDY.

5
 CONTENTS
CHAPTER 3. MATERIALS/ APPARATUS/ PROBLEM
FORMULATION/DESIGN/METHODOLOGY

3.1 SELECTION OF MATERIAL

3.2 RAW MATERIALS AND STANDARD MATERIALS
3.3 DEGIN CALCULATION FOR SHAFT AND BENT LINKS
3.4 DESIGN OF C-SECTION MATERIAL
3.5 DESIGNING OF ELBOW ROD
3.6 DESIGNING OF HUB
3.7 METHODOLOGY

CHAPTER 4. FINDINGS
4.1 CARRANGMENT OF PINS IN SHAFT
4.2 ANALYSIS OF MECHANISM
4.3 COMPARISON OF GEARED DRIVE WITH GEARLESS DRIVE
4.4 MANUFACTURING METHODS.
4.5 WWORKING PRINCIPLE
4.6 CAUSES OF FAILURE
4.7 LIFE AND EFFICIENCY

CHAPTER 5. RESULT AND DISCISSION

5.1 RESULTS.
5.2 ITS APPLICATIONS
5.3 ITS ADVANTAGES
5.4 ITS LIMITATIONS
5.5 METHOD OF IMPROVING ITS EFFICIENCY
5.6 POSSIBLE ADVANCEMENTS
CHAPTER 6. CONCLUSIONS

BIBLIOGRAPHY
 ABSTRACT

Gearless transmission mechanism transmits power from input to output shafts by means of
sliding links that form revolute pair with the hub. Links bent at required angle slide inside the
holes in the hub. Thus, as the holes in input hub rotate; it pushes the links and in turn output hub
is rotated. This mechanism can be used as a replacement for bevel gears in low cost, low torque
applications. It can transmit at any angle 0 to 1800. In this paper the mechanism is studied and a
possible go-kart transmission layout is fabricated and few future applications are suggested.

This review paper gives information about the Strength, Speed, Torque Transmissibility of
Elbow mechanism as this are very much important terms in defining applications of the
mechanism in replacement of gears. It mainly focused on the theoretical, analytical and FEA
method. Computation of various parameters like Number of pins, Material used, Dimensional
difference of elements, Speed, Torque. Many previous approaches were made to find out the
optimum design in order to make this mechanism better then old mechanism by using different
analysis software. It consists Theoretical & Analytical method for the design of elbow
mechanism

Power transmission for skew shafts is with the help of either crossed helical gear or worm gear
or hypoid gears in a machine, but the manufacturing of these gear is very complex, power loss in
gears due to sliding motion and the shaft orientations is very limited, so need arises for a better
system. In Gearless power transmission for skew shafts which reduce the losses, cost & save the
time and space. This system allows the changing in the orientation of shafts during motion which
is very interesting and fascinating about this mechanism. In this transmission system no. of pins
or links used must be odd 3,5,7,9... Pins or links are fixed in the drilled holes at the both shaft
ends due to which motion is transferred. The Working of this arrangement is very smooth &
work effectively with a very minimum amount of power losses.
Chapter-3

INTRODUCTION

1.1PROBLEM DEFINITION

Today’s world requires speed on each and every field. Hence rapidness and quick working is the
most important. Now a days for achieving rapidness, various machines and equipment’s are
manufactured by man. Engineer is constantly conformed to the challenges of bringing ideas and
design in to reality. New machine and techniques are being developed continuously to
manufacture various products at cheaper rates and high quality. The project “GEARLESS
TRANSMISSION” being compact and portable equipment, which is skillful and is having
something practice in the transmitting power at right angle without any gears being
manufactured. This project gives us knowledge, experience, skill and new ideas of the
manufacturing. It is a working project and having guarantee of the success. El-bow mechanism is
an ingenious link mechanism of slider and kinematic chain principle. This is also called as
“gearless transmission mechanism” this mechanism is very useful for transmitting motion at
right angles. However, in certain industrial application “gearless transmission at right angle” can
also work at obtuse or accurate angle plane can be compared to worm and worm gear or bevel
and pinion gear which are invariably used in the industry for numerous applications. The main
feature for mechanism comparatively high efficiency between the input and the output power
shafts with regards to the gear efficiencies.

The El-bow Mechanism transmits the I/P power towards the O/P side such away that the angular
Forces produced in the slacks are simply transmitted with the help of pins which takes up the I/P
power and the right angle drive is transferred towards the O/P slack and pin assembly. Hence
very little friction plays while the power is being transmitted; the Hunting and back lash are
absent.
Chapter-3

The Gearless transmission or El-bow mechanism is a device for transmitting Motions at any
fixed angle between the driving and driven shaft. The synthesis of this mechanism would reveal
that it comprises of a number of pins would be between 3 to 8 the more the pins the smoother the
operation. These pins slide inside hollow cylinders thus formatting a sliding pair. Our
mechanism has 3 such sliding pairs. These cylinders are placed in a Hollow pipe and are fastened
at 120* to each other. This whole assembly is mounted on brackets wooden table. Power is
supplied by an electric motor. These roads are located at in the holes equally spaced around a
circle and they are free to slide in & out as the shaft revolves. This type of drive is especially
suitable where quite operation at high speed is essential but only recommended for high duty.
The operation of this transmission will be apparent by the action of one rod. During a revolution.
If we assume that driving shaft “A” is revolving as indicated by arrow the driven shaft B will
rotate counter clockwise. As shaft A turns through half revolution C shown in the inner and most
effective driving position slides out of both shafts A & BThe first half revolution and rod “C”
then will be at the top then during The remaining half this rod “C” slide in wards until it again
reaches to inner most position shown in Fig. in the meanwhile the other roads have of course
passed through the same cycle of movements all rods are successively sliding inwards and
outwards.

1.2 PROJECT OVERVIEW/ SPECIFICATION

Today’s world requires speed on each and every field. Hence rapidness and quick working is the
most important. Now days for achieving rapidness, various machines and equipment’s are
manufactured. Gears are costly to manufacture. Its need to increase the efficiency of
transmission which cannot be done using geared transmission. Gearless transmission mechanism
is capable of transmitting power at any angle without any gears being manufactured. So here I
introduced a gearless power transmission system for skew shafts which reduce the losses, cost &
save the time and space. This system allows the changing in the orientation of shafts during
motion which is very interesting and fascinating about this mechanism. Also during analysis of
mechanism and working it is seen that this gearless transmission can be used for both
intersecting shafts and skew shafts but here we introduced a solution for skew shafts so main
attention is towards the skew shafts.A gearless transmission is provided for transmitting
Chapter-3

rotational velocity from an input connected to three bent links. Both the input shaft and the
housing have rotational axes. The rotational axis of the input shaft is disposed at an angle of 90
degree with respect to the rotational axis of the housing.
1.3WORKING PRINCIPLE-

FIGURE 1 – WORKING PRINCIPLE

The Gearless transmission or El-bow mechanism is a device for transmitting Motions at any
fixed angle between the driving and driven shaft. The synthesis of this mechanism would reveal
that it comprises of a number of pins would be between 3 to 8 the more the pins the smoother the
operation. These pins slide inside hollow cylinders thus formatting a sliding pair. Our
mechanism has 3 such sliding pairs. These cylinders are placed in a Hollow pipe and are fastened
at 120* to each other. This whole assembly is mounted on brackets wooden table. Power is
supplied by an electric motor. The working of the mechanism is understood by the diagram. An
unused form of transmission of power on shaft located at an angle. Motion is transmitted from
driving to the driven shaft through the roads which are bent to conform to the angles between the
shafts. These roads are located at in the holes equally spaced around a circle and they are free to
slide in & out as the shaft revolves. This type of drive is especially suitable where quite operation
at high speed is essential but only recommended for high duty. The operation of this transmission
will be apparent by the action of one rod. During a revolution. If we assume that driving shaft
“A” is revolving as indicated by arrow the driven shaft B will rotate counter clockwise. As shaft
A turns through half revolution C shown in the inner and most effective driving position slides
out of both shafts A & BThe first half revolution and rod “C” then will be at the top then during
Friction energy transmission mechanism consist a power transmitting wheel, a longitudinally
movable shaft impartial of and coaxial with stated wheel, inflexible pins projecting from the
facet of stated wheel, rigid arms extending radially from stated shaft close to stated wheel with
Chapter-3

their outer ends aperture and split, one end of the aperture port. The remaining half this rod “C”
slide in wards until it again reaches to inner most position.

1.4. NEED OF GEARLESS POWER TRANSMISSION

Today’s world requires speed on every and every area. as a result, rapidness and brief working is
the most essential. Now days for accomplishing rapidness, various machines and system are
synthetic by guy. Engineer is continuously conformed to the demanding situations of bringing
ideas and design in to fact. New system and strategies are being evolved continuously to
manufacture numerous merchandises at inexpensive charges and excessive high-quality. The
task “GEARLESS TRANSMISSION” being compact and portable system, which is skillful and
is having something practice in the transmitting power at right angle without any gears being
manufactured. Most of the material is made available by our college. The parts can be easily
made in our college-shop its price is also less. this project gives us knowledge, experience, skill
and new ideas of the manufacturing. It is a working project and having guarantee of the success.
This project is the equipment useful to improve the quality of the gear being manufactured and
may be made in much less time, consequently we have selected this undertaking el-bow
mechanism is an inventive link mechanism of slider and kinematic chain principle. That is also
called as “gearless transmission mechanism” this mechanism is very beneficial for transmitting
movement at right angles. But in sure commercial software “gearless transmission at proper
attitude” can also work at obtuse or correct angle plane can be in comparison to bug and Trojan
horse gear or bevel and pinion equipment which are perpetually used inside the enterprise for
several application. for the reason that factor referring to beneath frictional Forces among the
mating tools teeth, the erratic hunting of the gears, the back lash among the tooth cannot be
conquer and for this reason the performance can't be extra than 55% of recent gears of warm
bevel type are being manufactured in poly propelinear epoxy material where the Frictional
Forces are relatively eliminated. even though such gears are used for quite small programs the
efficiency isn't extra than forty two% .
Chapter-3

LITERATURE REVIEW

2.1 R. Somraj et al.

Analyzed the Design and Fabrication of Gearless Transmission For Skew Shafts. 3 Nos. of L-
pin rods were used. Overall mechanism is considered to be running on 0.25 HP motor with 140
RPM and Torque of 1238 N-mm. Design of Hub is done by Considering a hub of internal
diameter is 32mm and outer diameter is 92mm, length is 82mm. Design of shaft was done by
taking maximum tensile stress of 60 N/mm2 and maximum shear stress of 40 N/mm2 . Diameter
of elbow rods was 8mm. It Was Concluded that given arrangement can be used for any set of
diameters with any profile of shafts for skew shafts of any angle but the shaft’s must be having
the rotational motion about his own axis, transmission of motion is very smooth and desirable
and used only for the equal R.P.M. of driving shaft and driven shaft by employing links or given
type of links for appropriate joints for revolute pair. It was also found that successful mechanical
devices function smoothly however poor fly they are made while other does this only by virtue
of an accurate construction & fitting of their moving parts.

2.2 Neeraj Patil et al.

Researched on Gearless Transmission Mechanism and its Applications. link of C-45 was used.
Links bent at required angle slide inside the holes in the hub Mechanism can transmit at any
angle 0 to 180.The mechanism is studied and a possible go-kart transmission layout is fabricated
and few future applications are suggested. Into This weight of model along with rider Assumed
1500 N. Kart was loaded with 4 Nos. of tires each with 375 N of load. Coefficient of friction
between road and tire was Considered 0.7. Tire of radius 0.1778m Taken. Torque required to
move Was 46.67 N-m with Torque on each link 15.55 N-m Tangential force of 311.15N was
acting on links. Diameter of each link was 10mm. After study of the mechanism it was
concluded that this mechanism is mainly applicable to low cost applications where torque is low
to medium. With future development in low friction materials (graphene coating) and stronger
composite materials, the efficiency and capacity of this mechanism can be increased. Also if
instead of bent links, bolted links or links held by universal joints are used then transmission is
possible even when angle changes on the go.

2.3 Ashish Kumar et al.

performed study on Multi Angular Gearless Drive. The mechanism was loaded with 3 Nos. of
L-pins. Parts of mechanism were modeled on Solid Works and The analysis of the mechanism
was carried out on ANSYS. The study of mechanism was carried with 0.63 Moment of Inertia
(Provided by Solid Works). Behavior of system is plotted on different charts i.e. Velocity vs.
Time, Acceleration vs. Time, Angular Acceleration vs. Time, Separation Distance vs. Time.
From This it was concluded that The final design thus obtained is capable of transmitting torque
Chapter-3

and power at varied angles depending on the angular limitation of the hooks joint. With further
research and advanced analysis in the design wide-ranging applications of the drive can be
discovered.

2.4 Solanki Nehal et al.

studied Design And Analysis Of Gearless Transmission Through Elbow Mechanism which can
be used into the replacement of the bevel gears. 4 Nos. of L-pins was used into this fabricated
model. With input of 1HP motor. Links of 10mm diameter were used of S.S , M.S material.
Shafts are rotating with speed of 1440 RPM and 4947.066 N.mm of Torque. Stimulation is done
by the ANSYS 16.2 and analysis of mechanism was done at 50,100,150,200 RPM for both the
material. It is been concluded from that analysis that the mechanism with 6 elbow rods made up
of mild steel material is works perfectly. The mechanism runs smoothly when it is kept at 150
RPM Also it can be concluded that as the no of elbow rods increases smoother the operation
would be.

2.5 Shiv Pratap Yadav et al.

performed Real time Study for Design, Analysis and Fabrication of Gearless Power
Transmission by using Elbow Mechanism. They used 3 Nos. Of elbow rods inclined to the
90⁰.Modeling and rendering of mechanism is done into the CATIA V5 and the analysis was
carried on ANSYS. The mechanism was working between 80 to 100 RPM. after this it was
concluded that It has a high scope in future to replace the cumbersome usage of gears which will
be replaced simple, elegant usage of the shafts that will change the overall cost management of
the industries using gear technology presently to gain more profits.

2.6 BRIEFING OF GEARLESS POWER TRANSMISSION

The Gearless transmission or El-bow mechanism is a device for transmitting motions at any
fixed angle between the driving and driven shaft. The synthesis of this mechanism would reveal
that it comprises of number of rods would between 3 and more the rods the smoother the
operation.
Our mechanism has 3 such sliding pairs. The rod is placed in a hub at 120o angle to each other.
The whole assembly is mounted on channel. Power is supplied by an electric motor. A used form
of transmission of power on shaft located at an angle. The working of the mechanism is
understood This project is the equipment useful to improve the quality of gear being
manufactured and can be made in very less time. this project uses El-bow mechanism which is
an ingenious link mechanism of kinematic chain principle and slide. This is also called as
“Gearless transmission mechanism” and very useful for transmitting motion at right angles.
Transmits power at any angle without utilizing gears. Skew Shaft The term “shaft” , used in this
standards has a wide meaning and serves for specifications of all outer elements of the part ,
including those elements , which do not have cylindrical shapes And “skew” means non-parallel
and non-intersecting so the shafts which are nonparallel and non-intersecting are known as skew
shafts. Crossed helical gears - Helical or "dry fixed" gears offer a refinement over spur gears.
The leading edges of the teeth are not parallel to the axis of rotation, but are set at an angle. Since
the gear is curved, this angling causes the tooth shape to be a segment of a helix.
Chapter-3

Helical gears can be meshed in parallel or crossed orientations. The former refers to when the
shafts are parallel to each other; this is the most common orientation. In the latter, the shafts are
nonparallel, and in this configuration the gears are sometimes known as "skew gears".

FIGURE 2-GENERAL LAYOUT OF AN ELBOW MECHANISM

FIGURE 3- ACTUAL WORKING MODEL.

FIGURE 4- MULTIPLE GEARLESS MECHANISM

Chapter-3

2.7 SYSTEM STUDY

We have fabricated 3 pin gearless power transmission. gearless power transmission mechanism
is portable and compact equipment. mechanism consist of 2 hubs 3elbow rod 2 shafts motor
(A,c) motor ,belt drive .the motor & belt drive is coupled to the end of any one shaft.

As the power is transmission ton the shaft from the motor through belt drive the shaft rotates
along with hub the elbow rods placed in the holes of the hubs slides in and out of the both the
hubs due to the power from one shaft is transmitted to the another. in our project is comparing by
the bevel gear mechanism, comparing both mechanism

FIGURE 5- FLOW DIAGRAM OF SYSTEM STUDY

Although this transmission is an old one many mechanics are skeptical about its operation,
however it is not only practicable but has proved satisfactory for various applications when the
drive is for shafts which are permanently located at given angle. Although this illustration shows
a right angle transmission this drive can be applied also to shafts located at intermediate angle
between (0 and 90 degree) respectively.

In making this transmission, it is essential to have the holes for a given rod located accurately in
the same holes must be equally spaced in radial and circumferential directions, be parallel to
each rod should be bent to at angle at which the shaft are to be located. If the holes drilled in the
ends of the shafts have “blind” or closed ends, there ought to be a small vent at the bottom of
each rod hole for the escape of air compressed by the pumping action of the rods.
Chapter-3

MATERIALS/ APPARATUS/ PROBLEM FORMULATION/

DESIGN/METHODOLOGY

3.1. SELECTION OF MATERIAL

SELECTION OF MATERIAL The proper selection of material for the different part of a
machine is the main objective in the fabrication of machine. For a design engineer it is must that
he be familiar with the effect, which the manufacturing process and heat treatment have on the
properties of materials. The Choice of material for engineering purposes depends upon the
following factors:

1. Availability of the materials.

2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the ability of the
material to resist mechanical forces and load. We shall now discuss these properties as follows:

1. Strength: It is the ability of a material to resist the externally applied forces

2. Stress: Without breaking or yielding. The internal resistance offered by apart to an externally
applied force is called stress.

3. Stiffness: It is the ability of material to resist deformation under stresses. The modules of
elasticity of the measure of stiffness.

4. Elasticity: It is the property of a material to regain its original shape after deformation when
the external forces are removed. This property is desirable for material used in tools and
machines. It may be noted that steel is more elastic than rubber.

5. Plasticity: It is the property of a material, which retain the deformation produced under load
permanently. This property of material is necessary for forging, in stamping images on coins and
in ornamental work.

6. Ductility: It is the property of a material enabling it to be drawn into wire with the application
of a tensile force. A ductile material must be both strong and plastic. The ductility is usually
measured by the terms, percentage elongation and percent reduction in area. The ductile
materials commonly used in engineering practice are mild steel, copper, aluminum, nickel, zinc,
tin and lead. 7. Brittleness: It is the property of material opposite to ductile. It is the property of
Chapter-3

breaking of a material with little permanent distortion. Brittle materials when subjected to tensile
loads snap off without giving any sensible elongation. Cast iron is a brittle material.

8. Malleability: It is a special case of ductility, which permits material to be rolled or hammered

into thin sheets, a malleable material should be plastic but it is not essential to be so strong. The
malleable materials commonly used in engineering practice are lead, soft steel, wrought iron,
copper and aluminum.

9. Toughness: It is the property of a material to resist the fracture due to high impact loads like
hammer blows. The toughness of the material decreases when it is heated. It is measured by the
amount of absorbed after being stressed up to the point of fracture. This property is desirable in
parts subjected to shock an impact loads.

10.Resilience: It is the property of a material to absorb energy and to resist rock and impact
loads. It is measured by amount of energy absorbed per unit volume with in elastic limit. This
property is essential for spring material.

In engineering practice, the machine parts are subjected to various forces, which may be due to
either one or more of the following.
1. Energy transmitted
2. Weight of machine
3. Frictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts

Selection of the material depends upon factor of safety, which in turn depends upon the
following factors.

1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing
7. The extent loss of life if failure occurs
8. The extent of loss of property if failure occurs
Chapter-3

S.NO PART NAME MATERIAL QUANTITY DESCRIPTION

3.2. RAW MATERAILS AND STANDARD MATERIALS

Chapter-3

1. FRAME MS 1 C SECTION 75x40x4mm

2. MOTOR STD 1 0.25 hp, 1440 r.p.m

3. SHAFT MS 2 DIAMETER 20mmx350mm

4. HOUSING MS 2 DIAMETER 95x62mm

5. BENT LINK MS 3 DIAMETER 10x240mm

6. PULLEY CI 2 DIAMETER 45x250mm

7. PEDASTAL CI 4 P204
BEARING

8. BELT LEATHER 1 a-56

9. ANGLE ROD MS 1 35x35x5mm

10. NUT BOLT WASHER MS 10 M10

11. WELDING ROD ----- ----- ------

12. COLOUR ----- ----- -----

PROBLEM FORMULATION (CALCULATIONS)

3.3 DESIGNCALCULATIONFOR SHAFT AND BENT LINKS—

Max tensile stress = 60 N/mm2 Maxima shear stress = 40 N/mm2 Shaft design on basic of study
Considering 25 % overload

Tmax= 1238 x 1.25

= 1.525 x 10 3N-mm
Chapter-3

The shaft is subject to pure torsional stress We know

T= 3. 14/16 x fs x d3 15250
= 3. 14/ 16 x 70x d3 D =10.20mm

Taking factor of safety = 2 D

= 10 x 2 = 20mm

Same torque is transmitted to bent link shaft

So torque on each shaft = T /3

= 15250 /3 = 5083 N mm

T= 3. 14/16 x fs x d3 5083
= 3. 14/ 16 x 70x d3 D
= 7.17 mm

Taking factor of safety =1.4 D = 7 x 1 .4

= 9.8 =10mm

3.4 DESIGN OF C-SECTION MATERIAL—

M.S. The vertical column channel is subjected to bending stress Stress given by => M/I = f b / y
In above equation first we will find the moment of inertia about x and yAxis and take the
minimum moment of inertia considering the channel of ISLC 75 x 40 size.
We know the channel is subject to axial compressive loadIn column section the maximum
bending moment occurs at channel of section M = Ra x L/2 M = 750 x 1500/2 M
= 562500 N-mm

We know F b = M/Z Z = t (l x b + (b2/6)) Z

= 5 (40x 65 + (652/6)) Z
= 3304 mm3
Now check bending stress induced in C Section F b induced
= M/Z F b induced
= 562500 /3304
= 170.25 N / mm2
As induced stress value is less than allowable stress value design is safe.
F b = Permissble bending stress
= 320 N / mm² F b induced < f b allowable Hence our design is safe.

3.5 DESIGNING OF EL-BOW ROD—

We know that, Same torque is transmitted to bent link shaft

So torque on each shaft = T /3
Chapter-3

= 15250 /3 = 5083 N mm
T= 3. 14/16 x fs x d3 5083
= 3. 14/ 16 x 70x d3 D = 7.17 mm
Take approximately D=8mm.
Diameter of rod is 8mm and length is 300mm
𝑍 =0.78𝑅3 =0.78×43
= 49.92 kg/mm²
Bending stress of rod σ =PL/4Z =186.5×300/4×49.92 =280.19 N/mm²

3.6 DESIGNING OF HUB ---

Considering a hub of internal diameter is 32mm and outer diameter is 92mm, length is 82mm.
𝑝 =100×9.81=981
𝜎𝑏 =𝑝𝐷𝑖2 /𝐷02−𝐷𝑖2 =980×322 /922−322 =135.01N/mm

FIGURE 6- WORKING MECHANISM (ELBOW MECHANISM)

3.7. METHODOLOGY
Chapter-3

1.Study of research papers.

2. Design of shaft, rod and elbow.

3.Solid Works simulation feature is used to find out stress.

4. Fabrication of shaft, rod and elbow.

5.Mounting of shaft on wood board/iron board.

6.Assemble the all part.

7.Evaluating design moment and force and calculation.

8.Compare the actual result with model.

 FINDINGS

4.1 ARRANGEMENT OF PINS IN SHAFTS--

In the below diagram for basic arrangement of pins in the shaft holes are shown. The diagram
clearly shows that pins used are in odd no.3, 5, 7, 9… and centers of any two pin holes must not
be on that line which represent the diameter of the shaft and angle between all consecutive holes
should be equal for smoother power transmission. Value of angle such that it’s multiple with any
integral not equal to 180 degrees. Let the Value of angle = x degree, then n*x ≠ 180 degree.
Where n is an integral value. As mentioned, Angle between the centers of any two pin holes
must not be on that line which represent the diameter of the shaft because if this happen angle
between them is 180 degrees and during motion pins or links use are trying to overlap each other
because of this motion interrupted. Also, as we mentioned that pins no. should be odd and angle
between consecutive holes are equal so it can be easily understood by below table that why it is
necessary

4.2 ANALYSIS OF MECHANISM--

From the above diagrams and views the setup is clearly established in the mind, but as for
convenience here we use the front view of the setup for analyzing the mechanism of setup.

FIGURE 7- SETUP

Let at the starting instant shaft 1 starts rotation with 3 pins in anticlockwise direction and a
reaction force developed at the pin surface which in contact with the shaft and this force
transferred to the other end of the pin which is in the shaft and applying on the shaft 2 due to
which shaft 2 starts rotating in the same direction as shaft 1.

After 120 degree rotation pin 1 comes at the place of pin 2 & pin 2 comes at the place of pin 3 &
pin 3 comes at the place of pin 1 by sliding in shaft and self adjusting. This motion repeated for
next 120 degrees and further for next 120 degrees and pins are exchanging the position in
successive order as discussed before.

4.3 COMPARISON OF GEARED DRIVE WITH GEARLESS DRIVE

The gearless drive is capable of transmitting motion at any fixed angle between 0* to 90*. This
desired effect is also possible with help of bevel gear. Gearless differ to a great extent not only in
their manufacturing method or working principle but also in other aspects etc. the aspects have
been discussed below:

4.4 MANUFACTURING METHODS:- Bevel gears, which are straight teeth or spiral teeth are
manufactured on special purposes machines. These require large amount of calculation and every
pair or set of gear are made together and there is no interchangeability. The gearless drive has
this advantage that it can be machined and manufactured on conventional machines and it
provide complete freedom of interchangeability.

4.5 WORKING PRINCIPLE:- A gear comprises of a frustum of a cone with teeth out on its
periphery .The driving gear mounted on the input shaft meshes with the driven gear and thus
provides motion at right angle to the input shaft. The working of the gearless drive has been
explained in the earlier chapter and it obviously very different from the above.

4.6 CAUSE OF FAILURE:- Starting with the principle that failure id the result of the stress i.e.
condition more severe than the material can with stand. The various type of failures such as
pitting, corrosion, erosion, fatigue etc. Cause the wearing of the gear tooth resulting in the tooth
leads to the replacement of the entire gear set, which is very expensive.

4.7 LIFE AND EFFICIENCY:- Designed life represents the total period of operation,
regardless of any variations of torque or speed, which may occur during that the time. The geared
drive is capable of giving an efficiency of about 40% and certain errors like backlash, hunting
etc... cannot be eliminated. In the gearless drive, although the life has not been calculated but it is
assumed that its life will be in comparison to that of geared drive but its efficiency could be as
high as 85% to 92% with proper lubrication and cooling.
 RESULT AND DISCUSSION

5.1 RESULTS-

The final design thus obtained is capable of transmitting torque and power at varied angles
depending on the angular limitation of the hooks joint. With further research and advanced
analysis in the design wide-ranging applications of the drive can be discovered.

This project is the equipment useful to improve the quality of the gear being manufactured and
may be made in much less time, consequently we have selected this undertaking el-bow
mechanism is an inventive link mechanism of slider and kinematic chain principle.

That is also called as “gearless transmission mechanism” this mechanism is very beneficial for
transmitting movement at right angles. But in sure commercial software “gearless transmission at
proper attitude” can also work at obtuse or correct angle plane can be in comparison to bug and
Trojan horse gear or bevel and pinion equipment which are perpetually used inside the enterprise
for severa application. for the reason that factor referring to beneath frictional Forces among the
mating tools teeth, the erratic hunting of the gears, the back lash among the tooth cannot be
conquer and for this reason the performance can't be extra than 55% of recent gears of warm
bevel type are being manufactured in poly propqlenerand epoxy material where the Frictional
Forces are relatively eliminated. even though such gears are used for quite small programs the
efficiency isn't extra than forty-two%.

The model works correctly as per the design. With the help of this system, we can efficiently
reduce the cost in power transmission and further advancement in this technology can be made.

There is clear in design and Fabrication of our project is safe at 140rpm to 260rpm for gearless
transmission system.

5.2 ITS APPLICATION-

The featured product has its widest application as an extension for a socket wrench. Here the
design makes it easy to reach fasteners in the automotive and other mechanical industries, where
direct access to bolts and screws is often limited.

However, the possible applications for this technology extend into numerous fields. Just think of
the possibilities for power transmission in push bikes, toy sand hand-cranked equipment, or for
movement transmission in store and Outdoor signage.

 Driving for all kinds four faced tower clocks. The elbow mechanism was made use of the “Big
Ben Clock” having four dials on the tower of London. This clock was installed on 1630 AD and
still it is functioning in good condition.

 The mechanism is invariable used for multiple spindle drilling operation called the gang
drilling.

 Used for angular drilling between 0 to 90 degree position.

 Lubrication pump for C.N.C. lathe machines.

 The mechanism is very useful for a reaching a drive at a clumsy location.

 Air blower for electronic and computer machine.

 The mechanism has found a very usefully use in electronic and computer technology for
multiple.
 The elbow mechanism is used for movement of periscope in submarines.

 Tower clocks.

 Gang drilling (multi spindle drilling).

 Lubrication pump for CNC lathe.

5.3 ITS ADVANTAGES

 Complete freedom of Interchangeability.

  More efficient than gear.

 Power could be transfer to any desired angle.

 Ease of manufacturing.

 Misalignment of shafts can be tolerated to some extent.

 Simpler cooling systems.

 Low cost of manufacturing.

 Portability of parts.

5.4 ITS LIMITATIONS

1. Does not work at very low starting torque.

2. Improper whole drilling could pose much problem.

3. Sudden load would cause mechanism breakdown.

4. Speed ratio is always constant.

5. Links are to be placed after certain cycle time.

FIGURE 8- ORBITAL MECHANISM

POSSIBLE IMPROVEMENTS AND ADVANCES

5.5 METHOD OF IMPROVING EFFICIENCY

The main motion is transmitted with the help of a sliding pair which formed between pin & the
cylinder. These pins have to be lapped and cleaned and it should be capable of providing
complete interchangeability similarly with the cylinder, they too have to be hone or lapped so as
to provide smooth surface finish. This will result in less frictional loss and less heat generation.

1) LUBRICATION AND COOLING METHODS: - Lubrication and cooling are a must in

sliding members. One of the simple techniques applied for lubrication can be to drill oil holes in
the cylinder body for fill than up with oil. But this technique will not be very effective since the
weight and use of cylinders will increase.

2) MODIFICATION: - One of the methods by which efficiency or performance can be

enhanced is by increasing the number of pins. From the working of the mechanism we know that
the pin atthe inner most position is the drawing pin the pins the mechanism. Thus, if the no.
required for the next pin to attain the inner most position is considerable reduced and thus the
performance of the mechanism &its life increases.

5.6POSSIBLE ADVANCE--

We can also use this transmission system as

1. As lubricating pump while transmitting power.

2. Steam engine (eliminating the crank of shaft & complicated valve system).

1. LUBRICATING PUMP:- The small change which have to incorporate for this purpose is to
place stationary disc at the rear and it so fits with the cylinder that it avoids leak of gases.

WORKING: The slot position and length is so that adjusted that when pin is at inner most
position cylinder meshes with the suction port & suction of oil is started the slot remains open till
pin given maximum outward stroke, after that cylinder end is closed by the discs. Now the pin
starts moving inwards and thus compression stroke commences. The delivery slot location is so
adjusted that after the completion of 80 to 85% of compression stroke, the cylinder meshes with
the delivery stroke & thus the compressed fluid is discharged at high pressure. The delivery slot
length was such adjusted that remains in mesh with cylinder for 15to 20% of compression for
complete delivery of the compressed fluid. The suction slot length is adjusted for complete
outward stroke of pin.
 CONCLUSIONS

CONCLUSION OF THE REPORT--

During working on experimental setup and after a long discussion it is observed that proposed
arrangement used for any set of diameters with any profile of shafts for skew shafts of any angle
but the shaft’s must be having the rotational motion about his own axis, transmission of motion
is very smooth and desirable and used only for the equal R.P.M. of driving shaft and driven shaft
by employing links or given type of links for appropriate joints for revolute pair.

Some successful mechanical devices function smoothly however poor fly they are made while
other does this only by virtue of an accurate construction & fitting of their moving parts. This
projects which looks very simple & easy to construct was actually very difficult to conceive &
imagine without seeing an actual one in practice.

Motions demands to be studied first & we have done that very thing. We find that while
acceptable analysis for existing mechanism can often be Made quite easily we cannot without
insight .

imagination make effective synthesis of new mechanism hence we are mould to present this our
project gear less transmission at 90 degree (El-bow mechanism) which we have managed to
successfully device after long & hard input in conceiving its working principle.

During working on investigational system and after a lengthy argument it is pragmatic that
projected preparation used for any set of distances with any shape of tubes for tip shafts of any
direction but the tube’s must be having the revolving motion about his particular alignment.
We find that while acceptable analysis for existing mechanism can often be made quite easily
we cannot without insight & imagination make effective synthesis of new mechanism hence we
are mound to present this our project gearless transmission at 90*(El-bow mechanism) which we
have managed to successfully device after long & hard input in conceiving its working principle.

Designing of Multi-angular gearless drive instigated with assumptions and random dimensions
because no significant development has been done before in this unchartered territory. With
software support and assiduous endeavor the final optimal design has been obtained. The final
design thus obtained is capable of transmitting torque and power at varied angles depending on
the angular limitation of the hooks joint. With further research and advanced analysis in the
design wide-ranging applications of the drive can be discovered.

FIGURE 9—CROSS SECTIONAL OF GEARLESS MECHANISM

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