Q-29.

Explain the involute gear tooth profile and differentiate between Involute Gear Tooth Profile and cycloidal gear tooth profile. Ans. Involute Gear Tooth Profile Involute is the path generated by the end of a thread as it unwinds from a reel. In order to understand what is involute, imagine a reel with thread wound in the clockwise direction as in Fig.1.2. Tie a knot at the end of the thread. In the initial position, the thread is at B0 with knot on the reel at C0. Keeping the reel stationary, pull the thread and unwind it to position B1. The knot now moves from C0 to C1. If the thread is unwound to position B2 the knot moves to C2 position. In repeated unwinding, the taut thread occupies position B3, B4 while the knot moves to C3, C4 positions. Connect these points C0 to C4 by a smooth curve, the profile obtained is nothing but an involute, the illustration of which is given below. This forms the left side part of the tooth profile. If similar process is repeated with thread wound on the reel in anticlockwise direction in the same position, it forms the right side part of the same tooth. The completely formed involute tooth is shown in Fig.1.25.

Fig.1.23 The generation of involute profile on right side

Fig.1.24 The generation of involute profile on left side

Involute profiles have special properties. Imagine two involute teeth in contact as shown in Fig.1.26. If a normal is drawn at the contact point to the involute profile, it will be tangent to the generating circles. This can be visualized better from Fig. 1.23 where the taut thread is normal to the profile as well as tangent to the reel which forms the generating or the base circle. The profile will be involute above the base circle only. Below the base circle the profile will not be involute. The common normal to the profile at the contact point will be tangent to the base circles. It passes through a fixed point lying at the intersection of the tangent to the rolling/pitch circles and the line connecting the centres of the gear wheels. This point is known as the pitch point. As the gears rotate the contact point travels along the common tangent to the base circle. Hence this

line is also known as the line of action. The movement of the contact point along the line of action can be seen in the gear meshing later on.

Fig.1.25 Involute gear tooth profile appearance after generation

Fig. 1.26 Gear meshing

Advantages of involute gear profile: 1. Variation in centre distance does not affect the velocity ratio. 2. Pressure angle remains constant throughout the engagements which results in smooth running. 3. Straight teeth of basic rack for involute admit simple tools. Hence, manufacturing becomes simple and cheap. Comparison between involue and cycloidal gear profile In actual practice, the involute gears are more commonly used as compared to cycloidal gears, due to the following advantages: Advantages of involute gears: Following are the advantages of involute gears: 1) The most important advantage of the involute gears is that the center distance for a pair of involute gears can be varied within limits without changing the velocity ratio. This is not true for cycloidal gears which requires exact center distance to be maintained. 2) In involute gears, the pressure angle, from the start of the engagement of teeth to the end of the engagement, remains constant. It is necessary for smooth running and less wear of gears. But in cycloidal gears, the pressure angle is maximum at the beginning of engagement, reduces to zero at pitch point, starts increasing and again become maximum at the end of engagement. This results in less smooth running of gears. 3) The face and flank of involute teeth are generated by a single curve where as in cycloidal gears, double curves (i.e. epi-cycloid and hypo-cycloid) are required

for the face and flank respectively. Thus the involute teeth are easy to manufacture than cycloidal teeth. In involute system, the basic rack has straight teeth and the same can be cut with simple tools. The only disadvantage of the involute teeth is that the interference occurs with pinions having smaller number of teeth. This may be avoided by altering the heights of addendum and dedendum of the mating teeth or the angle of obliquity of the teeth. Advantages of cycloidal gears : 1) Since the cycloidal teeth have wider flanks, therefore the cycloidal gears are stronger than the involute gears, for the same pitch. Due to this reason, the cycloidal teeth are preferred specially for cast teeth. 2) In cycloidal gears, the contact takes place between a convex flank and concave surface, where as in involute gears, the convex surface are in contact. This condition results in less wear in cycloidal gears as compared to involute gears. However the difference in wear is negligible. 3) The cycloidal gears, the interference does not occur at all. Though there are advantages of cycloidal gears but they are outweighted by the greater simplicity and flexibility of the involute gears.

Q-30. Write a short note on Computer aided design. Ans: Introduction CAD if often defined in a variety of ways and includes a large range of activities. Very broadly it can be said to be the integration of computer science (or software) techniques in engineering design. At one end when we talk of modeling, it encompasses the following: Use of computers (hardware & software) for designing products Numerical method, optimizations etc. 2D/3D drafting 3D modeling for visualization Modeling curves, surfaces, solids, mechanism, assemblies, etc. The models thus developed are first visualized on display monitors using a variety of techniques including wire frame display, shaded image display, and hidden surface removed display and so on. Once the designer is satisfied, these models are then used for various types of analysis / applications. Thus, at the other end it includes a number of analysis activities. These could be: Stress (or deflection) analysis, i.e. numerical methods meant for estimating the behavior of an artifact with respect to these parameters. It includes tools like the Finite Element Method (FEM). Simulation of actual use Optimization Other applications like o CAD/CAM integration o Process planning

1.2

APPLICATIONS OF COMPUTER-AIDED DESIGN

In the field of product development there are often immense costs associated with the testing of new products. Every new product must undergo at least a small measure of physical testing not only to ensure that it meets minimum safety standards but also to ensure that it will successfully operate under the range of conditions to which it can expect to be exposed. For instance, the wing of an aeroplane must undergo stress tests to ensure that it will retain its integrity even under the most grueling weather and turbulence conditions before it is approved for use. Unfortunately, this testing can be ruinously time-consuming and expensive. If an aeronautical company has to physically build dozens of wings in the course of testing a new design then the final cost and time scale of the project can be far higher than projected. Fortunately, there is no need to physically test all of these designs. Instead, developers can run virtual stress tests using computer-aided design, substituting a wind tunnel for a CAD application that can simulate the same conditions. The benefits of virtual simulations are obvious. In addition to a reduction in the cost of product development and the time required to run tests there is also the advantage that conceptual designs can be modified instantly as the tests progress. Perhaps one of the best examples of this versatility can be seen in the design of the aeroplane wing. The science of aerodynamics is complex, and it is often the case that certain wing shapes can create unexpected turbulence under certain conditions. When this occurs during physical testing it can be a challenge to discover the problem and make alterations. When running virtual tests using CAD, however, alterations to the design can be made quickly and easily, so new designs can be tested and retested until the problem is resolved.

Q-31. What are the Principles of pneumatic control system? Ans. (a) Pneumatic circuit Pneumatic control systems can be designed in the form of pneumatic circuits. A pneumatic circuit is formed by various pneumatic components, such as cylinders, directional control valves, flow control valves, etc. Pneumatic circuits have the following functions: 1. To control the injection and release of compressed air in the cylinders. 2. To use one valve to control another valve. (b) Pneumatic circuit diagram A pneumatic circuit diagram uses pneumatic symbols to describe its design. Some basic rules must be followed when drawing pneumatic diagrams. (i) Basic rules 1. A pneumatic circuit diagram represents the circuit in static form and assumes there is no supply of pressure. The placement of the pneumatic components on the circuit also follows this assumption. 2. The pneumatic symbol of a directional control valve is formed by one or more squares. The inlet and exhaust are drawn underneath the square, while the outlet is drawn on the top. Each function of the valve (the position of the valve) shall be represented by a square.

Fig. 3/2 directional control valve (normally closed type)

Fig 3/2 directional control valve (normally closed type)

Arrows "" are used to indicate the flow direction of air current. If the external port is not connected to the internal parts, the symbol is used. The symbol underneath the square represents the air input, while the symbol represents the exhaust. Fig. shows an example of a typical pneumatic valve. The pneumatic symbols of operational components should be drawn on the outside of the squares. They can be divided into two classes: mechanical and manual .

(a)

Vertical piston lever (b) Pulley lever (c) Unilateral pulley lever . Mechanically operated pneumatic components

(a) Standard

(b) Lever

(c) Button

(d) Pull & push

Fig. Manually operated pneumatic components Pneumatic operation signal pressure lines should be drawn on one side of the squares, while triangles are used to represent the direction of air flow.

Fig.Pneumatic operation signal pressure line

(ii) Basic principles Fig. shows some of the basic principles of drawing pneumatic circuit diagrams, the numbers in the diagram correspond to the following points:

Fig. Basic principles of drawing pneumatic circuit diagrams

When the manual switch is not operated, the spring will restore the valve to its original position. From the position of the spring, one can deduce that the block is operating. The other block will not operate until the switch is pushed. Air pressure exists along this line because it is connected to the source of compressed air. As this cylinder cavity and piston rod are under the influence of pressure, the piston rod is in its restored position. The rear cylinder cavity and this line are connected to the exhaust, where air is released.

(iii) The setting of circuit diagrams When drawing a complete circuit diagram, one should place the pneumatic components on different levels and positions, so the relations between the components can be expressed clearly. This is called the setting of circuit diagrams. A circuit diagram is usually divided into three levels: power level, logic level and signal input level.

Fig. Power level, logic level and signal input level

Q-32. What are Different kinds of basic Pneumatic circuits and their applications? Ans A basic circuit is a pneumatic circuit designed to perform basic tasks, such as flow amplification, signal inversion, memory, delay, single acting cylinder control, double acting cylinder control, etc. (a) Flow amplification Cylinders with a large capacity require a larger flow of air, which can be hazardous to users. It is unsafe to manually operate pneumatic directional control valves with large flow capacity. Instead we should first operate manually a small control valve and use it to operate the pneumatic control system with large flow capacity. This is called flow amplification, which can greatly ensure the safety of the operators. During operation, valves with large flow capacity should be placed near the cylinder, while valves with smaller flow capacity should be placed on control boards some distances away. Fig. Shows a basic flow amplification circuit. Notice how different components are placed on different levels.

Fig. Flow amplification system

(b) Signal inversion The pneumatic diagram in Fig. shows how directional control valves can be switched. When operating control valve , control valve will stop producing pressure output. When control valve ceases operation and is restored to its original position, control valve will resume its output. Therefore, at any given time, the pressure output of control valve is the exact opposite of that of control valve .

Fig. Signal inversion system

(c) Memory Function Memory is a common basic function. It can keep a component at a certain state permanently until there is a change of signals. Fig. shows a memory function circuit. When control valve is operated momentarily (that is, pressed for a short time), the output signal of the 5/2 directional control valve will be set to ON. The signal will stay that way until control valve is operated momentarily and generates another signal to replace it, causing it to stay permanentlyat OFF.

Fig. Memory function circuit

(d) Delay function A pneumatic delay circuit can delay the operating time of the next control valve. Its principle of operation involves the use of an orifice to slow down the flow of air and control the time of pneumatic operation. Delay functions can be divided into two classes: ON-signal delay and OFF-signal delay. (i) ON-signal delay Fig. shows the circuit diagram of an ON-signal delay circuit, which delays the output of the next control valve. When control valve is operated, the one way flow control valve will slow down the flow of air, thus delaying the signal output of the outlet of control valve (A), resulting in a persistent ON-signal. The time when control valve will be restored to its original position is not affected.

Fig. Circuit diagram of an ON-signal delay circuit

(ii) OFF-signal Delay Fig. shows the circuit diagram of an OFF- signal delay circuit, which delays the output of the next control valve. This circuit is similar to an ON -signal delay circuit. The only difference is that the one way flow control valve is connected in the opposite direction. Therefore, when control valve is operated, the outlet of control valve (A) will continue to output signals. However, when control valve is restored to its original position, the release of air is slowed down by the one way flow control valve, resulting in a persistent OFF-signal.

Fig. Circuit diagram of an OFF-signal delay circuit

The application of pneumatic systems The application of pneumatic systems is very extensive. The following are some examples. (a) Transport system Fig. a shows a simplified industrial transport system. When the button switch is pushed, the cylinder will push one of the goods from the shelf onto the transfer belt. When the button switch is released, the cylinder will retract automatically. Fig. b shows the circuit diagram of the transport system.

(a) Operation of a pneumatic transport system

(b) Pneumatic circuit diagram of a pneumatic transport system

(b) Vehicle door operation system Pneumatic systems can be used to operate the doors of public vehicles (Fig. a) . Assuming that the opening and closing of the doors are controlled by two button switches ON and OFF. When the button switch ON is pressed, the doors will open. When the button switch OFF is pushed, the doors will close. Fig. b shows a pneumatic system that can be used to operate the doors of vehicles.

Fig. (a) Operation of a pneumatic system that controls the movement of vehicle doors

(b) Pneumatic circuit diagram