KINEMATICS OF MACHINERY

UNIT - III

KINEMATIC SYNTHESIS OF MECHANISMS

Synthesis of Mechanisms:

The synthesis of mechanism is the design or creation of a mechanism to produce a desired output
motion for a given input motion. In other words, the synthesis of mechanism deals with the determination of
proportions of a mechanism for the given input and output motion.

In the application of synthesis, to the design of a mechanism, the problem divides itself into the following three
parts:

1. Type synthesis, i.e. the type of mechanism to be used,

2. Number synthesis, i.e. the number of links and the number of joints needed to produce the required motion,

3. Dimensional synthesis, i.e. the proportions or lengths of the links necessary to satisfy the required motion
characteristics.

Design of Mechanisms:

 In designing a mechanism, one factor that must be kept in mind is that of the accuracy required of the
mechanism.
 Sometimes, it is possible to design a mechanism that will theoretically generate a given motion.
 The difference between the desired motion and the actual motion produced is known as structural error.
 In addition to this, there are errors due to manufacture.
 The error resulting from tolerances in the length of links and bearing clearances is known as mechanical
error.

Classifications of Synthesis Problem:

The problems in synthesis can be placed in one of the following three categories:
1. Function generation; 2. Path generation; and3. Body guidance.

These are discussed as follows:

1. Function generation.

The major classification of the synthesis problems that arises in the design of links in a mechanism is a
function generation. In designing a mechanism, the frequent requirement is that the output link should rotate,
oscillate or reciprocate according to a specified function of time or function of the motion of input link. This is
known as function generation.

A simple example is that of designing a four bar mechanism to generate the function y = f (x).In this
case, x represents the motion of the input link and the mechanism is to be designed so that the motion of the
output link approximates the function y.

2. Path generation.
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In a path generation, the mechanism is required to guide a point (called a tracer point or coupler point)
along a path having a prescribed shape. The common requirements are that a portion of the path be a circular
arc, elliptical or a straight line.

3. Body guidance.

In body guidance, both the position of a point within a moving body and the angular displacement of the
body are specified. The problem may be a simple translation or a combination of translation and rotation.

Precision Points for Function Generation:

 In designing a mechanism to generate a particular function, it is usually impossible to accurately

produce the function at more than a few points.
 The points at which the generated and desired functions agree are known as precision points or
accuracy points and must be located so as to minimise the error generated between these points.
 The best spacing of the precision points, for the first trial, is called Chebychev spacing.
 According to Freudenstein and S and or, the Chebychev spacing for n points in the range xS ≤ x ≤ xF
(i.e. when x varies between xS and xF) is given by

Where
xj= Precision points

Δ x = Range in x = xF − xS, and

j = 1, 2 ...n

The subscripts xS andxF indicate start and finish positions respectively.

The precision or accuracy points may be easily obtained by using the graphical method as discussed below.

1. Draw a circle of diameter equal to the range Δ x = xF − xS .

2. Inscribe a regular polygon having the number of sides equal to twice the number of precision points
required, i.e. for three precision points; draw a regular hexagon inside the circle, as shown in Fig.
3. Draw perpendiculars from each corner which intersects the diagonal of a circle at precision points x1, x2, x3.
Now for the range 1 ≤ x ≤ 3, xS = 1; xF = 3 , and
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Fig. Graphical method for determining three precision points.

Angle Relationships for Function Generation:

Consider a four bar mechanism, as shown in Fig. (a) Arranged to generate a function y = f (x) over a limited
range. Let the range in x is (xF – xS) and the corresponding range in θ is (θF − θS ) . Similarly, let the range in y is
( (yF − yS ) and the corresponding range in φ is (φF − φS ) .

The linear relationship between x and θ is shown in Fig. (b). from the figure, we find that
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Similarly, the linear relationship between y and φ may be written as

For n points in the range, the equation (i) and (ii) may be written as

Four Bar Mechanism: (Freudenstein’s Equation)

Consider a four bar mechanism ABCD, as shown in Fig. (a), in which AB = a, BC = b, CD = c, and DA
= d. The link AD is fixed and lies along X-axis. Let the links AB (input link), BC (coupler) and DC (output
link) make angles θ, β and φ respectively along the X-axis or fixed link AD.

The relation between the angles and link lengths may be developed by considering the links as vectors.
The expressions for displacement analysis is derived as discussed below:

Displacement analysis:
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For equilibrium of the mechanism, the sum of the components along X-axis and along Y-axis must be
equal to zero. First of all, taking the sum of the components along X-axis as shown in Fig. (b), we have

The equation (vii) is known as Freudenstein’s equation.

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Slider Crank Mechanism: (Freudenstein’s equation)

Fig. Slider crank mechanism.

A slider crank mechanism is shown in Fig. In the synthesis problem of the slider crank mechanism, the
displacement (s) of the slider C has to co-ordinate with the crank angle ( θ )in a specified manner.

For example, consider that the displacement of the slider is proportional to crank angle over a given interval,
i.e.

S− SS = C(θ − θS ) , for θS ≤θ≤ θF... (i)

Where
C = Constant of proportionality, and
S= Displacement of the slider when crank angle is θ .

The subscripts S and F denote starting and finishing positions. The synthesis of a slider crank mechanism for
three precision points is obtained as discussed below.

The three positions of the crank ( θ1, θ2 and θ3 ) is obtained and the corresponding three positions of the slider
(S1, S2 andS3) are obtained from the given condition as in equation (i). Now the dimensions a, band c may be
determined as discussed below:
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For the three different positions of the mechanism i.e. for (θ1,θ2 θ3) and (S1, S2, S3), the equation (ii) may be
written as

The equations (iv), (v) and (vi) are three simultaneous equations and may be solved for three unknowns k1, k2
and k3. Knowing the values of k1, k2 and k3, the lengths a, b and c may be obtained from equations (iii).

Graphical Synthesis of Four bar Mechanism:

Fig. Layout of four bar mechanism.

 The synthesis of four bar mechanism consists of determining the dimensions of the links in which the
output link is to occupy three specified positions corresponding to the three given positions of the input
link.
 Fig. shows the layout of a four bar mechanism in which the starting angle of the input link AB1 (link 2)
of known length is θ .
 Let θ12 , θ23 and θ13 be the angles between the positions B1B2, B2B3 and B1B3 measured anticlockwise.
 Let the output link DC1 (link 4) passes through the desired positions C1, C2 and C3 and φ12 , φ23 and φ13
are the corresponding angles between the positions C1C2 , C2C3 and C1C3 .
 The length of the fixed link (link 1) is also known.
 Now we are required to determine the lengths of links B1C1 and DC1 (i.e. links 3 and 4) and the starting
position of link 4 ( φ ).
 The easiest way to solve the problem is based on inverting the mechanism on link 4.

The procedure is discussed as follows :

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Fig. Design of four bar mechanism (Three point synthesis).

1. Draw AD equal to the known length of fixed link, as shown in Fig. 25.8.
2. At A, draw the input link 1 in its three specified angular positions AB1, AB2 and AB3.
3. Since we have to invert the mechanism on link 4, therefore draw a line B2D and and rotate it
clockwise (in a direction opposite to the direction in which link 1 rotates) through an angle
φ12 (i.e. the angle of the output link 4 between the first and second position) in order to locate
the point B2′ .
4. Similarly, draw another line B3D and rotate it clockwise through an angle φ13 (i.e. angle
the output link between the first and third position) in order to locate point B3′ .
5. Since the mechanism is to be inverted on the first design position, therefore B1 and B1′ are
coincident.
6. Draw the perpendicular bisectors of the lines B1′ B2′ and B2′ B3′ . These bisectors intersect at
point C1.
7. Join B1′C1 and C1D . The figure AB1′ C1D is the required four bar mechanism. Now the length
of the link 3 and length of the link 4 and its starting position ( φ ) are determined.

Graphical Synthesis of Slider Crank Mechanism:

Consider a slider crank mechanism for which the three positions of the crank AB (i.e.θ1, θ2 and θ3 ) and
corresponding three positions of the slider C (i.e. S1, S2 and S3) are known, as shown in Fig.

In order to synthesis such a mechanism, the following procedure is adopted.

 First of all, draw the crank AB1 in its initial position. If the length of crank is not specified,
it may be assumed.
 Now find the relative poles P12 and P13 as shown in Fig. The relative poles are obtained by fixing the
link A and observing the motion of the crank AB1 in the reverse direction. Thus, to find P12, draw angle
YAP12 equal to half of the angle between the first and second position ( θ12) in the reverse direction and
from AY draw IP12 equal to half of the slider displacement between the first and second position (i.e.

 From P12 and P13, draw two lines P12Q12 and P13Q13 such that ∠AP12I = ∠B1P12Q12 and ∠AP13I =
s12). Similarly P13 maybe obtained.

∠B1P13Q13. The lines P12Q12 and P13 Q13 intersect at C1, which is the location of the slider at its first
position. Now the length of the connecting rod B1C1 and the offset (e) may be determined.
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Coupler Curves:

It is often desired to have a mechanism to guide a point along a specified path. The path generated by a
point on the coupler link is known as a coupler curve and the generating point is called a coupler point (also
known as tracer point).

1. Four bar mechanism

Fig. Four bar mechanism with a coupler point.

Consider a four bar mechanism ABCD with an offset coupler point E on the coupler link BC, as shown in Fig.
Let the point E makes an angle α with BC in the anticlockwise direction and its co-ordinates are E (xE, yE).

First of all, let us find the value of BD, γ and β.

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From the above equations, the co-ordinates of the point E may be determined if a, e, θ ,αand β are known.

2. Slider crank mechanism

Fig. Slider crank mechanism with coupler point.

Consider a slider crank mechanism with an offset coupler point E, as shown in Fig. Let the point E makes an
angle α with BC in the anticlockwise direction and its co-ordinates are E (xE, yE).
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First of all, let us find the angle β . From right angled triangle BC1C,

From the above equations, the co-ordinates of the point E may be determined, if a, b, e, e1, θ ,α and β are
known.

PROBLEMS
QUESTION: 1

A four bar mechanism is to be designed, by using three precision points, to generate the function

y = x1.5 , for the range 1 ≤ x ≤ 4 .

Assuming 30° starting position and 120° finishing position for the input link and 90°starting position and
180° finishing position for the output link, find the values of x, y, θ and φ corresponding to the three
precision points.

Solution : Given : xS = 1 ; xF = 4 ; θS = 30° ; θF = 120° ; φS = 90° ; φF = 180°

Values of x

The three values of x corresponding to three precision points (i.e. for n = 3) according to Chebychev’s spacing
are given by

Values of y

Since y = x1.5 , therefore the corresponding values of y are

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Values of θ

The three values of θ corresponding to three precision points are given by

Values of φ

The three values of φ corresponding to three precision points are given by

QUESTION: 2

Design a four bar mechanism to co-ordinate the input and output angles as follows : Input angles = 15°,
30° and 45° ; Output angles= 30°, 40° and 55°.

Solution. Given: θ1 =15° ; θ2 = 30° ;θ3 = 45° ; φ1 = 30° ; φ2 = 40° ; φ3 = 55°

The Freudenstein’s equation for the first position of the input and output link (i.e. when θ1 =15° and φ1 = 30° )
may be written as

Similarly, for the second position (i.e. when θ2 = 30° and φ2 = 40°),
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and for the third position (i.e. when θ3 = 45° and φ3 = 55° ),

Solving the three simultaneous equations (i), (ii) and (iii), we get

Assuming the length of one of the links, say ‘a’ as one unit, we get the length of the other links as follows :

The designed mechanism with AB = a = 1 unit, BC = b = 0.74 units ; CD = c = 0.896 units and AD = d = 0.905
units, is shown in Fig.

QUESTION : 3

Determine the proportions of four bar mechanism, by using three precision points, to generate y = x1.5, where
x varies between 1 and 4. Assume θS = 30° ; Δθ = 90° ;φS = 90° ; and Δφ = 90° . Take length of the fixed
link AD as 25 mm.

Solution.Given : xS = 1 ; xF = 4 ; θS = 30° ; Δθ = θF − θS = 90° ; φS = 90° ; Δφ = φF − φS = 90° ; d = 25 mm

To find Values of x
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The three values of x corresponding to three precision points (i.e. for n = 3) according to Chebychev’s
spacing are given by

Values of y

Since y = x1.5 , therefore the corresponding values of y are

Values of θ

The three values of θ corresponding to three precision points are given by

To find Values of φ

The three values of φ corresponding to three precision points are given by

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The designed four bar mechanism AB2C2D in one position (i.e. for θ2 , x2 and φ2 , y2 ) is shown by thick lines in
Fig.
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QUESTION: 4

Synthesize a four bar linkage, as shown in Fig., using Freudenstein’sequation to satisfy in one of its
positions. The specification of position θ, velocity ω and acceleration α are as follows: θ = 60°, ω 2= 5
rad/s; α2= 2 rad/s2; φ = 90°; ω4= 2 rad/s; α4= 7 rad/s2.

Solution : Given : θ = 60° ; ω2 = 5 rad/s ; α2 = 2 rad/s2;φ = 90°, ω4 = 2 rad/s; α4 = 7 rad/s2

The four bar linkages is shown in Fig.

Let
AB = Input link = a,
BC = Coupler = b,
CD = Output link = c, and
AD = Fixed link = d.

The Freudenstein’s equation is given by

k1cos φ − k2cos θ + k3 = cos(θ − φ) ... (i)

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QUESTION : 5

Synthesize a four-bar mechanism to generate a function y = sin x for0 ≤ x ≤ 90°. The range of the output
crank may be chosen as 60° while that of input crank be 120°.Assume three precision points which are to
be obtained from Chebyshev spacing. Assume fixed link to be 52.5 mm long and θ1 = 105° and φ1 = 66°.

Solution. Given: xS = 0 ; xF = 90° ; Δφ = 60°; Δθ = 120° ; d = 52.5 mm;θ1 = 1.05°; φ1 = 66°

The three values of x corresponding to three precision points (i.e. for n = 3), according to Chebyshev spacing
are given by
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We have calculated above the three positions i.e. the angular displacements (θ1, θ2 and θ3)of the input crank and
the three positions (φ1, φ2 and φ3) of the output crank. Now let us find the dimensions of the four bar
mechanism.

Let
a = Length of the input crank,
b = Length of the coupler,
c = Length of the output crank, and
d = Length of the fixed crank = 52.5 mm (Given)
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QUESTION : 6

Synthesize a slider crank mechanism so that the displacement of the slider is proportional to the square
of the crank rotation in the interval 45° ≤ θ ≤ 135° . Use three precision points with Chebyshev’s spacing.

Solution: Given. θS= 45° ; θF = 135°

First of all, let us find the three precision points (i.e. x1, x2 and x3). We know that

Assuming the starting displacement of the slider (SS) = 100 mm and final displacement of the slider (SF) = 30
mm. It may be noted that for the crank rotating in anticlockwise direction, the final displacement will be less
than the starting displacement.
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Since it is given that the displacement of the slider (s)is proportional to the square of the crank rotation ( θ),
therefore, for the displacement from initial position (SS) to s when crank rotates from initial position ( θS ) to θ ,
we have
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