12th IFToMM World Congress, Besanon (France), June18-21, 2007

Analysis of Mechanical Error in Quick-return Shaper Mechanism

Nenad D. Pavlovi * Faculty of Mechanical Engineering, University of Ni, Serbia
AbstractWe are considering1 the mechanical error of the quick-return shaper mechanism. The effect of practical manufacturing tolerances (link lengths and link angles) on the accuracy of the stroke of this linkage is analyzed by using deterministic approach, based on the worst-case analysis of the individual tolerances (maximum output tolerance). Keywords: shaper mechanism, stroke accuracy, mechanical error

I. Introduction While designing a mechanism either for function generation [1] or for path generation [2] or for rigid-bodyguidance applications, it is necessary to take into account not only the structural error but also the mechanical error resulting due to tolerances on link-lengths, clearances in link joints [3], and static and dynamic deflection of links [4]. Various attempts have been made to analyze and synthesize the mechanical error of function and path generating linkages. There are two distinct approaches deterministic and stochastic. The deterministic approaches are based on worst-case analysis of individual tolerances [1], [2], [3], [5], [6]. On the other hand, Dhande, Mallik and Chakraborty [7], [8] have used a stochastic model to allocate tolerance and clearance in four-bar function generators,while Shi [9] allocated them in spatial linkages. In this paper, the effect of practical manufacturing tolerances is analyzed by using deterministic approach. It was observed on an example [2] (using a approach based on the worst case analysis of the individual tolerances) that the mechanical error resulting due to practical manufacturing tolerances is greater than the mechanical error resulting due to clearances in link joints. In addition, it was observed [3] by using software package visualNastran that the real mechanical error resulting due to clearances in link joints is significantly less than the worst-case, while the mechanical error resulting due to manufacturing tolerances is a result of a particular combination of components tolerances when assembling a mechanism, so it could cause a greater mechanical error. Due to all given above, in this paper attention is focused only on mechanism sensitivity to link-length and linkangle tolerances and an illustrative example is given.
*E-mail: pavlovic@masfak.ni.ac.yu 1 hello

Figure 1 shows the schematic drawing of a six-link single-degree-of-freedom mechanism, often called the quick-return shaper mechanism, after the name of the machine tool in which it is used (the majority of shapers ever built have been crank shapers). The objective in this linkage is to provide the cutting motion of shaping machine. Pin A, mounted in a sliding block which can reciprocate in a slot in a pivoted lever (2), induces a slow and fast cycle to the oscillation of the lever. As the slotted end of the lever (2) is linked to the shaper ram (pin C mounted in a sliding block), the slow motion is used for the cutting stroke and the fast motion to return the ram (3) on the non-cutting stroke. The nominal dimensions of the linkage are: l0=400 mm, l1=150 mm, k=250 mm [5]. If the length variations of the links due to manufacturing tolerances are considered, the kinematic and displacement accuracy of this mechanism will be changed. In this paper, analysis is presented to show the effects link-length and link-angle tolerancing have on the shaper ram stroke error, as well as sensitivity coefficients to link-length and link-angle tolerances. There

Fig. 1. Schematic drawing of a quick-return shaper mechanism [10]

12th IFToMM World Congress, Besanon (France), June18-21, 2007

are few literature sources dealing with the effect of the manufacturing tolerances on the accuracy of the stroke of the linkage [6], which is why that is exactly what was discussed in this paper. II. Sensitivity analysis A sensitivity analysis of the mechanism is of a great value to designers if a realistic and economical allocation of tolerances on link-lengths is to be achieved. Such analysis enables the designer to notice important trends, to identify most critical link of a given mechanism, and to allocate the tolerances optimally. Unsuitable choices for tolerancing the links may lead to unacceptable deviation in the output, due to the tolerances allocated to the more sensitive parameters being unnecessarily large, and/or higher manufacturing costs due to the tolerances allocated to the insensitive parameters being unnecessarily tight. Displacement equation of the quick-return shaper mechanism defines the functional dependence between the motion of the shaper ram (3), determined by the horizontal displacement of pin C (xC), and the motion of the input crank (1): l cos . (1) x C = (l 0 + k ) 1 l 0 + l1 sin Considering tolerances on link-lengths,the actual lengths of the links deviate from the nominal: li act = li nom + li. This dimensional variation of link-lengths affects the output:
x Cact = x Cnom + x C = x * (l 0 + l 0 , l1 + l1 , k + k ) . (2) C If the tolerances are much smaller than the structural parameters ti << li, the differential of the displacement equation of the quick-return shaper mechanism (1) may be written as:
x C act =
i =1 n

u
2

-1

-2

50

100

150

200

250

300

[]

350

Fig. 2. Sensitivity coefficients to link-length tolerances of the quickx C x C x C (----) return shaper mechanism: (), (), l1 l 0 k

x C nom l i

l i act

(3)

where x C nom is the partial derivative of the output (xC) with li respect to the ith parameter. This partial derivative is proportional to the change in xC due to a change in li (3) and therefore is a measure of the sensitivity of the output to small deviation in that parameter (sensitivity coefficient). The dimensionless values of partial derivatives x C nom in the operating range of the quick-return shaper li mechanism are plotted in figure 2. Output (xC) has different sensitivity to the errors in length of different links. Magnitude of the sensitivity coefficients for a component dimension indicates the relative importance

and influence of that dimension on the variation in the output. The plotted curves (figure 2) show that the output is most sensitive to the tolerancing of parameter l1 and less (approximately equal) sensitive to the tolerancing of parameters l0 and k. Consequently the smallest allowable deviation is in the parameter l1, and therefore stricter tolerance on l1 is demanded. The plotted curves (figure 2) show that in the positions of the mechanism when the crank (1) and the frame of the inverted slider-crank mechanism A0B0 are collinear (=90o and =270o), the values of all 3 sensitivity coefficients are zero and the output in these positions of the mechanism is not sensitive to the tolerancing of this structural parameters. The values of the sensitivity coefficients to link-length tolerances (figure 2) reach extreme values near the limiting positions of this mechanism (=202o and =338o), when the driving crank (1) is perpendicular to the pivoted lever (2). Figure 3 shows values of the sensitivity coefficients in the right limiting position of this mechanism.
2

x C l1

x C k
x C l 0

Fig. 3. Sensitivity coefficients to link-length tolerances on the shaper ram position xC in the right limiting position of the shaper mechanism

12th IFToMM World Congress, Besanon (France), June18-21, 2007

Sensitivity coefficient to link-angle tolerance for angle =900 (angle between the frame of the inverted slidercrank mechanism A0B0 and the rectilinear path of the pin C) reaches extreme values (figure 4) near the limiting positions of this mechanism too (=-22o).

The total mechanical error in the output is therefore the sum of the individual errors due to each of the parameters considered separately. The Eq. (5) shows the relative effect of each of the individual tolerances on the output. By assigning stringent values of tolerances, one may get the ram stroke quite close to the desired one. It is desirable to give as much of tolerance as possible so as to keep the manufacturing costs low. The mechanical stroke error will now be evaluated when a flat (rough) manufacturing tolerances of ti=0,2 mm for lengths l1, l0 and k and = 0,3o for link angle =900 are assigned (table I). The mechanical error xCact can be computed by entering the dimensional variation into Eq. (5). This can be used to determine whether the allowable output-dimension limits can be achieved with these manufacturing tolerances. structural parameter crank length l1 frame length l0 distance k angle nominal dimension 150 mm 400 mm 250 mm 90o tolerance 0,2 mm 0,2 mm 0,2 mm 0,3o

Fig. 4. Sensitivity coefficient to link-angle tolerance

x C

We can apply this sensitivity analysis not only to quickreturn shaper mechanism, but also to all other applications of the same kinematic scheme.

TABLE I. Nominal dimensions of the quick-return shaper mechanism and the assigned tolerances

III. Mechanical error

The difference between the actual (2) and the nominal output-dimension (xCnom) is the mechanical error in the function generation:
x C = x * (l 0 , l1 , k ) . C

(4)

Once tolerances on link-length of the linkage are known, the total error in the output can be evaluated. By expanding the right-hand side of Eq. (4) in Taylor series and neglecting the terms having order three and above, we obtain the expression for the mechanical error considering tolerances on link-length [6]:
x C =
i =0 2

x Cnom 1 2 2 2 x Cnom l i act + l j act l i act 2 j=0 i=0 l j l i l i

(5)

where 2 x Cnom is the partial derivative of the second order. l j li The terms in Taylor series expansion having order three and above could be neglected without appreciable loss of accuracy. This assumption is valid in the majority of cases. If in certain cases this introduces appreciable error, some other terms of the Taylor series expansion may be taken and suitable correction may be introduced.

The effect of practical manufacturing tolerances on the accuracy of the shaper ram position is analyzed by using a deterministic approach, based on the worst-case analysis of the individual tolerances (maximum output tolerance). The effects of these tolerances are presented in the form of mobility band for the linkage. The extreme deviation in output (xC) in the operating range of the quick-return shaper mechanism are computed using an existing software package, developed at IGM, Technical University (RWTH) Aachen, Germany [6]. This software has been written to analyze whether assembling a mechanism from components with dimensions at extreme tolerance limits (ti) or at certain values between the extreme tolerance limits leads to the maximum error in the output. Values of the sensitivity coefficients to crank-length (l1) and distance (k) tolerances in the right limiting position of the shaper mechanism are positive (figure 3). This means that these dimensions at upper tolerance limits (l1max and kmax) will cause in this mechanism position upper extreme mechanical error of the ram position and vice versa. Value of the sensitivity coefficient to frame-length (l0) tolerance in the right limiting position of the shaper mechanism is negative (figure 3). This means that this dimension at upper tolerance limit (l0max) will cause in this mechanism position lower extreme mechanical error of the ram position and vice versa. In figure 5 the generated output-function of the ideal linkage, i.e. the one without any error (solid line) and the extreme output deviations (dashed lines) governed by the

12th IFToMM World Congress, Besanon (France), June18-21, 2007

265

xC
264

263

Values of the sensitivity coefficients on the stroke error are twice as big as the values on the figure 3 (table II). The major portion of xC, and thereby of the shaper ram stroke error, is contributed by the tolerance on l1. structural parameter crank length l1 frame length l0 distance k
-10 -15 -20 -25

262

sensitivity coefficients on the stroke error +4.0806 [mm/mm] -0.72118 [mm/mm] +0.809 [mm/mm] +212.727 [mm/rad]

261

260

259

258

[]

-30

angle

Fig. 5. Upper and lower extreme mechanical error of the output xC (---) near the right limiting position of the shaper mechanism for tolerances of link-length li= 0,2 mm and link-angle = 0,3o

TABLE II. Sensitivity coefficients to link-length tolerances on the ram stroke error of the shaper mechanism

prescribed tolerances (upper and lower bound) are shown. In this paper we are considering the effects link-length and link-angle tolerancing have on the mechanical error of the shaper ram stroke: H= 2 l1 (l 0 + k )
2 2 l 0 l1

(6)

Subtraction of the shaper ram position errors in the right and left limiting positions of this mechanism determines the ram stroke error. This error defines ram displacement accuracy between two discrete mechanism positions. It makes the most sense to analyze the mechanical error of the ram stroke of the shaper mechanism not only since the stroke is a main functional output parameter, but also because of the greatest mechanical error near the limiting positions of this mechanism (figure 6).
1.2 1.0 0.8 0.6 0.4 0.2

The prescribed tolerances introduce appreciable mechanical error. The maximum variation in shaper ram stroke (H) for assembling the mechanism from components manufactured within prescribed tolerances is Hmax 4,472 mm. When the same tolerance on link-length (ti = 0,2 mm) but zero-tolerance for link angle =90o (=0) are assigned, the maximum variation in ram stroke (H) would be nearly half as the previous value: Hmax 2,2434 mm. It follows that the influence of the angle variation is much greater than the influence of the link-length variation. Since the limits of the mobility band (figure 5) are a result of a particular combination of tolerances (selecting the worst combination of tolerances), and since the mechanism members are likely to be received from the manufacturer with their dimensions following some sort of a statistical pattern, it can be concluded that the variation in shaper ram stroke could deviate significantly less than in the worst-case.

IV. Conclusion
In this paper the mechanical error of the quick-return shaper mechanism has been analyzed. Analysis is presented to show the effects link-length and link-angle tolerancing have on the shaper ram stroke error, as well as sensitivity coefficients to link-length and link-angle tolerances. It was observed that the output being most sensitive to the link-length tolerancing near the limiting positions of this mechanism; in these positions is therefore the greatest mechanical error in the output. The effect of practical manufacturing tolerances on the accuracy of the output is analyzed by using deterministic approach, based on the worst-case analysis of the individual tolerances (maximum output tolerance). The

xC

0.0 -0.2 -0.4 -0.6 -0.8 -1.0 -1.2 -80 -60 -40 -20 0 20 40 60 80

[]

Fig. 6. Upper () and lower (---) extreme mechanical error of the output near the right limiting positions of shaper mechanism for tolerances of link-length li= 0,2 mm and link-angle = 0,3o

12th IFToMM World Congress, Besanon (France), June18-21, 2007

effects of these tolerances are presented in the form of mobility band for the linkage. It was observed that the influence of the perpendicularity variation of the frame of the inverted slider-crank mechanism A0B0 and the rectilinear path of the pin C is much greater than the influence of the linklength variations. We can apply this sensitivity analysis not only to quickreturn shaper mechanism, but also to all other applications of the same kinematic scheme.

References
[1] Pavlovi N.D. Analysis of Mechanical Error in Function Generating Mechanism. In Proc. of the 11th World Congress on TMM, Vol. 3, pages 12401244, Tianjin, China, April 1-4, 2004. [2] Pavlovi N.D. Vergleichende Analyse von Entwurfsmethoden fr Fhrungsmechanismen. In Tagungsband des 47. Internationales wissenschaftliches Kolloquiums TU Ilmenau, pages 322323, Ilmenau, Germany, 2002. [3] Pavlovi N.D. Gelenkspielanalyse an einem ebenen Punktfhrungsmechanismus. In Festschrift zum Ehrenkolloquium anlsslich der Emeritierung von Univ.-Prof. Dr.-Ing habil Dr.h.c. Gnter Hhne und Univ.-Prof. Dr.-Ing. habil. Hans-Jrgen Schorcht, pages 207209, Ilmenau, Germany, May 2005. [4] Jovanovi M. and Pavlovi N. Optimization of a Portal Jib Crane Mechanisms. In Proc. of the 9th World Congress on TMM, Vol. 1, pages 101105, Milano, Italy, August 29/September 2, 1995. [5] Chatterjee G.B. and Mallik, A.K. Mechanical Error of a Four-Bar Linkage Coupler Curve. Mechanism and Machine Theory, 22(1):8588, 1987. [6] Hsing, M. Toleranzuntersuchung ebener mehrgliedriger Kurbelgetriebe hinsichtlich ihrer bertragungsfunktionen, Ph.D. Dissertation, RWTH Aachen, Germany, 1995. [7] Dhande S.G. and Chakraborty, J. Analysis and Synthesis of mechanical error in linkages - a stochastic approach. Trans. ASME, J. Engng. Ind., 95B:672676, 1973. [8] Mallik, A.K. and Dhande, S.G. Analysis and Synthesis of Mechanical Error in Path-Generating Linkages Using a Stochastic Approach. Mechanism and Machine Theory, 22(2):115123, 1987. [9] Shi, Z. Synthesis of Mechanical Error in Spatial Linkages Based on Reliability Concept. Mechanism and Machine Theory, 32(2):255 259, 1997. [10] Dittrich G. Maschinendynamik II, Lehrmaterialien, RWTH Aachen, Germany