Geneva Mechanism (AFNAN) (1) - 4
Geneva Mechanism (AFNAN) (1) - 4
Introduction
o Equipped with a pin (or multiple pins) that engages with the slots in the driven
wheel.
o Have slots (commonly four or five) that the driving pin engages with. The
number of slots determines the number of discrete steps the driven wheel makes.
o Ensures that the driven wheel remains stationary between the steps, providing
stability and preventing any unintended motion.
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Operational Function
Engagement:
• As the driving wheel rotates, the drive pin enters one of the slots in the driven wheel.
• This engagement causes the driven wheel to rotate a precise amount.
Rotation:
• The drive pin continues to move within the slot, forcing the driven wheel to rotate.
• The amount of rotation is determined by the geometry of the mechanism and the
number of slots.
Disengagement:
• Once the drive pin reaches the end of the slot, it disengages from the driven wheel.
Dwell Period:
• During the remaining rotation of the driving wheel, the locking disk on the driving
wheel engages with the outer edge of the driven wheel.
• This locking action holds the driven wheel stationary, creating the dwell period.
Repetition:
• The cycle repeats as the drive pin engages with the next slot, producing the
intermittent motion.
Purpose:
The primary purpose of a Geneva mechanism is to provide precise, intermittent motion. This
is valuable in applications where:
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1.2. History and Applications of Geneva Mechanisms
History:
Applications:
The Geneva mechanism's ability to produce precise intermittent motion has led to its use in a
wide variety of fields:
• Film Industry:
o A classic application is in film projectors and cameras, where it precisely
advances the film frame by frame.
o This ensures that each frame is held stationary for projection, creating a
smooth visual experience.
• Manufacturing and Automation:
o Indexing tables: Used in assembly lines and machining to accurately position
workpieces.
o CNC machines: Employed in tool changers for precise tool selection.
o Automated assembly lines: Integral to processes requiring precise, step-by-
step movement.
o Counting machines: Used for accurate counting of items.
• Mechanical Watches:
o As mentioned, it was initially used to prevent over winding of watch springs.
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• Other Applications:
o Plotters: Used in pen-switching mechanisms.
o Various forms of index able equipment
Key Components:
1. Filament Spool:
o Contains the thermoplastic filament (e.g., PLA, ABS) that will be used to
build the object.
2. Extruder:
o Heats the filament to its melting point.
o Pushes the melted filament through the nozzle.
3. Nozzle:
o A small opening that precisely deposits the melted filament onto the build
platform.
4. Build Platform:
o A surface where the object is constructed. It can be heated to improve
adhesion.
5. X-Y-Z Axes:
o Motors that move the nozzle and/or the build platform along the X, Y, and Z
axes to create the desired shape.
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The Printing Process
1. Design
• CAD Model:
o The process begins with creating a 3D model using Computer-Aided Design
(CAD) software. This digital design serves as the blueprint for the printed
object.
2. Slicing
• Slicing Software:
o The CAD model is imported into slicing software, which converts the design
into a series of thin horizontal layers. The software generates G-code, which
contains instructions for the 3D printer, including the path of the extruder and
the speed.
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3. Preparation
• Printer Setup:
o The 3D printer is prepared by loading the filament (thermoplastic material)
into the extruder. The build platform is leveled, and any necessary adjustments
are made to ensure optimal print quality.
4. Printing
• Layer-by-Layer Construction:
o The printer heats the filament until it becomes pliable. The extruder nozzle
deposits the melted material layer by layer onto the build platform, following
the path defined by the G-code.
o The printer head moves along the X and Y axes to create the shape of each
layer, while the build platform lowers (or the nozzle raises) after completing
each layer, allowing the next layer to be deposited on top.
5. Cooling
• Solidification:
o As the material is extruded, it cools and solidifies, bonding with the previous
layer. Cooling fans may be used to accelerate this process and improve print
quality.
6. Post-Processing
• Finishing Touches:
o Once the print is complete, the object is carefully removed from the build
platform. Depending on the application, post-processing steps may include
sanding, polishing, or painting to achieve the desired finish.
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Advantages:
• Cost-Effectiveness:
o FDM printers and materials are generally more affordable than other 3D
printing technologies, making it accessible to hobbyists and small businesses.
• Material Variety:
o A wide range of thermoplastic filaments is available, offering diverse
properties like flexibility, strength, and temperature resistance.
• Ease of Use:
o FDM printers are relatively easy to operate and maintain, with user-friendly
software and readily available resources.
• Scalability:
o FDM can be used for both small-scale prototyping and larger production
runs.
• Relatively fast print times for some applications:
o For larger less detailed parts, FDM can produce those parts relatively quickly.
Limitations:
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• Fine Detail:
o FDM is not the best choice for very fine detail. other printing processes like
SLA or resin printing are better suited for that type of work.
• Warping:
o Certain materials, like ABS, are prone to warping, which can distort the final
print.
Fused Deposition Modeling (FDM) is a widely used 3D printing technology with a broad
range of applications across various industries. Here's a breakdown of its key uses:
Applications of FDM
1. Prototyping
o Rapid Prototyping:
▪ FDM is widely used for creating functional prototypes quickly. This
allows designers and engineers to test and refine their designs before
mass production.
o Iterative Design:
▪ Prototypes can be easily modified and reprinted, enabling iterative
design processes.
2. Education
o STEM Education:
▪ FDM 3D printers are popular in schools and universities for teaching
concepts in science, technology, engineering, and mathematics
(STEM). Students can learn about design, manufacturing, and
problem-solving.
o Project Development:
▪ Used in educational projects and competitions, providing hands-on
experience with 3D printing technology.
3. Healthcare
o Medical Models:
▪ FDM is used to create anatomical models for surgical planning and
medical education. These models help surgeons practice procedures
and improve patient outcomes.
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o Assistive Devices:
▪ Customized prosthetics and orthotic devices can be 3D printed to fit
individual patients' needs.
4. Manufacturing
o Tooling and Fixtures:
▪ FDM is employed to create custom jigs, fixtures, and tooling
components for manufacturing processes. This reduces production time
and costs.
o Small-Batch Production:
▪ Ideal for producing small batches of parts, especially when traditional
manufacturing methods are cost-prohibitive.
5. Consumer Goods
o Customized Products:
▪ FDM allows for the creation of personalized items such as phone
cases, jewelry, and home decor. Consumers can design and print
unique products.
o Replacement Parts:
▪ Broken or missing parts can be easily replaced by printing new ones,
extending the life of products.
6. Automotive and Aerospace
o Functional Parts:
▪ FDM is used to produce functional components for vehicles and
aircraft. These parts can undergo testing and evaluation before being
implemented.
o Lightweight Structures:
▪ The ability to print complex geometries allows for the creation of
lightweight structures, improving fuel efficiency.
7. Art and Design
o Sculptures and Models:
▪ Artists and designers use FDM to create intricate sculptures, models,
and design pieces. The technology enables the realization of complex
and imaginative works.
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8. Research and Development
o Experimental Prototypes:
▪ Researchers use FDM to develop experimental prototypes for various
studies and innovations. It provides a cost-effective way to test new
ideas.
While traditional manufacturing methods can produce Geneva mechanisms, they often
involve complex machining and assembly processes. This project addresses the need for a more
efficient and accessible approach to creating functional Geneva mechanisms. By leveraging
FDM 3D printing, we aim to demonstrate the feasibility of producing a precise and operational
Geneva mechanism with reduced manufacturing time and cost. Furthermore, this project
explores the potential of 3D printing to create customized and optimized Geneva mechanisms
for specific applications.
• To design and model a functional Geneva mechanism suitable for FDM 3D printing.
• To fabricate the Geneva mechanism using FDM 3D printing technology.
• To evaluate the performance and accuracy of the 3D printed Geneva mechanism.
• To document the design, fabrication, and testing processes comprehensively.
• To explore the applications of 3D printed Geneva mechanism.
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2. Review of Literature
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2.2. Review of 3D Printing Applications for Mechanical Components
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3. Methodology
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Detailed Slot Geometry Design for Backlash Minimization (Using Curved Slots):
1. Engagement and Disengagement Points: Precisely determine the points where the
driving pin enters and exits the slot. These points are defined by the geometry related
to the center distance (C), Geneva wheel radius (R_g), and indexing angle (θ).
2. Circular Arc Slot Walls:
o Entrance Arc: Design the entrance of the slot with a circular arc that
smoothly guides the pin into the slot as the driving wheel rotates. The radius
of this arc and its center point should be carefully chosen to match the pin's
approach path.
o Exit Arc: Similarly, design the exit of the slot with a circular arc that allows
for smooth disengagement of the pin.
3. Slot Base: The base of the slot (the part that engages with the pin during indexing)
can be straight or slightly curved, depending on the desired motion characteristics.
For backlash minimization, ensuring a close fit with the pin in the indexing phase is
important.
4. Clearance and Tolerances: While aiming for minimal backlash, you must still
incorporate manufacturing tolerances and a small amount of clearance to prevent
jamming and ensure smooth operation. However, minimize excessive clearance that
leads to backlash.
• Layer Adhesion:
o FDM builds parts layer by layer, and the strength of the bond between these
layers can vary. This is a crucial concern for a Geneva mechanism, which
experiences repeated stress and impact.
o Impact: Weak layer adhesion can lead to premature failure of the mechanism,
especially in the drive pin and the slots of the Geneva wheel.
o Design Adjustments:
▪ Orient the parts during printing to minimize stress on layer lines.
▪ Increase wall thickness and infill density for added strength.
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▪ Consider post-processing techniques like chemical vapor smoothing to
improve layer bonding.
• Dimensional Accuracy:
o FDM printers have tolerances, and achieving precise dimensions can be
challenging. This is critical for a Geneva mechanism, where tight tolerances
are necessary for smooth operation.
o Impact: Inaccurate dimensions can cause binding, excessive play, and
inconsistent indexing.
o Design Adjustments:
▪ Design with generous clearances between moving parts to account for
dimensional variations.
▪ Calibrate the printer carefully and perform test prints to determine the
actual dimensions produced.
▪ Consider post-processing like sanding or machining to achieve precise
dimensions.
• Surface Finish:
o FDM prints have visible layer lines, resulting in a rough surface finish. This
can increase friction and wear in a Geneva mechanism.
o Impact: Increased friction can lead to premature wear and reduced efficiency.
o Design Adjustments:
▪ Minimize layer height for a smoother surface.
▪ Use post-processing techniques like sanding or chemical vapor
smoothing.
▪ Consider using lubricants to reduce friction.
• Anisotropy:
o The strength of a FDM printed part is not equal in all directions.
o Impact: Geneva mechanisms have forces applied in multiple directions, so
this can cause weak points.
o Design Adjustments:
▪ Carefully consider the orientation of the part during printing to
maximize strength in the directions of the applied forces.
▪ Design with rounded corners and fillets to reduce stress concentrations.
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PLA Material Properties and Their Impact:
• Layer Adhesion:
o As with all FDM prints, layer adhesion is a concern. PLA generally has good
layer adhesion, but it can still be a weak point.
o Impact on Design:
▪ Part orientation during printing is critical. Orient the parts so that the
layers are aligned with the direction of the applied forces.
▪ Increase wall thickness and infill density to improve layer bonding.
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• Dimensional Accuracy:
o PLA is relatively easy to print with, but dimensional accuracy can still be
affected by factors like temperature and printer calibration.
o Impact on Design:
▪ Design with generous tolerances, especially for moving parts.
▪ Test prints are essential to determine the actual dimensions produced
by the printer.
• Surface Finish:
o PLA produces a relatively smooth surface finish, but layer lines are still
visible.
o Impact on Design:
▪ While PLA's surface is relatively smooth, any friction can cause wear
over time. So consider lubrication.
▪ If a very smooth surface is required, post-processing techniques like
sanding or chemical vapor smoothing can be used.
• Reinforcement:
o Reinforce critical areas like the drive pin and slots.
• Stress Reduction:
o Use rounded corners and fillets to reduce stress concentrations.
• Tolerance:
o Design with generous tolerances to account for dimensional variations.
• Friction Reduction:
o Minimize friction to prevent wear and heat buildup.
• Orientation:
o Carefully consider part orientation during printing to maximize strength.
• Software Selection: Solid Edge software is used to create a 3D model of the Geneva
mechanism.
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• Parametric Modeling: Equations or formulas are used allow for easy adjustments to
design parameters.
• Assembly Modeling: Assembly model is created in software to verify the fit and
functionality of the individual components.
• STL File Generation: 3D model is exported as an STL file, the standard file format
for 3D printing.
PLA material is selected as the model is used for demonstration purpose only. With less
infilling it gives enough tensile strength, impact resistance to model at lower temperatures of
melting.
The FDM printing process will be optimized to achieve the desired accuracy and surface
finish. This will involve:
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4. Design and Calculations
Input:
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Drive pin diameter, p = 4.7 mm
Output:
Stop arc radius, y = a-(p*1.5) = 22.339, modified value = 29.389- 4.7 = 24.689 mm
Stop disc radius, z = y-t = 22.039, modified value = 24.689 – 2*0.3 = 24.089 mm
This section will outline the steps taken to create the 3D model of the Geneva mechanism.
Drive Wheel:
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• Extrude bigger circle to 5mm and smaller circle to 10mm. Again, extrude profile for
10mm.
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Driven wheel:
• Extrude circle of diameter 80.9mm to 5mm. Select profile to cut. Use pattern command to
create 5 items.
• Select above surface, draw 10mm diameter circle and extrude 10.6mm.
• Select above surface, draw 6.8mm diameter circle and extrude 1.2mm.
• Select above surface, draw 10mm diameter circle and extrude 13.2mm.
Shaft:
• Select above surface, draw 10mm diameter circle and extrude 10.6mm.
• Select above surface, draw 6.8mm diameter circle and extrude 1.2mm.
• Select above surface, draw 10mm diameter circle and extrude 13.2mm.
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• Select above surface,Draw a square of 5mm and extrude 8mm.
Crank:
• Extrude to 4mm.
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Handle:
• Select top plane. Draw a circle of 12mm diameter and extrude 27mm.
• select top surface, draw circle of 4.2mm diameter and cut to 25mm.
Foot:
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Column:
Pin:
• Extrude 10mm circle, 2mm height and on top of it extrude 2 mm circle, 20mm height.
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Assembly Modeling :
• Open assembly environment and add parts foot and column. Use Flash fit relationship to
place parts in position.
• Add driven wheel and use Axial align and mate options to assemble.
• Add drive wheel and shaft and use axial align, mate to assemble along with driven wheel.
• As with same relationships, assemble crank, handle and pin to complete assembly.
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5. Experimental Setup:
The QIDI Tech Q1 Pro is an FDM (Fused Deposition Modeling) 3D printer that has garnered
attention for its high-speed capabilities and advanced features. Here's a breakdown of its key
specifications and characteristics:
Key Features:
• High-Speed Printing:
o The Q1 Pro boasts a maximum print speed of up to 600mm/s and an
acceleration of 20000mm/s². This is achieved through its CoreXY structure
and independent dual Z-axis motors.
• Active Chamber Heating:
o It features an actively heated chamber, capable of reaching up to 60°C. This is
crucial for printing temperature-sensitive filaments like ABS, PA, and PC, as
it helps prevent warping and improves layer adhesion.
• Full-Auto Calibration:
o The printer incorporates automated dual sensors for precise auto-leveling,
simplifying the setup process and ensuring reliable first layers. It also has auto
Z offset measuring.
• Material Compatibility:
o The Q1 Pro is designed to handle a wide range of filaments, including:
▪ PLA, PETG, TPU, PVA, PET
▪ ABS, ASA, PA, PC
▪ Carbon fiber and glass fiber-filled filaments
o It has a 350°C bimetal nozzle.
• Smart Detection:
o It includes intelligent features like a Hall filament run out sensor and filament
tangle detection, which help prevent print failures.
• Connectivity and Monitoring:
o The printer is equipped with a 1080P HD camera for real-time monitoring and
time-lapse recording.
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o It offers Wi-Fi and Ethernet connectivity, and it is also able to be controlled
via a mobile app.
• Build Volume:
o The build volume is 245 x 245 x 240 mm.
• Software:
o It is based on Klipper firmware, allowing for custom optimization.
o It is compatible with QIDI Slicer, Orca Slicer, Cura, and PrusaSlicer.
Specifications Summary:
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PRINT SETTINGS
PRINT FOLDER
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PRINTER INTERFACE
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PRINTER SETTINGS
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Filament:
Solid Edge:
• Part Modeling:
o This is where users create individual 3D components. Solid Edge's
synchronous technology plays a significant role here, allowing for flexible and
efficient part design.
o Within part modeling, there are different approaches, such as ordered
modeling (historical, parametric) and synchronous modeling (direct, history-
free).
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• Assembly Modeling:
o This area is for assembling individual parts into larger assemblies. Users
define relationships and constraints between parts to simulate real-world
mechanisms.
o Solid Edge excels at handling large assemblies, allowing users to work
efficiently with complex designs.
• Drafting:
o This environment is for creating 2D engineering drawings from 3D models.
Users can generate various views, add dimensions, and create detailed
documentation.
• Sheet Metal:
o Solid Edge has dedicated tools for designing sheet metal parts, including
features for creating bends, flanges, and other sheet metal features
Simulation:
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Key Concepts:
• Synchronous Technology:
o This is a core feature of Solid Edge that allows for a more flexible and
intuitive design process. It blends the speed of direct modeling with the
control of parametric design.
• Cloud Capabilities:
o Solid Edge is increasingly offering cloud-based capabilities, enhancing
collaboration and accessibility.
QIDI Studio has hundreds of slicing parameters, which are used to adjust the behavior of the
slicer process to produce desired printing effects. These parameters are divided into three
categories: printer, filament and process.
In a category, once values for all parameters have been set, it can be saved as a parameter
preset. For ease of use, QIDI Studio provides some built-in presets for each category. Most of
the time, you can easily select presets according to your requirements to meet basic slicing
needs.
Printer presets:
Before slicing, please configure the correct machine model and nozzle type based on your
printer.
The printer preset includes all hardware settings of the printer, such as maximum print speeds
for each axis, print area limitations, and nozzle diameter.
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Filament presets:
Before slicing, you need to select the correct filament type parameters based on the filament
you are using to print the model. Different types of filament require different parameter
settings. Selecting the wrong settings can lead to a high risk of print failure.
Filament presets contain all of the filament-specific settings, such as print temperature,
hotbed temperature, and flow ratio.
Process presets:
You can choose corresponding parameter settings here based on your printing needs. The
number in front represents the layer height. A smaller layer height results in finer models.
The default is 0.2mm standard parameter.
The profile contains all settings for specific printing tasks, where you can adjust parameters
such as quality, strength, speed, supports, etc.
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6. Fabrication and Assembly
• STL Export: STL (Stereo lithography) is the most common file format for 3D
printing. It represents the 3D model as a mesh of triangles.
o In Solid Edge, open your 3D model.
o Go to File > Save As.
o In the "Save As" dialog box:
▪ Choose STL (*.stl) from the "Save as type" dropdown menu.
▪ Click the Options button to configure STL export settings.
▪ STL Export Options:
• Conversion Tolerance: Controls the accuracy of the STL mesh. A lower value results
in a more accurate mesh but increases file size and processing time. Adjust this based
on the complexity and detail of your model. A common range is 0.01mm to 0.1mm.
• Angle Tolerance: Defines the maximum angle between facets in curved areas. Lower
values create smoother curves but increase mesh density.
• Surface Plane Tolerance: Controls the deviation of flat surfaces. Lower values
improve flatness but increase mesh complexity.
• Coordinate System: Ensure the coordinate system is appropriate for your 3D printer.
Typically, the Z-axis is set as the vertical build direction.
• Output: Select "Binary" for a smaller file size, which is generally preferred.
▪ Click OK to save the STL export options.
▪ Choose the desired file location and name, then click Save.
• STEP Export: STEP (Standard for the Exchange of Product Data) files are CAD-
neutral, solid model files. While less directly used for 3D printing, they are excellent
for archiving, sharing, and potentially for advanced workflows.
o In Solid Edge, open your 3D model.
o Go to File > Save As.
o In the "Save As" dialog box:
• Choose STEP AP203/214/242 (*.stp, *.step) from the "Save as type" dropdown menu.
Select the appropriate STEP Application Protocol (AP) based on your needs (AP203 is
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common for General CAD, AP214 for automotive, AP242 for managed model-based
3D engineering). AP242 is generally recommended for its comprehensive nature.
• Click Options if you need to configure specific STEP export settings (usually defaults
are sufficient for basic use).
• Click OK to save the STEP export options.
• Choose the desired file location and name, then click Save.
Once you have exported the STL file, you need to prepare it for printing using specialized
software, often called a slicer. Slicers convert the 3D model into layers and generate machine
code (G-code) that your 3D printer can understand.
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o Sometimes, STL files can have errors (non-manifold geometry, holes, flipped
normals) that can cause printing issues.
o Slicer software often has built-in mesh repair tools that can automatically fix
minor errors.
o For more complex repairs, you might need dedicated mesh repair software
like:
▪ Mesh mixer (Autodesk - free, but no longer actively developed)
▪ Mesh Lab (Free and open-source)
▪ Netfabb Basic (Autodesk - free for personal use)
o Use these tools to:
▪ Check for Errors: Identify issues like open edges, flipped normals,
and self-intersections.
▪ Repair Mesh: Use automatic or manual repair functions to fix
identified errors.
▪ Simplify Mesh (Optional): Reduce the triangle count if the mesh is
excessively dense and causing performance issues, though this can
reduce detail.
• Generate Support Structures (If Needed):
o If your model has overhanging features (parts that print in mid-air), you'll need
to generate support structures.
o Slicer software offers various support types (e.g., tree supports, linear
supports) and settings to control:
▪ Support Density: How dense the support structure is. Higher density
provides more support but uses more material and can be harder to
remove.
▪ Support Overhang Angle: The angle at which supports start to be
generated.
▪ Support Placement: Control where supports are generated (e.g.,
everywhere, only touching the build plate).
▪ Support Interface: A denser layer between the support and the model
for better support but potentially harder removal.
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• Slicing and G-code Generation:
▪ Slicing Settings: Configure printing parameters within the slicer. These
are crucial for print quality and success and depend on your printer,
material, and desired outcome. Key settings include:
▪ Layer Height: The thickness of each printed layer. Lower layer heights
result in finer details and smoother surfaces but increase print time.
Common values are 0.1mm to 0.3mm.
▪ Infill Density: How solid the interior of the model is. Higher infill
increases strength and weight but uses more material and time. Common
ranges are 15% to 25% for general parts, higher for structural parts.
▪ Infill Pattern: The internal structure pattern (e.g., grid, gyroid, cubic).
Different patterns offer varying strength and print time characteristics.
▪ Wall/Perimeter Thickness: The number of outlines (walls) around the
model's perimeter. More walls increase strength and surface quality.
▪ Print Speed: The speed at which the printer moves. Slower speeds
generally improve quality but increase print time.
▪ Print Temperature: Temperature of the nozzle and build plate,
material-dependent.
▪ Bed Adhesion: Settings to improve the first layer's adhesion to the build
plate (e.g., brim, raft, skirt).
▪ Generate G-code: Once settings are configured, "slice" the model in
the slicer software. This process generates G-code, a numerical control
language that instructs the 3D printer on how to build the model layer
by layer.
▪ Preview: Use the slicer's preview function to examine the tool paths,
layers, and support structures before printing. This helps identify
potential issues.
• Save G-code:
o Save the generated G-code file to a format your 3D printer can read (usually
*.gcode or *.gco).
o Transfer the G-code file to your 3D printer (typically via SD card, USB, or
network connection).
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STEP files are primarily used for:
• Archiving and Sharing: STEP files are excellent for long-term storage and exchanging
CAD data because they are CAD-neutral and preserve the solid model information
accurately.
• Downstream CAD Editing: If you need to modify the 3D model in CAD software,
STEP files are ideal for importing and editing the solid geometry.
• Advanced Workflows (Less Common for Direct Printing): In some advanced
workflows, STEP files might be used in simulation or analysis before generating STL
for printing. Some specialized software might directly work with STEP data for
manufacturing preparation, but this is less typical for standard desktop 3D printing.
Filament Loading:
• The QIDI TECH Q1 Pro typically has an easy filament loading system.
• Prepare Filament: Ensure the filament end is cut at a sharp angle for smooth feeding.
• Load Filament:
o Navigate the printer's menu to the filament loading option.
o Follow the on-screen instructions to heat the nozzle.
o Insert the filament into the designated filament inlet until you feel it engage the
extruder gears.
o Continue feeding the filament until it extrudes smoothly from the nozzle.
Bed Leveling:
• Bed leveling is crucial for proper first-layer adhesion. The Q1 Pro often features
automatic bed leveling, but it's still important to understand the process.
• Automatic Bed Leveling:
o Navigate to the bed leveling menu on the printer's screen.
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o Initiate the automatic bed leveling process. The printer will use its sensor to
probe multiple points on the bed.
o The printer will automatically compensate for any bed irregularities.
• Manual Bed Leveling (if needed, or to verify):
o Some users may prefer to fine-tune the bed leveling manually, even after
automatic leveling.
o Use the printer's menu to move the nozzle to the home position.
o Place a piece of standard printer paper between the nozzle and the bed.
o Adjust the bed leveling knobs (if present) until the paper has slight resistance
when moved.
o Repeat this process at multiple points on the bed.
• Z-Offset:
o The Z-offset value is very important. It sets the distance between the nozzle and
the bed during the first layer.
o If the first layer is too close, the filament will be squished and may not adhere
correctly.
o If the first layer is too far, the filament will not adhere and will result in a poor
print.
o The QIDI printers have a process to adjust the Z-offset within the printer's
menu.
Nozzle Cleaning:
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o While the nozzle is hot, a brass brush can be used to clean the outside of the
nozzle.
Calibration Verification:
• After completing the setup and calibration, it's crucial to verify the results.
• First Layer Test Print:
o Print a simple first-layer test pattern. This pattern will typically consist of a
large, flat surface that allows you to visually inspect the first layer.
o Observe the first layer for any signs of over-extrusion, under-extrusion, or poor
adhesion.
o Adjust the bed leveling or Z-offset as needed.
• Calibration Cube:
o Print a calibration cube to verify the dimensional accuracy of the printer.
o Measure the dimensions of the cube and compare them to the expected values.
o Adjust the printer's settings (e.g., extrusion multiplier) as needed to achieve
accurate dimensions.
• Temperature Tower:
o Print a temperature tower. This print will print the same object multiple times,
each time at a different temperature. This allows you to visually see which
temperature produces the best result for the filament being used.
• Retraction Test:
o Print a retraction test. This test prints objects that show how well the printer
handles retractions. Retraction is when the printer pulls the filament back to
prevent stringing.
This test will help to dial in the correct retraction distance, and speed.
• Visual Inspection: Examine the print for consistent layer adhesion and smooth surfaces.
• Adjustments: If necessary, fine-tune the bed leveling, nozzle temperature, or filament feed
rate based on the test print results.
• Printing Parameters:
o layer height : 0.2 mm
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o infill density, : 20%
o sparse infill pattern : Grid
o Travel speed: 400 mm /s
o Normal printing: 3000 mm /s2
o Support type added : Normal
o Skirt loops: 2
o Fan speed: 100%
o Temperature : 2100 C
o 0.20 mm Standard @Q1Pro preset selected for generic PLA.
• Printing Process:
o Printing is done for all parts in one build. Models send to 3d printer through Wi-
Fi mode by connecting to laptop.
o Model Printing time : 2 h 29 m
o Total filament used : 21.21m(20.89 + 0.32m support) , 61.22g (60.28+ 0.94g
support)
o Model making material itself used as support material. In the image below green
color shows support material for two parts.
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• Post-Processing:
o The following post-processing steps taken to prepare the printed components
for assembly.
▪ Support structures are removed by hand or pliers.
▪ Deburring sharp edges using deburring tool.
▪ The parts are cleaned.
• Component Inspection:
o The inspection of the printed components is done using vernier calipers to
ensure they meet the required dimensions and tolerances.
• Assembly Procedure:
Foot → Column
Make proper cleaning of support structure in groove for shaft and driven
wheel parts. It is done with lot of patient using cutters and pliers.
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• Fit and Functionality Check:
Once assembly completed, crank handle rotated and verified smooth motion of
mechanism.
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7. Results and Discussion
• Visual Results:
o Printed model is visually good and has smooth surface finish. Only at supports
surface finish deteoriated
• Functional Performance:
• Manual Operation:
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• Indexing Accuracy:
• Dimensional Accuracy:
o Dimensions of printed parts are measured using vernier calipers.
o Deviation of ±0.05 is observed.
o Only for cut features dimension increased by tolerance value to get exact
dimensions.
• Tolerance Evaluation:
o Printing without considering tolerances causes tight fit which is not
removable. For entire model clearance of 1 to 2mm taken.
o Measured values using calipers to adjust if needed.
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7.3. Applications of the 3D printed Geneva Mechanism.
While using PLA for a Geneva mechanism might limit its use in heavy-duty industrial
applications due to PLA's inherent properties, there are still several real-world applications
where a 3D-printed PLA Geneva mechanism can be quite useful:
1. Educational Demonstrations:
• Low-Stress Automation:
o For prototyping automated systems with low-torque requirements, a PLA
Geneva mechanism can be used to test and validate design concepts.
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o This is especially useful in developing proof-of-concept models for light-duty
indexing systems.
• Hobbyist Projects:
o Many hobbyists and makers use 3D printing to create custom devices and
contraptions. A Geneva mechanism can be incorporated into projects requiring
precise, intermittent motion. Examples include:
▪ Automated display turntables.
▪ Simple automated toys or art installations.
▪ Custom timing mechanisms for small projects.
3. Light-Duty Indexing:
• Small-Scale Production:
o For very small-scale production or custom devices that require infrequent,
low-stress indexing, a PLA Geneva mechanism might suffice.
o This could include applications in custom jigs or fixtures for light assembly
tasks.
• Novelty Items and Displays:
o Geneva mechanisms can be used in novelty items, displays, or advertising
mechanisms where intermittent motion is desired.
o Because PLA is easy to print, it lends itself well to the creation of these kinds
of fun and interesting items.
1. Cost-Effective Prototyping:
o 3D printing allows for rapid and cost-effective prototyping, enabling designers
to test and refine their designs without the need for expensive tooling.
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2. Customization:
o 3D printing offers the flexibility to create customized parts tailored to specific
requirements, which is particularly useful for unique or low-volume
applications.
3. Complex Geometries:
o The ability to print complex geometries that may be difficult or impossible to
achieve with traditional manufacturing methods.
4. Reduced Weight:
o 3D printed parts can be designed with internal structures that reduce weight
without compromising strength.
Disadvantages:
1. Material Limitations:
o 3D printed parts are typically limited to thermoplastics, which may not have
the same mechanical properties as metals used in traditional manufacturing.
2. Surface Finish:
o The surface finish of 3D printed parts may require additional post-processing
to achieve the desired smoothness and precision.
3. Strength and Durability:
o 3D printed parts may have lower strength and durability compared to
traditionally manufactured parts, especially along the layer lines.
4. Dimensional Accuracy:
o Achieving high dimensional accuracy can be challenging with 3D printing,
and factors like warping and shrinkage need to be managed.
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3. Strength and Durability:
o Parts manufactured using traditional methods are generally stronger and more
durable, making them suitable for high-stress applications.
4. Precision:
o Traditional manufacturing methods can achieve high precision and tight
tolerances, which are essential for the proper functioning of the Geneva
mechanism.
Disadvantages:
1. Cost:
o Traditional manufacturing methods can be more expensive, especially for low-
volume production or prototyping.
2. Lead Time:
o The lead time for producing parts using traditional methods can be longer due
to the need for tooling and setup.
3. Complex Geometries:
o Creating complex geometries can be challenging and may require multiple
manufacturing steps or specialized equipment.
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8. Cost Estimation:
9. Conclusion
The project successfully demonstrated that FDM 3D printing is a viable method for designing
and fabricating a functional Geneva mechanism. The printed mechanism performed well,
showing accurate indexing and smooth operation. Challenges like dimensional accuracy were
managed effectively, and the chosen material provided sufficient strength. The study highlights
FDM's potential for cost-effective, functional prototyping, with future work recommended to
enhance performance and durability.
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10. References
• https://wiki.qidi3d.com/en/Q1-Pro
• "Geneva Wheel | PDF | Acceleration | Classical Mechanics - Scribd":
https://www.scribd.com/document/344163626/Geneva-wheel
• "Parametric Design and Motion Analysis of Geneva Wheel Mechanism Based on the
UG NX8.5 | Atlantis Press" : https://www.atlantis-press.com/article/25874056.pdf
• "DESIGN AND MANUFACTURING OF GENEVA MECHANISM USING
SOLIDWORKS AND CNC - IRJMETS" :
https://www.irjmets.com/uploadedfiles/paper//issue_10_october_2024/62081/final/fin
_irjmets1728377052.pdf
• "MULTI PURPOSE GENEVA MACHINE - IJCRT" :
https://ijcrt.org/papers/IJCRT2006466.pdf
• Manufacturer's datasheets for the specific 3D printer and filament used.
• Relevant CAD and slicer software documentation.
• Search terms like "3d printed indexing mechanisms" or "3d printed intermittent drive
systems" within academic search engines.
• Any relevant mechanical engineering textbooks or handbooks.
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DRAWINGS
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ASSEMBLY DRAWING
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