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Fitsum Moges 82266-07 PDF
Fitsum Moges 82266-07 PDF
Fitsum Moges 82266-07 PDF
Ins. Equbemariam
i. Acknowledgement
At first place I want to thank God. After that I would like to
acknowledge the support and politeness of my instructors Miss. Meron and
Mir equbemariam. I am grateful to all my friends for their suggestion,
comment and appreciable advice, especially to my dorm mates. After all I
appreciate all the peoples who support me.
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[Machine design project on bevel driven screw jack] December 20, 2017
ii. Abstract
As the name indicates Bevel driven screw jack is a screw jack that is
driven by a bevel gear. It has a various components that are integrated
together by different mechanisms for full operation of the machine. Bevel
driven screw jack have a various applications such as Paper industry, press
industry, printing industry, Gypsum factories, Sheet metal forming
machinery, Mechanical lifting applications, Platform lifting applications,
Food processing machinery, Construction sector, Mining industry, Lift tables
& Stage setup applications.
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iii. Objective
General objective
Specific objective
components
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Contents
1. INTRODUCTION ................................................................................................................................................ 6
1.1. General introduction ................................................................................................................................ 6
1.2. Basic Components of bevel driven screw jack ......................................................................................... 9
1.3. Working principle of bevel driven screw jack......................................................................................... 11
1.4. Material selection ................................................................................................................................... 12
1. Kinematic analysis of the system.................................................................................................................... 14
2. Design of Power Screws ................................................................................................................................. 16
2.1. Introduction ............................................................................................................................................ 16
2.2. Stresses on the power screw .................................................................................................................. 16
2.3. Design analysis........................................................................................................................................ 17
2.4. Material selection for power screw ....................................................................................................... 20
3. Design of Bevel Gear ...................................................................................................................................... 22
3.1. Introduction ............................................................................................................................................ 22
3.2. Stress in the bevel gear .......................................................................................................................... 22
3.3. Material selection ................................................................................................................................... 22
3.4. Design analysis........................................................................................................................................ 23
4. Design of Shaft................................................................................................................................................ 30
4.1. Introduction ............................................................................................................................................ 30
4.2. Stress in the shaft ................................................................................................................................... 30
4.3. Material selection ................................................................................................................................... 30
4.4. Design analysis........................................................................................................................................ 31
5. Design of fasteners ......................................................................................................................................... 38
5.1. KEY DESIGN ............................................................................................................................................. 38
5.1.1. Introduction .................................................................................................................................... 38
5.1.2. Stress in the KEY ............................................................................................................................. 38
5.1.3. Material selection ........................................................................................................................... 38
5.1.4. Design analysis................................................................................................................................ 39
5.2. Bolt design .............................................................................................................................................. 41
5.2.1. Introduction .................................................................................................................................... 41
5.2.2. Stresses on the power screw .......................................................................................................... 41
5.2.3. Design analysis................................................................................................................................ 41
5.2.4. Material of bolt ............................................................................................................................... 42
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6. Design of Handle............................................................................................................................................. 43
6.1. Material for the handle .......................................................................................................................... 43
6.2. Stress in the handle ................................................................................................................................ 43
6.3. Design analysis........................................................................................................................................ 43
7. Design of Nut .................................................................................................................................................. 47
8. Selection of Bearings ...................................................................................................................................... 48
8.1. Introduction ............................................................................................................................................ 48
I. Selection for the radial ball bearing ........................................................................................................... 48
8.2. Material selection ................................................................................................................................... 50
II. Design of collar bearing .............................................................................................................................. 50
9. Manufacturing methodology ......................................................................................................................... 52
a. Manufacturing methodology for screw and nut ........................................................................................ 52
b. Manufacturing methodology for Power screw .......................................................................................... 52
c. Manufacturing methodology for Bevel gear .............................................................................................. 52
d. Manufacturing methodology key ............................................................................................................... 52
e. Manufacturing methodology collar, body and base .................................................................................. 52
f. Manufacturing methodology for Washer................................................................................................... 53
10. Lubrication .................................................................................................................................................. 54
o Reference........................................................................................................................................................ 62
o Link.................................................................................................................................................................. 67
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1. INTRODUCTION
Machine design deals with the creation of machinery that works safely, reliably &
well. Machine Design is the innovation of new and effective machines or improving the
existing ones. In designing a machine component, it is necessary to have a good
knowledge of many subjects such as Mathematics, Engineering Mechanics, Strength of
Materials, Theory of Machines, Workshop Processes and Engineering Drawing. General
procedures of design are the following:-
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Since my design have modification of the existing designs into a new idea by
adopting a new material or different method of manufacture it can be said
development design. In addition in this design each component which may fail
during operation due to the applied force will be designed using different principles
and mathematical relations and this makes my design rational, empirical and
element design.
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First load will be applied on the handle. After that the handle will force the shaft
that drives the vertical bevel gear (driver gear) to rotate. The vertical gear mush with
the horizontal bevel gear and the nut starts to rotate. By the principle of inclined plane
the screw starts to lift as the nut starts to rotate.
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The selection of a proper material, for engineering purposes, is one of the most
difficult problems for the designer. The best material is one
which serves the desired objective at the minimum cost. The following factors should
be considered while selecting the material:
The properties of those materials and the reason why I select those materials will
be discussed on the next sections individually.
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If it is not true, there is no enough space for the screw inside the body of the jack for
the minimum lift. I.e. to attain the minimum lift the screw needs to go under the
ground and it is not possible.
Now we have 3 relations and four unknowns. To solve this let assume one of the
variables then calculate for the remains.
So let A = 10 mm
So we can take any value for D that is below 30 mm. D = 30 mm means there is no
clearance for the screw. (I.e. at the minimum lift the screw will touch the ground)
In this section we can get the required length of the screw “L” to attain the given
maximum and minimum lift.
Comment
From the above values I can say that the system is attainable.
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3.1. Introduction
The power screws (also known as translation screws) are used to convert rotary
motion into translation motion. In case of screw jack, a small force applied in the
horizontal plane is used to raise or lower a large load.
Different stresses are going to be induced when the load and the torque are
applied to power screw. The stresses that can be induced are:
Note: -
From the three threads (square, Acme or trapezoidal & Buttress) I select square thread
because square thread is more efficient than Acme and buttress thread.
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Assumptions
Since the dynamic load is smaller than the static load I can neglect the dynamic load
and only work with static load.
the load is uniformly distributed over the threads in contact
take Factor of safety F.S = 4
A little consideration will show that if one complete turn of a screw thread be imagined
to be unwound, from the body of the screw and developed, it will form an inclined
plane as shown in Figure below.
Where
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Since the load is being lifted, therefore the force of friction (F = μ.R N) will act
downwards
Resolving the forces along the plane (x) & perpendicular to the plane (y),
∑ ; RN = P sin α + W cos α
From the two equations by applying some mathematical method we will get,
∴ Torque required to raise the load (torque to overcoming friction between the screw
and nut)
Note: -
In machine design we can use two methods. The first one is specifying the size of our
machine components then we will calculate the maximum stress which will be induced
on the components. Based on the values we’ll select a material that is able to resist the
maximum induced stress. The second method is the reverse one. I.e. first we select the
material then we will determine the size. For the sake of simplicity I preferred the first
method to this machine component only.
Where
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( )
Where
When the screw is subjected to both direct stress and torsional shear stress, then the
design must be based on maximum shear stress theory, according to which maximum
shear stress on the minor diameter section.
√ √
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[ ( ) ]
Where
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[ ( ) ]
Comment
Since the screw will never buckle. Therefore the screw is safe for
buckling load.
Where
Then,
Now
Comment
The shear stress induced on the teeth of the power screw is greatly smaller than
the shear strength of the material. So the teeth are safe.
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4.1. Introduction
Bevel gears have teeth formed on conical surfaces and are used mostly for
transmitting motion between intersecting shafts.
But relative to the bending stress the compressive and shear stresses are very small so I
neglect them.
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Steel have higher strength than cast iron, but its cost per K.g is high and it
requires several conditioning process than cast iron after manufacturing process like
heat treatment. It makes the cost to increase to some extent. And cast iron has good
wearing properties, excellent machinability and ease of producing complicated shapes
by casting method, but its strength is lower than steel.
So to get the advantages of those two materials I select cast iron for the gear and
carbon steel for the pinion (because it needs stronger material). Using similar material
for the gear and pinion is a waste (I.e. we are adding excessive strength for the gear).
So from my material selection I can get the advantage of using steel (good strength)
and also the advantage of using cast iron (low cost) at the same time.
Assumptions
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a) Geometric analysis
Where
( ) ( )
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Where
b. Force analysis
Where
L is cone distance
Y’ Lewis factor for the equivalent number of teeth ( )
b face width
v peripheral speed in m/s
m Module
allowable stress
speed factor
According to Lewis law from the two gears the weaker one is identified by the value of
.
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By Solving the above equation using scientific calculator or MATLAB you will get
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Now
We have this relation to obtain the torque required at the pinion shaft to lift the load
From this
Where
But,
Where
√ √
But
Where
( )
Comment
Since the maximum wear load is much more than the tangential load on the
tooth, therefore the design is satisfactory from the standpoint of wear.
Comment
The dynamic load is less than both static and wear load. Therefore my design is
safe.
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⟾ =1 =2.75
⟾ Addendum angle
⟾ Dedendum angle
Where
“a” is Addendum,
“d” is Dedendum and
“t” is Thickness of the tooth
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5. Design of Shaft
5.1. Introduction
A shaft is a straight, mostly round bar, which is designed to have other rotating
parts of a mechanism mounted on it or to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque
(or twisting moment) set up within the shaft permits the power to be transferred to
various machines linked up to the shaft.
Based on those criteria’s I select carbon steel with ultimate tensile strength of
560 N/mm2 and yield strength of 320 N/mm2. Specific code of the material is 40 C 8
(Indian code). Property of the material is listed below,
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Assumptions
The shaft mass is negligible
Take factor of safety of 1.5
Uniform stress is induced
A person can apply a force of 300 – 400 N
the distance between the gear and the bearing Y=30 mm
a. Design on basis of strength
I Keep shafts as short as possible, with bearings close to the applied loads. This reduces
deflections and bending moments and increases critical speeds.
I used inexpensive steels for deflection-critical shafts, as all steels have essentially
the same elastic modulus.
Now let find the tangential force acted at the mean radius of the pinion
In order to determine the bending moment on the shaft let find the axial and radial
forces acting on the pinion shaft first.
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Where
√ √
Since the shaft is subjected to twisting moment (T) and bending moment (M) the
equivalent twisting moment will be
√ √
Then
→ → √
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Where
√ √
⁄ ⁄
√ ⁄
Comment
The diameter of the shaft that is obtained by using effective torque is higher than
by using effective moment. I.e. the shaft will fail by shear first. And in order to make
the design safe I need to take the larger ds = 11.387 mm.
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Where
⁄
⁄
⁄ Or per meter
Comment
For line shafts or transmission shafts, deflections 2.5 to 3 degree per meter
length may be used as limiting value. And since is less than 2.5o per meter my design
of shaft for rigidity is safe.
Since the two moments & are in different direction we can’t determine
the deflection of the shaft directly. Therefore let apply the principle of superposition.
That means calculate the deflection of the shaft due to each moment individually and
calculate for the resultant deflection.
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Here we can calculate constant of integration & by using the following boundary
conditions.
And
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∴ & ∴
Now the total deflection of the shaft will be equal with the resultant of the above two
deflections. Mathematically,
√ √
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Comment
This means the deflection of the shaft due to the tangential load
( is higher than the deflection due to the radial load ( . Therefore the effect of
the tangential load on the shaft is higher.
The value of the maximum deflection is and this value is very small
so my design will not have deflection problem.
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6. Design of fasteners
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Assumptions
I select gib-head sunk type of key for my system. Sunk keys are provided half in
the keyway of the shaft and half in the keyway of the hub or boss of the pulley. Since
the diameter of the shaft is 12mm we can know the cross section of the key.
w = t =5 mm
𝑙 & ⁄ 𝑙 ⁄
𝑙 & ⁄ 𝑙 ⁄
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From this
𝑙 𝑙 𝑒 𝑒
𝑙 𝑙 𝑙
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I select screw (Tap bolts) as fastener to join the housing with the base because
Screwed joints are highly reliable in operation, convenient to assemble and
disassemble, adapted to various operating conditions and Screws are relatively cheap
to produce due to standardization and highly efficient manufacturing processes.
There is no eccentricity (the load of the car is concentrated at the center of the
cap).
To remove the uncertainty due to the above assumption take a Factor of safety is
equal with 1.5
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The initial tension in a bolt, based on experiments, may be found by the relation
Where
Here like the power screw, I specify the size of the bolt then I select a material that can
support the induced initial stress.
I considered the M 7 bolt so that its core diameter and pitch will be 5.773 mm and 1
mm respectively.
⁄ ⁄
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7. Design of Handle
Assumptions
Take factor of safety as 1.5
Shear stress is negligible
assume F=300 N (handle force)
uniform stress (I.e. stress concentration is not considered)
The operator may not apply 300 N force that means the screw is subjected to higher
load (if the load is greater than 300 N and it is eliminated by the factor of safety that I
have taken previously) or the screw will not rise (if the load is less than 300 N and to
remove this uncertainty let increase the length of the handle to some extent).
Say
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Where
∑ ; But, F = 300 N
∑ ; But, x = 30 mm
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Since the shaft is subjected to twisting moment (T) and bending moment (M) the
equivalent twisting moment and equivalent bending moment will be
√ √
Now I obtain the maximum shear load and the maximum bending moment (that
is also shown on the diagram). I will design for the bending stress only because the
effect of shear load (shear stress) is very smaller and insignificant.
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√ ⁄
√ √
Now to make the design safe let take the larger diameter that will not cause
failure in both bending and shear.
Comment
The diameter obtained from the equivalent bending moment is lower than the
diameter obtained from equivalent torque. This indicates that the handle will fail in
shear first.
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8. Design of Nut
The purpose of the nut in my design is to lift the power screw up and
down. And it is manufactured with the gear. That means the gear will
have internal thread. Therefore it is made from grey cast iron and has
strength of 152 M.pa in ultimate. In the nut there is shear stress on the
teeth of the nut due to the external load. This stress is resisted by the
outer diameter cross section.
Let take a factor of safety of 4. Then the maximum shear stress that may appear in the
system will be 42.44 M.pa
Comment
is less than the material strength so the nut will not fail by the given applied
load.
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9. Selection of Bearings
9.1. Introduction
For my design I need two bearings which are radial bearing (bearing that support a
load acts perpendicular to the direction of motion of the moving element) for the
pinion shaft and thrust bearing (bearing that support a load acts along the axis of
rotation) at the nut or power screw.
I select ball bearing for the nut and the shaft because, it is Easy to mount and erect,
Low starting and running friction, Low cost of maintenance, as no lubrication is
required while in service and Reliability of service.
Assumption
For radial ball bearings, the basic static radial load rating (C0) is given by
Where
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Is a factor depending upon the type of bearing (f0 = 12.3, for radial contact
and angular contact groove ball bearings.)
∴ √
&
Where
V is a rotation factor (v = 1 for all types of bearings when the inner race is
rotating)
X is radial load factor
Y is axial or thrust load factor
is radial load
is Tangential load
is Equivalent dynamic load
Now by using the value of (Specification) & the condition 𝑒 we can read X & Y
from the table
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Where
[ ]
Now from the table radial ball bearing, we can obtain the bearing №. It is 201. It
indicates that the bore diameter = 12 mm, outer diameter = 32 mm and width = 10
mm.
It is assumed that the pressure is uniformly distributed over the bearing surface.
Where
The thickness of the collar “t” is kept as one-sixth diameter of the screw
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11. Lubrication
For the bearings in the system, we need a lubricant
to reduce friction and wear between the sliding parts of the bearing,
to prevent rusting or corrosion of the bearing surfaces,
to protect the bearing surfaces from water, dirt and
To dissipate the heat.
In general, oil or light grease is used for lubricating ball and roller bearings.
For this system I select mineral oil, because mineral oil is cheap and stable.
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Comment
There is slight red color at the end of ring like structure at which the shaft is inserted.
This indicates for the handle the maximum stress will occur on the red colored section.
And if there is over loading or possibility of failure, the part will fail on that section first.
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Comment
There is red color at the end the handle. This indicates the maximum deflection will
occur on the red colored section.
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appendix
Table b
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Table c
Table d
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Table e
Table f
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Table g
Table h
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Table i
Table J
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o Reference
Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA (2005)
fundamentals of machine component design fifth edition
Machine Elements Life and Design
Machine Elements In Mechanical Design fourth edition
Shigley’s Mechanical Engineering Design, Eighth Edition Budynas−Nisbett
Design Engineer’s Case Studies and Examples Keith L. Richards
VB Bandari; Design of Machine Elements, 1994, Tata McGraw Hill
Fundamentals of modern manufacturing Materials, Processes, and Systems
Fourth Edition Mikell P. Groover
Callister - Materials Science and Engineering
o Link
http://diequa.com
http://joycedayton.com
http://diequa.com
http://www.inkoma-albert.com
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