ADDIS ABABA SCIENCE AND TECHNOLOJY UNIVERSITY

SCHOOL OF MECHANICAL AND MANIUFACTURING

ENGINEERING
DIPARTMENT OF MECHANICAL ENGINEERING

SUBITED TO …………HIREDIN
SUBMITED BY……….MULUSEW ALAMIREW
ID NUMBER ………….ETS 0959/06
COURSE TYPE……….MASHINE DESIGN PROJECT

SUBMITION DATE ……...

ACKNOWLEDGEMENT

It is with a great sense of pleasure that we acknowledge the help and guidance. we would like to
take this opportunity to give our special thanks to our dedicated lecturer, HIREDIN for given
as this project and guiding this project at every stage with clarity, spending much time to discuss
and help with this project, and that priceless gift of getting things done by sharing his valuable
ideas as well as share his knowledge.

I received information from my FRIENDS to work this interesting design project. I am very
much thankful to them for all their support in conducting and writing up my work. Moreover, I
would like to express my heartfelt and sincere for their priceless guidance and support during my
work. Not forgetting my fellow friends who gave a lot of ideas, contributing in my development
of bevel gear bottle jack. Thanks to the almighty GOD; GOD forgive me the life and hope to
finish this project without any major problems.
ABSTRACT

A Bottle jack is a jack which works on the principle of gear and resembles a bottle in its shape.
Bevel bottle jacks depend on force generated by pressure. Bottle jack tend to be stronger and can
lift heavier loads higher. It can be used for lifting vehicles to undergo repair work or dealing with
flat tires. It can also be used in interconnection with more bottle jacks for lifting structures and
for some household purposes.
The purpose of this project is to modify the design of the existing bottle jack in terms of its
functionality and also human factors considerations. In this “ bevel bottle jack design project”,
the scopes of research were on the designing 10KN maximum lifting capacity with 260mm
minimum lifting height and 130mm maximum lifting height of bottle jack by using optimization
concept. The former model was carefully studied in terms of the design features, specifications,
capacity and with the help of new methodology an attempt was made to fabricate a new design
that can lift a load lower than or equal to 10KN, producing same capacity within the economic
range. The work consists of the fabrication of the new model and projects the advantages of the
new method over existing methods. The new design was successfully made and was able to
fulfill all the required objectives. The following work can be a new eye opener for the design
engineers dealing with making the jack work vertically.
The project on this includes the proper way of material selection by considering all the
mechanical and physical properties of the selected material to make a safe design. The force and
stress analysis is based on the design safety purpose. Unbalanced stress and forces have great
influence to the designed material.
The oil required to run the jack is determined for good performance. Then all the hydraulics
bottle jack parts are designed by considering the requirement of consideration. Considering
coating system also have great role to corrosion resistance. Then the design becomes safe when
all requirements are fulfilled by care attention.
INTRODACTION
This project is design a bottle jack with bevel gear. A bottle jack is a device used to
lift heavy loads and consists of a cylindrical body and a neck. The power screw, which
makes contact with the object to be lifted, emerges from the neck of the bottle jack.
People have started feeling the need of having a bottle jack that works vertically 10KN
lifting capacity with 130mm minimum lifting height and 260mm maximum lifting height.
However, in order to make the bottle jacks work like this vertically it requires that the
jack nut is internally threaded and makes the power screw to rotate towards the desired direction
i.e. upward or dawn-ward; to make this, the upper and lower thrust bearings have important role
for carrying load and to keep the position of lifting system. The main parts of this bevel gear type
bottle jack are, power screw, bearings, jack nut, bolts, pinion and spiral bevel gear, pinion shaft
bearings, the input shaft, housing, and vent all these are described with role and designed in
detail way.

In this project in-order to design, parts of bevel gear bottle jack are designed based on
numerically analysis, geometrical analysis, methodology, conceptual analysis and by considering
working principle of this machine.

The project includes rough sketch of two-dimensional assemblage the parts to show force and
power transmission.

BOTTLE JACK
Bottle jacks have a longer threaded power screw, however, it is possible to
get more lift per rotating the input shaft. The device itself is light, compact and portable, but is
capable, of exerting great force.

The input shaft is manually rotated and pinion forced to rotate the spiral bevel gear and then
power screw to move its piston; Torque is built on input shaft and transmitted through gears up-
to power screw using line of action law. Bevel gear bottle jack is based on the torque, which is
multiplied the force to be increased at the power screw for lifting the desired load.

Oil and grease are used for lubricating the internal forced part of the jack to perform smooth
motion in the system.
OBJECTIVE
Re-design improvement the existing bevel gear type bottle jack in terms of its functionality and
human factor consideration. Make a design of bottle jack that is user friendly and easier to
operate as do not required too much force to lift the load. The can lift 10KN maximum load and
minimum and maximum lifting height of 130-260mm respectively.

Therefore, we can design this type of bottle jack by considering the design analysis and its
specifications based on standards.

PARTS OF BEVEL GEAR BOTTLE JACK AND THEIR DISCRIPTIONS WITH

THEIR FUNCTIONS.

Power screw: used to hold (lifting the load) by moving up and also used to lift down
and regain the load into the original place.
Jack nut: the main function of this part is, in-order to keep lifting screw to move the
power screw up and down. To make this jack nut is internally threaded so, directional
motion of the power screw is controlled by the jack nut based on the thread and based on
the rotation of the input shaft.
Input shaft: manual force is applied on the shaft then the shaft rotates toward the
desired direction. This happened by torque which is developed on the input shaft to create
angular motion for the effect of other parts.
Pinion gear: used to drive the spiral bevel gear by creating angular motion and by
transmitting power to-wards the gear for further creation of motion for power screw.
Spiral bevel gear: used to control or give direction on the lifting screw to move up and
down based on bevel gear rotation.
Upper thrust bearing: important to keep up ward motion and carry the load.
Lower thrust bearing: in order to keep down ward motion and carry the load.
Input shaft bearing: since force is exerted on the input shaft to resist this load not to
bend and not to created stress on the shaft bearings have great role for carrying the load.
Mounting bolt: used for mount machine with desired place may be on the table.
Fill vent: used as the passage of lubricant fluid into the system.
Housing (casing): the main role of this part is used to protect internal parts from dust,
unwanted contamination and from unwanted external stress from the surrounding.
Power transmission of bevel gear type bottle jack (working principle).
Power transmitted means how the machine is work, to do this:

The machine is mechanically operated or using manual force, the force is applied on the input
shaft, then it becomes rotate to the desired position. In this system the shaft is probably rotate in
to two ways these are; towards clockwise and counter- clockwise direction. Based on this
position there will be specified movement of power screw. Now let us see the working principle
of the machine in each rotation of the shaft.

When the shaft rotates toward clockwise direction, manually using hand wheel attached to the
shaft; the input bearings protect the motion of the shaft by minimizing the friction and power is
transmitted into the pinion gear then it will forced to rotate the spiral gear towards
counterclockwise direction since they are mesh each other and then the lifting screw rotates
counterclockwise direction then the screw move up; finally, the load will lift up. To keep this lift
up motion the upper thrust bearing has great role for carrying the load not to become downward.

When the shaft rotates toward counterclockwise direction, manually using hand wheel attached
to the shaft; the input bearings protect the motion of the shaft by minimizing the friction and
power is transmitted into the pinion gear then it will forced to rotate the spiral gear towards
clockwise direction since they are mesh each other and then the lifting screw rotates clockwise
direction then the screw move down; finally, the load will becomes down. To keep this lift down
motion the lower thrust bearing has great role for carrying the load not to become downward.
GEOMETRICAL ANALYSIS
Geometric of the bottle jack is defined as the machine perform its task, the components of this
bevel gear bottle jack is show movement by changing its position. Geometry means the working
area of the machine.

The main two types of geometric indications are; when the screw move up and down its working
area will be happen.

1) When the lift screw move up;

A. When input shaft rotates clockwise directions, then the screw move up to
desired direction then lift screw move up “a to b” as shown the figure.
B. Input shaft rotate the pinion gear and then the spiral gear.
C. The gear transmits power towards the screw because of meshing each other with
their thread.
D. Load will be lift up by power screw towards position “c”.
2) When the lift screw move down;
A. Input shaft rotates counter clockwise direction by the help of hand wheel
mounted on the input shaft.
B. Shaft forced the pinion gear to by creating angular motion.
C. Pinion gear attached or meshed with the spiral bevel gear then the lift screw tray
to enter protective tube; then it loss load and screw run from “b to a”.
D. Finally, the screw at “b” loss its load or load will be placed its original place.

PART NO. PART NAME

1 Power screw
2 Jack nut
3 Spiral gear
4 Pinion gear
5 Input shaft
6 Mounting bolt
7 Input shaft bearing
8 Upper thrust bearing
9 Lower thrust bearing
10 Housing
Figure shows geometry of bevel gear bottle jack.
The figure shows geometry of the two gears

by mesh each other for properly

working.

Pinion gear will drive and then spiral

Gear will rotates.

This is the general nomenclature of bevel gear.

Conceptual analysis

SCREW JACK –
Bevel gear bottle jack is a portable device consisting of a screw mechanism used to raise or
Lower the load. This type of jacks most commonly used,
Mechanical
Merits of bottle jack –
1] Can be used to lift a heavy load against gravity.
2] Load can be kept in lifted position.
3] Due to hand wheel obtained by handle force required to raise load is very less & can be
applied manually also
Demerits of bottle jack –
1] Chances of dropping of load
2] Tipping or slipping of load.
3] This failure is not “SAFE FAIL”& can cause serious accidents.
Reasons of Accidents –
1] Load is improperly secured on jack.
2] The jack is overloaded.
3] Center of gravity is off center with axis of jack.
4] Jack is not placed on hard & level surface.
5] Using for other purpose instead of using it for which it is designed.
Detail description for parts.

Power screw –
Screw size – Screws is nothing but a member having Helical groove around periphery of solid
bar.
Thread profile – The screw or power screw thread is always a square type because it has more
efficiency than trapezoidal threads and there is no radial thrust on screw i.e. no Bursting
Pressure, so motion is uniform. Square threads usually turned on lathes using single point cutting
tool. It leads us to use free cutting steel.
Square threads are weak in roots. Wear of thread surface lead us to use “Unalloyed free cutting
steel”.
I select “25C12S14 UNALLOED FREE CUTTING STEEL”
It indicates - 025% carbon, 1.2% manganese, 0.14%sulphur
It has tensile strength of 560N/mm2 with 10% elongation. Sulphure gives resistance to wear &
0.25% carbon gives it sufficient strength to compensate weakness in roots. also easy in cutting
due to manganese.
Jack nut –
As we know there always a relative motion between screw and nut, which cause a friction. The
friction causes wear if some material is used for screw & nut it will wears both components. So,
one out of two has to be softer than other so as to ease of replacement. The size & shape of screw
is costlier than nut, so generally we use softer material for nut than screw. Phosphor bronze is
ideal material for nut which is a copper alloy having 0.2% of phosphor which increases tensile
strength. Ultimate tensile strength for this is 19mpa and coefficient of friction is 0.1
Bearing pressure is 10mpa.

Advantages of phosphor bronze are,

1] Good corrosion resistance.
2] Low coefficient of friction
3] Higher tensile strength than copper brass.

Input shaft
Shaft is subjected to bending moments due to over- hanging.
So Material selection “1018Steel Annealed” with yield strength Sy = 220MPa.
Parts of bevel gear bottle jack:-

 Power screw
 Jack nut
 Bevel Gear and pinion
 Shaft
 Bolt
 Bearing
 Fill vent
 Housing

Given data for designing:-

 Maximum distance lifting is hmax =260mm
 Minimum distance lifting is hmin =130mm
 Lifting distance is ∆h=130mm
 Lifting force is FL=10KN= W

Design and calculations

1. Design for power screw

Assumptions:-

 The screw is square threaded

 Screw material is steel
 Compressive stress for steel is syt =syc=560Mpa
 Factor of safety n=5
 Take coefficient of friction between the screw and respective thread on the bevel gear is
µ=0.18

Symbols:-

 dc → core diameter of screw

 do → major diameter of screw
 p → pitch of the screw
 α → helix angle
 ∅ → friction angle between screw and bevel gear
 d → pitch diameter

Assume the bevel gear acts as a nut for power screw and considering the screw is under
compressive stress.
 syc 560 Mpa
σc = n
=
5
= 112Mpa

σc = W/(π/4*dc2) = 112Mpa = 10KN/(π/4*dc2) ⇒dc = 11mm

From standard dimension of square thread fine serious take dc = 12mm
do = 14 and p =2mm
d o+d c
d= = 13mm
2
p 2 2
Assume screw has single start thread tan α= = tan−1 ( )=2.8˚
π∗d π∗13 π∗13

And from our assumption µ = 0.18 → tan ∅=0.18 ⇒ tan−1 ( 0.18 )=10.2˚

T = W* ( d2 ∗tan ( ∅+ α ) )=10 KN *( 0.0132 m ∗tan ( 13 ˚ ))=15 N . m

16 T 16∗15 0.5∗syt 0.5∗560
𝝉max = 3 = = 44.21Mpa 𝝉permissible = n
=
5
= 56Mpa
π∗d c π∗0.0123

56Mpa ¿ 44.12 Mpa therefore; power screw design is safe with factor of safety 5.

Design summary:-

 Maximum distance lifting is hmax =260mm

 Minimum distance lifting is hmin =130mm
 Lifting distance is ∆h=130mm
 Lifting force is FL=10KN= W
 The screw is square threaded
 Screw material is steel
 Compressive stress for steel is syt =syc=560Mpa
 Factor of safety n=5
 Take coefficient of friction between the screw and respective thread on the bevel gear is
µ=0.18
 dc → 12mm
 do → 14mm
 p → 2mm
 α → 2.8 ˚
 ∅→ 10.2˚
 d → 13mm
 2. Design of jack nut

Assume bearing pressure (pb) between steel screw and phosphorus bronze jack nut is 10Mpa.
For jack nut material is bronze.
Material selection phosphorus bronze with shear stress 𝝉s = 19MPa
4W 4∗10000
pb = = ⇒ Z =
π∗(d o ¿ ¿ 2−d c 2)∗Z ¿ π∗(0.014 ¿ ¿ 2−0.0112)∗Z ¿

4∗10000
2 6 = 16.98
π∗(0.014 ¿ ¿ 2−0.011 )∗10∗10 ¿
Take z =17 this is thread number of screw.
Height of jack nut calculated by:-
H= Z*p =17*2 =34mm
Transvers shear stress at the root of thread in nut is given by:-
2∗w 2∗10000
= = 13.4MPa
π∗p∗Z∗d o π∗0.002∗17∗0.014
Therefore; 13.4MP<19MPa jack nut is safe in transvers shear stress at the root.
Transvers shear stress at threads in screw is given by:-
𝝉=W / (π*dc*p/2*Z) = 10000 / (π*0.011*0.001*17) = 17.02MPa
Therefore; 17.02Mpa < 56MPa jack nut is safe in transverse shear stress at screw.
Fig. transverse shear area on the screw body.
σt = W/(π/4×(Do2-do2) = 112×106 = 10000/(π/4×(Do2-0.0142)
4
√
DO = (10000 ×
π × 112×10 6
+0.0142 ) =18mm

By empirical relations DO’ = 1.3DO = 1.3×18=24mm

Phosphorus bronze has shear stress 19Mpa.
Shear area of jack nut As from standard table at Do= 18mm As = 254mm2
As = 𝜋×Do×t t = As/( π × D o) → t = 254mm2/( π ×18 mm) = 3mm

Design summary:-

 H = 34mm
 t = 3mm
 Material used phosphorus bronze with allowable shear stress 19MPa
 DO’= 24mm
 DO = 18mm
 As = 254mm2

3. Design of pinion and spiral bevel gear.

Design assumptions:-
 Load is distributed over the inside cross-sectional area of spiral bevel gear.
 Assume pinion is rotated with NP = 50rpm
 Material for pinion gear semi-steel with BH=200 & allowable static stress = 85MPa
 Material for spiral gear grey cast iron with BH=160 & static stress = 55MPa
 Angle between the two shaft axis ϴs = 90˚
 P & G represent pinion and gear respectively
1
 Pressure angle for teeth 14 ˚ composite
2
0.684
 Y' = 0.124−¿
TE
 Modulus of elasticity EP = 210×109 Pa EG = 84×109Pa
 Surface endurance limit for grey cast iron σes = 630mpa
 10
 TP = 18 & V.R =
3
L
 Face width b =
3

 Symbols:-
 L → slant length  V.R → velocity ratio
 m → module in mm  T → number of teeth
 N → rotational speed  e → error tooth factor in mm
 D → diameter  a → addendum
 d → dedendum
Calculations:-
T = 60P/(2π × N) ⇒ P = (2×𝜋×N×T)/60 = (2×𝜋×50×15)/60 = 78.54 watt
−1 1 3
ϴP1 = tan ( )= tan−1 ( )= 16.7˚
V .R 10
ϴP2 = ϴS −ϴ P2 = 90˚ −¿ 16.7˚ = 73.3˚
TEP = TP× sec(ϴP1) = 18×sec(16.7˚) = 18.8
TEG = TG×sec(ϴP2) = 60×sec(73.3˚) = 208.8
0.684 0.684
Y'P = 0.124−¿ = 0.124−¿ =0.088
TEP 18.8
0.684 0.684
Y'G = 0.124−¿ = 0.124−¿ = 0.121
TEG 208.8
Cheek for designing:-
V.R= (NP/NG) = (10/3) = (30rpm/NG) ⇒ NG = 15rpm
σop × Y'P = 85MPa×0.088 = 7.48 σOG×Y'G = 55MPa×0.121= 6.7
since (σop × Y'P) >( σOG ×Y'P); design must be for the gear.
W T = 2×T/(DG) = 2×15/(m×TG) ………………. DG = m×TG.
WT = 500N/m
 π × D G × NG π × m×60 × 15
Pitch line velocity ….. V = = = (47.12m)×10-3 m/s
60 60
6 6
Velocity factor …………. Cv = =
6+V 6+47.12 ×10−3 × m
DG m×TG
Length of pitch cone element ………. L= = = ( 31.32×10-3×m) m
2× sin θp2 2× sin 73.3˚
L (31.32 ×10−3 × m)m
b= = = (10.44×10-3m) m.
3 3
Tangential load on the gear:-
L−b
WT = σOG × Y'P ×Cv × b× 𝜋 × m×
L
6
WT = 500N/m = 55×103[ ]×10.44×m2×𝜋×0.121×0.667
6+47.12 ×10−3 × m
873.53
WT = 500N/m = [ ]×m2 ……… by tray and error method m = 1.5 take m =
6+47.12 ×10−3 × m
2mm
DG = m×TG. = 2×60 = 120mm Dp = m×Tp = 2×18 = 36mm
V = 0.04712×m = 0.1 m/s say V = 1.25m/s based on standard design
WT = 500/m = 500/2 = 250N
Cv = 6/(6 + v) = 0.83
L = 0.03132×m = 63mm
b = 10.44×m = 21mm
From standard design for gear at pitch line velocity @ V=1.25m/s e = 0.0925mm
1
And take K = 0.107 for 14 ˚ composite
2
K ×e 0.107 ×0.0925
Dynamic factor C = [ + ] = [
1 1 1
+
1
] =593.98N/mm
EP EG 3
210 × 10 84 ×10 3

Dynamic load is given by:-

21× V ×( b× C+W T ) 21× 1.25 ×(21 ×593.98+ 250)
WD = WT + 21× V + √ (b ×C +W ) = 250 + 21× 1.25+ √ (21× 593.98+250) = 2652N
T

For static load:-

L−b 63−21
Ws = σe×b×𝜋×m× × Y'G = 630×21×𝜋×2× ×0.121 = 6708.9N
L 63
The static load is greater than dynamic load i.e. WS > WD design is safe.
Design from the standard point of wear:-
Load stress factor given by:-
σ 2es 1 1 1 1
K= × sin ∅ ×[ E + E ] = ¿ ¿[ + ] = 1.18MPa
210× 10 84 × 109
9
1.4 P G

2× T EG 2 ×208.8
Ratio factor Q =
T EG +T EP
= 208.8+18.8
= 1.84
The maximum or limiting load for wear for bevel gears is given by
DP × b ×Q × K 36 ×21 ×1.84 ×1.18
Wear load WW = = = 1713.7N
cos ϴ p 1 cos 16.7 ˚
Since maximum or limiting load is much more than tangential load design for bevel gear is safe.
Addendum a = 1m= 2mm
Dedendum d = 1.2m = 1.2×2= 2.4mm
Clearance = 0.2m = 0.2×2 = 0.4mm
Working depth 2m = 2×2 = 4mm
Thickness of thread = 1.5768m = 1.5768×2 = 3.154mm
b DP 36
Mean radius Rm = ( L− )× = ¿)× = 15mm
2 2× L 2× 63
−1 a −1 2
Addendum angle α =tan ( ) = tan ( )= 1.82˚
L 63
−1 d −1 2.4
Dedendum angle ¿ tan ( ) = tan ( ) = 2.18˚
L 63
Back cone radius of bevel gear is given by;

RB = Rp×sec (θ p1) = 18*sec(16.7) = 19mm ……………… for pinion.

RB = RG ×sec (θ p2) = 60*sec (73.3) = 209mm ……………..for the gear.

Outside diameter or addendum cone diameter given by;

DOP = DP + 2*a*cos(θ p1) = 36mm + 2*2*cos(16.7) = 40mm …………….for pinion.

DOG = DG + 2*a*cos(θ p2) = 120mm+2*2*cos(73.3) = 122mm ………….for the gear.

Inside diameter or dedendum cone diameter is given by;

Dd = DP – 2*d*cos(θ p1) = 36mm – 2*2.4*cos(16.7) = 32mm …………….. for pinion.

Dd = DG – 2*d*cos(θ p2) = 120mm – 2*2.4*cos(73.3) = 119mm …………. for the gear.

Design summary:-
Pinion Gear
Material Semi-steel Grey-cast iron
Teeth number 18 60
Rotational speed (rpm) 50 15
Diameter (mm) 36 120
Static load (MPa) 85 55
BH 200 160
Tooth profile (composite) 1 1
14 ˚ 14 ˚
2 2
TE 18.8 208.8
ϴP 16.7˚ 73.3˚
Modulus of elasticity (GPa) 210 84

Torque (N.m) 15

Power (watt) 78.54

Tangential load (N) 250

Static load (N) 6708.9

Wear load (N) 1713.7

Dynamic load (N) 2652

Module (mm) 2

Addendum (mm) 2

Dedendum (mm) 2.4

 Clearance (mm) 0.4

Working depth (mm) 4

Pitch line velocity (m/s) 1.25

Slant length (mm) 63

Face width 21

Velocity factor 10/3

Dynamic factor (N/mm) 593.98

ϴS 90˚

K (N/mm2) 0.107

Velocity factor 0.83

Load stress factor (MPa) 1.18

Ratio factor 1.84

4. Design for pinion shaft.

Assumptions:-

 Assume the shaft is over hang by bearing ho = 20mm

 Material selection “1018Steel Annealed” with yield strength Sy = 220MPa.
 Since the pinion shaft is over hanged; shaft stressed due to bending.
 Since the Worker rotate the input shaft which is attached to pinion gear; shaft stressed
due to twisting.
 Suitable length of the shaft is selected to be L= 200mm
Symbols:-

 dS → diameter of shaft
 Te → equivalent torque
 Mt → twisting moment
 Sy → yield strength of the shaft
 𝝉y → shear stress
Calculations:-
Axial force acting on the pinion;
WRH = WT× tan ∅ × sin ϴP 1= 250× tan 14.5× sin 16.7 = 18.56N
Vertical load on the pinion;
WRV = WT × cos θP 1 = 250 × tan 14.5× cos 16.7 = 61.93N
b DP 36
Mean radius Rm = ( L− )× = ¿)× = 15mm
2 2× L 2× 63
Bending moment due to axial and vertical load;
Mb = WRV×Overhang – WRH*Rm
= 61.93×0.02 – 18.56× 0.015 = 0.9602N.m
Bending moment due to tangential load;
MT = WT×Overhang = 250×0.02 = 5N.m
Equivalent bending moment;
Me = √ M b2+ M T 2 = √ 0.96022+ 52 = 5.1N.m
Since the shaft is subjected to twisting moment and bending moment;
Equivalent twisting moment given by;-
𝑇e = √ M e2 +T 2 = √ 5.12+ 152 = 15.84N.m
S 220
𝝉y = y = 2× 2 = 55MPa
2× n
π T 15.84
3

√
𝑇e = 16 ×𝝉y× dS3 ⇒ dS = (16 × e ) =
π ×τ y √
3
(16 ×

on standard shaft size and to fit with bore of bearing.

π ×55 ×106
) = 11.4mm say 15mm based

16 ×T 16 ×15
Shear stress due to shaft diameter 𝝉 = 3 = =27.84MPa
π ×d s π × 0.0153
Since 𝝉 < 𝝉e shaft design is safe.

Design summary:-
 Material used “1018Steel Annealed” with Sy = 220MPa
 dS = 15mm
 L = 200mm
 𝑇e = 15.84MPa
 Over hang height by bearing 20mm

5. Design for mounting bolt.

Design assumptions:-
 Material for bolt mild-steel with σC = 𝝉y = 40MPa.
  Number of bolts in the bevel gear are n = 6
 All bolts used to tighten bevel gear bottle jack ; so bolts subjected to compressive stress
due to load.
 Assume the load probable to fall down, so, bolts subjected to crashing stress to upward
direction.
Symbols:-
 .n → number of bolts
 dc → core diameter of bolt
 do → nominal diameter
 p → pitch
 P’ → load
 D → depth thread
Calculations:-
π × d 2c× n × σ c
⇒ dc = π 4×n× P× ’σ = 4 × 10000 6
P’ =
4 √
From standard stable for dc = 8mm;
c √ π ×6 × 40 ×10
= 7.3mm say 8mm.

do = 10mm
p = 2mm
Thread length for bolt L = 2×do + 6mm = 26mm
Cheek for shearing stress distributed in 6 bolts;
16 × T 16 ×15
𝝉 = π × n× d 3 = π × 6× 0.0083 = 24.87MPa
c

Working shear stress is less than induced shear stress i.e. 𝝉 < 𝝉 = 24.87MPa < 40MPa.
Design for bolt is safe.

Design summary:-
 dc = 8mm
 do = 10mm
 p = 2mm
 D = 1.2mm
 L = 26mm
 Material for bolt mild steel with σ = 𝝉y = 40MPa.
C

6. Design for bearing

6.1 Design of bearing for pinion bevel gear

Assumptions:-
 Bearings have great role in the machine to carry load so, they must have longer life.
Based on this idea assume the life to the bearing to be 10 years and 7 hours per day for
lifting the load.
 Material for bearing to be chrome- steel.
 Bearing type radial ball bearing is selected to carry load by to avoid stress concentrations.

Symbols:-
 LH → life of bearing in hours.
 L → life of bearing in revolutions.
 B → bore of bearing.
 DO → outer diameter of bearing.
 W → basic dynamic equivalent radial load.
 N → angular speed for pinion.
 R → radius of outer diameter.

Calculations:-
LH = years × days × hours

= 10 ×365×7

= 25,550 hours

L = 60×N×LH = 60×50×25550 = 7665×104 revolutions

Since shaft diameter is 15mm bore of the bearing is 15mm for contact roll bearing.

From table for standard dimension of radial ball bearing with bore 15mm, we can get:-

DO = 35mm, Width = 11mm , bearing number = 201.

T 15
W= = = 857.14 N
R 0.0175
1
L
Dynamic load rating C = W×
106 ( ) K

1
7665× 104
C = 857.14× ( 106 ) 3
= 3.641KN ………………. K = 3 for ball bearing.
From standard table, for the corresponding bearing number 201; C = 5.4KN

Design is safe by comparing with induced dynamic rating factor.

Design summary:-

 Material used chrome – steel

 LH = 25,550 hours
 L = 7665×104 revolutions
 DO = 35 mm
 Width = 11mm
 Bearing number = 201
 B = 15mm
 K=3
 C = 3.641KN (from calculation)
 C = 5.4KN (induced)

6.2 Design bearing for spiral bevel gear.

In this section design include for both upper and lower thrust bearings with same material and
dimensions.

Assumptions:-

 Bearing type is angular contact ball bearing with inner race rotating.
 Specification type for bearing is single row
 Load is uniform and steady.
 The life of bearing to be 10 years and 7 hours working per day.
 Chrome - steel selected as material suitable to carry load.

Symbols:-

 LH → life of bearing in hours

 L → life of bearing in revolutions
 WR →radial load
 WA → axial load
 T → torque
  N → rotational speed for gear in rpm
 X → radial load factor
 Y → axial load factor
 V → rotational factor

Calculations:-

Rotational speed for gear from above calculation is 15rpm.

LH = 10×365 ×7= 25550 hours.

L = 60× N ×LH = 60×15 ×25500 = 2295×104 revolutions.

From standard table radial ball bearing bore of 25mm, DO = 52mm, width = 15mm and

bearing number = 205.

T 15
WR = = = 857.14N
R 0.0175

Maximum axial load on bearing is with lifting force of power screw,

WA = FL = 10KN

Basic dynamic equivalent radial load given by;

W = X × V × WR + Y × WA

For single row angular contact bearing (inner race is rotating) rotational factor V = 1.

Since the selected bearing is angular contact ball bearing single row with bearing number 205
from standard basic static and dynamic capacity of radial ball bearing table, we can get;

WA 10000
= = 11.67
W R 857.14

From the values of X & Y based on the corresponding values at angular ball bearing with the
WA
specification of single row and = 11.67,
WR

WA
>e e = 1.14
WR

X = 0.35 y = 0.57

W = 0.35 ×1 ×857.14+ 0.57 × 10000

W = 6KN
1
L
C = W× ( )
106
K

1
2295× 104
C = 6000× (106 ) 3
……………. take K = 3.

C = 10.75KN

From the standard table C = 11KN …. So, design is safe with bearing number 205.

Design summary:-

 Bearing type is single row angular ball bearing

 Material for bearing is chrome steel
 B = 25mm
 DO = 52mm
 L = 2295×104 revolutions
 LH = 25550 hours
 Width = 15mm

7. Design of Fill vent

Fill vent used for lubricant passages but it is not subjected to stress during working of the
machine so; simply we can design theoretically by considering the relation between
lubricant and fill vent tube.
The material for this; must be aluminum not to be rust and grease may be oil or grease.
Assume tube is tapper to avoid turbulent flow of oil into system.

8. Design for housing (casing).

• FRAME SIZE - Most of the times frame is conical in shape and hollow internally to
accommodate a nut & screw assembly. The hollow conical shape insures a safe &
complete resting of a jack on ground. If it is provided with legs like structure , it quite
possible that in case of uneven distribution load may fail down because all legs will not
touch ground.
• FORCE ANALYSIS – The force by a load is directed by a cup to screw then is directed
by cup to screw then to threads of screw to nut then to frame so it is always compressive
in nature.
• MANUFACTURING PROCESS – The complex shape of frame leads us to use a
’Casting’ process for manufacturing For all this purpose We need to select a cast iron as
material for frame. We select a FG200 as material for frame such as it contains carbon
precipitates as “graphite flakes” as graphite is soft in nature it improves its ability to resist
a compressive load. FG200 = Graphite flakes Gray cast iron with ultimate tensile strength
of 200N/mm2.
 Appendix
The following table shows the principal dimensions for radial ball bearings. Table 1.

Table 2 Values of X and Y for dynamically loaded bearings.

Table 3 Basic static and dynamic capacities of various types of radial ball bearings.

Table 4 Values of maximum allowable tooth error in action (e) verses pitch line velocity, for
well cut commercial gears.