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Screw Jack Design
Screw Jack Design
Screw Jack Design
Reasons of Accidents –
1] Load is improperly secured on jack.
2] The screw 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.
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STEP – 1
Problem Statement: –
Design a screw jack for lifting a load of 75KN with manual operation for
0.5m of height.
STEP – 2
MATERIAL SELECTION: –
Screw jack has following parts :-
1] FRAME
2] SCREW
3] NUT
4] HANDLE
5] CUP
6] SET SCREW
7] WASHER
1] FRAME –
• 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.
2
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
FG200 microstructure
2] SCREW –
• Screw size – Screws is nothing but a member having Helical groove around
periphery of solid bar. It can be around 22 to 100mm diameter for square power
screws & 24 to 100mm for trapezoidal power screws.
• 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.
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• Square threads are weak in roots. Wear of thread surface lead us to use
“Unalloyed free cutting steel”.
3] 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%phospher which increases tensile strength. Ultimate tensile strength for this
is 190mpa 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.
4] HANDLE –
5] CUP –
6] SETSCREW –
4
• It can be of commercial steel.
7] WASHER –
STEP – 3
ERGONOMIC CONSIDERATION:-
• According to ergonomic consideration a mature man can lift weight up to 1/2 of
his weight.
• This criterion is applied when work is not continuous. Capacity is
1/3 for continues work.
• Thus average weight of person is 60KG.
• So he can apply 30KG i.e. 300N
• Suppose two worker are working the total force
= 300*2*0.9
=540N
STEP – 4
FACTOR OF SAFETY:-
• Many times workers have to work below heavy load such a high risk of work
leads to select higher factor of safety values. The dropping or slipping of weight
is life hazards. So it has to be foolproof. We select factor of safety as ‘5’ for
steel component and ‘6’ for cast iron.
STEP – 5
DESIGN OF SCREW:-
5
FROM SELECTED MATERIAL SPECIFICATION:
SPECIFICATION:-
SYC = SYT = 560 mpa
бc = compressive stress = 560/5
= 112 mpa.
1] CORE DIAMETER
б= W / (π/4)*dc2
112=(75*10^3) / π/4*(dc2)
dc = 30mm
The diameter only consider compressive stress but screw is subjected to torsion and bending
moments for that we increase a diameter to higher values we will use a screw with 55mm
nominal diameter & 9mm pitch .( IS 4694
4694-1968:basic dimensions for square threads)
eads)
d = 55mm p = 9mm
dc = 55-9 = 46mm > 30mm
dm = d-0.5p = 55-4.5 = 50.5mm
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Assuming Screw has single start threads.
l = p = 9mm
tanα = l/π*dm
= 9/(π*50.5)
α =3.246О
Coefficient of friction between screw and nut is 0.1 i.e. µ=0.1 Considering bad lubricating
conditions assume µ=0.18
tanФ = µ = 0.18
T = W*(dm/2) * tan(Ф+α)
= 452.898*10^3 N-mm
The diagram shows no cross section of screw is subjected to addition of collar friction torque &
nut torque.
At section x-x
= 23.697 mpa
= (0.5*560) / 5
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Stress due to bending:
Force due to hand i.e. P is responsible for bending of screw thus bending moment at any section
x-x can be given as,
Mb = P * l
So, l = 550+20+50
= 570mm
Mb = 300*570
= 171*10^3.
б=32Mb/(π*dc^3 )
= (32*171*10^3 )/ (π*46^3)
б
ζmax= ^2
.
= ^2 23.697^2
Buckling Criterion:-
When load is raised the screw acts as column & there are chances of buckling or crushing of it.
So we have to decide whether column is long or short.
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Since one end of screw is fixed & other is free the end fixity coefficient is 0.25 . border line
between short &long column is
560/2=0.25*π2*207000 / (l/k)2
l/k = 42.709
K=√(I/A)
I=inertia
K= Radius of gyration
I=π/4 * dc^4
=219.786*10^3mm^4
A= 1661.9925mm^2
K=11.5
= (0.25*207000*π^2*1661.9025) /(47.826)^2
Safe in Buckling.
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STEP – 6
DESIGN OF NUT :-
The permissible bearing pressure between steel screw & bronze nut is 10mpa
Z=10.50
=11
Height of Nut
H= z*p
=11*9
=100mm
ζ=W / (π*d*T*Z)
=(75*10^3) / (π*55*4.5*11)
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Fig. Transverse shear area on screw body
ζ=W / (π*dc*T*Z)
=(75*10^3) / (π*46*4.5*11)
=10.484 mpa<<56mpa
11
бt = W/(π/4*(Do^2-Di^2)
112 = 75*10^3/π/4(Do^2-55^2)
Do= 65mm
By emperical relations
Do’ = 1.3 * Do
=65 * 1.3
= 85mm
ζ= W/π*Do*t
19 = 75*10^3 / π*65*t
t=20mm
бc=W/(π/4)*(Do’^2-Do^2)
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STEP – 7
DESIGN OF CUP.
D = 1.6 * d
=1.6 * 55
=88mm
D’ = 0.8 * d
=0.8*55
=44mm
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STEP – 8
COLLAR FRICTIONAL TORQUE-
Tf = (µ*W/4)*(Do+Di)
=[(0.2*75*10^3) /(4)]*(88+44)
=495*10^3 N-mm
=947.898*10^3N-mm
947.898*10^3 = (300*0.9*2) * Lh
Lh = 1760mm
So we will replace sliding friction by rolling friction by introducing “Thrust ball Bearings” with
this friction torque becomes negligible,
For selecting bearing from manufacturers catalogue, we assume life of bearing to be 3000hrs and
rotated by handle at 10rpm.
L= (60*n*Lh) / (10^6)
=1.8milion revolution
C = PL^(1/3)
=91233.029N
It is assumed that bore diameter of bearing is equal to core diameter or more than that
Assume it to be 50mm
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We select 51310 having dynamic load carrying capacity equal to 97500 N
STEP – 9
DESIGN OF HANDLE / TOMMY BAR:-
Tc = F * Lh
452.89*10^3 = (300*2*0.9) * Lh
Lh = 850mm
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Mb = P * Lh
= 300 * 850
= 255*10^3 N-mm
dh = 40mm
STEP 10
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REFERENCES:-
DESIGN OF MACHINE ELEMENTS
V.B.BHADARI McGraw Hill publication
MATERIAL SCIENCE
KHODGIRE
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