MENSCHEN FÜR MENSCHEN FOUNDATION

AGRO-TECHNICAL AND TECHNOLOGY COLLEGE

MANUFACTURING TECHNOLOGY DEPARTEMENT

Machine design project report

Tittle: Design and fabrication of screw jack
Prepared by:-
1. ASHETU EJETA ----------------------------------- ATTC 039/19
2. BINIYAM ABEBE ---------------------------------- ATTC 058/19
3. BATIRU ASFAW ----------------------------------- ATTC 042/19
4. HENOK KIBRE ------------------------------------- ATTC 111/19
5. MEMEBERU TADELE ---------------------------- ATTC 145/19

Advisor: - Ins. NIGUSSIE A.

Harar, Ethiopia
January, 2024
 Acknowledgment
We want to express our deepest gratitude for the incredible support we received during our
project. Our faith in God has been a guiding force in overcoming all challenges and achieving
success. We are truly thankful for His wonderful assistance.

We also want to acknowledge and appreciate our advisor, Mr. NIGUSSIE ADEM His hard
work, advice, and guidance played a crucial role in helping us navigate the project. We are
grateful for his expertise and dedication.

Additionally, we extend our thanks to the staff members of the manufacturing technology
department at our college. Their kindness, hospitality, and support throughout our assessment
were truly remarkable. We are thankful for their sincerity and all the help they provided.

In conclusion, we feel blessed and grateful for the support we received. The guidance of our
advisor, and the assistance of the college staff were instrumental in our success. We are honored
to have worked with such wonderful individuals.

i
Contents
Acknowledgment.............................................................................................................................2
List Of Tables..................................................................................................................................5
List Of Figures.................................................................................................................................6
Acronym And Abbreviation............................................................................................................7
Abstract............................................................................................................................................8
Chapter One:..................................................................................................................................10
Introduction....................................................................................................................................10
1.1. Historical Background....................................................................................................10
Types Of Jacks...........................................................................................................................10
1.2. Problem Statement..........................................................................................................12
1.3. Objective.........................................................................................................................12
1.3.1. General Objective....................................................................................................12
1.3.2. Specific Objective....................................................................................................12
Chapter Two..................................................................................................................................13
Literature Review..........................................................................................................................13
Chapter Three................................................................................................................................16
Concept Development...................................................................................................................16
3.1. Concept Generated..............................................................................................................16
Concept 1: Scissor Jack..........................................................................................................16
Concept 2: Screw Drive Linked With Rotating Arm.............................................................17
Concept 3: Trolley Jack..........................................................................................................17
3.2. Concept Screening..........................................................................................................18
3.3. Concept Scoring..............................................................................................................18
3.4. Product Specification......................................................................................................19
Create A Link Between The Metrics And Need....................................................................20
Comparing Other Products In Order To Generate Ideal Value..............................................20
Final Specification..................................................................................................................20

ii
Chapter Four..................................................................................................................................21
Embodiment Design......................................................................................................................21
4.1. Product Architecture...........................................................................................................21
Create A Schematic Diagram Of The Product.......................................................................21
Cluster The Elements Of The Schematic...............................................................................22
Create A Rough Geometric Layout........................................................................................22
Identify The Fundamental And Incidental Interactions.........................................................23
4.2. Configuration Design......................................................................................................................23
4.3. Parametric Design...........................................................................................................................23
Chapter Five...................................................................................................................................25
Detail Design.................................................................................................................................25
5.1. Geometric Analysis...................................................................................................................25
5.2. Force Analysis...........................................................................................................................26
5.2.1. Design For Arm.................................................................................................................27
5.2.2. Design For Link.................................................................................................................28
5.2.3. Design Of Screw Shaft.......................................................................................................28
5.2.4. Design For Frame..............................................................................................................30
5.2.5. Design For Handle.............................................................................................................31
Chapter Six....................................................................................................................................33
Design For Manufacturing.............................................................................................................33
6.1 Manufacturing Cost.........................................................................................................................33
6.1.1 Component Cost...........................................................................................................................33
6.1.2 Assembly Cost;.............................................................................................................................33
6.1.3 Manufacturing Overhead..............................................................................................................35
Conclusion.....................................................................................................................................36
Recommendation...........................................................................................................................36
References......................................................................................................................................38
Appendix........................................................................................................................................39

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List of tables

Table 1: Criteria For Concept 1.....................................................................................................15

Table 2: Criteria For Concept 2.....................................................................................................16
Table 3: Criteria For Concept 3.....................................................................................................16
Table 4: Concept Screening...........................................................................................................17
Table 5: Rating Point.....................................................................................................................17
Table 6: Concept Scoring..............................................................................................................18
Table 7: Relative Importance Of The Metrics...............................................................................18
Table 8: Create A Link Between The Metrics And Need.............................................................19
Table 9: Comparing Other Products In Order To Generate Ideal Value.......................................19
Table 10: Comparison Of Marginal With Ideal.............................................................................19
Table 11: Final Specification.........................................................................................................19
Table 12: Alternative Design Options...........................................................................................23
Table 13: Component Cost............................................................................................................32
Table 14: Machine Hour Rate (Machine Cost)..............................................................................34

iv
List of figures

Figure 1: Scissor Jack......................................................................................................................7

Figure 2: House Jack.......................................................................................................................7

Figure 3: Hydraulic Jack..................................................................................................................8

Figure 4: Floor Jack.........................................................................................................................8

Figure 5: Bottle Jack........................................................................................................................8

Figure 6: Concept 1(Scissor Jack).................................................................................................12

Figure 7: Concept 2(Screw Jack)...................................................................................................13

Figure 8: Concept 3(Trolley Jack).................................................................................................13

Figure 9: Rough Geometric Layout...............................................................................................18

v
Acronym and Abbreviation
A…………………………… Area
B.M ………………………. Bending moment
D/d ……………………...… Diameter
E……………………...……. Young modulus of elasticity
F ……………………………Force
F.s …………………………. Factor of safety
L …………………………... Length
m ………………………...…. Mass
P…………………….……...Load
Sut……………….………...Ultimate tensile strength
Sy ……………………………………… yield strength
T …………………………...Torque, Tension
t…………………………… thickness
w……….………...………...Width
X ……………………….… X – axis
Y …………………………. Y - axis
ϴ…………………………...Angle of contact
σ……………….……...……Normal stress
σy……………….…………Yield stress

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Abstract
The design and fabrication of a screw jack involve a comprehensive process that encompasses
various engineering principles and manufacturing techniques. This abstract provides an overview
of the key stages involved in the design and fabrication of a screw jack. The first stage of the
process is the conceptual design, where the requirements and specifications of the screw jack are
analyzed. This includes determining the load capacity, stroke length, and operating conditions to
ensure the jack meets the intended purpose. Once the requirements are established, the detailed
design phase begins. This involves selecting the appropriate screw type, such as acme screw or
ball screw, as well as choosing the materials for the screw and nut. The dimensions of the jack
are also determined during this phase, considering factors such as stability, strength, and ease of
use. Following the design stage, the fabrication process commences. This involves machining the
components of the screw jack, including the screw, nut, and housing. Precision machining
techniques are employed to ensure the accurate dimensions and smooth operation of the jack.
Assembly of the components is then carried out, paying attention to proper alignment and
lubrication to optimize the jack's performance. Quality control measures are implemented
throughout the fabrication process to ensure the screw jack meets safety standards and
performance expectations. This includes conducting tests, such as load testing and endurance
testing, to validate the jack's functionality and durability. In conclusion, the design and
fabrication of a screw jack is a multi-step process that involves conceptual design, detailed
design, machining, assembly, and quality control. By following these stages meticulously, a
properly designed and fabricated screw jack can be achieved, capable of effectively lifting heavy
loads in various industrial applications.

vii
Chapter One:
Introduction
A mechanical lifting device is a broad term that encompasses various types of equipment
designed to lift heavy loads or objects. These devices use mechanical principles, such as gears,
pulleys, levers, or screws, to provide the necessary force and leverage to lift the load. Here are
some examples of mechanical lifting devices: Crane, Chain Hoist, Winch, Come-along and Jack.

These are just a few examples of mechanical lifting devices, and there are many more specialized
devices available for specific lifting applications. The choice of the lifting device depends on
factors such as the load capacity, lifting height, mobility requirements, and the specific task at
hand. A jack is a mechanical lifting device used to apply great forces or lift heavy loads. A
mechanical jack employs a screw thread for lifting heavy equipment. A hydraulic jack uses
hydraulic power. The most common form is a car jack, floor jack or garage jack, which lifts
vehicles so that maintenance can be performed. Jacks are usually rated for a maximum lifting
capacity. Industrial jacks can be rated for many tons of load [8].

1.1. Historical background

The personal name Jack, which came into English usage around the thirteenth century as a
nickname form of John, came in the sixteenth century to be used as a colloquial word for 'a man
(of low status)' (much as in the modern usage 'jack of all trades, master of none'). From here, the
word was applied to things which in some way take the place of a lad or man, or save human
labor. The first verification in the Oxford English Dictionary of jack in the sense 'a machine,
usually portable, for lifting heavy weights by force acting from below' is from 1679, referring to
'an Engine used for the removing and commodious placing of great Timber [8].

1
Types of jacks

Scissor jack (screw jack)

A scissor jack uses the mechanical advantage of a lead screw and 4-bar linkage
to allow a human to lift a vehicle by manual force alone. They are inexpensive
and are common in manufacturer-supplied breakdown kits. The jack shown is
made for a modern vehicle and the notch fits into a jack-up point on a anybody.
Figure 1: Scissor Jack
Earlier versions have a platform to lift on a vehicle's frame or axle [8].

House jack

A house jack is a mechanical device primarily used to lift buildings from their
foundations for repairs or relocation. A series of jacks is used and then wood
cribbing temporarily supports the structure. This process is repeated until the
desired height is reached. The house jack can be used for jacking carrying beams
that have settled or for installing new structural beams. On the top of the jack is a
cast iron circular pad that the jacking post rests on. This pad moves
independently of the house jack so that it does not turn as the acme- Figure 2: House Jack

threaded rod is turned with a metal rod. This piece tilts very slightly, but not enough to render the
post dangerously out of plumb. [8]

Hydraulic jack

A hydraulic jack uses a liquid, which is incompressible, that is forced into a cylinder by a pump
plunger. Oil is used since it is self-lubricating and stable. When the plunger pulls back, it draws
oil out of the reservoir through a suction check valve into the pump chamber. When the plunger
moves forward, it pushes the oil through a discharge check valve into
the cylinder. The suction valve ball is within the chamber and opens
with each draw of the plunger. The discharge valve ball is outside the
chamber and opens when the oil is pushed into the cylinder. At this
point the suction ball within the chamber is forced shut and oil
pressure builds in the cylinder. [8]

Figure 3:Hydraulic Jack

2
Floor jack (Car floor jack)

In a floor jack ('trolley jack') a horizontal piston pushes on the short

end of a bell crank, with the long arm providing the vertical motion
to a lifting pad, kept horizontal with a horizontal linkage. Floor
jacks usually include casters and wheels, allowing compensation
for the arc taken by the lifting pad. This mechanism provides a low
profile when collapsed, for easy maneuvering underneath the
Figure 4: Floor Jack
vehicle, while allowing considerable extension. [8]

Hydraulic Bottle jack

A bottle jack or whiskey jack is a jack which resembles a bottle in

shape, having a cylindrical body and a neck. Within is a vertical lifting
ram with a support pad of some kind fixed to the top. The jack may be
hydraulic or work by screw action. In the hydraulic version, the
hydraulic ram emerges from the body vertically by hydraulic pressure
provided by a pump either on the baseplate or at a remote location via
a pressure hose. With a single action piston, the lift range is somewhat
limited, so its use for lifting vehicles is limited to those with a
relatively high clearance. For lifting structures such as houses the Figure 5: Bottle Jack

hydraulic interconnection of multiple vertical jacks through valves enables the even distribution
of forces while enabling close control of the lift. [8]

1.2. Problem statement

The instability of the jack when applying turns to loosen the wheel nut is the most frequent issue
with scissor jacks. Furthermore, the typical jack's narrow base makes it difficult for it to give
enough support, particularly on uneven surfaces. For Off-road and any inclination in that jack is
not applicable
From the above description about jack specially scissor jack, the standing surface is too small,
the force or weight lift is concentrated on that small surface (in other word it is not distributed
force throughout the components).so we are going try to create larger surface for load
distribution.

3
1.3. OBJECTIVE

1.3.1. General objective

The general objective of this project is to design screw jack using slider joint with simple link
mechanism with the detail drawing
Scissor jack is used to lift the heavy loads in which rotary motion is converted into linear motion.
heavy load with different conditions. The main purpose and significance of this paper is to
design, optimize and standardize the current toggle jack to make the task easier and reliable.

1.3.2. Specific objective

Design and considering the following parts

Part to be designed
- To design screw spindle having square or ACHME threaded screws
- To design nut with roller aside
- To design lifting arm with shaft on one end
- To design body(frame) of screw jack
- To design the handle to drive the screw spindle
Forces to be considered
- To consider load applied
- To consider compressive stress
- To consider shear stress
- To consider bending stress

4
Chapter two
Literature review

The literature review section provides a summary of existing research and knowledge related to
the topic. It highlights the key findings and insights from previous studies, helping to establish
the context and significance of the current research.

"Design and Analysis of Center Jack for Cars" authored by PANDRA UDAY KUMAR and
G. RAMANJULU, focuses on the design and analysis of a center jack for cars, specifically
looking at the use of power screws and pneumatic systems. The authors emphasize the
decreasing efforts required in achieving desired output through better designs. It mentions that
power screws are used to convert rotary motion into translator motion, and a screw jack is an
example of a power screw. The mechanical advantage of a screw jack is explained as the ratio of
the load applied to the effort applied. The author then discusses the design and functionality of a
scissor jack, which is commonly used as a car jack. It explains that a small force applied in the
horizontal plane is used to raise or lower a large load. The scissor jack operates by turning a lead
screw, and the compressive force is obtained through the tension force applied by the lead screw.
The authors propose the integration of an electric motor with the screw jack, with the electricity
needed for operation taken from the battery of the vehicle. The author concludes with a section
on the design and analysis of the individual parts and discusses the loading conditions, material
properties, and stress and displacement analysis [11].

"Design of Toggle Jack Considering Material Selection of Screw-Nut Combination"

published in the International Journal of Innovative Research in Science, Engineering and
Technology. The author discusses the design and material selection considerations for a toggle
jack, which is a mechanism used to lift heavy loads. The study highlights the importance of
selecting the right material combination for the screw and nut of the toggle jack to ensure the
induced stress remains within safe limits. The report presents a unique design of a toggle jack
that can lift heavy loads in a stable state. Different material combinations are considered for the
screw and nut, and analytical design is conducted for different loading conditions. The design
section focuses on the formulation of the design for the screw, nut, pins in nuts, and links. It
provides equations and calculations for determining the dimensions and properties of these
5
components. The design considerations include the maximum load on the screw, the thickness
and height of the nut, the diameter of pins, and the load on each link. The document emphasizes
the need for the critical load to be higher than the design load to ensure the safety of the design
[13].

"Design of Toggle Jack" published in the International Journal of Science, Technology &
Management provides an overview of a modified version of the simple toggle jack, which
combines the trolley mechanism and the power screw mechanism. The authors, Prof. V. A.
SHAIKH, Prof. F. U. PATHAN, Prof. G. D. SONAWANE, Prof. S. U. GUNJAL, and PRAVIN
ADKE, are associated with the Department of Mechanical Engineering at Sandip Foundation
SITRC in Nashik, Maharashtra, India. The author explains that the toggle jack is a material
handling device that involves the use of two main mechanisms: the trolley mechanism and the
power screw mechanism. The power screw, which consists of square threads, is self-locking and
used to convert rotary motion into translatory motion. The toggle jack, allows for the raising or
lowering of large loads with a small force applied in the horizontal plane.

The study explains the concept of power screws, which are mechanical devices used to convert
rotary motion into linear motion and transmit power. Power screws have various applications,
including raising loads, obtaining accurate motion in machining operations, clamping work
pieces, and loading specimens. The power screw consists of three essential parts: the screw, the
nut, and a holding arrangement. Depending on the holding arrangement, power screws can
operate in two different ways. Also discusses the advantages of power screws, such as their large
load carrying capacity, compact construction, ease of design and manufacturing, and controlled
linear motion. It highlights the advantages of square threads over trapezoidal threads, including
higher efficiency and no radial pressure or side thrust on the nut. It concludes with the
determination of the torque required to raise a load using square threaded screws and provides
equations and calculations for this purpose [12].

6
Chapter three
Concept development
So, in order to build a screw jack this need should be satisfied
- At least it should lift moderate weight
- At least it should lift moderate height
- At least it should go through min height to lift
- The screw diameter should be greater than 20mm

3.1. Concept generated

in this stage by creating alternative concepts, it is possible to evaluate relatively with the
benchmark product. The generated concepts are differentiated by this parameter
- The mechanism it uses
- The lifting method

Concept 1: scissor jack

Scissor jack works mechanically by having a central

screw connected to the central piece of metal between
two layers of crossing metal pieces. The screw performs
the same task as screws in hydraulic car lift, supporting
the metal pieces in withstanding the oppressing weight.

7
 Figure 6:concept 1(scissor jack)

No Parameter Description
1. Min height of jack Enough
2. Max lifting length Good
3. Max lifting weight From simple to moderate
Table 1: criteria for concept 1

Concept 2: screw drive linked with rotating

arm

Screw drive linked with rotating arm work by

lifting the rotating arm with the link welded to
the arm which is connection with the nut on
the screw shaft.

Figure 7: concept 2(screw jack)

No parameter Description
1. Min height of jack Small
2. Max lifting length Moderate
3. Max lifting weight From simple to moderate
Table 2: criteria for concept 2

Concept 3: trolley jack

The hydraulic floor jack, or trolley jack, consists of a

horizontal ram piston pushing the short end of a bell
crank. The bell crank's long arm connects to the lift
pad, providing vertical motion of the load. The
horizontal cylinder and piston allow the floor jack to
operate with a low profile.

Figure 8: concept 3(trolley jack)

 1.2. Concept screening
No Parameter Description
These are selection criteria for the
1. Min height of jack Small screening process.
2. Max lifting length Moderate - Compactness
3. Max lifting weight Moderate to heavy - Portability
- Max weight of jack
Table 3: criteria for concept 3

- Smooth drive
Adding some other parameters on the list based on the designing requirements such as safety,
ergonomics and ease of manufacturing might help.
In this case let’s take concept 1 as bench mark.
No Selection criteria Concept 1 Concept 2 Concept 3
1. Compactness 0 + +
2. Portability 0 + +
3. Max weight of jack 0 + 0
4. Smooth drive 0 + +
5. Safety 0 + +
6. Ergonomics 0 0 +
7. Ease of manufacturing 0 + -
Plus 0 6 5
Minus 0 0 1
Rank 3 1 2
Continue No Yes Yes
Table 4: concept screening

1.3. Concept scoring

After concept screening, passed to the next selecting stage, which is concept scoring. Be-fore proceeding
to the scoring, first the criteria a rating scale to evaluate the core of the concept should be given.

5-point rating Description

0 Inadequate
1 Weak
2 Satisfactory
3 Good
4 Excellent
Table 5: rating point

No Selection criteria Weight Concept 2 Concept 3

9
 percent Rating Score rating Score
1. Compactness 20 4 0.8 3 0.6
2. Portability 20 4 0.8 3 0.6
3. Max weight of jack 20 4 0.2 3 0.6
4. Smooth drive 10 4 0.4 3 0.3
5. Safety 5 3 0.15 4 0.2
6. Ergonomics 5 3 0.15 4 0.2
7. Ease of manufacturing 20 3 0.6 1 0.2
Total score 3.1 2.7
Rank 1 2
Continue Yes No
Table 6: concept scoring

1.4. Product specification

This chapter presents a method for establishing product specifications. We intend the term
product specifications to mean the precise description of what the product has to do. Some firms
use the terms “product requirements” or “engineering characteristics” in this way. Other firms
use “specifications” or “technical specifications” to refer to key design variables of the product.
However, while such expressions are helpful in developing a clear sense of the issues of interest
to customers, they provide little specific guidance about how to design and engineer the product.
They simply leave too much margin for subjective interpretation. For this reason, development
teams usually establish a set of specifications, which spell out in precise, measurable detail what
the product has to do. Product specifications do not tell the team how to address the customer
needs, but they do represent an unambiguous agreement on what the team will attempt to achieve
to satisfy the customer needs.
The development of a metric for each need with higher relative importance value is needed for
scoring process.
No Metrics Unit Imp
1. Minimum height Mm 3
2. Max height Mm 4
3. Load capacity Kg 4
Table 7: relative importance of the metrics

10
Create a link between the metrics and need

Need Imp

Load capacity
Metrics

Maximum
Minimum
Need No

height

height
1. Size of the jack 3 *
2. Arm length 4 * *
3. Max weight of jack 4 * *
4. Smooth drive 2
5. Safety 4 * *
6. Ergonomics 2 *
7. Ease of manufacturing 2 * *
Table 8: Create a link between the metrics and need

Comparing other products in order to generate ideal value

Metrics Unit
Need No

trolley
Scissor
Metric

jack

jack
no

1. 1,6,7 Minimum height Mm 150mm 170mm

2. 2,3,5,6,7 Maximum height Mm 320mm 360mm
3. 3,2,5 Load capacity Kg 1100kg 1700kg
Table 9:Comparing other products in order to generate ideal value

Metric Metrics Unit Marginal Ideal values

no values
1. Minimum height Mm 150mm 120mm
2. Maximum height Mm 320mm 350mm
3. Load capacity Kg 1400kg 1200kg
Table 10: comparison of marginal with ideal

Final specification

Metric Metrics unit Ideal values

no
1. Minimum height mm 120mm
2. Maximum height mm 320mm
3. Load capacity kg 1200kg
Table 11: final specification

11
Chapter four
Embodiment design
Embodiment design is one of the main stages of the product design process. Its goal is to develop
the best, at least at this stage, design layout that would become a starting point for further
detailed design. In some sources the embodiment design is referred to as preliminary design or
system-level design.
Embodiment design phase activities can be divided into three sections or phases (figure 3).
Product architecture
Design configuration
Parametric design

4.1. Product architecture

In this portion, defining the type of architecture and modularity for the product is important.
Based on the parameters and selection criteria let’s set a foot on the modular architecture and
sectional modular architecture, then proceed to the process of product architecture session.
To establish a product’s architecture, a designer defines the geometric boundaries of the product
and lays out the proposed elements of the design within its envelope.
Four steps are recommended for product architecture process
1. Create a schematic diagram of the product.
2. Cluster the elements of the schematic
3. Create a rough geometric layout
4. Identify the fundamental and incidental interactions.

Create a schematic diagram of the product.

Upper surface Handle attached to The arm rotates on the

open frame the screw shaft to pin insert attached on
create motion the frame

The inclination angle

causes to rise or
elevate the arm
Provide support for
Guide the nut
the screw shaft and
wheel on the path
pin for the arm
provided
The motion of the nut
on shaft creates an
12 angle of inclination
Cluster the elements of the schematic

Upper surface Handle attached to The arm rotates on the

open frame the screw shaft to pin insert attached on
create motion the frame

The inclination angle

causes to rise or
elevate the arm
Provide support for
Guide the nut
the screw shaft and
wheel on the path Rotating arm
pin for the arm
provided
The motion of the nut
on shaft creates an
Frame Screw shaft
angle of inclination

Connecting rod

Create a rough geometric layout

Rotating arm

Connecting rod
Screw shaft

Frame

Figure 9: rough geometric layout

13
Identify the fundamental and incidental interactions

Frame Screw shaft Screw nut

Rotating arm Connecting rod

Diagram 5.4. Identify the fundamental and incidental interactions

4.2. Configuration design

Configuration design is a kind of design where a fixed set of predefined components that can be
interfaced (connected) in predefined ways is given, and an assembly (i.e. designed artifact) of
components selected from this fixed set is required that satisfies a set of requirements and obeys
a set of constraints.
The aim is to specify the configuration of the design and associated modules to meet their
intended function. Involves
- Preliminary selection of the materials
- Selecting component manufacturing methods
- Sizing of parts
So from all mateials low carbon steel is preferable because it cheap in the stock ,easly available
and the easiest material to work with. The most mating parts are mnifactured by welding and the
holes , shaft and nuts are produced by machining process. On the sizing stage the only
dimenssion that can be set is
Thickness of the link should be 5mm sheet metal
The base dimension should be about 350 mm welded sheet metal, like box
Including the supporting links, the max height of the frame should be about 120 mm

4.3. Parametric design

Once a final design configuration is selected the design variables (parameters) must be set
through evaluation

14
Design attributes for each component are identified in configuration design and become design
variables (component attributes that may be varied by designer)
This process involves detailed modeling and analysis to determine the final parameters
System level evaluation and parametric analysis output is:
-robust design
-final sizing of parts, tolerances flow rates, chemistry, etc.
Steps for parametric design
1. Generate alternative designs (combinations of design variables)
2. Analyze /evaluate the alternative design
3. Select best alternative design
4. Refine /optimize

The generation of an alternative designs can be

Table 12: alternative design options

no Part name and alternative Description

1. Arm pivot pt – hinge, hollow and Hollow and shaft – hallow shaft is attached on the
shaft end of the arm and the solid shaft is attached to the
support frame

2. Arm – RHS or bar type RHS – because it is economical

3. Link – single or double or triple Double – is enough because it medium weight

strand

4. Handle – welded shaft or round wheel Shaft – feasible and use less space to rotate

15
Chapter five
Detail design
The detailed design of a screw shaft involves careful consideration of various factors to ensure optimal
functionality and performance. Key aspects include the selection of appropriate materials based on load
capacity and environmental conditions, determining the dimensions such as diameter and length to
withstand expected loads without excessive deflection, choosing the suitable thread profile, pitch, and
accuracy for smooth engagement and precise positioning, providing proper end support through thrust
bearings or fixed supports to maintain alignment, and considering lubrication to reduce friction and wear.
By addressing these factors, engineers can design screw shafts that meet the required load capacity,
provide smooth operation, and ensure long-term reliability in a wide range of applications.

5.1. Geometric analysis

The aim of this stage to determine the final dimensions and the transmission angle of the mechanism. So,
before the analysis there are some dimensions given in the configuration design, by using those
dimensions the other can be found mathematically.

Initial known values

Max lift from the bottom is 320

Length of the base frame is 444

Initially the transmission angle is mostly 40-60 degrees,so the max transmission angle is gained from
engineering guess which is 60°(Ɵ3)

Formulas for slider crank mechanism:

L4 =L2 cos θ 2+ L3 cos θ 3 eq(1)

L3 sinθ 3=L1 + L2 sin θ2 eq(2)

L4 =L2 cos θ 2+ L3 cos θ 3

144=161 cos θ2 + L3 cos 60

144=161 cos θ2 +0.5 L3 -------------------- 3

L3 sin 60=60+161 sin θ2

L3=69.7+ 187.2sin θ 2 -------------------- 4

Substitute 4 into 3

144=161 cos θ2 +0.5(69.7+187.2 sin θ2)

2 2
1=2.175 cos θ 2+ 0.735 sin θ 2

16
From trigonometric identity rule
2 2
sin θ=1−cos θ
2 2
1=2.175 cos θ 2+ 0.735(1−cos θ2)

θ2=64.5°

Insert Ɵ2 in the forth equation to find L3

L3=229 mm

5.2. Force analysis

Force analysis for screw jack involves determining the input force required to lift a given load, as well as
calculating the mechanical advantage and the pitch of the screw thread. This analysis considers the
frictional forces, the angle of the thread, and the torque applied to the screw jack to understand the
relationship between the input force and the resulting output force. It is essential for designing and
choosing the right screw jack for a specific application, as well as for ensuring the safety and efficiency of
the lifting process.

64.5°
Y
Fx
X
Fy Link b
mg
F bx
mg
F by

Fay Fax
64.5°
Y Link a
Fdx
X R34 F Ex E
Link F F fx
F Ey
Fdy
F fy

W=mg =1400Kg * 9.81m/s2 =13.73KN

F y= W*cos64.5° = 6KN

17
F x= W*sin64.5° =12.4KN

+ ∑ F X =0

= 12.4 KN – F Bx + F Ax = 0 -------------------------- (1)

∑ M Ax =0
=12.4 KN * 447 mm – F Bx * 149 mm = 0 -------------- (2)
12.4 KN∗447 mm
From equation (2), F Bx = = 37.2 KN
149 mm
Then from equation (1), F Ax = 37.2 KN – 12.4 KN
= 24.8 KN

+∑ F y =0

= 6KN + F Ay – F By = 0, ------------------------------ (3)

But, F By = F Bx Cos 600 = 37.2KN * 0.5 = 18.6 KN.
From equation (3), F Ay = F By – 6KN
F Ay = 18.6 KN – 6KN = 12.6 KN

5.2.1. Design for Arm

The design of the arm of a screw jack is crucial for its functionality and strength. It needs to be able to
withstand the force applied when lifting heavy loads. The arm is usually made from durable materials
such as steel or iron, which can handle the pressure without bending or breaking. The design of the arm
may also include features such as reinforced sections or ergonomic handles to make lifting easier and
safer. Overall, the design and material of the arm play a critical role in the performance and reliability of a
screw jack. The arm of a screw jack can be made from a variety of materials, including steel, aluminum,
and other metals, depending on the specific requirements for strength, durability, and weight

+V

-V

+M

-M

18
 Kt∗Mc k ∗M∗t /2 k t∗FB 3670.4Nm
δ x= + Kt∗FB = t +
I ( t 3∗w ) /12 A
1.5∗3607.4∗t /2 18.6 KN
= +
( t 3∗w ) /12 w∗t
Let’s Assume, w = 4t.
8542.17 18600
Then, δ x = 3
+ 2
t 4t
8542.17 4650
= 3
+ 2
t t
Sy
By using yield strength theory, δ x= = 420MPa / 1.5 = 280 MPa.
N
8542.17 4650
280 MPa = 3
+ 2 ---------------------------- (*)
t t
Multiply both sides by, (t3) and, divided by 280 MPa.
t = 31 mm
w = 124 mm

5.2.2. Design for Link

The link of a screw jack is an integral component that transmits the input force to the screw and
ultimately raises or lowers the load. It is typically made of high-strength steel or other durable materials
to withstand the heavy loads and forces exerted on it during operation. The material is selected based on
the specific application and load requirements of the screw jack to ensure reliable and efficient
performance.

P 37.2 kN 37.2 kN
δ C= = = 2
A w.t 4t
37200
280mpa = 2
4t
37200 N
t2= 2 = 33.21mm
2
4∗280 N /mm
t = √ 33.21 mm2 = 5.8mm w=4t =23mm

5.2.3. Design of screw shaft

The design and material of a screw shaft are crucial aspects of its functionality. The design of the
screw shaft determines its ability to efficiently transmit torque and handle the load it is intended

19
 for. The material of the screw shaft also plays a significant role in its durability, strength, and
resistance to wear and corrosion. Common materials used for screw shafts include stainless steel,
carbon steel, and aluminum, each with specific properties that make them suitable for different
applications.

↑+ ∑ F y =0=R Dy + R Ey −R Fy=0

R Dy + R Ey −37.2 KN∗sin 60 °=0

R Dy + R Ey =32.2 KN --------------------------------------(a)

+ ∑ M Ey =0=32.2 KN∗148 mm−R Dy∗444 mm=0

R Dy = 10.73KN

10.73KN

+v

-v
21.47KN

3176.08Nm

+M

-M

20
 16
d3 =
πτmax
√( Mb )2 +( Mt )2
0.5 Sy 0.5∗320 mpa
But τ max = = = 106.67Mpa
F.s F.s
d
Mt = Ft , Ft = 37.2kN *Cos60° = 18.6kN = 18600N
2
d
Mt = 18600 = 9300d
2
16
6 √
d3 = ( ( 3176.08 )2 + ( 9300 d )2 )
3.14∗106.7∗10

d3 = 0.047*106( √ ( 10.08∗10 )6 + ( 86.49∗10 )6 d 2 )

d6 = 0.0022*10-12(10.08∗106 + ( 86.49∗10 )6 d 2)

d6 = 0.0022*10-6 + 0.2*10-6
d6 – 0.0000002d2 – 00000002 = 0
d = 52mm

5.2.4. Design for frame

The design of a frame for a screw jack is a crucial aspect that ensures the stability, strength, and
efficient operation of the jack. The frame serves as the structural support for the screw and nut
assembly, providing a stable base for lifting heavy loads. During the design process, factors such
as the load capacity, stroke length, and operating conditions need to be considered to determine
the appropriate dimensions and material selection for the frame. The design should ensure proper
alignment of the screw and nut, allowing for smooth and precise vertical movement.
Additionally, considerations such as weight distribution, reinforcement, and ease of maintenance
should be taken into account to optimize the overall performance and long life of the screw jack.
By carefully considering these design aspects, a well-designed frame can enhance the reliability
and functionality of the screw jack in various industrial applications.

21.4KN
10.73K
N
6KN 12.6KN

21
 A B
30mm
C

444mm

KN∗L
∗t
2
10.73
MCA FA 2 6 KN
δ A=δ bend A +δ tor A = + = +
I A 3
t L 0.25t
12
Sut 32190 241000
= 2 +
F .s t t
600 mpa 32190 241000
= 2 +
1.5 t t
Multiply both side by (t2)
2
400 mpat =32190+241000 t
2
t + 0.00006 t−0.0000804=0
t = 8.9mm
KN ∗L
∗t
2
21.47
2 12.6 KN
δ B =δ bend B +δ tor B= +
3
t ∗L 0.25 t
12
KN ∗L
∗t
2
21.47
Sut 2 12.6 KN
= +
F .s 3
t ∗L 0.25 t
12
600 mpa 64410 5041000
= 2 +
1.5 t t
Multiply both side by (t2)
2
600 mpa∗t =64410+ 504000∗t
t2 - 0.00126t - 0.000161 = 0
t = 12mm

22
 KN∗t
12.6 ∗30 mm
MC 2
δ B− A = =
I 3
t ∗444 mm
Sut 2268
=
F . s 0.444∗t 2
600 mpa 2268
=
1.5 0.444∗t
2

t = 4mm

5.2.5. Design for handle

The handle of a screw jack is a crucial component that enables the user to manually operate and
control the lifting and lowering process. It is typically attached to the top of the screw, allowing
for easy rotation and adjustment. The handle is designed to provide a comfortable grip and
sufficient leverage, ensuring that the user can apply the necessary force to lift or lower the load.
Depending on the specific design of the screw jack, the handle may be removable or permanently
fixed to the screw. It is important for the handle to be sturdy and durable, capable of
withstanding the forces involved in the lifting operation.
dm
T r = PR dm = d- 0.6p = 52 – 0.6p = 48mm
2
dc = d – p = 52 – 8=46mm

Pr=F ( πdm−µl
µπdm+l
)
= 18.6kN(
π 0.048−0.15∗0.008 )
0.15 π∗0.048+0.008
= 3.6kN

48 m
TR = 3.8kN* = 91Nm
2
dm
T L = PL
2

PL = F ( µπdm−e
µl+ πdm )

= 18.6kN(
0.15∗0.008+ π∗0.048 )
0.15 π∗0.048−0.008
= 1.8kN

23
 48
TL= 1.8kN* = 43Nm
2
Tt t = TR + TL = 134Nm
F app*L handle = 134Nm L handle = 0.46m
134 Nm
F app = = 297.7N
0.45

Chapter six
Design for manufacturing
6.1 Manufacturing cost
Manufacturing cost for a sheet metal roller bending machine project is include:
 Components cost
 Assembly cost
 Overhead cost

6.1.1 Component cost

It is cost of the material that are going to be machined or deformed for the production of the
machine.
Table 13 component cost

No Components Type of material Specification Unit Quantity Cost

name (ETB)

1 Support Frame Metal plate 180*250mm Pcs 1 1000

t=8mm
2 Arm Steel 60*447 Pcs 1 800

3 Link Steel 15*320mm Pcs 1 400

4 Handle Steel 20*70mm Pcs 1 200

5 Nut Steel 53*80 Pcs 1 50

24
 6 Screw shaft Steel shaft 52*428 Pcs 1 400

Total 2850

6.1.2 Assembly cost

Then the labor cost for each type of machining operation is calculated as below,
Assuming a monthly salary of someone working twenty two days per month to be 6,000
Birr, Then his labor rate is calculated as below.

Labor cost=

Labor rate=

Labor rate=272.72 Birr/day

Assuming the labor works 8 hrs. Per day then, his labor rate per hour is calculated
as below:

Labor rate per hour =

Labor rate per hour =

=34Birr/hour

Labor cost=
1. Labor cost on tool grinding machine
34 Birr/hr * 4 hr.

25
 =136Birr
2. Labor cost on lathe operation
34 Birr/hr * 10 hr
=340 Birr
3. Labor cost on welding operation
34 birr/hr * 15 hr.
= 510 Birr
4. Labor cost on radial drilling machine
34 Birr/hr. * 2hr
=68 Birr

Equipment and tool cost ------------------Br. 500

Total assembly cost is = 500 + 68 + 510 + 340 + 136 Birr
= 1554 Birr

6.1.3 Manufacturing overhead

Any manufacturing cost that is neither direct material cost nor direct labor cost is manufacturing
overhead, it includes
1. Indirect material cost.
2. Indirect labor cost.
3. Other indirect manufacturing cost.
Table 14 Machine hour rate (machine cost)
No Machine Machine Machining Machining Machining
time( time( cost(euro ) cost(Birr
1 Portable grinding machine ½ 1/4 15.38 843.1316
2 Lathe 50 20 2.31 126.6342
3 Welding machine 5 4 0.24 13.1568
4 Radial drilling ½ 1/4 4.08 223.6656
1. Cost on portable grinding machine = machining time (hr.) * machining cost (birr/hr.)

= 1/2hr * 800 Birr/hr.

= 400 Birr.
2. Cost on lathe machine = machining time (hr.) * machining cost (birr/hr.)
= 10 hr. * 120 Birr

26
 = 1200 Birr
3. Cost on welding machine = machining time (hr.) * machining cost (birr/hr.)
= 8 hr. * 14 Birr/hr.
= 112 Birr
4. Cost on drilling machine = machining time (hr.) * machining cost (birr/hr)
= ½ hr. * 224 birr.hr
= 122 Birr
Overall cost of machine = 400 + 1200 + 112+ 122
= 1834 Birr
Total cost of the screw jack = 1834 + 2850+ 1554
= 6238 Birr

27
Conclusion
In conclusion, the design and fabrication of a screw jack require a thorough understanding of
engineering principles and manufacturing techniques. This project report provides valuable
insights into the various stages involved in designing and constructing a screw jack.

The literature review section provides a comprehensive overview of different types of jacks,
including scissor jacks, house jacks, hydraulic jacks, floor jacks, and hydraulic bottle jacks. Each
type is discussed in terms of its functionality and specific applications.

The concept development section explores different concepts for the screw jack design, such as
scissor jack, screw drive linked with a rotating arm, and trolley jack. The concept screening and
scoring process helps identify the most suitable concept for further development.

The embodiment design section focuses on the product architecture and configuration design. It
includes creating a schematic diagram, clustering elements, and determining the fundamental and
incidental interactions. Parametric design is also discussed, ensuring the optimal dimensions and
functionality of the screw jack.

The detail design section investigates into geometric and force analysis to ensure the structural
integrity and performance of the screw jack. The design considerations for the arm, link, screw
shaft, and frame are highlighted, emphasizing the importance of stability, strength, and ease of
use.

The abstract provides a concise summary of the entire project, outlining the key stages involved
in the design and fabrication of a screw jack. It emphasizes the significance of conceptual design,
detailed design, machining, assembly, and quality control in achieving a well-designed and
functional screw jack.

Recommendation
Based on the findings of this project report, it is recommended that further research and
development be conducted to enhance the design and functionality of screw jacks. Some areas of
focus for future studies could include:

1. Material Selection: Investigate the use of advanced materials that offer improved strength-to-
weight ratio and corrosion resistance to enhance the performance and durability of screw jacks.

2. Ergonomics: Explore ergonomic design principles to optimize the user experience and ensure
ease of operation, particularly in scenarios where heavy loads need to be lifted.

3. Safety Measures: Conduct a comprehensive analysis of safety features and implement

additional measures to minimize potential hazards during the operation of screw jacks.

28
4. Automation and Integration: Investigate the possibility of incorporating automation and smart
technologies into screw jack designs to enhance efficiency and control.

5. Environmental Impact: Assess the environmental impact of screw jack manufacturing

processes and explore ways to minimize energy consumption and waste generation.

By addressing these areas of improvement, the design and functionality of screw jacks can be
enhanced, making them more efficient, safe, and environmentally friendly for various industrial
applications.

29
References
1. Shigley, J.E., Mischke, C.R. (2010). Mechanical Engineering Design. McGraw-Hill, New
York.
2. Norton, R.L. (2005). Machine Design: An Integrated Approach. Pearson, Boston.
3. Bhandari, V.B. (2010). Design of Machine Elements. McGraw-Hill Education, New
Delhi.
4. Hicks, T.G. (2006). Handbook of Mechanical Engineering Calculations. McGraw-Hill
Professional, New York.
5. Shigley, J.E., Mischke, C.R., Brown Jr., T.H. (2010). Standard Handbook of Machine
Design. McGraw-Hill Education, New York.
6. Sclater, N., Chironis, N. (2000). Mechanisms and Mechanical Devices Sourcebook.
McGraw-Hill, New York.
7. Lindeburg, M.R. (2019). Mechanical Engineering Reference Manual. Professional
Publications, Belmont, CA.
8. Jackscrew, wikipedia.org.2023, https://en.wikipedia.org/wiki/Jackscrew
9. Screw Jack, google.com.2024, https://en.wikipedia.org/wiki/Jackscrew
10. How a Screw Jack Works, power jacks precision
actuation,2023,https://www.powerjacks.com/
11. Kumar, P.U., & Ramanjulu, G. (Year). Design and Analysis of Center Jack for Cars. International
Journal of Innovative Research in Science, Engineering and Technology, Vol. 2
12. Shaikh, V. A., Pathan, F. U., Sonawane, G. D., Gunjal, S. U., & Adke, P. (2015). Design of
Toggle Jack. International Journal of Science, Technology & Management, Retrieved from
www.ijstm.com
13. Patel, N. R., Dalwadi, S., Thakor, V., & Bamaniya, M. (2013). Design of Toggle Jack
Considering Material Selection of Screw-Nut Combination. International Journal of Innovative
Research in Science, Engineering and Technology

30
Appendix

Part A: Part Drawings

 Arm
 Support
 Screw Shaft
 Frame
 Nut
 Link

31
32
Drawing 1: ARM

33
Drawing 2: Support

34
Drawing 3: Screw Shaft

35
Drawing 4: Frame

36
Drawing 5: Nut

37
38
Drawing 6: Link

39
Part B: Assembly dtawing

40
41