Chapter 4

4.Design analysis
Designing of components
To design the parts, components, products or system of mechanical nature and typically focus on
the feasibility of a components from cost analysis all the way through to function.

4.1 Design of rotating screw

The material selected to design the screw is steel and have a properties like;

ultimate strength1860MPa

yield point strength 520MPa

safety factor 2.5

used to transmit torque or power from the worm gear to the nut

have coefficient of friction 0.18 at starting 0.13 at running condition

use should select square thread because it has radial efficiency or bursting pressure on the nut
and it can’t be easily get wear

design procedure

step 1 calculating core diameter

2
π dc
σc=F/Ac Ac¿ Where; Ac is core area, Dc is core diameter
4

σc is compressive stress

F lifting load

Given 1.5 tone =1.5x1000=1500kg and

F=mg =1500x10=15000N

σc =Sy/FS σc =520/2.5=208MPa
σc =4F/(π〖dc〗^2 ) dc=√(4F/π σc) dc=√(4x15000/πx208)=√91.82=9.58mm

Core diameter is 10mm, from standard dimension of screw table

Core diameter=10mm

Nominal diameter(d)=12mm

Major diameter for bolt (d)=12mm

Major diameter for nut(D)=12.5mm

Depth of thread for the bolt (h)=1mm

Depth of thread for the nut(H)=1.25mm

Minor diameter= 10mm

Pitch=2mm

Area of core=78.5mm 2

Step 2 find

Find torque (T) =?

Shear stress (τ) =? Due to the load (compressive stress)

The body of screw it will form an inclined plane

Where Pi = pitch of the screw

d= mean diameter of screw

p= effort applied of the circumference of the screw to lift the load

W=load to be lifted

µ=coefficient of friction between the screw and the nut

µ=tan Φ

Φ= friction angle

From the figure 4.2

 pi 2 mm
tanα = = =3.3
πd π x 11
−1
tan ( 0.1818 )=10.3 = Φ

Then from the figure 3.1

T=?

d d
T= px =wctan ¿ α+Φ) where, W=mg=1500 x 10= 15,000N
2 2

11 dc+ do 10+12
T= 15,000N tan (10.3+3.3) ( ) d= = =11mm
2 2 2

T= (15,000) (0.24) (5.5)

T=19.97Nm this much torque is required to rotate the screw

1.shear stress due to torque (T)=

16 T
τ=
π ¿¿

2. Direct compressive stress due to the axial load

W
δc= π MPa
¿¿
4

3. maximum efficiency of a square thread screw is calculated by the formula

tanα tan ⁡( 3.3)

ῆ= = =24.02 %
tan(α+Φ ) tan(13.6)

 There for the efficiency is self-locking because it is less 50%.

Step 3: maximum principal stress (tensile or compressive)

1 1
A. δmax¿ ( δc ) + √δc + 4 τ =¿ ( 191 ) + √(191) + 4 (101) =95.5+278=373.5 MPa
2 2 2 2
2 2
B. Maximum shear stress

1 2 1
τmax =
2
√ δc +4 τ = √(191) + 4 (101) =139 MPa
2
2
2 2

 By using maximum shear stress theory find permissible stress

 σ y 560 Mpa
τper = = =112MPa
2 Fs 2 x 2.5

Step 4: checking the screw for bulking load

1
A. L=lift screw + height of Nut
2

Lift of screw = maximum lifting height – minimum lifting height= 148-80=68mm

W
B. Bearing pressure Pb = π
(do 2−dc 2)n
4

W 15,000
= =33.4 approximate ¿ 34
n= π 2 2 π 2 2
(do −dc ) Pb (12 −10 )13
4 4
C. Height of nut= 34 x 2 = 68mm

[ ] [ ]
2 2
Wc 1−σ y l 1−σ y l
Critical buckling load = σ y = , Wc= Ac. σ y = Ac. σ y
Ac 2
4 cπ Ek
2 2
4 cπ Ek
2

Wc=

Step 5: checking design whether it safe or not. By using different design theory

 Maximum principal stress theory

 Maximum shear stress theory
1. According to Maximum principal stress theory

σy 520
σt ≤ =201 ≤ =20.8MPa, then the design is safe according to this theory.
Fs 2.5

2. According to maximum shear stress theory

σy
≤ τmax , where τmax is induced maximum shear stress
2 x Fs

520
≤ 139 ,104 ≤139 ,this design is safe according to this theory.
2 x 2.5

4.2 Design of Nut

 Nut is of the part of the bottle car jack with have an internal thread in order to directly
mash with the screw and have an external thread in order to mash with the nut.
  Since, this design is needs two nut to lift a height which is greater than the total head of
the jack and reach the required height lift.
 Bronze is selected material for the nut with having copper and phospherus. So it has an
ultimate tensile strength of 290 MPa

4.2.1 Design of Nut 1

 The nut have an external (Nut) and internal (screw) thread on the surface.

Step 1: Dimension of the Nut are the first thing to find out

 The inner diameter of the nut (dc) is the outer diameter of the screw therefor it will be
dc=12mm
 The outer diameter of the screw of the thread on the nut (dc ) is the inner diameter of the
screw equal to dc= 10mm
 n=2.5, p=2, pd=13MPa

Step 2: outer diameter of the nut

 Considering tearing strength of the nut

2 4W 2 4W 2
π 2 2 σt Dc = + dc = +dc
W= ( Dc −dc ) , σt σt =
4 Fs π π
Fs Fs
Dc=
 Considering crushing of the nut
2 4W 2
π 2 2 σc Do = + Dc
W= ( Do −Dc ) , σt =
4 Fs π
Fs
Do=

W W
p 2
Step 3: t= = =1 mm , Pb= π , n= π h= nxp
2 2 (do 2−dc 2)n (do 2−dc 2) Pb
4 4

W W
τnut = = =¿
π . n . do . t π .n . do . t

σy σy σy
τnut < , =¿ τnut <
2 x Fs 2 x Fs 2 x Fs
σy
according to maximum shear stress theory the design of Nut is safe because τnut <
2 x Fs

4.2.2 Design of Nut 2

 The material is same as nut 1.
  This nut has same height as the previous but it has only internal thread directly mesh with
nut 1.

Step 1: calculating inner diameter of nut

o The inner diameter of the nut 2 is equal to outer of the nut 1. dc2=Do=
o The outer diameter of the nut 2 is equal to the inner diameter of nut 1.do2=Dc=

Step 2: calculate outer diameter (D2) of the nut 2 by considering compressive strength of the nut

2 4W 2
π 2 2 σc D2 = +dc
W= ( D 2 −dc ) , σt =
4 Fs π
Fs

D2=

Step 3: check whether the design is safe or not.

W W
τnut = = =¿
π . n . do . t π .n . do . t

σy σy
According to maximum shear stress theory τnut < , τnut <
2 x Fs 2 x Fs

Then the design is safe.

4.3 Design of worm and worm gear

o Worm gear are widely used for transmitting power at high velocity ratio between non-
intersecting shaft that are not necessary at right angle.
o In design of worm gear first design the worm.

4.3.1 Design of worm

o Worms are cylindrical in shape with uniform pitch diameter the worm made from harden
steel material.
 To calculate the worm assume the following parameters.
 Center distance between the worm and gear
 The worm rotate at 100 rpm (by human hand)
 20◦ involute worm
 Velocity ratio 1:12
 Let’s IN= Normal load, ʎ= lead angle, L= axial lead

cot ʎ =VR , cot ʎ =12 , cot ʎ =¿ ¿2.29 ʎ =23.6◦

3 3

X 1
=
[
1
+
VR
¿ 2 π sin ʎ cos ʎ = ¿ ]
180 1
=
1
[
+
VR
2 π sin 23.6 cos 23.6
180
, ¿ =2.5 ,∈¿ ]
180
2.5
  IN= 72mm
ln ln 72
 Axial lead (ℓ)= =cos ʎ , l = = =78.6 mm
L cos ʎ cos 23.6
From the table at VR=12 the number of starts threads on the worm n=Tw=4
 Axial pitch of the thread on the worm = (Pa=Pc)
l 78.6
Pa= = = 19.6mm
4 4
Pa 19.6
 Module (M)= Pa= πM , M= = = 6.25 approximate to 6mm
π π
The module should 6mm.
 Axial pitch of the thread on the worm
Pa= πM = π x 6=18.85mm
 Axial lead of the thread on the worm
h = Pa x n = 18.85 x 4 = 75.4mm
 Normal lead of the thread on the worm
ℓN= ℓcos ʎ =75.4 x cos 23.6=69.09 mm

 Center distance (X) = [

lN 1
+
VR
]
2 π sin 23.6 cos 23.6
= [
69.09 1
+
12
]
2 π sin 23.6 cos 23.6
=

X=
 Pitch circle diameter of the worm (Dw)
l 75.4
Dw = = = 55.04mm
πtan ʎ πtan (23.6)
 Number of teeth on the worm gear (TG)
TG= n x VR = 4 x 12 = 48
TG= 48
 Face length of the worm or the length of thread portion (l w ¿
l w=Pc( 4.5+0.02 Tw)where , Pa=Pc=18.85 mm , n=Tw=4
l w=18.85 ( 4.5+0.02 x 4 ) =18.85 x 4.58=86.33 mm
l w=86.33 mm

NB: this design have clearance 25mm for the feed marks produced by the vibrating grinding
wheel as it leave the thread root,

Lw= 86.33 + 25 =111.33mm

Lw= 111.33mm

 Depth of teeth (h) = 0.632 x Pc = 0.632 x 18.85 = 11.14mm

 Out side diameter of the worn Dwo= Dw+12A where, A- addendum of the worm teeth
Dw- diameter of worm
 Addendum (A)= 0.286 x Pc = 0.286 x 18.85 = 5.3911mm
 Dwo= 55.04 + 2(5.3911)= 65.82 mm
4.3.2 Design of the worm Gear
 Which made from phosphors bronze
 Pitch circular diameter of the worm gear( DG)= M x TG = 6 x 48 = 288mm
 Outside diameter of the worm gear (DoG)
DoG= DG + 0.8903(Pc)=288 + 0.8903(18.85)=304.78mm
 Throat diameter (DT)=DG+0.572Pc=288+ 0.572(18.85)= 298.78mm
 Face width (b)= 2.15 x Pc + 5mm = 2.115 x 18.85 + 5mm = 45.53mm
 Radius of the Gear Face (Rf)=0.914 x pc + 14 = 0.914 x 18.85 +14 = 31.2mm
 Radius of gear rim (Rm)= 2.1 x Pc + 14 = 2.1(18.85) + 14 mm= 53.5mm

Force analysis
Let’s Nw = speed of the worm, NG= speed of the worm gear, VR= velocity ratio which is 12

 Assume that the exert a force of 90N

 It can rotate the worm at Nw=100rpm
Nw 100
 VR= = = 8.33 rpm
NG 12
F x NG x 2 π 90 x 12 x 2 π
 Power = = = 78.5 w
60 60
p x 60 78.5 x 60
 Torque Transmitted (T)= = = 89.9 Nm
2 π x NG 2 π x 8.33

1. Tangential load acting

2 x T 2 x 89.9
WT= = = 624.3 N
DG 0.288
π x DG x NG π x 0.288 x 8.33
o Peripheral velocity of the worm gear(v) = = = 0.125
60 60
6 6
o Velocity factor (Cv) = = = 0.979
6+ v 6+o .125
o Tooth form factor for 20◦ involute gear
0.912 0.912
Y= 0.154 - = 0.154 - = 0.135
TG 48

Wt design = δo x Cv x b x π xM x Y ,where, δo = 84 N/m2 for phosphors bronze

Wt = 84 x 0.979 x 45.5 x 6 x 3.14 = 9527.3 N

There for Wt design > Wt induced, so the design is safe.

2. Dynamic load acting on the worm gear

Wt 624.3
WD = = = 637.7N, there for the design is safe because of WD>Wt.
Cv 0.979
3. Determine for static load or endurance strength (Ws)
 o Flexural endurance limit for phosphors bronze is δe=168 MPa
o Ws= δe x b x π xM x Y = 168 x 45.5 x 3.14 x 6 x 0.135 = 19451.6 N
Since Ws>Wt, there for the design is safe from static load.
4. Determine for the wear load (Ww)
o Worm for this design made from harden steal, there for load stress factor(k) for
harden steel worm and phosphorus bronze worm gear (k=0.55MPa) from table
o Ww=DG x b x K=288 x 45.5 x 0.55= 7207.2 N, which is greater than Wt induced
there for the design is safe from stand point of wear
Figure

4.4 Design of worm shaft

 It is a shaft which do have a worm gear profile unites length.
 A material selected to design the worm shaft is high strength low alloy steel type
(ASME)(A709)
 Also made from carbon steel
Properties – yield strength of low alloy steel =690MPa
- ultimate strength = 760 MPa
Step 1: Determine the force acting on the worm shaft
Let’s dw= diameter if worm shaft

A. Torque acting on worm gear shaft (Tgear)

1.25 x 60 x p 1.25 x 60 x 72
Tgear= = = 103.2Nm
2 x π x NG 2 x π x 8.33
B. torque acting on the worm shaft (Tworm)
Tgear
Tworm= ῆ- efficiency of the worm gear
VR . ῆ
π x Dw x Nw π x 0.3304 x 90
Rubbing velocity (Vr) = = = 16.98 m/mi= 0.283 m/s
cos ʎ cos 23.6
VR 0.283
Coefficient of friction (µ) = 0.025 + = 0.025 + = 0.25
18,000 18,000
µ= 0.25
o for the speed below 16.98 m/min
o for the speed below angle of friction Φ = tan−1 ¿ = tan−1 ¿=14.04
tan(ʎ ) tan(23.6)
o ῆ= = = 0.567
tan(ʎ )+Φ tan(23.6)+14
o ῆ=56.7 %

Tgear 103.2
Tworm= = = 15.17 Nm
VR . ῆ 12 x 0.567
 C. Tangential force acting on the worm
2 x Tworm 2 x 15.17
Wt= = =551.6 N
Dw 0.055
D. Axial force acting on the worm
2 x Tgear 2 x 103.2
WA= = = 716.6 N
DG 0.288
E. Radial spacing force on the worm
WR= WA x tan (Φ ¿ = 716 x tan (20)= 260.8N
Assume the distance between the bearing of the worm shaft is equal to the diameter of the
worm gear. X1=DG= 288mm

Bending Moment
1. Bending moment due to axial load (WA) in the vertical plane
WA x DW 716.6 x 0.288
M= = = 9.85 Nm
4 4
2. Bending moment on the vertical plane due to radial force
WR x X 1 260.8 x 0.288
M= = = 75.11 Nm
4 4
 Total bending moment on the vertical plane
My= 75.11 + 9.85 =84.96 Nm
3. Bending moment due to tangential force in the horizontal plate
WT x DG 551.6 x 0.288
M= = = 39.7 Nm
4 4
 Resultant bending moment on the worm shaft
Mworm= √ (84.96)2 +(39.7)2 = 92.7 Nm
4. Equivalent twisting moment on the worm shaft
Tequ= √ (Tworm)2 +(Mworm)2 = √ (15.17)2 +(92.7)2 = 93 Nm
π π 3
Tequ = x τ x (dw)3 , 93.9= x 50 x (dw)
16 16
dw= 21.2mm
Maximum shear stress induced
16 x Tequ 16 x 93.977
 Actual shear stress (τ) = 3 = 3 = 2.422 MPa
π x (dw) π x(21.2)
 Direct compressive stress on the shaft due to axial force
WA 716.6
δc = π = π = 2.02 MPa
x (dw)2 x (21.2)2
4 4

Maximum shear stress (τmax)=

1
2√ 1
δc2 +4 τ 2=¿ √ (2.02)2 +4 (2.4)2 ¿=2.6MPa
2

There for τmax < τ, so the design is safe

2.6 MPa < 50 MPa