Design of Power Screw for Compression Tester

Design Requirements
Max Compressive Load Applied (N) 55000.0000
Max Compressive Load Applied Per Lead Screw (N) 27500.0000
Factor of Safety (Material) 2.0000

Power Screw Calculations

Root Diamter of Screw (m) 0.0058
Root Diamter of Screw (mm) 5.8164
Selection of Next Standard Size, dc (mm) 23.0000
Selection of Next Standard Size, dc (m) 0.0230
Outer Diamter (mm) 28.0000
Pitch Fine Series (mm) 5.0000
No. of Starts 2.0000
Lead, L (mm) 10.0000
Area of Core (mm^2) 415.4756
Area of Core (m^2) 0.0004
Mean Diameter, dm 25.5000
Tan α = L/πdm 0.2590
Coefficent of friction, µ= tanϴ 0.1500

Power Screw Operation Requirements

Min Speed, (mm/min) 7
Max Speed, (mm/min) 150
Min Rotational Speed, (rpm) 1.4
Max Rotational Speed, (rpm) 30
Min Rotational Speed, (rad/s) 0.1466
Max Rotational Speed, (rad/s) 3.1416
Power to Operate at Min Speed, P, (kW) 0.0514
Power to Operate at Max Speed, P, (kW) 1.1015
ew for Compression Tester
Material Properties
Material Selected AISI 4340 Steel
Youngs Modulus, E (GPa) 210.0000
Material Yeild Strength (MPa) 930.0000
Compressive Strength (MPa) 2070.0000
Ultimate Tensile Strength (MPa) 1220.0000
Permissible Yeild Stress (MPa) 465.0000
Permissible Working Stess (MPa) 1035.0000

Power Screw Stress Analysis

Tangetential Force (N) 11702.1277
Tangetential Force (kN) 11.7021
Torque Required (kN.m) 0.3506
Direct Compressive Stresses, σ_c (Pa) 66189201.2859
Direct Compressive Stresses, σ_c (MPa) 66.1892
Shear Stresses (kPa) 146767.3594
Shear Stresses (MPa) 146.7674
Max Combined Stress (MPa) 150.4524

Power Screw Buckling Analysis

End Conditions Constant, C 4.0000
Effective Length, Leff (m) 3.0000
Yeild Stress (MPa) 469.0000
Area Moment of Inertia (mm^4) 482749.6935
Radius of Gyration, k (mm) 34.0870
Youngs Modulus, E (Pa) 2.00E+11
Critical Load (N) 302458.2256
Critical Load (kN) 302.4582
FOS (Buckling) 10.9985
 Gear Box Parameters
Input Speed,N1 (rpm) 1200
Output Speed (rpm) 30
Reduction Ratio 40 to 1
Module from AGMA Table 3
Gearing Stages 2
Over All Reduction Ratio 40
Min No of teeth to avoid interference 15
First Reduction ratio (N2/N1) 5.00
Second Reduction ratio (N4/N3) 8.00

Pitch Circle Diameters of the Gears

PCD of Gear 1 66
PCD of Gear 2 330
PCD of Gear 3 51
PCD of Gear 4 408

Force Analysis
Angular velocity of Gear 1, ω1 (rad/s) 125.66370614
Angular velocity of Gear 2, ω2 (rad/s) 25.132741229
Angular velocity of Gear 3, ω3 (rad/s) 25.132741229
Angular velocity of Gear 4, ω4 (rad/s) 3.1415926536
Pitch line velocity of Gear 1, V1 (m/s) 4.1469023027
Pitch line velocity of Gear 2, V2 (m/s) 4.1469023027
Pitch line velocity of Gear 3, V3 (m/s) 0.6408849013
Pitch line velocity of Gear 4, V4 (m/s) 0.6408849013
 No of Teeth and Tip Diameter of Each Gear
Teeth on Gear 1 22
Teeth on Gear 2 110
Teeth on Gear 3 17
Teeth on Gear 4 136
Tip Dia of Gear 1 (mm) 72
Tip Dia of Gear 2 (mm) 429
Tip Dia of Gear 3 (mm) 66
Tip Dia of Gear 4 (mm) 429

Center to Center Distance

Center to Center distance of Gear 1 and 2 198
Center to Center distance of Gear 3 and 4 198

Gear Strength Analysis

Lewis Form Factor (Gear 1), Y1 0.34
Lewis Form Factor (Gear 2), Y2 0.45
Lewis Form Factor (Gear 3), Y3 0.303
Lewis Form Factor (Gear 4), Y4 0.458
Velocity Factor (Gear 1), Kv 1.67982
Velocity Factor (Gear 1), Kv 1.67982
Velocity Factor (Gear 1), Kv 1.10506
Velocity Factor (Gear 1), Kv 1.10506
Load transmitted (Gear 1),Wt1 (kN) 0.43983
Load transmitted (Gear 2), Wt2 (kN) 0.43983
Load transmitted (Gear 3), Wt3 (kN) 2.84593
Load transmitted (Gear 4), Wt4 (kN) 2.84593
Circhular Pitch, p, (mm) 9.42478
Face Width, F, (mm) 47.1239
AGMA bending strength, σ1 (Gear 1) 15.371
AGMA bending strength, σ2 (Gear 2) 11.6137
AGMA bending strength, σ3 (Gear 3) 73.4187
AGMA bending strength, σ4 (Gear 4) 48.5718
 Material Properties
Material Selected AISI 4340 Steel
Youngs Modulus, E (GPa) 210.0000
Material Yeild Strength (MPa) 930.0000
Compressive Strength (MPa) 2070.0000
Ultimate Tensile Strength (MPa) 1220.0000
Factor of Safety (Material) 54.7059
Permissible Yeild Stress (MPa) 121.7647
Permissible Working Stess (MPa) 37.8387
 Worm Shaft Diameter
Ouptut Torque (N.m) 307.275
Effieceincy of Transmission (Assumed) 0.8
Input Torque (N.m) 409.7
Shear Strength of Material (Pa) ###
Diamter of Shaft (m) 0.01821081
Diamter of Shaft (mm) 18.2108132
 Number of load cycles
Years 20
Working Days/Week 6
working Hours/day 8
Weeks per year 52
Weeks per 10 year 1040
Day in 520 weeks 6240
Hour in 2600 days 49920
Minutes in 20800 hours 1248000
Rotational Velocity 800
Number of load cycles N 936000000