3

NOMENCLATURE
p - Pitch of screw thread
(mm) l - Lead of screw
thread (mm)
d - Nominal diameter of
screw (mm) dc - Core
diameter of screw (mm) dm -
Mean diameter of screw
- Helix angle of screw
(degree) W - Load (kg)
N - Normal reaction
- Coefficient of
friction P - Effort
(N)
- Friction angle
(degree) T - Torque
(N.m)
- Efficiency (%)
Fc - Direct compressive stress
(N/mm2) Ft - Torsional shear
stress (N/mm2)
Fs - Principal shear stress
(N/mm2) Ts - Transverse shear
stress (N/mm2)
t - Thread thickness at the core diameter (mm)
n - Number of threads in engagement with the nut.
Tn - Transverse shear stress at the root of the
nut (N/mm) Pb - Unit bearing pressure
(N/mm)
k - Least radius of gyration of the cross-section about
its axis (mm) I - Least moment of inertia of the cross-
section (mm4)
A - Area of the cross-section
(mm2) Pcr - critical load (N).
E - Modulus of elasticity (N/mm)
Syt - Yield strength of the material (N/mm2)
M - Maximum bending moment at the
critical section WT - Tangential load acting
at the tooth (N)
h - Length of the tooth (mm)
y - Half of the thickness of the tooth (t) at critical
section (mm) b - Width of gear face (mm)
Fw - Permissible working
stress y - Lewis form
factor
Fo - allowable static stress
(N/mm2) Cv - velocity factor.
v - Pitch line velocity
(m/s.) WD - Total
dynamic load (N)
WT - Steady transmitted load (N),
WI - Incremental load due to dynamic
action (N) C - A deformation or dynamic
factor (N/mm)
K - A factor depending upon the form of the teeth of a gear
EP - Youngs modulus for the material of the pinion in N/mm2
EG - Youngs modulus for the material of the gear in N/mm2

4
 e - Tooth error action in
mm WS - Static tooth
load (N) Wd - Dynamic
tooth load
Ww - Maximum or limiting load for
wear (N) Dp - Pitch circle diameter
of the pinion in mm Q - Ratio factor
K - Load stress factor (N/mm2)
- Surface endurance limit (N/mm)
- Pressure angle
N1 - Motor speed (RPM)
N2 - Output speed (RPM)
D2 - Diameter of the roller gear wheel (mm)
D1 - Diameter of the motor gear wheel (mm)

5
 ABSTRACT

With the increasing levels of technology, the efforts being put to

produce any kind of work has been continuously decreasing. The
efforts required in achieving the desired output can be effectively
and economically be decreased by the implementation of better
designs.

Power screws are used to convert rotary motion into translatory

motion. A screw jack is an example of a power screw in which a
small force applied in a horizontal plane is used to raise or lower a
large load. The principle on which it works is similar to that of an
inclined plane. The mechanical advantage of a screw jack is the ratio
of the load applied to the effort applied. The screw jack is operated
by turning a lead screw. The height of the jack is adjusted by turning
a lead screw and this adjustment can be done either manually or by
integrating an electric motor.

In this project, an electric motor will be integrated with the screw

jack and the electricity needed for the operation will be taken
from the battery of the vehicle and thereby the mechanical
advantage will be increased.
6
 CONTENTS
DECLARATION........................................................................................................................
2

ACKNOWLEDGEMENT.......................................................................................................
3

NOMENCLATURE..................................................................................................................
4

ABSTRACT................................................................................................................................
6

Chapter I. LITERATURE SURVEY.........................................................................

10

Chapter II. POWER SCREWS.................................................................................

14

Section 2.01 Applications...................................................................................

14

Section 2.02 Advantages....................................................................................

14

Section 2.03 Disadvantages.............................................................................

15

Section 2.04 Forms of Threads.......................................................................

16

(a) Advantages of square threads............................................................

16

(b) Disadvantages of square threads.....................................................

16

(c) Advantages of Trapezoidal Threads................................................

17

(d) Disadvantages of Trapezoidal Threads.........................................

17

(e) Advantages of Buttress Threads.......................................................

18
Section 2.05 Designation of Threads..........................................................
19

(a) Multiple Threaded Power Screws......................................................

19

Section 2.06 Terminology of Power Screw..............................................

20

Section 2.07 Torque Requirement- Lifting Load..................................

22

Section 2.08 Torque Requirement- Lowering Load............................

24

7
 Section 2.09 Self-Locking Screw....................................................................
25

Section 2.10 Efficiency of Square Threaded Screw..........................

26

Section 2.11 Coefficient of Friction..............................................................

27

Section 2.12 Buckling of Columns................................................................

27

Chapter III. SCREW JACK...........................................................................................

30

Section 3.01 The Screw........................................................................................

31

Section 3.02 Operation.........................................................................................

31

Section 3.03 Construction of a Screw Jack.............................................

32

Section 3.04 Function............................................................................................

32

Section 3.05 Features............................................................................................

32

Section 3.06 Benefits.............................................................................................

33

Section 3.07 Types...................................................................................................

33

(a) Mechanical Jacks..........................................................................................

33

(b) Hydraulic Jacks..............................................................................................

36

Section 3.08 Design of Screw Jack...............................................................

37

(a) Loads & Stresses in a Screw................................................................

 37

(b) Thrust Bearings.............................................................................................

39

(c) Operational Considerations of a Screw Jack..............................

40

Chapter IV. MOTORIZED SCREW JACK.............................................................

42

Section 4.01 Introduction....................................................................................

42

Section 4.02 Need for Automation...............................................................

42

8
 Section 4.03 Parts of Motorized Screw Jack...........................................
43

(a) Power Source..................................................................................................

44

(b) Toggle Switch..................................................................................................

45

(c) Control Cables................................................................................................

46

(d) 12V DC Motor.................................................................................................

46

(e) Connecting Shaft..........................................................................................

47

(f) Screw Jack..........................................................................................................

48

Section 4.04 Advantages....................................................................................

49

Chapter V. DESIGN CALCULATIONS.................................................................

50

Section 5.01 To Check the Safety of Lead Screw...............................

50

Section 5.02 To Check Buckling of Screw................................................

51

Chapter VI. conclusion...............................................................................................

52

Chapter VII. Bibliography.......................................................................................

53
9
 CHAPTER I. LITERATURE SURVEY

Screw type mechanical jacks were very common for jeeps and
trucks of World War II vintage. For example, the World War II jeeps
(Willys MB and Ford GPW) were issued the "Jack, Automobile,
Screw type, Capacity 1 1/2 ton", Ordnance part number 41-J-66.
This jacks, and similar jacks for trucks, were activated by using
the lug wrench as a handle for the jack's ratchet action to of the
jack. The 41-J-66 jack was carried in the jeep's tool compartment.
Screw type jack's continued in use for small capacity
requirements due to low cost of production raise or lower it. A
control tab is marked up/down and its position determines the
direction of movement and almost no maintenance.

The virtues of using a screw as a machine, essentially an inclined

plane wound round a cylinder, was first demonstrated by
Archimedes in 200BC with his device used for pumping water.

There is evidence of the use of screws in the Ancient Roman world

but it was the great Leonardo da Vinci, in the late 1400s, who first
demonstrated the use of a screw jack for lifting loads. Leonardos
design used a threaded worm gear, supported on bearings, that
rotated by the turning of a worm shaft to drive a lifting screw to
move the load - instantly recognizable as the principle we use today.
1
0
We cant be sure of the intended application of his invention, but
it seems to have been relegated to the history books, along with
the helicopter and tank, for almost four centuries. It is not until
the late 1800s that we have evidence of the product being
developed further.

With the industrial revolution of the late 18th and 19th centuries
came the first use of screws in machine tools, via English
inventors such as John Wilkinson and Henry Maudsley The most
notable inventor in mechanical engineering from the early 1800s
was undoubtedly the mechanical genius Joseph Whitworth, who
recognized the need for precision had become as important in
industry as the provision of power.

While he would eventually have over 50 British patents with titles

ranging from knitting machines to rifles, it was Whitworths work
on screw cutting machines, accurate measuring instruments and
standards covering the angle and pitch of screw threads that
would most influence our industry today.

Whitworths tools had become internationally famous for their

precision and quality and dominated the market from the 1850s.
Inspired young engineers began to put Whitworths machine tools
to new uses. During the early 1880s in Coaticook, a small town
near Quebec, a 24-year-old inventor named Frank Henry Sleeper
designed a lifting jack. Like da Vincis jack, it was a technological
innovation because it was based on the principle of the ball
bearing for supporting a load and transferred rotary motion,
through gearing and a screw, into linear motion for moving the
load. The device was efficient, reliable and easy to operate. It was
used in the construction of bridges, but mostly by the railroad
industry, where it was able to lift locomotives and railway cars.
11
Local Coaticook industrialist, Arthur Osmore Norton, spotted the
potential for Sleepers design and in 1886 hired the young man
and purchased the patent. The Norton jack was born. Over the
coming years the famous Norton jacks were manufactured at
plants in Boston, Coaticook and Moline, Illinois.

Meanwhile, in Alleghany County near Pittsburgh in 1883, an

enterprising Mississippi river boat captain named Josiah Barrett
had an idea for a ratchet jack that would pull barges together to
form a tow. The idea was based on the familiar lever and
fulcrum principle and he needed someone to manufacture it. That
person was Samuel Duff, proprietor of a local machine shop.

Together, they created the Duff Manufacturing Company, which

by 1890 had developed new applications for the original Barrett
Jack and extended the product line to seven models in varying
capacities.

Over the next 30 years the Duff Manufacturing Company became

the largest manufacturer of lifting jacks in the world, developing
many new types of jack for various applications including its own
version of the ball bearing screw jack. It was only natural that in
1928, The Duff Manufacturing Company Inc. merged with A.O.
Norton to create the Duff-Norton Manufacturing Company.

Both companies had offered manually operated screw jacks but

the first new product manufactured under the joint venture was
the air motor-operated power jack that appeared in 1929. With
the aid of the relatively new portable compressor technology,
users now could move and position loads without manual effort.
The jack, used predominantly in the railway industry, incorporated
an air motor manufactured by The Chicago Pneumatic Tool
Company.
Air Motor Power Jack

1
2
There was clearly potential for using this technology for other
applications and only 10 years later, in 1940, the first worm gear
screw jack, that is instantly recognizable today, was offered by
Duff-Norton, for adjusting the heights of truck loading platforms
and mill tables. With the ability to be used individually or linked
mechanically and driven by either air or electric motors or even
manually, the first model had a lifting capacity of 10 tons with
raises of 2 or 4.

Worm Gear Jack

Since then the product has evolved to push, pull, lift, lower and
position loads of anything from a few kilos to hundreds of tonnes.
One of the biggest single screw jacks made to date is a special
Power Jacks E-Series unit that is rated for 350 tonnes even in
earthquake conditions for the nuclear industry.

More recent developments have concentrated on improved

efficiency and durability, resulting in changes in both lead screw
and gearbox design options for screw jacks.

A screw jack that has a built-in motor is now referred to as a linear

actuator but is essentially still a screw jack. Today, screw jacks can
be linked mechanically or electronically and with the advances in
motion-control, loads can be positioned to within microns.
Improvements in gear technology together with the addition of
precision ball screws and roller screws mean the applications for
screw jacks today are endless and a real alternative to hydraulics in
terms of duty cycles and speed at a time when industry demands
cleaner, quieter and more reliable solutions.
1
3
 CHAPTER II. POWER SCREWS

A power screw is a mechanical device used for converting rotary

motion into linear motion and transmitting power. A power screw
is also called translation screw. It uses helical translatory motion
of the screw thread in transmitting power rather than clamping
the machine components.

Section 2.01 Applications

The main applications of power screws are as follows:

(i) To raise the load, e.g. screw-jack,

(ii) To obtain accurate motion in machining operations, e.g. lead-

screw of lathe,

(iii) To clamp a work-piece, e.g. vice, and

(iv) To load a specimen, e.g. universal testing machine.

There are three essential parts of a power screw, viz. screw, nut
and a part to hold either the screw or the nut in its place.
Depending upon the holding arrangement, power screws operate
in two different ways. In some cases, the screw rotates in its
bearing, while the nut has axial motion. The lead screw of the
lathe is an example of this category. In other applications, the nut
is kept stationary and the screw moves in axial direction. Screw-
jack and machine vice are the examples of this category.

Section 2.02 Advantages

Power screws offer the following advantages:

(i) Power screw has large load carrying capacity.

(ii) The overall dimensions of the power screw are small, resulting
in compact construction.
14
 (iii) Power screw is simple to design

(iv) The manufacturing of power screw is easy without requiring

specialized machinery. Square threads are turned on lathe.
Trapezoidal threads are manufactured on thread milling machine.

(v) Power screw provides large mechanical advantage. A load of 15

kN can be raised by applying an effort as small as 400 N.
Therefore, most of the power screws used in various applications
like screw-jacks, clamps, valves and vices are usually manually
operated.

(vi) Power screws provide precisely controlled and highly accurate

linear motion required in machine tool applications.

(vii) Power screws give smooth and noiseless service without any
maintenance.

(viii) There are only a few parts in power screw. This reduces cost
and increases reliability.

(ix) Power screw can be designed with self-locking property. In

screw-jack application, self-locking characteristic is required to
prevent the load from descending on its own.

Section 2.03 Disadvantages

The disadvantages of power screws are as follows:

(i) Power screws have very poor efficiency; as low as 40%.Therefore,

it is not used in continuous power transmission in machine tools,
with the exception of the lead screw. Power screws are mainly
used for intermittent motion that is occasionally required for
lifting the load or actuating the mechanism.

(ii) High friction in threads causes rapid wear of the screw or the
nut. In case of square threads, the nut is usually made of soft
material and replaced when worn out. In trapezoidal threads, a
split- type of nut is used to compensate for the wear. Therefore,
wear is a serious problem in power screws.
1
5
 Section 2.04 Forms of Threads

There are two popular types of threads used for power screws viz.
square and I.S.O metric trapezoidal.

(a) Advantages of square threads

The advantages of square threads over trapezoidal threads are as

follows:

(i) The efficiency of square threads is more than that of

trapezoidal threads.

(ii) There is no radial pressure on the nut.

Since there is no side thrust, the motion of the nut is uniform. The
life of the nut is also increased.

(b) Disadvantages of square threads

The disadvantages of square threads are as follows:

(i) Square threads are difficult to manufacture. They are usually

turned on lathe with single-point cutting tool. Machining with
single-point cutting tool is an expensive operation compared to
machining with multi-point cutting tool.

(ii) The strength of a screw depends upon the thread thickness at

the core diameter. Square threads have less thickness at core
diameter than trapezoidal threads. This reduces the load carrying
capacity of the screw.
1
6
 (iii) The wear of the thread surface becomes a serious problem in
the service life of the power screw. It is not possible to
compensate for wear in square threads. Therefore, when worn
out, the nut or the screw requires replacement.

(c) Advantages of Trapezoidal Threads

The advantages of trapezoidal threads over square threads are as

follows:

(i) Trapezoidal threads are manufactured on thread milling machine.

It employs multi-point cutting tool. Machining with multi-point
cutting tool is an economic operation compared to machining with
single point-cutting tool. Therefore, trapezoidal threads are
economical to manufacture.

(ii) Trapezoidal thread has more thickness at core diameter than

that of square thread. Therefore, a screw with trapezoidal threads
is stronger than equivalent screw with square threads. Such a
screw has large load carrying capacity.

(iii) The axial wear on the surface of the trapezoidal threads can be
compensated by means of a split-type of nut. The nut is cut into
two parts along the diameter. As wear progresses, the looseness
is prevented by tightening the two halves of the nut together, the
split-type nut can be used only for trapezoidal threads. It is used
in lead-screw of lathe to compensate wear at periodic intervals by
tightening the two halves.

(d) Disadvantages of Trapezoidal Threads

The disadvantages of trapezoidal threads are as follows:

(i) The efficiency of trapezoidal threads is less than that of square

threads.

(ii) Trapezoidal threads result in side thrust or radial pressure on

the nut. The radial pressure or bursting pressure on nut affects its
performance.
There is a special type of thread called acme thread. Trapezoidal and
acme threads are identical in all respects except the thread angle. In
acme thread, the thread

1
7
 angle is 29 instead of 30.The relative advantages and
disadvantages of acme threads are same as those of trapezoidal
threads.

There is another type of thread called buttress thread. It combines

the advantages of square and trapezoidal threads. Buttress
threads are used where heavy axial force acts along the screw
axis in one direction only.

(e) Advantages of Buttress Threads

The advantages of buttress threads are as follows:

(i) It has higher efficiency compared to trapezoidal threads.

(ii) It can be economically manufactured on thread milling

machine.

(iii) The axial wear at the thread surface can be compared by

means of spit-type nut.

(iv) A screw with buttress threads is stronger than equivalent

screw with either square threads or trapezoidal threads. This is
because of greater thickness at the base of the thread.

The buttress threads have one disadvantage. It can transmit

power and motion only in one direction. On the other hand,
square and trapezoidal threads can transmit force and motion in
both directions.

Square threads are used for screw-jacks, presses and clamping

devices. Trapezoidal and acme threads are used for lead-screw and
other power transmission devices in machine tools. Buttress threads
are used in vices, where force is applied only in one direction.
Buttress threads are ideally suited for connecting tubular
components

18
that must carry large forces such as connecting the barrel to the
housing in anti-aircraft guns.

Section 2.05 Designation of Threads

There is a particular method of designation for square and

trapezoidal threads. A power screw with single-start square
threads is designated by the letters Sq followed by the nominal
diameter and the pitch expressed in millimeters and separated by
the sign x. For example,

Sq 30 x 6

It indicates single-start square threads with 30mm nominal

diameter and 6mm pitch.

Similarly single-start I.S.O metric trapezoidal threads are

designated by letters Tr followed by the nominal diameter and
the pitch expressed in millimeters and separated by the sign x.
For example,

Tr 40x7

It indicates single-start trapezoidal threads with 40mm nominal

diameter and 7mm pitch.
(a) Multiple Threaded Power Screws

Multiple threaded power screws are used in certain applications

where higher travelling speed is required. They are also called
multiple start screws such as double-start or triple-start screws.
These screws have two or more threads cut side by side, around
the rod.
1
9
 Multiple-start trapezoidal threads are designated by letters Tr
followed by the nominal diameter and the lead, separated by sign
x and in brackets the letter P followed by the pitch expressed
in millimetres. For example,

Tr 40 x 14 (P7)

In above designation,

Lead=14mm pitch=7mm

Therefore, No. of starts =14/7=2

It indicates two-start trapezoidal thread with 40mm nominal

diameter and 7mm pitch. In case of left handed threads. The
letters LH are added to thread designation. For example,

Tr 40 x 14 (P7) LH

Section 2.06 Terminology of Power Screw

The terminology of the screw thread is as follows:

(i) Pitch: The pitch is defined as the distance, measured parallel to

the axis of the screw, from a point on one thread to the
corresponding point on the adjacent thread. It is denoted by the
letter p.

(ii) Lead: The lead is defined as the distance, measured parallel to

the axis of the screw, that the nut will advance in one revolution of
the screw. It is denoted by the
2
0
 letter l. For a single-threaded screw, the lead is same as the
pitch, for a double-threaded screw, the lead is twice that of the
pitch, and so on.

(iii) Nominal diameter: It is the largest diameter of the screw. It is

also called major diameter. It is denoted by the letter d.

(iv) Core diameter: It is the smallest diameter of the screw thread.

It is also called minor diameter. It is denoted by the letters dc.

(v) Helix angle: It is defined as the angle made by the helix of the
thread with a plane perpendicular to the axis of the screw. Helix
angle is related to the lead and the mean diameter of the screw.
It is also called lead angle. It is denoted by .

From the figure, dc = d [p/2 + p/2]

or, d = d (p)

The mean diameter of the screw is denoted by dm and it is given by,

dm = 0.5[d + dc]

= [d + (d-
p)]

or, dm= (d-0.5p)

Imagine that one thread of the screw is unwound and developed

for one complete turn. The thread will become the hypotenuse of
a right-angled triangle, whose base is (dm) and whose height is
the lead (l).Considering this right-angle triangle, the relationship
between helix angle, mean diameter and lead can be expressed
in the following form,
2
1
 Tan =

Where, is the helix angle of the thread.

The following conclusions can be drawn on the basis of the

development of thread:

(i) The screw can be considered as an inclined plane with as

inclination.

(ii) The load W always acts in vertically downward direction. When

the load W is raised, it moves up the inclined plane. When the
load W is lowered, it moves down the inclined plane.

(iii) The load W is raised or lowered by means of an imaginary

force P acting at the mean radius of the screw. The force P
multiplied by the mean radius (dm/2) gives the torque required to
raise or lower the load. Force P is perpendicular to load W.

Section 2.07 Torque Requirement- Lifting Load

The screw is considered as an inclined plane with inclination

.When the load is being raised, following forces act at a point on
this inclined plane:

(i) Load W: It always acts in vertically downward direction.

(ii) Normal reaction N: It acts perpendicular (normal) to the

inclined plane.

(iii) Frictional force N: Frictional force acts opposite to the

motion. Since the load is moving up the inclined plane, frictional
force acts along the inclined plane in downward direction.
22
(iv) Effort P: The effort P acts in a direction perpendicular to the
load W. It may act towards right to overcome the friction and raise
the load.

For an equilibrium of horizontal forces,

P = N cos + N sin (a)

For an equilibrium of vertical forces,

(b
W = N cos N sin )

Dividing expression (a) by (b),

( . + )
(c
= )
( . )

Dividing the numerator and denominator of the right hand side by

cos ,
=
( + ) (1
. )

The coefficient of friction is expressed as,

= tan (d) where, is the friction angle.

Substituting = tan in Eq. (c),

( + )

=
(1 . )

(e
or, P = W tan ( + ) )

The torque T required to raise the load is given by,

T = P . dm/2 = W . dm/2 . tan( + )

23
 Section 2.08 Torque Requirement- Lowering Load

When the load is being lowered, the following forces act at a point
on the inclined plane:

(i) Load W: It always acts in vertically downward direction.

(ii) Normal reaction N: It acts perpendicular (normal) to the

inclined plane.

(iii) Frictional force N: Frictional force acts opposite to the

motion. Since the load is moving down the inclined plane,
frictional force acts along the inclined plane in upward direction.

(iv) Effort P: The effort P acts in a direction perpendicular to the

load W.It should act towards left to overcome the friction and
lower the load.

For an equilibrium of horizontal forces,

P = N cos - N (a
sin )

For an equilibrium of vertical forces,

W = N cos + N (b
sin )
P = W tan ( -
Therefore, )

The torque T required to lower the load is given by,

T = W . dm/2 . tan( - )
24
 Section 2.09 Self-Locking Screw

The torque required to lower the load can be given by,

T = W . dm/2 . tan( - )

It can be seen that when, < ; the torque required to lower the
load is negative. It indicates a condition that no force is required
to lower the load. The load itself will begin to turn the screw and
descend down, unless a restraining torque is applied. This
condition is called overhauling of screw.

When, > ; a positive torque is required to lower the load.

Under this condition, the load will not turn the screw and will not
descend on its own unless effort P is applied. In this case, the
screw is said to be self-locking. The rule for self-locking screw is
as follows:

A screw will be self-locking if the coefficient of friction ids equal to

or greater than the tangent of the helix angle.

Therefore, the following conclusions can be made:

(i) Self-locking of screw is not possible when the coefficient of friction

() is low. The coefficient of friction between the surfaces of the
screw and the nut is reduced by lubrication. Excessive lubrication
may cause the load to descend on its own.

(ii) Self-locking property of the screw is lost when the lead is large.
The lead increases with number of starts. For double-start thread,
lead is twice of the pitch and for triple threaded screw, three
times of pitch. Therefore, single threaded is better than multiple
threaded screw from self-locking considerations.

Self-locking condition is essential in applications like screw-jack.

2
5
Section 2.10 Efficiency of Square Threaded Screw

Refer to the force diagram for lifting the load, illustrated in Fig.
Suppose the load W moves from the lower end to the upper end
of the inclined plane. The output consists of raising the load.
= tan( + )

From the above equation, it is evident that the efficiency of the

square threaded screw depends upon the helix angle and the
friction angle . The following figure shows the variation of the
efficiency of square threaded screw against the helix angle for
various values of coefficient of friction. The graph is applicable
when the load is lifted.

Following conclusions can be derived from the observation of

these graphs,

(i) The efficiency of square threaded screw increase rapidly up to

helix angle of 20.

(ii) The efficiency is maximum when the helix angle between 40

to 45.

(iii) The efficiency decreases after the maximum value is

reached.

(iv) The efficiency decreases rapidly when the helix angle

exceeds 60
2
6
 (v) The efficiency decreases as the coefficient of friction
increases.

There are two ways to increase the efficiency of square threaded

screws. They are as follows:

(i) Reduce the coefficient of friction between the screw and the nut
by proper lubrication, and

(ii) Increase the helix angle up to 40 to 45 by using multiple

start threads.

However, a screw with such helix angle has other disadvantages

like loss of self-locking property.

Section 2.11 Coefficient of Friction

It has been found that the coefficient of friction () at the thread

surface depends upon the workmanship in cutting the threads
and on the type of the lubricant. It is practically independent of
the load, rubbing velocity or materials. An average of 0.15 can be
taken for the coefficient of friction, when the screw is lubricated
with mineral oil.

Section 2.12 Buckling of Columns

When a short member is subjected to axial compressive force, it

shortens according to the Hookes law. As the load is gradually
increased, the compression of the member increases.

When the compressive stress reaches the elastic limit of the

material, the failure occurs in the form of bulging. However, when
the length of the component is large compared to the cross-
sectional dimensions, the component may fail by lateral buckling.
Buckling indicates elastic instability. The load at which the buckling
starts is called critical load, which is denoted by P cr. When the axial
load on the column reaches P cr, there is sudden buckling and a
relatively large lateral deflection occurs.
2
7
An important parameter affecting the critical load is the
slenderness ratio. It is defined as,

Slenderness ratio =

where, l = length of column (mm)

k = least radius of gyration of the cross-section about its
axis (mm)

The radius of gyration is given by,

=

4
where, I = least moment of inertia of the cross-section (mm )
2
A = area of the cross-section (mm )

When the slenderness ratio is less than 30, there is no effect of

buckling and such components are designed on the basis of
compressive stresses. Columns, with slenderness ratio greater
than 30 are designed on the basis of critical load. There are two
methods to calculate the critical load- Eulers equation and
Johnsons equation.

According to the Eulers equation,

2=
2
( ) where, Pcr =
critical load (N); n = end fixity coefficient

E = modulus of elasticity (N/mm); A = area of cross-section

(mm)

The load carrying capacity of the column depends upon the

condition of restraints at the two ends of the column. It is
accounted by means of a dimensionless quantity called end fixity
coefficient (n).

According to Johnsons equation,

2
8
 2
= [1 ( )]

2
4

Where, Syt is the yield strength of the material.

29
 CHAPTER III. SCREW JACK

A screw jack is a portable device consisting of a screw mechanism

used to raise or lower the load. The principle on which the screw
jack works is similar to that of an inclined plane. There are mainly
two types of jacks-hydraulic and mechanical. A hydraulic jack
consists of a cylinder and piston mechanism. The movement of
the piston rod is used to raise or lower the load. Mechanical jacks
can be either hand operated or power driven.

Jacks are used frequently in raising cars so that a tire can be

changed. A screw jack is commonly used with cars but is also
used in many other ways, including industrial machinery and even
airplanes. They can be short, tall, fat, or thin depending on the
amount of pressure they will be under and the space that they
need to fit into. The jack is made out of various types of metal,
but the screw itself is generally made out of lead.

While screw jacks are designed purposely for raising and lowering
loads, they are not ideal for side loads, although some can
withstand side loads depending on the diameter and size of the
lifting screw. Shock loads should also be avoided or minimized.
Some screw jacks are built with anti-backlash. The anti-backlash
device moderates the axial backlash in the lifting screw and nut
assembly to a regulated minimum.

A large amount of heat is generated in the screw jack and long

lifts can cause serious overheating. To retain the efficiency of the
screw jack, it must be used under ambient temperatures,
otherwise lubricants must be applied. There are oil lubricants
intended to enhance the equipments capabilities. Apart from
proper maintenance, to optimize the capability and usefulness of
a screw jack it is imperative to employ it according to its design
and manufacturers instruction. Ensure that you follow the speed,
load capacity, temperature recommendation and other relevant
factors for application.
30 | P a g e
Section 3.01 The Screw

The screw has a thread designed to withstand an enormous

amount of pressure. This is due to the fact that it is generally
holding up heavy objects for an extended amount of time. Once
up, they normally self-lock so that they won't fall if the operator
lets go, and they hold up well to the wear of repeated use. If they
are made with a ball nut, they will last longer because there is
less friction created with this type of jack. However, they will not
self-lock. This can be dangerous and handled carefully.

Section 3.02 Operation

The jack can be raised and lowered with a metal bar that is
inserted into the jack. The operator turns the bar with his hands in
a clockwise direction. This turns the screw inside the jack and
makes it go up. The screw lifts the small metal cylinder and
platform that are above it. As the jack goes up, whatever is placed
above it will raise as well, once the jack makes contact. The bar is
turned until the jack is raised to the level needed. To lower the
jack the bar is turned in the opposite direction. An automatic
screw jack has gears inside the jack that are connected to the
screw. Theses gears are connected by other gears and bars that
are turned by a power source to raise and lower the jack.

Although a jack is a simple and widely used device, the use of any
lifting device is subject to certain hazards. In screw-jack
applications, the hazards are dropping, tipping or slipping of
machines or their parts during the operation. These hazards may
result in serious accidents. The main reasons of such accidents
are as follows:

(i) The load is improperly secured on the jack

(ii) The screw-jack is over loaded

(iii) The centre of gravity of the load is off centre with respect to
the axis of the jack

31 | P a g e
(iv) The screw-jack is not placed on hard and level surface.

(v) The screw-jack is used for a purpose, for which it is not

designed.

Proper size, strength and stability are the essential requirements

for the design of the screw-jack from safety considerations.

Section 3.03 Construction of a Screw Jack

Screw jack consists of a screw and a nut. The nut is fixed in a cast
iron frame and remains stationary. The rotation of the nut inside
the frame is prevented by pressing a set screw against it. The
screw is rotated in the nut by means of a handle, which passes
through a hole in the head of the screw. The head carries a
platform, which supports the load and remains stationary while
the screw is being rotated. A washer is fixed to the other end of
the screw inside the frame, which prevents the screw to be
completely turned out of the nut.

Section 3.04 Function

The basic function of a screw jack is to lift a portion of a vehicle.

Typically this is used to change a tire although other maintenance
is sometimes performed.

Section 3.05 Features

All jacks have safety features to protect the user from accidental
injury. Wide bases help to stabilize a jack and prevent tilting or
sinking into soft soil. Most car jacks also come equipped with their
own handle or cranking mechanism, but alternately many of these
also will accept the flat end of a tire tool to jack up a vehicle. When
in the extended position, jacks will have a stop point that prevents
the user from overextending the jack beyond its rated capabilities.
When in the contracted

32 | P a g e
position, jacks that are provided by the manufacturer will have a
storage area specially formed or designed for the jack to rest in
when not in use.

Section 3.06 Benefits

Equipping motorists with car jacks has provided many benefits to

those who are on the road. Most importantly, jacks have equipped
drivers with the ability to change a tire in an emergency situation
without having to call for assistance, which can save service fees
and potential towing fees as well. Car jacks also provide the home
auto enthusiast with a tool to use in maintenance of their own
vehicle with the simpler tasks such as changing brake pads, oil
and belts. When used appropriately with safety in mind, car jacks
are an essential resource for anyone owning or operating a
motorized vehicle.

Section 3.07 Types

Screw Jacks are of mainly two types- mechanical and hydraulic.

They vary in size depending on the load that they are used to lift:
(a) Mechanical Jacks

A mechanical jack is a device which lifts heavy equipment. The

most common form is a car jack, floor jack or garage jack which
lifts vehicles so that maintenance can be performed. Car jacks
usually use mechanical advantage to allow a human to lift a
vehicle by manual force alone. More powerful jacks use hydraulic
power to provide more lift over greater distances. Mechanical
jacks are usually rated for maximum lifting capacity. There are
two types of mechanical jacks.
(i) Scissor Jacks

Scissors jacks are also mechanical and have been in use at least
since the 1930s.
33 | P a g e
A scissor jack is a device constructed with a cross-hatch
mechanism, much like a scissor, to lift up a vehicle for repair or
storage. It typically works in just a vertical manner. The jack
opens and folds closed, applying pressure to the bottom supports
along the crossed pattern to move the lift. When closed, they
have a diamond shape.

Scissor jacks are simple mechanisms used to drive large loads

short distances. The power screw design of a common scissor jack
reduces the amount of force required by the user to drive the
mechanism. Most scissor jacks are similar in design, consisting of
four main members driven by a power screw.

A scissor jack is operated simply by turning a small crank that is

inserted into one end of the scissor jack. This crank is usually "Z"
shaped. The end fits into a ring hole mounted on the end of the
screw, which is the object of force on the scissor jack. When this
crank is turned, the screw turns, and this raises the jack. The
screw acts like a gear mechanism. It has teeth (the screw thread),
which turn and move the two arms, producing work. Just by
turning this screw thread, the scissor jack can lift a vehicle that is
several thousand pounds.
1) Construction

A scissor jack has four main pieces of metal and two base ends.
The four metal pieces are all connected at the corners with a bolt
that allows the corners to swivel. A screw thread runs across this
assembly and through the corners. As the screw thread is turned,
the jack arms travel across it and collapse or come together,
forming a straight line when closed. Then, moving back the other
way, they raise and come together. When opened, the four metal
arms contract together, coming together at the middle, raising
the jack. When closed, the arms spread back apart and the jack
closes or flattens out again.
2) Design & Lift

A scissor jack uses a simple theory of gears to get its power. As the
screw section is turned, two ends of the jack move closer together.
Because the gears of the screw are pushing up the arms, the
amount of force being applied is multiplied. It takes a

34 | P a g e
very small amount of force to turn the crank handle, yet that
action causes the brace arms to slide across and together. As this
happens the arms extend upward. The car's gravitational weight
is not enough to prevent the jack from opening or to stop the
screw from turning, since it is not applying force directly to it. If
you were to put pressure directly on the crank, or lean your
weight against the crank, the person would not be able to turn it,
even though your weight is a small percentage of the cars.

(ii) Bottle (or cylindrical) jacks

Bottle screws may operate by either,

(i) Rotating the screw when the nut is fixed; or

(ii) Rotating the nut and preventing rotation of the screw.

Bottle jacks mainly consist of a screw, a nut, thrust bearings, and

a body. A stationary platform is attached to the top of the screw.
This platform acts as a support for the load and also assists it in
lifting or lowering of the load. These jacks are sturdier than the
scissor jacks and can lift heavier loads.
35 | P a g e
 (b) Hydraulic Jacks

Hydraulic jacks are typically used for shop work, rather than as an
emergency jack to be carried with the vehicle. Use of jacks not
designed for a specific vehicle requires more than the usual care
in selecting ground conditions, the jacking point on the vehicle,
and to ensure stability when the jack is extended. Hydraulic jacks
are often used to lift elevators in low and medium rise buildings.

A hydraulic jack uses a fluid, 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.
36 | P a g e
In a bottle jack the piston is vertical and directly supports a
bearing pad that contacts the object being lifted. With a single
action piston the lift is somewhat less than twice the collapsed
height of the jack, making it suitable only for vehicles with a
relatively high clearance. For lifting structures such as houses the
hydraulic interconnection of multiple vertical jacks through valves
enables the even distribution of forces while enabling close
control of the lift.

In a floor 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 castors and wheels, allowing compensation for the
arc taken by the lifting pad. This mechanism provide a low profile
when collapsed, for easy maneuvering underneath the vehicle,
while allowing considerable extension.

Section 3.08 Design of Screw Jack

(a) Loads & Stresses in a Screw

The load on the screw is the load which is to be lifted W, twisting

moment M, between the screw threads and force F at the handle
to rotate the screw.

The load W is compressive in nature and induces the compressive

stress in the screw. It may also lead the screw to buckle.

The load F produces bending and it is maximum, when the screw

is at its maximum lift. The screw also experiences twisting
moment due to F. the shear stress is also induced in the screw
due to the twisting moment between the threads of screw and
nut.
37 | P a g e
 Step I Problem Specification

It is required to design a screw jack for supporting the machine

parts during their repair and maintenance. It should be a general
purpose jack with a load carrying capacity of 50KN and a
maximum lifting height of 0.3m. The jack is to be operated by
means of a D.C motor.

Step II Selection of Materials

(i) The frame of the screw jack has complex shape. It is subjected to
compressive stress. Grey cast iron is selected as the material for
the frame. Cast iron is cheap and it can be given any complex
shape without involving costly machining operations. Cast iron
has higher compressive strength compared with steel. Therefore,
it is technically and economically advantageous to use cast iron
for the frame.

(ii) The screw is subjected to torsional moment, compressive force

and bending moment. From strength consideration, EN8 is
selected as material for screw.
38 | P a g e
 Screw

(iii) There is a relative motion between the screw and the nut,
which results in friction. The friction causes wear at the contacting
surfaces. When the same material is used for these two
components, the surfaces of both components get worn out,
requiring replacement. This is undesirable. The size and shape of
the screw make it costly compared with the nut. The material
used for the nut is stainless steel.

Nut

Step III Design of Screw

(i) The screw jack is an intermittently used device and wear of

threads is not an important consideration. Therefore, instead of
trapezoidal threads, the screw is provided with square threads.
Square threads have higher efficiency and provision can be made
for self-locking arrangement. When the condition of self-locking is
fulfilled, the load itself will not turn the screw and descend down,
unless an effort in the reverse direction is applied
(b) Thrust Bearings

Thrust ball bearings are used to replace the sliding force with
rolling friction. The friction torque is so small, that it can be
neglected.
39 | P a g e
Thrust ball bearing is suitable for a purely axial load. It is a single-
direction thrust ball bearing, because it can support axial load in
one direction only, i.e., vertically downward. This ball bearing
should not be subjected to radial load.

Single-direction thrust ball bearings are separable and the

mounting is simple as the components can be mounted
individually. There are three separable parts of this bearing known
as shaft washer, a housing washer and the ball and cage
assembly. The mounting of thrust bearing I shown in the figure
below.

Thrust Bearing

The inner diameter of the shaft washer is press fitted in the screw
body. The outer diameter of the housing washer is press fitted in
the cup. These two components are separately mounted before
final assembly. The life of thrust bearing is assumed to be 3000
hours.
(c) Operational Considerations of a Screw Jack

Maintain low surface contact pressure:

Increasing the screw size and nut size will reduce thread contact
pressure for the same working load. The higher the unit pressure
and the higher the surface speed, the more rapid the wear will be.

Maintain low surface speed:

Increasing the screw head will reduce the surface speed for the
same linear speed.
40 | P a g e
Keep the mating surfaces well lubricated:

The better the lubrication, the longer is the service life. Grease
fittings or other lubrication means must be provided for the power
screw and nut.

Keep the mating surfaces clean:

Dirt can easily embed itself in the soft nut material. It will act as a
file and abrade the mating screw surface. The soft nut material
backs away during contact leaving the hard dirt particles to scrap
away the mating screw material.

Keep heat away:

When the mating surfaces heat up, they become much softer and
are more easily worn away. Means to remove the heat such as
limited duty cycles or heat sinks must be provided so that rapid
wear of over-heated materials can be avoided.
41 | P a g e
 CHAPTER IV. MOTORIZED SCREW JACK
Section 4.01 Introduction

With the increasing levels of technology, the efforts being put to

produce any kind of work has been continuously decreasing. The
efforts required in achieving the desired output can be effectively
and economically be decreased by the implementation of better
designs.

A screw jack is an important tool in any car as it lifts the car for
any kind of service or for a quick tyre change. In this project, a DC
motor has been integrated with this screw jack to make the
process of lifting the car for any work a lot easier, just by
switching on a push button. All the heavy lifting would be done
by the motor.

This project concentrates on people who are not able to rotate the
screw jack properly (especially elderly people or women) or find it
difficult to do so, and it also caters to the needs of small and
medium automobile garages in which loads of cars have to be lifted
in a day, which could drain a lot of stamina and cause fatigue. This
is a simple automation project in which the process to lift the car in
an emergency is semi-automated, i.e. it also requires a little manual
or human effort.

The project along with achieving its main objectives, and strives
to stay compact so that it is also easily transported from one
place to another without any hassle.

Section 4.02 Need for Automation

The manufacturing operation is being atomized for the following

reasons:

To achieve mass production

To reduce man power

To increase the efficiency of the plant

To reduce the work load

To reduce the production cost

42 | P a g e

To reduce the production time

To reduce the material handling

To reduce the fatigue of workers

To achieve good product quality

Less Maintenance

Section 4.03 Parts of Motorized Screw Jack

Fig. Block diagram showing the different parts in the motorized screw jack and
their connections
by Anshit Malik

43 | P a g e
 (a) Power Source

For a motor to rotate and properly carry out its operations, it

needs certain amount of power. This project is not just about
integrating a motor into the screw jack, but to do it efficiently
such that the whole motorized screw jack stays compact, easy to
handle, use and effectively utilizes resources available easily
when on the road and in an emergency.

Therefore, the power source for the project is the 12 volt socket
which is present in almost every car these days.

44 | P a g e
 (b) Toggle Switch

The current through this power source flows into the motor,
through a toggle switch, which controls the flow of current to the
motor. This toggle switch controls the

A switch is used in order to start or stop the entire operation of

the screw jack. The type of switch that is used is known as a
toggle switch. A toggle switch is a class of electrical switches that
are manually actuated by a mechanical lever, handle, or rocking
mechanism.

Toggle switches are available in many different styles and sizes,

and are used in countless applications. Many are designed to
provide, e.g., the simultaneous actuation of multiple sets of
electrical contacts, or the control of large amounts of electric
current or mains voltages.

The word "toggle" is a reference to a kind of mechanism or joint

consisting of two arms, which are almost in line with each other,
connected with an elbow-like pivot. However, the phrase "toggle
switch" is applied to a switch with a short handle and a positive
snap-action, whether it actually contains a toggle mechanism or
not. Similarly, a switch where a definitive click is heard, is called a
"positive on-off switch".
45 | P a g e
 (c) Control Cables

These control cables are used to connect different electrical

components and transfer electrical signals. The connections are
made as shown in the block diagram above.

(d) 12V DC Motor

A 12V DC motor derives power from cars 12V socket through a

toggle switch which is controlling the direction of flow of current in
the motor. The direction of flow of current controls the horse shoe
electromagnet inside the motor which determines the direction in
which the motor will rotate the drive shaft.

This control over the rotation is very important as the screw jack
has to go both ways, upwards and downwards.

This is actuated using proper connections in a 6 pin toggle switch

which is used in the project.

As clearly visible in the photograph above, toggle switch has

three positions, one off and two on, one for clockwise rotation and
other for anti-clockwise.

The motor is further connected to connecting shaft.

46 | P a g e
 (e) Connecting Shaft

The connecting shaft is 16mm thick and made of Mild Steel to

take the stresses induced during the process. On one end, motor
is attached by drilling a blind hole and locking the rotation of both
together through a perpendicular drilled hole and key inserted.

On the other end, it is attached to the screw jack, using nut-bolt-

washer assembly.

When the motor rotates, the connecting shafts rotates with the
same direction & rpm and it then transfers the momentum to the
screw jack.
47 | P a g e
 (f) Screw Jack

The screw jack used in the project is a mostly used & easily
available mechanical scissor screw jack. The connections that
lead to the rotation of screw jack are visible in the picture below.

The toggle switch controls the rotation of motor and then it

rotates the screw jack in either direction which controls the
upward and downward motion in turn

48 | P a g e
 Section 4.04 Advantages

1. The loaded light vehicles can be easily lifted.

2. Checking and cleaning are easy, because the main parts

are screwed.

3. Handling is easy

4. No Manual power required.

5. Easy to Repair.

6. Replacement of parts are easy

49 | P a g e
 CHAPTER V. DESIGN CALCULATIONS
Section 5.01 To Check the Safety of Lead Screw

Maximum Load to be lifted = 5 Ton

= 50 x 103 N

= 50KN

For a 5 Ton capacity screw jack, the suitable screw is the one
whose nominal (major) diameter is 36mm.

Corresponding to the nominal diameter 36mm, the pitch (p)

selected is 6mm. The core diameter (dc) = 30mm

The mean diameter (dm) = 33mm

EN8 material is used for lead screw. The ultimate and yield
stresses are 450N/mm2 and 230N/mm2 respectively.

The compressive stresses induced in lead screw due to load of

50KN is given by:
= 70.73
2
= N/mm
2

Safety Factor = 230/70.73 = 3.25

. dm = 0.057

Hence lead screw will bear 50KN easily

The helix angle of screw = tan = P/

o
Therefore, = 3.31

Assuming coefficient of friction between

screw and nut, = tan = 0.14 ; = tan-
1(0.14) = 7.96

50 | P a g e
Since, < , hence it is a self-locking screw.

The turning moment required to rotate screw under design

load is given by, T = W (dm/2) tan
(+)

T = (50x103) (33/2) tan (3.31+7.96)

=164.40KN.mm The shear stress due to torque, Ft = 16T/
3
(dc )
3
= (16x164.40x103)/(30)
2
= 31.01N/mm
Direct stress is given by
2 2
Fs = (Fc + 4Ft )
2 2 2
= (70.73) + 4(31.01) = 47.03N/mm
2
The lead screw material has 115N/mm shear strength.
Safety factor = 115/47.03 = 2.44

Section 5.02 To Check Buckling of Screw

The maximum length of the screw above the nut when lifting the
load is 100mm. Radius of gyration (K) = d = x 30 = 7.5mm
2
Area = 4 = 706.85 mm2

L/K slenderness ratio = 100/7.5 = 13.33

51 | P a g e
 CHAPTER VI. CONCLUSION

Screw Jacks are the ideal product to push, pull, lift, lower and
position loads of anything from a couple of kilograms to hundreds
of tons. The need has long existed for an improved portable jack
for automotive vehicles. It is highly desirable that a jack become
available that can be operated alternatively from inside the
vehicle or from a location of safety off the road on which the
vehicle is located. Such a jack should desirably be light enough
and be compact enough so that it can be stored in an automobile
trunk, can be lifted up and carried by most adults to its position of
use, and yet be capable of lifting a wheel of a 4,000-5,000 pound
vehicle off the ground. Further, it should be stable and easily
controllable by a switch so that jacking can be done from a
position of safety. It should be easily movable either to a position
underneath the axle of the vehicle or some other reinforced
support surface designed to be engaged by a jack.

Thus, the product has been developed considering all the above
requirements. This particular design of the motorized screw jack
will prove to be beneficial in lifting and lowering of loads.
52 | P a g e
 CHAPTER VII. BIBLIOGRAPHY

Design of machine elements by V.B.Bhandari

A text book of machine design by Rajendra Karwa

Analysis and Design of Machine Elements by V K Jadon, Suresh
Verma

Tribology in Machine Design by T. A. Stolarski

A text book of Machine Design by R.S.Khurmi,J.K.Gupta

Design of Machine Elements by Farazdak Haideri

Machine Design by S.G.Kulkarni

Design of machine elements by K.Rao

http://en.wikipedia.org/wiki/Jack_(device)

http://hubpages.com/hub/Automobile-Jacks

http://www.powerjacks-de.com/Screw-Jacks-FAQ.html

http://www.radicon.com/screw-jacks.php

http://www.powerjacks.com/PowerJacks-History-The-Screw-

Jack-Story.php http://www.scribd.com/doc/38577261/Screw-

Jack-Design
53 | P a g e