Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

Design and Standardization of Toggle Jack

Dhamak C.S.1, Bajaj D.S.2, V.S.Aher3, G.S.Nikam4
1,2,3
Amrutvahini College of Engineering, Sangamner, Maharashtra, India

ABSTRACT
Toggle or Scissor jacks are simple mechanisms used to drive large loads for short distances and to lift the heavy
loads. The power screw design of a common Toggle jack reduces the amount of force required by the user to drive
the mechanism. Most of the Toggle jacks are similar in design, consisting of eight main members out of whom four
are driven by a power screw and rest of four by loading condition. A unique design of a Toggle jack is used to lift
the heavy loads at the stable state with the unique condition. A screw is moving part and nut is a stationary part.
Both the parts always work in meshing condition. Therefore there are stresses like shear and tensile stresses
induced in materials which are responsible for failure of screw. While a nut has bearing stress. Different materials
of screw and nut can induce different magnitude of stresses so it is necessary to select a pair of material
combination in such a way that a pair gives induced stress within safe limit. Car jacks are available in the market
has some disadvantages such as required more energy to operate, are not suitable for woman and cannot be used on
the uneven surface. So that, this design is modified for the existing car jacks in terms of its functionality and human
factor consideration.

Keyword:- Standardize, Power Screw, Scissor Jack ,Mechanism

1. INTRODUCTION

Car jack is a device used to lift up the cars while changing the tires during an emergency. Car jacks are
available at the market has some disadvantages such as requiring more energy to operate, are not suitable for women
and cannot be used on the uneven surface. The purpose of this project is to modify the design of the existing car jack
in terms of its functionality and also human factors considerations.
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 an electric motor.

Fig-1:Toggle Jack

1160 www.ijariie.com 179

Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

A toggle 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 toggle 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. Toggle jacks are usually rated for maximum lifting capacity.

2. DESIGN PROCEDURE

2.1 Design of Screw

The maximum load on the screw is when the jack is in the bottom most position. In this position of link CD is
shown in Fig.

Fig-2 : Geometry of Screw

Cos Θ =100-15/110 =39.4

 Pull in the screw, F =𝑊/2/𝑡𝑎𝑛𝜃
Where, F= force exerted on screw
W= load
 Total force in the screw due to both the nut, P1 = 2F
Where, P1= total force
 For the screw to be safe in tension,

where, dc= core diameter

σt= tensile stress
 Now, we adopt pitch= 6 mm
 Outside diameter of screw,
do= dc+p
 Mean diameter of screw,
dm=1/2(𝑑𝑐 + 𝑑𝑜)
 Helix angle,
𝛼= tan−1(𝑝/𝜋𝑑𝑚)
 Angle of friction,
∅=tan−1𝜇
Where, 𝜇= co-efficient of friction
 Effort required to rotate the screw,
P=P1×tan (𝛼 + ∅)
Where, P1= total force
 Torque, T=P × dm/2
 Torsional shear stress in screw,

,
Where, T= torque
 Direct tensile stress in screw,

,
where, p1= total force

1160 www.ijariie.com 180

Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

 Maximum principal stress in screw,

which should be less than 100 MPa, hence safe.

 Maximum shear stress,

which should be less than 50 MPa, hence safe

2.2 Design of Nut

Fig-3: Geometry of Nut

Let n= number of threads on nut.

Designing the nut in bearing of threads,
 Thickness of threads, t = p/2


We adopt n=4
 Height of nut, h= np
To prevent movement of nuts beyond 200 mm, rings of 8 mm thickness are provided on the screw on
bothsides and fixed by set screws.
Length of screw=200+h+2×thickness of rings+30 mm for spanner
 Length of spanner:
Let the operator apply a force of 50 N to the end of a spanner l mm long.
L=T/50

2.3 Design of Pins In Nuts

 The pins are in double shear. If dp is the diameter of pins then

 Diameter of pin head=1.5 dp

Thickness of pin head is taken as 3 mm.
Split pins are used to keep the pins in position.

2.4 Design of Links

Fig-4 : Geometry of Link

1160 www.ijariie.com 181

Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

 Load on each link = F/2

Let b1= width of link and t1= thickness of link
Assuming b1=3t1
 Area of cross-section of link,
A=3𝑡1²
 Moment of inertia,

 Least radius of gyration,

 For buckling of links in the vertical plane, the ends are considered hinged. Therefore, using Rankine-
Gordonformula,
For critical load,

For design load, 𝑃𝑐𝑟 =F.O.S×F

Critical load should be more than design load so design is safe.

2.5 Sample Design Calculation

Calculation for Medium carbon steel (C35Mn75) - Phos.bronze material:
Given data for sample calculation:

Load= 3 KN
For Medium carbon steel (C35Mn75)(screw)
σ t=100 MPa, σs=60 MPa
For Phos. Bronze(nut)
σt=50 MPa, σs=40 MPa, σc=45 MPa

2.5.1 Design of Screw

The maximum load on the screw is when the jack is in the bottom most position. In this position,
Cos Θ=100-15/110
Θ=39.4
 Pull in the screw,
F=𝑊/2/𝑡𝑎𝑛𝜃
=1.826 KN
 Total force in the screw due to both the nut,
P1=2F
=3.652 KN
 For the screw to be safe in tension,
dc =12 mm
 Now, we adpot pitch= 6 mm
 Outside diameter of screw,
 do= dc+ p
=12+6 =18 mm
 Mean diameter of screw,
dm=1/2(𝑑𝑐 + 𝑑𝑜)
=1/2(12 + 18)
= 15 mm
 Helix angle,
𝛼= tan−1(𝑝/𝜋𝑑𝑚)
=7.25⁰
 Angle of friction,

1160 www.ijariie.com 182

Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

∅=tan−1 𝜇
=tan−1 0.2
=11.310
 Effort required to rotate the screw,
P=P1×tan (𝛼 + ∅)
=3.653×tan (7.25 + 11.31)
=1.226 KN
 Torque,
T=P × dm/2
=1.226 ×10³× (15/2)
=9.19 Nm
 Torsional shear stress in screw,

=27.12 MPa
 Direct tensile stress in screw,

=32.30 Mpa
 Maximum principal stress in screw,

=47.23 MPa
 Maximum shear stress,

=31.56 MPa
2.5.2 Design of Nut
 Let n= number of threads on nut.
Designing the nut in bearing of threads,
 For the nut to be safe in tension,
dc =12 mm
Here, pitch, p=6
Outside diameter=10+6=16 mm
Mean diameter=1/2(10+16)= 13 mm
 Thickness of threads, t = p/2=3


= 6.46 MPa
 Height of nut, h= np=4×6=24 mm
To prevent movement of nuts beyond 200 mm, rings of 8 mm thickness are provided on the screw on both
sides and fixed by set screws.
 Length of screw=200+h+2×thickness of rings+30 mm for spanner =270 mm
 Length of spanner:
Let the operator apply a force of 50 N to the end of a Spanner l mm long.
L=T/50=148.9 mm

6.5.3 Design of Pins In Nuts

 The pins are in double shear. If dp is the diameter of pins then

1160 www.ijariie.com 183

Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

= 6 mm
 Diameter of pin head=1.5 dp= 1.5×6=9 mm
Thickness of pin head be taken as 3 mm.
Split pins are used to keep the pins in position.

6.5.4 Design of Links

 Load on each link=F/2= 913 N
Let b1= width of link and t1= thickness of link
Assuming b1=3t1
 Area of cross-section of link,
A=3𝑡1²
 Moment of inertia,

 Least radius of gyration,

 For buckling of links in the vertical plane, the ends are considered hinged. Therefore, using Rankine-
Gordon formula,
For critical load,

For design load,

F.O.S=2
𝑃𝑐𝑟 =F.O.S×F
=2×913
=1826 N

t1=4 mm
b1=12 mm
The link is considered to be fixed ends for bulking in a plane perpendicular to the vertical plane.
Therefore, 𝑙𝑒=1/2=55 mm

= 4643.39 KN

Critical Load Should Be More Than Design Load So Design Is Safe.

1160 www.ijariie.com 184

Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

Table-1: Calculated Values for Screw and Nut

Table-2 : Calculated Difference

1160 www.ijariie.com 185

Vol-1 Issue-2 2015 IJARIIE-ISSN(O)-2395-4396

3. CONCLUSIONS
From summery of calculated values and graph, it shows that for low load condition at 1KN, difference
between σt allowable and σ1max is higher. i.e -184.11 MPa, while for higher load at 5KN , it is higher. i.e -
120.52MPa. Same way, for load condition at 1KN, difference between τ allowable and τ max is higher. i.e -74.49
MPa and at 5KN, it is -43 MPa. The result shows that alloy steel for screw and phosphorus bronze for nut is the best
suitable combination for pair. The value shows that such kind of materials keep induced stresses (σ1max and τmax)
in screw within limit for safer design as compare to other materials. While difference between Pb Standard and σb
calculated for a nut has higher values at 1KN i.e -27.85 N/mm² and at 5KN i.e -19.24 N/mm² for Mild steel material.
The value shows that if there is a combination of MS – MS, it induces less magnitude of bearing stress in nut.

REFERENCES

[1] Prof. Nitinchandra R. Patel et.al.,“Design Of Toggle Jack Considering Material Selection Of Scerw -
Nutcombination” International Journal of Innovative Research in Science, Engineering and Technology
Vol. 2, Issue 5, (2013).
[2] TianHongyu and Zhang Ziyi, “Design and Simulation Based on Pro/E for a Hydraulic LiftPlatform in
Scissors Type”, International Workshop on Automobile, Power and Energy Engineering, Beijing Union
University, Beijing Chaowaibaijiazhuang, Beijing 100020, China, Procedia Engineering 16 ( 2011 ), 772 –
781.
[3] Thirugnanam et.al.“Analysis of Power Screw Using „Ansys‟ Middle-East Journal of Scientific Research 20
(7), ISSN 1990-9233, IDOSI Publications, (2014), 868-870.
[4] M.M. Noor et.al “Analysis Of Auto Car Jack”, National Conference in Mechanical Engineering Research
and Postgraduate Students 26-27 MAY 2010, FKM Conference Hall, UMP, Kuantan, Pahang, Malaysia,
(2010) , 198-203.
[5] VisheshRanglani et.al.“Design and Modification in the Existing Model of Trolley Jack 20261”
ȦDepartment of Mechanical Engineering, Shepherd School of Engineering & Technology, SHIATS,
Allahabad, India Accepted 10 May 2014, Available online 01 June2014, Vol.4, No.3 (June 2014)
[6] Ademola A. Dare and Sunday A. Oke“Vehicle jack with wedgemechanism”Maejo International Journal of
Science and Technology ISSN 1905-7873Received: 29 November 2007 / Accepted: 28 March 2008 /
Published: 31 March 2008
[7] Mohammed Abuzaid et.al “Inbuilt Hydraulic Jack in Automobile Vehicles” International journal of
innovation in engineering and technology (IJIET) Satyam Education and Social Welfare Sociaty Group of
Institutions, Bhopal, MP, India
[8] P.S. Rana et.al “Integrated Automated Jacks for 4-wheelers” European Journal of Applied Engineering and
Scientific Research, 2012, 1 (4):167-172 ISSN: 2278 –0041 Students of Priyadarshni College of
Engineering, Nagpur, IndiaAssistant Professor, Priyadarshni College of Engineering, Nagpur, India.

1160 www.ijariie.com 186