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DESIGN OF TOGGLE JACK

Article · February 2015

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International Journal of Science, Technology & Management www.ijstm.com
Volume No.04, Issue No. 01, January 2015 ISSN (online): 2394-1537

DESIGN OF TOGGLE JACK

Prof. V. A. Shaikh1, Prof. F. U. Pathan2, Prof. G. D. Sonawane3,

Prof. S. U. Gunjal4, Pravin Adke5
1,2,3,4
Asst. Prof., Department of Mechanical Engineering, Sandip Foundation SITRC, Mahiraavani,
Trimbak Road, Nashik, Maharashtra, Savitribai Phule Pune University, Pune, Maharashtra, (India)
5
Department of Mechanical Engineering, Sandip Foundation SITRC, Mahiraavani, Trimbak Road,
Nashik, Maharashtra, Savitribai Phule Pune University, Pune, Maharashtra, (India)

ABSTRACT
"Toggle jack as material handling device" is the modification of simple "Toggle jack" this project consist of
combination of two main mechanisms which are trolley mechanism and power screw mechanism. Power screw
consists of squire threads because the squire threads having low efficiency than acme threads, hence power
screw is self locking. Power screw are used to convert rotary motion into translatory motion, for example in
case of lead screw of a lathe machine, rotary motion available but tool has to be advanced distance in direction
of cut against the cutting resistance of a material. In case of screw small force applied in horizontal plane is
used to raise or lower the large load. Power also used in toggle jack, screw jack, vice, material testing machine
etc. In a toggle jack the has an axial motion against resisting axial force while screw rotates in a stationary
bearing. In screw jack, a screw rotates and moves axially against resisting force while nut is stationary.

Keywords: Toggle Jack. Mechanisms, Power Screw, Square Threads, Self Locking, Rotary Motion,
Axial Motion, Axial Force

I. INTRODUCTION

There are many industries the which use many material handling devices for proper material handling and safety
purpose like manual material handling, power operated material handling. Production on a tall machine it
difficult to carry material on machine, holding job on machine is difficult. For this purpose we make a suitable
material handling device name is "Toggle jack" as material handling and lifting device. In that device we use a
power screw mechanism and trolley mechanism combine for a handling a heavy row material [1]. Power screw
are used to convert rotary motion into translatory motion , for example in case of lead screw of a lathe machine,
rotary motion available but tool has to be advanced distance in direction of cut against the cutting resistance of a
material. In case of screw small force applied in horizontal plane is used to raise or lower the large load. Power
also used in toggle jack, screw jack, vice, material testing machine etc. In a toggle jack the has an axial motion
against resisting axial force while screw rotates in a stationary bearing. In screw jack, a screw rotates and moves
axially against resisting force while nut is stationary.

II. PROJECT SELECTION

After the complete understanding of a problem we had extensive market survey of various small scales
manufacturing industries. We came to know that the many manufacturing industries having problem of material
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handling. This included lot of time in the carrying the material from one place to another place. This process is
done by using fully manual effort. This is hazardous for human being and causes fatigue during working. By
manual material handling possibility of accident is more. This process increases the material handling as well as
total labor cost. Here is a chance of any breakage of material during the handling. To solve above all the
problems and to avoid fatigue during working by introducing toggle as material handling as well as lifting
device. By introducing this device we can able to carry the heavy loads at different positions and levels. By
using the device we can able to reduce the material handling cost and time.

III. THEORY OF POWER SCREW

3.1 Power Screw

A power screw is a mechanical device used for converting rotary motion into linear motion and transmitting
power. Power screw is also called translation screw. It uses helical translator motion of the screw thread in
transmitting power rather than clamping the machine components. The main applications of power screws are as
follows:
 To raise the loads, e.g. screw-jack,
 To obtain accurate motion in machining operations, e.g. lead-screw oflathe,
 To clamp awork piece, e.g. vice, and
 To load a specimen, e.g. universal testing machine.

There are three essential parts of the power 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's. While the nut has axial motion [2]. 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 example of this category.

3.1.1 Power Screw Offers Following Advantages

 Power screw has large load carrying capacity.
 The overall dimensions of the power screw are small. Resulting in compact construction.
 Power screw is simple to design.
 The manufacturing of power screw IS easy without requmng specialized machinery. Square threads are
turned on lathe. Trapezoidal threads are manufactured on thread milling machine.
 Power screws provide large mechanical advantage.Power screw provides precisely controlled and highly
accmate linear motion required in machine tool application.

3. 2 Terminology of Power Screw

The terminology of the screw thread is as follows:-
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 0 the adjacent thread. It is denoted by the letter 'p'.
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 letter' l' .
Nominal diameter: Nominal diameter is the largest diameter of the screw [3]. It is also called major diameter. It

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denoted by the letter'd'.

Core diameter: Core diameter is smallest diameter of the screw thread. It is also called minor diameter. It is
denoted by letters 'de'.
Helix Angle: The helix angle 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. Helix angle is denoted by u.

3.3 Forms of Threads

 Square threads
 Acme Threads
 Buttress threads
 Multiple threads
There are two popular types of threads used for power screws viz. square and I.S.0. metric trapezoidal, as shown
in Fig. 2 .

3.3.1 The Advantages of Square Threads Over Trapezoidal Threads Are As Follows
 The efficiency of square threads is more than that of trapezoidal threads.
 There is no radial pressure or side thlUst on the nut. This radial pressure is called 'bursting' pressure on the
nut. Since there is no side thmst, the motion of the nut is unifonn. The life of the nut is also increased.

3.4 Torque Required to Raise Load by Square Threaded Screws

The torque required to raise a load by means of square threaded screw may be determined by considering a
screw jack. The load to be raised or lowered is placed on the head of the square threaded rod which is rotated by
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the application of an effort at the end of lever for lifting or lowering the load [4]. A little consideration will show
that if one complete turn of a thread be imagined to be unwound, from the body of the screw and developed, it
will form an inclined plane.
Let P = Pitch of the screw
D = mean diameter of the screw

a = helix angle

N = normal reaction acts perpendicular to the inclined plane

P = effort applied at the circumference of the screw to lift the load

W = load to be lifted

μ = coefficient of friction

= tan Φ, where Φ is the friction angle

From the geometry of the figure, we find that

tan a = p / π d

For an equilibrium of horizontal forces [4, 5, 6, 7],

pcas a = F + Wsina

But , F = μ N

pcos a = μN + Wsina -------------------------- ( 1 )

For equilibrium of vertical forces, substitute of N in above equation,

pcosa = μ ( psina+W cosa )+ Wsina, pcosa=μ psina+ μ W cosa +Wsina

pcosa - μ psina=μ W casa +Wsina
P(cosa- μ sina) = W (μ cas a +sina )
P= W (μ casa +sina)/ (casa -μ sina)
Substitute μ = tan Φ
P= W ( tan Φ casa + sina ) / ( casa – tan ( Φ + a )
Multiplying n & d by cos Φ
P = W* tan ( Φ + a )
Torque to overcome the friction
T = P* d/2
T = W * tan ( Φ + a )* d/2
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3.5 Torque Required To Lowered the Load

For an equilibrium of horizontal forces,

pcosa = F - sina
But , F = μN
Pcosa = μN - W sina ------------- ( 1 )
For equilibrium of vertical forces
N= W cosa - Psina
Substitute this value of 'N' in above equation
pcosa = μ ( W cosa – psina ) - W sina
pcosa = ( μ W cosa – psina ) - W sina
pcosa = ( μ W cosa – psina ) - W sina
pcosa + μP sina = Wμ cosa - W sina
P= W ( μ cosa - sina ) / ( cosa + μsina )
substitute μ = tan Φ
P = W ( tan Φ cosa - sina ) / ( cosa + tan Φ sina )
Multiplying n & d by cos Φ
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P = W sin ( Φ - a ) / cos ( Φ - a )
P= W * tan ( Φ - a )
Torque to lower the friction
T=P*d/2
T= W * tan (Φ - a )*d/2

3.6 Overhauling
We have seen in Art . 17.5 that the effort required at the circumference of the screw to lower the load
is
P = W ( tan Φ - a )
And the torque required to
Lower the load ,
T=P*d/2 =W ( tan Φ - a )* d/2
In the above expression, <1> < a, then torque required to lower the load will be negative. In other words, the
load will start moving downward without the application of any torque. Such a condition is known as
overhauling of screws.

3.7 Self Locking

We have seen in that the effort required at the circumference of the screw to lower the load
P = W ( tan Φ - a )
And the torque required to
Lower the load
T=P*d/2 =W ( tan Φ - a )* d/2
In the above expression Φ > a, then torque required to lower the load will be positive. In other words, the
positive torque is required to lower the load is called as self-locking of screw [4].

3.8 Efficiency of Square Threaded Screw

The efficiency of square threaded screw may be defined as the ratio between the ideal effort to the actual load.

I.e. the effort required to move the load to the effort required to move the load friction into account.

The effort applied at the circumference of the screw to lift the load is ,

Po = W tan a

P = W tan ( Φ + a )

W = load to be lifted

a = helix angle

Φ = angle of friction

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μ = coefficient of friction between the screw and nut = tan Φ

Efficiency η = ideal effort / actual effort

η = W tan a / W tan ( Φ + a )

IV. DESIGN CONSIDERATIONS

Requirement of designs
Load w=500Kg = 4905N
Length of the links=400mm.
Factor of safety=5

4.l Design of Threaded Screw

Material =EN24
2
Permissible Tensile stress (σt ) =500N/mm =500/f.o.s.
2
500/5= 1 00N/mm
2
Permissible shear stress ( τ )=250N/mm =250/f.o.s.
2
250/5=50N/mm

2
Bearing pressure (Pb) =20N/mm
B try of fig.
y geome

Cos θ =350/400=0.875

θ =28.95° =29°

By using two nuts each nut carrying half load.

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F =W/2tanθ
F=4905/2tan29
F = 4424.42 N
Similar force on other side of the link nut [8]
W=2*F
W = 2 *4424 = 8848.85 N
By this way calculate core dia. ( dc)

Consider a screw is subjected to tensile due to load

Load = area * stress
W= π/ 4 * dc 2* σt

8848.85 = π/ 4 dc 2* 100
dc 2 = 8848.85 * 4/3.14 *100
= 112.56
dc = 10.74

Since the screw also subjected to torsional shear stress, therefore to account for this adopt
d0 = 17 mm , Pitch = 6 mm
d0 = dc + 6 = 23 mm
d = d0 + dc / 2= 20 mm

To check principle stresses W. K. T

tan a = p / πd
= 6 / π * 20
tan a = 0.09551
tan Φ = μ = 0.20
We know that effort required to rotate the screw,
P = W* tan ( Φ + a )
P = W* [ tan ( Φ + a ) ]

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P = 8848.85 * [ (0.09551 + 0.20 ) / ( 1 – 0.09551 * 0.2 )

P = 2665.53 N

Torque required to rotate the screw

T = P * d/2
2665.53 * ( 20 /2 )
T = 26665.33 N-mm

Shear stress due to torque :-

T = π / 16 * τ *( dc ) 3
τ = 16 T / ( 3.14 *( dc )3
= ( 16 * 26665.33 ) / ( 3.14 * 17 3 )
τ = 27.64 N/mm 2
We know that direct tensile stress in the screw,
σ = W / ( π / 4 ) * d c2
t
= 8848.85 / ( 0.785 ) * ( 17 2 )
σ = 39.04 N/mm 2
t
Maximum principle stress ( tensile )
2
σ ( max ) = σ /2+1/2*√σ + 4 ( τ 2)
t t t
= 39.04 / 2 + 1 / 2 * √ ( 39.04 ) 2 + 4 ( 27.64 2
)
2
σ ( max ) 53.32 N/mm
t =
Maximum Shear Stress ( τ max )
2
τ max = 1 / 2 * √ ( σ ) + 4 ( τ 2)
t
= 1 / 2 * √ ( 39.04 ) 2 + 4 ( 27.64 2
)
2
( τ max ) = 33.86 N/mm

Therefore the design of a screw will be state , all the maximum stresses are less than given stresses, hence the
screw is safe.

4.2 Design of Nut

Let, n=number of threads in contact with the screw(i.e. threaded rod)
Assuming the load 'w' is distributed uniformly over the cross sectional area of the nut, therefore bearing pressure
between the threads (Pb),

Pb= W /n/ 4[ (do 2)- ( dc2)] n

20 = 8848.85 / [ 0.785 * [ ( 23 2 - 17 2
)]n
n=3.51 ≈ 4 threads, For good stability and also prevent the rocking of screw in nut, we shall provide four (4)
thread in contact with screw.
Thickness of nuts ( t )
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t=n* p
Where, p = pitch of screw
t= 4*6
t = 24 mm

The width of the nut ( b )

Width= 1.5 *d
o
b= 1.5*23
b = 34.5 mm

4.3 Design of Pin

Consider a pin is subjected to double shear stress.
Let, d = dia. of a pin.
Since, pins are in double shear, therefore load on the pins(F)
2
F= 2 * π / 4 * ( d )*τ
1
2
4424.24 = 2 * 0.785 * ( d ) * 50
1
d = 10.65 ≈ 14 mm.
1
4.4 Design of Links
Due to the load, the links may buckle in two planes at right angles to each other.for buckling in the vertical
plane, the links are considered as hinged at both ends for buckling in plane perpendicular to the vertical plane, it
is considered as fixed at both the ends [9, 10]. We know that load on the link,
=F/2
=4424.24/2
=2212.12N
The factor of safety=5, the links must be design a buckling load of
3
Wcr=2212.12*5=11.06*10
3
Wcr=11.06*10
Let, t1 be the thickness of link
bl,the width of the link
Assuming that the width of the link is three times the thickness of the link,
b =3* t
1
therefore c/s of the link
A = b1 * t = t * ( 3 t ) = ( 3 t 2 )
1 1 1 1
And moment inertia of the cis of the link,
3
I=1/ 12*( b1 * t1)

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2
= 1 / 12 * t1 * ( 3 t )
1
4
=2.25*(t1 )

We know that radius of gyration

k = √ I / A = √ 2.25 * ( t14 ) / ( 3 t 2
)
1
= 0.866 t1
Since for buckling of the link in the vertical plane, ends are considered as hinged, therefore equivalent length of
the link,
L = 400 mm
Rankin's constant = a = 1 / 7500
Rankin's formula for buckling load ( Wcr = 11.06 * 103 )
Wcr = σ * A / 1 + a * ( L / k ) 2
c
= 100 * ( 3 t 2 ) / 1 + [ 1 / 7500 ( 400 / 0.866 t 2 )
1 1
t1 = 7.52 ≈ 8 mm
b1 = 8 * 3 = 24 mm

4.4 Length of Screw

1000 + ( 2 x 50 )= 1100 mm
The 50 mm distance in above calculation given for the lever attachment,
Length of the Lever
Assuming 300 N force easily applied by human ,
Length of lever = T / 300
L= ( 26703.38 / 300 )
For easy operation we take a length 200 mm.
5. ADVANTAGES
1 ) Toggle jack is used in material handling to save the material handing cost.
2) This device helpful to handle material in different position and level.
3) It is also used to load and heavy jobs on the machine table.
4) It is raise and lowers the load in small efforts as compare to other manual material handling devices.
5) It is transport the job and also lifts the job for required height.
6) The maintenance required is very less.
7) It is not required skill worker.
8) It is not consume power.
9) Pollution free device.

VI. APPLICATIONS

1) To transport the heavy jobs from one place to another place in a work shops or small scale industries.
2) To carry prime mover like electric motor from one machine another machine.
3) For the transportation of heavy jobs from vehicle from vehicle to machine table or vice-

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4) To load the heavy material on the press machine.

5) It is also used for the number of jobs at a time which save the time and cost.
6) This device helpful to handle material in different position and level.

VII. FUTURE SCOPE

The hand lever will modify by using a gear drive it helps to minimize the effort, it can be use in more efficient
way. It reduces fatigue to the operator. The sizes of links and dia. of the screw can be increase; it increases the
load carrying capacity and handles maximum heavy loads. The device can be drive by using electrical motor
drive the automation can be done. It can be improve the efficiency of the whole device.

VIII. CONCLUSION

By this project we are concluded that by using this device we can reduce material handling time and cost and
also reduce the production cost and increases plant efficiency. Possibilities of accidents are also reduced. At the
end of this project we are very glade to present it and are totally satisfied about it. We had great experience on
working on this project as a group. Each one we involved. Also we think from the bottom of our heart to
everyone who cooperated with us for our work and rendered direct or indirect help. We are thankful those whom
we have forgotten to thank us willingly. Finally but last but least a special thanks to our guides and all the staff.

REFERENCES

[1] Chinwuko Emmanuel Chuka, Chidi Ugochukwu Nonso, Ezeliora Chukwuemeka Daniel, Nwadike
Emmanuel Chinagorom, "Design and construction of a powered toggle jack system", American Journal of
Mechanical Engineering and Automation 2014; 1(6): 66-71 Published online October 30, 2014.
[2] Mounika.Kandi.Reddy, Priyanka CH, "Design and analysis of motorized screw jack for a four wheeler",
Department of Meachanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology.
[3] R. S. Khurmi and J. K. Gupta theory of machines (S. Chand and Company limited 2010).
[4] V. B. Bhandari design of machine elements (Tata McGraw-Hill Education 2010).
[5] www.machinedesign.com. [visited 21/12/2014].
[6] www.ctr.design.co.uk[visited 30/12/2014].
[7] www.engineeringbookstore.com.[visited 11/01/2015].
[8] I van Sunit Rout, Dipti Ranjan Patra, Sidhartha Sankar Padhi, Jitendra Narayan Biswal, Tushar Kanti Panda,
"Design and Fabrication of motorized automated Object lifting jack", IOSR Journal of Engineering
(IOSRJEN), 2278-8719 Vol. 04, Issue 05 (May. 2014), volume 5, PP 06-12.
[9] Gaurav Shashikant Udgirkar, Manoj Shantinath Patil, Rajesh Vijay Patil, Nilesh Ramchandra Chavan,
Prof. Mangesh Panchbhai, "Design, Development and analysis of electrically operated toggle jack using
power of car battery", International Journal of Computational Engineering Research (IJCER), Volume 04,
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[10] Version 2 ME, IIT Kharagpur, “Design of power screws”.

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