Module 1: Introduction to Power Screws and its types:

POWER SCREWS

The power screws (also known as translation screws) are used to convert rotary motion into
translator motion. For example, in the case of the lead screw of lathe, the rotary motion is available but
the tool has to be advanced in the direction of the cut against the cutting resistance of the material.

In case of screw jack, a small force applied in the horizontal plane is used to raise or lower a large
load. Power screws are also used in vices, testing machines, presses, etc.

Types of Screw Threads used for Power Screws

Following are the three types of screw threads mostly used for power screws:

Square thread: A square thread, as shown in Fig. a, is adapted for the transmission of power in either
direction. The square threads are employed in screw jacks, presses and clamping devices.

Acme or trapezoidal thread: An acme or trapezoidal thread, as shown in Fig. b, is a modification of

square thread. The slight slope given to its sides lowers the efficiency slightly than square thread and it
also introduce some bursting pressure on the nut, but increases its area in shear.

Buttress thread: A buttress thread, as shown in Fig. c, is used when large forces act along the screw
axis in one direction only. It is stronger than other threads because of greater thickness at the base of
the thread.

Multiple Threads:

The power screws with multiple threads such as double, triple etc. are employed when it is
desired to secure a large lead with fine threads or high efficiency. Such types of threads are usually
found in high speed actuators.

Module 2: Power Screw - Problem

Problems
A vertical screw with single start square threads of 50 mm mean diameter and 12.5 mm pitch is
raised against a load of 10 kN by means of a hand wheel, the boss of which is threaded to act as a
nut. The axial load is taken up by a thrust collar which supports the wheel boss and has a mean
diameter of 60 mm. The coefficient of friction is 0.15 for the screw and 0.18 for the collar. If the
tangential force applied by each hand to the wheel is 100 N, find suitable diameter of the hand
wheel.

An electric motor driven power screw moves a nut in a horizontal plane against a force of 75 kN
at a speed of 300 mm / min. The screw has a single square thread of 6 mm pitch on a major
diameter of 40 mm. The coefficient of friction at screw threads is 0.1. Estimate power of the
motor.
Module 3: Power Screw - Problem

The cutter of a broaching machine is pulled by square threaded screw of 55 mm external

diameter and 10 mm pitch. The operating nut takes the axial load of 400 N on a flat surface of 60
mm and 90 mm internal and external diameters respectively. If the coefficient of friction is 0.15
for all contact surfaces on the nut, determine the power required to rotate the operating nut
when the cutting speed is 6 m/min. Also find the efficiency of the screw.

A vertical two start square threaded screw of a 100 mm mean diameter and 20 mm pitch
supports a vertical load of 18 kN. The axial thrust on the screw is taken by a collar bearing of
250 mm outside diameter and 100 mm inside diameter. Find the force required at the end of a
lever which is 400 mm long in order to lift and lower the load. The coefficient of friction for the
vertical screw and nut is 0.15 and that for collar bearing is 0.20
Module 4: Power Screw - Problem

The mean diameter of the square threaded screw having pitch of 10 mm is 50 mm. A load of 20
kN is lifted through a distance of 170 mm. Find the work done in lifting the load and the
efficiency of the screw, when 1. The load rotates with the screw, and 2. The load rests on the
loose head which does not rotate with the screw. The external and internal diameters of the
bearing surface of the loose head are 60 mm and 10 mm respectively. The coefficient of friction
for the screw and the bearing surface may be taken as 0.08.
The lead screw of a lathe has Acme threads of 50 mm outside diameter and 8 mm pitch. The
screw must exert an axial pressure of 2500 N in order to drive the tool carriage. The thrust is
carried on a collar 110 mm outside diameter and 55 mm inside diameter and the lead screw
rotates at 30 r.p.m. Determine (a) the power required to drive the screw; and (b) the efficiency of
the lead screw. Assume a coefficient of friction of 0.15 for the screw and 0.12 for the collar.
Module 5: Stresses in Power Screws - Problem

A power screw having double start square threads of 25 mm nominal diameter and 5 mm pitch
is acted upon by an axial load of 10 kN. The outer and inner diameters of screw collar are 50
mm and 20 mm respectively. The coefficient of thread friction and collar friction may be
assumed as 0.2 and 0.15 respectively. The screw rotates at 12 r.p.m. Assuming uniform wear
condition at the collar and allowable thread bearing pressure of 5.8 N/mm2, find: 1. the torque
required to rotate the screw; 2. the stress in the screw; and 3. the number of threads of nut in
engagement with screw.
 WELDED JOINTS
Introduction

A welded joint is a permanent joint which is obtained by the fusion of the edges of the two
parts to be joined together, with or without the application of pressure and a filler material. The heat
required for the fusion of the material may be obtained by burning of gas (in case of gas welding) or
by an electric arc (in case of electric arc welding).

Welding is extensively used in fabrication as an alternative method for casting or forging and as a
replacement for bolted and riveted joints.

Advantages and Disadvantages of Welded Joints over Riveted Joints

Following are the advantages and disadvantages of welded joints over riveted joints.

Advantages
  The welded structures are usually lighter than riveted structures. This is due to the reason, that
in welding, gussets or other connecting components are not used.
 The welded joints provide maximum efficiency (may be 100%) which is not possible in case of
riveted joints.
 Alterations and additions can be easily made in the existing structures.
 In welded connections, the tension members are not weakened as in the case of riveted joints.
 The process of welding takes less time than the riveting.

Disadvantages

 Since there is an uneven heating and cooling during fabrication, therefore the members may get
distorted or additional stresses may develop.
 It requires a highly skilled labour and supervision.
 Since no provision is kept for expansion and contraction in the frame, therefore there is a
possibility of cracks developing in it.
 The inspection of welding work is more difficult than riveting work.

Welding Processes

The welding processes may be broadly classified into the following two groups:

 Welding processes that use heat alone e.g. fusion welding.

 Welding processes that use a combination of heat and pressure e.g. forge welding.

Types of Welded Joints

Following two types of welded joints are important from the subject point of view:

 Lap joint or fillet joint, and

 Butt joint.
The other type of welded joints are corner joint; edge joint and T-joint as shown in Fig Below

The main considerations involved in the selection of weld type are:

 The shape of the welded component required,

 The thickness of the plates to be welded, and
 The direction of the forces applied.

Module 9: Problem –welded joint

Problems 1: Determine the length of the weld run for a plate

of size 120 mm wide and 15 mm thick to be welded to another
plate by means of 1. A single transverse weld; and 2. Double
parallel fillet welds when the joint is subjected to variable
loads.

Given : Width = 120 mm ; Thickness = 15 mm In Fig. 10.16, AB represents the single

transverse weld and AC and BD represents double parallel fillet welds.

2. Length of the weld run for a double parallel fillet weld subjected to variable loads

Let l2 = Length of weld run for each parallel fillet, and

s = Size of weld = Thickness of plate = 15 mm
Assuming the tensile stress as 70 MPa or N/mm 2 and shear stress as 56 MPa or N/mm 2 for
static loading. We know that the maximum load which the plate can carry is
Module 10: Eccentric Loaded welded joints -Problem

Problem 2: A 200 × 150 × 10 mm angle is to be welded to a steel plate by fillet welds as shown in
Fig. If the angle is subjected to a static load of 200 kN, find the length of weld at the top and
bottom. The allowable shear stress for static loading may be taken as 75 MPa.
Module 11& 12: Welded joints subjected to fluctuating load - Problem

Problem 3: A 50 mm diameter solid shaft is welded to a flat plate as shown in Fig. If the size of
the weld is 15 mm, find the maximum normal and shear stress in the weld.

Given : D = 50 mm ; s = 15 mm ; P = 10 kN = 10 000
N ; e = 200 mm

Let t = Throat thickness.

The joint, as shown in Fig. 10.25, is subjected to

direct shear stress and the bending stress. We know
that the throat area for a circular fillet weld,
Problem 4: A rectangular cross-section bar is welded to a support by means of fillet welds as
shown in Fig. Determine the size of the welds, if the permissible shear stress in the weld is
limited to 75 MPa.

Given: P = 25 kN = 25 × 103N; τmax = 75 MPa = 75N/mm2; l = 100 mm; b = 150 mm; e = 500 mm
Let s = Size of the weld, and
t = Throat thickness.
The joint, as shown in Fig, is subjected to direct shear stress and the bending stress. We
know that the throat area for a rectangular fillet weld,

Screw thread, its terminology, Advantages and Disadvantages

Screwed Joints
 A screw thread is formed by cutting a continuous helical groove on a cylindrical surface.
  A screw made by cutting a single helical groove on the cylinder is known as single
threaded (or single-start) screw and if a second thread is cut in the space between the
grooves of the first, a double threaded (or double-start) screw is formed.
 Similarly, triple and quadruple (i.e. multiple-start) threads may be formed. The helical
grooves may be cut either right hand or left hand.
 A screwed joint is mainly composed of two elements i.e. a bolt and nut. The screwed
joints are widely used where the machine parts are required to be readily connected or
disconnected without damage to the machine or the fastening.
Advantages and Disadvantages of Screwed Joints
Advantages
1. Screwed joints are highly reliable in operation.
2. Screwed joints are convenient to assemble and disassemble.
3. A wide range of screwed joints may be adopted to various operating conditions.
4. Screws are relatively cheap to produce due to standardization and highly efficient
manufacturing processes.
Disadvantages
The main disadvantage of the screwed joints is the stress concentration in the threaded
portions which are vulnerable points under variable load conditions.
Important Terms Used in Screw Threads
The following terms used in screw threads, as shown in Fig. Are important from the subject
point of view:
Major diameter: It is the largest diameter of an external or internal screw thread. The screw is
specified by this diameter. It is also known as outside or nominal diameter.
Minor diameter: It is the smallest diameter of an external or internal screw thread. It is also
known as core or root diameter.
Pitch diameter: It is the diameter of an imaginary cylinder, on a cylindrical screw thread, the
surface of which would pass through the thread at such points as to make equal the width of the
thread and the width of the spaces between the threads. It is also called an effective diameter. In
nut and bolt assembly, it is the diameter at which the ridges on the bolt are in complete touch
with the ridges of the corresponding nut.
Pitch: It is the distance from a point on one thread to the corresponding point on the next. This
is measured in an axial direction between corresponding points in the same axial plane.
Mathematically,
Pitch = 1 /No. of threads per unit length of screw
Lead: It is the distance between two corresponding points on the same helix. It may also be
defined as the distance which a screw thread advances axially in one rotation of the nut. Lead is
equal to the pitch in case of single start threads, it is twice the pitch in double start, thrice the
pitch in triple start and so on.
Crest: It is the top surface of the thread.
Root: It is the bottom surface created by the two adjacent flanks of the thread.
Depth of thread: It is the perpendicular distance between the crest and root.
Flank: It is the surface joining the crest and root.
Angle of thread: It is the angle included by the flanks of the thread.
Slope: It is half the pitch of the thread.
Module 7: Types Screw thread & Types of Screw Fastenings
Forms of Screw Threads
British standard Whitworth (B.S.W.) thread. This is a British standard thread profile and has
coarse pitches. It is a symmetrical V-thread in which the angle between the flankes, measured in
an axial plane, is 55°. These threads are found on bolts and screwed fastenings for special
purposes
British association (B.A.) thread. This is a B.S.W. thread with fine pitches.. These threads are
used for instruments and other precision works.
American national standard thread. The American national standard or U.S. or Seller's thread
has flat crests and roots. The flat crest can withstand more rough usage than sharp V-threads.
These threads are used for general purposes e.g. on bolts, nuts, screws and tapped holes.
Square thread. The square threads, because of their high efficiency, are widely used for
transmission of power in either direction. Such types of threads are usually found on the feed
mechanisms of machine tools, valves, spindles, screw jacks etc
Acme thread. It is a modification of square thread. It is much stronger than square thread and
can be easily produced. These threads are frequently used on screw cutting lathes, brass valves,
cocks and bench vices.

Knuckle thread. It is also a modification of square thread. It has rounded top and bottom. It can
be cast or rolled easily and can not economically be made on a machine.

Buttress thread. It is used for transmission of power in one direction only. The force is
transmitted almost parallel to the axis. This thread units the advantage of both square and V-
threads.

Metric thread. It is an Indian standard thread and is similar to B.S.W. threads. It has an
included angle of 60° instead of 55°.

Common Types of Screw Fastenings

Following are the common types of screw fastenings:
Through bolts:
 A through bolt (or simply a bolt) is shown in Fig. (a).
 It is a cylindrical bar with threads for the nut at one end and head at the other end. The
cylindrical part of the bolt is known as shank.
 It is passed through drilled holes in the two parts to be fastened together and clamped
them securely to each other as the nut is screwed on to the threaded end.
 The through bolts may or may not have a machined finish and are made with either
hexagonal or square heads. A through bolt should pass easily in the holes, when put
under tension by a load along its axis.
 If the load acts perpendicular to the axis, tending to slide one of the connected parts along
the other end thus subjecting it to shear, the holes should be reamed so that the bolt
shank fits snugly there in.
 The through bolts according to their usage may be known as machine bolts, carriage
bolts, automobile bolts, eye bolts etc.
Tap bolts.
 A tap bolt or screw differs from a bolt. It is screwed into a tapped hole of one of the parts
to be fastened without the nut, as shown in Fig. 2
Studs.
 A stud is a round bar threaded at both ends. One end of the stud is screwed into a tapped
hole of the parts to be fastened, while the other end receives a nut on it, as shown in Fig.3
 Studs are chiefly used instead of tap bolts for securing various kinds of covers e.g. covers
of engine and pump cylinders, valves, chests etc.
Cap screws:
 The cap screws are similar to tap bolts except that they are of small size and a variety of
shapes of heads are available as shown in Fig.

Stresses in Screwed Fastening due to Static Loading and its problem.

Stresses in Screwed Fastening due to Static Loading
The following stresses in screwed fastening due to static loading are important from the subject
point of view:
1. Internal stresses due to screwing up forces,
2. Stresses due to external forces, and
3. Stress due to combination of stresses at (1) and (2).
Problem: Two machine parts are fastened together tightly by means of a 24 mm tap bolt. If the
load tending to separate these parts is neglected, find the stress that is set up in the bolt by the
initial tightening.

Module 9: Stresses in Screwed Fastening due to Static Loading and its problem.
Problem:

A steam engine cylinder has an effective diameter of 350 mm and the maximum steam pressure
acting on the cylinder cover is 1.25 N/mm 2. Calculate the number and size of studs required to
fix the cylinder cover, assuming the permissible stress in the studs as 33 MPa.
Design of a Nut

 When a bolt and nut is made of mild steel, then the effective height of nut is made equal to the
nominal diameter of the bolt.
 If the nut is made of weaker material than the bolt, then the height of nut should be larger, such
as 1.5 d for gun metal, 2 d for cast iron and 2.5 d for aluminium alloys (where d is the nominal
diameter of the bolt).
 In case cast iron or aluminium nut is used, then V-threads are permissible only for permanent
fastenings, because threads in these materials are damaged due to repeated screwing and
unscrewing.

Bolted Joints under Eccentric Loading- Parallel to the Axis of Bolts & its problem
Bolted Joints under Eccentric Loading

There are many applications of the bolted joints which are subjected to eccentric loading
such as a wall bracket, pillar crane, etc. The eccentric load may be

 Parallel to the axis of the bolts,

 Perpendicular to the axis of the bolts, and
 In the plane containing the bolts.

Eccentric Load Acting Parallel to the Axis of Bolts

Problem: A bracket, as shown in Fig. above, supports a load of 30 kN. Determine the size of
bolts, if the maximum allowable tensile stress in the bolt material is 60 MPa. The distances are:
L1 = 80 mm, L2 = 250 mm, and L = 500 mm.

From Table (coarse series), we find that the standard core diameter of the bolt is 28.706 mm and the
corresponding size of the bolt is M 33.

Eccentric Load Acting Perpendicular to the Axis of Bolts

Determine the size of the bolts and the thickness of the arm for the bracket as shown in Fig., if it
carries a load of 40 kN at an angle of 60° to the vertical.

The material of the bracket and the bolts is same for which the safe stresses can be assumed as70, 50
and 105 MPa in tension, shear and compression respectively.
Since the induced shear stress is less than the permissible stress (50 MPa), therefore the design is safe.