UNIVERSTIY OF GONDAR INSTITUT OF TECHNOLOGY DEPARTEMENT OF MECHANOCAL ENGINNERING DESING PROJECT:-SCISSOR JACK Student Name Jd Ermiyas getent 00407/09 Solomon girma -01050/09 Submitted to Instructor Mr. KIRUBEL Submission date 23/10/11 F.CACKNOWLEDGMENT First of all we would like to express our heartfelt thanks for our instructor Mr. KIRUBEL for his consistent initiations and advices in doing this project work. Then, the role of our fiiend’s involvement and support through this project also cannot be left unmentioned, since they have gone through so many discouraging challenges with us, we would like to thank our family in advising and encouraging us to attendee our education, and our university for its facilities such as digital library, reference books, Wi-Fi and so onABSTRACT A Scissor Jack is a mechanical device used to lift a heavy vehicle from the ground for changing the wheel and for maintenance purpose. The most important fact of a jack is that, it gives the user a mechanical advantage by changing the rotational motion into linear motion and allowing user to lifta heavy car to the require height. This design project was focuses on the detail design and anatysis of each of mechanical scissor car jack and to draw out the detail drawing of each component and assembly drawing using AutoCAD software, different literatures are reviewed and a reasonable justification and conclusion was made. Based on them, the detail design was developed in accordance with specification, technical criteria and economic criteria and overall dimensions, component shapes and material were determined. In addition, Calculate stresses induced in its different part which are responsible for failure and To Reduce its cost, generally we try to design each component of mechanical scissor jack by using proper procedure and materials, which are available, strong, economical and good corrosion resistance.Table of Contents ACKNOWLEDGMENT. ABSTRACT. CHAPTER ONE...... 1.1 INTRODUCTION. 1.1.1 BACKGROUND OF THE PROJECT. 1.1.2 HISTORICAL BACKGROUND 1.1.3 APPLICATION OF CAR JACK 1.1.4 ADVANTAGE OF SCISSOR CAR JACK. 1.1.5 CLASSIFICATION OF SCISSOR CAR JACK. 1.1.6 DEFINITION OF SCISSOR CAR JACK 1.1.7 WORKING PRINCIPLE 1.1.8 COMPONENTS 1.2 PROBLEM STATEMENT. 1.3 OBJECTIVES 1.3.2 SPECIFIC OBJECTIVES. 1.4 SCOPE CHAPTER TWO CHAPTER THREE METHDOLOGY 3.1 IDENTIFICATION OF THE NEED. 3.3 DESIGNING STEPS CHAPTER FOUR 4, DETAIL DESIGN AND ANALYSIS4.1 Introduetion. 4.2 GENERAL DESIGN CONSIDERATIONS. 4.3 DETAIL DESIGN AND ANALYSIS OF SCISSOR JACK COMPONENT. 4.3.1 GEOMETRY ANALYSIS. 4.3.2 FORCE ANALYSIS 4.6. DESIGN OF CONNECTING MEMBER, 4.7. DESIGN FOR CUP AT THE TOP (BREAK) 3.8, DESIGN OF PINS. 4.9. DESIGN OF THE DRIVING HANDLE 4.10. DESIGN OF BASE PLATE... 4.11. DESIGN OF BOLT 4.12. DESIGN OF NUT 4.13. DESIGN OF WASHER, 4.14. COST ANALYSSIS..... CHAPTER FIVE... 5, RESULET AND DISCUSSION, 5.1.1, RESULT... 5.1.2 DISCUSSION CHAPTER SIX, 6. CONCLUSION AND RECOMMENDATION 6.1. CONCLUSION 6.2. RECOMMENDATION 3D DRAWING PARTS OF SCISSOR JACK. REFERENCE.Appendices. Figure 12-power screwCHAPTER ONE INTRODUCTION 1.1 INTRODUCTION In this design project we will design a mechanical scissor jack step by step by using our methodology 1.1.1 BACKGROUND OF THE PROJECT Doing work in a bent or squatting position for a period of time is not ergonomic to human body. A mechanical Scissor jack is one of machine type which is used to Lift a load specially ear. Car jack is commonly used to lifting up the car during maintenance or changing the tire. An automotive jack is a device used to raise all or part of vehicle maintenances or break down repairs, Most people are families with the basic car jack (manual operated) and it’s included as standard equipment for most of the new cars Generally, they are used to lift a load depending on the design specification to with stand to lift different load. . The mechanical advantage is the factor by which a mechanism multiplies the force or torque applied to it, An automotive jack is a device used to raise all or part of a vehicle into the air in order to facilitate repairs. Most people are familiar with the basic auto jack that was still included as standard equipment with most new cars. These days, fewer people than ever have had to use a car jack. This is due to the continuing improvements in modem tires that have made “getting a flat” rare. Even so, people who like to rotate their tires themselves or who may install snow Scissor jack is divided in specifically two types. Those are hydraulic and mechanical type. It also divided in to different type depending on linkage arrangements. Tire before the winter and remove them in the spring need to use a jack to perform the job [4] 1.1.2 HISTORICAL BACKGROUND 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. Leonardo’s 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 wwe use today. We can’t 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 futher. 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 .A screw jack that has a built-in motor is now referred to as a linear actuator but is essentially still a screw jack. Whitworth’s have become intematioually famous for their precision and quality, and dominated the market from the 1850th. Inspired young engineers began to put whit worth’s machine tools to new uses. During the early 1880th in Coati cook, a smal] town near Quebec, a 24-year-old inventor named Frank Henry Sleeper designed a lifting jack. Like da Vinei’s 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 screw, in to 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 rail road industry, where it was able to lift locomotives and railway cars. Arthur Osmore Norton spotted the potential for sleeper’s design and in 1886th hired the young man and purchased the patent and then Norton jack was born, Over the coming years the famous ‘Norton jack were manufactured at plants in Boston, Coati cook, Moline and Ilinois. 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 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After the industrial revolution, with the advent of Machine, the Machine Shop was also faced with the challenge of load lifting, because of the bulkiness of some Machine parts, The Machine Shop deals with various components made of metal, rubber, ceramics, polymers, etc., assembled mechanically to move people and goods from one place to the other. Because of the interface between the Machine and human lives, there is need for standardization of its component parts to improve its performance and efficiency and to reduce failure. For this reason care has to be taken during production and assembly of its component parts. Many tools and equipment used in the Machine Shop are designed to help the personnel working in a production facility. Other tools are produced to help the operators of the machine. Such tools include the lifting device, generally called jack [4] 1.1.3 APPLICATION OF CAR JACK Scissor car jack has so many applications generally application of scissor car jack is listed below e To lift machine, vehicle equipment and prefabrication part in mechanical assembly ‘Used to lift buildings from their foundations for repairs or relocation adjusting the height of truck loading platforms and mill tables It can be used for jacking carrying beams that have settled or for installing new structural beams > Lifting device to lift heavy loads or apply force in vehicles. > A series of jacks is used and then wood cribbing temporarily supports the structure. 1.1.4 ADVANTAGE OF SCISSOR CAR JACK The advantages of scissor type automobile screw jack are:- > Construction is very simple. Capital investment and installation cost are relatively low. Easy to operate, easy to maintain and easy to carry. Operation time is in short period. There is no require fuel, electricity and other power sources to operate this jack> The strength of the jack is more compact than other type of the jacks. The size of the Jack is so small and the overall weight of the jack is so light 1.1.5 CLASSIFICATION OF SCISSOR CAR JACK Based on working principle scissor car jack into two eategories;- > Bottle car jack > Scissor car jack i Bottle Jacks A device which is uses a high mechanical advantage that may be operated by using either: (a) Rotating the screw when the nut is fixed: or (b) 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. Figure I Bottle jack 4B. Hydraulic jack 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-Iubricating and stable, When the plunger pulls back, it draws oil out of the reservoir through a suction check valve into 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 eylinder Types of hydraulic jacks are: I. Floor Jack ii, Bottle Jack i, Floor jack: Ina floor jack (aka ‘trolley 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 are taken by the lifting pad, This mechanism provides a low profile when collapsed, for easy maneuvering underneath the vehicle, while allowing considerable extension. Figure 2 Hydtaulic floor jack Bottle Jack:A bottle jack or whiskey jack is a jack which resembles a bottle in shape, having a cylindrical body and a neck. Within is a vertical lifting ram with a support pad of some kind fixed to the top. The jack may be hydraulic or work by serew action. In the hydraulic version the hydraulic ram emerges fiom the body vertically by hydraulic pressure provided by a pump either on the baseplate or at a remote location via a pressure hose. With a single action piston the lift range is somewhat limited, so its use for lifting vehicles is limited to those with a relatively high clearance, For lifting structures such as houses the hydraulic interconnection of multiple vertical jacks through valves euables the even distribution of forces while enabling close control of the lift, te! Figure 3 Hydraulic Bottle jack Scissor jack: Are the simplest mechanism used to drives large loads short distance. The power screw design of commion seissor jack reduces the amount of force required by user to drive the mechanism. It mnueh likely a scissor jacks to lift up a vehicle for repair or storage. It typically works with just a vertical manner. A scissor jack uses a simply theorem of gears to gets its power as the screw section is tuned, two ends of links jack move closer together because the gears of the serew are pushing up the arms.The amount of force being multiplied will take a very small amount of force to form the crank handler. Figure 4 Mechanical scissor jack 1.1.6 DEFINITION OF SCISSOR CAR JACK 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. A scissor jack is a device which is used to lift heavy vehicles, partially or fully in the air for breakdown and maintenance. Scissor jack includes one power screw which is rotating, two fixed nuts, four links which is connected to nuts, eight pins used to fixed that four links, two rings provided at screw end and load platform supported by upper two Links [9], 1.1.7 WORKING PRINCIPLE As the screw section is turned, two ends of the jack move closer together. Because the gears of the serew are pushing up the ams, the amount of force being applied is multiplied. It takes a 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 tum it, even though your weight is a small percentage of cars by using screw to obtain its force for operating [4] 1.1.8 COMPONENTS The main components of scissor jack are;~ = Power screw handle Bolt ‘Nut Washer Pins Connecting member Base plate Power screw Lifting members Cup Driving (power screw) handle: The handle is used for lifting mechanism to those applied loads by engaging the handle and power screw driver in order to lifting and lowering the desired load. Bolt: Is a threaded fastener designed to pass through holes in the mating members and to be secured by tightening a nut from the end opposite head of the nut? The body of the bolt, called shank is cylindrical in form and the head square or hexagonal in shape is formed by forging. Nat: Isa threaded fastener used to hold two parts together and Nuts in general are square or hexagonal in shape. The muts with infernal threads engage with the corresponding size of the extemal threads of the bolt. For nuts, hexagonal shape is preferred to the square one, as itis easy to tighten even in a limited space. This is because, with only one-sixth of a tum, the spanner can be re-introduced in the same positionWasher: Washer is simply a flat, doughnut-shaped part that serves to inerease the area of contact between, the bolt head or nut and the clamped part. A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is normally used to distribute the load of a threaded fastener such as a screw or nut In general they are used for the purpose of. > To prevent the loosening of the associated screw, bolt, and nut > To distribute the compressive force over areas larger than that of the head or the aut, In order to decrease the friction that occurs when nut is tightened, especially when the surface of the patt is having poor surface finish. Pins. The pins are used as fasteners at the various joints of the members. The existence of the jack will depend on the ability of the pin not to fail under sudden shear, tensional and compressive forces. They are used to hold parts together or limit travel of moving parts, Connecting member These fasteners as used to fully transfer the applied load fiom the break, to the rivet, which connects the upper arm with the fastener. Base plate: the base plate should with stand the applied load plus the whole component or linkage load by itself, the force, we have to select the material during the design process in order to resist the above all loads Power screw: Power screws are used to convert rotary motion in to translational motion. It is also called translational serew. They find use in machines such as universal tensile testing machines, machine tools, automotive jacks, vises; aircraft flap extenders, trench braces, linear actuators, adjustable floor posts, micrometers, and C-clamps. A screw thread is formed by cutting a continuous helical groove around the cylinder. These grooves are cut either left hand or right 9hand. The power screw is a single Acme threaded screw with collar at both ends, with one end in contact with Member and the other end having a square key way to enable the transmission of torque fiom the gears. The collar is assumed to be frictionless and the power screw has been designed to be self-locking. Lifting members: These members are made fiom simple c-shapes. The web of the lifting member is cut out near the pin connections to allow proper serviceability of the seissor jack at its maximum and minimum heights, Cup: This cup is subjected to compressive stress and bending stress which is placed at the top of the frame and should with stand the applied load without failure. 1.2 PROBLEM STATEMENT Nowadays in this country, most of the cars were equipped with the many different jack. We found that many of those car jacks were very difficult to be used especially by women because they needed more strength and energy to operate. Thus, we want to develop a product based from the problem faced by the users who drive a car regarding to this issue. To overcome this problem. a research has been conducted to find the solution on how to design a car jack for the car using the simplest and cheapest way while it is energy saving. Although there were many ways to solve this problem, we recommend tat the design this car jack system is the practical way when we considered all the factors and consequences especially about the analysis to develop this product, During the research, we have found that most of the car user has difficulties in maintaining their vehicles breakdown especially cars in the scope of changing tires. The normal car jack we have in the market is operated using bare hands and it is time consuming. It also requires much energy from the person to rotate the jack. Hence, this report had been prepared to recommend the design of the car jack that is user friendly and easier to operate as do not required too much money to develop this product. 13 OBJECTIVES 1.3.1 MAIN OBJECTSDesign improvement the existing car jack in terms of its functionality and human factor consideration. And also to design Mechanical scissor car jack that has the capacity to increase or decrease load of vehicle based on the given specification. 1.3.2 SPECIFIC OBJECTIVES In our project the specific objectives are listed below;~ Design of power screw Design of links Design of driving handle Design of connecting member Design of base plate Design of cup Design of nut Design of Bolt Design of washer Design of pin Geometric and force analysis of the jack Careful selection of appropriate material for each component crease load of vehicle based on the given specification 1.4 SCOPE This project is about the designing the car jack. ‘The types of car jack that we were used in this project were mechanical scissor car jack as it is more reliable and easy to operate. In order to develop new concept of the car jack design, we do some research on many type of scissor concerning the people use the jack. The scopes of research were on the designing 1 ton maximum lifting capacity of ear jack by using optimization concept, For optimizing the human power, the concepts that will be used in this product by replacing with mechanically operated jack. Therefore By this, the mechanical advantage while lifting can be reducing. In our design we were using machine drawing instrument to draw out the detailed and assemble drawing of each component of our product. The project cost can be analyzed based on material cost in kilogram, labor cost which can be take time off manufacturing of part and standard material cost. ulCHAPTER TWO LITERATURE REVIWE CS. Dhamak et al [9] researched on design, optimize and standardize the current toggle jack to make the task easier and reliable and to avoid field failure. They mainly focused on designing and standardization of scissor jack model of automobile L.M.V. sector and trying for weight reduction of scissor jack with good strength. They conclude that for safe design of screw and nut a bearing pressure need to be considered and if we take combination of different material for each pair of screw and nut so we can find best suitable material for design at maximum load. Shashikant A. Pekhale and Prof. S. V. Karanjkar [10] works on modification and analysis of the current mechanical scissor jack by incorporating an electric DC motor in the serew in order to make load lifting easier for lifting motor vehicles with using power of car batter (12 Volts) they conelude that The existing jack was modified by making small alteration and making use of an electric motor to drive power serew, connecting gear with the pinion mounted on the motor shaft and then it will save time, be faster and easier to operate and requires less human energy and additional work to operate. Chetan $.Dhamak et al [7] presented their research on designing and optimization of mechanical scissor jack at the same time maintaining its strength and service life. After they study failure modes made a mathematical model analytically and by using ANSYS software. They concluded that scissor jack is failed due to wear of teeth on both links at lower end, Due to excessive use and high impact on screw starts getting wear and head of jack starts bending due to the fatigue load acting continuously again & again over the head. A. S. Akinwonmi and A. Mohammed [8] presented their work on modification of the existing motor screw jack by incorporating an electric motor in the screw in order to make load lifting easier. In this modified design, the power screw is rotated through its connecting gear with the pinion gear when electrical power flows through the cigarette lighter receptacle connected to the motor, plugged to the automobile 12 V battery source to generate power for the prime mover (Motor), which transmits its rotating speed to the pinion gear meshing with the bigger gear connected to the Power screw to be rotated with required speed reduction and increased torque to rtdrive the power screw. They concluded that the modified design will save time, faster and easier to operate and requires less human energy. Alexander et al, 1978, Smith, 1981, Nelkon, 1985 ) [4]. A lifting device is a system that allows small foree (effort) to overcome a large force or load There are practically ndseds of uses for lift tables in manufacturing, warehousing and distribution facilities. The Addition of this device (Lift table) makes job faster, safer and easier. Some typical Applications include: machine feeding and off-loading, product assembly, inspection quality control repair, feeding and offloading conveyor levels. The commonest method for operating a scissors lift is the use of a power serew We can see that from the above literature review that we can make our design easier by using electric motor to rotate the power screw in order to make lifting easier, less labor energy and make it easier to operate. scissor jack is failed due to wear of teeth on both links at lower end, Due to excessive use and high impact on screw starts getting wear and head of jack starts bending due to the fatigue load acting continuously again & again over the head. We can design our design to be simpler by using the above Knowledge.CHAPTER THREE METHDOLOGY Methodology: - means a general guideline, steps, procedures that are followed during designing or solving of the problem.so this section of the report includes guideline system for solving the problem which is stated in problem statement; with specific component such as phases, tasks, methods, techniques and tool. 3.1 IDENTIFICATION OF THE NEED Frist we have to identify the parameter that is needed or given in scissor jack design before we start the design analysis, Such as > The Weight of vehicle that used > Maximum height of jack that the jack could rise the vehicle > Minimum height of jack 3.3 DESIGNING STEPS Step 1:- The first work on the design process is selection a proper material with suitable price and best property should be chosen. We will select the materials based on the following eriteria:~ > Performance characteristics (such as mechanical properties): selecting the right material with the right properties is needed. > Processing (manufacturing) properties:-simple way of producing is advantageous. Environmental profile step 2:- Design and analysis of scissor jack component Design of lifting member (Links) :-These members will make from simple c-shapes Design of the Power Screw Design of connecting member Design for cup at the top (break)Design of pins Design of the driving handle Design of base plate Design of Bolt Design of Nut «Design of washer Step 3 cost analysis: - In this section we see the all cost the machine take to manufacture means cost for labor, cost for each material, and cost of standard components of scissor jackCHAPTER FOUR 4. DETAIL DESIGN AND ANALYSIS 4.1 Introduction In this section ‘we will be selecting a material and computing/designing each part dimension fiom the given design specification. Table 1 specification table Design of mechanical scissor jack Parameters Weight of vehicle Value Unit Maximum height of jack ‘Minimum height of jack 4.2 GENERAL DESIGN CONSIDERATIONS, Type of load and stress caused by load Motion of parts or kinematics of the machine Selection of material —it is important that the designer should select appropriate and most important material. By identifying characteristics of material like strength, durability, flexibility, resistance to heat, machinability, welded or hardness. Convenient and economical features Use of standard parts because of related to cost Safety operation 16> Workshop facilities > Cost of constuction 4.3 DETAIL DESIGN AND ANALYSIS OF SCISSOR JACK COMPOD 4.3.1 GEOMETRY ANALYSIS Scissor car jack where it’s maximum lifting capacity of 350mm and a minimum height of 150mm. to find a suitable length of links and the degree of angle of a maximum and minimum height. If consider two cases where at minimum position aud maximum position, Case 1 of minimum position, Figure 6 Let us assume the value of the following unknown value. a=30mm b=30uun ¢=20mum d=20mm e=20mm, Ymin = 150 ~ (a+) mm Ymin = 150 — (30 + 20) mm Y min = 100mm,In analysis of this we formulate equation for length L.1 and L2 with in 6 min and @ max opposite SiN Gp = — 'snin ~ hypotenes Figure 7 angles between links. Yin 2 Ly somm == Equation 1 Case 2 of maximum position, We formulate the length of link | and link 2 and within angle of @ max and y max.Figure 8 - angles between links. Ymav = 350 — (4 + €)nm Yaz = 350 — (30 + 20) mm 150 l= Equation 2 2 Sinemaw ajuation By using equation 1 and equation 2 and 6min as iteration calculate the value of L1 and @ maxTable 2 iteration 8, Li 2864.924mm a5 '955.36mm. 22.35 '573.68mm_ 40.9 '502.36mm_ 55.56 465.78mm_ 64.32 410.2674mm 72.378 319.622mm Does not exist 50 sind Ly = 359.264 max = 72.4° Generally from this iteration the value of L 1 and © max are determined Figure 9 - angles between links @ = 9° = 61= 02 and also the angle of B =180-90-0; when 6=9° psi" ‘Therefore, we have found the values of links and angles of inclination 1 =359.264 mm, @ =9°and B=81% 4.3.2 FORCE ANALYSIS The force analysis consideration is based on the assumption that, the scissor jack holds vertically symmetrical [2]Figure 10 - Force analyses Fbd [2] Maximum mass=1500kg. We=mg=1500kg*9.81m/s2=14715N F=FA+EB AO = OB=CP=PD FA=FB= “2 N=73575N At maximum raising height of the jack, B= min=8° F__73575) cos® cose Hence (FAE| = |FCE) = |FBF| = |FDF| FE =Facssin 8 + Fee-sin B Fr-2*Fae*sin B Fe-Fr= 2330.8 N (because of vertically symmetrical) 6. At minimum raising height of the jack. =@,,4,-81° F_7372.37N_, cosB cosa” Hence (\FAE| = |FCE| = |PBF| = |FDF| =47127.SN) Far= 7127.5 Fe=Fas*sin 82°+Foe*sin 81°Fe=2"Par*sin 81°=2"547127.5*sin 81°=93094.6N -Fs=93094.6N (tensile force in the power screw), Since the maximum loading force will act at the minimum raising height of the jack. The design stresses will be analyzed at that point, 4.4. DESIGN OF LIFTING MEMBER (LINKS) These members are made from simple e-shapes. The web of the lifting member is cut out near the pin connections to allow proper serviceability of the scissor jack at its maximum and minimum heights [2] figurel1 - lifting member Material selection The life span of the jack will depend greatly on the type of materials used for each component to avoid failure We select GS-52.3 cast steel material to design bolts because of > High level of ductilityHigh strength Wear resistance Ease of producing component parts Economical. For GS-52.3 cast steel: Tensile strength = 650 MN/m? Yield strength = 360 MN/m? Factor of Safety From dimension and force analysis: Length of lifting member, (L) = 359.264 mm Force in a lifting member at minimum raising height of the jack, (Paz) =52972.66N Design stress, Sd = SS¥¢seenet — 38° _ 1 20m? 2 47127.5N 2 2 Tapco A= 392.72mm A> 392.7mm?. For design consideration an area of lifting member, (A,,) ~ 467mm? will be chosen. Tensile strength, 5x = a = aun = 101N/mm?2 = 101MN/m? From the maximum distortion energy theorem: wheresy = 0 and txy = 0. max = JOx? + by? — Oxdy + Stay? 101MN me bmax = (1017 F0—0 +30) = The design is safe, because 6d > Smax; i.e 120MN/m? > 101MN/m?Design of the links for buekling Effective length i.e = 1 x C; where L = 359.264 mm and C = 1.0 (for pinned-pinned fixity Le = 359.264 x 1.0 = 359,264 mm The crippling load, Per = F.s x F = 3 x 47127.5N = 141382.5N. 4.5. DESIGN OF THE POWER SCREW Power screws are used to convert rotary motion in to translational motion, It is also called translational serew. They find use in machines such as universal tensile testing machines, machine tools, automotive jacks, vises; aircraft flap extenders, trench braces, linear actuators, adjustable floor posts, micrometers, and C-clamps. A screw thread is formed by cutting a continuous helical groove around the cylinder. These grooves are cut either left hand or right hand, The power screw is a single Acme threaded screw with collar at both ends, with one end in contact with Member and the other end having a square key way to enable the transmission of torque from the gears The collar is assumed to be frictionless and the power screw has been designed to be self-locking A power screw is advice used in machinery to change angular motion in to linear and usually, to transmit power. This must have adequate strength fo with stand axial load and the applied torque (), Figure 12-power screwMaterial selection The life span of the jack will depend greatly on the type of materials used for each component to avoid failure. We select GS -52.3 cast steel material to design bolts because of - > High level of ductility > High strength > Wear resistance > Ease of producing component parts For GS -52.3 cast steel Tensile strength = 650MN/m? Yield strength = 360 MN/m2 Factor of Safety Dimensional analysis ‘Tensile strength The design stress,6d = 2 Total axial force in serew (F), F Hence, the axial force (F) in a screw is maximum when (0) is minimum, 14715N P= = 92906.8N tand Design stress, 5d = 28 = 2 = 216,666MN/m? sa— F_920068N _ , _ 92906.8N oA A "216.666 mde? 4A [4 x 428.8 A= sede= [Rao RE WL 234mm 4 Vr 7 de=23.4mm_ From appendices, Table A.1, say de = 23.4mm standard size. Core diameter (de) = 26mm 428.8mm? Outer diameter (do) = 32mm.Mean diameter (dq) Pitch (p) = 6mm Root diameter (d,) = do — p > dr = 32-6 Cheek for self-locking - P a re | Figure 13 Thread geometry analyses ‘Where P= pitch of the serew d= mean diameter of the serew ochelix angle P= Effort applied at the cireumference of the serew to lift the load, I= Load to be lifted, and i= Coefficient of friction, between the screw and nut = tan 9, where @ is the friction angle Helix angle, tan(ce) = iat Lead=p; since the screw has a single start square thread 6 tan@) = Tas Helix angle « = 3.7678° for square thread take from 0.1 — 0.15: take = 0.14 Friction angle, () = tan™'(u) = @ = tan-1(0.14) = 8° 26Force analysis: w. Total axial force in power serew, (F) = = = = 92906.85N Effort required to raise the load, (P,)= Wtan(9 + 3.7678) = 14715N + tan 11.7678 = 3127.77N Tuming moment of the serew to raise the load, (T,)T, = effort = 3127.77 + Nm «< g,i.€ 3.7678 < 9; the load will remain in position after removal of the ef fort. The effort required to lower the load will be, (PI) = Wtan(9 — 3.7678) = 14715 x tan 5.2322 = 1347.5N The tuning moment required to lower the load, (TI) = w (3°) tan(9 ~ 3.7678) = 14715 14.5 x tan 5.2322 = 19.538Nm Required torque, (Tf) = ew x tan(a +) = wee x tan 11.7678 = 280644.1253Nmm Ising _ i-sing Ising — 1+sine Efficiency of threads,(n) = .756 = 75.6%. TE _ 2006041253 Actual torque required, (7) = 7 = SESS = 371222.387Nmm Strength analysis: = 216.666MN/m? _ Syt _ 485 _ 2 tall = 55 = —G = 108.33MN/m The direct tensile stress in screw body, (6t) = 4% = #5 — 27,71556MN/m? mack 266Tr _ 16x45952.665 Shear stress due to torque, (ts) = 5 = SERBS — 13. 141MN/m? Maximum principal stress theory, (Smax) = $+ 2 V8 +4 x te? = 2 + i 2777+ Ex 12.88") = 37.8268MN/m? The design is safe, because Smax < dall, i.e 37.8268MN/m? < 161.67MN/m? Maxinnum shear stress theory. (rmax) = | oe 41s? = a + (12.882) = 18.91MN/m2 The design is safe, because tmax < rall,i.e 18.91MN/m? < 80.83MN/m? 4.6. DESIGN OF CONNECTING MEMBER These fasteners as used to fully transfer the applied load from the break, to the rivet, which connects the upper arm with the fastener. The applied force at two points will have same magnitude (FA = FB = F2) and this loads FA and FB on the two rivets will be transferred to the arms [1] Figure 14 connecting member 50 40 f&—Figure 15 Top fastener strength analyses Material selection The life span of the jack will depend greatly on the type of materials used for each component to avoid failure We select GS-52.3 cast steel material to design bolts because of: High level of ductility High strength, Wear resistance > Ease of producing component parts > Economical ForGS-52.3 cast steel: Tensile strength = 650 MN/m* Yield strength = 360 MN/m?. Factor of Safety byt £90 108.333MN/m? Ws 2x3 0° i tall = 4aF 1 F(do® — de*)Pb , where Pb are bearing pressure and consider 65 4x 92906.8N "TGP 267765 = 5.52954 ~ 6 Length of side member, (I)= n x P = 6x 5 = 30mm Height of side member, (h)= 2.5 x do = 2.5 x 32 = 80mm Check for shear failure of side member threads, 29929068 max = The design is safe, because tmax < tall, i.e 6.586834MN /m? < 80.83MN/m? 4.7. DESIGN FOR CUP AT THE TOP (BREAK) This cup is subjected to compressive stress and bending stress which is placed at the top of the fiame and should with stand the applied load without failure [2]Figure 16 design of cup at the top ‘Material selection The life span of the jack will depend greatly on the type of materials used for each component to avoid failure We select steel alloy4340 material to design bolts because of: > > Good machinability Good duetility High strength Wear resistance Ease of producing component parts Economical For steel alloy 4340 © normalized(@8700-c) ay =862Mpa Gun= 1200Mpa 2-25 oan =344. 8Mpa n 25 Gmmax = E but Ggy= 0.577=497.374Mpa Now axial compressive stress gai =F / A; where A = b * w=S0mm * 10mm = $00mm2 =0.000Sm2 14715N / 0,000Sm2 =29.43Mpa Since 6 < ag it safe When = 344.8Mpa and F = 14715N area should be A715 / 344.8Mpa = 4.2*10°m? 3.8. DESIGN OF PINS The pins are used to joining a rotating link axis. The existence of the jack will depend on the ability of the pin not to fail under sudden shear, tensional and compressive forees. They are used to hold parts together or limit travel of moving parts [1] a Figure 17 pin 32Material selection The material selection is done by first taking less expensive steel material, which is to be changed depending upon the various outcomes of the design procedure (Strength analysis) We select steel, a 1045 grade steel material to design bolts because of © Good heat treatment > High strength > Wear resistance > Ease of producing component parts > Ultimate Tensile Strength (But) = 565 MPa Yield Strength (Sy) = 310 MPa Factor of safety = 3 fb 30 46. y= =32 =1ssMPa ty _ 155 tall zz 51.666MPa Shear stress due to maximum applied load force tall = 51.666 «7 d=19.0428mm =20mm Diameter of head is dy =1.5* dyin Omm 5.8549MPa Hence the material is safe.4.9. DESIGN OF THE DRIVING HANDLE The handle is used for lifting mechanism to those applied loads by engaging the handle and power serew driver in order to lifting and lowering the desired (certain load). The normal person can apply a force from 150N — 3S0N. For our case I have choose a force of (F= 180N) [2]. Figure 18 driving handle Material selection The life span of the jack will depend greatly on the type of materials used for each component to avoid failure. We select ASTM A 36 mild steel material to design bolts because of: High level of ductility High strength Wear resistance Ease of producing component parts For ASTM A 36 mild steel oy=450Mpa = 250Mpa n=15Sey = 0.577 oy = 0.577 * 250 = 144.25 aq= 2 =250 / 1.5 =166.666Mpa Considering bending moment about A =Ma=0 Mg =F * r= 180N * 80mm Ma= 14.44Nm Note: It is also taken as torque since it’s due to rotational effect about A. The combined stress due to the bending moment and torque developed can be determined as follows MA T aM 7a oy= ~*; where oy sass 028° Op: oy= 6.68Mpa Which implies o,< gq : therefore our design is safe 4.10, DESIGN OF BASE PLATE Here the base plate should with stand the applied load plus the whole component or linkage load by itself, the force, we have to select the material during the design process in order to resist the above all loads [ Design of upper base plateFigure 20 upper base plate We select steel material to design bolts because of: Resist over overcome load Good ductility High strength Wear resistance Ease of producing component parts Tensile strength=1241Mpa Yield strength=965Mpa ‘Young modulus=E=210Gpa { e Figure 21 base plate lay out = 2 For L==400mm (m=) z For L>300mm radius of inertiaTsecond moment order We=seetion modulus I,=first moment of area for half eross section b,=distance between center of compressive Xcthe distance of shear center from axis of y-y -fiom standard table H=80mm, ‘Omm y=Smm 19mm, dote=20mm_ First check buckling since bending stress is applied on base © 4Asending Abvending = thending-drote 4 +180 14715 oo 5180 oy = 20.4375Mpa Sinceoy< yield strength it is safeTo check the bending stress on load Figure 22 part of upper base Use section y-y LS wiz Figure 23 section y-y 7357.5*x-Myy=0 M y= 7357.5 Atx=0 Myy=0Atx=30 M, 7.530 M,=220725Nmm Myy=220.725Nin From section 2-2 —j Figure 24 section 2-2 14715 715 -F 7357.5 DMez-0 #49 z= 40mm 7357.5 * Xp — 14715 + (Xo_Xy) x) = 30mmMzz = 7357.5 + 30mm — 14715 + (30 — 40) Mzz = 367875Nmm Mzz = 367.875Nm Atx=80mm_ Mzz = 7357.5 * 80mm — 14715(80 — 40) Mzz = 0 Calculate shear stress due to bending moment My oT = 367875 +2), 4, 75 oy oy = 430Mpa The material is safe since2.88<4 Design of lower baseFigure 25 Lower base plate F/A F/4 F/4| F/4 Figure 26 2D drawing of base plate We select steel Resist overcome load Reduce stress concentration Good corrosion allowance Good heat treatment Tensile strength = 1241Mpa Yield strenath= 965Mpa Young modulu: 10GpaFigure 27 right side views Por L<=400mm 2 SFor L>=400mm, From table value of hy, bl, rl, 12, and t b=70mm b-35mm y=6mm, Simm,Calculate the moment and force on lower base of any distance from one of the end By using section c-¢ +t RS Figure 28 section view -7357.5+X-M=0 Atx=0 Moc = 0 Atx=35mm=0.035m 0 = 7357.5 + 0.035 — Moc Meg = 257.5Nm At section ded Fy= —7357.5N + 14715N — Fy Fy = —7357.5N ~7357.5 +x +w(x— 35) —M= Atx=0.035m > Mga = —257.5Nm Atx=0.07m4.11. DESIGN OF BOLT Is a threaded fastener designed to pass through holes in the mating members and to be secured by tightening a nut from the end opposite head of the nut? The body of the bolt, called shank is cylindrical in form and the head square or hexagonal in shape is formed by forging. Bolt joints are one of the most common elements in construction and machine design. They consist of fasteners that a capture and join other part and are secure with the mating of bolt joints designs or sorew threads There are two main type of bolted joint design: 1) Tension joint 2) Shear joint In the tension joint the bolt and clamped component at the joint are designed to transfer the extemal tension load through the joint by away of clamped component through the design of proper balance of joint and bolt stiffiess. The second type of bolted joint transfer the applied Joad in a shear on the bolt shank and relies on shear strength of the bolt, tension loads on such joints are only identically [1] Figure 2 9Bolt at lower plate‘We select mild steel material to design bolts because of: easily workable very hard yet malleable good for construction easy to shape and machine Very flexible and can be harden. Table 3 material selection for bolt design [2] Steel grade Measured direction | Yield strengih(Mpa) | Tensile strength(Mpa) Mild steel 2 497 To design bolts we have taken all necessary parameter from Table .5, Basie dimensions for square threads in mm (normal series) according to IS: 4694-1968 (Reaffirmed 1996) Table 4 Basic dimensions for square threads in mm (normal series) according to IS: 4694-1968 (Reaffirmed 1996) [1] ‘Nominal Major ‘Minor Pitch(p) Depth of ‘Area of diameter(d,) | diameter(d) | diameter(d,) thread(h) core(Ac) 4.12. DESIGN OF NUT Is a threaded fastener used to hold two parts together and Nuts in general are square or hexagonal in shape. The nuts with intemal threads engage with the corresponding size of the external threads 45of the bolt. For nuts, hexagonal shape is preferred to the square one, as itis easy to tighten even in a limited space. This is because, with only one-sixth of a turn, the spanner can be re-introduced in the same position [1] Figure 30 Nut We select mild steel material to design Nuts because of: > easily workable > very hard > yet malleable > good for construction easy to shape and machine Very flexible and can be harden Table Smaterial selection for nut design [2] Steel grade Measured direction | Yield strength(Mpa) _| Tensile strength(Mpa) Mild steel A 452 497 To design nuts we have taken all necessary parameter from Table. 7- Basie dimensions for square threads in mm (normal series) according to IS: 4694-1968 (Reaffirmed 1996)Table 6 Basic dimensions for square threads in mm (normal series) according to IS: 4694-1968 (Reaffirmed 1996) [1] Nominal Major Minor Pitch(p) Depth of Area of diameter(d,) | diameter(D) | diameter(d.) thread) core(A.) 2 325 26 325 531 Let mis the number of threads in contact with the screw Let us assumed that the load is uniformly Distributed over the cross sectional area of the nut. Let Pb be the Allowable Bearing pressure between the threads, Bearing pressure is assumed as 65 Ninm2 Pb = (2+ T)/((n/4) * (do® — de*) « n) 65 = (104914.26)/ ((w/4)*(287-257)"n) n= 12.925 Number of threads, n = 12.925 In order to have good stability let n=13 Thickness of Nut = 8*p = 13*3-39mm Width of Nut b =1.5*do=1,5*28=42mm 4.13. DESIGN OF WASHER Washer is simply a flat, doughnut-shaped part that serves to increase the area of contact between the bolt head or nut and the clamped part. A washer is a thin plate (typically disk-shaped) with a hole (typically in the middle) that is normally used to distribute the load of a threaded fastener, such as a screw or nut. In general they are used for the purpose of, © To prevent the loosening of the associated screw, bolt, and nut © To distribute the compressive force over areas larger than that of the head or the nut, © Inorder to decrease the friction that occurs when nut is tightened, especially when the surface of the partis having poor surface finish [2].Figure 31 Washer Material selection in our design we select low alloy steel to design the washer because of: © Ithas high working stress compared to others, © Has high atmospheric corrosion resistance capacity © Suitable to welding. To calculate the outer diameter of the washer we can use the following formula: Do waster=1-SDo ssren*3mnm Where outer diameter of the screw is=28mm_ Do sashe=1.5*28un-+3mm=45mam To calculate the thickness of the washer we use the following formula washer Therefore the outer diameter of the washer is=45mm, The thickness of the washer is=3.Smm 4.14. COST ANALYSSI:In this section we see the all cost the machine take to manufacture means cost for labor, cost for each material, and cost of standard components of scissor jack. Total cost of scissor jack C Total =C manufacture = C labor +C standard > Material cost Material cost means the cost of each material in project. Means the cost each material have regarding its material property, the mass of each material have and cost it be sold per kilogram. » Labor cost: Labor cost means the cost of all components should have regarding its process of manufacturing, and time it take to manufactured. Not only this one labor cost means expenditure made of on the salaries, wages, overtime, bonuses, etc. of the employer of the inter price. In our design the labor cost takes 196.5birr > Standard cost: Standard cost means the cost of standard material gated from shop. As shown on table 7 table of cost analysis below; the material cost and standard components cost can be listed. ‘Table Teost of material Partname | Qty | Mass | material Cost/k | Cost of raw (kg) g(birr) | material(bi rr) Manufactured parts Power 1531 | GS-523CAST | 17.23 | 26.379 screw STEEL Upper link 1.62 | GS-52.3 CAST 17.23 | 55.8252 STEEL Lower link 2.36 | GS-52.3 CAST 17.23 | 81.3256 STEEL Base plate 2.78 | MALTENSTIC 16.5 45.87 STEEL break 64 | STEELALOY [ia | 896 4340 ‘Connecting 1.87 | GS-52.3 CAST 128.88 member STEELwasher LOW ALLOY 14 STEEL Handle MILD STEEL 15.2 drive andard selected parts Pin ‘81045 GRADE 95.32 STEEL Bolt 8 MILD STEEL 53.63 Nut 8 MILD STEEL 70 Total cost = 520.186birr Now, the total material cost is 437.14birr. Generally the total cost of scissor jack must be as our project design is = 437.14 + 196.5 = 633.64binrCHAPTER FIVE 5. RESULET AND DISCUSSION 5.1.1. RESULT Table result Components Dimensions 1. power screw A=392.72mm2 2.Comnecting members 3. Lifting members(L inks) A 467mm" L.= 179.6324mm 4. Break(cup) w=l0mm, 30mm 3. Pin = 28.45mm 6 Driving handle7. Base plate d= 32mm 2mm A= 531mm? = 45mm 3.5mm §.1.2 DISCUSSION, In this process, we perform the geometrical analysis and force analysis of the mechanical seissor jack, Then we try to calculate stress and strength analysis for each component and we designed power screw, connecting member, pin, link, cup, driving handle, bolt, and nut by selecting the appropriate material all of the mechanical scissor jack are designed by using appropriate formulas for each and their factors of safety are checked for strength to avoid failure,CHAPTER SIX 6. CONCLUSION AND RECOMMENDATION, 6.1. CONCLUSION In this project generally we analysis the mechanical scissor jack is feasible or applicable is safe with safety factor 2 to 3. In addition, all most all parts of the mechanical scissor jack can easily have manufactured in the workshop in such manners. On calculating the designs of various components of scissors jack by taking four different materials. We concluded that out of four materials AISI 104SgradedSteel is also good for carrying maximum load but in comparison to mild steel it is more.GS -52.3 cast steel is also falls under the safe limit so it can also be consider for manufacturing purpose of scissors jack. In this Paper, we conchided that all four materials falls under the safe limit, which is very important to avoid the failure 6.2. RECOMMENDATION Besides the major achievements of the project, some other recommendation should be given for the future work. We have some recommendations regarding the project mechanical seissor jack design should include the shock, vibration and wobble effect in which it was delivered within order to have accurate design results the components of the mechanical scissor jack should be design by using Simulation software. The mechanical scissor jack should be test in laboratory before use. Mechanical scissor jack should be checked every time before and after we useDRAWING OF SCISSOR JACK PARTS 2D DRAWING a. power serewc. lower base plate d. driving handlef. connecting memberh. washeris link j.nutk. 2D assembly 3D DRAWING PARTS OF SCISSOR JACK5) Connecting memberd) base plate) driving handleg)_washer nh). break3D ASSEMBLYREFERENCE [1JA textbook of machine design, R.S. KHURMI & JK, GUPTA, [A Textbook for the Students of BE. / B.Tech. U.S.C. (Engg. Services); Section ‘B’ of A.M.LE. (I]] EURASIA PUBLISHING HOUSE (PVT.) LTD. RAM NAGAR, NEW DELHI-110 055 [2] WWW.Google.Com (3]Vigaykumarjacon, sureshverme, analysis and design of machine element. [4] Alexander et al, 1978, Smith, 1981, Nelkon, 1985) [5] ChetanS. Dhamak et alareview paper on design and optimization of mechanical scissor jack, journal of Amrutvehini college engineering sangamner [Ms], savitribaiphulepune university. [6]A. S. Akinwonmi and A. Mohammed works on modification power screw of mechanical scissor jackJoumal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 3 (4): 581-588. [7] C.S Dhamak et alpresent his research on design and standardization of mechanical scissor jack to avoid field failure, Department of Mechanical Engineering, SavitribaiPhule Pune University journal of Ammutvahini College of Engineering, Sangamner. [MS], India-422608. [8] Shashikant A. Pekhale and Prof. S. V. Karanjkar works on Design Modification and Analysis of Electrically Operated power screw for Light Motor Vehicles, journal of Institute of Engineering Bhujbal Knowledge City NashikAppendices Table 9Basic dimensions for square threads in mm (normal series) according to IS: 4694-1968 (Reaffirmed 1996 Nominal Major diameter diameter (4) Bolt Nut @ ) 2 2 25 4 45 26 26 26.5 28 30 2 36 Table 9Bolt standard dimensions