Selection of manufacturing

methods for machine element

s for Toggle Jack

Presentation by:
Sarthak Gangurde
Madhura Gayate
Prayag Gite
Shubham Hardikar
 What is toggle jack?

Toggle jacks are simple mechanisms used to

drive large loads short distances and to lift the
heavy loads.
 Elements of toggle jack :

• Screw
• Nut
• Pin
• Spanner
• Link
 Screw
MATERIALS : Screws are generally made from low to medium
carbon steel wire, but other tough and inexpensive metals may
be substituted, such as stainless steel, brass, nickel alloys, or
aluminum alloy
Design of screw
 Thread Rolling
The blank is cut using one of three techniques. In the reciprocating
die, two flat dies are used to cut the screw thread. One die is
stationary, while the other moves in a reciprocating manner, and
the screw blank is rolled between the two. When a centerless
cylindrical die is used, the screw blank is rolled between two to
three round dies in order to create the finished thread. The final
method of thread rolling is the planetary rotary die process. It holds
the screw blank stationary, while several die-cutting machines roll
around the blank.
 Nut
Materials : Bronze and cast Iron.
 Manufacturing :
There are mainly three basic procedures which are followed
for manufacturing nuts and bolts.
1. Machining:
In this process different-different procedures are used like
turning, milling, grinding or reaming.
2. Forming without cutting:
• Hot forming- Hot forming is mainly used for manufacture
large diameter nuts and bolts.
• Cold forming- In this procedure, the binder is formed,
usually in multistage processes, by pressure forging, cold
extrusion and reducing, or a combination of these
procedures.
 3. Threading:
The threading in nuts are either done by tap or turning depending upon the size and specification. The threading on bolts are
usually rolled or turned or made using Die.
 Pin
Material : Steel or wrought-iron.
Manufacturing Process :
Pin may be forged casted or fabricated
1.FORGING : In forging the metal is shaped by means of
applications of sudden blows or steady pressure and makes
the use of characteristic of plasticity of materials.
It involves use of dies and is mostly used in mass production.
2. Casting :
It is the process in which parts of desired shape are produced
by pouring the molten metal or alloy into a prepared mould
and then allowing the metal or alloy to cool or solidify
 Spanner
Material : Chromium-vanadium alloy

Manufacturing Process :
Most types of spanner are made using the drop forging
process.
Steel billets are run through an induction coil which heats the
metal up to make spanners.
Steel rods are cut into short lengths, called billets, and each
one is passed through an induction heating coil which uses
electromagnetism to heat the metal to about 1000 degrees
Celsius.
Drop forging machinery showing the ram, anvil and dies which
form the spanner shape.
The billet is placed in three dies (also known as 'moulds') in
succession. The upper die drops onto the billet, forcing it into
shape. The first die provides the rough shape of the spanner,
the second the finished shape and the third trims the excess
metal from the formed spanner.
Information (manufacturer, product number, size) stamped
on spanner surface with hydraulic press.
The 'trim line' (the place where the two halves of the die
come together) is ground down to produce a smooth surface
and a hydraulic press stamps the manufacturer's name and
the product details into the spanner's surface.
 Links
Material :They are generally produced from stainless steel,
carbon steel, alloy and case hardening steel and aluminum
Manufacturing :
Hot rolling :
It consists of passing the hot ingot through the hot rolls
rotating in opposite direction at uniform peripheral speed
hot-rolled links are available in a wide range of sizes. They are
characterized by close tolerances, excellent straightness as
well as roundness, good surfaces and low decarburization.
This makes them ideally suited for forging.
Cold rolling
It is drawn through a die reducing the cross-sectional area of
the bar, and giving it a smooth ‘drawn’ finish. Depending on
the shape of the die, the finished product can have a round,
hexagonal, square, or flat cross section. Cold drawn bars have
greater size accuracy, straightness, and increased tensile and
yield strength, as well as improved machinability.
 Result table:
Sr no Component Material Manufacturing
name Used process
1. Screw Low carbon & Thread rolling
medium
carbon steel
2. Nut Low carbon n Forging
stainless Steel
3. Pin Steel, Forging,
wrought-iron casting
4. Spanner Chromium- Drop forging
vanadium
alloy
5. Links Stainless Steel Rolling
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