ACKNOWLEDGMENT

First of all we would like to thanks almighty God before every things. Next to that we record our
sincere gratitude to Mr. Beyene G. Dept. of Mechanical Engineering and for assigning the
project “MACHINE DESIGN PROJECT ON SCREW JACK”. Their encouraging attitude and
continuous guidance made it possible to understand the project better & its fulfillment. It is not
possible to acknowledge sufficiently their important contribution of talent and time given
unselfishly in proceeding with this work so their constant voice of advice and constructive
criticism has been our source of inspiration. we wish to record his heartfelt gratitude to his
project coordinators some mechanical engineering students for helping his at each and every step
in bringing out this report.
Abstract
A Screw jack is a portable device consisting of a screw mechanism used to raise or lower the
load. There are two types of jacks-mechanical and hydraulic Mechanical jacks can be either hand
operated or power driven. The hydraulic jack consist of cylinder and piston mechanism Although
a jack is a simple device used to raise various types of loads Proper size, strength and stability
are essential requirements for the design of the screw jack from safety consideration.

A screw jack serves to give mechanical advantage by changing rotational force to linear
force thus allowing one to lift a load and support it at a given height.
The aim of the project was to come up with a design procedure for a simple screw jack and
coding in Matlab to form a program that would require one to enter the mechanical properties of
the materials to be used, lift and the desired load to be supported.
This case study is divided into various sections that describes classification of screw threads,
parts of the screw jack and selection of materials used for construction that are in agreement with
current industry practice of screw jack design.
The design procedure adopted here is from design of machine elements by V. B. Bhandari and
coded the design procedures using Matlab to serve the same function fast and efficient. This is
realized as we obtained the similar theoretical and Matlab solutions as coded. Application of the
procedure manually is tedious and extraneous since its lengthy and time consuming. Using
Matlab for the same makes work easier, efficient and fast for designers since only material
properties and specific design requirements such as lift and load are the only required input.
A factor of safety of 5 and above should be used in this design to reduce high chances of failure
due to dynamic loadings and impact loadings. Dynamics loading is as a result of external
interferences such as whirl wind, earth tremors and external forces while impact loading is such
as load is applied suddenly with a short time and results into high stresses which can cause
failure hence this calls for a high factor of safety.
 CHAPTER ONE

SCREW JACK

1.1. Introduction

A screw jack or jackscrew is a mechanical device used as a lifting device to lift heavy loads or to
apply great forces. A mechanical jack employs a screw thread for lifting heavy equipment. A
hydraulic jack uses hydraulic power. The most common form is a car jack , floor jack or garage
jack , which lifts vehicles so that maintenance can be performed. Jacks are usually rated for a
maximum lifting capacity (for example, 1.5 tons or 3tons). Industrial jacks can be rated for many
tons of load.[1]

A jack is a mechanical device which uses a screw thread or a hydraulic cylinder to lift heavy
loads or apply great linear forces. The most common forms of jacks available in the market are
Scissor car jacks, House jacks, Hydraulic jacks, Pneumatic jacks and Strand jacks that are
extensively used in Construction, Industrial, Automobile and Engineering segments.[2]

Nowadays, mechanical artifacts are commonly found in general routine life. They are widely
used in many fields of appeal such as office, industrial automation, hospital operation, security
systems and military task. It is easy to observe that the mechanical designs and instruments plays
very wide role in assisting human life. The mechanical jack is used to lift the car during side road
emergency i.e. tire puncher. A mechanical toggle jack is a device which is used to lift bulky
equipment and all or part of a vehicle into the air in order to facilitate vehicle for its
maintenances or breakdown repair. Changing a flat tire is not a very good experience.
Nowadays, different kinds of types of car jacks have been developed for lifting an automobile
from a ground surface. Available car jacks, however, are generally manually operated; therefore
require substantial laborious physical effort on the part of the user. These are such relevant
difficulties of jack for the elderly and handicapped people. It further requires the operator to
remain in prolonged bent or squatting position to operate that jack. Doing work in a squatting or
bent position for a long period of time is not suitable for human body. It will arise body problems
like back ache problems.[3]
Mechanical jacks are either hand operated or driven by power. Jacks are used normally in lifting
cars so that a tire can be changed. A screw jack is mostly used in cars but also used in many
other ways, including industrial machinery & even airplanes. They may be short, may be tall, fat,
or thin depending on the amount of pressure they will be under and the area or the space which
they need to fit into. The jack is manufactured by various types of metal, screw jacks are
designed purposely for lifting or lowering loads, they are not designed or ideal for side loads,
though few can withstand side loads it’s all depend upon the diameter and size of the lifting
screw. The Shock loads must also be minimized. Few screw jacks are built or designed with anti-
backlash. The anti-backlash mechanism moderates axial backlash in the lifting Nut and Screw
assembly to a regulated minimum. To have the good efficiency of the screw jack, it should be
used in ambient temperatures, or else lubricants must be applied at required place. Oil lubricants
purpose is to enhance the capability of equipment’s. To optimize the usefulness of screw jack it
is advised to employ it according to the designers or manufactures instruction.

Fig.1.1 simple screw jack

An advantage of screw jack over some other types of jack is that they are self-locking in nature
that means when we removed the rotational force it will remain motionless where it was left and
its motion will not rotate backwards, irrespective of how much weight it is going to support. [4]

There are typically two type’s screw jacks. These two jacks vary in their size depending upon
how much load they are going to lift.

1) Mechanical Jacks: The mechanical jack lifts heavy load of equipment. The most common
form of mechanical jack is a car jack, a floor jack or a jack used in garage.

There are two types of mechanical jacks:

A) Scissor Jacks: Scissors jacks are a typical mechanical jack and it has been used at least since
the 1930s. A scissor jack is a device or utility constructed by making use of a cross-hatch
mechanism, much like a scissor, this jack is mainly used for lifting up a vehicle or any car for
repair or maintenance of vehicle or storage of goods at greater heights. This scissor jack typically
works in just a vertical manner that is it only work along vertical direction. This jack opens and
can be fold close, by applying pressure at the base supports along the way of crossed pattern to
perform the required lift, and when closed, it has a diamond shape.

Fig.1.2. Scissor car jacks

Scissor jacks are simple mechanisms used to drive large loads for short distances. The power
screw design of a common scissor jack reduces the amount of force required by the user to drive
the mechanism. Most scissor jacks are similar in design, consisting of four main members driven
by a power screw. These kinds of jack put in to working simply by rotating a small crank which
is inserted through the one of the end of the scissor jack. This crank is look like ‘Z’ shaped
component. The end fits into a of ring hole which is fixed at the end of the screw, and the object
is placed on the scissor jack. When we are going to turn this crank, then the screw turns, and this
mechanism ultimately raises the jack. The screw in this mechanism exactly acts like atypical
gear mechanism. It has we called this as teeth (the screw thread), which turn & ultimately move
the two arms, producing required work. Just by doing the rotating motion of screw thread, we see
that the scissor jack ultimately going to lift the vehicle that is of weight several thousand pounds.

B) Bottle (cylindrical) Jacks: Bottle screws as usually operate either by turning the screw when
the position of nut is fixed; or may be by Rotating motion of the nut and preventing turning
motion of the screw. Bottle jacks made by a screw, a nut, thrust bearings, and a body as shown
below. A static platform is attached at the top of the screw. This static platform performs as a
support for the load which comes on it and also assists in raising or lowering of the working
load. These kinds of jacks are sturdier as compared to scissor jacks and ability of this kind of
jack is it can lift.

2. Hydraulic jacks are typically used for shop work, rather than as an emergency jack to be
carried with the vehicle. Use of hydraulic jacks not designed for a specific vehicle, it requires
more care in selecting ground conditions, and the jacking point on the vehicle. Hydraulic jacks
are often used to lift elevators in low and medium rise buildings. 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-lubricating and stable. When the plunger pulls back, it draws oil out of the reservoir through
a suction check valve into the 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 cylinder.

Fig.1.3. hydraulic jack

In this jack piston is always in vertical position and directly supports bearing pad. This is in
contact with the object that being going to lift. The lift is somewhat little less than 2 times
collapsed height of the jack, with single action piston which makes its use suitable for the vehicle
for which clearance is relatively high. to lift the structure such as houses, the use of inter
connection of hydraulic jacks with valve enable us for evenly distributions of forces at the time
of enabling close control of lift. The piston in floor jack which is horizontal pushes on short end
of bell crank, and long arm providing vertical linear motion for the pad which is to be lifted is
kept always horizontal with horizontal link. The Floor jacks consist of castors & wheels, and
allowing compensation for arc used by pad which is going to lift. This kind of mechanism when
collapsed provides a low profile, for easy going below any vehicle, as well as to allow
considerable extension.[5]

1.2. Background

Engineers play a key role in the development of our society, contributing towards building the
economy and inspiring changes that improve on the quality of life. They possess the ability to
comprehend technological processes and creative thinking skills which can help in the solving of
the present problems in both business and the industrial world. Due to global and technological
changes in the world today there is a need for research and development activities to help counter
this, and this can be in terms of complete or slight changes from the existing technology and all
this work requires an engineer. In an effort to improve the quality of life a power screw was
invented, which is also called a translational screw that converts rotary motion into translation
motion. Power screws have many applications such as in vices, fastening machines, screw jack
and many others. The screw jack is one of the power screws in which a small force is required to
be applied to raise or lower a large load (Bhandari, 2010).

A lifting jack was first designed by Leonardo da Vinci in the late 1400s who demonstrated the
use of a screw jack for lifting loads using a threaded worm gear that was supported in bearings
and rotated by turning the worm shaft to drive a lifting screw to move the load. In the early
1880s Frank Henry Sleeper designed a lifting jack which was also based on the principle of ball
bearings for supporting a load and transforming rotary motion into translation motion. This
design patent was bought by Arthur Osmoses Norton leading to the first Norton jacks, which
were produced in Boston.

In 1883 a Mississippi river boat captain named Josiah Barrett came up with an idea of the ratchet
jack which was based on the familiar lever and fulcrum principle. Duff manufacturing company
took up that chance and started the production of Barrett jacks. More recent screw jack designs
have concentrated on improved efficiency and durability (Collection, 2015).[6]

The personal name Jack , which came into English usage around the thirteenth century as a
nickname form of John , came in the sixteenth century to be used as a colloquial word for 'a man
(of low status)' (much as in the modern usage 'jack of all trades, master of none'). From here, the
word was 'applied to things which in some
way take the place of a lad or man, or save human labor'. The first attestation in the Oxford
English Dictionary of jack in the sense 'a machine, usually portable, for lifting heavy weights by
force acting from below' is from 1679, referring to 'an Engine used for their moving and
commodious placing of great Timber. [7]

1.3. Problem Statement

Many authors for example Eng. Nyangasi, Van Kudoth Naik, Gupta R.S. Khurmi, J.Keith
Nisbett, and Richard G. Budynas came up with varying procedures for the design of power
screws. These procedures are mostly lengthy and tedious to work with. The purpose of this
project is to come up with a software or program that can be used to design a power screw in this
case a screw jack, so as to save future designers from the tedious work involved in the
procedures available.

1.4. Objective

1.4.1. General objective

In this project We want to design the bottled mechanical screw (screw)jack which have
high strength and reliable and also which can lift with the capacity 5KN,minimum lifting
height 302mm and maximum lifting height 414mm.

1.4.2. Specific objective

 Select a material with desired properties for the design of a power screw more
specifically a screw jack.
 To design and draw all parts of screw jack
 To come up with a design procedure for the design of a screw jack.
 To assemble well the screw jack.
1.5. Scope of the project

The scope the project is starting from acknowledge, abstract, nomenclature, introduction to
screw, literature review, material selection, force analysis, design analysis, design analysis, result
and diction, conclusion, recommendation.

Collection of input data from research work:

  Study of weight dimensional parameters
 Study of stress deformation in lift
 Study of vibration and impact resistance
 Study of keeping of service life at different loading
 Study of reliable operation.
1.6. Significance of the project

A jackscrew, or screw jack, is a type of jack that is operated by turning a lead screw. It is
commonly used to lift moderately heavy weights, such as vehicles; to raise and lower the
horizontal stabilizers of aircraft; and an adjustable supports for heavy loads, such as the
foundations of houses.

1.7. Limitations

Screw jacks are limited in their lifting capacity. Increasing load increases friction within the
screw threads. A fine pitch thread, which would increase the advantage of the screw, also
reduces the speed of which the jack can operate. Using a longer operating lever soon reaches the
point where the lever will simply bend at its inner end. And also our project is limited by:

 Lifting capacity 6.25KN

 Minimum lifting height 308mm
 Maximum lifting height 420mm
 Lifting height 112mm.
 CHAPTER TWO

LITERATURE REVIEW

2.1. Literature review

Screw type mechanical jacks were very common for jeeps and trucks of World War II vintage.

For example, the World War II jeeps (Willys MB and Ford GPW) issued the "Jack, Automobile,
Screw type, Capacity 1 1/2 ton", Ordinance part number 41-J-66. These jacks, and similar jacks
for trucks, were activated by using the lug wrench as a handle for the ratchet action to the jack.
The 41-J-66 jack was carried in the jeep's tool compartment. Screw type jacks continued in use
for small capacity requirements due to low cost of production to raise or lower the load. A
control tab is marked up/down and its position determines the direction of movement and with
no maintenance. The virtues of using a screw as a machine element, which is 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, rotated by the turning of a worm shaft to drive a lifting screw to move the load.

People were not 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 people have evidence of the product being developed further [4].

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 as important in
industry. While he would eventually have over 50 British patents with titles ranging from
knitting machines to rifles, it was Whitworth’s work on screw cutting machines, accurate
measuring instruments and standards covering the angle and pitch of screw threads that would
most influence our industry today.

Whitworth’s tools have become internationally famous for their precision and quality and
dominated the market from the 1850s. Inspired young engineers began to put Whitworth’s
machine tools to new uses. During the early 1880s in Coati cook, a small town near Quebec, a
24- year-old inventor named Frank Henry Sleeper designed a lifting jack. Like da Vinci’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 a screw, into 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 railroad industry, where it was able to lift locomotives
and railway cars. Arthur Osmore Norton spotted the potential for Sleeper’s design and in 1886
hired the young man and purchased the patent and then Norton jack was born. Over the coming
years the famous Norton jacks were manufactured at plants in Boston, Coati cook and Moline,
Illinois. 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 [10].

Over the next 30 years the Duff Manufacturing Company became the largest manufacturer of
lifting jacks in the world, developing many new types of jack for various applications including
its own version of the ball bearing screw jack. It was only natural that in 1928, The Duff
manufacturing Company Inc. merged with A.O. Norton to create the Duff-Norton Manufacturing
Company. Both companies had offered manually operated screw jacks but the first new product
manufactured under the joint venture was the air motor-operated power jack that appeared in
1929. With the aid of the relatively new portable compressor technology, users now could move
and position loads without manual effort. The jack, used predominantly in the railway industry,
incorporated an air motor manufactured by The Chicago Pneumatic Tool Company.

There was a clear potential for using this technology for other applications and only 10 years
later, in 1940, the first worm gear screw jack, that is instantly recognizable today, was offered by
Duff-Norton, for adjusting the heights of truck loading platforms and mill tables. With the ability
to be used individually or linked mechanically and driven by either air or electric motors or even
manually, the first model had a lifting capacity of 10 tons with raises of 2′′ or 4′′ [4].

2.2 Operation
The jack can be raised and lowered with a metal bar that is inserted into the jack. The operator
turns the bar with his/her hands in a clockwise direction. This turns the screw inside the jack and
makes it go up. The screw lifts the small metal cylinder and platform that are above it. As the
jack goes up, whatever is placed above it will raise as well, once the jack makes contact. The bar
is turned until the jack is raised to the required level. To lower the jack the bar is turned in the
opposite direction.

2.3 Construction of a Screw Jack

A screw jack consists of a screw and a nut. The nut is fixed in a cast iron frame and remains
stationary. The rotation of the nut inside the frame is prevented by pressing a set screw against it.
The screw is rotated in the nut by means of a handle, which passes through a hole in the head of
the screw. The head carries a platform, which supports the load and remains stationary while the
screw is being rotated. A washer is fixed to the other end of the screw inside the frame, which
prevents the screw from being completely turned out of the nut. Figure 2.1 below shows a screw
jack and its parts and description as labeled.

Table 1፦Bill of Materials

Figure 2.1 Sample screw jack and parts

2.4 Parts of screw jack

Screw jack has following parts:-

1) Frame

2) Screw

3) Nut

4) Handle

5) Cup

6) Set Screw

7) Washer
1) Frame Size - Most of the times frame is conical in shape and hollow internally to
accommodate a nut & screw assembly. The hollow conical shape insures a safe & complete
resting of a jack on ground. If it is provided with legs like structure , it quite possible that in case
of uneven distribution load may fail down because all legs will not touch ground.

Figure 2.2 Frame part

2) Screw size – Screws is nothing but a member having Helical groove around periphery of
solid bar. It can be around 22 to 100mm diameter for square power screws & 24 to 100mm for
trapezoidal power screws.

Thread profile – The screw or power screw thread is always a square type because it has more
efficiency than trapezoidal threads and there is no radial thrust on screw i.e. no Bursting
Pressure, so motion is uniform.

 Square threads usually turned on lathes using single point cutting tool. It leads us to use
free cutting steel.
 Square threads are weak in roots. Wear of thread surface lead us to use “Unalloyed free
cutting steel”.

Figure 2.3 Screw part

3) Nut –As we know there always a relative motion between screw and nut, which cause a
friction. The friction causes wear if some material is used for screw & nut it will wears both
components. So one out of two has to be softer than other so as to ease of replacement. The size
& shape of screw is costlier than nut, so generally we use softer material for nut than screw.
Phosphor bronze is ideal material for nut which is a copper alloy having 0.2%phospher which
increases tensile strength. Ultimate tensile strength for this is 190mpa and coefficient of friction
is 0.1.Bearing pressure is 10mpa.
Advantages of phosphor bronze are,

1) Good corrosion resistance.

2) Low coefficient of friction

3) Higher tensile strength than copper brass.

Figure 2.4 Nut part

4) Handle – is subjected to bending moments. so plain carbon steel with 0.3%carbon i.e. 30C8
can be selected. Yield strength in tension is 400mpa.

Figure 2.5 Handle part

5) Cup –Shape of cup is again complex and so economical to manufacture by Casting process,
hence material will be cast iron with grade FG200.

Figure 2.6 Cup part

6) Set Screw – Purpose of set screw is to resist motion of nut with screw. It can be of
commercial steel.

7) Washer – is to provide uniform force of tightening nut over screw force by enlarging area
under actions of force. We can use commercial steel.
2.5 Advantages and Disadvantages of the Screw Jack

2.5.1 Advantage of Screw jack :

 Can be used to lift a heavy load against gravity.

 Load can be kept in lifted position.
 Due to leverage obtained by handle force required to raise load is very less & can be
 Applied manually
 The efficiency of square threads is more than that of trapezoidal threads.
 There is no radial pressure on the nut. Since there is no side thrust, the motion of the nut
is uniform. The life of the nut is also increased.
2.5.2 Disadvantage of screw jack :

 Chances of dropping of load

 Tipping or slipping of load.
 This failure is not “SAFE FAIL”& can cause serious accidents.
 Power screws have very poor efficiency; as low as 40%.Therefore, it is not used in
continuous power transmission in machine tools, with the exception of the lead screw.
Power screws are mainly used for intermittent motion that is occasionally required for
lifting the load or actuating the mechanism.
 High friction in threads causes rapid wear of the screw or the nut. In case of square
threads, the nut is usually made of soft material and replaced when worn out. In
trapezoidal threads, a split- type of nut is used to compensate for the wear. Therefore,
wear is a serious problem in power screws.
 The major disadvantage of the screw jack is that chances of dropping, tipping or slipping
of the load are high and can cause serious accidents hence the device is termed as not
safe fail.

Accidents caused by screw jack are due to the following reasons:

 Load is improperly secured on jack.
 The screw jack is overloaded.
 Center of gravity is off center with axis of jack.
 Jack is not placed on hard & level surface.
 Using for other purpose instead of using it for which it is designed.
Precaution: Long lifts should be avoided since they can cause serious overheating and generate
a large amount of heat. It should therefore be used under ambient temperatures with the use of
the required lubricants. Design and manufacturer’s instructions such as speed, load capacity and
recommended temperatures must be followed to avoid accidents. Always keep the mating
surfaces clean after use and check for wear and damage on the surfaces.
2.6 Mechanical Advantage (M.A)
The mechanical advantage of a screw jack can be referred to as the ratio of the force the jack
exerts on the load to the input force on the lever, neglecting friction. However, most screw jacks
have large amounts of friction which increase the required input force, so the actual mechanical
advantage is often only 30% to 50% of this figure (Bhandari, 2010).
 Fload
M.A =
Feffort
Where ፦
𝐹𝑙𝑜𝑎𝑑= 𝑇ℎ𝑒 𝑓𝑜𝑟𝑐𝑒 𝑡ℎ𝑒 𝑗𝑎𝑐𝑘 𝑒𝑥𝑒𝑟𝑡𝑠 𝑜𝑛 𝑡ℎ𝑒 𝑙𝑜𝑎𝑑
𝐹𝑒𝑓𝑓𝑜𝑟𝑡= 𝑇ℎ𝑒 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑒𝑥𝑒𝑟𝑡𝑒𝑑 𝑜𝑛 𝑡ℎ𝑒 ℎ𝑎𝑛𝑑𝑙𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑗𝑎𝑐𝑘
2.7 Common Types of Screw Jack
Screw Jacks are of mainly two types.

 Mechanical
 Hydraulic.

2.7.1 MECHANICAL SCREW JACK

They vary in size depending on the load that they are used to lift Mechanical Jacks: A
mechanical jack is a device which lifts heavy equipment. The most common form is a car jack,
floor jack or garage jack which lifts vehicles so that maintenance can be performed. Car jacks
usually use mechanical advantage to allow a human to lift a vehicle by manual force alone. More
powerful jacks use hydraulic power to provide more lift over greater distances. Mechanical jacks
are usually rated for maximum lifting capacity.

There are two types of mechanical jacks:

 Scissor Jacks
 Bottle (cylindrical) Jacks

Scissor Jacks: Scissors jacks are also mechanical and have been in use at least since the 1930s.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. It typically works in just a vertical manner. The jack opens and
folds closed, applying pressure to the bottom supports along the crossed pattern to move the lift.
When closed, they have a diamond shape. Scissor jacks are simple mechanisms used to drive
large loads short distances. The power screw design of a common scissor jack reduces the
amount of force required by the user to drive the mechanism. Most scissor jacks are similar in
design, consisting of four main members driven by a power screw. A scissor jack is operated
simply by turning a small crank that is inserted into one end of the scissor jack. This crank is
usually "Z" shaped. The end fits into a ring hole mounted on the end of the screw, which is the
object of force on the scissor jack. When this crank is turned, the screw turns, and this raises the
jack. The screw acts like a gear mechanism. It has teeth (the screw thread), which turn and move.
Figure 2.7 scissor jack

Bottle (Cylinder) Jack፦ Bottle screws may be operated by either rotating the screw when the
nut is fixed or by 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. In a bottle
jack the piston is vertical and directly supports a bearing pad that contacts the object being lifted.
With a single action piston the lift is somewhat less than twice the collapsed height of the jack,
making it suitable only for vehicles with a relatively high clearance.

Figure2.8 Bottle screw jack

2.7.2 HYDRAULIC JACKS:

Hydraulic jacks are typically used for shop work, rather than as an emergency jack to be carried
with the vehicle. Use of jacks not designed for a specific vehicle requires more than the usual
care in selecting ground conditions, the jacking point on the vehicle, and to ensure stability when
the jack is extended. Hydraulic jacks are often used to lift elevators in low and medium rise
buildings. 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 lubricating and stable. When the plunger pulls back, it
draws oil out of the reservoir through a suction check valve into the 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 cylinder.

Figure2.9 Hydraulic screw jack

2.8 Factors to Consider in Selection of the Best Jack for Application Purposes
 Consider the load carrying capacity of the lifting screw (column load) when jacks are
loaded in compression. How high do you need to lift the load? One must choose a jack
whose lifting screw is stout enough to handle the load at full rise.
 Consider the travel speed of the dynamic load. The speed at which the load will be
moved is a limiting factor. How fast do you need to move the load. Sometimes double
lead machine screw jacks or ball screw jacks are a better choice in a given application.
 How frequently will the jack need to move the load? Remember that heat builds up
between the machine screw and nut during normal operation. Duty cycles for machine
screw jacks must include periods of rest to dissipate that heat.
 CHAPTER THREE
CLASSIFICATION OF SCREW THREADS

3.1 Introduction
Screw jacks commonly use various forms of threads, namely; square threads, ISO metric
trapezoidal threads and buttress thread.

3.1.1 Square Thread

As the name suggest, it has a square cross section of the thread. It is the most common form used
by the screw jack and used especially in high load applications.

3.1.1.1 Nomenclature of Square Thread

`
Figure 3.1: Nomenclature of square thread

3.1.1.2 Advantages of the Square Thread

The advantages of square threads are as follows:
(i) They have high efficiency.
(ii) They have lower friction coefficient hence less power loss in lifting the load.
(iii)Motion of the nut is uniform since there is no side thrust and radial pressure on the nut.

3.1.1.3 Disadvantages of Square Thread

The disadvantages of square threads are as follows:
(i) The threads are usually turned on a lathe machine with a single point cutting tool hence
expensive compared to machining with multi-point cutting tools. This makes them more difficult
to manufacture.
(ii) The strength of a screw depends upon the thread thickness at the core diameter. Square
threads have less thickness at core diameter than trapezoidal threads. This reduces the load
carrying capacity of the screw.

(iii) It is not possible to compensate for wear in square threads since wear of the thread surface
becomes a serious problem in the service life of the power screw. Therefore, replacement of the
nut or the screw is required when worn out.

Applications: Square threads are used for screw-jacks and presses.

3.1.2 ISO Metric Trapezoidal Threads
These are threads with trapezoidal outline profile. They are most commonly used for lead
screws. They offer high strength and ease of manufacture.
3.1.2.1 Nomenclature of ISO Metric Trapezoidal Thread

Figure 3.2: Nomenclature of ISO metric trapezoidal thread

3.1.2.2 Advantages of the Trapezoidal Thread

(i) They are cheap to manufacture as compared to square threads. Multi-point cutting tools are
employed for machining compared to single point cutting tools that are used in machining square
threads.
(ii) The trapezoidal thread has greater thickness at core diameter than that of the square thread.
Therefore, a screw with trapezoidal threads is stronger than an equivalent screw with square
threads. Such a screw has large load carrying capacity.
(iii) The axial wear on the surface of the trapezoidal threads can be compensated by means of a
split-type of nut. The nut is cut into two parts along the diameter. As wear progresses, the
looseness is prevented by tightening the two halves of the nut together. The split-type nut can be
used only for trapezoidal threads. It is used in lead-screw of lathe to compensate wear at periodic
intervals by tightening the two halves.
3.1.2.3 Disadvantages of Trapezoidal Threads
The disadvantages of trapezoidal threads are as follows:
(i) The efficiency of trapezoidal threads is less than that of square threads.
(ii) Trapezoidal threads result in side thrust or radial pressure on the nut. The radial
pressure or bursting pressure the nut affects its performance.

Application: Trapezoidal and acme threads are used for lead-screw and other power
transmission devices in machine tools.
3.1.3 Buttress Thread

Figure 3.3: Nomenclature of buttress thread

3.1.3.1 Advantages of Buttress Thread
The advantages of buttress threads are as follows:
(i) It has higher efficiency compared to trapezoidal threads.
(ii) It can be economically manufactured on a thread milling machine.
(iii). The axial wear at the thread surface can be compensated by means of split-type nut.
(iv). A screw with buttress threads is stronger than equivalent screw with either square threads
or trapezoidal threads. This is because of greater thickness at the base of the thread.

3.1.3.2 Disadvantages of Buttress Thread

The buttress threads have one disadvantage. They can transmit power and motion only in one
direction as compared to square and ISO metric trapezoidal threads, which can transmit force
and motion in both directions.
Application: Buttress threads are used in vices, where force is applied only in one direction.

3.2 Thread Series

There are three standard thread series in the unified screw thread system;
 Fine series
 Coarse series
 Normal series

Fine thread series have more threads per axial distance and thus have a smaller pitch while
coarse thread series have a large pitch (fewer threads per axial distance). This shows that fine
series threads are stronger as compared to coarse thread series of the same dimensions (diameter)
(Fasteners, 2005).
Fine series has advantages over the other series, these are;
 They have large stress areas hence are strong in compression.
 They have a larger minor diameter which develops higher torsional and shear strength.
 They have smaller helix angle therefore permitting closer adjustment accuracy.

3.3 Definition of Screw Thread Basic Terms

Figure 3.4: Screw Nomenclature (Bhandari, 2010)

The terminologies of the screw thread are defined as follows (Gupta, 2005):
(i) Pitch (𝒑)
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 on the adjacent thread.
(ii) Lead (𝒍)
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.
For a single threaded screw 𝒍=𝒑
For a double threaded screw 𝒍=𝟐𝒑
(iii) Nominal or Outside Diameter (𝒅𝒐)
It is the largest diameter of the screw. It is also called major diameter.
(iv)Core or Minor Diameter (𝒅𝒄)
It is the smallest diameter of the screw thread.
𝑑𝑐 = 𝑑𝑜−𝑝
(v) Mean Diameter (𝒅𝒎)

(do +dc)
𝑑𝑚 =
2
𝑑𝑚 = 𝑑𝑜−0.5𝑝
(vi) Helix Angle (𝜶)
It is defined as the angle made by the helix of the thread with a plane perpendicular to the axis of
the screw. The helix angle is related to the lead and the mean diameter of the screw.
Taking one thread of the screw and unwinding, one complete turn is developed. The thread will
become the hypotenuse of a right-angled triangle with the base 𝜋𝑑𝑚 and height being equal to
the lead 𝑙.

Figure 3.5: Unwound thread

This right-angled triangle gives the relationship between the helix angle, mean diameter and
lead, which can be expressed in the following form:
l
tan𝛼=
π dm
Where ፦
𝛼= 𝑇ℎ𝑒 ℎ𝑒𝑙𝑖𝑥 𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑡ℎ𝑟𝑒𝑎𝑑.
The following conclusions can be drawn on the basis of the development of thread:
 The screw can be considered as an inclined plane with 𝛼 as the angle of inclination.
 The load 𝑊 always acts in the vertical downward direction. When the load 𝑊 is raised, it
moves up the inclined plane. When the load 𝑊 is lowered, it moves down the inclined
plane.
  The load 𝑊 is raised or lowered by means of an imaginary force 𝑃 acting at the mean
radius of the screw. The force 𝑃 multiplied by the mean radius (𝑑𝑚/2) gives the torque
‘𝑇’ required to raise or lower the load. Force ‘𝑃’ is perpendicular to load 𝑊.

3.4 Torque Requirement - Lifting Load

The screw is considered as an inclined plane with inclination 𝛼 when the load is being raised.
The following forces act at a point on this inclined plane:

Figure 3.6: Force diagram for lifting load

Load 𝑾: It always acts in the vertical downward direction.

Normal reaction 𝑵: It acts perpendicular (normal) to the inclined plane.

Frictional force 𝝁𝑵: Frictional force acts opposite to the motion. Since the load is moving up
the inclined plane, frictional force acts along the inclined plane in downward direction.

Effort 𝑷: The effort 𝑃 acts in a direction perpendicular to the load 𝑊. It may act towards the
right to overcome the friction and raise the load.

Resolving forces horizontally,

𝑃=𝜇𝑁cos𝛼+𝑁sin𝛼 (1)

Resolving forces vertically,

𝑊=𝑁cos𝛼−𝜇𝑁sin𝛼 (2)

Dividing equation (1) 𝑏𝑦 (2) we get:

W (μcosα +sinα )
𝑃= (3)
(cosα−μsinα )

Dividing the numerator and denominator of the right hand side of equation (3) by 𝑐𝑜𝑠 𝛼 we get:
W ( μ+tanα )
𝑃¿ (4)
(1−μtanα)

The coefficient of friction μ can be expressed as follows:

 𝜇=tan𝜃 (5)
Where ፦
𝜃 = the friction angle.

Substituting (5) into equation (4),

W (tanθ +tanα )
𝑃= (6)
(1−tanθtanα )

𝑃=𝑊tan(𝛼+𝜃) (7)

The torque 𝑇 required to raise the load is given by:

dm
𝑇=𝑃×
2

Whence

[Wtan(α + θ)]dm
𝑇= (8)
2

3.5 Torque Requirement - Lowering Load

When the load is being lowered, the following forces act at a point on the inclined plane:

Figure 3.7: Force diagram for lowering load

Load 𝑾: It always acts in the vertical downward direction.

Normal reaction 𝑵: It acts perpendicular (normal) to the inclined plane.

Frictional force 𝝁𝑵: Frictional force acts opposite to the motion. Since the load is moving down
the inclined plane, frictional force acts along the inclined plane in the upward direction.
Effort 𝑷: The effort 𝑃 acts in a direction perpendicular to the load 𝑊. It should act towards left
to overcome the friction and lower the load.

Resolving horizontally,

𝑃 = 𝜇 𝑁 𝑐𝑜𝑠 𝛼 − 𝑁 𝑠𝑖𝑛 𝛼 (9)

Resolving vertically,

𝑊 = 𝑁 𝑐𝑜𝑠 𝛼 + 𝜇 𝑁 𝑠𝑖𝑛 𝛼 (10)

Dividing expression (9) by (10) we get as follows:

W (μcosα−sinα )
𝑃= (11)
(cosα + μsinα )

Dividing the numerator and denominator of the right hand side of equation (11) by cos α:

W (μ−tanα)
𝑃= (12)
(1+ μtanα)

Substituting equation (5) into Equation (12),

W (tanθ−tanα )
𝑃= (13)
(1+tanθtanα )

Whence

𝑃 = 𝑊 𝑡𝑎𝑛 (𝜃 − 𝛼) (14)

The torque 𝑇 required to lower the load is given by,

 dm
𝑇=𝑃×
2
Whence

[Wtan(θ−α )]dm
𝑇= (15)
2

3.6. Over Hauling and Self-Locking Screws

From equation (15), we know torque required to lower load is given by:

[Wtan(θ−α )]dm
𝑇=
2

Case 1: When 𝜽<𝛼

The torque required to lower the load becomes negative. This indicates a condition that no force
is required to lower the load and the load itself will begin to turn the screw and descend down,
unless a restraining torque is applied. This condition is called overhauling of the screw.

Case 2: When 𝜽>𝛼

The torque required to lower the load becomes positive. Under this condition, the load will not
turn the screw and will not descend on its own unless effort 𝑃 is applied. This condition is called
self- locking.

The rule for self-locking screw states that: A screw will be self-locking if the coefficient of
friction is equal to or greater than the tangent of the helix angle.

For self-locking screw,

tan𝜃≥tan𝛼

Or
 l
𝜇≥
πdm

Therefore, the following conclusion are made:

(i) Self-locking of the screw is not possible when the coefficient of friction (μ) is low. The
coefficient of friction between the surfaces of the screw and the nut is reduced by lubrication.
Excessive lubrication may cause the load to descend on its own.

(ii) The self-locking property of the screw is lost when the lead is large. The lead increases with
number of starts. For double-start thread, lead is twice of the pitch and for triple threaded screw,
three times of pitch. Therefore, the single threaded screw is better than multiple threaded screws
from self-locking considerations.

Self-locking condition is essential in applications like screw jack (Naik, Apr 15, 2015).

3.7 Efficiency of the Square Threaded Screw

Referring to Figure 3.6: Force diagram for lifting the load, the output consists of raising the load
if the load moves from the lower end to the upper end of the inclined plane.

Therefore,

𝑊𝑜𝑟𝑘 𝑜𝑢𝑡𝑝𝑢𝑡 = 𝐹𝑜𝑟𝑐𝑒 𝑥 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑓𝑜𝑟𝑐𝑒

𝑊𝑜𝑟𝑘 𝑜𝑢𝑡𝑝𝑢𝑡 = 𝑊 𝑥 𝑙

The input consists of rotating the screw by means of an effort P.

𝑊𝑜𝑟𝑘 𝑖𝑛𝑝𝑢𝑡 = 𝐹𝑜𝑟𝑐𝑒 𝑥 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡𝑟𝑎𝑣𝑒𝑙𝑙𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑑𝑖𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑓𝑜𝑟𝑐𝑒

𝑊𝑜𝑟𝑘 𝑖𝑛𝑝𝑢𝑡= 𝑃 𝑥 (𝜋𝑑𝑚)

The efficiency 𝜂 of the screw is given by,

work output
𝜂= (16a)
work input

Wl
𝜂= (16b)
Pπdm
This equation can also be expressed as:

w l
𝜂= ( ) (16c)
P πdm
And

l
tan𝛼=
πdm
Therefore

W
𝜂= tan𝛼 (16d)
P

Substituting for 𝑃=𝑊tan(𝛼+𝜃) we get;

tanα
𝜂= (16e)
tan(α +θ)

From the above equation, it is evident that the efficiency of the square threaded screw depends
upon the helix angle 𝛼 and the friction angle𝜃. The following figure shows the variation of the
efficiency of the square threaded screw against the helix angle for various values of the
coefficient of friction. The graph is applicable when the load is being lifted.
Figure 3.8: Graph of efficiency against helix angle for various 𝝁

From the graph the following observations are made (Gupta, 2005):

i The efficiency of the square threaded screw increase rapidly up to a helix angle of 20°.
ii The efficiency is maximum when the helix angle is between 40o to 45°.
iii The efficiency decreases after the maximum value is reached.
iv The efficiency decreases rapidly when the helix angle exceeds 60°
v The efficiency decreases as the coefficient of friction increases.

There are two ways to increase the efficiency of square threaded screws:
i. Reduce the coefficient of friction between the screw and the nut by proper lubrication.
ii. Increase the helix angle up to 40o to 45° by using multiple start threads. However, a screw
with such a large helix angle has other disadvantages like loss of the self-locking property.

3.8 Efficiency of Self-Locking Screw

The efficiency of square threaded screw is given by (From equation 16e):

tanα
𝜂=
tan(α +θ)
For self-locking screw 𝜃≥𝛼
Substituting the limiting value (𝜃 = 𝛼) into the equation above

tanθ
𝜂≤ (17a)
tan(θ+θ)

tanθ
𝜂≤ (17b)
tan(2θ)

And from trigonometric identities

2 tanθ
tan2𝜃= 2
1−tan θ

Substituting for tan2𝜃 into the above expression,

tanθ(1−tan2 θ)
𝜂≤ (17c)
tan(2 θ)
Simplifying

1
𝜂≤ (1−𝑡𝑎𝑛2𝜃) (17d)
2

From the above expression we can deduce that the efficiency of self-locking square threaded
power screw is less than 0.5 or 50%. If the efficiency is more than 50%, then the screw is said to
be overhauling (Gupta, 2005).

3.9 Coefficient of Friction, 𝝁

It has been found that the coefficient of friction (𝜇) at the thread surface depends upon the
workmanship in cutting the threads and on the type of the lubricant used. It is practically
independent of the load and dependent on rubbing velocity or materials. An average of 0.1 can
be taken for the coefficient of friction when the screw is lubricated with mineral oil (Gupta,
2005).
Table 3.1: Coefficient of friction under different conditions (Gupta, 2005)

Table 3.2: Coefficient of friction when thrust collars are used (Gupta, 2005)

3.10. Buckling of Columns

According to Johnson’s Formula for columns, a short member subjected to axial compressive
force shortens. Compression for the member increases with gradual increase in load. Therefore,
the member fails by buckling when the compressive stress reaches the elastic limit of the
material. Buckling indicates elastic instability. The load at which the buckling starts is called
critical load,
which is denoted by 𝑊𝑐𝑟. When the axial load on the column reaches 𝑊𝑐𝑟 there is sudden
buckling and a relatively large lateral deflection occurs. An important parameter affecting the
critical load is the slenderness ratio 𝑅= . Mathematical expression for buckling is as shown
below (Gupta, 2005), (Marshek, 2012) & (Nisbet, 2015):

[ ( )]
2
σy Leff
𝑊𝑐𝑟=𝐴𝑐.𝜎𝑦 1− (18)
4 Cπ 2 E k

Where

𝜎𝑦= Yield stress = 385𝑀𝑃𝑎

𝐶 = End fixity coefficient. The screw is considered to be strut with lower end
fixed

and load end free. Therefore 𝐶 = 0.25

𝑘 = The radius of gyration =

√ I
A
= 0.25𝑑𝑐= 0.007

𝐼= Moment of inertia of the cross section.

This is a parabolic formula that was proposed by Johnson to determine the crippling or the
critical load of straight column.

The following table shows the values of end fixity coefficient (C) for various end conditions
Table 3.3: Values of end fixity coefficients(c) (Nisbet, 2015)
 CHAPTER FOUR

Material selection

4.1. Introduction

Material selection is an important process in design processes. Selecting materials is a process

that is design-led in that the material selection process uses the design requirements as the input
so as to come up with materials that have the desired properties for the part to be designed to
function well. The selection of a proper material, for engineering purposes, is one of the most
difficult problem for the designer. The best material is one which serve the desired objective at
the minimum cost. The following factors should be considered while selecting the material :

1. Availability of the materials,

2. Suitability of the materials for the working conditions in service, and

3. The cost of the materials.

The important properties, which determine the utility of the material are physical, chemical and
mechanical properties.

4.2. Engineering Materials for Components

The common engineering materials used in making machine components include;

 Cast iron,
 Steel (all types of steel),
 Copper and its alloys,
 Aluminum and its alloys, Plastics.
Therefore, the right materials for the design of the screw jack parts should be selected. Selection
requires one to consider the following factors which give the best material fit for the design job:

a) Specific strength and mass. It is preferable to select a material of high yield stress with ability
to carry external load without failure and low density in order to realize a screw shaft of high
strength and low mass. Therefore, the material selection process should aim to maximize the
quantity termed as the specific strength.

b) Resistance to abrasive wear.Most of engineering materials in contact with one another are
subjected to surface wear due to relative motion. It is therefore desirable to select a material from
the candidate materials with low wear rate or capacity to resist abrasive wear at the thread
surfaces.

c) Resistance to buckling. Heavy loads may cause the screw to buckle once the critical load is
exceeded. It is preferable to select a material with high resistance to buckling of the screw, that
is, excellent elasticity and deflection behavior in response to application of an external load.

d) Availability, Cost and Affordability.It is also preferable to choose a material with the highest
affordability rating. Relative cost of the materials is used in finding or calculating the affordable
rates. Therefore, the availability of the material and the cost of processing the material into the
finished product need to be taken into account and considered as supporting information when
making the final choice of the material.

e) Heat transmission properties. As we know there always a relative motion between screw and
nut, which cause a friction that generates heat which can cause change in the mechanical
properties of the material.

f) Other relevant properties include; resistance to corrosion, electrical and mechanical properties,
heat transmission properties etc.

4.2 Steps for Selection of Materials for Components

Selection of materials in engineering design involves the following steps (Prof. F.M. Oduori,
2016):

 Translation of design requirements into specifications for a material.

 Screening out those materials that do not meet the specifications in order to leave only
the viable candidates.
 Ranking of the surviving materials to identify those that have the greatest potential.
 Using supporting information to finally arrive at the choice of material to be used.

The first three steps involve mathematical analysis, use of various charts and graphs of specific
property such as specific strength, wear resistance, buckling resistance and affordability. The
materials are compared, ranked as per the indices of merit and available supporting information
is used to reach the final decision (Ashby, 2005).

In this project, information from case studies on previous designs of similar products is used in
material selection for the screw jack components/parts. However, other factors such as
availability of the candidate materials, purchase price of the candidate materials, manufacturing
processes and properties, forms and sizes in which the materials are available are also
considered.

4.3 Components and their Specific Materials Selected

The goal of material selection is to come up with an appropriate material that best meets the
design requirements. The approach is to identify the connection between functional requirements
and the material properties so as to help us reduce the number of candidate materials from which
to select from.
The following are components and materials required in the design of a power screw (screw
jack):

4.3.1 Frame (Body)

Most of the frames are in conical shape and hollow internally to accommodate both the nut and
screw assembly. The frame works to ensure that the screw jack is safe and has a complete rest on
the ground. The purpose of the frame is to support the screw jack and enable it to withstand
compressive load exerted on it. The frame is a bit complex and thus requires casting as a
manufacturing process. For this reason, grey cast iron as a material is selected for the frame. This
is also evident from the case study on previous design of the same product (Nyangasi, 18
December, 2006).

Cast iron is cheap and it can give any complex shape without involving costly machining
operations. Cast iron has higher compressive strength compared to steel. Therefore, it is
technically and economically advantageous to use cast iron for the frame. Graphite flakes cast
iron with an ultimate tensile strength of 220MPa is considered suitable for the design of the
frame. The graphite flakes improve the ability to resist compressive load.

Material properties British standards specification

Tensile strength (MPa) 220
Compressive strength (MPa) 766
Shear strength (MPa) 284
Endurance limit (MPa) 96
Young’s modulus (GPa) 89 – 114
Modulus of rigidity (GPa) 36 – 45
Hardness number (HB) 196
Table 4.1: Mechanical Properties of Cast iron – Appendix A (Marshek, 2012)
4.3.2 Screw
The screw is subjected to torsional moment, compressive force and bending moment. The screw
profile is square type because of its higher efficiency and self-locking but not compared to
trapezoidal threads. Square threads are usually turned on lathes using a single point cutting tool
also square threads are weak at the root and this leads to use of free cutting steel. Screws are
usually made of steel where great resistance to weather or corrosion is required. Most fasteners
close to 90% use carbon steel because steel has excellent workability, offers abroad range of
attainable combinations of strength properties and it is less expensive. Medium plain carbon steel
can be heat treated for the purpose of improving properties such as hardness, strength (tensile
and yield), the desired results are therefore obtained (Fasteners, 2005). This leads to the use of
plain carbon steels.

Mate British Production Max. Yield Tensile Elongat Hardnes

r standar in process section strengt Strerengt e s
Ial d size,m h Mpa h Tion n% number
m Mpa HB

0.30 080M3 Hardened 63 385 550-700 13 152-207

C 0 &
Timbered
Table 4.2: Mechanical Properties of Plain carbon steel – Appendix B (Nyangasi, 18 December,
2006)

4.3.3. Nut
There exists a relative motion between the screw and the nut which causes friction, friction in
turn causes wear of the material used for screw and nut. Therefore, it requires one of the two
members to be softer. A suitable material for the nut is therefore phosphor bronze which is a
copper alloy with small percentage of lead and has the following advantages;

 Good corrosion resistance.

 Low coefficient of friction.
 High tensile strength
Bronze has 0.2% phosphor to increase tensile strength and the yield stresses may be taken as;
tension = 125MPa, compression = 150MPa, yield stress in shear = 105MPa with safe bearing
pressure of 15MPa, ultimate tensile strength is 190MPa and a coefficient of friction of 0.1.

Type of jack Screw material Nut material Bearing Rubbing speed

pressures
Screw jack Steel Bronze 11-17Mpa 3m/s
Table 4.3: Safe Bearing Pressures for Power screws – Appendix C (Nyangasi, 18 December,
2006) & (Gupta, 2005)
4.3.4 Handle

The handle is subjected to bending moments so plain carbon steel of BS 080M30 with yield
strength of 385MPa can also be used. It has the same mechanical properties and process as in.

4.3.5. Cup
Shape of cup is complex and thus requires casting process. It also has the same properties as in
Table 4.1. Taking graphite flakes cast iron with an ultimate tensile strength of 200MPa. The
graphite flakes improve the ability to resist compressive load.

4.3.6. Set Screw and Lock nut + Washer

The purpose of the set screw is to resist motion of nut with screw. The lock nut + washer on the
other hand is used to provide uniform force by enlarging the area under the action of the force.
We can use plain carbon steel for both and they have the same manufacturing process and
properties as in Table 4.2.
 CHAPTER FIVE

DESIGN PROCEDURE FOR THE SCREW JACK

5.1. Introduction

The generalized adopted design procedure for a screw jack to raise a load of 2460 kg for
example a large truck to a height of 200 mm.

Table 5.1 Average weight of vehicles in USA

5.2. ANALYSIS OF PROJECT BY GIVEN DATA

 Type of jack =Bottle

 Driving mechanism=Mechanical (Screw)
 Capacity = 5KN=5000N
 Minimum lifting height=Hmin=302mm
 Maximum lifting height =Hmax=414mm
 Lifting height=114mm

5.3. OPERATING PREPARATION

When placing the jack in hydraulic, apply a light film of lubricating oil, on outer bearing surface
of ram. Wipe away any excess of oil to prevent accumulation of dust and grit on ram surfaces.
Open the releasing screw slightly and collapse rams until flush remove vent and five screws to
check reservoir for proper fluid content. If oil level is low, add correct fluid.

NOTE: - always fill reservoir with fresh, clean oil in case of emergency operation flush jack with
clean hydraulic oil and refill reservoir. In order to get numbers of rams, thickness of neck, and
achieving minimum and maximum height to required amount the following procedure have to
follow.

Hmax−Hmin
Number of rams = , where Hmax=414mm, Hmin=302mm which are given
Hmin
Where Tmax - Tmin =414-302=112mm...................given But in order to get N rams base height

and cap height must be subtracted from the given value above.

Assuming that, base height =25mm and,

cap height =10mm

 H min = Hmin total - Bheight - Cheight Hmin = 112mm – 25mm -10mm= 77mm And,

 Hmax = HTmax- Bheight - Cheight Hmax = 414mm – 25mm – 10mm= 379mm

Hmax−H min 379 mm−77 mm

Therefore:-Nrams = = = 4,
H min 77 mm

Nrams=4

Where, Hmax= maximum lifting height

Hmin=minimum height

Bheight= Base height

Cheight= cup height

5.3.1. THICKNESS OF NECK

Since l= Hmin=77mm, therefore l=y+2t

H max−H min 379−77

But, y = = =151mm
2 2
y = 151mm

H max− y 379−151
=> t= = =114mm, t = 114mm
2 2
C) CHECKING
Hmax= Hmin +2y=77mm +2(151mm)=379mm

Hmax = 379mm, therefore the analysis is correct

5.3.2. PRESSURE DISTRIBUTION

By using Pascal‘s principles, that is intensity of pressure is transmitted equally in a directions

through a mass of fluid at rest. The force at two cylinders will be proportional to their respective
cross-sectional areas. A force Fp is applied to the plunge and a force Fr is applied to the rams.
Since the pressure is the same everywhere it is easy to solve the force applied on ram and plunge.

Therefore F =PA=P(πr2 ) But Pram=Pplunge..............Pascal principle

Fram Fplunge
=
Aram Aplunge

where,
Aram =πdrxdr/4 dr=diameter of the ram

Aplunge =πdpxdp/4 dp =diameter of the plunge

Fr Fp
Fr Fp
Since = => π 2 = π 2
Ar Ap dr dp
4 4

Fr Fp
2
=¿ 2 T h ere fore Pascal‘s law is satisfied
dr dp

5.4. FORCE ANALYSIS

5.4.1. FOR JACK HANDLE AND PUMP FORCE

Let Fp............pin force

Fh............human force (usually it is taken to be (100 to 200N))
Ff.............fulcrum force
L.........overall handle length (again most of the time ithas to be taken (300-500mm))
l................pin to pin length (it also taken (30-50mm))

Using equilibrium condition i.e

1) ΣMA =0

(Fh x L) – (Ff x l) = 0

F h xL
Ff = ............................ (1)
L

2) ΣFy = 0, then Ff-Fp-Fh = 0

Fp=Ff - Fh........................... (2) And pressure of the pump is given by,

 Fp
Ppump = Where, Ap......plunge cross-sectional area and
Ap
P pump...........pump pressure

π
But, Ap= Dp2..................cylinder bore area (circular area)
4

D p...................plunge diameter varies (10 to 16mm) it is standard.

From this range let use D p =10mm and,
therefore Ap= πd2/ 4 =π*0.01m2/4=7.85x10-5m2=78.5mm2.This implies that
Fp
pump = ..................... (3)
Ap
Using Pascal‘s law, P pump= P plunge = Pram = P cylinder

Therefore Pp= Pc => Pc=Fc/Ac

Where Pc=cylinder pressure
Ac=cylinder cross-sectional area
Fc=cylinder force
=> Fc/Ac (N/mm2) or MPa............................ (4)

5.5. PRESURE RANGE SELECTION

Assumption: - assume that the interval cylinder diameter and the hollow ram diameter are equal.
Therefore Dci = Dhr
Where ፦Dci = internal cylinder diameter
Dhr =hollow ram diameter
 Let assume that Dci = Dhr= 60mm
Therefore Ac =πDhr2/4
Ac = π (60mm) 2/4
= 2827.43mm2
Hence the minimum pressure to raise the given weight is: -
W
Pcmin = Where: - W= 5KN=5000N...........Is the given design weight
Ac
5000
Pcmin = =1.768Mpa
2827.43
Therefore Pcmin = 1.768MPa, the internal pressure to be designed should be greater than the
minimum pressure since there are parts to be lifted with this pressure.
Hence Pcdesign> Pc min=1.768MPa

In order to fit the internal design pressure, length of the handle, force of fulcrum plunge force
and pin to pin length first let us assume the human force and length range for handle.
Assuming
Fh = 150N from the range of (100N to 200N) And
L = (300mm to 500mm), assuming, L =500mm
l = (30mm to 50mm), and also assume l = 30mm by using equation (1) to equation (4)
 Fp
Pp= , Fp=PpxAp=⍴ghxAp=1000x9.81x112x10-3x78.5x10-6=0.08625N,
Ap
Fp=0.08625N,
Pp=1098.7Pa

Where፦ lifting height =114mm (given), ⍴=1000Kg/m3, g=9.81m/s2

FhL 150 Nx 500 mm

Ff= =
l 30 mm

Ff =2500N

L(mm) L(mm) Ff(N) Fp(N) Pp(pa)

30 500 0.08625 1098.7

 Selected quantities are: - L = 500mm, Ff = 2500N, Fp = 0.08625N/mm2,

Pp=1098.7N/m2,l =30mm

5.6 .STRESS ANALYSIS

5.6.1. Designs for Screw Shaft

Material specification selected for the screw shaft is plain carbon steel to British Standard
specification BS 970 080M30, Hardened and Tempered, whose properties are as shown in
Appendix B and the material yield strength is 700 MPa both in tension and pure compression
and 450 MPa in shear.

5.6.1.1 Core Diameter

The core diameter is determined by considering the screw to be under pure compression. That is;

𝑊=𝜎𝑐×𝐴𝑐 (1)

Where

𝜎𝑐 = Pure compression stress = 700MPa

𝐴𝑐 = Cross sectional area of the screw shaft = 𝜋4(𝑑𝑐)2

𝑑𝑐= Core diameter

Whence
 π
𝑊=𝜎𝑐× (𝑑𝑐)2 (1a)
4

𝑑𝑐=
√ 4W
σc × π
(1b)

Taking factor of safety 𝑓.𝑠 = 5……………………………………..assumption

√
4W
𝑑𝑐= σc (1c)
×π
f.s

√
4 × 6250
𝑑𝑐= 700 ×10 6
×π
5

𝑑𝑐=0.00754𝑚=7.54𝑚𝑚

For square threads of fine series, the following dimensions of screw are selected from Appendix
D (Gupta, 2005) hence,

The core diameter 𝑑𝑐=16𝑚𝑚, 𝑑𝑜=18𝑚𝑚 and pitch 𝑝=𝑙 = 4𝑚𝑚.

Figure 5.1 Section of screw spindle

5.6.1.2 Torque required to rotate the screw

We know that torque required to rotate the screw is the same torque required to lift the load
which is given by;

P × dm [Wtan(α + θ)]dm
𝑇1= =
2 2
(2)
We know that

(do +dc) (20+16)

𝑑𝑚¿ = =18𝑚𝑚
2 2

And

l 2
tan𝛼= = =0.03745
πdm π ×17

Assuming coefficient of friction between screw and nut,

𝜇=tan𝜃=0.1

Then

[5000 tan( 2.1447+5.71)]0.018

𝑇1= =12.33𝑁𝑚
2

5.6.1.3 Screw Stresses

Compressive stresses due to axial load using the new core diameter is,
W W 4 ×500 0 2000 0
σc= = = = =24.86 Mpa
A 2 2
( dc) π ×0.016 8.043∗10
−4
π
4
And the shear stress due to this torque using the new core diameter is given by;
T 1 dc
τ=
2J
4
πdc
Where J =Polar momente=
32

16 T 1 16 × 12.33 197.28
Where τ= 3
= 3
= −5
=24.5 Mpa
πdc π × 0.016 8.043∗10
5.6.1.4 Principal Stresses

Maximum principal stress is as follows:

1
σ cmax = ¿+√ ¿ ¿ =39.9Mpa
2

700
The design value of σ c = =140 Mpa
5

And maximum shear stresses as follows:

 1
τ c= √ σ 2+ 4 τ 2 = 12 √ ¿ ¿ =27.47Mpa
2 c

420
The design value of τ = =84Mpa
5

Check: These maximum shear and compressive stresses are less than the permissible stresses,
hence the spindle or shaft is safe.

5.6.2 Design for Nut

5.6.2.1 Height of the Nut

We find the height of the nut (h) by considering the bearing pressure 𝑃𝑏 on the nut. The bearing
pressure on the nut is given by;

W
𝑃𝑏= π
[(do)2−(dc )2]n
4

Where

𝑛 = Number of threads in contact with screwed spindle

Material specification for the nut is phosphor bronze which has tensile stress = 150MPa,
compressive stress = 125MPa, shear stress = 105MPa, safe bearing pressure not exceed 17MPa
and a coefficient of friction of 0.1.
Assuming the load is uniformly distributed over the entire cross section of the nut and
substituting for the known values we get the number of threads in contact,

5000
55265717.57
17×106= π =
¿¿ n
4

n=3.2509

say n=4

Then height of the nut is as follows;

ℎ=𝑛×𝑝
ℎ=4×4=16𝑚𝑚
Check: For a safe nut height ℎ≤4𝑑𝑐=64𝑚𝑚

5.6.2.2 Stresses in the Screw and Nut

Shear stress in the screw is as follows;
W
𝜏(𝑠𝑐𝑟𝑒𝑤)=
πn . dc .t
p
Where 𝑡=𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤= =2𝑚𝑚
2

5000
𝜏(𝑠𝑐𝑟𝑒𝑤)= =12.434𝑀𝑃𝑎
π × 4 × 0.016 ×0.002

And shear stress in the nut is as follows;

W
𝜏(𝑛𝑢𝑡)=
π n . do . t

p
Where 𝑡=𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤= =2𝑚𝑚
2

5000
𝜏(𝑛𝑢𝑡) = =9.94𝑀𝑃𝑎
π × 4 × 0.02× 0.002

105
The given value of 𝜏= =21𝑀𝑃𝑎
5

Check: These stresses are within permissible limit; hence, design for the nut is safe.

5.6.2.3 The outer diameter of Nut

Outer diameter 𝐷1 is found by considering the tearing strength of the nut.

W
𝜎𝑡= π
[(D 1)2−(do) 2]
4

Where 𝜎𝑡 = 𝑇𝑒𝑎𝑟𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑛𝑢𝑡 = 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠

150
𝜎𝑡 = =30𝑀𝑃𝑎
5

5000
Then we get 𝐷1 as follows; 30= π
[(D 1)2−(20)2]
4

𝐷1=18.42𝑚𝑚,
Say 𝐷1=18𝑚𝑚

5.6.2.4 The outside diameter of Collar

Outside diameter 𝐷2 is found by considering the crushing strength of the nut collar.
W
𝜎𝑐 = π
¿¿
4

Where 𝜎𝑐 = 𝐶𝑟𝑢𝑠ℎ𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑛𝑢𝑡 = 𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠

125
𝜎𝑐 = =25𝑀𝑃𝑎
5
5000
Then we get 𝐷2 as follows; 25= π
¿¿¿
4

𝐷2=22.45𝑚𝑚, Say 𝐷2=22𝑚𝑚

Figure 5.2: Section of Nut collar 1

5.6.2.5 Thickness of the Nut Collar

The thickness of nut collar 𝒕𝟏 is found by considering the shearing strength of the nut collar.

W
𝑡1=
π D 1. τ

105
Shearing strength of nut collar = =21𝑀𝑃𝑎
5

5000
Therefore 𝑡1=
π ×18 × 21

𝑡1=34.21,𝑆𝑎𝑦 𝑡1=4𝑚𝑚

5.6.3 Design for Head and Cup

5.6.3.1 Dimensions of Diameter of Head on Top of Screw and for the Cup 𝑫𝟑
Assuming

𝐷3=1.75𝑑𝑜

Then 𝐷3=1.75×20=35𝑚𝑚

The seat for the cup is made equal to the diameter of the head and then chamfered at the top. The
D3
cup prevents the load from rotating and is fitted with pin of diameter 𝐷4= approximately
4
(Gupta, 2005).

Therefore 𝐷4=8.75𝑚𝑚. Say D4 =9mm

The pin should remain loose fit in the cup.

Figure 5.3: Section of Pin

Take length of pin to be 9mm.
Other dimensions for the cup are taken as:
Diameter at the top of the cup = Diameter of the head = 52mm
Height of cup = 9mm
Thickness of cup = 3mm
Fillet radii = 1mm
Figure 5.4: Section of Cup

5.6.3.2 Torque Required to Overcome Friction

We know that by assuming uniform pressure condition torque required to overcome friction is
given as follows;

1
𝑇2= ×𝜇1𝑊¿]
3

Where
𝐷3= Diameter of head = 35mm

𝐷4= Diameter of pin = 9mm

Substituting for the known values we get;

1
𝑇2= ×0.1×6250¿]
3

=7.6752Nm

5.6.3.3 Total Torque Subjected to the Handle

Total torque to which the handle is subjected is given by

𝑇=𝑇1+𝑇2
𝑇=15.52+7.6752=23.195𝑁𝑚
Table 5.2: Maximal Isometric Force by General European Working Population for Whole
Body Work in a Standing Posture

Therefore taking the force of 96N in domestic use (J.J. Fereira, 2004) then the length of the
handle required is 𝐿=𝑇/96

23.195
Then 𝐿=
96
=0.2416𝑚=241.6𝑚𝑚

𝑆𝑎𝑦 𝐿=242𝑚𝑚

The length of the handle may be fixed by giving some allowance for gripping 70mm.
Therefore, the length of the handle/lever is 646.30mm.

Figure 5.5: Section of Lever

5.6.3.4 Diameter of Handle/Lever

The diameter of the handle/lever,𝐷 may be obtained by considering bending effects. We know
that bending moment;

π
𝑀= ×𝜎𝑏×𝐷3
32

700
While 𝜎𝑏=𝜎𝑡=𝜎𝑐= =140𝑀𝑃𝑎
5

and maximum bending moment on the lever/handle 𝑀=𝐹𝑜𝑟𝑐𝑒 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 × 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑙𝑒𝑣𝑒𝑟

𝑀=96×0.6463=62.0448𝑁𝑚

π
Then 62.0448 = ×140×106×𝐷3
32
 𝐷=16.5269, Say 𝐷 = 17𝑚𝑚

Figure 5.6: Section of Lever – Diameter

5.6.3.5 Height of Head

The height of head is usually taken as twice the diameter of handle.

𝐻 = 2𝐷

Therefore 𝐻 = 2×17=34𝑚𝑚

Figure 5.7: Section of Screw Head

5.6.3.6 Design Check against Instability/Buckling

1
Effective length of screw, 𝐿𝑒𝑓𝑓=𝐿𝑖𝑓𝑡 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤+ 𝑜𝑓 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑛𝑢𝑡
2

h
𝐿𝑒𝑓𝑓=𝐻1+
2
 16
𝐿𝑒𝑓𝑓=200+
2

𝐿𝑒𝑓𝑓=208𝑚𝑚

When the screw reaches the maximum lift, it can be regarded as strut whose lower end is fixed
and the load end is free. Therefore, buckling or critical load for this given condition is as follows

σy Leff 2
𝑊𝑐𝑟=𝐴𝑐.𝜎𝑦[1− 2 ( )]
4C π E k

Where

𝜎𝑦= Yield stress = 385𝑀𝑃𝑎

𝐶 = End fixity coefficient. The screw is considered to be strut with lower end
fixed and load end free. Therefore 𝐶 = 0.25

𝑘 = The radius of gyration =

√ I
A
= 0.25dc=0.25(0.016) = 0.004

𝐼= Moment of inertia of the cross section.

The buckling load as obtained by the above expression and must be higher than the load at which

the screw is designed. Substituting for the known values:

π σy Leff 2
𝑊𝑐𝑟= (𝑑𝑐)2.𝜎𝑦 [1− 2 ( )]
4 4C π E k

π 385 ×10 6 0.208 2

𝑊𝑐𝑟= (0.016)2×385×106[1− 2 9 ( )]
4 4 × 0.25 × π × 200 ×10 0.004

𝑊cr=36583.65𝑁

While 𝑊=5000𝑁

𝑊𝑐𝑟>𝑊 , hence there is no chance for the screw

5.6.4 Design of Body

5.6.4.1 Dimensions for the body of the screw

The dimension of the body may be fixed and given as in shown in the figure above (Gupta,
2005):

1. Diameter of the Body at the Top

𝐷5=1.5𝐷2

𝐷5=1.5×36=54𝑚𝑚

2. Thickness of the body

𝑡2=0.25𝑑𝑜

𝑡2=0.25×20=5𝑚𝑚,𝑆𝑎𝑦 𝑡2=5𝑚𝑚

3. Inside Diameter at the Bottom

𝐷6=2.25𝐷2

𝐷6=2.25×36=81𝑚𝑚

4. Outer Diameter at the Bottom

𝐷7=1.75𝐷6

𝐷7=1.75×81=141.75𝑚𝑚

5. Thickness of Base

𝑡3=2𝑡1

𝑡3=2×3mm=6𝑚𝑚

6. Height of the Body 𝐻𝑏

𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑜𝑑𝑦=Max𝑙𝑖𝑓𝑡+𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑛𝑢𝑡+𝐸𝑥𝑡𝑟𝑎 50𝑚𝑚

𝐻𝑏 = 200+16+50=266𝑚𝑚

Finally, the body is tapered in order to achieve stability of the jack.

Figure 5.8: Section of Frame (Body)

5.6.5 Efficiency of the Screw Jack

Efficiency of screw jack is given as follows:

¿ ¿
𝜂=Torque required ¿ rotate screw withno friction Total torqure output = T

¿
𝜂= T
 dm
But 𝑇𝑜=𝑊tan𝛼 ×
2
𝑇𝑜=6250×0.018×0.0172

𝑇𝑜=1.935𝑁𝑚

And 𝑇=23.195𝑁𝑚

1.935
Therefore 𝜂= =0.0834𝑜𝑟 8.34%
23.195

5.6.6 Matlab Script File

5.6.6.1 Screw Jack Matlab Design Script/Code
 CHAPTER SIX

PART AND ASSEMBLE DRAWING OF SCREW JACK