Fitsum Moges 82266-07 PDF

Mekelle University
School of Mechanical & Industrial

Engineering
Machine design project on bevel driven
screw jack
Prepared By: - Fitsum Moges

ID: - Eitm/ur82266/07
Section: - 04
Submitted To: - Ins. Meron
Ins. Equbemariam
Submission Date: 19/12/2017

[Machine design project on bevel driven screw jack] December 20, 2017
i. Acknowledgement
At first place I want to thank God. After that I would like to
acknowledge the support and politeness of my instructors Miss. Meron and
Mir equbemariam. I am grateful to all my friends for their suggestion,
comment and appreciable advice, especially to my dorm mates. After all I
appreciate all the peoples who support me.
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ii. Abstract
As the name indicates Bevel driven screw jack is a screw jack that is
driven by a bevel gear. It has a various components that are integrated
together by different mechanisms for full operation of the machine. Bevel
driven screw jack have a various applications such as Paper industry, press
industry, printing industry, Gypsum factories, Sheet metal forming
machinery, Mechanical lifting applications, Platform lifting applications,
Food processing machinery, Construction sector, Mining industry, Lift tables
& Stage setup applications.
In this design project I tried to analyze the design of critical components

using basic principle of design like the five failure theories, principal stress
principle and others.
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iii. Objective
General objective
The General objective of this project is in order to design a bevel driven
screw jack which is used to lift an automobile during tyre replacement.
Specific objective
To apply basic principle of machine design while we are designing each
components
To have knowledge on how to design a machine
To correlate all the courses that we have taken so far
To know basic techniques and procedures of designing a machine
To relate the theoretical concepts with the real world
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Contents
1. INTRODUCTION ................................................................................................................................................ 6
1.1. General introduction ................................................................................................................................ 6
1.2. Basic Components of bevel driven screw jack ......................................................................................... 9
1.3. Working principle of bevel driven screw jack......................................................................................... 11
1.4. Material selection ................................................................................................................................... 12
1. Kinematic analysis of the system.................................................................................................................... 14
2. Design of Power Screws ................................................................................................................................. 16
2.1. Introduction ............................................................................................................................................ 16
2.2. Stresses on the power screw .................................................................................................................. 16
2.3. Design analysis........................................................................................................................................ 17
2.4. Material selection for power screw ....................................................................................................... 20
3. Design of Bevel Gear ...................................................................................................................................... 22
3.1. Introduction ............................................................................................................................................ 22
3.2. Stress in the bevel gear .......................................................................................................................... 22
3.4. Design analysis........................................................................................................................................ 23
4. Design of Shaft................................................................................................................................................ 30
4.1. Introduction ............................................................................................................................................ 30
4.2. Stress in the shaft ................................................................................................................................... 30
4.4. Design analysis........................................................................................................................................ 31
5. Design of fasteners ......................................................................................................................................... 38
5.1. KEY DESIGN ............................................................................................................................................. 38
5.1.1. Introduction .................................................................................................................................... 38
5.1.2. Stress in the KEY ............................................................................................................................. 38
5.1.3. Material selection ........................................................................................................................... 38
5.1.4. Design analysis................................................................................................................................ 39
5.2. Bolt design .............................................................................................................................................. 41
5.2.1. Introduction .................................................................................................................................... 41
5.2.2. Stresses on the power screw .......................................................................................................... 41
5.2.3. Design analysis................................................................................................................................ 41
5.2.4. Material of bolt ............................................................................................................................... 42
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6. Design of Handle............................................................................................................................................. 43
6.1. Material for the handle .......................................................................................................................... 43
6.2. Stress in the handle ................................................................................................................................ 43
6.3. Design analysis........................................................................................................................................ 43
7. Design of Nut .................................................................................................................................................. 47
8. Selection of Bearings ...................................................................................................................................... 48
8.1. Introduction ............................................................................................................................................ 48
I. Selection for the radial ball bearing ........................................................................................................... 48
II. Design of collar bearing .............................................................................................................................. 50
9. Manufacturing methodology ......................................................................................................................... 52
a. Manufacturing methodology for screw and nut ........................................................................................ 52
b. Manufacturing methodology for Power screw .......................................................................................... 52
c. Manufacturing methodology for Bevel gear .............................................................................................. 52
d. Manufacturing methodology key ............................................................................................................... 52
e. Manufacturing methodology collar, body and base .................................................................................. 52
f. Manufacturing methodology for Washer................................................................................................... 53
10. Lubrication .................................................................................................................................................. 54
o Reference........................................................................................................................................................ 62
o Link.................................................................................................................................................................. 67
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1. INTRODUCTION
1.1. General introduction

The word design is from the Latin word “designare” meaning “to designate, or
mark out”. Engineering design can be defined as “the process of applying the various
techniques and scientific principles for the purpose of defining a device, a process, or a
system in sufficient detail to permit its realization.”
Machine design deals with the creation of machinery that works safely, reliably &
well. Machine Design is the innovation of new and effective machines or improving the
existing ones. In designing a machine component, it is necessary to have a good
knowledge of many subjects such as Mathematics, Engineering Mechanics, Strength of
Materials, Theory of Machines, Workshop Processes and Engineering Drawing. General
procedures of design are the following:-
Recognition of need or problem

Definition of problem: - A full specification of the product desired by the
company should be written. This allows the design team to identify whether
their design proposals meet the original request.
Synthesis: - This is often identified as the formative and creative stage of
design. Some initial ideas must be proposed or generated in order for them to
be assessed and improved. Concepts can be generated by imagination,
experience or by the use of design techniques, such as morphological charts.
Analysis: - Once a concept has been proposed it can then be analyzed to
determine whether constituent components can meet the demands placed on
them in terms of performance, manufacture, cost and any other specified
criteria. Alternatively, analysis techniques can be used to determine what size
components need to be to meet the required functions.
Optimization: - Inevitably there are conflicts between requirements. Cost
minimization may call for compromises on material usage and manufacturing
methods.
Evaluation: - Once a concept has been proposed and selected and the details of
component sizes, materials, manufacture, costs and performance worked out,
it is then necessary to evaluate it.
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Figure 1 General procedures of machine design
The machine design may be classified as follows:
1. Adaptive design: - In most cases, the designer’s work is concerned with

adaptation of existing designs.
2. Development design. This type of design needs considerable scientific training
and design ability in order to modify the existing designs into a new idea by
adopting a new material or different method of manufacture. In this case,
though the designer starts from the existing design, but the final product may
differ quite markedly from the original product.
3. New design. This type of design needs lot of research, technical ability and
creative thinking. Only those designers who have personal qualities of a
sufficiently high order can take up the work of a new design. The designs,
depending upon the methods used, may be classified as follows
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 Rational design: - This type of design depends upon mathematical

formulae of principle of mechanics.
 Empirical design: - This type of design depends upon empirical formulae
based on the practice and past experience.
 Industrial design: - This type of design depends upon the production
aspects to manufacture any machine component in the industry.
 Optimum design: - It is the best design for the given objective function
under the specified constraints. It may be achieved by minimizing the
undesirable effects.
 System design: - It is the design of any complex mechanical system like
a motor car.
 Element design: - It is the design of any element of the mechanical
system like piston, crankshaft, connecting rod, etc.
 Computer aided design: - This type of design depends upon the use of
computer systems to assist in the creation, modification, analysis and
optimization of a design.
Since my design have modification of the existing designs into a new idea by
adopting a new material or different method of manufacture it can be said
development design. In addition in this design each component which may fail
during operation due to the applied force will be designed using different principles
and mathematical relations and this makes my design rational, empirical and
element design.
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1.2. Basic Components of bevel driven screw jack

1. Bevel gear: -The bevel gears are used for transmitting power at a constant velocity
ratio between two shafts whose axes intersect at a certain angle. It is used to
change the axis of rotation of a shaft for a specific purpose.
2. Body (housing): - is the body that covers the gear arrangements.
3. Cup (top plate): - is the top plate of the jack and the load which is gone be lifted is
positioned on it.
4. Base: - is another component of our machine which supports the whole
components.
5. Bearing: -A bearing is a machine element which supports another moving machine
element. It permits a relative motion between the contact surfaces of the members,
while carrying the load.
6. Handle: - is one of the components of our system which is used to run the bevel
gear by applying a force on it.
7. Fasteners: -there are two types of fastening mechanisms in my design. Those are
screw and key.
A key is a piece material (component) inserted between the
shaft and hub or boss of the pulley to connect these together in order to
prevent relative motion between them and in my work it is used to connect
the shaft with the gear and the handle.
A screwed joint is mainly composed of two elements i.e. a bolt and nut. In my
project this component is used to fasten the housing of gear arrangement
with the base.
8. Power screw: - Power screws, sometimes called linear actuators or translation
screws, are used to convert rotary motion of either the nut or the screw to relatively
slow linear motion of the mating member along the screw axis. The purpose of
many power screws is to obtain a great mechanical advantage in lifting weights, as
in screw-type jacks, or to exert large forces, as in presses and tensile testing
machines, home garbage compactors, and C-clamps.
9. Other components: - shaft, end cap (used to enclose the opening of the housing),
shim (used to avoid contact or friction between the end cap and the housing) and
screw (for closing inlets of lubricant).
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1.3. Working principle of bevel driven screw jack

The principle of screw jack is similar to that of an inclined plane. The movement
of nut on the screw jack is similar to the movement of a weight on an inclined plane,
since when one thread is developed, it is an inclined plane as shown in figure 1 and nut
taking place of the weight. The base of the inclined plane will be equal to πdm.
α = Helix angle & p = pitch threads Then Tan α = P/πdm
First load will be applied on the handle. After that the handle will force the shaft
that drives the vertical bevel gear (driver gear) to rotate. The vertical gear mush with
the horizontal bevel gear and the nut starts to rotate. By the principle of inclined plane
the screw starts to lift as the nut starts to rotate.
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1.4. Material selection

The knowledge of materials and their properties is of great significance for a
design engineer. The machine elements should be made of such a material which has
properties suitable for the conditions of operation. In addition to this, a design
engineer must be familiar with the effects which the manufacturing processes and heat
treatment have on the properties of the materials.
The selection of a proper material, for engineering purposes, is one of the most
difficult problems for the designer. The best material is one
which serves the desired objective at the minimum cost. The following factors should
be considered while selecting the material:
Availability of the materials

Suitability of the materials for the working conditions in service, and
The cost of the materials. The important properties, which determine the
utility of the material, are physical, chemical and mechanical properties.
So for my project I select the different materials for each component: -
Shaft 40 C 8 carbon and alloy steel

Top plate Cast iron
Nut Gray Cast iron
Housing Cast iron
Bevel gear Grey cast iron /for the GEAR/ & Carbon steel (
f (forged and casehardened) /for pinion/
Base Cast Iron
Handle ASTM A220 Malleable Cast Iron
Key carbon steel AISI 1020
Screw joint (bolt and nut) AISI 303 Austenitic stainless steel
Bearing lead based Babbit
Power screw 1010 A carbon steel
Bolt stainless steel
The properties of those materials and the reason why I select those materials will
be discussed on the next sections individually.
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The Given specifications

Type: Bevel driven screw jack
Maximum lift load: 6 KN
Minimum lifting height: 160 mm
Maximum lift height: 280 mm
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2. Kinematic analysis of the system

Before doing any stress and force analysis, we have to check whether the system
can exist or not base on the given maximum and minimum lift.
Figure 1 Assembly drawing
Let introduce variables as shown in the figure
…............................ (Maximum lift)
….................................... (Minimum lift)
The system to exist this condition must be satisfied
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If it is not true, there is no enough space for the screw inside the body of the jack for
the minimum lift. I.e. to attain the minimum lift the screw needs to go under the
ground and it is not possible.
Now we have 3 relations and four unknowns. To solve this let assume one of the
variables then calculate for the remains.
So let A = 10 mm
Therefore from the above relations C = 150 mm and B = 120 mm
From the last relation
So we can take any value for D that is below 30 mm. D = 30 mm means there is no
clearance for the screw. (I.e. at the minimum lift the screw will touch the ground)
In this section we can get the required length of the screw “L” to attain the given
maximum and minimum lift.
Assume 7 mm clearance then L = 143 mm.
Comment
From the above values I can say that the system is attainable.
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3. Design of Power Screws
3.1. Introduction
The power screws (also known as translation screws) are used to convert rotary
motion into translation motion. In case of screw jack, a small force applied in the
horizontal plane is used to raise or lower a large load.
3.2. Stresses on the power screw

There are two loads on this power screw. The first one is the load that is to be
lifted (compressive load). And the second one is torsion that is applied on the power
screw when a force is applied on the handle.
Different stresses are going to be induced when the load and the torque are
applied to power screw. The stresses that can be induced are:
i. compressive stress due to an axial load

ii. Torsional shear stress
iii. Shear stress due to axial load: - The threads of the screw at the core or root
diameter and the threads of the nut at the major diameter may shear due to the
axial load.
iv. Bearing stress: - Depends upon the materials of the screw and nut, relative
velocity between the nut and screw and the nature of lubrication
v. Buckling load: - When the axial load is compressive and the unsupported length
of the screw between the load and the nut is long the design must be based on
column theory assuming suitable end conditions.
Note: -
From the three threads (square, Acme or trapezoidal & Buttress) I select square thread
because square thread is more efficient than Acme and buttress thread.
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3.3. Design analysis
Assumptions
Since the dynamic load is smaller than the static load I can neglect the dynamic load
and only work with static load.
the load is uniformly distributed over the threads in contact
take Factor of safety F.S = 4
The effect those assumptions will be removed by the factor of safety.
A little consideration will show that if one complete turn of a screw thread be imagined
to be unwound, from the body of the screw and developed, it will form an inclined
plane as shown in Figure below.
Where
 p = Pitch of the screw,

 d = Mean diameter of the screw,
 α = Helix angle,
 P = Effort applied at the circumference of the screw to lift the load,
 W = Load to be lifted, and
 μ = Coefficient of friction, between the screw and nut = tan φ, where φ is the
friction angle.
From the geometry of the Figure 4
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Since the load is being lifted, therefore the force of friction (F = μ.R N) will act
downwards
Resolving the forces along the plane (x) & perpendicular to the plane (y),
∑ ; P cos α = W sin α + F = W sin α + μ.RN
∑ ; RN = P sin α + W cos α
From the two equations by applying some mathematical method we will get,
∴ Torque required to raise the load (torque to overcoming friction between the screw
and nut)
Note: -
In machine design we can use two methods. The first one is specifying the size of our
machine components then we will calculate the maximum stress which will be induced
on the components. Based on the values we’ll select a material that is able to resist the
maximum induced stress. The second method is the reverse one. I.e. first we select the
material then we will determine the size. For the sake of simplicity I preferred the first
method to this machine component only.
Therefore let take do = 20 mm the for this value of do pitch will be P = 2 mm
Where
 Is Helix angle is &

 is Angle of friction
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( ) But R1 = 11 mm and R2= (1.4 up to 1.5) times of R1

∴ R2 = 16 mm
( )
Now the total torque T will be
Where
 T1 is torque required to overcome friction between screw and nut

 T2 is torque required to overcome friction at the collar
 & are inner and outer radius of collar respectively
Then the torsional shear stress will be: -
The compressive stress will be
When the screw is subjected to both direct stress and torsional shear stress, then the
design must be based on maximum shear stress theory, according to which maximum
shear stress on the minor diameter section.
√ √
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Let take Factor of safety F.S = 4
3.4. Material selection for power screw

Now I need a material that can withstand with this stress. Therefore I select Carbon and
alloy steels (specifically AISI 1010 A) material for the screw because its strength.
It has the following properties:-
Table 1 Property of 1010 A carbon steel
modules Modules Ultimate Yield Max. Safe

of of rigidity tensile tensile Shear Bearing
elasticity in G.pa strength strength in strength pressure
in G.pa (G) in M.pa M.pa in M.pa in M.pa
(E)
207 79 303 200 100 11.2
Remaining design analysis that can be solved after material

selection
Let check for the buckling using Rankine-Gordon formula or J.B. Johnson’s formula
[ ( ) ]
Where
 C is end fixity coefficient (C = 0.25)

 K is radius of gyration (k = 0.25 )
 L is length of the screw (L = 110 mm I obtained this value from the kinematic
analysis)
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[ ( ) ]
Comment
Since the screw will never buckle. Therefore the screw is safe for
buckling load.
The bearing stress will be
Where
 t is Thickness or width of screw (t= p / 2)

 n is Number of threads in contact with the nut ( n= h/p)
 h is Height of the nut
Then,
Now
The shear stress on the teeth of the screw will be
Comment
The shear stress induced on the teeth of the power screw is greatly smaller than
the shear strength of the material. So the teeth are safe.
The efficiency of the power screw will be
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4. Design of Bevel Gear
4.1. Introduction
Bevel gears have teeth formed on conical surfaces and are used mostly for
transmitting motion between intersecting shafts.
4.2. Stress in the bevel gear

The forces acting at the center of the tooth are shown in Figure below. The
resultant force W has three components: a tangential force WT, a radial force WR, and
an axial force WA.
From the trigonometry of the figure,
The stresses induced in the gear are
Bending stress due to the tangential

load
Axial compressive stress due to the radial load
Shear stress due to the axial load
But relative to the bending stress the compressive and shear stresses are very small so I
neglect them.

The material used for the manufacture of gears depends upon the strength and
service conditions like wear, noise etc. The gears may be manufactured from metallic
or non-metallic materials. The metallic gears with cut teeth are commercially
obtainable in cast iron, steel and bronze.
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Steel have higher strength than cast iron, but its cost per K.g is high and it
requires several conditioning process than cast iron after manufacturing process like
heat treatment. It makes the cost to increase to some extent. And cast iron has good
wearing properties, excellent machinability and ease of producing complicated shapes
by casting method, but its strength is lower than steel.
So to get the advantages of those two materials I select cast iron for the gear and
carbon steel for the pinion (because it needs stronger material). Using similar material
for the gear and pinion is a waste (I.e. we are adding excessive strength for the gear).
So from my material selection I can get the advantage of using steel (good strength)
and also the advantage of using cast iron (low cost) at the same time.
Some properties of those materials are listed below
Table 2 property of the gear and pinion material
Grey cast iron Carbon steel (forged and

Properties
/GEAR/ case hardened) /pinion/
Static strength (M.pa) 70 126
Endurance limit (M.pa) 84 525
Surface endurance limit

630 770
(M.pa)
Brinell hardness № 160 300
Assumptions
Stress due to the axial load and radial load is negligible

Uniform stress
System of gear teeth 14 ½ composite gear (∴ pressure angle, )
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The number of teeth of pinion Tp = 12 (because to avoid interference the

minimum number of teeth for composite pinion gear is 12)
Velocity ratio V.R = 2
Angle between the two shafts
Cone length is three times face width (b = L/3)
Speed of pinion Np = 70 r.p.m
a) Geometric analysis
Where
 V.R is velocity ratio

 is № of teeth of the gear
 is № of teeth of the pinion
Figure 6 bevel gear geometry
( ) ( )
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Where
 the angle between two shafts

 pitch angle of pinion and gear respectively
 NP & NG angular speed of pinion and gear respectively (in r.p.m)
b. Force analysis
…. //Modified Lewis equation for bevel gear
Where
 L is cone distance
 Y’ Lewis factor for the equivalent number of teeth ( )
 b face width
 v peripheral speed in m/s
 m Module
 allowable stress
 speed factor
According to Lewis law from the two gears the weaker one is identified by the value of
.
For the gear
For the pinion
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Therefore we need to design only for the gear.
Now let substitute all parameters on the Lewis equation
By Solving the above equation using scientific calculator or MATLAB you will get
To make standard value let take
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Now
We have this relation to obtain the torque required at the pinion shaft to lift the load
(Note here T is not number of teeth instead it is torque)
From this
Where
 C A deformation dynamic factor in N/mm

 WD Total dynamic load in N
 V(in m/s) b(in mm) WT in N
But,
For m = 3 mm, e= 0.0125 mm (From the table by assuming precision gear)
By using the values e = 0.01 and we can get
c = 79 N/mm (From table)
Where
 e Tooth error in action( in mm)

 K A factor depending upon the form of the teeth
 Young's modulus of pinion and gear respectively
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√ √
But
Where
 maximum wear load in N

 Q Ratio factor [ ⁄ ]
 K Load stress factor in M.pa
 Surface endurance strength in M.pa
 pressure angle
( )
Comment
Since the maximum wear load is much more than the tangential load on the
tooth, therefore the design is satisfactory from the standpoint of wear.
Comment
The dynamic load is less than both static and wear load. Therefore my design is
safe.
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Remaining geometric analysis that can be known after force

analysis are: -
⟾ =1 =2.75
⟾ =1.2 2.75 =3.3
⟾ 𝑜 𝑖 𝑔 𝑒p ℎ=2 2.75 =5.5
⟾ 𝑙𝑒 𝑒=0.2 2.75 =0.55
⟾ =1.5708 2.75 =4.3197
⟾ Addendum angle
⟾ Dedendum angle
Where
 “a” is Addendum,
 “d” is Dedendum and
 “t” is Thickness of the tooth
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5. Design of Shaft
5.1. Introduction
A shaft is a straight, mostly round bar, which is designed to have other rotating
parts of a mechanism mounted on it or to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque
(or twisting moment) set up within the shaft permits the power to be transferred to
various machines linked up to the shaft.
5.2. Stress in the shaft

In shaft the following stresses may be induced,
Shear stresses due to the transmission of torque

Bending stresses (tensile or compressive) due to the forces acting upon
gears as well as due to the weight of the shaft itself (but the mass of the
shaft is negligible so in my design I consider only bending due to loads on
the gear)

The material used for shafts should have the following properties:
It should have high strength

It should have good machinability.
It should have low notch sensitivity factor.
It should have good heat treatment properties.
It should have high wear resistant properties.
Based on those criteria’s I select carbon steel with ultimate tensile strength of
560 N/mm2 and yield strength of 320 N/mm2. Specific code of the material is 40 C 8
(Indian code). Property of the material is listed below,
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Table 3 Property of 40 C 8 carbon steel
modules of Modules of Ultimate Yield tensile Density in

elasticity in rigidity in tensile strength in Mg/m3
G.pa G.pa strength in M.pa
(E) (G) M.pa
207 79 560 320 7.7
Assumptions
The shaft mass is negligible
Take factor of safety of 1.5
Uniform stress is induced
A person can apply a force of 300 – 400 N
the distance between the gear and the bearing Y=30 mm
a. Design on basis of strength
I considered the following general concepts during my design of shaft
I Keep shafts as short as possible, with bearings close to the applied loads. This reduces
deflections and bending moments and increases critical speeds.
I used inexpensive steels for deflection-critical shafts, as all steels have essentially
the same elastic modulus.
………… (Obtained when I design for the bevel gear)
Now let find the tangential force acted at the mean radius of the pinion
In order to determine the bending moment on the shaft let find the axial and radial
forces acting on the pinion shaft first.
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Where
 is axial force acting on the gear

 is radial force acting on the gear
The bending moment due to and will be
The bending moment due to will be
∴ The resultant bending moment will be
√ √
 Effective twisting moment or torque ( is the equivalent twisting moment may

be defined as that twisting moment, which when acting alone, produces the same
shear stress (τ) as the actual twisting moment.
Since the shaft is subjected to twisting moment (T) and bending moment (M) the
equivalent twisting moment will be
√ √
Then
→ → √
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Where
 ds diameter of the shaft

 allowable shear stress
According to Maximum Shear Stress Theory (Guest’s or Tresca’s Theory)
√ √
 Me Effective moment is the equivalent bending moment may be defined as

that moment which when acting alone produces the same tensile or compressive stress
(σb) as the actual bending moment.
Now let find Me will be
⁄ ⁄
√ ⁄
Comment
The diameter of the shaft that is obtained by using effective torque is higher than
by using effective moment. I.e. the shaft will fail by shear first. And in order to make
the design safe I need to take the larger ds = 11.387 mm.
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Approximate the value
b. Design of Shafts on the basis of Rigidity
Where
 J Polar moment of inertia of the cross-sectional area about the axis

of rotation
 G modules of rigidity
 L length of the shaft
 Torsional deflection or angle of twist in radians,
⁄
⁄
⁄ Or per meter
Comment
For line shafts or transmission shafts, deflections 2.5 to 3 degree per meter
length may be used as limiting value. And since is less than 2.5o per meter my design
of shaft for rigidity is safe.
c. Checking for deflection
Since the two moments & are in different direction we can’t determine
the deflection of the shaft directly. Therefore let apply the principle of superposition.
That means calculate the deflection of the shaft due to each moment individually and
calculate for the resultant deflection.
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I. Deflection due to M1 only
Here we can calculate constant of integration & by using the following boundary
conditions.
 At x = 30 mm (the fixed point) the slope and deflection is equal to zero

 &
From the above relations
And
Now the deflection of the shaft will be
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The maximum deflection will be at the free end that means at x = 0 mm
II. Deflection due to M2 only
Similarly, we can calculate constant of integration & by using the previous

boundary conditions
∴ & ∴
Now the deflection of the shaft will be
The maximum deflection will be at the free end that means at x = 0 mm
III. Total Deflection
Now the total deflection of the shaft will be equal with the resultant of the above two
deflections. Mathematically,
√ √
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Comment
This means the deflection of the shaft due to the tangential load
( is higher than the deflection due to the radial load ( . Therefore the effect of
the tangential load on the shaft is higher.
The value of the maximum deflection is and this value is very small
so my design will not have deflection problem.
37 | P a g e
6. Design of fasteners
6.1. KEY DESIGN

6.1.1. Introduction
A key is a part inserted between the shaft and hub to connect these together in
order to prevent relative motion between them. It is always inserted parallel to the axis
of the shaft. Keys are used as temporary fastenings.
6.1.2. Stress in the KEY

There is two type of stresses induced in the key while it transmit a torque or
power. Those are
Shear stress and

Crushing stress
6.1.3. Material selection

I select carbon steel AISI 1020 material for the key because the material retain
good ductility as indicated by a percent elongation value greater than about 10%,
particularly when shock or impact loads could be encountered. It also has an adequate
strength for my application.
Table 4 Property of carbon steel AISI 1020
Yielding strength in Ductility (percent Brinell

N/mm2 elongation in 2 inches) hardness
(HB)
207 25 111
38 | P a g e
6.1.4. Design analysis
Assumptions
forces due to fit of the key are neglected and

it is assumed that the distribution of forces along the length of key is uniform
Take factor of safety F.S = 5
I select gib-head sunk type of key for my system. Sunk keys are provided half in
the keyway of the shaft and half in the keyway of the hub or boss of the pulley. Since
the diameter of the shaft is 12mm we can know the cross section of the key.
From table for ds = 12 mm
w = t =5 mm
a. considering a shear stress
………………… (Obtained in the bevel gear design)
𝑙 & ⁄ 𝑙 ⁄
From this 𝑙 but

⁄
b. considering a crushing stress
𝑙 & ⁄ 𝑙 ⁄
39 | P a g e
From this
𝑙 𝑙 𝑒 𝑒
𝑙 𝑙 𝑙
40 | P a g e
6.2. Bolt design

6.2.1. Introduction
Tap bolt is screwed into a tapped hole of one of the parts to be fastened without
the nut, as shown in Figure below.
I select screw (Tap bolts) as fastener to join the housing with the base because
Screwed joints are highly reliable in operation, convenient to assemble and
disassemble, adapted to various operating conditions and Screws are relatively cheap
to produce due to standardization and highly efficient manufacturing processes.
6.2.2. Stresses on the power screw

In my design the screw will face only initial stresses due to Screwing up Forces.
I.e. there is no Stress due to External Forces unless there is any eccentricity. Smaller
diameter screws(less than M 16 or M 18 bolts) may fail during tightening.
6.2.3. Design analysis

Assumption
There is no eccentricity (the load of the car is concentrated at the center of the
cap).
To remove the uncertainty due to the above assumption take a Factor of safety is
equal with 1.5
41 | P a g e
The initial tension in a bolt, based on experiments, may be found by the relation
Where
 is Initial tension in a bolt

 d is Nominal diameter of bolt, in mm
Here like the power screw, I specify the size of the bolt then I select a material that can
support the induced initial stress.
I considered the M 7 bolt so that its core diameter and pitch will be 5.773 mm and 1
mm respectively.
Then the induced initial tensile stress will be
⁄ ⁄
To remove uncertainties let take a factor of safety
6.2.4. Material of bolt

I select a stainless steel for producing this bolt, Specifically AISI 303 Austenitic stainless
steel. I select stainless steel because; stainless steels can be cut, formed, machined and
fabricated easily. And it also has good strength. It has the following properties
 Yield strength and ultimate strength 770 M.pa

 Elongation present is equal to 22 %
42 | P a g e
7. Design of Handle
7.1. Material for the handle

 I select malleable cast iron. Specifically ASTM A220 Malleable Cast Iron with ultimate
tensile strength of 360 M.pa, because of its low cost.
 I select circular cross section because circular cross sections have better resistance to
the induced stresses than rectangular or other shapes. It saves cost by reducing
excessive material used when those shapes are used. (but since the size of the handle is
not bigger the effect may be small or insignificant)
7.2. Stress in the handle

 In the handle there is bending stress due to the applied load or effort.

 A person can apply a force of 300 – 400 N. therefore assume F=300 N
Assumptions
Take factor of safety as 1.5
Shear stress is negligible
assume F=300 N (handle force)
uniform stress (I.e. stress concentration is not considered)
The handle needed to create a torque on the shaft that is equal to

………… (Obtained when I design for the bevel gear)
The operator may not apply 300 N force that means the screw is subjected to higher
load (if the load is greater than 300 N and it is eliminated by the factor of safety that I
have taken previously) or the screw will not rise (if the load is less than 300 N and to
remove this uncertainty let increase the length of the handle to some extent).
Say
43 | P a g e
Where
 x is the vertical length of the arm and

 T is the torque required at the pinion gear to raise the load.
∑ ; But, F = 300 N
∑ ; But, x = 30 mm
Figure 8 Shear and Bending moment diagram
And the torque will be
Where y is the horizontal distance of the handle
44 | P a g e
Figure 9 (b) 3D model of the handle that is prepared on Solid work
Since the shaft is subjected to twisting moment (T) and bending moment (M) the
equivalent twisting moment and equivalent bending moment will be
√ √
Now I obtain the maximum shear load and the maximum bending moment (that
is also shown on the diagram). I will design for the bending stress only because the
effect of shear load (shear stress) is very smaller and insignificant.
45 | P a g e
√ ⁄
According to Maximum Shear Stress Theory (Guest’s or Tresca’s Theory)
√ √
Now to make the design safe let take the larger diameter that will not cause
failure in both bending and shear.
Comment
The diameter obtained from the equivalent bending moment is lower than the
diameter obtained from equivalent torque. This indicates that the handle will fail in
shear first.
46 | P a g e
8. Design of Nut
The purpose of the nut in my design is to lift the power screw up and
down. And it is manufactured with the gear. That means the gear will
have internal thread. Therefore it is made from grey cast iron and has
strength of 152 M.pa in ultimate. In the nut there is shear stress on the
teeth of the nut due to the external load. This stress is resisted by the
outer diameter cross section.
The shear stress on the teeth of the screw will be
Let take a factor of safety of 4. Then the maximum shear stress that may appear in the
system will be 42.44 M.pa
Comment
is less than the material strength so the nut will not fail by the given applied
load.
47 | P a g e
9. Selection of Bearings
9.1. Introduction
For my design I need two bearings which are radial bearing (bearing that support a
load acts perpendicular to the direction of motion of the moving element) for the
pinion shaft and thrust bearing (bearing that support a load acts along the axis of
rotation) at the nut or power screw.
I select ball bearing for the nut and the shaft because, it is Easy to mount and erect,
Low starting and running friction, Low cost of maintenance, as no lubrication is
required while in service and Reliability of service.
I. Selection for the radial ball bearing

In order to select a most suitable ball bearing, first of all, the basic dynamic radial load
is calculated. It is then multiplied by the service factor (Ks) to get the design basic
dynamic radial load capacity.
Assumption
Uniform and steady load so Ks = 1
For radial ball bearings, the basic static radial load rating (C0) is given by
Where
 i is Number of rows of balls in any one bearing ( Assume 1)

 Z is Number of ball per row ( Assume 8)
 D is Diameter of balls, in mm ( Assume 4 mm)
 is Nominal angle of contact i.e. the nominal angle between the line of
action of the ball load and a plane perpendicular to the axis of bearing ( assume
100 ) and
48 | P a g e
 Is a factor depending upon the type of bearing (f0 = 12.3, for radial contact
and angular contact groove ball bearings.)
……………. ( Is obtained in the analysis of shaft)
√ ……………..… (Because the resultant force of the tangential load

and the vertical component of the radial force on the shaft analysis is radial force on
the bearing)
∴ √
&
Is smaller than the smaller value of e = 0.22 ∴ 𝑒
Where
 V is a rotation factor (v = 1 for all types of bearings when the inner race is
rotating)
 X is radial load factor
 Y is axial or thrust load factor
 is radial load
 is Tangential load
 is Equivalent dynamic load
Now by using the value of (Specification) & the condition 𝑒 we can read X & Y
from the table
49 | P a g e
Where
 L is rating value life in revolutions (assume

rev)
 C is Basic dynamic load rating
 W is equivalent dynamic load
 K is constant. For ball bearing K = 3
[ ]
Now from the table radial ball bearing, we can obtain the bearing №. It is 201. It
indicates that the bore diameter = 12 mm, outer diameter = 32 mm and width = 10
mm.

I select lead based Babbit metal because it satisfy most requirements for general
applications, recommended where the maximum bearing pressure (on projected area)
is not over 7 to 14 N/mm2, good conformability & excellent corrosion resistance. Its’
composition is Lead 84% ; Tin 6% ; Anitmony 9.5% ; Copper 0.5%.
II. Design of collar bearing

In my design, the collar thrust bearing is required in order to allow the screw to rotate
without the cap. That means the load will not rotate when the screw is rotating.
It is assumed that the pressure is uniformly distributed over the bearing surface.
Where
 W is Load transmitted over the bearing surface

 n is Number of collar
 R is Outer radius of the collar
50 | P a g e
 r is Inner radius of the collar

 N is r.p.m of the power screw
 P is bearing pressure (For very slow speeds, the bearing pressure may be taken
as high as 14 N/mm2)
The thickness of the collar “t” is kept as one-sixth diameter of the screw
Power loss due to the friction in the form of heat
51 | P a g e
10. Manufacturing methodology

a. Manufacturing methodology for screw and nut
I preferred to manufacture the teeth of the nut and smaller screw fastener (tap
bolt) by machining process (threading) using Centre lathe machine because its’
simplicity, very high output, high dimensional accuracy and surface quality.
b. Manufacturing methodology for Power screw

I select forming (cold Rolling) process for manufacturing of a power screw. Since
the thread of the power screw is supporting the load applied on the system (the load of
the car), it must has enough strength. So I select cold Rolling because, It attributes
more strength and toughness to the threaded parts.
c. Manufacturing methodology for Bevel gear

I preferred to manufacture the bevel gear teeth by form milling process because
milling cuter is less expensive. In the finishing operation there is Casehardening heat
treatment. It is the process of hardening the surface of metal, often low carbon steel,
by infusing elements into the material's surface, forming a thin layer of a harder alloy. I
need only the teeth to be stronger. So instead of using hardening heat treatment, I
select case hardening and it makes only the teeth of the gear to be stronger
d. Manufacturing methodology key

I suggest the key to be manufactured by casting. Because it is simple shape and
casting process is not expensive.
e. Manufacturing methodology collar, body and base

I preferred to manufacture the base and the body by machining process
(forming) using Centre lathe machine. Because forming yields very high output, high
dimensional accuracy and surface quality. In addition it is simple and used to form
irregular shapes (the base has irregular shape).
52 | P a g e
f. Manufacturing methodology for Washer

The washer is manufactured by blanking (to make circular coin like structure)
and Punching (to make the hole on the blank or coin like structure).
53 | P a g e
11. Lubrication
For the bearings in the system, we need a lubricant
 to reduce friction and wear between the sliding parts of the bearing,
 to prevent rusting or corrosion of the bearing surfaces,
 to protect the bearing surfaces from water, dirt and
 To dissipate the heat.
In general, oil or light grease is used for lubricating ball and roller bearings.
For this system I select mineral oil, because mineral oil is cheap and stable.
54 | P a g e
12. Simulations of some parts using solid works (CAD

software)
I tried the stress and deflection simulation of some part on solid work. The snapshotted
pictures will answer the specific location of maximum deflection and maximum stress.
The color in those parts indicates the stress and the deflection.
Von Mises stress simulation For the handle
Comment
There is slight red color at the end of ring like structure at which the shaft is inserted.
This indicates for the handle the maximum stress will occur on the red colored section.
And if there is over loading or possibility of failure, the part will fail on that section first.
55 | P a g e
Deflection simulation for the handle
Comment
There is red color at the end the handle. This indicates the maximum deflection will
occur on the red colored section.
56 | P a g e
Von Mises stress simulation for the cap
57 | P a g e
Deflection simulation for the cap
58 | P a g e
Von Mises stress simulation for the gib head key
59 | P a g e
Deflection simulation for the gib head key
60 | P a g e
61 | P a g e
appendix
Tables used for the analysis

Table a
Table b
62 | P a g e
Table c
Table d
63 | P a g e
Table e
Table f
64 | P a g e
Table g
Table h
65 | P a g e
Table i
Table J
66 | P a g e
o Reference
Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA (2005)
fundamentals of machine component design fifth edition
Machine Elements Life and Design
Machine Elements In Mechanical Design fourth edition
Shigley’s Mechanical Engineering Design, Eighth Edition Budynas−Nisbett
Design Engineer’s Case Studies and Examples Keith L. Richards
VB Bandari; Design of Machine Elements, 1994, Tata McGraw Hill
Fundamentals of modern manufacturing Materials, Processes, and Systems
Fourth Edition Mikell P. Groover
Callister - Materials Science and Engineering
o Link
http://diequa.com
http://joycedayton.com
http://diequa.com
http://www.inkoma-albert.com
67 | P a g e

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Mekelle University

School of Mechanical & Industrial

Prepared By: - Fitsum Moges

Submitted To: - Ins. Meron

Submission Date: 19/12/2017

In this design project I tried to analyze the design of critical components

The General objective of this project is in order to design a bevel driven

screw jack which is used to lift an automobile during tyre replacement.

To apply basic principle of machine design while we are designing each

To have knowledge on how to design a machine

To correlate all the courses that we have taken so far

To know basic techniques and procedures of designing a machine

To relate the theoretical concepts with the real world

1.1. General introduction

Recognition of need or problem

Figure 1 General procedures of machine design

The machine design may be classified as follows:

1. Adaptive design: - In most cases, the designer’s work is concerned with

 Rational design: - This type of design depends upon mathematical

1.2. Basic Components of bevel driven screw jack

1.3. Working principle of bevel driven screw jack

α = Helix angle & p = pitch threads Then Tan α = P/πdm

1.4. Material selection

Availability of the materials

So for my project I select the different materials for each component: -

Shaft 40 C 8 carbon and alloy steel

The Given specifications

2. Kinematic analysis of the system

Figure 1 Assembly drawing

Let introduce variables as shown in the figure

…............................ (Maximum lift)

….................................... (Minimum lift)

The system to exist this condition must be satisfied

Therefore from the above relations C = 150 mm and B = 120 mm

From the last relation

Assume 7 mm clearance then L = 143 mm.

3. Design of Power Screws

3.2. Stresses on the power screw

i. compressive stress due to an axial load

3.3. Design analysis

The effect those assumptions will be removed by the factor of safety.

 p = Pitch of the screw,

From the geometry of the Figure 4

∑ ; P cos α = W sin α + F = W sin α + μ.RN

Therefore let take do = 20 mm the for this value of do pitch will be P = 2 mm

 Is Helix angle is &

( ) But R1 = 11 mm and R2= (1.4 up to 1.5) times of R1

Now the total torque T will be

 T1 is torque required to overcome friction between screw and nut

Then the torsional shear stress will be: -

The compressive stress will be

Let take Factor of safety F.S = 4

3.4. Material selection for power screw

It has the following properties:-

Table 1 Property of 1010 A carbon steel

modules Modules Ultimate Yield Max. Safe

207 79 303 200 100 11.2

Remaining design analysis that can be solved after material

 C is end fixity coefficient (C = 0.25)

The bearing stress will be

 t is Thickness or width of screw (t= p / 2)

The shear stress on the teeth of the screw will be