STATEMENT OF THE PROBLEM

The screw of a shaft straightener, as shown in Fig. P 12-5, exerts a load P=6,000

lb. The screw is 3 in. in outside diameter and has four square threads per inch.

(a.) Determine the force required at the rim of the 12-in.-diameter hand wheel,

assuming that the coefficients of the thread and collar friction are 0.125 and that the mean

diameter of the collar is 2½ in.

(b.) Determine the maximum compressive stress in the screw, the bearing pressure

on threads, and the shearing stress in threads.

(c.) Determine the efficiency of straightener.

(d.) Determine the size of the two bolts required to fasten the straightener to the

base, assuming the allowable stress is 8,000 psi. Neglect tightening-up stresses.

Page |1
 COMPLETE SKETCH OF THE ASSEMBLY

(NOT TO SCALE)

12’’

6”

6”

4”

14”

POWER SCREW FIGURE

Page |2
 Design Computation

Page |3
Given:

W = P = 6,000 lb. D rim = 12 in.

Do = 3 in f c = 0.125 (coefficient of friction on the

collar)

Threads per inch = 4 f = 0.125 (coefficient of friction on the thread)

D m = 2½ (mean diameter)
c

Where:

P= Axial pitch or the distance, measured axially, from a point on one thread to the

corresponding point on an adjacent thread.

(DOME 4th Edition. By Virgil Morin Faires). Page. 246.

D o = outside diameter of screw/major diameter/nominal diameter, in.

D m = mean diameter of screw/ pitch diameter, in.

Di = root diameter of screw/minor diameter, in.

∝ = lead angle of threads

θ = friction angle

T R =Torque to raise the load, lb.-in.

T L = Torque to lower the load, lb.-in.

Required:

a. Force required at the rim

If: D rim = 12 in.

f c = 0.125 (coefficient of friction on the collar)

Page |4
 f = 0.125 (coefficient of friction on the thread)

Dm = 2½ (mean diameter)
c

b. Compressive Stress in screw, σ c

Bearing Stress/Pressure, σ b
Shearing Stress, τ
c. Efficiency of the Straightener, ℮
d. Size of the two bolts required to fasten the straightener.
Assuming the allowable stress is 8,000 psi.
Neglecting the tightening-up stress.

(A.) Force and Torque required at the rim

Solving for Mean Diameter, D m

From: Machine Design Manual of Engr. John Ike Uvas ;( p.65)

P
Dm=D o− Where: P = pitch
2

L (lead) = P for single threading

Solving for Pitch:

1
P=
number of threads per inch

Pitch

1
P=
4

P = 0.25

Solving for Mean Diameter, D m

P
Dm=D o−
2

Page |5
 0.25∈.
Dm=3∈.− Di
2
D m=2.875∈. Dm
P
Solving for Root Diameter Do
2
Or Inside Diameter, D i Pitch
P
D m=Di +
2
P
D i=Dm −
2
0.25∈.
D i=2.875∈.−
2
D i=2.75∈.
Solving for Friction Angle on the thread, θ
Tan θ = f
θ = tan −1 f
θ = tan −1 (0.125)
θ = 7.125°
Solving for Lead Angle on thread, α
L
Tanα =
π Dm

−1 L
α = tan
π Dm

−1 0.25∈.
α = tan ( )
π (2.875∈.)

α = 1.5855°

Where: θ > α = self-locking screw

From: Machine Design Manual of Engr. John Ike Uvas ;( p.65)

Qr=Wtan(α +θ)

Qr=6,000lb[ tan(1.5855+7.1250)]

Qr=919.25lb .

Page |6
From: Machine Design Manual of Engr. John Ike Uvas ;( p.65, 66, 67)

Solving for Torque: T

Qr Dm
T=
2

Dm
T= .Q
2

(919.25 lb .)(2.875 lb.)

T=
2

T =1321.4219lb .−¿ .

Force required at the rim, F

T =F . r

T
F=
r

Where:

Drim =12∈¿

Drim
r=
2
r= 6 in
12∈ ¿ Drim= 12 in
2
r=¿

r=6∈¿

Therefore;

Page |7
 T
F=
r

6∈¿
1321.4219 lb.−¿
F= ¿

F=220.2369lb

Torque to Lower the Load, T L

Dm
T L =W tan ⁡( θ−α )
2

2.875∈.
T L =6,000 lb.( ) tan ⁡( 7.125−1.5855)
2

T L =¿ 836.4947 lb.-in.

Torque needed to raise the Load P, T r

Dm
T R=W tan ⁡( α +θ)
2

2.875∈.
T R=6,000lb .( ) tan ⁡( 1.5855+ 7.125)
2

T R=1321.428133lb .−¿ .

Torque without Friction, T o

Dm
T o=W tanα
2

T o=6,000 lb. ( 2.875∈.

2 )
tan ( 1.5855 )

Page |8
 T o=238.7336 lb.−¿ .

Total Torque to Raise the Load, T TR (with collar friction)

Dm
T TR =W tan ( α +θ )+ W f c r c
2

Dmc
Where: r c =
2

T TR =6,000 lb . ( 2.875∈.
2 ) 1
tan (1.5855+ 7.125 )+ 6,000lb .(0.125)( )
2

T TR =1696.4281 lb.−¿ .

Total Torque to lower the load, T TL (with collar)

Dm
T TL=W tan ( θ−α ) +W f c r c
2

2.875∈. 1
T TL=6,000lb .( )tan ( 7.125−1.5855 ) +6,000 lb.(0.125)( )
2 2

T TL=1211.4947 lb.−¿ .

(B.) Compressive Stress in screw, σ c

Bearing Stress/Pressure, σ b

Shearing Stress, τ

Solving for Compressive Stress, σ c

From: Machine Design Manual of Engr. John Ike Uvas

Page |9
 P
σc =
A

Where:

π Di2
A=
4

2
π ( 2.75 )
A=
4

A= 5.9395 ¿2

Therefore:

P
σc = π D i2
4

6,000lb .
σc = π (2.75)
2

σc = 1010.1735 psi.

Solving for Bearing Stress, σ b

From p.259, Machine Design by Black and Adams

4Q
σb= 2 2
nπ (D o −Di )

Where:

Q = applied force

Page |10
 D o=¿ Outside or major diameter

n = no. of threads in engagement

n = 6 in. x 4 threads per inch

n = 24

D i=¿ Root or minor diameter

Therefore:

4(6,000 lb .)
σb=
(24)π (32−2.752 )

σ b =221.43 psi

Solving for Shearing Stress, τ

From p.259, Machine Design by Black and Adams

Q Q
τ screw= , τ nut =
nπ Di t nπ D o t

Where:

Q = applied force D o=¿ outside or major diameter

n = no. of threads in engagement Di=¿ root or minor diameter

P
n = 6 in. x 4 threads per inch t = width of thread,
2

Page |11
 0.25
n = 24 t= = 0.125
2

Therefore:

6,000 lb . 6,000lb .
τ screw= , τ nut =
(24)π (2.75)(0.125) (24) π (3)(0.125)

τ screw=231.498 psi , τ nut =212.21 psi

(C.)Efficiency of the Straightener, ℮

(Shaft straightening machines an automatic straightening line to straighten rotary

parts, such as shafts, connecting rods, and other rotary parts.)

From: Machine Design of Engr. John Ike Uvas (p.67)

torque without friction

Efficiency = x 100
torque friction

Let: T o=torque without friction

Dm
T o=W tanα
2

T R=torque friction

Page |12
 Dm
T R=W tan ⁡( α +θ)
2

Therefore:

238.7336 lb.−¿ .
Efficiency = x 100
1321.4281 lb .−¿ .

Efficiency = 18.1%

Determining the Length of the Screw, L

Since there is no type of material is given. We select a material with the yield

strength and ultimate strength that suits to the application of the power screw.

Selected Material: AISI 1045 Medium Carbon Steel

We use this materials because its black as rolled, black as forged or

normalised and bright drawn or smooth turned, offering good strength, toughness

and wear resistance .Will through harden in sections up to 63mm – with a tensile

strength of 620 – 850 MPa.

Description of materials:

CF 1045 is a medium carbon steel is used when greater strength and hardness is

desired than in the “as rolled” condition. Extreme size accuracy, straightness and

Page |13
concentricity combine to minimize wear in high speed applications. Turned, ground and

polished.

Introduction

AISI 1045 steel is a medium tensile steel supplied in the black hot rolled or

normalized condition. It has a tensile strength of 570 - 700 MPa and Brinell hardness

ranging between 170 and 210.AISI 1045 steel is characterized by good weld ability, good

machinability, and high strength and impact properties in either the normalized or hot

rolled condition. AISI 1045 steel has a low through-hardening capability with only

sections of size around 60 mm being recommended as suitable for tempering and

through-hardening. However, it can be efficiently flame or induction hardened in the

normalized or hot rolled condition to obtain surface hardness’s in the range of Rc 54 - Rc

60 based on factors such as section size, type of set up, quenching medium used etc.

Chemical Composition

AISI 1045 steel lacks suitable alloying elements and hence does not respond to the nit

riding process.

Element Content (%)

Iron, Fe 98.51 - 98.98 %
Manganese, Mn 0.60 - 0.90 %
Carbon, C 0.420 - 0.50 %
Sulfur, S ≤ 0.050 %
Phosphorous, P ≤ 0.040 %

Physical Properties

Page |14
Properties Metric Imperial
Density 7.87 g/cc 0.284 lb/in³

Mechanical Properties

Tensile strength 565 MPa 81900 psi

Yield strength 310 MPa 45000 psi
Shear modulus (typical for steel) 80 GPa 11600 ksi
Bulk modulus (typical for steel) 140 GPa 20300 ksi
Elastic modulus 200 GPa 29000 ksi
Poisson’s ratio 0.290 0.290
Elongation at break (in 50 mm) 16.0 % 16.0 %
Reduction of area 40.0 % 40.0 %

Hardness, Rockwell B (converted from Brinell hardness) 84 84

Hardness, Brinell 163 163
Hardness, Knop (converted from Brinell hardness) 184 184
Hardness, Vickers (converted from Brinell hardness) 170 170
Machining

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Stainless Steels - Specifications, Grades and Properties, Supplier Data by Aalco

Page |15
AISI 1045 steel has good machinability in normalized as well as the hot rolled condition.

Based on the recommendations given by the machine manufacturers, operations like

tapping, milling, broaching, drilling, turning and sawing etc. can be carried out on AISI

1045 steel using suitable feeds, tool type and speeds.

Welding

Certain facts about welding of AISI 1045 steel are:

AISI 1045 steel is readily welded when correct procedure is followed.

Welding AISI 1045 steel in through-hardened, tempered and flame or induction hardened

condition is not recommended.

Low hydrogen electrodes are preferred for welding AISI 1045 steel. The work piece is

pre-heated at 200°C–300°C (392°F - 572°F) maintained at the same temperature during

welding cooled slowly using sand, ashes etc. and stress relieved at 550°C - 660°C

(1022°F - 1220°F).

Heat Treatment

AISI 1045 is subjected to the following processes:

Forging

Heat to 850°C - 1250°C (1562°F - 2282°F).Hold until the temperature is uniform. Cool in

furnace

Annealing

Page |16
Heat to 800°C - 850°C (1472°F - 1562°F). Hold until the temperature is uniform. Cool in

furnace.

Normalizing

Heat to 870°C - 920°C (1598°F-1688°F). Hold until the temperature is uniform. Soak for

10 - 15 minutes .Cool in still air

Stress Relieving

Heat to 550°C - 660°C (1022°F - 1220°F). Hold until the temperature is uniform. Soak

for 1 hour per 25mm of section. Cool in still air

Hardening

Heat to 820°C - 850°C (1508°F - 1562°F). Hold until the temperature is uniform. Soak

for 10 - 15 minutes per 25mm of section. Quench in water or brine

Tempering

Re-heat to 400°C - 650°C (752°F - 1202°F) as required. Hold until the temperature is

uniform. Soak for 1 hour per 25mm of section. Cool in still air

Applications

AISI 1045 is widely used for all industrial applications requiring more wear resistance

and strength. Typical applications of AISI 1045 are as follows:

Page |17
Gears Pins Rams Bolts Ratchets Light gears

Shafts Rolls Sockets Studs Crankshafts Guide rods

Axles Spindles Worms Connecting rods Torsion bars Hydraulic

clamps

P a g e | 18
From: Machine Design Manual of Engr. John Ike Uvas (p.47)

Assume that the column is short.

Using J.B. Johnson Equation.

K Le 2
Sy( )
r
1− ]
4 π2 E
Pcr = A S y ¿

2
K Le
P cr Sy( )
=1−¿ r
A Sy 2
4π E

2
K
Sy( ) Le 2
r P cr
2
=1−
4π E A Sy

Therefore:

2
P cr 4 π E
Le2 =(1− )( 2
)
A Sy K
( )
Sy
r

Solving for Critical Load, Pcr

Pcr =P x N

Where:

P = load applied N = factor safety

P = 6,000 lb. N = 3 (for short column)

Therefore:

Pcr =6,000 lb . x 3

P a g e | 19
 Pcr =18,000 lb

For End Fixity Factor, K

Use K = 2.1 (for fixed free)

Solving for the Area of the power screw, A

2
π Dr
A=
4

π (2.75∈.)2
A=
4

A=5.9396 ¿ .2

Solving for r,

Dr
r=
4

2.75∈.
r=
4

P a g e | 20
 r=0.6875∈.

Substituting values to J.B. Johnson Equation.

45,000 psi
2.1
¿( 0.6875∈. )
¿
(¿ 2¿)
2
4 π ( 29,000,000 psi)
¿
18,000lb .
Le2 =(1− )¿
(5.9396∈.)(45,000 psi .)

Le2 =2,543.1574 ¿ .2

√ L = √2,543.1574 ¿ .
e
2 2

Le =¿ 50.4297 ¿ .

Solving for Actual Length, L

Le =K x L

Le
L=
K

Where:

Le = effective length of the column

L = actual length

K = end fixity =2.1

Therefore:

50.4297∈.
L=
2.1

L=24.0141∈.

Checking if the assumption is correct by considering,

P a g e | 21
 KL
[ ¿ < Cc
r A

Where:

KL
¿ = actual slenderness ratio
r A

C c = transition slenderness ratio

Solving for Actual Slenderness Ratio,

From: Machine Design Manual of Engr. John Ike Uvas (p.46)

KL ( 2.1 ) (24.0141∈.)
¿A =
r 1.375∈.

KL
¿ =36.67608
r A

Solving for Transitional Slenderness Ratio,

From: Machine Design Manual of Engr. John Ike Uvas (p.46)

C c=
√ 2 π2 E
Sy

C c=
√
2 π 2 (29 x 106 psi .)
45,000 psi.

C c =112.78

Since:

KL
[ ¿ < Cc
r A

Therefore:

-The column is short.

-J.B. Johnson predict the critical length of the screw.

P a g e | 22
(D.) Size of the two bolts required to fasten the straightener. The allowable stress is

8,000 psi. Neglecting the tightening-up stress.

(The purpose of the two bolt is to fasten the screw of the shaft straightener so that

when it starts on working it won’t lose tight when the pressure is applied on the

shaft)

Given:

P = 6,000 lb.

σ = 8,000 psi.

Since two bolts is required:

FBD (two bolts)

Therefore: P1=3,000 lb.

P
P2=3,000 lb.

From: Machine Design Manual of Engr. John Ike Uvas

Stress formula:

P1 P2
σ1 = , σ2 =
A1 A2

Where:

π D r2 π D r2
A1 = , A2 =
4 4

Therefore:

P a g e | 23
 P P
2 2
σ1 = π Dr , σ2 = π Dr
4 4

π Dr2 P π D r2 P
= , =
4 σ 4 σ

4P 4P
D r 2= , D r 2=
πσ πσ

Dr1=
√ 4P
πσ
, Dr2 =
√ 4P
πσ

Dr 1=
√ 4(3,000lb .)
π (8,000 psi.)
, Dr2 =
√ 4 (3,000lb .)
π (8,000 psi.)

Dr 1=0.691∈. , Dr2 =0.691∈¿

Using a bolt to fasten the straightener. (Coarse Thread)

Solving for Root Area, Ar

π D r2 π D r2
Ar 1= , Ar 2=
4 4

π (0.691∈.)2 π (0.691∈.)2
Ar 1= , Ar 2=
4 4
2 2
Ar 1=0.3750∈. , Ar 2=0.3750∈.

Choosing the Root Area, Ar

From Table 9-1. From Machine Design by Black and Adams (p.185)

Table 9-1 Unified and American Screw-Thread Sizes

Coarse Threads Fine Threads

P a g e | 24
 Size Threads per Root area, Threads per Root area,

inch. ¿ .2 inch. ¿ .2
7 9 0.4193 14 0.4805
8
1 8 0.5510 12 0.6245
1 7 0.6931 12 0.8118
1
8
1 7 0.8898 12 1.0237
1
4
3 6 1.0541 12 1.2602
1
8
1 6 1.2938 12 1.5212
1
2
3 5 1.7441
1
4

A r =0.3750∈.2 ≈ 0.4193∈.2

Therefore by Table 9-1,

7
Size of the bolt =
8

Threads per inch = 9 (single threading)

l = p (for single threading)

Solving for pitch and lead of Bolt,

1
p1 = , p2 =
number of threads per inch

1
number of threads per inch

1 1
p1 = , p2 =
9 9

p1 = 0.1111 in , p2=0.1111∈¿

P a g e | 25
Therefore:

l 1 = 0.1111in. , l 2 = 0.1111in.

Solving for Mean Diameter of the Bolt, Dm

p p
Dm1=Dr + , Dm2=Dr +
2 2

0.1111∈. 0.1111∈.
Dm1=0.0 .691∈.+ , Dm2=0.0 .691∈.+
2 2

Dm1=0.74655∈. , Dm2=0.74655∈.

Solving for Outside Diameter of Bolt, Do

p p
Do 1=Dm + , Do 2=D m +
2 2

0.1111∈. 0.1111∈.
Do 1=0.74655∈.+ , Do 2=0.74655∈.+
2 2

Do 1=0.8021∈. , Do 2=0.8021∈.

Solving for the length of Bolt, L

1 1
L1 = Do + , L2 = Do +
2 2

1 1
L1 = (0.8021∈.)+ , L2 = (0.8021∈.)+
2 2

L1 = 1.3021in. , L2 = 1.3021in.2

P a g e | 26
 Specification of the Design

Material Used: AISI 1045 steel, wrought steel

Thread per Inch, Th. in. ------------------------------------------------------------------------- 4

Th .
¿.

Pitch, P ---------------------------------------------------------------------------------------- 0.25 in.

P a g e | 27
Outside Diameter, D o ---------------------------------------------------------------------------

3 in.

Mean Diameter, D m ----------------------------------------------------------------------- 2.875

in.

Root Diameter, D r ---------------------------------------------------------------------------

2.75 in.

Coefficient of Friction on the Collar, f c ----------------------------------------------------

0.125

Coefficient of Friction on the Thread, f ---------------------------------------------------- 0.125

Mean Diameter of the Collar, Dm c

--------------------------------------------------------- 2 ½

in.

Average Angle of Friction, θ --------------------------------------------------------------- 7.125°

Lead Angle, α ------------------------------------------------------------------------------- 1.5855°

Forced required at the Rim, F ---------------------------------------------------------- 220.24 lb.

Torque, T --------------------------------------------------------------------------- 1321.43 lb. - in.

Torque to lower the Load, T l --------------------------------------------------- 836.4947 lb. -

in.

Torque needed to raise the Load, T r ---------------------------------------- 1321.42813 lb. -

in.

Torque without Friction, T o ---------------------------------------------------- 238.7336 lb. -

in.

Torque to raise the Load, T TR (with collar) ---------------------------------- 1696.4281 lb. -

in.

P a g e | 28
Torque to lower the Load, T TL (with collar) -------------------------------- 1211.4947 lb. -

in.

Compressive Stress in screw, σ c --------------------------------------------------- 1010.174

psi.

Bearing Stress/Pressure, σ b ------------------------------------------------------------ 221.43

psi.

Shearing Stress, τ screw ---------------------------------------------------------------- 231.498

psi.

Shearing Stress, τ nut -------------------------------------------------------------------- 212.21

psi.

Efficiency of the Straightener, ℮ ----------------------------------------------------------- 18.1%

Size of the Bolt -----------------------------------------------------------------------------------

7
8

Column ------------------------------------------------------------------------------------------ short

Critical Load, Pcr ------------------------------------------------------------------------- 18,000

lb.

Factor of Safety, N ---------------------------------------------------------------------------------- 3

Radius of Gyration, r ---------------------------------------------------------------------- 1.375 in.

End Fixity Factor, K ---------------------------------------------------------------------------- 2.10

Actual Length, L ------------------------------------------------------------------------ 24.0141 in.

KL
Actual Slenderness Ratio, -----------------------------------------------------------------
r

90.65

P a g e | 29
Transition Slenderness Ratio, C c -----------------------------------------------------------

112.78

BILL OF MATERIAL

FROM WILLIAM HARDWARE & ROBINSONS BUILDING

DESCRIPTION QUANTITY UNIT PRICE AMOUNT

AISI 1045

(normalized)

3 in. Ø x 24.0141 1 Php. 494.25/ft Php. 988.5

in.

Power Screw

P a g e | 30
 12 in. Ø 1 Php. 305 Php. 305

Handle

DESCRIPTION QUANTITY MACHINE AMOUNT

OPERATION AND

LABOR
AISI 1045

(normalized) 1pc. Php. 134/inch Php. 268

3inØ x 24.0141 in.

Power Screw
MACHINE OPERATION COST AND LABOR COST

BOLT PRICE

QUANTITY DESCRIPTION UNIT PRICE AMOUNT

2 1 in. x 2.7 in. Php. 255 Php. 510

Bolt and Nut

PRICE

MATERIAL COST: Php. 988.5

Hand wheel Handle Php. 305

BOLT PRICE: Php. 510

P a g e | 31
MACHINE AND LABOR COST: Php. 268

OVERALL TOTAL COST FOR POWER SCREW: Php 2,071.5

BIBLIOGRAPHY

Black, Paul H & Adams, O. Eugene Jr. “Machine Design,” 3rd Edition, Tokyo:

McGraw Hill Companies, Inc. 1968

Faires, Virgil Moring. “Design of Machine Elements,” 4th Edition, New York:

Macmillan Co, 1969

Uvas, John Ike A. “Instructional Manual in Machine Design I”

Retrieved, August 09, 2018 https://www.azom.com/article.aspx?ArticleID=6129

P a g e | 32
Retrieved, August 10, 2018 www.Engineering.com

Retrieved, August 10, 2018 www.steel-grades.com › Steel Grade › Carbon Steel

Retrieved, August 10, 2018 www.matweb.com/search/datasheettext.aspx?matguid..

Retrieved, August 10, 2018 www.efunda.com/materials/..../show_carbon.cfm

P a g e | 33