COURSE CODE : 5021
DESIGN OF MACHINE ELEMENTS
MODULE-1
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EXPECTED OUTCOMES
1.1.0 Understand the factors governing the Design of Machine elements
1.1.1 List the factors governing the design
1.1.2 Define the general procedure for design
1.1.3 Illustrate the methods of design – analytical and empirical
1.1.4 Explain design stress, working stress and factor of safety
1.2.0 Design of Bolts, Nuts and Keys using analytical and empirical methods
1.2.1 Define the important terms used in screw threads
1.2.2 List the standard dimensions of screw threads and empirical formulae
1.2.3 Explain the designation of screw threads
1.2.4 Identify the stresses due to static loading, initial stresses and stresses due to
external forces, stresses due to combined forces
1.2.5 Estimate the size of the screw from above stresses
1.2.6 Design cylinder covers
1.2.7 Simple problems related to design of cylinder covers
1.2.8 Explain the bolts of uniform strength
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EXPECTED OUTCOMES
1.2.9 Classify the various types of keys
1.2.10 Determine the proportions of sunk key
1.2.11 Calculate the strength of rectangular sunk key and square sunk key
1.2.12 Select the key size using empirical proportions, simple problems
1.3.0 Analyze the working efficiency of screw jack
1.3.1 Determine the effort, torque required and efficiency of a square threaded
screw jack with collar and without collar fiction
1.3.2 Calculate the maximum efficiency of a square threaded screw
1.3.3 Describe overhauling and self locking
1.3.4 Calculate the efficiency of self locking screw jack
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TEXT BOOKS AS PER SYLLABUS
TEXT BOOKS
1. A text book of Machine Design - R.S. Khurmi and J.K. Gupta
2. A text book of Theory of Machines - R.S. Khurmi and J.K. Gupta
3. A text book of Strength of Materials - Dr. R.K. Bansal
REFERENCE
1. A Text book of Automobile Engineering - T.R. Banger and Nathu Singh
2. Machine Design - Dr. Sadhu Singh.
3. Design of Machine elements [Link].
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INTRODUCTION
Machine is a mechanical device consisting of interrelated parts that modifies force or
motion in order to perform useful work by consuming some form of energy . The
interrelated parts are called machine elements.
Design of machine element is the process of determining the size, shape and material of
machine elements by considering the forces and motions experienced by the elements.
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TYPES OF MACHINE DESIGN
The machine design may be classified as follows :
1. Adaptive design.
•Adaptation of existing designs.
•The designer only makes minor modification in the existing designs.
•Ordinary technical training is sufficient . No special knowledge or skill needed
2. Development design.
•Modify the existing designs into a new idea by adopting a new material or different
method of manufacture.
•Starts from the existing design, but the final product may differ from the original
product.
•Needs considerable scientific training and design ability
3. New design.
• Needs lot of research, technical ability and creative thinking.
•The designs, depending upon the methods used, may be classified as follows :
(a) Rational design - Depends upon mathematical formulae of principle of mechanics.
(b) Empirical design - Depends upon empirical formulae based on past experience.
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FACTORS GOVERNING THE DESIGN
•Strength •Weight
•Cost •Control
•Reliability •Existing products
•Shape •Maintenance
•Size •Thermal consideration
•Friction •Styling
•Corrosion •Stiffness
•Service life •Wear
•Safety •Lubrication
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GENERAL PROCEDURE FOR DESIGN
•Identification of need
•Synthesis (Study of Mechanisms)
•Analysis of forces
•Material selection
•Determine the Size of components
•Modification
•Detailed drawing
•Production
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DESIGN STRESS, WORKING STRESS AND FACTOR OF SAFETY
Design Stress
It is the maximum stress to which the component is designed. That is it is the stress used in
mathematical calculation of the required size of the component.
Working Stress
It is the stress actually developed in the component under working condition.
Factor of Safety
It is the ratio of the ultimate stress to the design stress.
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IMPORTANT TERMS USED IN SCREW THREADS
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IMPORTANT TERMS USED IN SCREW THREADS cont...
Major (nominal) diameter
This is the largest diameter of a screw thread, touching the crests on an external thread or
the roots of an internal thread.
Minor (core) diameter
This is the smallest diameter of a screw thread, touching the roots or core of an external
thread (root or core diameter) thread (root or core diameter) or the crests of an internal
thread.
Pitch diameter
This is the diameter of an imaginary cylinder, passing through the threads at the points
where the thread width is equal to the space between the threads.
Pitch
It is the distance measured parallel to the axis, between corresponding points on adjacent
screw threads.
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IMPORTANT TERMS USED IN SCREW THREADS cont...
Lead
It is the distance a screw advances axially in one turn.
Flank
Flank is the straight portion of the surface, on either side of the screw thread.
Crest
It is the peak edge of a screw thread, that connects the adjacent flanks at the top.
Root
It is the bottom edge of the thread that connects the adjacent flanks at the bottom.
Thread angle
This is the angle included between the flanks of the thread, measured in an axial plane.
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FORMS OF SCREW THREADS
British Standard Whitworth (B.S.W.) thread
This type of thread has V-form and thread
angle of 55°. The crest and roots are rounded
of to avoid sharp corners which reduces
stress concentration. This type of thread is
used for general engineering purpose
British association (B.A.) thread
This type of thread has V-form and thread
angle of 47.5°. The crest and roots are rounded
of to avoid sharp corners which reduces stress
concentration. This type of thread is used for
precision work such as in electrical fittings and
instruments.
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FORMS OF SCREW THREADS cont...
American national standard thread
This thread is also known as Seller‘s thread. It
is similar to V thread and has flat crests and
roots. It has thread angle of 60°. The flat crest
can withstand more rough usage than sharp V-
threads. These threads are used for general
purposes e.g. on bolts, nuts, screws and
tapped holes.
ISO Metric thread
This thread is also known as Unified national
thread or Unified thread. It has a V form and
thread angle of 60°. It has flat crests and
curved roots. The flat crest can withstand more
rough usage. These threads are used for
general purposes.
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FORMS OF SCREW THREADS cont...
Square thread
This thread has a square form This type of
threads are used in machine tools and screw
jack etc.
Acme thread
This thread is a modification of square thread
and has thread angle of 29°. These threads are
stronger than square threads and used in
power transmission. These threads are used in
lead screw of lathe.
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FORMS OF SCREW THREADS cont...
Buttress thread
It is used for transmission of power in one
direction only. This thread units the advantage
of both square and V-threads. It has a low
frictional resistance characteristics of the
square thread and have the same strength as
that of V-thread. The spindles of bench vices
are usually provided with buttress thread..
Knuckle thread
It is a modification of square thread. It has rounded
top and bottom. These threads are used for rough
and ready work. They are usually found on railway
carriage couplings, hydrants, necks of glass bottles
and large moulded insulators used in electrical
trade.
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DESIGNATION OF SCREW THREADS
•The designation of screw thread is based on Indian standards, IS : 4218 (Part IV). The size
of the screw thread is designated by the letter `M' followed by the major diameter and
pitch in mm, the two being separated by the sign X.
M Diameter X Pitch
Example :
M 8 X 1.25
M 12 X 1.75
M 12 X 1.25
•If no pitch is mentioned, it shall mean that coarse pitch is selected.
Example :
M 12
M 12 X 1.25 indicate a fine pitch screw thread.
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DESIGNATION OF SCREW THREADS cont...
•For a complete designation, class of fit should also be mentioned. There are mainly three
classes of fits.
[Link] fit – 5H/4h
[Link] fit – 6H/6g
[Link] fit – 7H/8g
Example :
M 10 X 1.25 -4h
M 10 X 1.25 -7H
M 14 X 1.5 – 6H/6g
Etc
•If no information about class of fit is given a medium fit is assumed.
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STANDARD DIMENSIONS OF SCREW THREADS
•The standard dimensions of screw thread are based on Indian standards, IS : 4218 (Part III).
Core diameter, dc = 0.84 d
Where,
d is the major diameter.
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STRESSES IN SCREWED FASTENING DUE TO STATIC LOADING
•The following stresses in screwed fastening due to static loading are important.
1. Initial stresses due to tightening
2. Stresses due to external forces
3. Stress due to combined forces
The following stresses are developed in a screw fastener while tightening.
•Tensile stress due to stretching of bolt
•Torsional shear stress during tightening
•Bending stress
•Shear stress across the threads
•Compression or crushing stress on threads
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INITIAL STRESSES DUE TO TIGHTENING
Tensile stress due to stretching of bolt
The initial tensile force in a bolt due to tightening is calculated by following relation. This
relation is developed based on experiments.
Pi = 2840d N
Where,
Pi = Initial tension in a bolt , in N
d = Nominal diameter of bolt, in mm.
Tensile stress developed,
Where,
Core diameter, dc = 0.84 d
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INITIAL STRESSES DUE TO TIGHTENING cont...
Torsional shear stress during tightening
The torsional shear stress is developed due to the frictional resistance between the threads
of screw and nut during tightening.
The torsional shear stress is calculated using the torsion equation.
Torsional shear stress,
Where,
T = Torque applied
dc = Minor or core diameter of the thread.
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INITIAL STRESSES DUE TO TIGHTENING cont...
Bending stress
If the surfaces under the head or nut are not perfectly perpendicular to the bolt axis, then
the bolt will be subjected to bending action. The bending stress (σb) induced in the shank
of the bolt is given by
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INITIAL STRESSES DUE TO TIGHTENING cont...
Shear stress across the threads
The threads tend to shear off about its roots .
The average thread shearing stress for the bolt is
The average thread shearing stress for the nut is
Where,
P = applied load
dc = Minor or core diameter of the thread.
d = Nominal diameter of nut.
b = Width of the thread section at the root.
n = number of threads in engagement.
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INITIAL STRESSES DUE TO TIGHTENING cont...
Compression or crushing stress on threads
The compression or crushing stress between the threads (σc) is obtained by using the
relation
Where,
P = applied load
dc = Minor or core diameter of the thread.
d = Nominal diameter of nut.
n = number of threads in engagement.
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STRESSES IN SCREWED FASTENING DUE TO EXTERNAL LOADING
•The following stresses in screwed fastening due to static loading are important.
1. Tensile stresses
2. Shear Stresses
3. Combined tensile and shear stress
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STRESSES DUE TO EXTERNAL LOADING cont...
Tensile stress due to external load
The tensile stress due to external load in bolt is,
If ‘n’ number of bolts are resisting the applied load then the tensile stress developed in
each bolt is,
Where,
P = applied external load
Core diameter, dc = 0.84 d
d = Nominal diameter of bolt
Design of bolt based on material tensile allowable
If P is the applied load, ta is the allowable material tensile stress and n is the number of
bolts resisting the applied load, then the size of the bolt is calculated as
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STRESSES DUE TO EXTERNAL LOADING cont...
Shear stress due to external load
The shear stress due to external load in bolt is,
If ‘n’ number of bolts are resisting the applied load then the tensile stress developed in
each bolt is,
Where,
P = applied external load
d = Nominal diameter of bolt
Design of bolt based on material tensile allowable
If P is the applied load, sa is the allowable material tensile stress and n is the number of
bolts resisting the applied load, then the size of the bolt is calculated as
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STRESSES DUE TO EXTERNAL LOADING cont...
Combined tension and shear stress
When the bolt is subjected to both tension and shear loads, then the diameter of the shank
of the bolt is obtained from the shear load and that of threaded part from the tensile load.
Out of these the largest diameter is considered and stresses due to combined load should
be checked for the following principal stresses.
Maximum principal shear stress,
Maximum principal tensile stress,
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PROBLEMS
M1.P1) Two machine components are connected together tightly by a M24 bolt. Calculate
the tensile stress induces in the bolt due to initial tightening.
Nominal diameter of the bolt, d = 24mm
Initial load, Pi = 2840d N = 2840 x 24 = 68160 N
Core diameter of the bolt, dc = 0.84d = 0.84 x 24 = 20.16 mm
Tensile stress developed, where,
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PROBLEMS cont…
M1.P2) A machine weighing 9kN has to be provided with an eye bolt for lifting purpose.
Find the diameter of the bolt if the permissible stress on the bolt is 20N/mm2.
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PROBLEMS cont…
M1.P3) A machine weighing 25kN has to be provided with an steel eye bolt for lifting
purpose. Find the diameter of the bolt if the ultimate tensile strength of steel is 480N/mm2.
Consider a factor of safety of 6 in the design. (2018 OCTOBER 7 Marks)
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PROBLEMS cont…
M1.P4) Two screws for a pipe hanger must hold a tensile load of 10kN. Calculate the most
suitable size of screw. Take the working stress in tension is 45MPa. (2019 APRIL 6 Marks)
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PROBLEMS cont…
M1.P5) A generator weighing 20kN is to be provided with an eye bolt in the housing for
lifting purposes. Find the size of bolts if it is made of C- 40 steel. If the ultimate tensile
strength of C- 40 steel is 600 MPa and the factor of safety is 6 ? (2018 APRIL 6 Marks)
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PROBLEMS cont…
M1.P5) Answer
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PROBLEMS cont…
M1.P6) An eye bolt carries a tensile load of 18kN. Find the size of the bolt, if the tensile
stress is not to exceed 100 MPa.? (2018 APRIL 7 Marks)
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PROBLEMS cont…
M1.P6) Answer
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PROBLEMS cont…
M1.P7) Two shafts are connected by means of a flange coupling to transmit torque of
210 N-m. The flange of the coupling are fastened by four bolts of the same material at a
radius of 50 mm. Find the size of the bolts, if the allowable shear stress for the bolt
material is 40 MPa. (2018 APRIL 7 marks)
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PROBLEMS cont…
M1.P7)
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DESIGN OF CYLINDER COVER BOLTS
The cylinder covers may be secured by means of bolts or studs.
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DESIGN OF CYLINDER COVER BOLTS cont...
DESIGN OF CYLINDER COVER BOLTS cont...
The bolts or studs, cylinder cover plate and cylinder flange may be designed as discussed
below:
Pitch circle diameter, Dp = D + 2t + 3d1
Outside diameter of the cover, Do = Dp + 3d1 = D + 2t + 6d1
Where, Where,
D = Diameter of the cylinder n = number of bolts
d1 = Diameter of the hole for bolt or stud
t = Thickness of the cylinder wall 42
DESIGN OF CYLINDER COVER BOLTS cont...
Assumptions for design of cylinder cover bolt
•Initial stresses in bolts due to tightening are neglected.
•The effect of gasket is neglected
•Total load due to the pressure inside the cylinder is equally shared by the bolts.
•There is no stress concentration on the threads.
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DESIGN OF CYLINDER COVER BOLTS cont...
Design of bolts or studs
Let,
D = Diameter of the cylinder
p = Pressure in the cylinder
dc = Core diameter of the bolts or studs
n = Number of bolts or studs
σtb = Permissible tensile stress for the bolt or stud material
Then,
Upward force acting on the cylinder cover,
This force is resisted by n number of bolts or studs provided on the cover
From the above two equations
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DESIGN OF CYLINDER COVER BOLTS cont...
•From the above equation, the number of bolts or studs may be obtained, if the size of the
bolt or stud is known and vice-versa.
•If the value of n as obtained from the above relation is odd or a fraction, then next higher
even number is adopted.
•A bolt or a stud less than 16mm diameter should never be used.
•The circular pitch should be between and
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PROBLEMS cont…
M1.P8) The effective diameter of a cylinder is 0.5m and the highest pressure of steam
acting on the cylinder head is 1.2MPa. Allowable stress in tension of bolt material is 35MPa.
If the cylinder head is held by 10 bolts, find the size of the bolts. (2018 APRIL 8 Marks)
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PROBLEMS cont…
M1.P9) A cylinder cover of a steam engine is secured by 12 studs. The cylinder is 0.3m
diameter and has a steam pressure of 1.2 N/mm2gauge. Calculate the diameter of the
studs, assuming the permissible stress to be 30 N/mm2. (2017 OCTOBER 8 Marks)
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PROBLEMS cont…
M1.P9) Answer
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PROBLEMS cont…
M1.P10) In a steam engine the maximum steam pressure is 1 N/mm2 absolute and back
pressure is 0.015 N/mm2 absolute. The cylinder diameter is 300 mm. Determine the
diameter of the screwed end of the piston rod, when the allowable stress is 45 N/mm2 in
tension. (2018 OCTOBER 8 marks)
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PROBLEMS cont…
M1.P10) Answer
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PROBLEMS cont…
M1.P11) A steam engine cylinder has an effective diameter of 340mm and the maximum
steam pressure acting on the cylinder cover is 1.25 N/mm2. Calculate the number and size
of studs required to fix the cylinder cover, assuming the permissible stress in the studs as
30Mpa. (2019 OCTOBER 8 marks)
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M1.P11)
52
M1.P11cont.)
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M1.P11 cont.)
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M1.P11 cont.)
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M1.P11 cont.)
56
BOLTS OF UNIFORM STRENGTH
•In an ordinary bolt, the stress in the threaded part of the bolt will be higher than that in
the shank since the core diameter is less than the shank diameter. Hence the threaded
portion may fracture because of its small length.
•If the shank of the bolt is turned down to a diameter equal or even slightly less than the
core diameter of the thread (dc), then shank of the bolt will undergo a higher stress.
•The bolt, in this way, becomes stronger and lighter and known as bolts of uniform strength.
•An alternative method of obtaining the bolts of uniform strength is, an axial hole is drilled
through the head as far as the thread portion such that the area of the shank becomes
equal to the root area of the thread.
Let,
dh = Diameter of the hole
Ordinary bolt
d = Major diameter of the thread
dc = Root or core diameter of the thread
Reduced Shank Bolt with axial hole
57
STRESSED DUE TO COMBINED INITIAL AND EXTERNAL LOAD
•The resultant load due to initial load and external load is given by
P = P1 + kP2
Where,
P1 = Initial load
P2 = External load
k = stiffness constant,
Kb = stiffness of bolt
Kp = stiffness of connected parts
•For gasketed joints with soft material the value of k =1
•For metal to metal contact joints the value of k = 0
•For all other types of joints the value of k is between 0 and 1
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KEYS
•A key is a machine element inserted between the shaft and pulley or shaft and gear to
connect these together in order to prevent relative motion between them.
•Keys are used as temporary fastenings and are subjected to considerable crushing and
shearing stresses.
•A keyway is a slot or recess in a shaft and hub of the pulley to accommodate a key.
•The following types of keys are important
1. Sunk keys
2. Saddle keys
3. Tangent keys
4. Round keys
5. Splines
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SUNK KEYS
•The sunk keys requires keyway in the shaft and in the hub. The sunk keys are of the
following types:
[Link] sunk key
The usual proportions of this key are :
Width of key, w = d / 4
thickness of key, t = 2w / 3 = d / 6
Where,
d = Diameter of the shaft or diameter of the hole in the hub.
[Link] sunk key
The only difference between a rectangular sunk key and a square sunk key is that its width
and thickness are equal, i.e.
w= t= d / 4
[Link]-head key
It is a rectangular sunk key with a head at one end known
as gib head. It is usually provided to facilitate the removal
of key.
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SUNK KEYS cont...
[Link] key
A key attached to one member of the
connected torque transmitting members and
which permits relative axial movement is known
as feather key. It is a special type of parallel key
which transmits a turning moment and also
permits axial movement. It is fastened either to
the shaft or hub.
[Link] key
It is a semi circular disc having similar keyway. A
woodruff key is capable of tilting in the keyway
so can be easily adjusted. This key is largely used
in machine tool and automobile construction.
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SADDLE KEYS
•The saddle keys are of the following two types :
1. Flat saddle key
2. Hollow saddle key
A flat saddle key is a key which needs a keyway in the hub and is flat on the shaft. It is likely
to slip round the shaft under load. Therefore it is used for comparatively light loads.
A hollow saddle key’s face which touches shaft is shaped to fit the curved surface of the
shaft. Since hollow saddle keys hold on by friction, these are suitable for light loads.
Flat saddle key Hollow saddle key
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TANGENT KEYS
The tangent keys are fitted in pair at an angle. Each key is to withstand torsion in one
direction only. These are used in heavy duty shafts.
63
ROUND KEYS
The round keys, are circular in section and fit into holes drilled partly in the shaft and partly
in the hub. They have the advantage that their keyways may be drilled and reamed after the
mating parts have been assembled. Round keys are usually considered to be most
appropriate for low power drives.
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SPLINES
Sometimes, keys are made integral with the shaft. Such shafts are known as splined shafts.
These shafts usually have four, six, ten or sixteen splines. The splined shafts are relatively
stronger than shafts having a single keyway. The splined shafts are used when the force to
be transmitted is large in proportion to the size of the shaft as in automobile transmission
and sliding gear transmissions.
65
STRENGTH OF RECTANGULAR SUNK KEY AND SQUARE SUNK KEY
Let
T = Torque transmitted by the shaft
F = Tangential force acting at the circumference of the shaft
d = Diameter of shaft
l = Length of key
w = Width of key
t = Thickness of key
τ = Shear stresses for the material of key
σc = crushing stresses for the material of key
t
l
w
66
STRENGTH OF RECTANGULAR SUNK KEY AND SQUARE SUNK KEY
Due to the power transmitted by the shaft, the key may fail due to shearing or crushing.
Considering shearing of the key, the tangential shearing force acting at the circumference of
the shaft,
F = Area resisting shearing × Shear stress = l × w × τ
∴ Torque transmitted by the shaft,
Considering crushing of the key, the tangential crushing force acting at the circumference
of the shaft,
∴ Torque transmitted by the shaft,
67
STRENGTH OF RECTANGULAR SUNK KEY AND SQUARE SUNK KEY
The key is equally strong in shearing and crushing, if
The permissible crushing stress for the key material should be atleast twice the permissible
shearing stress for equal width and thickness.
68
STRENGTH OF RECTANGULAR SUNK KEY AND SQUARE SUNK KEY
In order to find the length of the key to transmit full power of the shaft, the shearing
strength of the key is equal to the torsional shear strength of the shaft.
Shearing strength of key,
Torsional shear strength of the shaft,
Equating these two equations
By taking w = d/4
If the key material is same as that of the shaft,
Length of key,
69
STANDARD DIMENSIONS OF RECTANGULAR AND SQUARE SUNK KEY
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PROBLEMS cont…
M1.P12) A 40 mm diameter shaft is subjected to a tangential force of 20kN around it's
circumference. Determine the size of key. The allowable shear stress in key is 60 N/mm2.
(2018 OCTOBER 7 marks)
71
PROBLEMS cont…
M1.P12)
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PROBLEMS cont…
M1.P13) A steel shaft has a diameter, of 25 mm. The shaft rotates at a speed of 600 rpm
and transmits 7 kW through a gear. Design a suitable key for the gear. The allowable shear
and crushing stress for the material of the key can be taken as 60MPa and 120MPa
respectively. Assume the same material for both shaft and key. (2019 OCTOBER 8 marks)
73
PROBLEMS cont…
M1.P13)
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PROBLEMS cont…
M1.P13 cont.)
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PROBLEMS cont…
M1.P14) A rectangular sunk key of 75 mm long , 14mm wide and 10 mm thick has to
transmit 1200 N-m torque from a 50mm diameter solid shaft. Determine if the designed
length is sufficient to transmit the torque if the allowable shear strength and crushing
strength of the key material are 80Mpa and 180Mpa respectively.
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PROBLEMS cont…
M1.P14)
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PROBLEMS cont…
M1.P15) A shaft of 50mm diameter is transmitting 150 kW at 3000 rpm. If a key of length
75mm, width 16mm and thickness 10mm is used, calculate induced shear stress and
crushing stress in the key.
78
PROBLEMS cont…
M1.P15)
79
POWER SCREWS
•The power screws are used to convert rotary motion into translatory motion. Power
screws are used in lathes, screw jacks, vices, testing machines, presses etc.
•In power screws, the relative motion between screw and nut can be following types.
[Link] nut moves axially against the resisting axial force while the screw rotates in
its bearings.
[Link] screw rotates and moves axially against the resisting force while the nut is
stationary.
[Link] nut rotates while the screw moves axially with no rotation.
•Following are the three types of screw threads mostly used for power screws
[Link] thread
[Link] thread
[Link] thread
80
SCREW JACK
•Screw jack is a device used wherever there is a need to lift or hold heavy loads.
•Screw jack convert rotational motion into linear motion.
•A screw jack consists of a vertical screw with a table mounted on its top, which screws
into a threaded hole (act as nut) in a stationary support frame.
•It works on the principle same as that of incline plane.
•It utilizes the property of a screw thread providing a mechanical advantage i.e. it can
be used to amplify force.
81
SCREW JACK cont…
Effort required to raise the load
If T is the torque required to raise the load then,
T= P xL
P x L = Ps x dm/2
Where,
P = Effort applied at the end of the handle
L = length of handle
Ps = imaginary force acting at mean
circumference of the screw.
dm = Mean diameter of the screw
dm = (d+dc)/2
dm = dc+0.5p
dm = d-0.5p
d = Nominal diameter of the screw
dc = Core diameter of the screw
p = Pitch of the screw
Ps
82
SCREW JACK cont…
Development of a screw thread
α = Helix angle
tan α = n p / π dm
Where,
p = Pitch of the screw
n = number of starts
For single start thread, n = 1
For double start thread, n = 2 etc..
83
SCREW JACK- TORQUE REQUIRED TO RAISE LOAD
•Screw jack works on the principle same as that of incline plane.
W = Load to be lifted
Ps = Effort applied at the circumference of the screw
PF = Frictional load
α = Helix angle
μ = Coefficient of friction between the screw and nut
μ = tan φ, where φ is the friction angle
Effort to be applied at circumference of the screw to lift the load, Ps = W tan(φ + α)
Torque to be applied at circumference of the screw to lift the load, T = Ps dm /2
T = W tan(φ + α) dm /2
84
SCREW JACK- TORQUE REQUIRED TO LOWER LOAD
W = Load to be lifted
Ps = Effort applied at the circumference of the screw
PF = Frictional load
α = Helix angle
μ = Coefficient of friction between the screw and nut
μ = tan φ, where φ is the friction angle
Effort to be applied at circumference of the screw to lower the load, Ps = W tan(φ - α)
Torque to be applied at circumference of the screw to lower the load, T = Ps dm /2
T = W tan(φ - α) dm /2
85
SCREW JACK- TORQUE REQUIRED CONSIDERING COLLAR FRICTION
To prevent the rotation of the load a collar is provided at the top of the screw head. Collar
friction takes place at the contact surface between screw head and collar.
Let,
μ c= Coefficient of friction between the screw head and collar
R1 = Internal radius of bearing surface of collar in mm
R2 = External radius of bearing surface of collar in mm
Mean radius considering uniform wear,
Mean radius considering uniform pressure,
Collar friction torque, Tc = μ c WR
Torque to be applied at circumference of the screw to lift the load considering collar friction
T = Ps dm /2 + Tc
T = W tan(φ + α)(dm /2) + μ c WR
Torque to be applied at circumference of the screw to lower the load considering collar
friction
T = Ps dm /2 + Tc
T = W tan(φ - α) (dm /2) + μ c WR
86
SCREW JACK- EFFICIENCY
The efficiency of screw jack is defined as the ratio between the ideal effort (i.e. the effort
required to move the load, neglecting friction) to the actual effort (i.e. the effort required to
move the load taking friction into account).
Actual effort, P = W tan(φ + α)
Where,
α = Helix angle, φ = friction angle
Ideal effort is the effort required to move the load, neglecting friction.
Ideal effort, Po = W tan α
The efficiency of a screw jack is independent of the load raised.
87
SCREW JACK- EFFICIENCY CONSIDERING COLLAR FRICTION
Considering collar friction,
Actual torque, T = P dm /2 + μ c WR
Ideal torque, To = Po dm /2
Where,
P = Actual effort, Po = Ideal effort, dm = Mean diameter of the screw
μ c= Coefficient of friction between the screw head and collar
R = Mean radius
88
SCREW JACK- MAXIMUM EFFICIENCY
The efficiency of screw jack is given as
Multiplying the numerator and denominator by 2,
The efficiency given by the above equation will be maximum when sin (2α + φ) is maximum,
i.e. when
sin (2α + φ) = 1
Means, 2α + φ = 90°
∴ 2α = 90° – φ
α = 45° – φ / 2
Maximum efficiency of screw jack,
89
SCREW JACK- OVER HAULING AND SELF LOCKING
The effort to be applied at circumference of the screw to lower the load, Ps = W tan(φ - α)
The torque to be applied at circumference of screw to lower the load, T = W tan(φ - α) dm /2
Where,
W = Load to be lifted, dm = Mean diameter of the screw
α = Helix angle, φ = friction angle
In the above expression, if φ < α, then torque required to lower the load will be negative. In
other words, the load will start moving downward without the application of any torque. Such
a condition is known as over hauling of screws.
If however, φ > α, the torque required to lower the load will be positive, indicating that an
effort is applied to lower the load. Such a screw is known as self locking screw. In other words,
a screw will be self locking if the friction angle is greater than helix angle.
The efficiency of a self locking screw is less than 50%.
If the efficiency of a screw jack is 50% the screw is at the point of reversal.
If the efficiency is more than 50% the screw jack is overhauling.
90
PROBLEMS cont…
M1.P16) A screw jack having square threads of 50 mm mean diameter and 12.5 mm pitch is
operated by a 500 mm long hand lever Coefficient of friction at the thread is 0.1.
[Link] the Efficiency of screw jack.
[Link] Whether it is self locking or overhauling
[Link] the force needed to be applied at the end of the lever to lift the load
of 20kN. (2017 OCTOBER 8 marks)
91
PROBLEMS cont…
M1.P16)
92
PROBLEMS cont…
M1.P16 Cont.)
93
PROBLEMS cont…
M1.P17) Find the force to be applied at the end of one meter long handle of a screw jack so
that a load of 7 kN is lifted with constant velocity. The screw is square threaded having a
pitch of 16mm and root diameter 50mm. The coefficient of friction between the screw and
nut is 0.16. (2018 APRIL 8 marks)
94
PROBLEMS cont…
M1.P17)
95
PROBLEMS cont…
M1.P18) A load of 2500 N is to be raised by a screw jack with a screw of 75 mm mean
diameter and pitch of 12 mm. Find the efficiency of the screw jack, if the coefficient of
friction of screw and nut is 0.075. (2018 OCTOBER 8 marks)
96
PROBLEMS cont…
M1.P18)
97
PROBLEMS cont…
M1.P19) A load of 10000 N is to be raised by a screw jack with a square threaded double
start screw of 75mm mean diameter and pitch of 10 mm. Find the efficiency of the screw
jack, if the coefficient of friction of screw and nut is 0.1.
98
PROBLEMS cont…
M1.P19)
99
PROBLEMS cont…
M1.P20) A turn buckle is used to tighten a wire rope. The threads are single right and left
hand and square in section. The outside diameter of the screw is 40 mm and the pitch is 8.5
mm. The coefficient of friction between the screws and nuts is 0.15. What torque on the
turn buckle is necessary, if the rope is to be tightened to a tension of 8 kN ?
(2018 APRIL 9 marks)
100
PROBLEMS cont…
M1.P20)
101
PROBLEMS cont…
M1.P21) An electric motor driven power screw moves a nut in a horizontal plane against a
force of 75kN at a speed of 300mm/min. The screw has a single square thread of 6mm pitch
on a major diameter of 40 mm. The coefficient of friction at screw threads is 0.1. Estimate
power of the motor. (2019 OCTOBER 7 marks)
102
PROBLEMS cont…
M1.P21)
103
PROBLEMS cont…
M1.P21 cont.)
104
PROBLEMS cont…
M1.P22) A screw jack having square threaded screw of pitch of 16mm and nominal
diameter 50mm. The coefficient of friction between the screw and nut is 0.16 and screw
and collar is 0.18. The outside and inside diameter of collar is 80 mm and 50 mm
respectively. Find the force to be applied at the end of one meter long handle of a screw
jack so that a load of 7 kN is lifted with constant velocity considering
I. Uniform wear at collar
II. Uniform pressure at collar
105
PROBLEMS cont…
M1.P22)
106
PROBLEMS cont…
M1.P22 cont.)
107
PROBLEMS cont…
M1.P22 cont.)
108