Chapter 7: Power Screws – Basics
7.1 Introduction
Power screws are essential machine elements designed to transmit power and motion through
the conversion of rotary motion into linear motion. They are widely used in lifting devices,
presses, vises, and other machinery where large forces must be applied with relatively low input
power. The principle of operation of a power screw lies in the geometry of its threads, which
form an inclined plane wrapped around a cylinder. When a screw rotates, the nut moves
linearly, and vice versa, depending on the constraints of the system.
The efficiency and reliability of a power screw depend on its thread form, material properties,
lubrication, and load conditions. Unlike ordinary fastening screws, power screws are designed to
sustain repeated load cycles, transmit significant torque, and provide self-locking characteristics
in many applications.
Diagram 7.1: Square vs ACME thread profiles (square thread has straight flanks, ACME has
trapezoidal flanks with 29° included angle).
7.2 Function of Power Screws
The primary function of power screws is to convert rotary motion into linear motion while
transmitting power. They serve in applications where mechanical advantage is needed to lift
heavy loads or apply clamping forces. Common functions include:
1. Lifting: Power screws in jacks raise automobiles or heavy machinery with moderate
human or motor input.
2. Clamping: In vises and presses, power screws apply controlled compressive forces.
3. Positioning: Lead screws in lathes and CNC machines move the cutting tool accurately.
4. Force multiplication: They enable small input forces to generate very large output loads
by increasing mechanical advantage.
Another key function is self-locking, where the screw remains stationary under load without
back-driving. This property is critical in jacks and presses for safety.
7.3 Types of Threads Used in Power Screws
The thread profile plays a vital role in determining the efficiency, strength, and wear resistance
of power screws. The most common types are:
Square Threads
• Have flat flanks perpendicular to the axis.
• Offer high efficiency due to minimum friction.
• Difficult and expensive to manufacture.
• Weaker than trapezoidal threads due to sharp corners.
ACME Threads
• Have a trapezoidal shape with 29° included angle.
• Easier to manufacture compared to square threads.
• Stronger cross-section due to thicker flanks.
• Slightly less efficient than square threads due to wedge angle.
• Common in jacks, vises, and machine tools.
Trapezoidal Threads
• Standardized thread form (e.g., ISO metric trapezoidal threads).
• Similar to ACME but with 30° angle.
• Easy to machine and widely available.
• Provide good balance of strength and efficiency.
7.4 Materials of Power Screws
Power screws are subjected to heavy loads, wear, and friction. Thus, material selection is
critical:
1. Carbon steels (C35, C45, EN8): Commonly used for general applications. Provide good
strength and wear resistance.
2. Alloy steels (EN19, EN24): Used in heavy-duty applications such as lifting jacks and
presses.
3. Phosphor bronze: Often used for nuts due to low friction and wear resistance against
steel screws.
4. Cast iron: Economical, but weaker; used in light-duty machinery.
5. Composites/plastics: Used in CNC lead screws where light loads and corrosion
resistance are priorities.
Lubrication is essential in all cases to reduce wear and increase efficiency.
7.5 Applications of Power Screws
Power screws are versatile and find applications across industries:
• Jacks: Car jacks, screw jacks, and lifting mechanisms rely on power screws to raise loads.
• Presses: Used in screw presses for metal forming and printing.
• Machine tools: Lead screws in lathes and milling machines move carriages and slides.
• Clamping devices: Bench vices, C-clamps, and other holding fixtures.
• Valves and actuators: Gate valves use screw mechanisms for precise linear motion.
• Heavy lifting equipment: Marine winches, elevators, and cranes.
These applications demonstrate the versatility and importance of power screws in engineering
practice.
7.6 Design Considerations
Several factors must be addressed when designing power screws:
1. Load capacity – depends on core area of screw and material strength.
2. Efficiency – affected by thread angle, coefficient of friction, and lubrication.
3. Self-locking condition – screw must not rotate under axial load if back-driving is
undesirable.
4. Buckling resistance – long screws must resist column buckling under compressive load.
5. Wear life – thread material pairing (steel screw with bronze nut) improves durability.
6. Thermal effects – continuous operation generates heat from friction, influencing
lubrication and wear.
7.7 Diagram
Diagram 7.1: Square vs ACME thread profiles
• Left: Square thread with perpendicular flanks, flat top and bottom.
• Right: ACME thread with trapezoidal cross-section, flank angle 29°.
7.8 Solved Questions
Q1. Define power screw.
A power screw is a mechanical device that converts rotary motion into linear motion and
transmits power using a threaded screw and nut. Unlike ordinary fastening screws, power
screws are designed for load transmission in applications such as jacks, presses, vises, and
machine tools.
Q2. Sketch square and ACME threads.
Diagram 7.1 shows:
• Square thread: perpendicular flanks, flat crest/root.
• ACME thread: trapezoidal profile with 29° included angle.
Q3. Why is ACME preferred over square?
Although square threads are more efficient due to minimal radial forces, ACME threads are
easier to machine, stronger, and more durable. Their trapezoidal profile distributes stresses
more evenly, reducing thread shear failures. ACME threads also allow
engagement/disengagement of split nuts, making them suitable for machine tools like lathes.
Q4. List 3 applications of power screws.
1. Car jacks for lifting vehicles.
2. Lead screws in lathes for carriage movement.
3. Screw presses used in metal forming.
Q5. Identify failure modes in power screws.
• Thread shear due to overload.
• Buckling under axial compression in long screws.
• Fatigue failure under cyclic loading.
• Wear of threads due to inadequate lubrication.
• Seizure when friction and heat damage occur.
Chapter 8: Power Screws – Torque & Efficiency
8.1 Introduction
Power screws are extensively used in engineering applications where large axial forces need to
be transmitted with mechanical advantage. In the previous chapter, we studied the basics of
power screws, their thread forms, materials, and applications. In this chapter, the focus shifts to
torque and efficiency analysis. Specifically, we analyze the torque required to raise and lower a
load, conditions for self-locking, the efficiency of screw threads, and the influence of friction
angle and helix angle.
Power screws operate by converting rotary motion into linear motion. When a screw rotates,
the nut moves along its axis depending on the helix formed by the screw threads. This is
analogous to an inclined plane wrapped around a cylinder. To raise a load, torque must be
applied to overcome both the axial load and the friction between the contacting surfaces.
Conversely, when lowering a load, torque is required to resist the load’s tendency to rotate the
screw backward. Understanding these mechanics is essential for designing safe and efficient
screw jacks, presses, and clamping devices.
Diagram 8.1: Forces on power screw thread
• Shows load W, helix angle λ, normal reaction, and frictional force acting on the screw
flank.
Chapter 9: Roller Chains – Basics
9.1 Introduction
Roller chains are widely used mechanical components for transmitting power between two
rotating shafts. They belong to the family of positive drives, meaning that power transmission is
achieved through direct mechanical engagement rather than friction. Unlike belt drives, which
depend on surface friction, chains engage with sprocket teeth, ensuring no slip occurs. This
makes roller chains especially suitable where precise velocity ratios and high torque are
required.
A roller chain is made up of a series of connected links, each containing rollers that engage with
the sprocket teeth. The design allows for reduced wear, lower noise, and higher load-carrying
capacity compared to earlier chain types. The roller mechanism reduces sliding friction between
the chain and sprocket into rolling friction, greatly improving durability.
Diagram 9.1: Roller chain with labeled parts
• Labels: inner link, outer link, roller, pin, bush.
9.2 Construction and Characteristics
The construction of a roller chain consists of alternating inner and outer links. The inner link
includes bushings and rollers, while the outer link includes pins that connect the inner links
together. When assembled, the rollers rotate freely around the bushings, allowing smooth
engagement with sprocket teeth.
Key characteristics of roller chains:
1. Positive drive – no slip between chain and sprocket.
2. High efficiency – typically above 95%.
3. Capability to transmit large torques at relatively small dimensions.
4. Durability – chains are resistant to wear if properly lubricated.
5. Compactness – compared to belt drives of similar power.
6. Flexibility in speed ratios – by adjusting sprocket sizes.
However, chains also have limitations: they produce more noise than belts, require lubrication,
and are less suitable for very high speeds.
9.3 Types of Chains
Roller Chains
The most common type used in power transmission. Each link has a roller that engages with
sprocket teeth. Advantages include low wear, low friction, and ability to transmit high loads.
Silent Chains (Inverted-tooth Chains)
These chains use interlocking teeth instead of rollers. Engagement is smoother, reducing
vibration and noise. They are often used in automotive timing drives.
Diagram 9.2: Chain drive system
• Shows roller chain meshing with two sprockets, driver and driven.
9.4 Terminology of Roller Chains
To properly understand chain drives, several terms are important:
• Pitch (p): The distance between centers of two consecutive pins. This determines
sprocket size and chain strength.
• Roller diameter (d): Diameter of rollers engaging with sprocket teeth.
• Pitch line: Line connecting centers of all rollers when chain is straight.
• Link: A single section of the chain, consisting of inner and outer link assemblies.
• Sprocket: A toothed wheel that engages with the chain rollers.
• Number of teeth (z): Determines velocity ratio between driver and driven sprockets.
9.5 Chain Selection
Selecting the proper chain involves considering:
1. Power to be transmitted (kW).
2. Speed of driver sprocket (rpm).
3. Service conditions – load type, shock, lubrication.
4. Number of teeth in sprockets – standard recommendations: driver sprocket ≥ 17 teeth
to reduce wear.
5. Pitch length of chain – determined from empirical formulas and power ratings.
6. Center distance between shafts.
Proper selection ensures long service life, safety, and efficiency.
9.6 Advantages of Chain Drives
• No slip (positive drive).
• Compact design.
• Can transmit more power than belts for same size.
• Long life if maintained properly.
• Can operate in harsh environments with proper lubrication.
Disadvantages:
• Heavier and noisier than belts.
• More expensive.
• Requires lubrication and maintenance.
9.7 Applications of Roller Chains
• Bicycles and motorcycles: Transmission between pedal/crank or engine and wheels.
• Automobiles: Timing chains for camshaft drives.
• Industrial machines: Conveyors, hoists, elevators, and packaging machinery.
• Agricultural equipment: Harvesters, tractors, and seed drills.
• Marine applications: Anchor handling and lifting systems.
9.8 Solved Questions
Q1. Define roller chain with diagram.
A roller chain is a series of interconnected links with rollers that engage with sprocket teeth to
transmit power without slip. Unlike belts, roller chains are positive drives.
Diagram 9.1: Roller chain with labeled parts – rollers, pins, bushes, inner and outer plates.
Q2. List main components of roller chain.
1. Roller: Provides rolling contact with sprocket teeth.
2. Bush: Houses the roller and allows free rolling.
3. Pin: Connects inner and outer links.
4. Inner plate: Part of inner link assembly.
5. Outer plate: Part of outer link assembly.
Q3. Differentiate roller vs silent chain.
Feature Roller Chain Silent Chain
Contact type Rolling Sliding/meshing teeth
Noise Moderate Lower
Efficiency High (>95%) High but slightly lower
Applications Bicycles, motorcycles, conveyors Automotive timing drives
Chapter 10: Roller Chains – Design & Length
10.1 Introduction
Roller chains are widely used in mechanical systems where precise velocity ratios and positive
transmission of power are required. The performance and longevity of a chain drive depend not
only on the chain type and material but also on correct design, length determination,
lubrication, and maintenance. Unlike belt drives, where slip and creep are unavoidable, chains
ensure positive engagement with sprocket teeth. However, improper chain length or poor
maintenance can result in premature wear, high noise, and reduced efficiency.
This chapter discusses methods of calculating chain length, procedures for fitting and adjusting
chains, lubrication requirements, and inspection techniques to ensure reliable operation.
Diagram 10.1: Chain length calculation geometry
• Shows two sprockets with center distance CCC, number of teeth N1N_1N1 and
N2N_2N2, and pitch ppp.
10.2 Chain Length Calculation
The length of a roller chain depends on the number of teeth on the driver and driven sprockets,
the pitch of the chain, and the center distance between sprockets. The chain length is measured
in pitches and must be an even number so that the chain ends can be joined using connecting
links.
The general formula for chain length in pitches: