Design and Fabrication of Power Scissor Jack

Introduction

Jack : Jack is a mechanical device used to lift heavy loads or apply great forces.
A mechanical jack employ a square thread for lifting heavy equipment.

The most common form is a car jack, floor jack or garage jack which lifts
vehicles so that maintenance can be performed. Mechanical jacks are usually
rated for a maximum lifting capacity (for example, 1.5 tons to 3 tons).

The car jack in our project is generally termed as Scissor Jack because of its
shape which is much like a scissors.
 Objectives

To design a power scissor jack which is safe and reliable to raise and lower the
load easily.

To fabricate the prototype of a scissor jack which is operated by a gun powered

by the car battery.
 Scissor Jack
A scissor jack is a device constructed
with a cross-hatch mechanism, much like
a scissor, to lift up a vehicle for repair.

The main parts of scissor jack are top

plate, bottom plate, arms, trunions and
power screw

Most scissor jacks are similar in design,

consisting of four links driven by a
power screw .

The power screw design of a common

scissor jack reduces the amount of force
required by the user to drive the
mechanism.
 Power Screws
Applications
To raise the load, e.g.
screw-jack, scissor jack,

To obtain accurate motion in

Mechanical device used for converting rotary
machining operations, e.g.
motion into linear motion and transmitting lead-screw of lathe,
power.
To clamp a work piece, e.g.
Three essential parts of a power screw are vice, and
screw, nut and a part to hold either the screw To load a specimen, e.g.
or the nut in its place. universal testing machine.
 Advantages Disadvantages
Mechanical Advantage

Large Load Carrying Capacity

Compact construction Power screws have very poor

Simple to design efficiency; as low as 40%

Fabrication is easily done on a lathe High Friction causes rapid wear of

machine thread

It can be designed with a self locking

property
Forms of Threads

Square Thread

Trapezoidal Thread

Acme Thread
 Square Thread
used in high load applications such as lead screws and jackscrews.

It gets its name from the square cross-section of the thread.

It has the lowest friction and is most efficient thread form.

Advantages Disadvantages

Efficiency of square threads is more

than that of trapezoidal threads
Due to the lack of a thread angle
there is no radial pressure on the nut
Square threads are difficult to
manufacture
Square threads have less thickness at
core diameter, which reduces its
strength
Terminology of Power Screw
Pitch: p, The distance measured parallel to the axis of the screw, from a point on

one thread to the corresponding point on the adjacent thread.

Lead: L, The distance measured parallel to the axis of the screw that the nut will

advance in one revolution of the screw. For a single-threaded screw, the lead is

same as the pitch, for a double-threaded screw, the lead is twice that of the pitch.

Nominal diameter: do the largest diameter of the screw. It is also called major

diameter. It is denoted by the letter.

Core diameter: dc The smallest diameter of the screw thread. It is also called

minor diameter.

Helix angle: The angle made by the helix of the thread with a plane

perpendicular to the axis of the screw. Helix angle is related to the lead and the

mean diameter of the screw. It is also called lead angle.

 Self Locking Screw
When , a positive torque is required to lower the
load

Under this condition, the load will not turn the screw and
will not descend on its own unless effort P is applied. This
is called self locking.

A screw will be self-locking if the coefficient of friction is

equal to or greater than the tangent of the helix angle

self-locking of screw is not possible when the coefficient

of friction () is low.
 Efficiency
Efficiency = Work output/ Work input

= W x L/ P x ( d)

= (W/P)* tan ( )

= tan ( )/tan ( + )

For our scissor jack prototype =

tan (4.85)/tan (11.3+4.85) = 0.28 = 28%

There are two ways to increase the efficiency of

square threaded screws. They are as follows:

1. Reduce the coefficient of friction between the

screw and the nut by proper lubrication
2. Increase the helix angle up to 40 to 45 by using
multiple start threads.
 DESIGN
W
 Power Screw
Material selected Mild Steel
Assumptions The weight of the car is considered as 1.5 ton. The weight acting on front and
rear axle is 60% and 40% of total weight respectively, hence the weight acting on front axle
i.e.; 900 kg is considered for designing the jack. A weight of 450 kg acts on each wheel. And
the maximum load on screw act when jack is at its lowest position. A double start square
thread with a friction coefficient of 0.20 is considered.
 Design Calculations
Length of each arm = L1 =L2 =L3 =L4 =160mm
Length of the power screw = (w1+w2+w3) = 350mm
w1 = w3 = 150 mm
w2 = 50 mm
Maximum lift of the jack = (h1+h2) = 300 mm
is the angle made by link with horizontal when jack is at its lowest position.
cos ( ) = (175-25)/160 = 20.36
W = (load * g) = (450*10) = 4500 N = 4.5 kN
The tension T acting on the power screw is shown in the Fig.
Tension, T = W/2*tan ( )
Total tension = 2*T = W/tan ()
For a power screw under tension we can take t = 124 N/mm2 for mild steel
Let dc be the core diameter of the screw. But load on the screw is
Load = (/4)* dc2 * t
So,
2*T = W/tan ( ) = (/4)* dc2 * t
2*T = 4.5 kN/tan (20.36) = 12123.44 N
dc2 = (W/tan ( ))*(4/ (* t))
Hence, dc = 11.34 mm
Since the screw is subjected to torsional shear stress we adopt, dc = 14 mm
Taking pitch, P = 2 mm
Outer diameter, do = dc + P = (14+2) = 16 mm
Mean diameter, d = do P/2 = 16-2/2 = 15 mm
.
Check for self-locking

tan () = Lead/*d; = helix angle

Lead L = 2*P; since the screw has a double start square thread.

tan ( ) = 2*p/*d = 2*2/ *15 = 0.084

Helix angle; = 4.85

Coefficient of friction; = tan ( ) = 0.20; friction angle; = 11.3

> hence the screw is self-locking

Effort required to support the load = 2*T tan ( + )

= 12123.44 (tan ( ) + tan ( ))/ (1- (tan ( ) * tan ( ))) = 3510.715 N

Torque required to rotate the screw = effort *d/2 = 3510.715 * 15/2 = 26330.36 N-mm
Shear stress in the screw due to torque = 16*T/ (* dc3) = 16*26330.36/ (*143) =
48.87N/mm2

But tensile stress t = 2*T/ (/4) * dc2 = 12123.44/ (/4) * 142 = 78.755 N

Maximum principal stress t max = t/2 + ( t2 + 2)/2 = 102.13 N/mm2

Maximum shear stress max = ( t2 + 2)/2 = 62.76 N/mm2

Since the maximum stresses t max and max within the safe limits, the design of double start
square threaded screw is satisfactory
 Nut
Material Selected Bronze

Design Calculations
Let n be the number of threads in contact with the screw assumed that load is Uniformly
Distributed over the cross section area of the nut. Bearing pressure is assumed as 15 N/mm 2
Pb = (2*T)/((/4)*(do2-dc2)*n)
15 = (12123.44)/ ((/4)*(162-142)*n)
Number of threads, n = 10.6 11
Thickness of Nut = n*p = 11*2=22 mm
Width of Nut b =1.5*do =1.5*16=24 mm
To control the movement of nuts beyond 300 mm the rings of 8 mm thickness are fitted on the
screw with the help of set screw
The length of screw portion = 300 + (8*2) + 22 = 338 mm 350 mm
Total length of screw is 350 mm.
 Pins in Nut
Material selected Mild Steel

Design calculations
Let d1 = diameter of pins in the nuts
Since Pins are in double shear stress
Load on pins = W/2 = 2*(/4)*d12* =12123.44/2
= Shear stress = 50 MPa for steel
Hence d1 = 8.78 mm say 10 mm

Diameter of pins head is taken as 1.5*d1 = 15 mm and thickness be 4 mm

 Arms
Material selected Mild Steel
Design calculations
yt for mild steel = 248 N/mm2
Factor of safety (F.S) = 2.5
t = yt/F.S=248/2.5=99.2 N/mm2
c = 1.25*t = 1.25*99.2 = 124 N/mm2
Cross section area (A) = (40*3) + (24*3) + (40*3) = 312 mm 2
Moment of Inertia Ixx = 47376 mm4, Iyy= 51009.38 mm4
Radius of Gyration Rx= 12.323 mm, Ry= 12.786 mm
Rankines constant (a) =1/7500
Ends are hinged (Leff = L)
Pcr in vertical plane
c= crippling stress = 330 N/mm2
Pcr = (c*A)/(1+a*(L/ Ry)2)= (330*312)/(1+(1/7500)*(160/12.786) 2 = 100854.26 N
Pcr in horizontal plane
c= crippling stress = 330 N/mm2
Pcr = (c*A)/(1+a*(L/2*Rx)2)= (330*160*40)/(1+(1/7500)*(160/2*12.323) 2)= 2100198.258 N
Since Buckling load is more than Design load the dimensions of the link safe.
 Top Plate (Loading Platform)
Material used Mild Steel

Design calculations
Moment, M = (p*l)/4
p = 5000 N
l = 50 mm
M = (5000*50)/4 = 250000/4 = 62500 N-mm
Z = (b*h2)/6 = (36*402)/6 = 9600 mm3
b = 36 mm, h = 40 mm
b = M/Z = 62500/9600 = 6.51 N/mm2

Conclusion The permissible stress for mild steel is 124 N/mm2 and it is greater than

2
 Bottom Plate (Support)

Material used Mild Steel

The size and shape of the bottom plate have been selected to provide the stability to

the power Scissor Jack.

The size of bottom plate has been fixed as 120*70*3 mm.

 Drawings
Power Screw
Trunion
Top Arm
Bottom Arm
Top Plate
Bottom Plate
Assembly Drawing
Exploded Front View
Exploded Side View
Bill of Materials
 Manufacturing Methods

Production of Screw Threads Possible Methods

Casting
Forming (Rolling)
Removal process (Machining)
Semi finishing and finishing (Grinding)
Precision forming to near net shape
Non-conventional process (EDM, ECM etc.)
 Processes, Machines and Tools Used For Producing Screw
Threads

Machining
Rolling
Grinding
 FABRICATION
Top Arms and Bottom Arms

S Machine Operation Tools Time

no. (min)
1 Stores Check the raw Try square, steel 20
material rule, and dot punch

2 Welding shop Welding of a flat plate Welding gun, Files 120

to the angular to and Emery paper
obtain channel
section.
3 Grinding Grinding the plate in Grinding wheel 60
machine vice
4 Radial Drilling Drilling 10 mm holes Drill bit, dot punch , 40
machine at both the ends of hammer and steel
the plate rule
 power screw

S Machine Operation Tools Time

no. (min
)
1 Stores Check the raw material Outer calipers, 5
steel rule
2 Sawing machine Cutting the length of the Hack saw 25
rod as per requirement

3 Lathe machine Turning the diameter to Single point 35

16 mm cutting tool
4 Lathe machine Threading of square Threading tool 60
thread
5 Shop Floor Inspection Vernier calipers 5
 Trunions

S Machine Operation Tools Tim

no. e
(min
)
1 Stores Check the raw material Inner calipers, 5
steel rule
2 Sawing Cutting the length of the Hack saw 25
machine rod as per requirement

3 Lathe machine Turning the outer Single point 35

diameter to 24 mm cutting tool
4 Lathe machine Boring the Trunions to Boring tool 15
16mm diameter
5 Lathe machine Threading of square Internal 60
thread Threading tool
6 Shop Floor Inspection Vernier calipers 5
 Top and Bottom Plates

S Machine Operation Tools Tim

no. e
(mi
n)
1 Stores Check the raw material Try square, 15
steel rule, dot
punch
2 Welding shop Welding of a flat plate Welding gun, 120
to the angular to Files and
obtain channel section. Emery paper
3 Grinding Grinding the plate in Grinding 90
machine vice wheel
4 Radial Drilling Drilling 10 mm holes at Drill bit, dot 60
machine both the ends of the punch ,
plate hammer and
steel rule
5 Shop Floor Inspection Vernier 10
calipers
 Conclusion and Scope for future work
Conclusion
In this project a prototype of power scissor jack which can be operated by a power
gun has been designed and fabricated. The jack has been designed to a pay load of
4.5kN. The salient features of the present fabrication are elimination of human effort
to operate the jack, through a simple electrical device which can be actuated by a 12 V
battery and provision of a light source to facilitate convenient operation during night
time. All the elements of the jack are fabricated in the machine shop. The assembly of
the component can be achieved in 100 minutes. Another feature of the unit is
provision of two trunions on both the sides of the jack to ensure jerk free operation.
The elements which are useful are readily available commercially for each and early
replacement of failed components if required.
Scope for future work
As a development the web part of the arms can be replaced by stiffening ribs to reduce
the overall weight .the top and base plates can be made foldable to make the unit more
compact. Permanently mounted jacks on the vehicle can be developed so that tire
change can be completely automated.