Addis Ababa Science And Technology University

School Of Mechanical And Manufacturing Engineering

Department of Mechanical Engineering
Machine Design Project Individual Assignment
Design of Mechanical Bottle Jack With Bevel Gears

Name : Daniel Tilahun G.

ID No. ETS0599/06

Instructor Mr. Hairedin I.

Sub. Date: 25 May 2008 EC.
INTRODUCTION
Mechanical bottle jack is a simple machine that is used to lift different object/materials having
different loads. It has different parts such as screw, jack nut, gears (including pinion), bearing,
pinion shaft and handling. Each part has its own application during lifting.
In this design project, I will focus on the design of mechanical bottle jack having an arrangement
of bevel gears with given conditions of maximum lifting 450mm and minimum lifting 120mm at
a load of 9KN.
Working principle of bottle jack
Force is applied manually by the operator on the handling (pinion shaft). By this force the pinion
shaft rotates and causes the pinion to rotate. The pinion is a small gear arranged horizontally and
it is meshed with the vertically arranged gear and these gears convert the horizontal rotation to
vertical rotation. Then after the axis of rotation is changed, it will be transmitted to the screw
through the gears and bearing system. Using this motion the screw starts to lift the load up and
down based on the direction of the given force. i.e. if the person rotates the pinion shaft in
clockwise direction, the screw will move upward and lift the load up. But, if the direction is
counter clockwise, the screw will move downward and lift the load down.
Screw Design

 Screw is one component of the mechanical bottle jack. It used to hold and lift the given
load up and down based the direction needed. It is subjected to compressive and torsional
stresses.

From standard table select material steel with Syc=560Mpa.

Assume safety factor n=4

Syc 560
Then δc= = =140 Mpa
n 4

Given, load W=9KN, max lift=450mm, min lift=120mm

 Core diameter of screw dc can be found as

W
δc= =9000 N /¿πdc2/4¿=140Mpa
Ac

dc=9mm,

But, since the screw stressed by compressive stress and subjected to torsional stress, high value
of diameter should be taken.

Assume d=20mm

Pitch=4mm ∴ dc=d− p=16 mm

dmean=d-0.5p=18mm
let screw has single start thread and then α =tan−1 ¿ ¿)=4°

 Assume there is friction between jack nut and screw due to poor lubrication, let μ=0.2
and then ∅=tan−1 (¿ μ) ¿=11.3°

 Torque needed to overcome friction between screw & nut and to lift up the load

T=W*(dm/2)*tan¿=9000N*9x10-3*tan15.3 °=22.2Nm
π
T= τ maxdc3
16
τ max=16*22.2/π(0.0163)¿ 27.57 Mpa

For the design to be safe, permissible shear stress must be greater than the maximum stress of the
Syc
screw. τ perm= =560/8=70Mpa ∴ 70Mpa>27.57Mpa……design is safe.
2n

During lifting up and down, the screw always rotates. So there is no bending stress occurred on
the screw. Therefore, the combined stress=τ max=27.57Mpa.

Jack Nut Design

 It is a nut used to support the screw.

Assume the nut is made up of bronze and the permissible bearing pressure between the nut and
screw iis assumed to be 11.2Mpa.

 Number of thread in the jack nut,

W
Pb= π ∴ n= (4∗9000 N) =7
n (do 2−dc 2) ¿¿
4
 Height of nut, h=np=7*4=28mm

Transverse shear stress at root of thread in the nut is

W
τ trans= =9000/(8π ( 0.002 )2)=89.5Mpa
π ¿¿

From standard table phosphorus bronze has 19Mpa as shear stress

4W
δc= ∴Do=22mm but, empirical diameter of nut D=1.3Do=29mm
π ( Do 2−d 2)

τ bronze=19Mpa=W/(πDt) ∴ t=5.2mm
 but, D≥d+2t

29≥20+2t ∴ t≤4.5mm

Gear and Pinion Design

 Gear and pinion are used to transfer the power from the operator to the screw to lift the
load up and down. Gear is arranged vertically and pinion is arranged horizontally.

Assume 14.5° composite system,

From the table, take σ oP=85Mpa, σ Og=55Mpa

Let, V.R=3:1 and Tp=16

Assume a person rotate machine at 30rpm i.e. NG=30rpm, then by ratio Np=90rpm and TG=48

Gear and pinion are perpendicular i.e. θs=90°

−1 1
θp1= tan =18.43°
V .R

θp2= tan−1(V.R)=71.57°

For 14.5° composite system, TEP=Tpsec (θ p 1¿)¿=17

TEG= TG sec (θ p 2¿) ¿=152

0.684
then Yp=0.124-( )=0.08
TEp

0.684
YG=0.124-( )=0.1195
TEG

σ oP*Yp=85*0.08=6.8

σ oG*YG=55*0.1195=6.57 since σ oP*Yp¿ σ oG*YG, the design is for pinion.

let a person produce 300 watt power

60 P
∴ T= =31.8Nm
2 πNp
 2 T (2∗31.8) 4000 N
WT= = =
Dp (mTp ) m

πDpNp
 Pitch line velocity v= =75.4m*10-3m/s
60
6
 Velocity factor Cv==
6+0.0754 m
Dp mTp
 Length of pitch cone element L= = =25m
2sin θ p 1 2sin θp 1
 Face width b=12.5m

WT=σ oP* Cv*bπm* Yp

6
=85( ¿ (12.5m)(πm)(0.08)
6+0.0754 m

By try and error method, m=2.5mm≅3mm

From table at m=3, take tooth error e=0.051mm, k=0.107

 Dynamic factor c, from the table, Ep=210Gpa&EG=84Gpa

ke
therefore, c= 1 1 =327.42N/mm
+
E p EG
21 v ( bc+W T )
 Dynamic load WD= WT+
21 v+ √(bc +W T )

4000
WT= =1333N
m

v=0.0754m=0.2262m/s

b=12.5m=38mm

21∗0.2262(0.038∗327420+1333)
∴ WD=1333+ =1869N
21∗0.2262+ √ (0.038∗327420+1333)

 Static loading

Assume, δe for cast iron from the table=84Mpa

Ws=δe*b*πm*Yp=84*38*π*3*0.08=2407N

Since Ws>WD> WT, the design is safe.

From standard,
 Addendum=1m=3mm

Dedendum=1.2m=3.6mm

Clearance=0.2m=0.6mm

Working depth=2m=6mm

Teeth thickness=1.5708m=4.7mm

Design Of Pinion Shaft

 It is used to transmit manual power from the handle to the pinion (small gear).

Assume the length of shaft is 100mm.

Splitting force or load (tangential on the gear) in to components

Axial load, Wa=WT tan ∅ sin θ p 1=84.2N

Vertical load Wv= WT tan ∅ cos θ p 1=252.7N

 Bending moment due to axial (horizontal) and vertical loads

Assume, pinion shaft overhang by 25mm

M1=Wv*overhang-Wa*Rm Rm=mean radius of pinion

=(L-0.5b)*(Dp/2L)=18mm

=252.7*0.025-84.2*0.018=4.94Nm

M2=WT*overhang=1333*0.025=32.5Nm

M=√ (M 12+ M 22)=√ (4.982 +32.52)=32.88Nm

We have T=31.8Nm

Te=√ (M 2 +T 2)=√ (32.882 +31.82 )=45.74Nm

π
Te= τ d3
16 max s

Let the shaft material be annealed steel i.e. δ y =358Mpa

 Take safety factor n=3

δ y 358
Therefore, τ max= = =59.67 Mpa
2n 6

π (59.67∗10 6)(d s3)

Te=45.7Nm=
16

∴ diameter of shaftds=15.7mm≅16mm

Design Of Ball Bearing

 Bearing is used to reduce the friction.

From the table,

Select, bore=20mm=dia of screw and then we can have the following dimensions.

From bearing no. 304, outer diameter do=52mm and width w=14mm.

Let Lh=bearing life in hour, L=bearing life in revolutions

Bearing has longer life with 10years and 7hours per day.

Lh=year*day*hour=10*7*365=25550 hours

L=60*N*Lh=60*90*25550=137.97*106 revolutions, N=revolution of pinion gear

Using the above dimensions of bearing no. 304

31.8 Nm
W=T/Ro=( )=1223N T=torque for gears=31.8Nm
0.026 m

L 1k
C=W*( ) =6.32KN k=3 for ball bearing
106

But, from the table for single row ball bearing of bearing no.304, C=10.6KN

Calculated C is less than C induced and therefore, The design is safe.

Design of Pinion Shaft Bearing

Assume bearing has longer life, 8 years and 5 hours per day. N=revolution of gear
Lh=years*days*hours=8*365*5=14600hours

L=60*N*Lh=60*30rpm*14600=26280000 revolutions

From table select bearing no. 202 with dimensions

Do=35mm, bore=16mm and width=11mm

W=T/R=31.8Nm/0.0175m=1817N

L 1k
C=W*( ) =5.4KN k=3 for ball bearing
106

From table, for bearing no. 202, C=5.4KN therefore, the design is safe.

Design of bolt

 It used to connect the casings (outer cover of jack).

Since it is not subjected to loading, we can simply select appropriate type from standard
table.
Therefore, take bolt type M10X2 with its length=25mm

Design of handling

We can select any handling (any metal) to rotate the pinion gear. But, it should withstand the
force that we apply on. Therefore, simply take a handling which is shaft type with length=50mm
and diameter=10mm.

Appendix
The following table shows the principal dimensions for radial ball bearings.
Table 1 Bearings with bore, outer diameter and width.
Table 1.
Table 2 Basic static and dynamic capacities of various types of radial ball bearings.

Table 3 Values of maximum allowable tooth error in action (e) verses pitch line velocity, for
well cut commercial gears.