Design of Machine Elements I

Prof. G. Chakraborty
Department of Mechanical Engineering
Indian Institute of Technology – Kharagpur

Lecture - 18
Power Screws

Let us begin the lecture on machine design Part 1. This is lecture number 18 and the topic is
Power Screws. Now Power Screws are important device to transfer the rotational motions
into the translational motion. Now you might have heard of the name rack and pinion drive
which serves the same purpose that is it converts the rotational to the translational and vice
versa.

But the important difference between the power screw and the rack and pinion drive is that in
the power screw the access of rotation and the direction of translations are collinear whereas
in rack and pinion drive the access of rotation is orthogonal to the direction of translations.
Now power screws were used even in antiquity since the days of Greeks as we can see from
the historical documents.

They even named power screws as one of the 5 elements of machines. Even today power
screws find importance in the machine design.
(Refer Slide Time: 02:03)

Now let us look at the reasons behind so much wide application of power screw drives. The
first one is a large mechanical advantage. So this part which we are going to explain in this
lecture is very important that the machine must have a good mechanical advantage. Then the
second is possibility of obtaining slow motions. Now this is also important because
sometimes we need very slow movement.

And with any other drives it may not be very much possible, but this is much possible in the
power screw drive. It has high load capacity with small overall size so that is again a very
important factor the machine could load capacity, but it must be convenient in shape and size.
Then the forth point is highly accurate motion for adjustment. Sometimes we need very
accurate motions.

For example, in positioning instruments we need accurate adjustment of the motions for
example in telescopes to look at the stars we need to get fine adjustment of the motions and
this is possible by power screws. Now it is very simple to design such power screws and that
is very, very important from today’s point of view. The ease in manufacturing is of course
there as we have already known for the threaded fasteners.

That it could be manufactured very easily by turning process or by rolling process. This is
very important factor. So now we see the advantages of such power screw drives.
(Refer Slide Time: 03:59)

Then let us look at the typical fields of applications of such power screws. Now it is used for
raising load you might have seen the screw jack which is used in automobile industry to raise
the automobile now screw jacks are very useful there. Then the second application is that
loading specimens in testing machines, again the testing machines are used to load the
members for various experimental purposes and here you will see that the power screws find
their applications.

Then the third application is obtaining required motions in machining and press working. You
might have seen the lathe machine and there you might have also seen the lathe carriage
which carries the tool and it is given a feed motion. Now this feed motion is given to the tool
by means of the power screws, also it is useful in the press working operations. Then we
require sometimes very precise indexing motions.

And there power screws are very much applicable. Indexing motions are very important in
designing and manufacturing certain things for example in gear manufacturing you see the
indexing is very important and if indexing is not perfect then the gear profile may be
inaccurate and that leads to inefficiency in the gear transmission. So indexing is very
important thing and the power screw could be useful there.

Then providing motions of operating members of robots. These days’ robots are used and to
have the movements we used sometimes the power screws because it has high load capacity
and it is small in size. Therefore, these are the typical fields of applications, but this is not
exhaustive and apart from this there are numerous others applications also possible.
(Refer Slide Time: 06:05)

Now come to the Kinematic arrangement of screw and nut pair. Now depending upon the
fixation of screw and nut there are 2 members in the screw mechanism one is screw and
another is nut. Now screws have thread cut on the external surface whereas nuts have thread
cut in the internal side. Now depending upon the fixation of the screw and nut we may have 3
possibilities.

One is the rotating screw and nut moving axially that is here the screw rotates and the nut
moves axially. This is very common in use and just now I have mentioned about the feed
motion in lathe and there you will find the screw rotates. Here we have the lead screw which
is known as lead screw which rotates and the nut moves forward and this nut carries the tool
holder which holds the tools.

So therefore feed motion is given by this mechanism. Then the second category is the
simultaneous axial and rotational motions of screw with fixed nut. Here the nut is held fixed
and the screw moves as well as it rotates. Now you might have seen the screw jack here the
mechanism is just like that. We have the fixed nut and then the screw is rotated and it moves
in the same direction of rotations.

So this is one arrangement. There may be arrangement where the rotating nut and screw
travelling axially. It is just a reverse that is the nut rotates and the screw moves axially. Let us
see here suppose we have 2 screws this is right handed and let us say this is left handed and
we have a fixed nut here which is rotated. Rotational motion is given to the nut and because
of that the screw advances in the opposite directions.

And it gives a force in this 2 direction T1 and T2. Now this is important to give tension to
cables and this could be taken as a threaded fasteners. Here also the screw is travelling
axially, but the nut is held fix this is known as the Turnbuckle.
(Refer Slide Time: 09:13)
Now let us come to the basic thread types in power screws. In lecture 16, we mentioned about
the different threads and the geometry of the threads in some more details. And there we have
mentioned that in power screws the most frequently used threads are square or
Acme/trapezoidal thread or Buttress thread. Now let us look again at the mean geometric
parameter of such a thread.

Now here the square thread, the geometry of the square thread is somewhere like this. Here
the pitch is P, and this length is P/2, and this is again P/2 and the height of the thread is P/2.
Now what are the advantages? Advantage is that because of this surface which makes angle
90 degree it is quite efficient that is the frictional loss is less. But what are the disadvantages?
Disadvantage is that the thread area is very small.

So of the entire pitch only P/2 has some material so therefore the strength of this screw is
very small. And secondly and that is very important that it is difficult to machine that is it is
we will see that we need a good surface finish of the screw threads and it is difficult to have a
good surface finish for this kind of square thread. So we will now go to the next type that is
Acme or Trapezoidal thread. Here some of the difficulties are removed.

The thread profile here looks like for well again this is the pitch length but this angle which is
known as thread angle is taken to be 29 degree for acme thread. And for trapezoidal thread it
is 30 degree. Then we have some of the advantages of this thread that is here we have of
course large mechanical loss that is large frictional loss, but not it is possible or it is easy to
machine this thread and secondly the route strength is quite high.
So the disadvantages of the square threads are now taken care of here in trapezoidal or acme
thread. And in some machines where we need frequent engagement and disengagement of the
screw and nut then this is very useful. You will see that here this kind of square thread is not
very useful for that purpose. Now this kind of frequent engagement and disengagement are
very common you might have seen the Lead screw in the lead machine.

Of course we have a spiral cam which is used for engaging and disengaging the nut with the
screw and there the acme thread is very much beneficial. Now let us look at the Buttress
thread. Some of the advantages of the square thread as well as Acme thread are now
combined here. The thread profile is very much like this. This angle is very, very small
roughly taken to be 7 degree only for the ease of manufacturing and this angle is quite large
about 45 degrees.

Now you see the advantage is that here the friction loss is very small whereas the route
strength is quite high. So therefore if we have a nut which is engaged here then it is easy and
efficient to transfer power from one direction, but the disadvantage is that it can transfer
power only in one directions and in reverse it is very much inefficient. So these are the 3
common types of threads used for the power screws.

Now there are standards for the square threads as well as Acme and Buttress threads. The
standard for square threads is (()) (14:51) and the standard is named as IS 4694 and it was (())
(14:59) in 1968 and Reaffirmed in 1983. In any machine design handbook, you will find such
tables. Now you should know how to read those tables. You will find different parameters
mentioned there. One is the nominal diameter of the screw and that is equal to the major
diameter of the screw.

Then we have the minor diameter of the screw and the minor diameter of the nut. We have
the pitch and we have the height of the thread for screw, height of the thread for the nut and
as well as the stress area that is the smallest area at the route. Now I urge that you must look
at those tables and try to use those tables as often as possible.
(Refer Slide Time: 16:12)
Now we come to the Kinematic and static analysis of the screw. Let me draw the basic
geometry of the screw now it is a cylinder and we have the thread cut on the surface. Here
this length is denoted by L and this is the length by which the nut or screw advances
depending upon which is fixed and which is movable by the length L for a single term that is
the movement for 2 Pi revolution or for a single revolution that is 2 Pi radium is L and this is
known as the lead of the screw.

Now this is also the pitch of the screw because the thread is single thread. But now if we use
another thread in the cut in the unthreaded region of the same cylinder look something like
this then the pitch length is this much. This is the pitch. Now this is multiple threaded screw
and the pitch is here and the lead is equal to twice that of pitch. Now the general rule is that
lead equal to n times pitch where n is the number of threads.

That is in a double multiple threaded screw if there are n threaded then we have this
relationship L= n times P. Now also you will see that as it is gradually wrapped up so
therefore there is an angle phi and how to measure this angle. So if you rotate it by one
revolutions then if this diameter is let us say d of p pitch diameter then if you revolve by 2 pi
then this is pi times d p.

And then the lead is L. Therefore, this angle which is constant angle is = phi let us say and
therefore we have Tangent Phi=L/Pi dp or L is Pi dp Tangent of phi so this is the relationship.
Now when it moves by one revolution it advances by L. So therefore what will be the axial
velocity of this screw then definitely the axial velocity will be equal to L which is per
revolution and if the number of the revolution per second is F let us say the frequency. It is
moved with frequency F then the axial velocity is F times L.

But now we see that whenever the screw moves then this is the axial velocity, but the real
velocity of the screw material is along that direction and what is that, this will be= if you see
that V and this is Va. So therefore this is phi and Va will be = V Sin phi and V= Va/ Sin phi.
So phi is very small. Now you will see that even if the axial velocity is very small, but the
rubbing velocity is quite high and that is very important because depending upon the rubbing
speed the wear and tear takes place.

So therefore if the speed is quite high then it may be very high and that is why we should not
have too much running speed of the machine. This is one of the disadvantages of the power
screw that there will be wear and tear and that is one of the important aspects which we have
to take care of in design or in finding out the suitable material.
(Refer Slide Time: 21:25)

Now sometimes we want a very small movement and therefore we used 2 threads 1 thread
here and on the same screw we have another kind of thread with a different pitch. And if we
have 2 nuts then we will see if the pitch is P1 and P2 and if it is single sided screw then of
course per revolution this nut moves by amount P1 and this nut moves by amount P2. So
therefore the relative displacement will be P1-P2 which could be very, very small.

Therefore, it is possible by combining 2 threads to get a very slow movement and that is why
this screw derives is very useful in getting the slow motions. This mechanism is known as the
differential screw mechanism. Now we may have another kind of screw which suppose we
have thread here a different thread, but the handedness is different. Now it was right handed
now this is left handed and if we now have the similar arrangement.

Now whenever the screw rotates then it moves either towards each other or away from each
other. But then the relative velocity will be or that is relative displacement will be= P1+ P2.
So now it is possible to get a very fast movement. Therefore, by suitable choice of the screw
threads we can have either very slow movement or very fast movement and this mechanism
is known as the compound screw.

This is roughly about the kinematics of the screw. Now we come to the static analysis of the
screw force. Now we come to the static analysis. Now here we assume that the screw is rigid
in order to find out what are the forces and movements acting on the screw. So we now come
to the rigid body mechanics.
(Refer Slide Time: 25:12)

We consider the example of a screw jack which looks somewhat like this. So this is a fix nut
on which there is a screw on top of it we have some load. This is used to hoist the
automobiles. Therefore, the automobile weight will come over here. And there is a long
handle by which we apply the force and the screw turns and when it turns it lifts up, so this is
the mechanism of a screw jack. Now let us see what are the forces acting on the screw.

Now if you draw the free-body diagram of the screw a part will look somewhat like this if
this is right-handed. So this is the cross section of the screw and you will see that this is
excess symmetric problem that is from whatever angle you look like you will see the same.
Therefore, my exact nature of slantedness is not very important, but what is important that
(()) (27:19) is right handed nature.

Then you see that whenever load is applied then this side will be in engagement with the nut
only the bottom portion and the pressure will be on the thread throughout. And if you assume
the uniform distribution of the pressure then of course we can safely assume that the resultant
force will act on the mean diameter of the screw that is the mean of the major diameter and
the minor or the code diameter.

Now if you look at the section a little bit closely then you will see that so this is the part of
the thread. This is the center of the screw and this distance is let us say d mean we consider as
d. Now whenever it rotates it rotates in that direction then of course there will be the sliding
motions and because of that the friction force will always oppose the motion and it will act in
that direction.

The normal force will be again normal to the surface this is N. Now if you look at this picture
then you will see that the friction force acts here along this direction and the normal force
here where as this angle is the angle of helix and this is=phi. Now if you write down the force
balanced equation that is the components of the force along the vertical direction then you get
N cosine phi –f sin phi and that is the total upward force and that must be balanced by this
force P.

Therefore, we have this kind of relationship and now we use the important fact that the
friction force is related to the normal force. Now getting the exact nature of the friction force
is very difficult, but we safely use the Coulomb's Law of Friction which says that friction is
proportional to N only whenever there is a motion involved, there is a movement already is it
is impending to move that is the motion is about to begin only then this 2 cases we have this
relationship.

Whereas whenever we have the impending motions mu is denoted as mu S whereas in case of

the kinetics that we have mu K which is the kinetic coefficient of frictions and usually mu S
is little bit greater than mu K, but for the metal these are almost same. Now if you use this
relationship then what you get is N=P/cosine phi-mu sin phi. So this is the relationship
between N and P. Now let us look at the torque definitely there is no force along the radial
directions because this 2 forces are acting on the vertical plane both of them are acting on the
vertical plane.

So there is no component along the radial direction.

(Refer Slide Time: 31:10)

So the tangential component will be= this is the F tangent and that will be= N sin phi+ f
cosine phi and if you again use the same relationship between f and N you get N times sin
phi+ mu cosine phi.
(Refer Slide Time: 32:04)

So therefore we get these relations that is we have P= N times cosine phi-mu sin phi. And
then therefore the torque will be=Ft times this d/2 and that is =N d/2 we have sin phi+ mu
cosine phi.
(Refer Slide Time: 33:30)

If you use again this 2 relationship what you get is the very well known formula that is T= P
d/2 times sin phi+ mu cosine phi/cosine phi-mu sin phi and then if you use the fact that if you
write down mu as tan of lambda which is lambda is the friction angle, then you can write
down this as p d/2 tangent of phi+ lambda. So this is very important relationship that is the
torque we have to apply this is the torque which we have to apply that is=P d/2 that is the
mean radius of the thread times tangent of phi+ lambda.
(Refer Slide Time: 34:52)

Now let us look at the efficiency of this machine. We see that by one turn of the thread say
for one revolution this weight moves by amount the lead. Therefore, the work output will
be=p times the lead. So this is work output. So what is the work input? Work input we are
doing work only by applying torque and the total work input is T times twice by only per
revolutions. So therefore the efficiency which is denoted by work output/work input=PL/T
times twice pi.

Again if you use the same relationship then you get P and L we know pi dp that is the pitch
diameter and tangent of the helix angle phi/ again T is p d/2 times tangent phi+ lambda times
twice pi which is = now here we make this assumption as dp is almost= d/2 and this is so for
the square thread. And therefore we have the important relationship that is the efficiency is
almost= tangent phi/ tan of phi=+ lambda.

Now we see that if lambda is increased again we know that tangent lambda is nothing, but
mu. So therefore if mu is increased lambda is increased and if lambda is increased frequency
goes down, but what is the relationship between lambda and phi that is the helix angle
whether there exists any relationship between them or what is the variation of this efficiency
with phi. Let us look at it.
(Refer Slide Time: 37:30)

Then efficiency is tangent phi/ tangent phi+ lambda. Let us find out the maximum efficiency
now for finding out the maximum efficiency we will have to find out the corresponding phi
for which efficiency is maximum and that is taken by this formula and what is that this is sec
square phi tan phi+ lambda-tan phi sec square phi+ lambda/ tan square phi+ lambda and that
is=0.

If you rearrange this terms a little bit, then what you get is cosine phi sin phi= cosine phi+
lambda times sin phi+ lambda and that means that sin 2 phi= sin twice phi+ lambda.
Therefore, we have twice phi+ lambda= pi- twice phi.
(Refer Slide Time: 39:02)

Now if you use this relationship then you get phi max= pi/4- lambda/2. So therefore the
maximum angle that is angle of helix for which that is the efficiency achieves is maximum
depends also on the lambda. If the friction is increased, then the maximum value of phi goes
little bit down and what is the maximum efficiency then eta max is tangent of phi max which
is= pi/4- lambda/2 and divided by again tangent phi+ lambda if you write down then this pi/4
+ lambda/2 and that becomes you can verify that this exactly becomes = 1- sin lambda/ 1+ sin
lambda.

That is the maximum value of efficiency goes down with lambda as you can see from these
expressions. Now let us draw roughly the variations of efficiency with phi.
(Refer Slide Time: 40:56)
Suppose here we draw for various values of phi and this is let us say 0 to pi/2 it cannot have
value more than pi/2 and here we plot eta then we see that it becomes somewhat like this.
This is for one value of mu. Now if we increase the mu then the maximum shifts little bit
towards left and something like this and so on. So therefore this is with increasing mu and for
representative value of mu which is about 0.1 say then roughly it becomes 0.7 the maximum
efficiency becomes 0.7.

So therefore now you see the importance of these 2 things the helix angle as well as the value
of mu that is the coefficient of friction.
(Refer Slide Time: 42:27)

Now let us come to the mechanical advantage. Mechanical advantage as I said that if you
look at the screw a little bit closely then we need to give a torque T and this torque is applied
by means of a handle. So now here we apply a force P prime let us say such that if this length
is L then it gives (()) (43:00) T. Therefore, T= P prime l and again if we use this relationship
that is T is P d/2 tangent phi+ lambda then what we get is P/ P prime=twice l/d times tangent
phi+ lambda.

So therefore if this d is very, very small compared to l if the handle length is sufficiently long
then we have very large mechanical advantage also this is enhanced by this fact that this
value is not very large. So therefore we can have a very large mechanical advantage with the
help of the screws. Now let us look at the case when we want to lower this load how does it
affect?
(Refer Slide Time: 44:18)

Now instead of taking this load up that is instead of trying to raise this load we want to lower
this load in that case what happens? Now again the screw will now rotate in the opposite
direction. Screw rotate in the opposite direction and therefore the friction force will be along
that directions and if you do the same kind of static analysis what you get that is if you can
get the same that is the value of the torque required will be = p d/2 tangent instead of +
lambda.

We now have – lambda because the direction of the friction force has changed now. Now we
see one important thing that is if phi is> lambda then what lambda then what happens then in
that case this is positive that is now we have chosen our direction here. So therefore
whenever phi is> lambda then we need to give a torque in the same direction in order to
lower this that is it lowers by itself and whenever the lambda value is very, very small that is
phi> lambda then it lower itself.

But if lambda value is quite large then this becomes negative whenever this becomes negative
that means that we will have to apply the torque in the opposite direction in order to lower
this that is if we do not apply the torque then of course it will stay there forever and this is the
phenomena of the self locking that it get locked by itself. So the self locking occurs only
when lambda < phi this is for the over hauling.

This is called the over hauling which is the situation when it comes by its own and then this is
self-locking. Now we can find out very easily.
(Refer Slide Time: 47:05)

That the maximum efficiency for a over hauling system is we can find out the maximum
efficiency for a system which is non self locking that is just over hauling is half that could be
easily found out and I ask you to derive this at your leisure time. Now I give you 2 formulas
for this eta max that is the maximum efficiency. One for the case of differential= d1 if there
are 2 threads with diameter d1 that is mean diameter d1 and pitch P 1.

Then this becomes tangent phi 1 where phi 1 is the helix angle of the first thread and d 2
times tangent phi 2/d1 tangent phi 1+ lambda- d2 tangent phi 2+ lambda and whenever we
have eta. So this is for the case of eta differential. Now you can prove this every easily by
going to the first principle that is by balancing the forces and finding out the net torque
etcetera, etcetera and I am not going to derive this here.
For the case of compound screws, we have instead of - we have here +. So these 2 are the
important formula for the compound screw as well as for the differential screw. Now here we
have talked only of the square thread. Now if the thread is not square that is it has some
thread angle as for example happens in the case of Acme or Trapezoidal threads then what
happens.
(Refer Slide Time: 49:35)

Then if you draw this part of the thread this is slanted this way then you see the friction force
acts again over here. So the direction of friction force is there, but that of the normal force is
not entirely on the vertical plane. So if you draw a vertical plane it is not here or in that
direction, but there will be a tilt with the vertical plane that is because of the thread angle.
Now that will be clear if you draw the same on the thread cross-sections.

Suppose this is the cross-section of the thread here the friction force acts the direction is
towards you, but the direction of the normal force is now not along this, but along this line.
So this is the direction of the normal force N and this makes an angle theta where 2 theta is
the thread angle. Now if you do these calculations then what you get is this form.
(Refer Slide Time: 51:20)
That is the torque required again assuming the same appliance as the screw jack, but instead
of square thread we now have for example the Acme thread or Trapezoidal thread with some
thread angle. In that case this becomes P d/2 and here we have sin phi cosine theta. Cosine
theta comes because of this component + mu times cosine phi/ cosine phi cosine theta – mu
sin phi.

You can derive these same expressions if you wish. Now again this becomes again the same P
d/2 then this is tangent phi + mu/ cosine theta/1- mu/ cosine theta times tangent phi. So again
if you denote this by equivalent mu that is mu dash= mu/cosine theta. Now you see that for
the square thread theta=0. So therefore mu prime= mu, but whenever theta is non zero then
this is less than 1 therefore mu prime is more than mu.

Therefore, in Trapezoidal thread or in Acme thread the coefficient of friction gets a little bit
increased because of this thread angle. Now if you denote the equivalent friction angle by
lambda prime where mu prime= tan lambda prime. Then this is= you can write P d/2 tangent
phi+ lambda prime. So you have seen the efficiency relationship. Now let us come back to
the coefficient of friction.
(Refer Slide Time: 54:10)
Now in the coefficient of friction we have the friction in power screws. The coefficient of
friction here depends on the materials of screws and nuts then the surface finish or
workmanship then the sliding velocity of the screw and the lubricant used. Now these are
very important as you can see that the materials of screws and nuts they are to be chosen
properly.

The surface finish or the workmanship this is also very important and the sliding velocity also
it does not depend too much, but also it still depends and the lubricants used. It is very
difficult to use lubricants there, but the machines oils are used there and whenever such
things are used then we see the coefficient of friction goes little bit down as expected.
(Refer Slide Time: 54:54)

Now you can use this following table for finding out the mu for different cases. Here the
screw and the nut you see the screw material could be steel. It may be dry or it may be with
machine oil. The nut materials maybe steel or brass or bronze or cast iron. Now you see with
the oil of course mu goes little bit down, but this depends again on different material.
(Refer Slide Time: 55:32)

Now there are few special power screws which are used to reduce the friction. One is the
screw and the rolling-friction nut drive. Here instead of the sliding frictions we sometimes
use the rolling friction drive and that is very efficient because you know the rolling friction is
always lesser than the sliding frictions. So whenever we use rolling friction the efficiency
goes little bit high and the load carrying capacity is very large for this case as well as the
backlash error which is typical error in power screw would be removed.

We have the second type which is roller type screw and nut pair. Here the arrangement is very
similar to that of sun and planet gear mechanism. Here instead of the direct contact between
the screw and the nut it is mediated by a few rollers. Here the rollers will have threads cut on
their surface and we have less friction here. The hydrostatically lubricated screws and nuts
pair are also very useful.

Now the roller type of screws is manufactured by (()) (56:41) company in France and that is
very efficient. The efficiency may go as high as up to 0.9. Now these are very modern type of
power screws and if you want to know more then you should consult some book.
(Refer Slide Time: 57:00)
Then here is a small homework problem. Now here the position of an automobile jack as
shown here this is the automobile jack is controlled by screw ABC. Here these are the ABC
this is the screw and it has 2 handedness. The screw has nominal diameter 20 millimeter and
the acme thread, but screw and nuts are made of steel. Now you will have to determine the
magnitude of the couple to raise the load.

Now you see the nominal diameter is given, but it is acme thread so you will have to consult
the table. The screw and the nut materials are still therefore you have to calculate mu the
coefficient of frictions from the table. And then with the help you will have to determine the
magnitude of the couple to raise the load.
(Refer Slide Time: 58:00)

Now let us come to the last home assignment that is lecture 17 we used a cylinder head of a
steam engine then the pressure is 0.7 megapascal it was held by 12 bolts then soft copper
gaskets. If you use the soft cooper gaskets, then C value you can take it up to 0.4 or 0.5 then
if you use this then you see that you get from the calculations you get the nominal diameter
you get almost 51 point something.

Now if you look up at the table the IS code 4218 then you get the next higher series is 52.
Therefore, we can get the bolt as M 52 and this is the safe design of this type of bolt. Then we
come to the end of this lecture. What we have learn we have learnt about the efficiencies how
to make the power screw quite better efficient and we have seen what is the important
applications of the screws with this in mind.

We now go to the design of power screws and that is done in the next lecture that is in lecture
19. So thank you.