4.

5 Design of key
Key is other machine which is inserted between the shaft and hub to connect parts together in
order to prevent relative motion between them.

For a key to function properly both the shaft and rotating elements such as gear , pulley ,and
coupling must have a key way and a key seat .

High strength low alloy steel type of material are used to design key and have properties like

Have yield strength=690MPa

Ultimate strength =76MPa

kg
Density 7860 3
m

Step 1 determine the dimension of key

Where; t is thickness of key

w is width of key

L is length of the key

Shaft diameter (dw) from the previous dw-21.2mm as standard tapered keys dw-22mm from
table width =8mm and thickness 7mm

Step 2 determine the length of key (l)

 Considering shearing of the key and torque transmitted by shaft

3
πxτd
T= yield strength of mild steel ≈ 600MPa
16

600
τ= =120MPa
2 x 2.5
3
πx 12022
T= =11403.9 Nmm
16

d 22
And T=lxwxτx =lx8x120x ; 11403.98=10560l
2 2

L=1.0799m=108mm

 By considering crushing of the key

σc=crushing stress due ¿ mild steel is 250 MPa

T=lxt /2 x σc xt /2 =lx7/2x250x22/2 ,9625l=11403.98

 L=1.185m=118.5mm

Take the larger of the two values, the length of the design key should be “l”=118.5mm

4.6 Design of handle

Handle used for transferring torque to worm shaft

A part with the operator force is directly applied on it

Selection material aluminium alloy 707S

 The tensile yield strength =500MPa

 The tensile ultimate strength =570MPa
 Ultimate shear strength=330MPa
 Yield shear =170MPa

Step 1 determining length of the handle

T=T1+T2

d
T1-Wtan(∝+ ∅ ¿
2

11
=15000xta(10.2+3. .3 ¿ =15000x0.24x5.5
2
2
2 R 3−R 4
T1=19.8Nm and T2= xμW [ 2 2
] the torque required to overcome friction
3 R 3 −R 4

Do 1.75 do 1.75 x 12
R3¿ = = =10.5mm
2 2 2

R 3 10.5
R4= = =5.25mm
2 2

R 3+ R 4
T2= μxW [ ]=0.307x15000x¿=36.26Nm
2

T=T1+T2=19.8+36.26

=56.06Nm

Assuming that the average human force exerted on the handle to be 165N

T 56.06
L= = =0.3397mm≈ 339 mm
F 165

Step 2 calculating the diameter of handle by using the force

M=FxL=165x339=55935Nm where M is bending moment and L is length of lever

 π 3 3 32 M 32 x 55935
M= σbx D ,D= = =¿ 3351.5
32 πσb πx 170

D=√3 3351.3=14.96mm≈ 15 mm

Step 3 stress analysis

W −W
σc−
μ = μ
(D 22−D 12 ) (D2 )
4 4

15000
15000
μ 2 =
(15 ) 176.7
4

σy 500
σc =84.89MPa therefore = =200MPa
F . S 2.5

84.89¿ 200 MPa , so the design is safe

4.7 Design of collar

Collar is used to support the nut from buckling

Aluminium alloy of type 1100(material type)

Properties of material is

 Density =2710kg /m3

 Yield point strength=15MPa
 Ultimate strength=110MPa
 Safety factor=2.5

Step 1 calculating the dimension for the collar

Height of collar =nut =68mm

D1=outer diameter of nut-2 with some allowance

D1=19.5+0.3=19.8mm≈ 20 mm

Then calculating D2

π
W= ( D 22−D 12 ¿ σc
4

4 W (F . S ) 4 x 15000(2.5)
D 22 = + D 12= +202
μσc μx 95

D2=30mm
Step 2 stress analysis

W 15000
σc− =σc−
μ μ
(D 22−D 12 ) (302−20 2)
4 4

σc=38.2 MPa

4.8 Design of top plate

Mounting plate used to carry the load directly on it

High strength steel is selected material for the design

 Ultimate tensile strength =620MPa

 Yield strength=415MPa
kg
 Density=7860 3
m

Step 1 first let get a symbolical representation of each dimension from the drawing and find
each dimension properly.

The dimension (d) is equal to the inner diameter of nut-2 d=25mm

Step 2 stress analysis in order to determine height (h) and the outer diameter (D)

The load is distributed evenly though the top surface their will be bending and shearing
induced on the plate

W
Let w =distributed load = which will produce a shear force (v)
D

dv
=−w
dx
D

v=∫ −wdx=−WD
0

dM
=v
dx
D
M =∫ (−WD ) dx =-W D2 is maximum bending induced on the mounting plate
0

|−v| WD
= 4 W τy
Therefore shear stress(τ ¿ = As π 2= =
D πD FS
4

4 WxFS 415000 x 2.5

D== = =
πτy πx 620
D=77mm

My
Crushing stress induced ( σc ¿=
I
3
Dh
Where I is moment of inertia =
12

12 M 12 MFS 12WFS
σc = 2 ,h2 = =
Dh D σy σy

12 x 15000 x 2.5
=
415

h=32.93mm

4.9 Design of bearing

In this design the bearing used for worm shaft at both ends of the handle (shafts) as well as a
single bearing is required for the screw to rotate about its axis with nut any axial movement.

This bearing is a ball bearing type this have high coefficient of friction as it is outstanding
advantage of bearing. Since he rolling elements are subjected to high local stress of varying
magnitude then the material selected is high carbon chromium steel .

Step 1 life of bearing? Average life of bearing is 5years at 10hours per day

Assuming 300 working days

LH=5x10x300=15000hours

Therefore life of bearing in revolution

L=60xNxLH where N is speed n rpm =100rpm

=60x100x15000

L=90 x 10 6rev

Step 2 Wr( radial load)? And Wa(axial load)

Since in radial direction the worm shaft mesh with the gear the human load is directly applied
Fapplied
on the bearings. Thus Wt= assume 100N applied by human
2

100
Wt= =50 N the radial load on the bearing therefore we need to find Wa
2

Step 3 determine radial load factors (xo and yo), axial load factor

Wa
Take where Co is basic static load capacity
Co
 Wa Wa
Let we take =0.5 and when Wr=Wt=50N
Co Wr

From appendix table 27.6 let us select the bearing number 3200 the statical load (Co)=2.24
kN

Wa
=0.5 Wa=0.5x2.24x1000=1120N
Co

Wa 1120
= ¿0.44
Wr 50

Wa Wa
From appendix table27.4 find the value of xo and yo corresponding to =0.5 and >¿
Co Wr
0.44 x=0.56 and y=1

Step 4 determine dynamic equivalent radial load

W=x¿ v∗Wr+ y∗Wa=0.56x1x50+1x1120

W=1148N

Step 5 determining basic dynamic load rating

( )
1
L K
C=W 6 where K=3 for ball bearing factor
10

( )
6 1
120 x 10 3
C=1148 6 =5.1446kN
10

From appendix table 27.6 the bearing number 30 having dynamic equivalent C=6.3KN its
should be selected.

4.10 Design of body

The body include all the part which cover all mechanical component of mechanically
operated bottle car jack.

The material selected for this components is structural steel type of ASTM .A360 which has
250MPa yield point strength and 7860 kg /m3 density.

Diameter of cover at the top (D)

D=1.5Do2=1.5(18.37) where Do2 =the outer diameter of the nut 2

D=27.56mm

Thickness of the body (t)

t=0.25do=0.25x12 where do diameter of the screw

 =3mm

Inside diameter of at the bottom of the jack handle cover

D6=2.25Do2=2.25x18.37

=40.78mm

Outer diameter of the bottom

D7=1.75D6=1.75x40.78

=71.38mm

4. 11 Design of base
The base is the components of mechanically operated bottle car jack which is found at the
bottom of all the often components and thus carry both the load as well as the total mass of
the components .

The material selection for this components is high strength steel

 Density=7860
 Ultimate tensile strength=620MPa
 Yield strength=415MPa
 Safety factor=2.5

In order to design this components its important follow the following procedure .

Step 1 find the width of the base and corresponding height

Width =outside diameter of the body +some clearance

w=D+15mm=71.38+15

w=86.38mm since its square L=w=86.38mm

Step 2 finding the thickness of the bottom plate

t=2t=2x3=6mm where t is thickness of the body

4. 12 Design of bolt
Bolt is a metal rod or pin for fastening objects together that usually has a heat at one end and
a screw thread at the another and is secured by a nut

It used to assembly the body part to the base of the jack

Where dc; core diameter of the bolt

Do is nominal diameter of the bolt

d is depth of thread
 p is pitch

n is number of bolt which is four(4)

the bolt suffered to highly shear stress so it need to made from high hardness and strength
material.

Mild steel is preferable material and has ultimate strength 40MPa

Step 1 determine the core diameter dc by using crushing stress

√ √
P P p 15000
σc= = dc= =
4 A π dc 2 πxσc πx 40

Dc=10.9mm and do=12mm,p=2mm

Step 2 determine thread length

L=2xdo+6mm=2x12+6

=30mm

Step3 force and stress analysis of bolt

16 T 16 x 13
τ= 3= 3 =3.56MPa
πn dc πx 4 x 10.9

τ y of materials is 40MPa and shear stress design less than ultimate strength , so the design is
safe.

4.12.1 Design of bolt nut

Nut are generally in the form of hexagonal or square prisms

So hexagonal more preferable because more efficient

Carbon steels material used for design

D=1.5do+3mm=1.5x12+3=21mm

Radius of chamfer R=1.4do=1.4x12=16.8mm

Angle of chamfer =30°