Screw Jack Project Report

1. Introduction to Project Topic

Mechanical engineering projects bridge theoretical concepts and practical applications,
fostering skills critical for solving real-world problems. Our screw jack project epitomizes
this synergy, involving the design, fabrication, and testing of a mechanical device that
transforms rotational input into linear motion for lifting heavy loads. By focusing on
simplicity and functionality, this project underscores the relevance of fundamental
engineering principles in everyday tools.

The screw jack plays a pivotal role in multiple industries. From automobile repair shops to
construction sites, it is a device engineers and technicians rely on for safe, efficient lifting.
Our project sought to replicate this essential tool while addressing challenges such as
resource constraints, material limitations, and precision manufacturing.

Key aspects of our project include:

- Objective: To design and fabricate a screw jack using discarded materials from the auto lab
and workshop.
- Scope: Develop a functional, durable, and cost-effective design by leveraging machining
skills and teamwork.
- Learning Outcomes: Gain proficiency in machining techniques, such as welding, cutting,
turning, threading, and grinding; understand material selection and testing; and improve
project management skills.

The project aligns with sustainability goals by emphasizing the reuse of materials and
minimizing waste. The hands-on approach allowed us to explore innovative solutions and
refine our understanding of mechanical systems, preparing us for future challenges in
engineering practice.

2. Background
The screw jack represents a culmination of centuries of engineering innovation. Its
operation is rooted in the principles of the screw—a simple machine known since antiquity.
Early civilizations utilized screw mechanisms for irrigation and grain processing. Over time,
these principles were adapted to create lifting devices capable of moving heavy loads with
minimal effort.

The modern screw jack emerged during the Industrial Revolution, a period marked by
advances in metallurgy and manufacturing techniques. With the development of stronger
materials and precision machining, screw jacks evolved to handle heavier loads while
maintaining user safety and ease of operation.

Significance of Screw Jacks in Engineering:

- Versatility: Screw jacks are used across industries for lifting, stabilizing, and aligning heavy
machinery or structures.
- Mechanical Advantage: By converting torque into linear motion, screw jacks demonstrate
the effective application of simple machine principles.
- Safety: Screw jacks are designed to lock in place, ensuring the load remains stable without
continuous input.

In the context of this project, we aimed to replicate the robustness and efficiency of
commercial screw jacks using limited resources. This required careful planning, innovative
material use, and meticulous execution to ensure functionality comparable to industrial
standards.

3. Applications of Product + Novelty of Model

Applications of the Screw Jack:
- Automotive Maintenance: Used to lift vehicles for repairs, inspections, and tire changes.
- Construction Industry: Supports temporary structures and elevates building materials to
required heights.
- Industrial Operations: Helps in lifting machinery during maintenance, repairs, or
alignment.
- Domestic Use: Provides a reliable solution for lifting heavy furniture or equipment during
repairs or relocations.

Novelty of Our Design:

- Innovative Use of Salvaged Materials: Demonstrates the feasibility of creating functional
tools from discarded components.
- Enhanced Load Distribution: The inclusion of welded brackets improves the stability and
load-handling capacity.
- Customizable Torque Arm: The drilled hole in the threaded rod accommodates
interchangeable arms, allowing users to adjust the torque application.

These innovations reflect our commitment to resource efficiency and adaptability, making
our screw jack a practical and environmentally conscious engineering solution.

4. Existing Material Used for Product/Assembly

The selection of materials is a critical aspect of any engineering project, significantly
influencing the product's performance, durability, and overall functionality. In this project,
we relied on materials salvaged from the auto lab and workshop, emphasizing the reuse of
available resources while maintaining structural integrity and reliability. The materials
used for the screw jack include:
1. AISI 4130 Hollow Tube
2. Mild Steel Threaded Rod and Nuts
3. Mild Steel Plates and Brackets

Each material was selected for specific properties that align with the functional
requirements of the screw jack. Below is an in-depth analysis of each material:
- **AISI 4130 Hollow Tube**: This material is known for its excellent strength-to-weight
ratio, corrosion resistance, and weldability. These properties make it ideal for the central
support structure in our screw jack. Its high tensile strength ensures the stability of the load
while maintaining the device's lightweight design.
- **Mild Steel Threaded Rod and Nuts**: Mild steel offers high machinability, tensile
strength, and cost-efficiency. The threaded rod forms the core of the lifting mechanism,
converting rotational motion into linear displacement. The nuts, fabricated from the same
material, complement the rod's function, providing smooth motion and load-bearing
capability.
- **Mild Steel Plates and Brackets**: Plates and brackets provide the foundational stability
and structural support for the screw jack. Their weldability and robustness ensure that the
assembled components can withstand heavy loads and repeated use.

5. CAD Model Drawing and Drafting Views

The CAD models created for the screw jack were instrumental in visualizing and refining the
design before manufacturing. The 3D models and drafting views provided precise
dimensions, helping ensure accurate machining and assembly of components. The design
process included the following stages:
- Development of initial sketches to conceptualize the screw jack layout.
- Creation of 3D models using CAD software, focusing on component compatibility and
manufacturability.
- Generation of orthographic views for the base plate, hollow tube, threaded rod, and top
plate.
- Dimensional analysis and interference checks to guarantee a seamless assembly process.

Key manufacturing tolerances were considered during the CAD modeling phase to ensure
that machining processes such as turning, threading, and drilling could be executed with
precision. These tolerances included allowances for thread fit, weld shrinkage, and
component alignment.

6. Methodology Used to Manufacture the Screw Jack

The manufacturing process followed a structured methodology that encompassed material
preparation, machining, assembly, and finishing. The detailed steps are as follows:
1. **Material Preparation**: Salvaged materials were sorted, cleaned, and inspected for
defects to ensure their suitability for the project. Rust and debris were removed using
abrasive tools, and measurements were taken to confirm material dimensions.
2. **Cutting**: The base plate and hollow tube were cut to precise lengths using a cutting
wheel and laser cutting machine. These tools ensured accurate dimensions and smooth
edges, critical for subsequent assembly steps.
3. **Turning and Threading**: The threaded rod was machined on a lathe, with external
threads added using threading dies. This process required careful monitoring to achieve the
desired thread pitch and depth, ensuring smooth operation.
4. **Welding**: The base plate, hollow tube, and top plate were welded together using an
arc welding setup. Special attention was given to maintaining proper alignment and
minimizing thermal distortion during welding.
5. **Drilling**: Holes were drilled in the threaded rod and top plate to facilitate assembly
and accommodate the torque arm. Precision drilling ensured a tight fit for bolts and other
components.
6. **Grinding and Finishing**: The assembled screw jack was smoothed and deburred using
a grinder to eliminate sharp edges and enhance its appearance. Surface finishing was
applied to protect the device from corrosion and wear.

7. Approximate Time for Each Operation

Time allocation for each manufacturing operation reflects the complexity and precision
required for the screw jack fabrication. The breakdown is as follows:
- **Material Preparation**: 2 hours were dedicated to sorting and cleaning salvaged
materials to ensure they met the project requirements.
- **Cutting**: 3 hours were spent on cutting the base plate, hollow tube, and top plate to
specified dimensions using a combination of cutting wheels and laser cutting tools.
- **Welding**: 5 hours were required for welding components together, ensuring structural
stability and load-bearing capability.
- **Turning and Threading**: Machining the threaded rod took 3 hours, with an additional 6
hours for threading operations to achieve a precise fit.
- **Grinding and Finishing**: 1 hour was allocated for smoothing edges and applying
surface finishes to enhance safety and durability.
- **Drilling**: 30 minutes were used to drill precise holes for assembly alignment and
torque arm accommodation.