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LESSON 25 INTRODUCTION TO POWER SCREWS
25.1 Introduction
Power screw is a mechanical device used to convert rotary motion into linear
motion and to transmit power. Unlike the threaded fasteners which are used to
clamp the machine members, power screws are used to transmit power. Common
applications of power screws are:
1. Screw jacks: to lift weight
2. Lead screw of lathe: for axial movement of tool and its precise positioning.
3. Tensile testing machine: to exert large force.
4. Vice: to clamp the work piece
Power screw comprises of two main components: screw and nut, and can operate in
following three ways:
1. Screw rotates in bearings and nut moves axially
2. Screw rotates and also moves axially while nut is kept fixed
3. Nut rotates and screw moves in axial direction
Power screws have large load carrying capacity, are compact, provide large
mechanical advantage, provide very accurate and precise linear motion, have
smooth and noiseless operation, are reliable and have lesser cost. Disadvantages are
that power screws have poor efficiency and high rate of wear.
25.2 Materials
Screw is subjected to torque, axial compressive load and bending moment also,
sometimes. Screws are generally made of C30 or C40 steel. As the failure of power
screws may lead to serious accident, higher factor of safety of 3 to 5 is taken.
Threads may fail due to shear, which can be avoided by using nut of sufficient
height. Wear is another possible mode of thread failure as the threads of nut and
bolt rub against each other. Nuts are made of softer material than screws so that if at
all the failure takes place, nut fails and not the screw, which is the costlier member
and is also difficult to replace. Plastic, bronze or copper alloys are used for
manufacturing nuts. Plastic is used for low load applications and has good friction
and wear properties. Bronze and copper alloys are used for high load applications.
25.3 Thread Forms for Power Screws
Thread forms used in threaded fasteners are not suitable for power screws. The
purpose of threads used in fasteners is to provide high friction to minimize the
chances of loosening. But in power screws, low friction between nut and bolt is
desired as those are to be used for power transmission. Types of threads commonly
used for power screws are:
i) Square Threads ii) Acme or Trapezoidal Threads iii) Buttress Thread
These thread forms are shown in figure 25.1.
Figure 25.1 Thread Forms for Power Screws
25.3.1 Square Threads
Square thread can be used to transmit power in either direction. Square threads have
maximum efficiency and there is no radial or bursting pressure on the nut,
increasing the life of the nut and making its motion uniform. But it is difficult to
manufacture square threads. These are difficult to cut with taps and dies and are
usually cut on a lathe with a single point cutting tool, making it expensive. Also, it
is not possible to compensate for wear in square threads as split nut cannot be used
with it. Therefore, nut or screw has to be replaced, when worn out. The square
threads are used in screw jacks, presses and clamping devices.
25.3.2 Acme or Trapezoidal Threads
Acme thread is used for power transmission. It has higher load carrying capacity in
comparison to square threads, because of larger root thickness. Acme threads are
manufactured on a milling machine using a multi-point cutting tool and are
therefore economical to cut. Due to the slope provided on its sides, efficiency of
acme threads is less than the square threads and the nut is subjected to radial or
bursting pressure. Wear can be compensated in this case by using split nut, which is
a nut cut into two halves along its diameter. These two halves are tightened together
after certain intervals to take care of the wear taken place.
25.3.3 Buttress Thread
Buttress thread is designed to take large loads in one direction. This is the strongest
of the thread forms due to greater root thickness. Its efficiency is comparable with
the square threads, is easier to cut and is compatible with the split nut also. Buttress
thread finds its application in light jack screws and vices.
25.4 Torque Required to Raise & Lower the Load
Figure 25.2 Development of Thread
Power screws are used to convert the applied
torque into useful axial force, e.g. screw jack converts torque into axial force which
is used to lift load. It is important to know the torque required to raise or lower a
given load.
Let p = Pitch of the screw
dm = Mean diameter of the screw
α = Helix angle
l = Lead of the screw
P = Effort applied at the circumference of the screw to lift the load
W = Load to be lifted
μ = Coefficient of friction, between the screw and nut
A screw thread can be considered as an inclined plane wrapped around a cylinder to
form helix and the relative motion between the nut and the screw against the
external load is analogous to the movement of a weight on an inclined plane. For
simplicity of the analysis, this is assumed to be a point load, though the actual load
is distributed on the thread surface. Figure 25.2 shows the right-angled triangle
formed by un-wrapping a single thread. Thread forms the hypotenuse of the triangle
and can be considered as an inclined plane. Length of the base of the triangle is p
dm and its height is equal to lead, l. This gives the following relation between helix
angle, mean diameter and lead of the screw:
Figure 25.3 Force Diagram for
Raising Load
Figure 25.4 Force Diagram for Lowering Load
Figure 25.3 and figure 25.4 show the forces acting at a point on the inclined plane,
while raising and lowering the load respectively. Forces acting at the point are: P –
Applied Effort, W – Load to be raised and lowered, N – Normal Reaction and mN –
Frictional Force.
Both the cases are discussed below:
Figure 25.5 shows load acting on the surface of a trapezoidal thread. In this case the
load acting normal to the surface of the thread is W.secq. As frictional force is a
function of the normal load, it increases by a factor ‘secq’. Effort and torque
required to lift or lower the load in case of trapezoidal threads can be obtained by
replacing ‘m’ with ‘m secq’. For example:
Figure 25.5 Force Diagram for Trapezoidal Thread
25.5 Condition for Self-locking
The torque required to lower the load is given by,
From the equation, it is clear that if, the torque required to lower the load is
negative i.e. in such condition load will descend without requiring any external
torque. Such condition is known as overhauling of the screw. But this an undesired
condition for applications like screw jacks as it may lead to accident. On the other
hand, if φ > a, a positive torque is required to lower the load and the load cannot
descend on its own without application of external torque. Such screws are called
self-locking screws. So, the condition for the screw to be self-locking is:
25.6 Efficiency of a Square Screw Thread
Referring to figure 25.3, suppose the load W moves from the lowest point to the
highest point along the inclined plane. Then the output and input work are given by,
The efficiency of the screw is given by,
References
1. Design of Machine Elements by VB Bhandari
2. Analysis and Design of Machine Elements by V.K. Jadon
3. Machine Design by R.S. Khurmi
4. Design of Machine Elements by C.S. Sharma & K. Purohit
5. Mechanical Design by Peter Childs
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LESSON 26 DESIGN OF POWER SCREWS
26.1 Materials
Screw is subjected to torque, axial compressive load and bending moment also,
sometimes. Screws are generally made of C30 or C40 steel. As the failure of power
screws may lead to serious accident, higher factor of safety of 3 to 5 is taken.
Threads may fail due to shear, which can be avoided by using nut of sufficient
height. Wear is another possible mode of thread failure as the threads of nut and
bolt rub against each other. Nuts are made of softer material than screws so that if at
all the failure takes place, nut fails and not the screw, which is the costlier member
and is also difficult to replace. Plastic, bronze or copper alloys are used for
manufacturing nuts. Plastic is used for low load applications and has good friction
and wear properties. Bronze and copper alloys are used for high load applications.
26.1 Design of Screw and Nut
26.2.1 Compressive & Torsional Shear Stress in Screw Body
Figure 26.1 Screw and Nut
Screw body is subjected to axial compressive load, W and torque, T as shown in
figure 26.1.
Direct Compressive Stress,
Torsional Shear Stress,
where T = Applied Torque
J = Polar moment of inertia
r =
The principal shear stress is given by,
26.2.2 Shear Stress in Threads
The threads of the screw and nut are subjected to transverse shear forces due to the
load W. Shear stress is maximum near the root diameter for the threads of the
screw.
Maximum transverse shear stress in the threads of screw is given by,
where, b – thread thickness at the core diameter
n - number of threads in engagement
In the threads of the nut, transverse shear stresses is maximum at the nominal
diameter and is given by,
26.2.3 Bearing Pressure Between Surfaces of Screw and Nut
The bearing pressure between the contacting surfaces of the screw and nut is given
by,
26.3 Design of Screw Jack
Screw Jack is a device, in which screw mechanism is used to raise or lower the
load. Manually operated, portable type screw jack is the simplest and most
commonly used. Its construction is shown in figure 26.2. In this, nut is fixed to the
frame and remains stationary. When screw is rotated with the help of the handle, it
moves axially. A cup is provided at the top to support the load. Cup remains
stationary as the screw rotates and they rub against each. Applied torque has to
overcome this friction also, which is known as collar friction. To avoid screw to
completely turning out of the nut, washer is fixed on the lower end of the screw.
Figure 26.2 Screw Jack
In order to design a screw jack for a load W, the following procedure may be
adopted:
1. Calculate core diameter of the screw, considering only the compressive stress,
Value of core diameter should be standardized and corresponding values of mean
diameter (dm) and outer diameter (d) should be taken.
2. Calculate the effort at the handle and the torque required to lift load, W.
3. Calculate the direct compressive stress and torsional shear stress and find the
principal shear stresses.
4. Find the height of nut (H), considering the bearing pressure on the nut.
Calculate the number of threads, n required for given allowable bearing
pressure, by using equality sign in above relation.
Then, height of nut, H = number of threads X pitch = n p
5. Check the shear stress in the threads of screw and nut.
Note that allowable value of shear stress is different for screw and nut as
different materials are used for them.
6. Find outer diameter (D) of the nut by considering its tearing failure.
7. Find outer diameter of the nut collar (D1) considering crushing failure of the nut.
8. Find thickness of the nut collar (t) considering shear failure of the collar.
9. Assume outer and inner diameter of cup, coming in contact with the head as:
Outer Diameter, Do = 1.6 d
Inner Diameter, Di = 0.8 d
10. Calculate the torque required to overcome collar friction,
11. Total input torque required to lift load, W,
This is the total torque to be applied with the help of hand lever. Assuming that
a force of 300 N (approximately) can be applied by hand. Required length of the
handle is then given by,
12. Calculate diameter of the handle (dh) considering its bending failure.
where, Applied bending moment, M = P lh
Moment of inertia, I =
Distance of the farthest fiber from the neutral axis,
13. Take height of the head = 2 dh
14. Check the screw for buckling.
Effective or unsupported length of the screw is given by,
Critical Load is given by,
Where, Sy = Yield Strength of Screw Material
E = Modulus of Elasticity of Screw Material
n = End Fixity Coefficient = 0.25 (for one end fixed and load end free)
k = Radius of gyration = 0.25 dc
A = Cross-sectional Area of Screw
This critical load must be higher than the load for which the screw is designed.
15. Draw the sketch of the screw jack showing all its dimensions.
16. Find efficiency of the screw jack.
References
1. Design of Machine Elements by VB Bhandari
2. Analysis and Design of Machine Elements by V.K. Jadon
3. Machine Design by R.S. Khurmi
4. Design of Machine Elements by C.S. Sharma & K. Purohit
5. Mechanical Design by Peter Childs
