Engineering Design Group 15 Richard Kempin Adriano Sanchez Yacoub Anand Timothy Kolade 379467 637604 407357 477008

Contents
1. Design Brief and Specification .................................................................................................................................. 4 1.1. 1.2. 1.3. 1.4. 2. Learning Outcomes ........................................................................................................................................... 4 Design Brief ....................................................................................................................................................... 4 Specification ...................................................................................................................................................... 4 Task Allocation Gantt Chart .............................................................................................................................. 5

Survey, Design Types and Operation applications .................................................................................................... 6 2.1. 2.2. Screw Jack Survey ............................................................................................................................................. 6 Types of Screw Jack ........................................................................................................................................... 6

3. 4.

Existing Design Analysis ............................................................................................................................................ 7 Concept Design Analysis ........................................................................................................................................... 8 4.1. 4.2. 4.3. 4.3.1. 4.4. 4.4.1. 4.5. 4.5.1. 4.6. Variant 2 Analysis .............................................................................................................................................. 8 Variant 2 Parts Description ............................................................................................................................. 10 Concept 1 ........................................................................................................................................................ 11 Concept 1 Description ................................................................................................................................. 11 Concept 2 ........................................................................................................................................................ 12 Concept Description .................................................................................................................................... 12 Final Concept................................................................................................................................................... 13 Final Concept Analysis................................................................................................................................. 14 Part Design Considerations ............................................................................................................................. 15

5.

Material and Manufacturing Selection and Jestification ........................................................................................ 16 5.1. 5.2. 5.3. 5.4. 5.5. Material Survey ............................................................................................................................................... 16 Material Justification....................................................................................................................................... 17 Manufacturing Justifications ........................................................................................................................... 18 Welding Method Survey ................................................................................................................................. 19 Welding Method Justifications ....................................................................................................................... 19

6.

Thread Survey and Justification .............................................................................................................................. 20 6.1. 6.2. 6.3. Thread Survey ................................................................................................................................................. 20 Thread Requirements ..................................................................................................................................... 21 Thread Justification ......................................................................................................................................... 21

7. 7.1.

Bearings and Bushes ............................................................................................................................................... 22 Bearings............................................................................................................................................................... 22 Bearing Survey ................................................................................................................................................ 22 Bearing Justification ........................................................................................................................................ 22 Bushes ................................................................................................................................................................. 23 Bush Survey ..................................................................................................................................................... 23

7.1.1. 7.1.2. 7.2. 7.2.1.

7.2.2. 8. 8.1. 8.2.

Bush Justification ............................................................................................................................................ 23

Bearings and Bushes ............................................................................................................................................... 24 Nut Survey ........................................................................................................................................................... 24 Locking Nut Justification ..................................................................................................................................... 25

The nylon locking nuts have been selected to secure the safety plate in position. It is relatively cheap to purchase this nut than manufacturing. In term of weight is much lighter than the metal nuts. The main advantage of this nylon locking nut is that it is has resistance to torque. ............................................................................................................ 25 9. 10. Safety Factor Justification ....................................................................................................................................... 26 Power Screw Specification .................................................................................................................................. 27 Power Thread Calculations ......................................................................................................................... 27 Accuracy Screw ....................................................................................................................................... 28 Distance Screw ........................................................................................................................................ 34

10.1. 10.1.1. 10.1.2. 11. 12. 13. 14. 15.

Nut Design Calculations ...................................................................................................................................... 39 Contact Plate ....................................................................................................................................................... 42 Contact Plate Housing Calculations .................................................................................................................... 44 Housing Desing Calculations ............................................................................................................................... 45 Handle Design Calculations ................................................................................................................................. 48 Accuracy Screw Handle Calculations........................................................................................................... 48 Distance Screw Handle Calculations ........................................................................................................... 51

15.1. 15.2. 16.

Handle Design Ergonomics.................................................................................................................................. 53 Ergonomics Background.............................................................................................................................. 53 Grip Background.......................................................................................................................................... 53 Hand Sizes ................................................................................................................................................... 53 Ergonomic Grip Choice................................................................................................................................ 54

16.1. 16.2. 16.3. 16.4. 17.

Conclusion ........................................................................................................................................................... 55

1. Design Brief and Specification 1.1. Learning Outcomes

Apply Mechanical Engineering Design and Design for Quality Manufacture; Appraise the influences of human factor considerations on engineering design; Demonstrate an understanding of the constraints on the designer;

1.2. Design Brief Your design group has been commissioned to redesign a hand driven Screw Jack using the main concepts provided in Further Information and according to BS and ISO standards. The client requires an efficient design of a screw jack of general use for supporting machine parts during their repair and maintenance on the shop floor, load capacity of X kN and lifting height of Y m. 1.3. Specification This project is to redesign a hand driven Screw Jack using specific criteria and adding others. Specific Criteria; Minimum lifting capacity of 19kN Minimum lifting height of 0.3m Safety factor between 3 and 4 Additional Criteria; Adding additional safety features Improving the initial design Making the Screw Jack simple to use Increase the Screw Jack accuracy The initial design (Variant 2) is a basic Screw Jack design that will be analysed in the report. Improving the Variant 2 design is a task that requires thought about the characteristics of the Jack and the effect of any changes. Some of the characteristics that need to be assessed are; Existing Screw Jack Types Materials Used Thread Used Screw Diameter Lifting Handle Handle Size and Ergonomics Safety Factors

1.4. Task Allocation

Task Group Leader Secretary Initial research Design brief Gantt Chart Screw Jack Survey Existing Design Analysis Variant 2 Analysis Conceptual Designs and Analysis Design Considerations Material Consideration and Justification Manufacturing Considerations and Justifications Nut Survey and Justification Thread Considerations and Justifications Bearing and Bush Survey and Selection Safety Factor Determination Part Calculations Handle Housing Screws Nut Contact Plate Contact Plate Housings Safety Plate Ergonomics Part Design Handle Housing Screws Nut Contact Plate Contact Plate Housings Safety Plate Ergonomic Grips Bushes Nut Securing Plate Detail Drawings Instructional Manual Meeting Minutes Report

Person Allocated Adriano Sanchez Timothy Kolade Richard Kempin, Adriano Sanchez, Yacoub Anand, Timothy Kolade Richard Kempin Adriano Sanchez Richard Kempin Richard Kempin Richard Kempin, Adriano Sanchez Richard Kempin, Adriano Sanchez Richard Kempin Timothy Kolade, Adriano Sanchez, Richard Kempin Richard Kempin, Adriano Sanchez, Timothy Kolade Timothy Kolade Yacoub Anand, Adriano Sanchez Richard Kempin, Adriano Sanchez Richard Kempin Adriano Sanchez Adriano Sanchez Adriano Sanchez Adriano Sanchez Richard Kempin Richard Kempin Adriano Sanchez Yacoub Anand Adriano Sanchez Richard Kempin, Adriano Sanchez Adriano Sanchez Adriano Sanchez Richard Kempin Richard Kempin Timothy Kolade Yacoub Anand Richard Kempin, Adriano Sanchez Adriano Sanchez Richard Kempin, Adriano Sanchez, Yacoub Anand, Timothy Kolade Yacoub Anand, Richard Kempin Timothy Kolade Richard Kempin

2. Survey, Design Types and Operation applications

2.1. Screw Jack Survey A Screw Jack is a type of jack that is operated by turning a lead screw to lift or hold a weight. The screw jack is an invention that can be accredited to Leonardo Da Vinci and uses concepts that date back to Archimedes in 2000 BC. There are various different types of Screw Jacks available that all have their own advantages and disadvantages. This section will analyse the different types of Screw Jack and how they differ from each other. The simplest way of doing this is to break down the concepts of a Screw Jack, look at how they differ and then compare a selection of current models and see how they are used.

2.2. Types of Screw Jack

Type of Screw Jack Axially Translating Screw Jack Description Uses rotary motion of a screw in a nut or a nut in a casing to move the screw axially. Can utilise a worm gear to accommodate different handle designs. Can incorporate bearings to reduce friction. As the screw is rotated, the Loading Nut will travel up or down the screw depending on the direction of rotation. Can utilise a worm gear to accommodate different handle designs. Can incorporate bearings to reduce friction. As the screw rotates in a horizontal direction, it causes the scissor design to squeeze together raising its height. Advantages Simple design Cheap to manufacture Cheap to purchase Wide choice of materials available Wide choice of size and lifting capacity Disadvantages Limited operational ability Cheaper manufactures use cheaper/weak er materials Lack of bearings make it hard to use and increase wear Loading Nut requires force acting upon it to prevent it turning with the Screw. Excess lubrication may counter the effect of self-locking thread Total jack size fixed at maximum. Requires regular lubrication or high likelihood of locking. Common Uses Machinery alignment Lifting of portable buildings (multiple jacks used in parallel) Used on construction sites as cable jack Machinery alignment Linear actuator Micrometers Load Capacities 5kN to i 1000kN depending on model Supporting Image(s) Figure 2.1

Rotating Screw with Traveling Nut

Very simple design Cheap to manufacture Wide choice of load capacity and Screw lengths Wide choice of materials available Cheap to purchase

5kN to ii 1000kN depending on model

Figure 2.2

Scissor Jack

Very simple design Very cheap to manufacture Light weight compact Wide choice of materials available

Lifting cars to replace tyres

Max load 19kN to iii 40kN depending on model

Figure 2.3

www.techdrives.co.uk www.techdrives.co.uk iii www.4x4jack.com

ii

3. Existing Design Analysis

Type of Screw Jack Axially Translating Screw Jack Cost Range ( per unit) 150 to 5000i depending on model requirements Ease of Operation and Operation Requirements Simple to operate Requires upper body strength Can be hard to turn handles depending on handle length/size Hazards Human factors such as kicking the handle when friction is too great Wear on the screw may cause the self-locking attributes to fail. May require bearings to prevent the load turning with the screw Plate will not turn if not loaded Limited contact area for load Uneven loading may cause uneven wear Design Requirements Self-locking screw Handle ergonomics Handle length (from centre) Friction to overcome. Bearing requirements

Rotating Screw with Traveling Nut

64.11 ($100US)ii to 128.22 ($200US)iii depending on model requirements 7.44iv to 297.20v depending on model requirements

High level of strength requirement to turn screw when plate is loaded Can be hard to turn handles depending on handle length/size Very simple to operate Requires significant levels of upper body strength when loaded Compact and easily storable when unused

Scissor Jack

Can cease if unused and unlubricated Can cause injury if used incorrectly

Self-locking screw Load friction Handle length (from centre) Required force Plate strength Methods of fixing load to plate Light weight Self-locking screw Compact

www.screwjack.en.alibaba.com www.alibaba.com iii www.alibaba.com iv www.valuemedia.co.uk v www.jtote.com

ii

All Screw Jacks will suffer from common hazards as well. These include; Shearing of threads Crushing of weaker parts Exposure to corrosive substances Instability (damaged Housing or uneven ground) Human errors: Misuse such as kicking handles Dropping Excessive loading Impact loading Over lubrication

All Screw Jacks will have to consider common design requirements such as; Safety factors Manufacturing costs Ergonomics Material stresses and strengths

4. Concept Design Analysis

4.1. Variant 2 Analysis
Nut

Screw and Nut Threads

Securing Screw

Housing

Screw

Bolt and Safety Plate

Figure 4. 1 Variant 2 Drawing 1

Figure 4. 2 Variant 2 Drawing 2

4.2. Variant 2 Parts Description Nut This is the threaded Nut that the screw rotates in. It is fixed in place in the Housing by Securing Screws. If the Screw is rotated, the stationary nut will force the Screw either up or down depending on the direction of rotation. The Nut will need to be capable of supporting the load without shearing or buckling. As a separate part to the Housing and Screw, it is replaceable. Securing Screw This is a screw that secures the Nut into the Frame ensuring it does not rotate or fall out. This part is not load bearing and is usually batch ordered. Housing This is the outer shell of the Screw Jack. It houses the Nut and acts as a base for the Screw. The main purpose of the Housing is to transfer the load transmitted to the screw through to the ground. It also acts as a casing for the Screw when not in use. This is a large piece that requires to be made from a strong material. Due to its size it will need to be cast. It has to tapped holes in the side for the Securing Screws. Screw This is the load bearing part of the Screw Jack. When it is rotated it will either raise or lower (depending on the direction of rotation) adjusting the height of the Screw Jack. This is probably the most important part of the Screw Jack. If the Screw fails, the entire Jack is unusable. The screw thread can come in different types depending on the requirements of the screw. These will be discussed later. This part must also be able to withstand the load put on the Jack without sheering or buckling. These characteristics are dependent on the thread thickness, thread depth and Screw diameter. Bolt and Safety Plate These are two pieces attached to the bottom of the Screw as a safety feature. The Washer is bolted to the Screw using a Bolt in a pre-taped hole in the bottom of the Screw. The washer will have a wider diameter than the Screw as so to not travel past the Nut preventing the Screw travelling too far out of the Piece. This will be set at the Screws maximum length as to prevent any accidents. Contact Plate (Arial and horizontal view) The Contact Plate will be in contact with the load. This design is cone shaped as to give it a greater surface area contact with the load. This also allows the centre of the cone to be hollow so it can be bolted to the Handle Carrier. Depending on the dimensions of the design, this could also incorporate a bearing bellow it allowing it to rotate if needed. The wide surface area will also allow for uneven loads. Handle Carrier (Internally Threaded) This piece is connected to both the Screw and the Cone. It has a threaded hole through it for the handle to be attached in. It can be connected to the Screw and Cone either by welting or threading. This piece must be able to withstand both the load on the Jack as well as the force applied through the handles. Handle This is the method used to turn the Screw. It is threaded in the centre allowing it to be fixed in position within the Handle Carrier. The handle is designed to withstand bending from the force exerted upon it from the user.

4.3. Concept 1

Figure 4. 1 Initial Concept Drawing

4.3.1. Concept 1 Description The Nut is bolted into the Housing from above using Securing Bolts. The Screw is rotated in this by the Handle. The Handle is attached at the top of the Screw through a Handle Carrying Attachment. The contact plate is attached above the Handle Carrying Attachment with Bearings between. The Bearings will allow the Contact plate to rotate freely under load as required relieving the turning friction.

4.4. Concept 2

Figure 4. 2 Concept Drawing 2

4.4.1. Concept Description This design has two Screws. A Distance Screw and an Accuracy Screw. The Distance Screw will lift the load a specific height in a fewer turns than the Accuracy Screw which will be used to raise the load accurate amounts. The Distance Screw rotates in the Nut, which is bolted into the Housing, by the handle attached at the top of the Screw. The Accuracy Screw rotates inside the Distance Screw (threaded hole inside the Distance Screw) and is rotated by the handle attached at the top of the Screw. The contact Cone is attached above the Accuracy Screw on Bearings.

4.5. Final Concept

NOT TO SCALE

Grub Screw Plate Housing

Contact Plate

Handle Bearings Bolt

Un-Threaded Screw

Screw (Accuracy)

Weld

Screw (Distance)

Handle Securing Cap Bolt

Nut Securing Cap Bearings

Handle Carrying Attachment Securing Plate

Bolt

Housing
Figure 4. 3 Final Concept Drawing

4.5.1. Final Concept Analysis Bearings Three sets of Bearings. The uppermost will take the load on the Jack and allow the Contact Plate to rotate freely if required. The middle Bearings are designed to reduce the friction caused by the Nut Securing Cap pushing on the Nut. The lowest Bearings will take the entire load placed on the Jack while it is rotating. It will be placed between the Nut and the Housing allowing the Nut to be rotated without friction. Contact Plate A cylindrical piece with a grove towards the bottom and an internal hole to save material. It is designed to withstand the load on the Jack. It sits on a Bearing inside the Contact Plate Housing. The grove is for Grub Screws to keep it in the housing. The top surface will be hatched to give it better grip. Contact Plate Housing Houses the Contact Plate and the bearing. Has taped holes through it for Grub Screws to keep the Contact Plate in place. It is welded to the Accuracy Screw. Grub Screw Placed through the Contact Plate Housing and into the grove of the Contact Plate to prevent the Contact Plate from falling out or being accidentally removed. This part is not load bearing. Handle Two sets of handles. One welded to the top of the Accuracy Screw (Unthreaded section) to turn the Accuracy Screw. The other welded to the Nut to rotate it. The sizes are determined by the amount of force applied on them. They will also have ergonomic handles for the user. Housing The main body of the Jack. This houses the Distance Screw when it is not extended. Has an open bottom allowing the Distance Screw to be removed from bellow. Has taped holes in the top for the Securing Cap Bolts. Contains a ridge inside as a platform for the Bearings. Nut As the nut rotates, it pushes the screw up or down. It sits inside the Housing on Bearings and secured by the Nut Securing Cap (between a Bush). Has Handles welded to it in order to rotate it. Nut Securing Cap Bolted to the Housing by the Securing Cap Bolts. Pushes on the Nut (via Bush) holding it in the Housing. Screw (Accuracy) This is the smaller Screw that lifts the Jack small amounts for every turn(one turn raises the Jack 5mm). It sits in the Distance Screw. Has an unthreaded section at the top for the Handles to be welded to. The Contact Plate Housing is bolted to the top. Screw (Distance) This is the larger Screw that lifts the Jack further for each turn (one turn raises the Jack 16mm). Sits in and is rotated by the Nut. Has a threaded hole in the top for the Accuracy Screw. Has a Securing Plate bolted to the bottom to prevent it from being removed while in use. Securing Cap Bolt Used to bolt the Nut Securing Cap to the Housing.

Securing Plate Metal plate bolted to the bottom of the Distance Screw. Its diameter is wider than the Distance Screw and had 4 keys as part of the design that will run in the channels cut into the housing to prevent the Distance Screw from turning. The Securing Plate will contact the housing in the event the Distance Screw is extended beyond its limit. Its purpose is to prevent the Screw from being removed too far from the Nut compromising the safety of the Jack.

4.6. Part Design Considerations

Part Bearings Bearing Bushes

Design Considerations To bear the dynamic load on the Jack To reduce friction To prevent wear on the Bearings Fast wearing material Easy to replace To fail before the Bearings To withstand the load without receiving damage To fail before the Contact Plate Housing Be removable Easy to remove or replace Cheap to manufacture To fail after the Contact Plate To hold the Contact Plate and Bearing Withstand the load on the Jack Long enough to overcome the torsion of the Jack Thick enough to withstand bending from force applied to it Ergonomic design Strong enough to withstand the load on the Jack Wide enough for stable base To house and protect bearings and Screws from damage Machined key channels to keep the Distance Screw aligned High enough for welded handles Self-locking thread To hold the Nut in place Prevent the Nut and Bearings from being accidentally removed from the Housing

Contact Plate

Contact Plate Housing Handles

Housing

Nut Nut Securing Cap Screw (Accuracy)

Screw (Distance)

Securing Plate

Self-locking thread Unthreaded section for welded handles Close pitch for accurate distance per turn Withstand the load without buckling Self-locking thread Internal thread for Accuracy Screw Larger pitch for greater distance per turn Withstand the load without buckling Wider that Distance Screw Strong enough to withstand low level impact when in use Machined keys to keep the Distance Screw aligned

5. Material and Manufacturing Selection and Jestification

5.1. Material Survey

Material

Specific Code CZ121

Standard

BS 2874

Yield Stress 2 (N/mm ) 150-400

Manufacturing Options Milling Lathing

Common Uses

General Properties Hard and durable at low temperatures East to machine Non sparking Corrosion resistant Machinability = 100 High metal removal rate High metal removal rate Cheap Low Tensile Strength Malleable Increasable surface hardness Expensive to manufacture Durable Hardened through flame or induction Welding not through flame Very strong Expensive Machinability = 40 Machinability = 16 Low metal removal rate Hard to machine Sand casting Hard wearing Extremely strong and hard wearing Very expensive Light weight Corrosion resistant Cheap Light weight Easy to machine Light weight Easy to machine Corrosive resistant

CZ128 Brass

BS 2874

150-380

Milling Lathing

High speed machined components Locks Hinges Pistol firing pins Jewellery Horse shoes

Low Carbon Steel (Cold drawn)

220M07

BS 970:1991

355-465

Milling Lathing

Medium Carbon Steel

AISI 1045

BS 970:1991 IS:9001:2000

505

Milling Lathing

Machinery parts Wires Sprocket and chain assemblies Explosive forming tools Dies/Bolts/Rods Vehicles Shafts Bushings Crankshafts Connecting rods

High Carbon Steel (Manganese) Austenitic Stainless Steels (Softened) Grey Cast Iron

EN31

BS 970:1991 IS:9001:2000

>600

Milling Lathing

Tool manufacture Specialist requirements Screws Gears Aircraft fittings Bushings Shafts Automotive part manufacture Cooking utensils Construction materials Gas turbine engines Helicopter rotors Spacecraft Golf clubs Bicycle frames

303S31

BS 970:1991

>190

Milling Lathing

FG 200

IS:210 1978

200

Casting

Titanium

Ti-6Al2Sn-4Zr6Mo

ASTM B 265 ASTM B 338 ASTM B 367

1100

Casting Forging Milling

Aluminium bronze

CA104

BS 2874 EN 12163

370

Milling Lathing

Valve and pump components Fasteners Engine components Architectural applications Window frames Doors Irrigation tubing

Aluminium Alloy

6063

BS EN 120201:2008

62-172

Milling Lathing Stamping Casting

5.2. Material Justification

Part No Component Name Material Section Quantity Material Justification

Contact Plate

Contact Plate Housing

Handles

Handle Grips

Housing

Nut

Nut securing cup

Mild Steel 220M07 BS970:1991 (IS:9001:2000) Medium Carbon steel AISI 1045 BS970:1991 (IS:9001:2000) Medium Carbon steel AISI 1045 (IS:9001:2000) Natural Moulded Rubber BS 3734 Grey cast iron FG 200 (IS:210 1978) Medium Carbon steel AISI 1045 BS970:1991 (IS:9001:2000) Brass CZ128 BS 2874

Low cost Economical to machine Will fail before Contact Plate Housing Can be cast for complex shape Will fail after Contact Plate Can be machined for tolerance fits Material available in rolled bars Strong enough to withstand bending force Ergonomic material Vibration absorbing Economic to manufacture Can be cast for complex shape Strong enough to hold load on Jack Economical to manufacture Strong enough material to withstand the load on the jack Practical to manufacture

Screws ( Accuracy)

Screw ( Distance)

10

Securing Plate

Medium Carbon steel AISI 1045, BS970:1991 (IS:9001:2000) Medium Carbon steel AISI 1045 BS970:1991 (IS:9001:2000) Mild steel 220M0 BS970:1991 (IS:9001:2000)

Low cost Economic to manufacture Hard and durable at low temperatures to protect the nut assembly High yield strength Screws will not bend or buckle Threads unlikely to strip Can be welded to

Low force requirements on part Can be machined for key sections

5.3. Manufacturing Justifications

Part Contact Plate

Manufacturing Method Sand Casting Turning/Milling Die Casting Turning/Milling Cold rolling, drawing Grinding Injection Moulding Sand Casting

Contact Plate Housing

Handles Handle Grips Housing

Nut

Turning Milling

Nut Securing Cap Screw (Accuracy)

Turning Turning Grinding Turning Grinding Milling

Screw (Distance)

Securing Plate

Justification Sand Casting will give a suitable surface finish of 12.5m Required Surfaces can be machined for suitable finishes of 6.3m and 1.6 m Die Casting will give a suitable surface finish of 0.8m for the inside dimensions ready for use Required Surfaces can be machined for suitable finish of 6.3 m Cold rolling steel will give a surface finish of 3.2m Grinding the end that will be welded will have a finish of 3.2m An economical manufacturing method that will mass produce the parts ready to use Sand casting will give a cheap surface finish of 25m allowing for sand blasting or painting if required The inside requires a better finish of 12.5m for the fit with the bush The inside will need to be threaded by turning The smaller outer diameter will be turned then grinded to surface finish of 3.2m for welding The larger outside diameter will be turned to a surface finish of 3.2m due to the fit with the bush Required surface finish of 6.3m due to outer exposure to user and inner fit with bush Turning for the thread Grinding the unthreaded section to a finish of 3.2m for welding of Handles Turning for the outer thread and inner thread Grinding the underside to a finish of 3.2m for welding of Securing Plate Bolt Milling for accurate fits and tolerances for the keys

5.4. Welding Method Survey

Name Brazing Characteristics This mechanical joining process, that use fillers having a significantly higher melting points ( 450 to 800o ) The heat to produce fusion of the parent metal and filler rod is provided by burning a suitable gas in oxygen or air, since it burns in oxygen and gives a high flame temperature of 3100o - 3200o. C. In this process an arc is drawn between a coated consumable electrode and the work piece. The metallic core-wire is melted by the arc and is transferred to the weld pool as molten drops. This process is used widely for automated welding using robots. The metal inert gas process uses a consumable electrode of wire form and an inert gas shield of carbon dioxide when welding carbon steel This process was developed for welding magnesium, even though, it is now used for welding aluminum, copper, stainless steel, and a wide range of other metals that are difficult to weld. This process involves the welding arc being continuously submerged under a mound of granular flux. The resulting weld is uniform with good physical and chemical properties. A concentrated beam of electrons bombards the base metal, causing it to melt and fuse. Therefore the process is most efficient when done in a vacuum chamber The laser beam is a concentrated beam of light with sufficient energy to generate the heat at the base metal surface to cause fusion. Applications The process is used widely for mechanical joining and sealing for higher performance applications on copper based alloys Justification This kind of processes are to slow and they are most widely used on copper alloys

Gas Welding

It is widely used for welding pipes and tubes, as well as repair work

The speed of this process makes it too slow for the welding of the handles, rising cost. The seller recommend welding the material under especial considerations as this kind of welding processes, enable to use low hydrogen electrodes, it will be the one being use to weld the handles

Metal Arc Welding

The process is generally limited to welding ferrous materials, though special electrodes have made possible the welding of cast iron, nickel, aluminum, copper, and other metals Was originally developed for welding aluminum and other nonferrous materials in the 1940s, however, was soon applied to steels because it allowed for lower welding time compared to other welding processes It is most commonly used to weld thin sections of stainless steel and non-ferrous metals such as aluminum, magnesium, and copper alloys This process got a wide range of welding applications such as; carbon steels, low alloy steels, stainless steels and nickel-based alloys.

MIG Welding

This process is suitable to weld the handles but rise the production cost due to the prices of inert gas.

TIG Welding

This process is suitable to weld the handles but rise the production cost due to the prices of inert gas.

Submer ged Arc Welding

The process is suitable to weld the handles but the slowness of the welding rise the cost.

Electron Beam Welding

This process is able to melt any known material and the ability to weld dissimilar metals This is a versatile process, capable of welding carbon steels, HSLA steels, stainless steel, aluminum, and titanium.

The process is a high quality welding but to get the best from it, it needs the vacuum chamber, so cost are risen The use of this process is cost effective but too expensive for the manufacturing process.

Laser Welding.

5.5. Welding Method Justifications

The Metal Arc Welding process have been selected, because several considerations, such as; This process is flexible and enables the use of low hydrogen electrodes that the seller recommends It reduces the cost of manufacturing Its ideal for repairs as this kind of process are mobile increasing the versatility of it.

6. Thread Survey and Justification

6.1. Thread Survey

Purpose of Power Threads Transmit force by converting rotational motion into linear motion

There are four main types of Power Thread. Below are the characteristics;
Thread Type Acme (Trapezoidal) Characteristics Most common form of Power thread Trapezoidal and Acme threads have a difference of 1 Used for power/force transmission Low friction No imposed radial forces Advantages Disadvantages Supporting Images Economic to Low efficiency thread Figure 6.1 manufacture Resultant Radial Higher load capacity pressure/side thrust Can be self-locking High efficiency Radial pressure/side thrust imposed on the nut. Can be self-locking Figure 6.2 Difficult and expensive to manufacture Low thread thickness results in low load capacity When worn, cannot be repaired. Only replaced Figure 6.3 It can only transmit power in one direction

Square

Buttress

Ball Screw

Combines the advantages of square and trapezoidal threads Used for heavy unidirectional axial forces Uses ball bearings to reduce friction and distribute force Used in accurate machinery alignment

High Efficiency Economic to manufacture Can be self-locking

Very low friction Highly accurate

Low load capacity Expensive to manufacture Not self-locking

Figure 6.4

Figure 6.1 Trapezoidal Thread

Figure 6.2 Square Thread

Figure 6.3 Buttress Thread

Figure 6.4 Ball Screw Thread

6.2. Thread Requirements

Displace load axially, minimum requirement is one direction Limited Friction Self locking Economical to manufacture Load bearing threads

6.3. Thread Justification

Thread Surface Chosen Thread Reason

Both Screws (alternate directions) Buttress Thread Low Friction High load bearing capacity Economic to manufacture Only one direction load direction required

Table 6. 2 Thread Type Justification

Research source design of Machine Elements, Third Edition, 2010, V.B Bhandari

7. Bearings and Bushes 7.1. Bearings

7.1.1. Bearing Survey

There are many types of bearings available for use today and they all have their own specific characteristics and reasons for use. This survey will look at the different types and their properties
Bearing Type Thrust Ball Bearing Advantages Capable of taking high dynamic loads Low cost Internal clearance for alignment Can take radial load High radial load capacity Take less space High load capacity Disadvantages Can only take load in one direction Cannot take radial load Uses Plant machinery Pumps Thrust shafts

Roller Bearing

Needle Roller Bearing

Tapered Roler Bearings

Very High Load capacity Efficient design

Cannot take axial loads Take up more room than needle roller bearings Can only take load in one direction Cannot take radial load Wider than Roller Bearings for same capacity Very expensive Minimum size requirements

Transmissions Printing Motorcycles Precision applications Gearboxes Automotive differentials

Trailer and Caravan axles Transmissions

7.1.2. Bearing Justification

The chosen bearings used will be Thrust Bearings. The reason for this will be the cost and axial load efficiency of the bearings. We have chosen to use a bearing with dimensions 50x95x31 for the Nut load bearing (dynamic load capacity of 88.4kN) and a bearing with dimensions 50x95x31 for the Contact Plate bearing (dynamic load capacity of 55.3kN) and

Figure 7. 1 Needle Roller Bearing

Figure 7. 2 Tapered Roller Bearing

Figure 7. 3 Roller Bearing

Figure 7. 4 Thrust Bearing

7.2.

Bushes

7.2.1. Bush Survey

Types Solid sleeve Flanged A bush is an independent plain bearing that is inserted into a Split Clenched housing to provide a bearing surface for rotary applications. Description Characteristics Solid tube. Solid sleeve with a flange extending radially outward from the outside diameter to provide a thrust surface or used to allocate the bushing when it is installed. Splits bushes has a cut along its length. Clenched bushes have the same cut as split bushes but with a clench across the cut.

7.2.2. Bush Justification

A split bush has been selected to be placed into the housing between the nut and the cap to absorb the wear as a solid bearing cannot be placed there. Solid sleves have been selected to be placed between the bearings and their housings to prevent wear on the walls of the housing. The company Xingya Non-Ferrous Metal Casting Co., Ltd. is able to manufacture the selected bushes.

Figure 7. 5 Solid Sleeve Bush

Figure 7. 6 Flanged Bush

Figure 7. 7 Split Bush

Figure 7. 8 Clenched Bush

8. Bearings and Bushes

8.1.

Nut Survey

There are many different types of nut available for us to use when securing the Safety plate onto the Distance Screw. This table will show the different types.
Nuts Materia ls Type Locking Nuts Aero tight Stainless 304(M5 Selflocking Nut All Metal (Aerotight) A2 Stainless)A2 . Mode of operation Require a bolt to travel through a space, which is actually too small for its diameter and threads. As the bolt passes into the narrowed area of the nut the nut holds it i quite firmly. By tightening the clamping bolt, the slot is narrowed, and the nut located without clearance. The nut has a tight fit on the shaft thread so that it cannot turn. Tightened in the same manner as a normal steel nut, except the nylon thread inside one end will mould to the thread and grip tight prevent it being shaken or vibrated loose. Advantages Disadvantages Expensive Architectural metal work Construction Internal marine applications Application Images Figure 8.1

Steel

Allows to hand turn into the bolt for the first turns. Great temperature resistance (600oC) than nylon insert locknuts. Withstand vibration

HMS Lock nuts

ii

Split HMS lock nuts trapezoidal thread to ISO 2903:1993, grade 7H

Does not require No keyway when in use on shaft Easy to mount No problem with fretting corrosion during dismounting

Expensive

Gears Flywheels Shafts Wind turbines

Figure 8.2

Nylon lock Nut

DIN986 TUV CERT ISO9001:20 iii 00

Metric BZP Wing Nuts M5 Metric BZP Wing Nuts M10 Metric BZP Dome Nuts M5 Metric BZP Dome Nuts M10 It has two wings on it side that grip for easy loosen and tighten by hand It can be hand tide to some extend.

Wing Nut

Zinc plated steel

It is lighter compare to metal locknut Does not rust Does not conduct electricity Low in cost Allow reused a limited number of times. Lock washers are not used with prevailing torque lock nuts Resistance to torque Reduces hand afford during tighten and loosening Weather resistant It can be use for all type of application mention in the application

Not good for elevated temperature Not advisable in chemical area Contaminates of the bolt affect the performance of the nylon

Wheels or axles Aerospace Agricultural equipment Appliances Vehicles

Figure 8.3

It is considered as a weaker nut because of the arm strength It can be bolted or screw depending on the thread depth.

Loose tightening Weak material holding Car wheels Bike parts Engine rocker covers

Figure 8.4

Dome Nut

Zinc plated steel

Figure 8.5

www.mymilescity.com www.skf.com

ii

Dome Nut

plated steel

Metric BZP Dome Nuts M10 mention in the application depending on the thread depth.

Engine rocker covers

www.mymilescity.com www.skf.com www.kaimametal.com

ii

iii

8.2.

Locking Nut Justification

The nylon locking nuts have been selected to secure the safety plate in position. It is relatively cheap to purchase this nut than manufacturing. In term of weight is much lighter than the metal nuts. The main advantage of this nylon locking nut is that it is has resistance to torque.

Figure 8. 1 Steel Lock Nut

Figure 8. 2 HMS Lock Nut

Figure 8. 3 Nylon Lock Nut

Figure 8. 4 Wing Nut

Figure 8. 5 Dome Nut

9. Safety Factor Justification

Safety factors are an integral part of modern design processes. The can be described as a form of redundancy. The higher the safety factor, the higher the safety redundancy. The safety factor is usually designed into the part from the start. This chosen safety factor will be determined by the type of product being designed. Low safety factors (between 1 to 2) are usually used for simple designs with very little risk. The type of material, the manufacturing process, the purpose and the usage environment will also impact on the safety factor. If the materials are known and have been tested, the loads and stresses are constant and low, the exposure to weather and corrosive substances limited then the designed safety factor can be low. If however , these factors can change or are unknown then the safety factor will need to be higher. The purpose of the designed piece can also raise the safety factor. For example; impact, high speed or vibration characteristics will raise the required safety factor to above 5. The design for this screw jack will have a minimum safety factor of between 3 and 4. The only exception to this will be the safety factor of the Bearings which will have a dynamic safety factor of at least 1.5. Unlike the environmental characteristics, which are undeterminable, the material characteristics are known allowing safety factor will be calculated into the designs of each part. this will be done on each part by assuming the required load capacity being at least 3 times greater. This means all parts must withstand of a minimum load of 57kN.

10.

Power Screw Specification

Power Thread Calculations

10.1.

Calculation Symbol Designation

= = = = = Youngs Modulus = Lead Distance = = = = =

= = = = + = = = = = = =

10.1.1. Accuracy Screw

Figure 10. 1 Accuracy Screw Buttress Thread Profile

= 25.97 = 22 = 18.35 = 5 = 7.9390 mm /2 = 3.9695 mm 1 = 3.75 = 1.31920 = 0.589 = 0.589 = 0.2236 = 1.096 3 = 4.339 = 0.621

To know the compressive stress allowable for 19000 N, the needs to be divide for the safety factor of 3. = =
500 3

= 166.67

One of the first approaches to have an idea of which diameter will support the load is to transpose the formula to make dc the subject = 2 4 = 4 4 19000 166.67

= 12.04 Closest core diameter of buttress thread available is 13.058mm. = tan = = 3 = 1 tan cos = 2.970 = 1 tan 30 cos 8.760
8 16.529

= 2 tan = 0.154 = 8.760

Self-Locking demonstration: cos 0.15 0.154 0.15 8 cos 2.97 16.529

The screw will not be Self-Locking, for the next calculations the Lead will be take equal to the Pitch

Buckling Calculations: 2 = (1 ) 4 2

= 0.25

= 120 + =
4 4

1 60 2

= 150 =
13.058 4 4 2

= 3.27 = 133.922

2
2

(13.058)2

500/2 150 2 = 133.92 500/ (1 ) 4 0.25 2 207103 /2 3.27 = 32477.2

As the critical load is less than three times the required load (to allow for safety factor), the chance of buckling is too high. Therefore this diameter screw is not strong enough. The next diameter we will try is 16.2mm.

= 0.25 = 120 + =
4 4 1 60 2

= 150 =
18.35 4 4 2

= 4.59 = 264.462

2
2

(18.35)2

500/2 150 2 = 264.46 500/ (1 ) 4 0.25 2 207103 /2 4. .59

= 97632.11

As this critical load exceeds the safety factor of three times the required load, there will be no chance of buckling. The resultant safety factor is 5.14.

 = tan = = 3

5 22

= tan = 0.07 = 4. .140

= 1 tan cos = 2.990

= 1 tan 30 cos 4.550

Self-Locking demonstration: cos 0.15 0.08 0.15 5 cos 2.99 20

This demonstrates, the accuracy screw is self-locking.

Y W X Y

n x cos

Tangential forces:

= 0;

+ = 0

= ( + )

Axial forces:

= 0 ; +

( + )

19000 (0.15 4.14 + 2.99 4.14)

= 19285.35 = 19285.35 0.15 4.14 + 2.99 4.14

= 4275.64

Torque to lift the weight: 2 22 2 = 47032.04 .

= 4275.64

Bending: 2 = 18.35 47032.04 . 2 = 4 32 18.35 = 38.77 /2

32

= 453 150 = 67950 .

18.35 112.02 . 2 = 18.35 4 64

64

= 112.02 /2 = 2
2

+ 2

112.02 2

+ 38.772 /2

= 68.12 /2

= 2 = 500 / 2 2

= =

250 /2 68.12 /2

= 250 / 2

= 3.67

As the safety factor for bending stress for this diameter is 3.67; this column wont fail by bending stress.

10.1.2. Distance Screw

Figure 10. 1 Distance Screw Buttress Thread Profile

= 45.69 = 39.668 = 33.684 = 8 = 12.7024 mm /2 = 6.3512 mm 1 = 6 = 2.11072 = 0.942 = 0.2828 = 1.828 3 = 6.942 = 0.994

= 26 = 22.25 = 18.5 = 5

As the design is a hollow circle one of the first approach to be taken into account is considering the minimum thickness, which will be able to support the safety factor of 3, that have been mentioned before. = = = 2 2 57000 (2 16.84 166.67 /2 = 3.23 The minimum thickness required to support the load without failing for stress is 3.23 mm, so the diameter could be 32.43mm. However, according to buckling calculations the screw will fail, that is why an upper diameter have been selected, to give us a major thickness to accomplish bending and buckling calculations with a safety factor over 3.

Buckling Calculations 2 ) 4 2

= (1 = 0.25 = 300 + =
4 4

1 100 2

= 350
33.684 4

= ()2 4 (

= 8.421 =
4

)2

(33.684)2 4 (25.97)2

= 361.422 = 361.422 500/2 (1 = 104310.3 500/2 350 2 ) 4 0.25 2 207103 /2 8.421

This diameter accomplishes the buckling calculations with a safety factor of 5.49, being secure enough to be used.

 = tan = = 3

2(8 ) 39.668

= 2 tan = 0.13 = 7.320

= 1 tan cos = 2.980

= 1 tan 30 cos 7.320

Self-Blocking demonstration: cos 0.15 0.128 0.15 16 cos 2.98 39.668

This demonstrates, the main screw is self-blocking.

Y W X Y

n x cos

Tangential forces:

= 0;

+ = 0

= ( + )

Axial forces:

= 0 ; +

( + )

19000 (0.15 7.32 + 2.98 7.32)

= 19559.46

= 19559.46 0.15 7.32 + 2.98 7.32

= 5398.73 Torque to lift the weight: 2

= 5398.73

39.668 2

= 107078.41 . Bending:

2 33.684 2 4 25.97 4 33.684

( 4 4 ) 32

= 32

107078.41 .

= 22.07 /2

 2 = 33.684 135900 . 2 = 4 (12.985)4 ) 4 ((16.842)

4 4 4

= 453 300 = 135900 .

= 56.01 /2

+ 2

56.01 2

+ 22.072

2 = 35.66 /2

= 2 500 = / 2 2 = 250 / 2

250

2 = 35.66 2 = 7.01

As the safety factor for bending stress of this diameter is 7.01; this column wont fail by bending stress.

11.
-

Nut Design Calculations

Frictional Torque

= ( = 0)

( = 0) =

cos 2 cos

( = 0) =

19000 46 16 cos 2.98 2 46 cos 2.98

( = 0) = 48070 .

= 107078.41 . 48070 . = 59008.41 .

Bending Stress 4 62 4 4

= =

19000 = 1357.17 2

46 4

= 1357.17 2 = 13.99 /2

Shear stress due to Torque for Lifting 2 ( 4 4 ) 32 32 62

4

= =

62 59008.41 . 2 = 1011090.18 4

46

= 1011090.18 4

 = 1.81 /2

Principal Shear Stress

+ 2
2

13.99 2

+ 1.81

2 = 7.23 /2

250 /2 = 7.23 /2 = 34.58 The safety factor of 34.58 says that the nut is totally secure. A nut with a smaller height could have been used to reduce cost, however, it make the design more than 11.52 times secure, due to the stress being spread between the threads.

Transverse Shear Stress (stripping of threads)

= =

19000 46 100 = 1.32 /2

= =

250 /2 1.32 /2

 = 189.39

Maximum Allowable Bearing Pressure

= 4 = 4

12.5

= =
2

100 8

19000 62
2

46

12.5

= 12.5

= 1.12 /2

12.

Contact Plate
To determine the minimum thickness required for the Contact Plate, first the c must be calculated. c = c = y

355 N/mm2 3

c = 118.33 N/mm2

From this, the can be calculated. = = 2 355 2

= 177.5 /2

And the maximum allowable ( ). =

177.5 /2 = 3

= 59.17 /2

With this data, the minimum required thickness of the contact plate surface can be calculated. = =

57000 50 59.17 /2 = 6.132

This is the minimum thickness. For practicality, the plate will be 57mm high to accommodate for the Grub screw grove and its requirement to sit in the Contact Plate Housing.

As the Contact Plate will be hollow inside, the buckling stress will have to be calculated for the wall thickness.

2 = (1 ) 4 2

= 1

= 57

50 1

= 50

()2

)2

(60 )2

(50 )2

= 863.94 2

= 863.94 2 355 /2 (1

355 /2 4 1 2 200103 /2

57 2 ) 50

= 303631.7

This allows the walls to be 5mm thick with a safety factor of 16.14

13.

Contact Plate Housing Calculations

To determine the minimum thickness required for the Contact Plate Housing, first the must be calculated. = = 500 /2 3

= 166.67 /2

From this, the can be calculated. = = 2 500 2 2

= 250

And the maximum allowable ( ). = = 250 / 2 3

= 83.3 / 2

With this data, the minimum required thickness of the Contact Plate Housing can be calculated. The diameter used is that of the Accuracy Screw. Because of the difference in diameter, the calculation uses sheer stress. = = 57000 26 83.3 /2

= 8.38 This is the minimum thickness. For practicality, the Contact Plate Housing will be 9 mm thick. To accommodate for the Grub Screw holes, the thickness of the walls will be 11 mm.

14.

Housing Desing Calculations Minimum thickness for the housing

= = =

2 2

57000 (2 50 66.67 /2 = 2.72

Buckling Calculations 2 = (1 ) 4 2

= 0.25 = 464 =
4 4

=
2

100 4 2

= 25 =
4

(125 )2 4 (100 )2

= 4417.882

= 4417.882 200/2 (1

200 /2 464 2 ) 4 0.25 2 105103 /2 25

= 842456.6 Safety Factor

= =

842456.6 19000 = 44.34

The safety factor demonstrates that the housing will not fail for buckling.

Housing Contact Surface Calculations

= 2 = 157.08

57000 N

B =1

= =

57000 25 15 2250 4

= =

1 12

1 1 30 12

= 2250 4 = 9500 /2

As the load is being taken between 157 points of 1 mm.

9500 /2 157

= 60.51 /2

As the = 66.67 /2 for Cast Iron the circumference got the thickness enough to support the safety factor load of 57000 N.

15.

Handle Design Calculations

Accuracy Screw Handle Calculations

15.1.

Handle Calculations =

Angle of application Hand Force Total Hand Force

Pull L 180 222

Push R 60 151 373

Pull Push Pull Push L R L R 150 90 120 120 187 160 151 160 347 311 Figure 15. 1
Handle Force Data

Pull L 90 142

Push R 150 187 329

Pull Push L R 60 180 116 222 338

Total Hand Force

400 350 300 250 180 - 60 150 - 90 120 - 120 Total Hand Force 90 - 150 60 - 180

Graph 15. 1 Total Hand Force

250 200 150 100 50 0 180 150 120 Right Left 90 60

Graph 15. 2 Hand Force Pushing Against Pulling (Right and left)

According to the graph bellow the optimal length for the handle will be 138.99 mm. as this size cut the graph in two points. However, there are some manufacturing considerations for the handle and as it is better and cheaper to produce a handle with a preferred size.

Handle Lenght (mm.)

160.00 150.00 140.00 130.00 120.00 110.00 373 347 311

329 338

Handle Lenght (mm.)

373 126.09

347 311 135.54 151.23 Graph 15. 3

Accuracy Screw Handle Length

329 142.95

338 139.15

= = 138.99 18.35 = 120.64 So, the final length will be 125 mm.

Handle bending calculations:

2 18 2
4

32

47032.04 . = 32 18

= 41.07/2 2 64

18 56625 . 2 = 4 64 18 = 98.9 /2 2
2

= 453 125 = 56625 .

+ 2

98.9 2

+ 41.072 /2 = 64.28 /2

= =

2 500 /2 2

= 3.9

= 250 /2 With a safety factor of 3.9, the diameter of the handle demonstrates that will not fail for bending.

15.2.

Distance Screw Handle Calculations

Handle Length Calculations =

According to the graph bellow the optimal length for the handle will be 316.45 mm. as this size cut the graph in two points. However, there are some manufacturing considerations for the handle and as it is better and cheaper to produce a handle with a preferred size.

Handle Lenght (mm.)

360.00 340.00 320.00 300.00 280.00 260.00 240.00 373 347 311

329

338

Handle Lenght (mm.)

373 287.07

347 308.58

311 344.30

329 325.47

338 316.80

Graph 15. 4 Distance Screw Handle Length

= = 316.45 33.684 = 282.77

So, the final length will be 290 mm.

Handle bending calculations:

2 26 2
4

32

107078 . = 32 26

= 31.03 /2

2 26 2
4

64

= 453 290 = 131370 . = 76.13 /2

131370 . = 64 26

+ 2

76.13 2

+ 31.032 /2 = 49.11 /2

= 2 = 500 / 2 2

250 /2 = 49.11 /2 = 5.1

= 250 / 2

The calculations shown above demonstrate that the main screw will not fail for bending.

16.

Handle Design Ergonomics

Ergonomics Background

16.1.

Handles are the parts an operator will come in contact with most often, therefore it is imperative they are designed ergonomically without jeopardising the safety factor. Undersized handles could cause danger to operator during use. Oversized handles could make the screw jack un-ergonomic.

16.2.

Grip Background

There are two types of grip, the Power Grip and the Precision Grip. The Power Grip uses the muscles of the hand and forearm effectively, reduces stress during use. The handle is designed to be held in a power grip which requires the operator to align the fingers so they work in conjunction with each other. A slightly rough surface will be used to achieve an anti-slip coating to create sufficient friction preventing slip. The grip is designed for bare hand operation, contoured to the curve of the palm.

Fitting The Human, Karl H E Kroemer, Sixth Edition (2008) Figure 13. 1
Power Grip

16.3.

Hand Sizes

Hand measures

Population

Mean

Length Breadth at Knuckles Maximal breadth Circumference at knuckles

British British British British

180 85 105 nda

SD (Standard deviation) 10 5 5 ndai

Table 16. 1 Average British Male Hand Sizes

1

Fitting The Human, Karl H E Kroemer, Sixth Edition (2008)

5th percentile Calculation - mean standard deviation 5p = - 1.65 x

# Figure 16. 2 Illustration of Hand Measurement

Mean hand width (mm) Standard deviation of hand width(mm) 5th percentile hand width (mm) Mean Vertical Length(mm) Standard Deviation of vertical length(mm) 5th percentile Vertical length (mm )
Table 16. 2 Refined Hand Size Data

85 5 76.75 180 10 163.5

16.4.

Ergonomic Grip Choice

The grip selected is a standard grip made from textured rubber. It provides good grip and reduces required effort for effective use. The chosen cylindrical shape will generate low wrist deviation ensuring arm and wrist postures are not affected. The grip will be placed on the cylindrical handle bars. The recommended size is 40 mm but in order to fit all sizes, we have chosen 45 mm.

17.

Conclusion

This project was to design a manual Screw Jack that can lift a load of 19kN 0.3 metres. We had to encompass mechanical engineering design knowledge in order to successfully design a working screw jack that can be manufactured and mass produced. The design was constrained by the specifications as well as manufacturability, human factors and any other characteristics we chose to encompass. We looked at many designs and developed our own initial concepts. This was a more difficult process than we had initially envisaged as choosing original and working designs was complicated due to the options available. This was complicated further by the calculations and material standards that would determine dimensions of each part. These constraints helped us understand the complications associated with designing a mechanical devices. The design also had to consider human factors that would affect its construction, appearance and operation. This project turned up many complications at every stage while designing the Jack. These were such things as struggling to find suitable materials to use for each part, to finding a method of keeping the first (Distance) Screw from rotating while the nut is turned. The biggest challenge was the battle against time. We discovered late in the time scale that we had issues with parts of our designs and given more time we would have been able to rectify them properly to produce a better screw jack. The keyed insert for the housing to prevent the distance screw from rotating will be very difficult to manufacture to tolerance. We have realised that there are other methods of doing this such as inserting keyed channels as a separate part and even other designs. We also realised that the contact plate could have been better designed. Given the chance, we would have redesigned it to be manufactured from a hardened plastic or a carbon fibre compound to reduce weight and material cost. The main complication with our design was the use or a rotating stationary nut as this restricted how we attached the handles. If we redesigned to incorporate removable handles, our design would be greatly improved in both ergonomic design and efficiency of use and manufacture. We had more designs that we wanted to encompass to improve the design efficiency and effectiveness but we could not due to time. We know this project is only to design but it would be interesting to see our Screw Jack manufactured into a working model. Undertaking this project with only academic experience is a daunting task. Having some industrial experience such as Richards experience in the Royal Navy and Adrianos experience in aeronautics was a great help. This helped with understanding of the uses, application and the manufacture of parts. Overall we found this project enjoyable due to its ability to make us think as well as providing an engineering based challenge. We also found this to be a useful project as we have all gained valuable engineering knowledge that will prove very useful later in our careers. We believe that this project is currently complete to the best of our current abilities as our Screw Jack can lift and support loads of 19kN (to a safety factor of 3) in excess of 0.3 metres in a simple manner, it can overcome any friction caused by the load and incorporates a method of raising small distances with increased accuracy if needed. As we gain more experience in engineering, we will be able to improve on our methods and current levels of designs.