DESIGN AND OPTIMIZATION OF SCISSOR JACK

1
Chetan S.Dhamak, 2D.S.Bajaj, 3V.S.Aher
Department of Mechanical Engineering, Amrutvahini College of Engineering,
Sangamner. [MS], Savitribai Phule Pune University
Email: [email protected], [email protected], [email protected]

Abstract Every engineering product The day to day usage of cars is keeping on
involve cost effective manufacturing and its increasing as the world moves on to a hectic
versatility in application maintaining its stage. One big problem everyone faces is a flat
aesthetics as well as assign service life without tyre on a voyage to any destination. If the tyre
failure keeping those parameters in mind we gets punctured the driver has to undergo a lot of
focused our intention on designing and pressure and rigorous mechanical work to lift the
analyzing the scissor jack model for actual car using a screw jack. Then the changing of a
loads for varying models of automobile tyre is a job that can be done systematically and
L.M.V. sectors. Automobile sectors are very relatively easy.
keen at their productivity and customer
satisfaction. We also keen at designing and
optimization of scissor jack at the same time
maintaining its strength and service life.
After studying failure modes we made a
mathematical model analytically and by
using softwares thereby made a new versatile
scissor jack that can be used for varying
models of L.M.V automobile sector. Also Fig.Scissor Jack
modeling made by CATIA and mathematical Today, many people are familiar with the jack
model made by Visual Basic software can be that is included with their vehicle. Some vehicles
tested by ANSYS software. bear screw jacks and others carry a hydraulic
Index Terms-Mathematical Model, jack. Automotive jacks are of three types
Optimization and Scissor. mainly:-
1. Screw Jacks
I. INTRODUCTION 2. Trolley Jacks
3. Bottle Jacks
Car jack is a device used to lift up the cars while
Each has its own advantages and disadvantages.
changing the tires during an emergency. Car
Screw jack is lesser in cost, as compared to
jacks are available at the market has some
trolley jacks and bottle jacks. While trolley jack
disadvantages such as requiring more energy to
and bottle jack can provide a greater lift with
operate, are not suitable for women and cannot
lesser application of force. [5]
be used on the uneven surface. The purpose of
With the increasing levels of technology,
this project is to modify the design of the
the efforts being put to produce any kind of work
existing car jack in terms of its functionality and
has been continuously decreasing. The efforts
also human factors considerations.
required in achieving the desired output can be
effectively and economically be decreased by
the implementation of better designs.

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Scissor or Toggle Jack III. FAILURE ANALYSIS OF SCISSOR

A toggle or Scissor jack is a device which lifts JACK
heavy equipment. The most common form is a To study the reliability and performance of
car jack, floor jack or garage jack which lifts scissor jack, it is tested under various conditions
vehicles so that maintenance can be performed. for failure analysis. In this case we will get to
Car jacks usually use toggle advantage to allow a know the effectiveness & performance of scissor
human to lift a vehicle by manual force alone. jack on field, when customer implements it for
More powerful jacks use hydraulic power to replacing the tire. The failure analysis is
provide more lift over greater distances. conducted under following cases.
There is a one screw in the toggle jack which is
rotating. Case I: Justification for failure analysis :
There are two nuts which are fixed. This analysis is required to be conducted due
There are four links connected to both nuts and to its critical application under emergency, also
eight pins to fix all links. it is essential due to following reasons:
There are two rings at both ends of the screw. A. Impact of the problem
There is a one platform which is connected to the Impact on customer:
upper two links for put load. 1. Affecting safety of customer.
Working of Toggle Jack 2. Dissatisfaction of customer
The jack can be raised and lowered with a Impact on Departmental goal:
metal bar that is inserted into the jack. 1. Quality indicators effected.
The operator turns the bar with his hands in a 2. Increase in warranty cost.
clockwise direction for makes it go up.
When the screw lifts the load on the platform Case II: Diagnosing the problem:
which placed above will also raise. In this case, the actual area where the jack is
The bar is turned until the jack is raised to the failed is detected. Practical tests are conducted
level needed. for this analysis by physically replacing the jack
To lower the jack the bar is turned in the and results are calibrated for getting the solution
opposite direction. by operating the jack for replacement of tire of
Bolero. Following results are concluded by
II. METHODOLOGY
performing this case:
Start
Failure I: Arm teeth wear:
The scissor jack is failed due to wear of teeth
Failure Analysis and Need on both links at lower end. Due to this the jack
gets toppled as shown in figure below. Due to the
use of jack over and over again, the teeth starts
getting wear and after certain time the jack gets
Literature Survey
toppled from actual position as shown below:

Problem Definition

Formulation of Design

Sample Case Study Design

Conclusion

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 INTERNATIONAL JOURNAL OF ADVANCES IN PRODUCTION AND MECHANICAL ENGINEERING (IJAPME)

Fig. Teeth Wear of Lower Arm

Failure II: Screw Failure:

This failure is caused after using the jack for
certain amount of time. Due to excessive use and
high impact on screw, it starts getting wear. Due
to this the jack gets toppled from its actual
position as shown below:

Fig. Failure of Jack Head

IV. SAMPLE DESIGN CALCULATION

Type of Vehicle = Mahindra Bolero
Fig. Failure of Screw and Arm Teeth Weight of Vehicle =1615 kg
Assuming 65-35 Distribution
Weight on Front Axle = 1050 kg
Weight on Each Wheel of Front Axle = 525 kg
For Safe Design we take maximum capacity of
jack = 700kg
Since while jack is used other three wheels are in
contact with ground so assumption of 700 kg is
safe.
Ground Clearance of Vehicle = 280 mm
According tyre dimension, we take lift of jack as
100 mm
Maximum Height of Jack = 355.4 mm
Minimum height of jack = 254 mm
Fig. Toppled Scissor Jack due to Arm teeth
Failure Assumption:-
Material for Link, Screw, Pin, Bracket is
Failure III: Jack head failure: selected as Medium Carbon Steel (30C8)
After certain duration and use of jack the head Since links are in tension-compression and
of jack starts bending due to the fatigue load bending mode, higher yield strength as well as
acting continuously again & again over the head less elongation is primary requirement.
as shown in figure below. This defect occurs due Medium Carbon Steel has good yield strength
to improper design of shape and geometry of (Syt) as well as due to medium carbon content
existing head design. (0.30%) has good hardness and toughness.
For Nut, Phosphor Bronze (Bearing Pressure =
10 Mpa) is Selected. Since in case of wear with
screw, nut will fail and costly screw will be
saved from failure.

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Phosphor Bronze is softer than Medium Carbon When the jack is in bottom position, the link will
Steel (30C8) be inclined at an angle
Length of link = 200 mm
=39.42o
Maximum Capacity of Jack is 700 kg,
So that Load (W) =7009.81=6867 N=7000 N
(Approx.)
Load (W) = 7000 N
By Calculating Pull in the Screw, Total Force
due to upper and lower link, Core Diameter,
Outer Diameter, Mean Diameter, Helix Angle,
Friction Angle, Effort Required to Rotate the
Screw, Torque Required, Torsional Shear Stress,
Maximum Principle Stress and Maximum Shear
Stress etc.following results are obtained.
Fig. Jack Is In Top Most Position Material Selected for Screw= Medium Carbon
Steel (30C8)
Syt = 400 MPa
L1= 216 mm F.O.S. = 4
And Similarly, When Jack is in lowest position- Permissible Tensile Stress (t)=100 MPa
Permissible Shear Stress (Ssy) =0.5(Syt) =50 MPa
Our Calculated Value,
L2= 339 mm = 30.84 < 50 MPa is Safe.
t= 42.34 <100 MPa t is Safe.
max= 58.57 <100 MPa max is Safe.
A. Design of Screw:-
max= 37.40 <50 MPa max is Safe.

B. Design of Nut

Fig. Geometry of Screw

Maximum load on screw will occurs when the
jack is at bottom most position. The load in the
screw will be tensile.

Fig.Geometry of Nut
There are two nuts in the assembly of Scissor or
Toggle Jack.Nut is a stationary part having
internal thread inside which is used to rotate the
screw by meshing with external thread of the
Screw.Nut is also used to hold the lifting arm or
links at there both end.
By calculating Number of threads inside the nut,
Height of nut etc. following results is obtained.
No. of Internal Thread =6
Height of Nut =36 mm

Fig. Diagram of Top Corner Link
C. Design of Pin

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Pins or Rivets are the most important parts in Load on each link=F/2 sec
the assembly of Scissor jack or Toggle Jack = F/2 sec 39.2
which is used to make the Scissor Jack in =2.7670 KN
assembled form throughout its operation and Let b1= width of link and t1= thickness of link
working. There are total six pins are used in the Assuming, b1=3t1
assembly of screw jack, out of that two pins are Area of cross-section of link,
used to assemble load carrier member with upper A=31
lifting arm or links, Two pins are used to For buckling of links in the vertical plane, the
assemble base and lower lifting arm of the of the ends are considered hinged. Therefore by using
scissor jack and another two pins are used to Rankine - Gordon formula.
assemble Nut and both lifting arms or links.
These pins are in Double Shear, By calculating various values like Moment of
Inertia, Least Radius of Gyration, Both critical
loads etc. following results are obtained.
With F.O.S.=5
For design load, = F.O.S(F/2) 3
= 13.832 KN
Now, For Critical Load
So that,
We Select Diameter of Pin =8 mm
Length of Pin =40 mm
Pcr =17.28 KN
Diameter of Pin Head (dph) = 1.5 dp =1.5 8 =
Here Critical Load (17.28 KN) > Design Load
12 mm
(13.832 KN)
Thickness of Pin Head (tph) = 2 mm
Design of Link is Safe.
Split Pins are used to keep the pins in position.
D. Design of Link V. CONCLUSION
The result shows that alloy steel for screw and
phosphorus bronze for nut is the best suitable
combination for pair. The value shows that if
there is a combination of MS MS, it induces
less magnitude of bearing stress in nut.
Based on the input parameter & result obtain
from the design, As the helix angle increases the
efficiency increases up to certain limit after
which it decreases, the critical load decreases,
the no of threads decreases, turning moment
Fig. Geometry of Link reduces, outer diameter decreases, core diameter
decreases, the pitch does not change it remains
Links or Lifting Arms are the main component in constant up to certain value & then it reduces.
the assembly of Scissor or Toggle Jack. We can
say that links are the heart of Scissor Jack. There REFERENCES
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