DEBRE TABOR UNIVERSITY

FACULITY OF TECHNOLOGY
DEPARTEMENT OF MECHANICAL ENGINEERING
PROJECT ON:
DESIGN OF MECHANICAL PULLER
Done by:
1. Fasikaw Mekuria ID No , 301/10
2. Solomon Kindu ID No , 690/12
3. Molla Biyadgie ID No , 695/12
4. Henok Daba ID No , 908/10
5. Melese Getnet ID No , 521/10
6. Yosef Sewunet ID No , 875/10
7.
TO : Ms KALKIDAN N.

February, 2021
Debre tabor, Ethiopia
 DESIGN OF MECHANICAL PULLER

ACKNOWLEDGEMENT

First of all, we would like to give our thanks to omnipotent GOD and his SAINTS for his kind blessing
throughout our work. Next we have a full testimony with thankful for our families’ priceless support
through education. Then we want to express our gratitude for our instructor Ms . Kalkidan N.. for her
useful explanation of research writing terms and contents. And the role of all our teachers give the course
related to technical writing and research methodology in the can’t left unmentioned. Lastly we would like
to thank our technology faculity for this facilities and with this fortune we want to give our word to work
our best to the enhancement of the faculity.

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ABSTRACT
This project work deals with a detailed study and design procedure of hand operating
mechanical puller. Removing hard fit and stumped components is very frequent and mandatory task for
mechanics to maintain and change spear of automotive and different machines internal part. And it is
engineers primary task to design a puller structure that with stand at harsh circumstance. A detailed
study and numerical design analysis of component of mechanical puller components like screw spindle,
cross-arm (collar), leg and handle are included in the paper.

The beginning chapter mention the over view, background, problem statement, objective, methodology,
organization, scope, and limitation of the project. On way it raise the definition, component, type,
background and working principle of mechanical puller. The general and specific objective, range in
which the design reach, over view of method to perform the whole design, justification of Problem for the
need of project and limitation of design is also stated in this chapter. The second chapter titled literature
review express about, experts comment and different scholars work about the topic which helps us to
access related material easily and visualize familiar problems will face in the design. The third chapter
talk about the detailed numerical design of each components of mechanical puller considering the
maximum possible loads that will on it. The forth chapter inform generalized solution technique to solve
design problem. The fifth chapter compress main result of the whole design and discussion about the
result by relate with the given specification. The six chapter conclude the design the whole design and
recommend important idea should be noticed for other scholars who will design puller later.

The final and seventh chapter contain the drawing development of each designed parts and assembled
mechanical puller with SOLID WORK 2018.

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Table of Content
CHAPTER ONE ............................................................................................................................................. 1
1. Introduction ........................................................................................................................................ 1
1.1 Background of the study ............................................................................................................. 1
1.2 Over view of the project ............................................................................................................. 1
1.2.1 What is puller?...........................................................................................................................2
1.2.2 Types of puller............................................................................................................................2
1.2.3 Components of mechanical puller.............................................................................................6
1.3 problem statement.........................................................................................................................12
1.4objective of the study......................................................................................................................13
1.4.1 General objective.....................................................................................................................13
1.4.2 Specific objective.....................................................................................................................13
1.5 methodology..................................................................................................................................13
1.6 scope and limitation of the study...................................................................................................14
1.6.1 Scope of the project.................................................................................................................14
1.6.2 Limitation of the project..........................................................................................................15
1.7 organization of the project.............................................................................................................15
1.7.1 Planning the project.................................................................................................................15
1.7.2 Collecting data to justify the problem......................................................................................15
1.7.3 Idea generation of the project.................................................................................................15
1.7.4 Analysis of the project..............................................................................................................15
Chapter two..............................................................................................................................................16
2. Literature review..................................................................................................................................16
Chapter three...........................................................................................................................................17
3. Detail design of mechanical puller components...................................................................................17

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3.1 Specification of design product.......................................................................................................17

3.2 Components of mechanical puller to be designed..........................................................................17
3.3 Material selection...........................................................................................................................17
3.4 Determination of Factor of Safety..............................................................................................23
3.5 Detail design of components..........................................................................................................24
3.5.1 Design of screw spindle/power screw......................................................................................24
3.5.2 Design of Nut...........................................................................................................................34
3.5.3 Design of longitudinal collar/cross-arm...................................................................................35
3.6.4 Design of handle......................................................................................................................44
3.5.5 Design of leg.............................................................................................................................45
3.7 COST ANALYSIS...............................................................................................................................52
Chapter four.............................................................................................................................................57
3. Solution techniques..............................................................................................................................57
Chapter five..............................................................................................................................................58
5. Result and discussion............................................................................................................................58
5.1 Result..............................................................................................................................................58
5.2 discussion.......................................................................................................................................60
Chapter six................................................................................................................................................61
6. Conclusion and recommendation.........................................................................................................61
6.1 conclusion.......................................................................................................................................61
6.2 Recommendation...........................................................................................................................61
CHAPTER SEVEN.......................................................................................................................................62
7. SOFTWARE DEVELOPMENT/SOLIDWORK PART AND ASSEMBLY DRAWING.........................................62
7.1SOLIDWORK PART DROWING..........................................................................................................62
7.2 SOLIDWORK ASSEMBLY DRAWING.................................................................................................64
Reference and Citation.............................................................................................................................67
Appendix..................................................................................................................................................68
APPENDEX A, FIGURE............................................................................................................................68
APPENDEX B, TABEL..............................................................................................................................69

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List of figure……………………………..
…………………………………………………………….page

Figure [Link] puller ............................................................................................................................. 2

Figure [Link] ended reversible leg puller ............................................................................................... 3
Figure [Link] adjustable leg pullers ..................................................................................................... 4
Figure [Link] jaw leg pullers ........................................................................................................................ 4
Figure [Link] ended reversible, triple leg puller ..................................................................................... 5
Figure [Link] jaw leg pullers ........................................................................................................................ 5
Figure [Link] adjustable leg pullers ..................................................................................................... 6
Figure [Link] screw spindle .................................................................................................................... 7
Figure [Link] thread ................................................................................................................................ 8
Figure [Link] or trapezoidal thread ........................................................................................................ 8
Figure [Link] thread ............................................................................................................................ 9
Figure [Link] nut. ................................................................................................................................. 9
Figure [Link] cross arm ...................................................................................................................... 10
Figure [Link] .handle .......................................................................................................................... 11
Figure [Link] leg/arm ......................................................................................................................... 11
Figure 16..How is puller work. .................................................................................................................. 12
Figure [Link] and cross-section of cross arm ..................................................................................... 36
Figure [Link] reaction on cross-arm ................................................................................................. 37
Figure [Link] cross-arm to the left for shear equation ................................................................... 37
Figure [Link] cross-arm to the left for moment equation .............................................................. 38
Figure [Link] force diagram for cross-arm ............................................................................................ 39
Figure [Link] moment diagram for cross-arm .................................................................................. 39
Figure [Link] of maximum deflection.................................................................................................... 43
Figure [Link] of elastic curve ............................................................................................................... 43
Figure [Link] of reverse curvature ....................................................................................................... 43
Figure [Link] of reverse moment curvature ......................................................................................... 43
Figure [Link] of jaw .............................................................................................................................. 45
Figure [Link] side of jaw ................................................................................................................... 47
Figure [Link] concentration area on the jaw ........................................................................................ 50
Figure [Link] distribution on the jaw.................................................................................................... 50
Figure 36.3D SOLID WORK screw spindle.................................................................................................. 62
Figure 37.3D solid work for leg ................................................................................................................. 63
Figure 38.3D solid work for cross- arm ..................................................................................................... 63
Figure 39.3D solid work for handle ........................................................................................................... 64
Figure [Link] assembly drawing ................................................................................................. 64
Figure 412D ssolid work for leg ................................................................................................................. 65
Figure 42.2D solid work for handel ........................................................................................................... 65
Figure 43.2D solid work for cross-arm ...................................................................................................... 66
Figure 44.2D solid work for spindle .......................................................................................................... 66
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List of table
Table [Link] of selected steel: 4340 .................................................................................................. 22
Table [Link] of gray cast iron/grade FG 150 ...................................................................................... 23
Table [Link] of screw spindle ......................................................................................................... 58
Table [Link] of nut .......................................................................................................................... 58
Table [Link] of collar cross-section ................................................................................................. 59
Table [Link] of handle .................................................................................................................... 59
Table [Link] of leg .......................................................................................................................... 60
Table [Link] concentration factor for flat bar with fillet ........................................................................ 68
Table [Link] dimensions for square threads in mm (Fine series) ............................................................ 69
Table [Link] of table 9 .................................................................................................................... 70
Table [Link] dimensions for square threads in mm (Normal series) ..................................................... 71
Table [Link] of Table 11 ................................................................................................................. 72
Table 13.. Basic dimensions for square threads in mm (Coarse series) .................................................... 73
Table [Link] of table 13 .................................................................................................................. 74
Table [Link] dimensions for trapezoidal threads in mm (Coarse series) ............................................... 75
Table 16. Limiting values of bearing pressures. ........................................................................................ 76
Table [Link] property of some common metals .......................................................................... 77
Table [Link] property of typical cast iron .................................................................................... 77
Table [Link] of rolled steel shape. ................................................................................................... 78
Table [Link] of table 19 .................................................................................................................. 79

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Key word
Collar, inclined plane, Slippy, tightening force power screw and hard fit.
Nomenclature (if not specified on the document)
Wcr= Critical load, L =
Length of screw, k = Least
radius of gyration, C = End-
fixity coefficient, E =
Modulus of elasticity,
G=modules of rigidity,

W = Axial load on the screw, n = Number of

threads in engagement, dc= Core or root diameter
of the screw, do= Outside or major diameter of nut
or screw, and t = Thickness or width of thread.
Greek letter σy= Yield stress, σc= Stress induced
due to load W

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|Page Department of Mechanical engineering

CHAPTER ONE

1. Introduction
1.1 Background of the study
After the time of English revolution the concept of simple machine to multiple force and speed specially
inclined plane, mechanics try to use this scientific concept to multiple human force to a large amount of
force that can perform a task require a huge amount of force. Even if mechanics in many automotive
garage and industry use this idea to pullout stumped components KUKKO was the first to manufacture
puller in company level with many standard. Founded in 1919 by Alfred Kleinbongartz and his brotherin-
law Emil Kaiser, the KUKKO Tool Factory has remained to this very day a family owned,
unincorporated partnership. Our brand name is an acronym of the founders' initials. Kukko as the inventor
of a whole new category of tools, has consistently set new and higher, unsurpassed and exemplary
standards of use and quality with its pullers, separators, internal extractors and numerous other pulling
and extracting tools. No wonder, then, that has long since become a global synonym for push/pull
devices.

Now a day many company produce puller in well-organized business company. Across the world the
following are huge tool company that produce advancer mechanical and hydraulic puller and pusher

1.2 Over view of the project

Before the invention of pulling device, mechanics applies a crude way of pulling objects to remove
to stamped objects which was mostly applied in removing bearing and pulley out of a shaft. The virtues of
using a screw as a machine, essentially an inclined plane wound round a cylinder make this task very
easy. Through time with the advancement of technology as other tools, puller also modified to easier and
more effective way by using hydraulic and electronic actuators.

This project add its value on a mechanical puller in dimension to suite the puller sizes for a task
commonly done our internship company, minister of defense department of defense logistic heavy vehicle
overhaul center.

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1.2.1 What is puller?

Puller is a tool used to remove a part such as bearings brake drums, pulleys or gears from a shaft or from
brake shoe. They have leg, typically two or three which circle around the back or inside of a part and they
also have a power screw which centers up against the end of the shaft.

Specifically bearing puller is a tool used to remove bearing sets from a rotating machine shaft or from a
blind bearing hole. The most common application is removing a caged set of ball or tapered bearings from
a rotating shaft, such as in a car's transmission. [1]

1.2.2 Types of puller

There are different types of pullers. For inside or outside use, separators and bearing puller s are generally
classified as either hydraulic or mechanical based on the source of power to operate the tool. There are
many variation within these two classes. [1]

1. Hydraulic puller

These have a simple, grease-filled ram instead of a mechanical force screw, producing extra power with
ease. The spring loaded plunger provides direct, non-twisting application of thrust which is more effective
and more secure.

Figure [Link] puller

2. Mechanical Pullers

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These use a hydraulic mechanical force screw to pull out the work [Link]-armed pullers are mostly
preferred to two-arm pullers because of providing more secure grip when pulling. Two-armed pullers are
used in situations where space is limited.

Based on the number of leg to anchor the workpeice puller can be classified in to two as follow.

Twin leg mechanical puller

• Two legs for removing gears, pulley, bearings and sprockets.

• Automotive and industrial applications.

• Drop forged steel legs, beam and jaws.

• Heat treated for strength and durability

• Can be upgraded for triple leg pulling.

• Different leg styles available as follow.

Figure [Link] ended reversible leg puller

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Figure [Link] adjustable leg pullers

Figure [Link] jaw leg pullers

Triple leg puller

• Three legs for removing gears, pulley, bearings and sprockets.

• Automotive and industrial applications.

• Double ended legs for external use.

• Drop forged steel legs, beam and jaws.

• Heat treated for strength and durability.

• Different leg styles available - see the variation below.

Double Ended Reversible, Triple Leg Pullers

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Figure [Link] ended reversible, triple leg puller

Figure [Link] jaw leg pullers

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Figure [Link] adjustable leg pullers

1.2.3 Components of mechanical puller.

Mechanical puller constructed from the following simple and rugged. [1]

1. Power screw/screw spindle,

2. Nut,

3. longitudinal collar for nut/cross arm,

4. handle, and

5. Leg/arm

1. Power screw

The power screws (also known as translation screws) are used to convert rotary motion into translator
motion. For example, in the case of the lead screw of lathe, the rotary motion is available but the tool has
to be advanced in the direction of the cut against the cutting resistance of the material. In case of screw
jack, a small force applied in the horizontal plane is used to raise or lower a large load. Power screws are
also used in vices, testing machines, presses, etc.[7]
In most of the power screws, the nut has axial motion against the resisting axial force while the screw
rotates in its bearings. In some screws, the screw rotates and moves axially against the resisting force
while the nut is stationary and in others the nut rotates while the screw moves axially with no rotation.

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Figure [Link] screw spindle

Types of Screw Threads used for Power Screws

The following are the three types of screw threads mostly used for power screws: [7] A.
Square thread.

A square thread is adapted for the transmission of power in either direction. This thread results in
maximum efficiency and minimum radial or bursting pressure on the nut. It is difficult to cut with taps
and dies. It is usually cut on a lathe with a single point tool and it cannot be easily compensated for wear.
The square threads are employed in screw jacks, presses and clamping devices. The standard dimensions
for square threads according to IS : 4694 – 1968 (Reaffirmed 1996), are shown in Table 9 and 10 on
appendix A

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Figure [Link] thread

[Link] or trapezoidal thread.

An acme or trapezoidal thread Is a modification of square thread as shown in fig 10. The slight slope
given to its sides lowers the efficiency slightly than square thread and it also introduce some bursting
pressure on the nut, but increases its area in shear. It is used where a split nut is required and where
provision is made to take up wear as in the lead screw of a lathe. Wear may be taken up by means of an
adjustable split nut. An acme thread may be cut by means of dies and hence it is more easily
manufactured than square thread. The standard dimensions for acme or trapezoidal threads are shown in
Table 10

Figure [Link] or trapezoidal thread C.

Buttress thread.

A buttress thread is used when large forces act along the screw axis in one direction only. This thread
combines the higher efficiency of square thread and the ease of cutting and the adaptability to a split nut
of acme thread. It is stronger than other threads because of greater thickness at the base of the thread. The

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buttress thread has limited use for power transmission. It is employed as the thread for light jack screws
and vices.

Figure [Link] thread

D. Multiple Threads
The power screws with multiple threads such as double, triple etc. are employed when it is
desired to secure a large lead with fine threads or high efficiency. Such type of threads are usually
found in high speed actuators

2 Nut

A nut is a type of fastener with a threaded hole. Nuts are almost always used in conjunction with a mating
bolt to fasten multiple parts together. The two partners are kept together by a combination of their threads'
friction, a slight stretching of the bolt, and compression of the parts to be held together.

Figure [Link] nut.

Nuts are usually stronger than the bolts they are on, which is to say that the bolt will usually break before
the nut strips. It is often said that two threads must be exposed above a nut.

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3. Cross arm/ Longitudinal collar beam.

Cross arm is an arm fastened at right angles to an upright (as the horizontal member of a cross or a
traverse on two vertical member.

A beam is a structural element that primarily resists loads applied laterally to the beam's axis. Its mode of
deflection is primarily by bending. The loads applied to the beam result in reaction forces at the beam's
support points. The total effect of all the forces acting on the beam is to produce shear forces and bending
moments within the beam, that in turn induce internal stresses, strains and deflections of the beam. Beams
are characterized by their manner of support, profile (shape of cross-section), equilibrium conditions,
length, and their material.

A collar beam or collar commonly defined in structural world as a horizontal member between two
rafters and is very common in domestic roof construction. A tie in building construction is an element in
tension rather than compression and most collar beams are designed to work in compression to keep the
rafters from sagging.

For a mechanical puller commonly dual and triple leg cross arm are used.

Figure [Link] cross arm

4. Handle

Handle is the component of a puller assembled at the head of screw spindle or power screw to apply
driving moment to the screw.

Mainly it is circular cross-section and designed on the base of bending moment.

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Figure [Link] .handle

5. Leg/arm

Leg mainly slide or arranged over the collar to vary radius to many range with reversible jaws to ensure
proper grip on a wide range of jobs. Reversible Jaws for inside & outside pulling.

Figure [Link] leg/arm

1.2.4 Working principle of mechanical puller.

Pullers are tools for loosening component compounds which can’t be loosened by hand because they hold
into position by their own friction force. With the aid of a screw or a hydraulic press the necessary force
is applied to separate the components. Depth and width can be adjusted variably

The legs or arms can be slide and removed from the cross arms and placed the other way inverted to enable
the legs to swap from internal to external use. The forcing screw sits against the center of the shaft.
It pushes against a shaft or casing while the legs pull and remove the part.

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Figure 16..How is puller work.

1.3 problem statement

Removing a part such as bearings, gears, pulleys or brake drums from a shaft or from brake shoe is day to
day activity of automotive garage mechanics. But due to the reason mentioned below this task face a
difficulty for mechanics in our host company. Hard fit a type of connection in which the size of two
mating material have a little millimetric fractional difference at the mating surface to restrict the relative
motion between the two machine components. Hard fit is the most common connection in mechanical
world to fit some design or functional requirement. It is very difficult task to pull out a bearing, pulley, or
gear if it is held in to the shaft with a hard fit. In a similar fashion the brake drum of a car wheel may stick
to its brake shoe due to malfunctioning of one or more components in a brake line system or due to
unstandardized (in size) assemblage of brake drum and brake shoe by mistake. Due to a high tightening
property of a hard fit it is not possible to pull out the parts by human hand [Link] it becomes necessary
to use a simple machine to multiple a small amount of force in which one mechanic can exert in to a
larger amount of force that can pullout the part out of the shaft.

1.4objective of the study

1.4.1 General objective
The main objective of this project is to design an advanced dual leg mechanical puller that has
the capacity to pullout tightened parts out of position without damage based on the given

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specification to make the task of garage mechanics easier and to reduce the cost of the puller by
using material of low cost.

1.4.2 Specific objective

Designing of mechanical puller stated in the general objective achieved by careful analysis of its
components like power screw, nut, longitudinal collar, driving handle and leg by using different
standardization tables and graphs.

To the point, the specific objective of this project is;

 To select proper sized standard power screw from table.

 To determine the proper number of legs and dimension of it.

 To select compatible cross-sectional shape of longitudinal collar/cross arm with

its function and adequate size to handle the stress on it.

 To design ergonomic (portable for mechanics to use) handle both in length and
diameter.

 To decrease cost by using the economical material.

1.5 methodology
Methodology is the way of identifying problems, design of device, specify the process, selecting
the proper materials that are suitable for the device and determine the simplified way of
fabrication and methods of using developed solid work software.

General we use manual analytical methodology to design each components of a mechanical

puller. Procedurally the methodology to design each components is described as follows step by
step;

1. Specify the component of mechanical puller and there configurations for functioning.
2. Select a suitable material for all components such as screw spindle, handle,
longitudinal collar, and legs by considering a mechanical load that may exerted on it
and mechanical property of materials.

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3. Reading the tensile, compressive, shear strength and modules of elasticity of selected
material from material data book.

4. Mathematically(using Arithmetic Algebra) determine the appropriate the geometry of

the mechanical puller components by analyzing the stress induced on each component
based on the specification of physically quantity (the capacity a puller can pull) and
the strength of selected material.

5. Check for all susceptible failure/stress analysis that may happen on a given
component

6. If there is any failure in step 4 analysis, resize the component that have a relation with
the type of stress in which it failure happen. If no failure is happen (safe design) take
the value as a final result.

7. After analyze the result we will draw conclusion and give some comment about it.

8. After designing all components the final result presented by Part drawing, assembly
drawing and simulation of the mechanical puller using SOLIDWORK 2018 software.

1.6 scope and limitation of the study

1.6.1 Scope of the project
This project is about the designing of machine component puller that can be used on automotive
garage especially on military automotive garage .The type of puller going to be designed is a
mechanical puller operated by human effort/hand operated. Taking in to account time and
resources we have the scope of the project includes material selections for each parts of hand
operated mechanical puller component; it covers the detail design and analysis of each
component of mechanical puller and to draw out the detail drawing of each component and
assembly drawing using AutoCAD software with the help of optimization concept and design
procedure. After giving detail design and analysis of the results will give some conclusion and
recommendation about the design.

1.6.2 Limitation of the project

Our project is to design mechanically operated puller based on a given specification but we are
limited to apply practical laboratory to check exactness of our result. Even though there are
numerous works and journals done on mechanical puller it is hard to find them since they are not

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properly documented; there sample design are not available even on world widely known
famous internet search engines like Google, Wikipedia, Yahoo and Being. The difficulty to get
internet connection to browse some important topics was the major hindrance throughout our
designing time.

1.7 organization of the project

1.7.1 Planning the project
The planning methods of this
project are;
• Considering the impact of tightening load of shaft and bearing.
• Consideration of the material cost
• The parts are easily manufacture in the company
1.7.2 Collecting data to justify the problem
o Primary data collection method such as;
 Interview, ask mechanics difficulty orally.
 Observation, observe time consuming and difficult task during internship
project
o Secondary data collection method; manual and books

1.7.3 Idea generation of the project

We have generated this idea most of the time the mechanics troubled to dis-assemble the gear
box parts and other components contain bearing.
As a result they lose their power and their time in un proper way.

1.7.4 Analysis of the project

This is the way of identifying problems, design of device, specify the process, selecting the Proper
materials that are suitable for the device and determine the simplified way of fabrication And
simulation developed by using solid work and analyzed theoretically.

Chapter two

2. Literature review
Harold E. Keister, Rockford, Ill. Application June 7, 1954, Serial: - This invention of mechanical puller
is, in fact, adapted to be used wherever the work of removal must be accomplished in very close quarters

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where it is necessary to have a strong yet simple and compact tool having a very solid gripping action and
very great pulling power in rotating parts like bearing of the machines, cares and so on.[10]

Michael J. Punaro 4730 Twin Hickory Lake Drive Glen Allen, May 9, 2009:- A mechanical puller a safe
and efficient manner and tooling to remove bearings, bushings, gears, etc. The invention is simple and
highly efficient is its design and use due to incorporating multiple design elements into the main collets or
bearing adapters. My present invention uses a simple split collet machined accurately to precisely fit the
bearing being removed, in addition the same collet incorporate rates an upper threaded section to allow
the removal sleeve to easily and precisely fit to the collet while at the same time the threaded removal
sleeve securely keeps the collet together and properly aligned with the bearing and shaft axis to provide
easy and accurate operation. Another design integrated into my puller is the ball thrust bearing on the end
of the pressure or removal Screw. This anti-friction thrust bearing eliminates undue friction and provides
very free rotation of the pressure screw. [11]

Chapter three

3. Detail design of mechanical puller components

3.1 Specification of design product

The mechanical puller going to designed in this project can pull a bearing, brake drum, gear, flywheel,
and tire wheel held up to an axial load of 20 KN with a diameter.

• 20cm(front bearing of Ural gear box),

• 50cm(brake drum of Ural wheel),and

• 70cm(engine flywheel)

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3.2 Components of mechanical puller to be designed

Various parts of a mechanical puller which has unreplaceable role in removing hardly fitted bearing,
heavy wheel or rusted drum on the brake shoe is listed below;

1. Power screw/screw spindle

2. Nut

3. longitudinal collar for nut,

4. Head at the top of the screwed spindle for handle and handle,

5. Leg/arm

3.3 Material selection

Material selection is a step in the process of designing any physical object. In the context of product
design, the main goal of material selection is to minimize cost while meeting product performance goals.
The fact is, material selection is so important because engineers have to plan for any potential
consequences that certain materials may present. In the long run, this will make the process of
engineering design analysis easier and give the project the best chance of success.

Mechanical properties are also used to help classify and identify material.

Mechanical properties are physical properties that a material exhibits upon the application of forces.
The important mechanical properties of material from the consideration design are strength, rigidity,
toughness, resilience, shock resistance, wear resistance, creep characteristic, corrosion resistance,
frictional properties and hardness.

In the scope of Mechanical Engineering, the materials which are commonly used are Mild-steel, Stainless
steel, Cast Iron, glass, plastic. To make different parts, alloy steel is used. Nickel, chromium, vanadium,
zinc, Copper, Manganese is available used in alloy steel.

There are several steps to the material selection process. The materials selection process for a component
or joint between components involves these steps:

1. Identify the design requirements.

2. Identify the materials selection criteria.
3. Identify candidate materials.
4. Evaluate candidate materials.

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5. Select materials.

1. Identify the design requirements.

Design requirement for each components of puller are specified as follow

i. Power screw/screw spindle, handle, and Leg/arm

o High axial strength since it is tensile and compressive member. Even the handle need to have
high tensile and compressive strength to resist bending stress on both internal and external side

o Good machinability for the ease of manufacture

o Relatively low cost ii. Longitudinal collar for nut,

o Low cost o High wear resistance during sliding action of leg over the collar.
o Slippy property without oil lubrication for the slide connection between leg and collar

2. Identify the materials selection criteria.

Factors Effecting in the selection of Materials for engineering purpose.

• Availability of the materials.
• Suitability of the materials for the working conditions in service.
• The cost of the materials.

3. Identify candidate materials.

It obvious that the object should made from metal and let us deal about classes of metal.

The engineering materials are mainly classified as:

1. Metals and their alloys, such as iron, steel, copper, aluminum, etc.
2. Non-metals, such as glass, rubber, plastic, etc.

The metals may be further classified as:

1. Ferrous metals..

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The Ferrous metals are those which have the iron as their main constituent, such as cast iron,
wrought iron and steel.
2. Non-ferrous metals
The Non-ferrous metals are those which have a metal other than iron as their main constituent, such
as copper, aluminum, brass, tin, zinc, etc.

The ferrous metals commonly used in engineering practice are cast iron, wrought iron, steels and alloy
steels. The raw material for all ferrous metals is pig iron which is obtained by smelting (Extract metals by
heating) iron ore with coke and limestone (A sedimentary rock consisting mainly of calcium that was
deposited by the remains of marine animals), in the blast furnace.

i. For Power screw/screw spindle, handle, and Leg/arm

Steel
It is an alloy of iron and carbon, with carbon content up to a maximum of 1.5%. The carbon occurs in the
form of iron carbide, because of its ability to increase the hardness and strength of the steel. Other
elements e.g. silicon, sulphur, phosphorus and manganese are also present to greater or lesser amount to
impart certain desired properties to it. Most of the steel produced now-a-days is plain carbon steel or
simply carbon steel. Carbon steel is defined as steel which has its properties mainly due to its carbon
content and does not contain more than 0.5% of silicon and 1.5% of manganese.

By manipulating the amount of carbon and other constituents the compressive strength of a steel can be
increased significantly. Among the series of steel in data book steel 4340 contain more amount of carbon
and more amount of compressive strength.

ii. For Longitudinal collar for nut,

Cast Iron

The cast iron is obtained by re-melting pig iron with coke and limestone in a furnace known as cupola.

Property of series of cast iron for longitudinal collar for nut.

1. Grey cast iron:

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It is an ordinary commercial iron having the following compositions:

Carbon = 3 to 3.5%; Silicon = 1 to 2.75%;

Manganese = 0.40 to 1.0%; Phosphorous = 0.15 to 1%;

Sulphur = 0.02 to 0.15%; and the remaining is iron.

The grey color is due to the fact that the carbon is present in the form of free graphite. It has moderate
tensile strength, high compressive strength and no ductility. It can be easily machined. A very good
property of grey cast iron is that the free graphite in its structure acts as a lubricant. Due to this reason, it
is very suitable for those parts where sliding action is desired. The grey iron castings are widely used for
machine tool bodies, automotive cylinder blocks, heads, housings, fly-wheels, pipes and pipe fittings and
agricultural implements.

2. White cast iron:

The white cast iron shows a white fracture and has the following approximate compositions:

Carbon = 1.75 to 2.3%;

Silicon = 0.85 to 1.2%;

Manganese = less than 0.4%;

Phosphorus = less than 0.2%;

Sulphur = less than 0.12%, and the remaining is iron.

The white color is due to fact that it has no graphite and whole of the carbon is in the form of carbide
(known as cementite) which is the hardest constituent of iron. The white cast iron has a high tensile
strength and a low compressive strength. Since it is hard, therefore, it cannot be machined with ordinary
cutting tools but requires grinding as shaping process. 3. Chilled cast iron: It is a white cast iron produced
by quick cooling of molten iron. The quick cooling is generally called chilling and the cast iron so
produced is called chilled cast iron. Chills are used on any faces of a casting which are required to be hard
to withstand wear and friction.

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4. Mottled cast iron:

It is a product in between grey and white cast iron in composition, color and general properties. It is
obtained in castings where certain wearing surfaces have been chilled.

5. Malleable cast iron:

The malleable iron is a cast iron-carbon alloy which solidifies in the condition in a graphite free structure,
i.e. total carbon content is present in its combined form as cementite (Fe3C). It is ductile and may be bent
without breaking or fracturing the section. The tensile strength of the malleable cast iron is usually higher
than that of grey cast iron and has excellent machining qualities. It is used for machine parts for which the
steel forgings would be too expensive and in which the metal should have a fair degree of accuracy, e.g.
hubs of wagon wheels, small fittings for railway rolling stock, brake supports, parts of agricultural
machinery, pipe fittings, door hinges, locks etc.

4. Evaluate candidate materials.

i. For Power screw/screw spindle, handle, and Leg/arm

By manipulating the amount of carbon and other constituents the compressive strength of a steel can be
increased significantly. Among the series of steel in data book steel 4340 contain more amount of carbon
and more amount of compressive strength.

ii. For Longitudinal collar for nut

Among the materials enlisted for the collar gray cast iron fit the design requirement better. A very good
property of grey cast iron is that the free graphite in its structure acts as a lubricant. Due to this reason, it
is very suitable for those parts where sliding action is desired.

5. Select materials.

Selection of a suitable material must be taken into account the suitability of the material for fabrication as
well as the compatibility of the materials with the environment.
I. For Power screw/screw spindle, handle, and Leg/arm

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Mechanical property of selected material for screw spindle/handle and nut/longitudinal collar from table 7
and table 8
For screw spindle, handle and leg/arm (all stress values are given in MPa) [5]
Table [Link] of selected steel: 4340
Metal Ultimate Yield strength Shear(torsional) Young’s Modules of Fracture
form tensile strength modules, Rigidity(GPa) toughness
strength Tensile compressive Ultimate Yield E (GPa) (GPa)

Steel:4340 126 117 131 87 75 207 81 110

See table 17 on appendix A.

II. For Longitudinal collar for nut

For nut and longitudinal collar. (All stress values are given in MPa) [5]
Gray cast iron, General purpose metal at normal and elevated temperature with good machinability.
Table [Link] of gray cast iron/grade FG 150
Metal Axial and shear strength Density Fatigue Young’s modules, Modules
form (Kg/m3) limit E/GPa of
tensile compressive Shear Tensile compressive Rigidity/
GPa

Gray cast 345 600 173 7050 68e 100 100 40

iron/grade
FG 150

See table 18 on appendix A.

3.4 Determination of Factor of Safety

It is defined, in general, as the ratio of the maximum stress to the working stress.

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The selection of a proper factor of safety to be used in designing any machine component depends upon a
number of considerations, such as the material, mode of manufacture, type of stress, service conditions
and shape of the parts. Before selecting a proper factor of safety, a design engineer should consider the
following points:

1. The reliability of the properties of the material.

2. The reliability of test results and accuracy of application of these results.

3. The reliability of applied load.

4. The certainty as to exact mode of failure.

5. The extent of simplifying assumptions.

6. The extent of localized stresses.

7. The extent of initial stresses set up during manufacture.

8. The extent of loss of life if failure occurs.

9. The extent of loss of property if failure occurs.

Each of the above factors must be carefully considered and evaluated. The high factor of safety results in
unnecessary consumption of material and low probability of failure. The values of factor of safety based
on ultimate strength for different materials and type of load. Since if failures happen the damage is
significantly serious and used materials are relatively low coast let us take higher safety factor.

Factor of safety n= 3.

3.5 Detail design of components

3.5.1 Design of screw spindle/power screw
[Link] Stresses in Power Screws
A power screw must have adequate strength to withstand axial load and the applied torque. The following
types of stresses are induced in the screw.
1. Direct tensile or compressive stress due to an axial load.

The direct stress due to the axial load may be determined by dividing the axial load (W) by the minimum
cross-sectional area of the screw (Ac) i.e. area corresponding to minor or core diameter (dc).

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Therefore Direct stress (tensile or compressive)

This is only applicable when the axial load is compressive and the unsupported length of the screw
between the load and the nut is short. But when the screw is axially loaded in compression and the
unsupported length of the screw between the load and the nut is too great, then the design must be
based on column theory assuming suitable end conditions. In such cases, the cross-sectional area
corresponding to core diameter may be obtained by using Rankine-Gordon formula or J.B.
Johnson’s formula. According to this,

Note : In actual practice, the core diameter is first obtained by considering the screw under simple
compression and then checked for critical load or buckling load for stability of the screw.

2. Torsional shear stress

Since the screw is subjected to a twisting moment, therefore torsional shear stress is induced. This is
obtained by considering the minimum cross-section of the screw. We know that torque transmitted by the
screw,

Or shear stress induced,

When the screw is subjected to both direct stress and torsional shear stress, then the design must
be based on maximum shear stress theory, according to which maximum shear stress on the
minor diameter section,

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It may be noted that when the unsupported length of the screw is short, then failure will take place
when the maximum shear stress is equal to the shear yield strength of the material. In this case,
shear yield strength,

3. Shear stress due to axial load.

The threads of the screw at the core or root diameter and the threads of the nut at the major diameter may
shear due to the axial load.

Assuming that the load is uniformly distributed over the threads in contact, we have

4. Bearing pressure.

In order to reduce wear of the screw and nut, the bearing pressure on the thread surfaces must be within
limits. In the design of power screws, the bearing pressure depends upon the materials of the screw and
nut, relative velocity between the nut and screw and the nature of lubrication. Assuming that the load is
uniformly distributed over the threads in contact, the bearing pressure on the threads is given by

Where

d = Mean diameter of screw, t = Thickness

or width of screw = p / 2, and n = Number of
threads in contact with the nut

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Therefore, from the above expression, the height of nut or the length of thread engagement of the screw
and nut may be obtained.
Table 5 in the appendix shows some limiting values of bearing pressures.

Due to the similarity of loading type and stress condition, the collar and spindle of bearing puller have the
same mathematical analysis with collar and spindle of screw jack.

In order to design a mechanically operated puller for a load W (holding force), the following procedure
may be adopted;

1. First of all, find the core diameter (dc) by considering that the screw is under pure compression, i.e.

The standard proportions of the square threaded screw are fixed from Table 9.

2. Find the torque (T1) required to rotate the screw and find the shear stress (τ) due to this torque.
We know that the torque required to lift the load,

Where

P = Effort required at the circumference of the screw, and

d = Mean diameter of the screw

There for Shear stress due to torque T1,

Also find direct compressive stress (σc) due to axial load, i.e.

3. Find the principal stresses as follows:

Maximum principal stress (tensile or compressive),

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And maximum shear stress,

These stresses should be less than the permissible stresses.

4. Find the height of nut (h), considering the bearing pressure on the nut. We know that the bearing
pressure on the nut,

Where

n = Number of threads in contact with screwed spindle.

Height of nut, h = n × p where, p
= Pitch of threads.
5. Check the stresses in the screw and nut as follows:

Where t = Thickness of screw = p / 2

6. Fix the dimensions for the diameter of head (Dh) on the top of the screw.
Take Dh = 1.75do

7. Assuming that a force of 300 N is applied by a person intermittently, therefore length of handle
determined;

From T=F*L

Where F=applied force

L= (perpendicular distance from point of rotation) Length of the handle.

The length of handle may be fixed by giving some allowance for gripping.

8. The diameter of handle (D) may be obtained by considering bending effects. We know that bending
moment,

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Where σb is the smaller of σt or σc

9. Maximum possible unsupported length of the screw can be determine from the buckling of spindle,

Where; σy= Yield stress,

E=modules of elasticity.

C = End fixity coefficient, which is 0.25

k = Radius of gyration = 0.25 dc

Let dc= Core diameter of the screw..

Where σc=allowable compression stress,

W=the maximum load on the power screw

The screw under maximum compression (131 MPa), with a load (W=20 kN),

Take n=3 is factor of safety

Solving for the corresponding dc dc=

24.2mm say dc=26mm

For square threads of normal series, the following dimensions of the screw are selected from Table
11 on APPENDEX B.
Core diameter, dc= 26 mm
Nominal or outside diameter of spindle, do= 32 mm

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Pitch of threads, p = 6 mm
Now let us check for principal stresses:
We know that the mean diameter of screw,

And tan α=p/πd tan

α=6/ (π*29)=0.0658

Assuming coefficient of friction between screw and nut,

∴ Torque required to rotate the screw in the nut,

T1=60.236*10^3 N-mm
And shear stress due to the torque,

Now compressive stress due to axial load,

∴ Maximum principal stress (tensile or compressive),

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The given value for σc, for compressive stress is equal to 131/3=43.5 N/mm2 and,

For tensile stress is equal to 117/3=39 N/mm2.

Since the maximum principal stress (tensile and compressive) is greater than the given allowable stress the
design of spindle is not [Link] core diameter (dc) of higher value should be taken.

Take dc=33 mm instead of 26 mm

For square threads of normal series, the following dimensions of the screw are selected from Table
11 on APPENDEX B.
Core diameter, dc= 33 mm
Nominal or outside diameter of spindle, do= 40 mm
Pitch of threads, p = 7 mm

Now let us check for principal stresses:

We know that the mean diameter of screw,

And tan α=p/πd tan α=7/

(π*36.5) =0.061

Assuming coefficient of friction between screw and nut,

∴ Torque required to rotate the screw in the nut,

T1=73.996*10^3 N-mm

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And shear stress due to the torque,

Now compressive stress due to axial load,

∴ Maximum principal stress (tensile or compressive),

We know that maximum shear stress,

The given value of allowable τ is equal to 75/3=25 N/mm2

Since the maximum shear stress is lower than allowable shear stress the design of spindle is safe in shear.
The given allowable stress value σc, for compressive stress is 131/3=43.5 N/mm2 and,

For a tensile stress is 117/3=39 N/mm2.

Since the maximum principal stress (tensile and compressive), which is 27.37 N/mm2 is less than the

given allowable stress for newly designated core diameter (dc=33 mm), so design of spindle is safe.

Maximum possible unsupported length of the screw can be determine from the buckling of spindle,

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Where σy= Yield stress of spindle material,

E=modules of elasticity=207GPa=207*103MPa

C = End fixity coefficient, which is 0.25 k =

Radius of gyration = 0.25 dc

−92.004 ∗ 103 = −0.105𝐿2

𝐿2 = 876228.57

𝐿 = 936 𝑚𝑚 𝑜𝑟 93.6𝑐𝑚

Taking buckling length safety factor 1.8,L=93.6/1.8=52 cm say 50cm

The length of spindle up to L=93.6 cm is free from buckling. But the shorter length of the spindle is more
safe from buckling and preferable for compactness, economy and ergonomic property of the tool.
Actually taking 50 cm is all economical, compact and ergonomic. Take

L=50 cm

3.5.2 Design of Nut

Let n = Number of
threads in contact with the screwed spindle, h = Height of
nut = n × p, and
ts = Thickness of screw = p / 2 = 7 / 2 = 3.5 mm
Assume that the load is distributed uniformly over the cross-sectional area of nut. We know that the bear

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ing pressure (pb),

From table 16 on APPENDEX B, limiting value of bearing pressure for steel screw and cast iron nut,
pb=17.5 N/mm2

n=2.84 say n=5 h=n*p=5*7=35mm

t=p/2=7/2=3.5mm

Now let’s check the stress induced in the nut and screw thread in contact

Shear stress in the screw

Allowable shear stress of screw material 87/3=29……………….. From table on material selection part

Shear stress in the nut;

Allowable shear stress of nut material 173/3=57.6-----------------from table on material selection part

Since these stresses are within permissible limit, therefore design for nut is safe.

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3.5.3 Design of longitudinal collar/cross-arm

The longitudinal collar have the same loading condition with simply supported beam with concentrated
load at the mid span of the beam. Two legs at the end considered as a support and the screw load at the
collar considered as a concentrated load at the mid span of the beam.

Due to this loading condition of longitudinal collar there is no susceptibility of torsional, shear and axial
failure. But it is intensely examined by bending stress.

The length of the collar is 70cm (specification of the puller) which is the maximum diameter for bearing,
drum, wheel or gear to be pulled. And P is the load on the collar by the spindle due to tightening of the
workpice, (bearing, drum, wheel or gear).

Figure [Link] and cross-section of cross arm

Use I cross-section beam to use the shape of I cross-section as a sliding connection between the
longitudinal collar and fitly designed leg/arm.

Sliding connection enable the puller work universally to all size in the range of collar length.

Procedural design of collar dimension/size [8]

1. First determine the value of σall for the material selected from a table of properties of materials.

You can also compute this value by dividing the material strength by safety factor (F.S=3).
From table σt=117 N/mm2 and σc=131 N/mm2
Take the smaller stress (σt) as a design requirement

2. Draw the shear and bending-moment diagrams corresponding to the specified loading conditions, and
determine the maximum absolute value (Mmax) of the bending moment in the beam.

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First draw shear force and bending moment diagram as follow to determine the maximum bending
moment. [7]
i. Determine external reaction
We first determine the reactions at the supports from the free-body diagram of the entire beam.
Compute summation of force along y axis considering upward direction positive

ΣFy=-P+RA+RB=0
RA+RB=P
Since the beam is symmetric RA=RB=R
Solving the above equation

RA+RB=P
R+R=P
2R=P
R =RA=RB =P/2

Figure [Link] reaction on cross-arm

We find that the magnitude of each reaction is equal to P/2.

ii. Develop equation for shear force and bending moment for two sections, which is to left and right
part of concentrated load.
a) To the left of concentrated load (A-C) or 0<x<L/2

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Figure [Link] cross-arm to the left for shear equation o

Shear equation.

Summation of force along Y axis assuming upward direction positive. ΣF y=0.5P-V=0

o Moment equation.

Summation of moment about the section point assuming counter clock wise positive.

b) To the right of concentrated load (C-B) or L/2<x<L

Figure [Link] cross-arm to the left for moment equation o

Shear equation.

Summation of force along Y axis assuming upward direction positive. ΣF y=0.5P-P-V=0

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o Moment equation
For simplification purpose it is better to use the symmetric property of the given beam and loading
condition for moment.
By symmetry

iii. Draw shear force and bending moment diagram.

o Shear force diagram

Figure [Link] force diagram for cross-arm

o Bending moment diagram

Figure [Link] moment diagram for cross-arm

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3. Determine the maximum bending movement and shear force

From drown shear force diagram and bending moment diagram the following maximum values can be
determined.

o Maximum shear force

ǀVmaxǀ=ǀ-0.5Pǀ=ǀ0.5Pǀ=1/2P

o Maximum bending moment

P=W=20 KN=20*103 N…………………...............the maximum tightening force on design specification

L=70cm (700mm)…………………….the maximum length on design specification (diameter of

flywheel, which is the largest component in size among components to be pulled)

ǀVmaxǀ=ǀ-0.5Pǀ=ǀ0.5Pǀ=1/2P

4. Determine the minimum allowable value Smin of the section modulus of the beam.

The stress at any given point in the section is given by.

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Where,

I is the moment of inertia of the cross section with respect to a centroid axis perpendicular to

the plane of the couple, y is the distance of a given point from the neutral surface,

and c is the maximum possible value of y.

The design of a beam is usually controlled by the maximum absolute value M max of the bending moment
that will occur in the beam. The largest normal stress σm in the beam is found at the surface of the beam
in the critical section where Mmax occurs.

Where, Section modules(S), S=I/c

5. For a rolled-steel beam (Flatten or spread in to different shape with a roller), refer the appropriate table
in Appendix of table for selected type of cross-section. Of the available beam sections, consider only
those with a section modulus S >Smin and select from this group the section with the smallest weight
per unit length. This is the most economical of the sections for which S >Smin.

From extended table 20, On APPENDEX B. read the corresponding value for S x-x.(since the stress are
along X-axis)

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Designation Area Depth Flange Web Axis x-x Axis Y-Y

A,mm2 [Link] Width Thickness thickness Ix Sx rx Iy Sy ry
[Link] [Link] [Link] mm mm mm mm mm mm
W100x19.3 2480 106 103 8.8 7.1 4.77 90.0 43.9 1.61 31.3 25.5

Table Taken from table 20 on APPENDEX B.

As a safety allowance after the sufficient size are determined from stress analysis, the upper part of collar
is machined to a shape with a reverse curvature of elastic curve.

Figure [Link] of maximum deflection

Shape of elastic curve for a given loading condition

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Figure [Link] of elastic curve

The shape of reverse curvature looks like.

Figure [Link] of reverse curvature

Alternatively the shape of the collar is best approximated by the bending moment diagram of a given
loading condition but the maximum height at the middle of span sized by the height of screwed nut(h r=35
mm).

Figure [Link] of reverse moment curvature

3.6.4 Design of handle

Let the diameter of the head on the top of the screwed rod is D H, usually taken as 1.75 times the outside
diameter of the screw (do). [7]

𝐷h = 1.75 ∗ do = 1.75 ∗ 40 = 70mm

As calculated before torque required to rotate the screw in the nut,

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T= T1=73.996*10^3 N-mm

Assuming that a force of 300 N is applied by a person intermittently, therefore length of handle
determined;

From T=F*L

Where F=applied force

Lh= (perpendicular distance from point of rotation) Length of the handle.

Allowing 50 mm length for gripping, we shall take the length of handle as 300mm.

L h=300mm=30cm

A little consideration will show that an excessive force applied at the end of lever will cause bending.
Considering bending effect, the maximum bending moment on the handle,[7]

M = Force applied * Length of lever

M=300KN*300mm=90*103 N-mm

Since the material selected for the handle is same as that of screw, therefore taking bending stress;

σb = σt =117/3=39 N/mm2

Let D = Diameter of the handle.

D = 3√23505.96 = 28.64mm say 30mm

D = 30mm

The height of head (H) usually taken as 2D.[7]

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H = 2D = 2 ∗ 30

H = 60mm

3.5.5 Design of leg

Most of the dimension are common for the sliding connection between collar and leg of the puller.

Figure [Link] of jaw

Determine the Length of leg

Length of the leg can be determined from dimensional analysis of the spindle length and the maximum
thickness workpice the puller can be used in the specification of the product.

Ll=LS-dc-hn
Where

Ll=Length of leg/arm LS=Length of screw dc=the length

designated by d on collar cross-section hn=height of screwed nut

which is above the flat part of the collar

𝐿𝑙 = 𝐿𝑠 − 𝑑𝑐 − ℎ𝑛

𝐿𝑙 = 500 − 106 − 35

𝐿𝑙 = 359 𝑚𝑚 𝑠𝑎𝑦 360𝑚𝑚

𝐿𝑙 = 360𝑚𝑚

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𝐿𝑙 = 36𝑐𝑚

Thickness and width of the leg

Tensile strength of steel (leg material) is 117N/mm 2. σall=117/3=39

N/mm2

𝑤 = 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑒𝑔

𝑡 = 𝑡𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑒𝑔

Any value of w and t for A=w*t>513mm2 is safe for tensile load of 20 KN.

Take 3:1 ratio

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Determine the dimension of the thinnest cross section of the jaw from the tensile stressed induced in the
specified area;

Figure [Link] side of jaw

Tensile strength of steel (leg material) is 117N/mm 2. σall=117/3=39

N/mm2

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𝑤 = 3𝑐𝑚
Total all width (WT) of the jaw can be calculated as follow;

WT=2*wt+bf
WT=2*30+103
WT=163mm
WT =16.3cm
Check for shear stress induced on the jaw at the sliding connection.
From basic definition of shear stress;

But area of shear (As) is the product of the thickness of jaw and leg (t),nand (d-2*t f)……..refer dimension
designation of collar cross-section so;

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Shear strength of leg material, steel is 75 N/mm 2 τall=75/3=25

N/mm2
Since the induced shear stress is less than allowable shear stress the jaw at the sliding connection is safe.
Determination of L-shaped hook
Explicitly the L hook subjected to shear [Link] design the thickness of the hook based on shear strength
of leg material.
Shear strength of leg material, steel is 75 N/mm 2

τall=75/3=25 N/mm2 τ=w/AS

Where AS=area of shear

AS=Wl*tL

Where

Wl=width of leg tL=thickness

of L-shape hook

Stress concentration at the connection of jaw of the leg and lower tensile part of the leg.

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Figure [Link] concentration area on the jaw

Figure. Area where high localized stresses can occur.

When a structural member contains a discontinuity, such as a hole or a sudden change in cross section,
high localized stresses can also occur near the discontinuity.

The figure below refers a flat bar consisting of two portions of different widths connected by fillets; it
shows the stress distribution in the narrowest part of the connection, where the highest stresses occur.

Figure [Link] distribution on the jaw

Figure. Stress distribution near fillet in flat bar under axial loading.

Stress distribution are independent of the size of the member and of the material used; they depend only
upon the ratios of the geometric parameters involved, i.e., upon the ratios r/d and D/d in the case of flat
discontinuous member connected with fillets. Furthermore we are more interested in the maximum value
of the stress in a given section, than in the actual distribution of stresses in that section, since our main
concern is to determine whether the allowable stress will be exceeded under a given loading, and not
where this value will be exceeded. For this reason designers defines the ratio of the maximum stress over

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the average stress computed in the critical (narrowest) section of the discontinuity. This ratio is referred to
as the stress-concentration factor (k) of the given discontinuity.

To determine the maximum stress occurring near a discontinuity in a given member subjected to a given
axial load P, the designer needs only to compute the average stress σave= W/A in the critical section, and
multiply the result obtained by the appropriate value of the stress-concentration factor K.

Note that the average stress must be computed across the narrowest section: σ ave = W/td, where t is the
thickness of the bar.[9]

First compute the ratios

K=2.6

Since is less than tensile strength of material (σt=117 N/mm2) the member is safe at the
specified area.[8]

3.7 COST ANALYSIS

Cost is one of the main consideration in almost all engineering [Link] precisely guess the cost of our
mechanical puller let us analyses the cost of each components.
Cost of each components analyzed as follow.

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1. Cost of Power screw/screw spindle

Steel screw with the following size.

Dimensions

The density of mild steel is approximately 7.85 g/cm3 (7850 kg/m3 or 0.284 lb/in3)[9]

L=50 cm

D=4cm

𝑉𝑆 = 𝐴 ∗ 𝐿

Mass (M) =density* volume

M=628*7.85g/cm2=4.93 kg
Steel Prices per Lb, Kg and Ton
Some purchasers need to make a price estimation or evaluation to the cast steel casting prices. The
following table is listing the normal carbon steel castings prices per lb, kg and ton made by Dandong
foundry in China. Hope it could help the buyers to do the approximate evaluation for the carbon steel,
such as mild steel, medium carbon steel and high carbon steel castings.

The following cast steel prices updated by 12th. Mar. 2019

• Complex structure, good surface quality – meaning that your casting parts have complex design,
complex inside or outside shapes, which means the steel foundry needs to use water glass

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investment casting process. This casting process also could make good surface quality. Refer to
[Link].
• Not complex structure, normal surface quality – meaning that your casting parts have simple or

normal complexity, the outside and inside shapes are not complex. Moreover, you do not have high

requirements to the surface quality, such as surface smoothness and defects. Price of our spindle

Ps=M*COST/mass

Ps=4.93*1.38$

Ps=6.803$

2. Cost of longitudinal collar for nut,

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Material; gray cast iron

Dimensions

Length=70cm

Height=10.6 cm

Width=10.3 cm

Dimension of Negative area height on full rectangular solid.

Height =10.3-2*0.88=8.54cm

Width=10.6-2*2*0.71=9.81 cm

Volume (V)=(70*10.6*10.3)-2*(70*8.54*9.81)
V=408.6 cm2
Mass (M) =density* volume
M=408.6*7.85g/cm2=3.2 kg

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Ps=M*COST/mass

Ps=3.2*1.21$

Ps=3.87$

3. Cost of handle;

Steel cylinder with the following size.

Dimensions

The density of steel is approximately 7.85 g/cm 3 (7850 kg/m3 or 0.284 lb/in3)[9]

L=60 cm

D=30mm

𝑉𝑆 = 𝐴 ∗ 𝐿

Mass (M) =density* volume

M=423.9*7.85g/cm2=3.327 kg

Price of our spindle

Ps=M*COST/mass

Ps=3.27*1.38$

Ps=4.51$
4. Cost of leg
From the size of one leg and dimensional complexity to manufacture the cost of one leg estimated best
around 8$.

Ps=2*8$=16$

Total cost of pulling machine

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Pt=4.51+3.87+6.08+16=30.46$
Total price in Ethiopian birr
Using Current exchange rate between dollar and birr.
Total Price =30.46$*28.97
Total Price =882.46 Birr
Curent price of equivalent puller in europian market is 38$.including the transport cost and national port
cost its cost elivated to 50$.so from the point of cost our design is relativelly cheaper.

Chapter four

3. Solution techniques
General we use manual analytical techniques to design each components of a mechanical puller.
Procedurally the design of each components is described as follows step by step;

After select a suitable material for all components such as screw spindle, handle, longitudinal
collar, and legs by considering a mechanical load that may exerted on it and mechanical property
of materials. Then Reading the tensile, compressive, shear strength and modules of elasticity of
selected material from material data book.

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After determining the strength of the material and the load Mathematically(using Arithmetic
Algebra) determine the appropriate the geometry of the mechanical puller components by
analyzing the stress induced on each component based on the specification of physically quantity
(the capacity a puller can pull) and the strength of selected material. Check for all susceptible
failure/stress analysis that may happen on a given component. If there is any failure in analysis,
resize the component that have a relation with the type of stress in which it failure happen. If no
failure is happen (safe design) take the value as a final result. After analyze the result we will
draw conclusion and give some comment about it. Finally designing all components the final
result presented by Part drawing, assembly drawing and simulation of the mechanical puller
using SOLIDWORK 2018 software. The mathematical analysis made manually by ordinary
adding machine.

Chapter five

5. Result and discussion

5.1 Result
The geometric (dimension and shape) result of the design presented as follow in the form of table.
Table [Link] of screw spindle
Dimension of screw spindle(all dimensions in mm)

Core diameter(dc) 33

Nominal/outer diameter(do) 40

Pitch(p) 7

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Length(Ls) 500

Table [Link] of nut

Dimension of nut

Thickness of screw(ts) 3.5 mm

Number of screw(n) 5

High of screwed nut(hn) 35mm

Collar cross-section

Table [Link] of collar cross-section

Dimension of collar cross-section
Designation Area Depth Flange Web Axis x-x Axis Y-Y
A,mm2 [Link] thickness
Width Thickness Ix Sx rx Iy Sy ry
[Link]
[Link] [Link] mm mm mm mm mm mm

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W100x19.3 2480 106 103 8.8 7.1 4.77 90.0 43.9 1.61 31.3 25.5

Longitudinal length (L=70 cm)

Height of reversed curvature of deflection above the I cross-section h r=35 mm
Table [Link] of handle
Dimension of handle(all dimensions in mm)

Diameter of head at the top of screw (DH) 70

Height of head at the top screw spindle (H) 30

Length of handle (Lh) 60

Table [Link] of leg

Dimension of leg (all dimensions in cm)

Length (Ll) 36

Width of leg (Wl) 4.5

Thickness(t) 2

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Width of thinnest section on the jaw (Wt) 3

Total Width of jaw (Wj) 16.3

Thickness of L member 2

5.2 discussion
The results we finally found almost have shown us some progresses and successes in our design
project. Because, as we can see from the overall design analysis, the loads on the components of
puller are almost within the range of the maximum tensile strength and design stress of the
material.
Chapter six

6. Conclusion and recommendation

6.1 conclusion
In our design project we are planning to design a mechanical puller that has the capacity pullout a
bearing, pulley, gear, drum and wheel tightened by 20KN frictional force. Then we try to perform
geometric analysis, force analysis, stress analysis, part drawing and assembly drawing. From this design
analysis we got successful results. All analysis of the mechanical puller is feasible and we get applicable
and ergonomic dimension with ensured safety (safety factor 3). And almost all parts of the mechanical
puller can be easily manufactured in the work shop. And in addition to that, by accomplishing the project
of mechanical puller successfully we felt that we have obtained enough confidence and knowledge
regarding to this topic and general designing scheme with full of satisfaction and forward the project to
concerned.

6.2 Recommendation
For a machine designer going to design a puller in the future we recommend some improvements beyond
this paper or this design. Primarily

 To eliminate the need of human effort it is better to use electrically driven electric motor
(ACmotor) instead of human operated handle to pull out the component from tightening area.
Secondly

 To have accurate design results the whole designing process of mechanical puller components
should be assisted by appropriate number computing software and Simulation software.

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 Someone who is going to design a puller that can pull out components of huge machinery should
design its puller based on a principle of hydraulic power multiplication (Pascal’s law) instead of
mechanical power multiplication, since hydraulically operated machines can exert huge amount
of force than mechanically operated machines relatively.

 After the time of manufacture the mechanical puller should be tested in laboratory before used
practically on garage.

 It is better to treat manufacturing material by temperature to have extra strength.

CHAPTER SEVEN

7. SOFTWARE DEVELOPMENT/SOLIDWORK PART AND ASSEMBLY DRAWING

7.1SOLIDWORK PART DROWING

Figure 31.3D SOLID WORK screw spindle

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Figure 32.3D solid work for leg

Figure 33.3D solid work for cross- arm

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Figure 34.3D solid work for handle

7.2 SOLIDWORK ASSEMBLY DRAWING

Figure [Link] assembly drawing

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Figure 362D ssolid work for leg

Figure 37.2D solid work for handel

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Figure 38.2D solid work for cross-arm

Figure 39.2D solid work for spindle

Reference and Citation

[1] Kukko_catalogue

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[2] [Link] (mechanics)

[3] [Link]

[4] [Link]

[5] Machine design datebook, Downloaded from Digital Engineering Library @ McGraw Hill
([Link]) Copyright © 2004 The McGraw-Hill Companies.

[6] Kenneth S. Edwards, Jr, and Robert B. McKee, Fundamentals of Mechanical Component Design,
McGraw-Hill, Inc., 1991, which is drawn from the Structural Alloys Handbook, published by the
Metals and Ceramics Information Center, Battelle Memorial Institute, Columbus, Ohio, 1985.

[7] A Textbook of Machine Design by [Link] AND [Link] [tortuka]

[8] Mechanics of Materials 5th Ed by beer and johnston_2

[9] Read for corresponding value of stress concentration factor (K) for the ratios from the text
referenced by W. D. Pilkcy, Peterson's Stress Concentration Factors. 2" cd.. John Wiley & Sons,
New York. 1997.

[10] Harold E. Keister, Rockford, Ill. Scientific journal Application June 7, 1954, Serial

[11] Michael J. Punaro 4730 Twin Hickory Lake Drive Glen Allen, May 9, 2009

Appendix

APPENDEX A, FIGURE
Table [Link] concentration factor for flat bar with fillet

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Fig Stress concentration factors (K) for flat bars under axial loading.

APPENDEX B, TABEL
Table [Link] dimensions for square threads in mm (Fine series)

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Table [Link] of table 9

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[Link] dimensions for square threads in mm (Normal series)

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Table

Table [Link] of Table 11

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13.. Basic dimensions for square threads in mm (Coarse series)

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Table

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Table
[Link] of table 13

[Link] dimensions for trapezoidal threads in mm (Coarse series)

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Table

16. Limiting values of bearing pressures.

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Table

[Link] property of some common metals

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Table

Table [Link] property of typical cast iron

[Link] of rolled steel shape.

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Table

[Link] of table 19

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Table

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