1 Chapter one

1.1 INTRODUCTION
Service jack are a type of hydraulic jack .hydraulic involves asset of two
pistons one small another large, work is done on the small cylinder
(pushing) and this force is transmitted to the large one via hydraulic
fluid
Where mechanical advantage is gained and the output piston produces a
Great force.
A jack is a powered device used as a lifting device to lift heavy loads or
apply nearly high forces. More power full jack uses hydraulic power to
provide more lift over great distance. A jack is a mechanical device used
as a lifting device to lift heavy loads or apply great forces jacks employ
a screw three d or hydraulic cylinder to apply very high forces more
power ful jacks uses hydraulic power to provide more lift over great
distance. Hydraulic service jacks are typically used for shop work they
are used to lift vehicle and other loads use of jacks not designed for a
specific vehicle requires more than the usual care in selecting ground
condition the jacking point on the vehicle and ensuring stability when
the jack is forced.

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1.2 Problem statement
Now a day in this country, the most of the cars were equipped with
scissor car jack. We found that the scissor car jack were very difficult to
be used by human being this types of jack needed more strength and
energy to operate this jack by turning the lead screw. Thus, we want to
develop a product based from problem faced by the users who drive a
car regarding to this issue. To overcome this problem a research has been
conducted to find the solution on how to design a hydraulic service
jack(floor jack) for the car using the simplest and cheapest way while it is
energy saving

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1.3 OBJECTIVE
1.3.1MAIN OBJECTIVE

Design of a hydrualic serivice jack.

1.3.2 Sepecific objective

To design a hydrualic serivice having a maximum lifting height of
375mm and a minimum lifting height of100mm and about 20.55 lifting
capacity.

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1.4 Significance of the project

 This project is important for maintenance purpose for the

drivers to serivice their car and theProject is means of income
for persons who design the project and it reduce human power
becuse This jack easily lift high wight materiale

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 2 Chapter two
2.1 Literature review

An automotive jack is used to lift whole vehicle or just a section of it to

make the repair work facile.
Today, many people are familiar with the jack that is included with their
vehicle. Some vehicles bear screw jacks and others carry a hydraulic
jack. Automotive jacks are of three types mainly:-
1. Screw Jacks
2. Trolley Jacks
3. Bottle Jacks
Each has its own advantages and disadvantages. Screw jack is lesser in
cost, as compared to trolley jacks and bottle jacks. While trolley jack
and bottle jack can provide a greater lift with lesser application of force.
Blaise Pascal studies fluid hydrodynamic and hydrostatics, centralized
on principles of hydraulic fluid. His inventions includes the hydraulic
press which multiplied smaller force acting on a larger area into the
application of a large force totalled over a smaller area transmitted
through the same pressure at both locations (Blaise Pascal,1623-1662).
One of the exceptional feature of a hydraulic jack is it can lift heavy
loads despite it itself has a light weight and is portable. Joseph Bramah
was working on a press. William Geroge Armstrong (sir-1st Baron) a
contemporary of Bramah, was an industrialist and the founder of
Armstrong Whitworth. He first designed a rotary engine from the
concept but later moved it to a hydraulic piston type of design that could
move a crane. At a time when the scientific field of hydraulic

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engineering was not yet recognized Armstrong and Bramah were
applying Pascal’s laws to their inventions. Joseph Bramah got a patent
for his inventions of the hydraulic press in 1795.( Joseph Bramah, 1785).
Hydraulic Jack works on the principal of Pascal. It states that pressure
on a interned liquid is conveyed evenly in all the directions. The jack is
operated with the help of liquid that is preferably oil as it can lubricate
the parts of the jack as well.
When the plunger is pulled upwards, the fluid is pulled from the
reservoir through a check-valve suction pump. When the plunger is
pressed, it sends fluid through another valve into the main cylinder. The
suction valve opens when the plunger is pulled again. A document was
compiled which includes research information pertaining to portable and
stationary lifting devices that could be found in most mechanic shops.
The purpose of this research is to gain information related to the
development of a belly pan jack to aid in the removal and installation of
belly pans on large excavating equipment. This research includes
information on current state of the art developments in this field as well
as related patents and subsystems thereof. The areas covered give a good
base of information on which to develop new ideas (Gibbs et al,
2010).The force exerted by the fluid in the main cylinder aids in the
movement of piston in the upward direction.[1]

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2.2 Parts of hydraulic service jack

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[2]

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 2.3 Advantages of hydraulic service jack

 High lifting capacity up to 10tons and also lift higher.

 Have a sturdy construction which a mounts to their large size.
 Due their size they even have wheels,so do not imagine carrying
one around in the boot of your car[3].

2.4 Disadvantage of hydraulic service jack

 Service jack, may require serious maintenance due to presence of

hydraulics which have to be checked for leaks and therefore
overall maintenance cost may come in to play.
Require large working space[3] .

2.5 WORKING PRINCIPLE

A2
F1S1=F2S2 → S2=(F1/F2)S1
OR S1= (F2/F1) S2
S1=(F2/F1)S2 implies that we have to move the fluid in the smaller
cylinder a distance that is greater than s2 by a factor of F2/F1[3]
THE WORKING PRINCIPLE OF A HYDRAULIC SERVICE
JACK CAN EASILY PUT AS IN THE FOLLOWING STEPS AND
EXPLANATIONS
 oil is poured into the oil reservoir via the oil vent
 the release valve is rotated clockwise to lock it
 the pump will suck oil from the reservoir and as it is pushed down a steel
ball locks the way back to the reservoir therefore; oil will be deliverd to the
cylinder to develop the pressure necessary to move the piston
 repeated motion of the pump will cause the piston to move forward
 as the piston slides forward it draws the linking rods that are attached with
the connecting square bars

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 the motion of the linking rods result in an upward motion of the saddle and
the arms
 The whole lifting mechanism can be considered as rocker-slider
mechanism. it can easily be illustrated in the following figure.

3Chepter three
3.1 Geometrical analysis

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To design the geometry we should determine L1, L2, L3, L4, Ѳ, ỿ, α, β, m, b1, b2,
and p

At minimum lifting position

The force on link 2 can be shown as

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𝑇ℎ𝑒 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑙𝑖𝑛𝑘 1 𝑐𝑎𝑛 𝑏𝑒 Should as:
Σ𝑀𝑜=0, FL1Sin𝛽 – L L2Cosα = 0
F = L2/L1 [cosα/sin𝛽] L should be minimum
We should determine the values of L1, L2,β and α that will give the
minimum force in specified range of each parameter.

At the maximum lifting position

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At link 3

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Σ𝐹𝑥 = 0 , F23cosm = F
Σ𝐹𝑦 = 0 , F23sinm - F03 + F03’=0
At link 2

F12 = F32 = F23 = F/cosm

F12 = -F21
│F21│ = F/cosm where symbols
0=Ѳ
Y=ỿ
b=β

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 At link 1

Σ𝑀0 = 0

 h1L1cosѲ + (F21sinm) (L2cos𝛾) (F21cosm) (L2sin𝛾) =0

h1L1cosѲ+F21L2 (sinm cos𝛾-cosm sin𝛾) =0

F21L2 (cosm sin𝛾-sinm cos𝛾)=h1L1cosѲ

F21L2 (sin (𝛾-m)) =h1L1cosѲ

F21= (L1/L2) [cosѲ/sin(𝛾-m)]h1 →should be maximum

For the minimum lifting position

Let (L1/L2) =L and

2.80≤𝛾≤ 8.20

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 100≤α≤160

420≤𝛽≤540

F=L1/L2 (cosα/sin𝛽) h1=L (cosα/sin𝛽)→should be

Minimum

Let’s iterate to find the values of L, α and 𝛽 that will give the

minimum possible F in the range specialized for each parameter

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 F will be minimum for 𝛾=2.8
α= 16
𝛽=54

For the maximum lifting position

𝛾=2.8 Determined from previous iteration

66°≤𝜃≤74°
F21=L1/L2 [cosα/sin(𝛾−𝑚)h1→should be minimum assuming that

30°≤𝛾≤36° 8°≤𝑚≤10°
Let’s iterate to find the values of 𝜃,𝛾 𝑎𝑛𝑑 𝑚 that will give the
maximum position of F:

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 F will be maximum for 𝜃=74° 𝛾=36° 𝑚=8°

Take: C1=45mm and C2=30mm

(Hmax-C1)- (hmin-C1) =d1+d2=d1+d2=hmax-hmin

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 L1sin74+L2sin16=375-100

L1= (375-100)/ (sin74+sin16)

L1=222.33mm

But L1/L2=2.8 , L2=L1/2.8

L2=250.6/2.8

L2=79.4mm

L1=L2sin54-L2sin36

L1=79.4(sin54-sin36)=17.57mm

Sin8=L1/L3 , L3=L1/sin8

L3=17.57/sin8=126.2mm

To find the maximum stroke(S):

S=(L2cos54+L2cos36+L3cos8)-L3

S=(79.4cos54+79.4cos36+126.2cos8)-126.2

S=109.678mm

To find the pivoted diameter (P):

P= (hmin-C1) +d1

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 P= (100-45) +L1sin16=

P=116.28mm

The value block assembly (hydraulic base unit) will be put at d3+t

distance from pivoted o .And t will be determined after an appropriate

standard cylinders is selected

b2=P-L2sin54

b2=52.044

b1=hmin-75+𝜑2/2

b1=65+𝜑2/2, take 𝜑2=10mm

b1=100-75+5=30mm

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 4 chapter four
4.1Force analaysis

TO ANALYZE THE FORCE ON THE HYDRAULIC SERVICE [Link] SHOULD

FIRST DETERMINE POSITION AT WHICH THE FORCES ON THE LINKS AND

SUPPORTS WILL BE MINIMUM TO DO THAT, WE HAVE TO FIND

GOVERNING RELATIONSHIP BETWEEN THE PISTON FORCES (F) AND THE

FORCES IN THE LIMBS.

The saddle mills have reaction forces at a and b these forces will be
transmitted to

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The saddle mills have reaction forces at a and b these forces will be
transmitted to link 1and the supports

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Ra and Rb on the links and supports respectively mill not change both in
magnitude and direction for any angle t° or s°.hence, we could have
analyzed the forces on the link and supports at any angle t°or s°if we
were concerned only about Ra and [Link], F21 will change with
angle k° ,s° and t° .therefore, we should find the angles at which F21
will be maximum to analyze the forces on the links and supports

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 CCW Σ𝑀 = 0
→for 54°≤𝑡≤126°

0=h1L2cosA°-(F21cosF) l2sint-(F21sinF) L2cost

F21L2 (cosksint+sinkcost) =h1l1cosA
F21=L1/L2 [cosA/sin (t+k)]h1 but L1/L2=2.8

→for 126°≤𝑡≤144° it can be shown that

F21=2.8[cosA/sin (t+k)]h1

F21=L1/L2[cosA/sin(180-t-k)h1
F21=2.8[cosA/sin (180-t-k) h1
The relationship between angles is calculated as:
A=(180°-t+110°) → A=(70-t)
Sink=(L2sint-L2sin54)/L3 → k=sin¯¹[89.5(sint-sin54)/142.3]
K=[sin¯¹(0.629sint-0.5089)]
Lets iterate the relations found in the previous page to find the position
where f21 will be maximum

CCW Σ𝑀 = 0
→for 54°≤𝑡≤126°

0=L1L2cos5°-(F21cosK) l2sint-(F21sinK) L2cost

F21L2 (cosksint+sinkcost) =h1l1cosA
F21=L1/L2 [cosA/sin (t+k)]L1 but L1/L2=2.8

→for 126°≤𝑡≤144° it can be shown that

F21=2.8[cos5/sin (t+k)]L1

F21=L1/L2[cosA/sin(180-t-k)h1
F21=2.8[cos5/sin (180-t-k) L1
The relationship between angles is calculated as:
A=(180°-t+110°) → A=(70-t)
Sink=(L2sint-L2sin54)/L3 → k=sin¯¹[79.4(sint-sin54)/126.2]

K=[sin¯¹(0.629sint-0.4149)]

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Lets iterate the relations found in the previous page to find the position
where f21 will Be

TABLE

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the forces on the links and supports @ the minimum lifting position will
have to be determine e maximum

FIG

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 At the minimum lifting position :=𝛽=54° 𝐴=𝛼=16°
Link 2: F32=F23=F
SΣ𝐹=0 →F12=F32=F
Link 3: F23=F and F03=F'03 and Link 1: F21=F12 and F21=F

4.1.1 FORCE ANALYSIS FOR THE SADDLE

Σ𝐹𝑥=0 →RAx-RBx=0 -------------------eqn1

sΣ𝐹𝑦=0 → RAY+RBy=20.55------------------eqn2
CCWΣ𝑀A=0 → RBy*20-RBx*15-L*5=0
20RBy-15RBx=20.55*5
4RBy-3RBx=20.55--------------------eqn3
Mb=L*5-RAy*20-RAx*15=0
4 RAy+3 Rax=61.65

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 4Ray+3Rax=61.65……………………………………………eqn 4
Let’s put the four equations in matrix form and use gauss-eliminations
method to solve it
RAX-RBX=0..........1
RAY+RBY=20.55.......2
4RBY-3RBX=20.51.................3
4RAY+3RAX=61.65............4

whane we solve this equation we get

RBY*O=0

The set of equation has infinitely many solution.

We have infinitely many solutions for the reactions @a and b .lets take
a clever estimation to get the reaction forces @ a and b. the reaction
forces @ b is transmitted to the supports and the function of the
supports is to hold the saddle firmly in the horizontal position by taking
some portion of the load (l).hence let’s assume the reaction force @b
to

be less than that of @a and design Rby to take only 30% of the vertical
load l. Now we can have a solution that is possible
RBy=0.3L→ RAy=0.7L
Therefore use equation 2 → (RAy+RBy=20.55kN) RAy=14.39kN
Ray+(0.3*20.55kN)=kN RBx=1.37KN
RAy=14.39kN and RBy=6.165kN
Using equation 3 → 4RBy-3RBx=20.55kN RA=14.455kN
-3RBx=20.55-(4*6.165kN) RB=6.315kN
RBx=1.37kN
Using equation 1
RAx=RBx →RAx=1.37kN

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 a=tan¯¹(Ray/Rax) → a=84.56 °
b=tan¯¹(Rby/Rbx)=

Ra=𝑅2𝑎𝑥+𝑅2𝑎𝑦=
b= 77.47 °

RB=𝑅2𝑏𝑥+𝑅2by=
RA= 14.455KN

Rb=6.315

4.1.2 Force analysis for the arm

we Have two symmetrical arms as in fig a, hence: only half of RAy ,RAx
and f21are applied on each arm
let RAy=RAy/2= RAy=7.195kN
RAx=RAx/2= RAx=0.685kN and F2=F21/2
@ the minimum lifting position(as in fig)
ΣFx=0 → F21+R0x-Rax=0
F21+R0x=0.685………………………………………………………….equation*
ΣFy=0 → -RAy+Roy=0

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 Roy=RAy → R0y= 7.195kN
ΣMo=0
F21(L2sin54)-Ray(l1cos16)-Rax(l1sin16)=0

F21=24.59kN

Using equation * F21+R0x=0.685kN

Rox=0.685kN-35.89kN
Rox=-23.91Kn

4.1.3 Force analysis for the rods (link2)(linking rods)

For every arm we have two linking rods(connecting rods).henceonly

half of F'21=F'12 will be transmitted to each linking rods (link2).

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 F12''=F12'/2=F12'/2
F12''=12.3kN
ΣF0
F12''=F32''F32''=12.3kN
4.5 Force exerted by the piston (F)

We have four rods (link 2) that transmit a forces of F23''=F32'' each.

F32=4F32''
Σ Fx=0→ F=F32=4F32''=49.2kN

F=49.2KN the maximum force exerted by the piston

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4.1.5 Forces analysis for the support arms

We have two symmetrical support arms

Hence only half of RBx and RBy are exerted on each.
RBx'=RBx/2=0.685kN
RBy'=RBy/2=3.0825kN
→ΣFx=0 →RAx'=RBx→→ REx'=1kN

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 4.1.6 Force analysis for the handle

Clockwise as positive ΣMf=0→→Fh*1300-FG*100=0

Fg=120*1300/100=Fg=1.56kN
ΣFy=0→→-F11+Fg+Rf=0
Rf=-1.56kN+0.12Kn=-1.44

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 4.8 Force analysis for the hydraulic system

We can easily analyze this by we put it as in the following figure.P1=P2

Fg/A1=F/A2 but,A1=𝜋d1²/4 , A2=𝜋d2²/4

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 F/Fg=A2/A1 → 𝜋𝑑1²/4÷𝜋D1²/4 →→
F÷Fg=49.2kN÷1.58Kn=31.14
D2²÷D1²= 31.14 →→D2/D1=5.58
D2=5.58d1

Decision: take d2=7d1

Assume: d2=32mm
D1=32/7
D1=4.57mm~4.6m

5 Chapter
five
5.1 STRENGTH ANALYSIS
The following materials are to be made for the components the
hydraulic service jack. They are selected on the basis that they have
high strength, easy machinability and comparatively low cost.
ASTM grade 30 cast iron
- Bulk modules=65 GPa
- Compressive strength=752 MPa
- Density=71g/cm3
- Elastic modules=98 Gpa
- Elongation at brake=0.6%
-Fracture roughness=400 Mpa
- Hardness=210
-Poissons ratio=0.26
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- Shear modules=50 Gpa
- Tensile ultimate strength=214Mpa
- yield strength=130Mpa
AISI 1045 carbon steel
- Density=7.8g/cm3
- Elongation at brake=15%
- Hardness=170
- Ultimate strength=645Mpa
- Yield strength=415Mpa
- Elastic modulus=200Gpa

AISI 1095 carbon steel

- Elongation at brake=10%
- Ultimate tensile strength=825Mpa
- Yield strength=525Mpa)
- Elastic modulus=207Gpa

Hard drawn wire ASTM A 227

- Exponent m=0.192
- Diameter=0.7-12.7
- Modulus of elasticity=198.6Gpa
- Shear modulus=80.7Gpa
- A([Link])=1783

5.1.1 STRENGTH ANALYSIS FOR THE SADDLE

360°=2*3.14*50mm
X=16°X=13.96mm
A1=(16𝜋502)/360-(16𝜋482)/360
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 A1=27.27𝑚𝑚2
At=4A1=4*27.27=109.47𝑚𝑚2
The main stresses on the saddle are compressive and shear stresses
Check for compressive strength
Material: ASTM 30 cast iron σ=F/At=30KN/109.47=274.05Mpa
n=Sut/σ=752Mpa/274.05=2.74
Check for shear strength
SECTION A-A
The saddle is subjected to shear strength.
The shear area will be
A=2𝜋𝑅2*0.005mm
A=2𝜋∗0.048*0.005=0.00090478𝑚2
Using distortion energy theory
Say=0.577Sy
Say=τmax=0.577+130=75.01Mpa
τ=F/A=30KN/9.0478𝑚2
τ =33.16Mpa
n=τmax/τ=75.01/33.16
n=2.26Page 38 of 62
The principal stresses
σ'=(σa+σb)/2+√(𝜎𝑎−𝜎𝑏)²2+𝜏𝑚𝑎𝑥²

σ' = 274.05/2 + √274.0522+ 19.89²

σa = 274.01MPa ,σb = 0 ,τmax = 19.89MPa

σ' = 275.49MPa
check for fafty factors for Von misses stresses
n = Suc/σ' = 752/275.49 =2.73 → safe

5.1.2 strength analysis for the saddle holder

The saddle holder is subjected to normal stress, shear stress and

bearing stress
Material; ASTM 30 cast iron and safety factor is n = 3
Check for normal stress
σall = 752MPa/3 = 250.67MPa

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 σall = F/Acr → Acr = F/σall = 30KN/250.67MPa
= 119.68mm²
A ˃ Acr → safe [A is much greater than Acr because A =
(80*113)-𝜋15²/4 = 8863.28mm²]
Check for bearing stress
At A
Ap = projected area ,d = diameter ,
Ap = td here the thickness is to be 4mm
σb all = 𝐹𝑎/2𝑡𝑑 , but σb all = σall/n = 752MPa/3= 250.67MPa
σb all = 21.1𝐾𝑁/24𝑚𝑚∗𝑑 → d = 10.55/1002.68 = 10.52mm
At B
σall = 250.67MPa = 𝐹𝑏/2𝑡𝑑 → d = 9.2/24𝑚𝑚∗250.67 = 4.59mm
check for shear stress
using distortion energy theorem
τmax = 0.577Sy = 0.577*130MPa
= 75.01MPa
And take n = 1.5
τall = τmax/n = 75.01/1.5
= 50MPa
τall = F/A → A =td and we have that d = 0.08 – 0.01 =0.07mm
So, τall = 30KN/(0.07)d → t = 30KN/0.07*50MPa = 8.57mm

5.1.3 Strength analysis for the arm

The arm is mainly subjected to normal stress, shear stress, bearing

stress and bending stress
Material; ASTM 30 CAST IRON and take n = 3
Strength analysis will be done for the minimum lifting height position
for the reason stated in the force analysis.

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 Take t = 4mm and
decompose the forces tn to the X0-Y0 axis
F'axSin16 - F'axCos16 = 2.89KN -0.96KN
Fx = 1.93KN
F'ayCos16 + F'aySin16 = 10.37KN
Fy = 10.37KN
Check for normal stress C – C [the smallest cross sectional area]
σall = 752MPa/3 = 250.67MPa
σall = Fx/A → A = 1.93KN/250.67MPa = 7.7mm²
A = St – td → St = A + td
S = (7.7 + 4*11)/4 = 12.925mm
Check for shear stress [using DET]
τmax = 0.577Sy = 0.577*130MPa
= 75.01MPa
τmax = Fy/A → A = 10.37KN/75.01MPa = 138.24mm²
A = St – td → St = A + td
S = (138.24 + 4*11)/4 = 45.56mmCheck for bearing strea
σall = 750MPa/3 = 250.67MPa
σb = 𝐹𝑎/2𝑡𝑑 = 2.11/24∗11 = 239.77MPa
σb all ˃ σb → safe
At section D – D
Take t = 4mm
Decomposing F'21 in to X1-Y1 axis
Fax1 = 35.89Sin54 = 29.04KN
Fay1 = 35089Cos54 = 21.1KN
Check for normal stresses
σall = 752MPa/3 = 250.67MPa
σall = Fay1/A → A = 21.1KN/250.67MPa

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= 84.38mm²
A = S1t – td2 → S1t = A + td2
S1 = (84.38+4*11)/4 =32.1mm
Check for shear
τmax = 75.01MPa
τmax = Fax1/A → A = 29.04KN/75.01MPa = 387.15mm²
A = S1t – td2 → S1t = A + td2
S1 = (387.15 + 4*11)/4 = 107.79mm
Check for bearing stress
σb all = 752MPa/3 = 250.67MPaσb = 35.89KN/td2 = 35.89KN/4*11 =
815.68MPa
σb all ˂ σb → not safe
Change t and d2 let take t = 6mm and d = 24mm
σb = 35.89KN/6*24 = 249.2MPa
σb all ˃ σb → now it is safe.

5.1.4 Strength analysis for the supporter arm

At minimum lifting position we have that

Decomposing the forces in to X2-Y2 axis
Fbx2 = F'bxCos16 + F'bySin16 → Fbx2 = 2.2KN
Fby2 = F'bxSin16 + F'byCos16 → Fby2 = 4.05KN
This supporter arm is subjected to normal stress , shear stress ,bending
stress and buckling
Take d = 5mm and n = 3
σall = Fbx2/A ,but σall = 752MPa/3 = 250.67MPa
A = 2.2KN/250.67MPa = 8.78*10⁻⁶mm²
A = th – td → ht = A + td
h = (8.78*10⁻⁶ + 6mm*5mm)/6mm = 6.46mmcheck for shear stress
and using DET

Page | 46
 τall = 75.01MPa = Fby2/A = 4.05KN/ht – td
h = [4.05KN/6mm(75.01MPa)]+ 6mm*5m=13.99mm

Fb = √2.22+4.05² = 4.61KN
Check for bearing stress

σb = Fb/A = 4.61KN/6*5 =153.67MPa

σb all = σut/3 = 752/3 = 250.67MPa
σb ˂ σb all → safe
check for bending stress
Decomposing the forces in X2-Y2 axis and we will have
M = Fby2 * X
Maximum moment when X = 89.5mm
M = 4.052KN * 0.0895m = 362.475Nm
Section 1-1
ᴊ = 1*0.008*0.02ᶾ/12 = 5.33*10⁻⁹mm⁴
And then we have that
σb =362.475*0.01/5.33*10⁻⁹
= 680.07MPa
But → σall = σult/3 = 214MPa/3 = 71.33MPa
Therefore → σb ˃ σall → not safe
Change material; let take AISI 1095 CARBON STEELn = σult/σb =
825MPa/680.07MPa
= 1.3 → safe

Page | 47
Check for buckling

Buckling in the
X-Y plane
ᴊ = 20*8ᶾ/12 = 853.3mm⁴
A =20mm*8mm = 160mm²
R² = ᴊ/A = 853.3/160 = 2.31mm

(L/R)1 = √(2𝜋2𝐶𝐸/𝑆𝑦) , where C = end condition constant

L/R = 250.6/2.31 =108.48

(L/R)1 = √(2𝜋2∗0.5∗207𝐺𝑃𝑎/525𝑀𝑃𝑎)= 62.38

Pcr = 𝜋2𝐸𝐽/ℎ𝑒² = 𝜋²*207*10⁹*853.3*10⁻¹²/(125*10⁻ᶾ)² = 111.04KN

L/R ˃ (L/R)1He = L/2 = 125.3mm

safe

5.1.5 Strength analysis for the connection lining rods

Material ;AISI 1045 CARBON STEEL
It will be subjected to normal stress and bearing stress
Page | 48
Check for normal stress
σ = F'12/bh = 17.95/6mm*25mm = 119.67MPa
n = σult/σ = 695MPa/119.67MPa =5.8
Check for bearing stress
σb all = F'12/ dt
For bearing n = 2 and σall = σult/n = 695/2 = 347.1MPa
Then d = F'12/σb all*t = 17.95KN/6mm*347.5MPa
= 8.61mm

5.1.6 Strength analysis for the pins

At pin A it was determined that the diameter should be 11mm and the
pin is subjected to stress
Fa = 21.1KN
Material; AISI 1045 CARBON STEEL
τmax = 0.577Sy = 0.577*415MPa =239.46MPa [using DET]
τ = 𝐹𝑎𝜋𝑑2/4 = 21.1𝐾𝑁𝜋0.0112/4 → τ =222.03MPa
τ ˂ τmax → safeAt pin B, the diameters was taken to be d = 5mm
Material; AISI 1045 CARBON STEEL
τmax = 239.46MPa
τ = 𝐹𝑏𝜋𝑑2/4 but Fb = 9.2KN
τ = 9.2𝜋0.0052/4= 468.55MPaMPa
τ ˃τmax → not safe
Change material and diameter let d = 7mm and material; AISI 1095
CARBON STEEL
τmax = 0.577Sy = 0.577*52MPa
= 303MPa
τ = 9.2𝜋0.0072/4= 239.06MPa
τ˂ τmax → safe
At pin c diametres was taken as d = 7mm
Material;AISI 1045 CARBON STEEL
τmax = 239.68MPa

Page | 49
τ = 35.89𝜋0.0072/4 = 377.68MPA
τ ˃ τmax → not safe
change material and diameter let d = 14mm and material ;AISI 1095
CARBON STEEL
τmax = 0.577Sy = 303MPa
τ = 35.89𝜋0.0142/4= 233.15MPaτ ˂ τmax → safe
At pin and F21 = 35.89KN and material; AISI1095 CARBON STEEL
τmax = 0.577Sy = [Link]
Take d = 14mm [as pin C]
τ = 35.89𝜋0.0142/4 = 233.15MPa
τ ˂τmax → safe

5.1.7 Strength analysis for the piston rod

The piston is subjected to compression stress and buckling and

Material; AISI 1045 CARBON STEEL and take n = 3
Check for the normal stress
σ = F/A , but σall = 695MPa/3 = 231.67MPa
A =F/σ = 71.8KN/231.67MPa → A = 0.3099mm²A = 𝜋𝑑24 = 0.3099 → d =
19.86mm

ᴊ = 𝜋𝑑4/64 = 𝜋0.024/64 → ᴊ =7.854*10⁻⁹mm⁴

Check for buckling

A =𝜋𝑑24 = 3.14*10⁻⁴
R² =ᴊ/A = 7.854*10⁻⁹/3.14*10⁻⁴ = 4*10⁻⁴mm

Page | 50
(L/R)1 = √(2𝜋2𝐶𝐸𝑆𝑦) , C = 1
L/R =123.6/5 = 24.72

(L/R)1 = √(2𝜋2∗1∗109415∗10⁶) = 97.53

L/R ˂ (L/R) 1 so no need to use Euler's formula to check for buckling [no
buckling]

5.1.8 Strength analysis for the cylinder

Pressure in the cylinder P = F/A

Diameter of the cylinder was determined in the force analysis to be d =
32mm and t = 8mm
Then, P = 71.8𝐾𝑁𝜋𝑑2/4 = 71.8𝐾𝑁𝜋∗0.0322/4 → P = 89.3MPa
Circumferential (hoop stress) in the cylinder is given by:
σh = Pd/2t
Materials: AISI 1040 CARBON STEEL and take n = 3
σall = 695MPa/3 = 231.67MPa
σall = σh = Pd/2t → Pd/2σh =116.61MPa*28mm/231.67MP =
7.05mmLongitudinal (axial) stress on the cylinders is given by:
σL = Pd/4t
Material: AISI 1045 CARBON STEEL and take n = 3
σall = 231.67MPa = σl
Then t = Pd/4σl = 116.61MPa*28mm/4*231.67MPa
= 3.52mm
Take the thickness of the cylinder to be t = 8mm

5.1.9 Design for helical extension spring

Material; HARD DRAWN WIRE ASTM A 227 and condition both ends
pivoted
Page | 51
Assume the index C to be C = 6, wire diameter d = 4mm, D/d = 6 → D =
24mm, numbers of body coils
Nb = 40
Then Na = Nb + G/E = 40 + 80.7GPa/198.6GPa
= 40.41
Kb = (4C+2)/(4C-3) = (4*6+2)/(4*6-3)
= 1.238
K = d²G/8DᶾNa = 0.004²*80.7*10⁹/8*0.024ᶾ*40.41

The deflection from geometry analysis, 𝛿 = 123.6mm

= 4621.6N/m , K = spring constant

Then F = K*𝛿 = 4621.6*0.1236 = 568.46N

τ = Kb*8FD/𝜋𝑑ᶾ= 1.238*8*568.46*0.024/0.004²*𝜋
= 672.04MPaSut = A/dᵐ= 1783.12MPa/0.004ᵐ, where m = 0.19
= 1370.12MPa
τmax = Ssu = 0.67Sut
= 917.98MPa
n = τmax /τ = 971.98MPa/672.04MPa
= 1.37 → safe
To find the pressured initial loading
τin = 0.6Sut/C = 0.6*1370.12/6
= 137MPa
τin = 8FD/𝜋𝑑ᶾ → F = τin*𝜋𝑑ᶾ/8D = 137MPa*𝜋∗0.004ᶾ/8*0.024
= 143.47N

5.1.10 Design for helical compression spring

Material: HARD DRAWN WIRE ASTM 227

Page | 52
ends) 𝛼=0.5
End condition: spring supported between flat parallel surface (fixed

Total coils Nt = 7 , nut squared and ground ends

→ Na = Nt – 2 = 7 – 2 → Na = 5
→ take C = 8, d = 4mm and we have that D = Cd = 32mm
Sut = A /dᵐ = 1783/4ᵐ where m=0.19
= 1370.12MPa
Ssy = τall = 0.45Sut
= 0.45*1370.12 = 616.56MPaSut = A/dᵐ= 1783.12MPa/0.004ᵐ, where
m = 0.19
= 1370.12MPa
τmax = Ssu = 0.67Sut
= 917.98MPa
n = τmax /τ = 971.98MPa/672.04MPa
= 1.37 → safe
To find the pressured initial loading
τin = 0.6Sut/C = 0.6*1370.12/6
= 137MPa
τin = 8FD/𝜋𝑑ᶾ → F = τin*𝜋𝑑ᶾ/8D = 137MPa*𝜋∗0.004ᶾ/8*0.024
= 143.47N

5.1.11 Plunger design

Material: AISI 1045 CARBON STEEL

→The plunger is subjected to normal stress and buckling
Check for normal stress
σ = Fg/A = 1.56KN/7.85*10⁻⁵ = 19.86KPa
σall = 695MPa/n , for n = 5
= 139MPa
σ ˂ σall ↔ safe
Check for buckling

Page | 53
 ᴊ = 𝜋𝑑464 , A =𝜋𝑑24 but R² =ᴊ/A = 𝜋𝑑264/𝜋𝑑24 = d²/16
R = d/4 = 10/4
= 2.5mm

Pcr/𝜋 ∗ 0.012 4 = 415*10⁶ - (415*10⁶*80/2𝜋 ∗ 2.5)²*1/1*200GPa

→for intermediate length columnPcr/A = Sy – ( Sy*L/2𝜋𝐾)²*1/CP

Pcr = 30.84KN
Fg ˂ Pcr ↔ safe

5.1.12 Strength analysis for the handle

Material : AISI 1045 CARBON STEEL

Check for shear

Page | 54
 τ = 0.577Sy [using DET] τ = 239.46MPa
τ = F/A = 1440N/1.13*10⁻⁴ =12.74MPa ↔ τ ˂ τmax then it is safe
check for bending
σben = MC/ᴊ, but C = 10mm
= 144Nm*0.01M/4.69*10⁻⁹m⁴
= 310.34MPa
Then n = σult/σben = 695MPa/310.34MPa
= 2.24 ↔ it is safe

5.1.13 Wheel design

To design a wheel we to calculate force exerted on it
From geometric analysis we have(at maximum lifting position)

+↑ Σ𝐹𝑦= 0 → Rn + Rm – F = 0
→ for minimum lifting position

+C.W. Σ𝑀𝑤 = 0 → 410Rm – 310F = 0

Rn + Rm = 30KN

Rm = 30*340/410 = 24.5KN AND Rn = 5.1KN

→ For maximum lifting position

+C.W. Σ𝑀𝑤 = 0 → Rm*241.8 = 30KN*168.2

+↑Σ𝐹𝑦 = 0 → Rn +Rm = 30KN

Rm = 20.9KN AND Rn = 9.1KN

Here the front wheel should be designed for minimum lifting position
and the rear wheel at maximum lifting position At minimum lifting
position.

5.1.14 Design for the front wheel

Lets have two symmetrical front wheels each will have a section R'm =
Rn/2

Σ𝐹𝑦 = 0 → Rty1 = R'm = 12.45KN

R'm = 24.9/2 = 12.45KN

KΣ𝐹𝑥 = 0 → Rtx1 = Ff whereFf is force of friction

Page | 55
Ff = 𝜇𝑅′𝑚 = 0.3*12.45 = 3.735KN
So, Rtx = Ff = 3.735KN
At maximum lifting position

Σ𝐹𝑦 = 0 → Rty2 = R'm2 = 10.45KN

R'm = 20.9KN/2 = 10.45KN

BΣ𝐹𝑥 = 0 → R'tx2 = Ff = 3.135KN since Ff = 0.3*10.45 3.135KN

Design for the rear castor wheel
Here we have symmetrical rear wheels
for minimum lifting position
R'n1 = Rn1/2 =5.1/2 = 2.55Kn
σmin = R'n1/A = 2.55/25*10⁻⁶ → σmin = 102MPa
For maximum lifting position
R'n2 = RN2/2 = 9.1/2 → R'n2 = 4.55KN
σmax = R'n2/A = 4.55/25*10⁻⁶ → σmax = 182MPaPage 55 of 62

5.2 Standard machine elements

5.2.1 BOLTS
Material: CARBON STEEL

Bolt F (Qty = 2) Bolt T (Qty = 2)

M10*1.5mm M 12*1.75
K = 6mm K = 7mm
b = 20 + 6 = 26mm b =30mm
Ds = 9.5mm Ds = 125mm
S = 16mm S =18mm
L = 33.2mm L = 41.3mm
Bolt Q1and Q2 (Qty = 4) Bolt O (Qty =2)
M 8*1.25 M 24*3
K = 5mm K = 15mm

Page | 56
 B = 22mm b = 32.5mm
Ds = 7.5mm S = 36mm
S = 13mm L = 38.5mm
L = 22.6mm1) Bolt Y1 and Y2 (Qty = 4) Bolt in the piston(Qty = 1)
M 24*3 M 12*1.75
K = 15 K = 7mm
b = 30mm b = 12mm
S = 36mm Ds = 11.5mm
L = 36.5mm S = 18mm
L=
5.2.2 PINS
Materials: CARBON STEEL
Pins A:

Domet pin 12*12 standaredduty

 Pins B:

Domet pin 8*12 standaredduty

Pins C:

Domet pin 14*20 standaredduty

Pins D :

Domet pin 14*20 standaredduty

Pins E :

Domet pin 8*16 standaredduty

5.2.3 Cylinders and pistons

From the strength at is found that:

Stroke = 123.6mm

Page | 57
 Base size = 28mm

≫Bolt size = 32mm

Piston rod diameter = 20mmStandards

≫Strok = 125
≫ F = 9mm
≫H = 9mm
≫𝛼2 = 25mm
≫Piston rod diameter = 20mm
≫ m = 22
≫d1 = 12mm
5.2.4 O – rings and back up rings
O – Rings = D 28.55*1.75 – (Qty = 1) [10*d]
Buck up = 32*2.3*1.4 – (Qty =2) [OD*W*T]
O – Rings D 76.44*1.78 – (Qty = 2)
Back up ring = 80*3.1*1.7 – (Qty = 4)
→at the plunger
O – Ring = 16.93*1.7 (Qty = 1)
Back up rings = 20*1.5*1.4 (Qty = 20
5.2.5 Cotter pin
Material: stainless steel
Standard: D 4*80
5.2.6 Wheel
Front wheel
carbon steel and tried wheel
Standard D = 75mm
w = 45mm
Bearing hole diameter = 30mmMaximum load capacity = 1600kg
Rear castor
Material: carbon steel
D = 50mm
w = 25mm
Maximum load = 280Kg
Page | 58
5.2.7 Universal joint
Standard D0= 50mm
E = 2.24cm
h = 4.48cm
C = 1.42cm
D2 = 6mm
Breaking torque = 42Nm

5.2.8 Steel balls

D 9.5 (Qty = 2)
D 6.35 (Qty =5)
D 6.74 (Qty = 1)
5.2.9 Lock washers
Material: steel
Standard flat washer normal series grade A
→M8– d2 = 8.5, d0 = 15,t = 1.6 (Qty= 4)
M10–d2 =12.5, d0 = 18, t =1.6 (Qty = 2) M12 – d2 = 13, d0 = 20, t = 2.5
(Qty = 2.5)
M24 –d2 = 25, d0 = 38.5, t = 1.6 (Qty = 6)
5.2.10 Compression spring
Standard Material hard drawn wire
D0 = 30mm where, D0 =outer diameter
D2 = 22mm Di= inner diameter
d= 4mm d = wire diameter
L0 = 60mm L0 =length
Minimum working length = 36.31mm
K= 21.978KN/m
Total coils= 9/2
5.2.11 Extension spring
Standard Material: hard drawn wire
D2 = 28.58mm
d = 3.18mm
Page | 59
 L0 = 177.8mm
K = 1559N/m
Total coils = 46 and [Link] length = L1 =337.57mm

6 Reference
[1]=www.[Link]
[2]=sales @black [Link].
[3]=[Link] [Link].
Project design made by wollo university students.
Project design made by Addis Ababa university students

Page | 60