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CERTIFICATE
It is certified that the work contained in the project report titled Mechanical Lever Jack
by Akshay Gare (13103169), Manesh Sikarwar (13103173), Anish Dhal (13103174), Sudhin
Poduval (13103180), Tarang Mehta (13103197), Nishit Desai (13103205) has been carried
out under my supervision and that this work has not been submitted elsewhere for a degree.
Guide
Mr. Adil Khan
Mechanical Department
School of Science and Engineering
Navrachana University
April 2016
Declaration
We declare that this written submission represents our ideas in our own words and where
others' ideas or words have been included, we have adequately cited and referenced the
original sources. We also, declare that we have adhered to all principles of academic honesty
and integrity and have not misrepresented or fabricated or falsified any idea/data/fact/source
in my submission. We understand that any violation of the above will be cause for
disciplinary action by the Institute and can also, evoke penal action from the sources which
have thus not been properly cited or from whom proper permission has not been taken when
needed.
Date: 20/03/2016
3
Acknowledgement
In the journey of the present project work, numerous personalities, directly or
indirectly have extended their support and co-operation. We are truly indebted to them and
hereby acknowledge their contributions.
We acknowledge our delightful thanks to our dean Prof. P Prabhakaran, for his
patronage & encourage in completing the project work successfully.
This journey would have been impossible if we had not received the mentoring and
guidance of Head of the Department and our project guide Mr. Adil Khan. We are deeply
grateful to him for his valuable guidance throughout the course. Every discussion with them
during the course of this work was extremely useful.
We extend our cordial thanks to project coordinator, Mr. Mukesh Keshwani,
Assistant professor for his support and guidance. We acknowledge the support and guidance
of Mr. Ravi Sevak, Assistant professor.
We consider it a privilege to express our thanks to our faculty members of Mechanical
Engineering Department of Navrachana University, Vadodara for their support and
invaluable guidance.
Abstract
With the increasing levels of technology, the efforts being put to produce any kind of work
has been continuously decreasing. The efforts required in achieving the desired output can be
effectively and economically be decreased by the implementation of better designs.
According to Vishnu Mathur (Director General of SIAM), the sales of cars have surged by
8% in 2015-2016. As number of cars is increasing, the problem of changing tyres now and
then has also increased. For this type of situation, the mechanical lever jack can be very
handy and easy to use. The mechanical lever jack is used for such applications as
lifting, winching, clamping, pulling and pushing. In India majority of the time the ground is
uneven and using a standard jack can be quite hazards and most of the time rendered useless.
When your car is bogged, the mechanical lever jack will, in most cases, enable you to get
your car high enough to get something underneath the wheel to help get you out.
Contents
Sr No.
1
2
3
4
5
6
Title
Page No.
Abstract
List of Figures
List of Tables
Nomenclatures
Chapter: 1
Introduction
Chapter: 2
Working of Mechanical Lever Jack
Chapter: 3
Design of major components of mechanical lever jack
3.1 Design of Large Runner
10
Chapter: 6
11
12
References
Annexure 1 : Manufacturing Drawing
List of Figures
1.1
1.2
3.1
subcomponents
3.2
3.3
3.4
List of Tables
1.1 Parts of Mechanical Lever Jack
4.1 Details of Manufactured Parts
7
Nomenclatures
Kt
Chapter-1
Introduction
Introduction
Load end is the element on which load is distributed. In effort end, human effort is applied.
The fulcrum is the point against which a lever is placed, or on which it turns or is supported.
The manufacturers of mechanical lever jack are mainly Hi-lift and Pittsburgh.
Name
Quantity
Material
10
Mild Steel
2.
Mild Steel
3.
Handle socket
Mild Steel
4.
Pitman pin
Mild Steel
5.
Pitman
Mild Steel
6.
Mild Steel
7.
Large runner
Mild Steel
8.
Cross pin
Mild Steel
9.
Climbing pin
Mild Steel
10.
EN 9
11.
Small runner
Mild Steel
High Carbon
Steel
Mild Steel
12.
13.
11
12
Chapter-2
Working of Mechanical Lever Jack
13
The lever mechanical jack mainly has three main parts. The large runner, small runner
and pitman arm. There are load end, fulcrum and effort end distributed in such a way that
only the force of 200N can lift 10000N.
Working of the jack only aims to constantly move the fulcrum point above each time.
While working, the fulcrum and the load end changes. When the user moves the bar below
(gives clockwise moment), in that case the load end will be the large runner and the fulcrum
will be smaller runner.
While the user when gives anti clockwise moment to the bar the fulcrum point will be
the large runner and the load end will be small runner.
While lowering down the user pushes the leverage bar below which releases the
compressed spring between lowering cam bar. There after the cross pin slides on the
protrusions on the lowering cam bar and thus the sliding pin moves outside the holes on the
steel bar and thus the whole moves down and thus the fulcrum point moves down.
14
Chapter-3
Design of Major Components of Mechanical Lever Jack
15
Fig.3.1: Large runner shown in solid work as a component labeled with its subcomponents
As we can see in the image there are two main welds on which the load is distributed.
Following are the designs:-
16
3.1.1 Design of Weld 1: Assumptions:a. Load to be lifted is 1000 kg i.e.; 10000 Newton (N).
b. Distance between two holes on the steel bar is 15mm.
c. Designing part is done by using fundamental equations for static loading.
Maximum load on the foot rest is 10000 N, so, there are two welding on the interference of
foot rest and the large runner. The total load is distributed on two weld surfaces F1 and F2. As
welds are similar and at equidistant from the center of gravity F1=F2=5 KN.
A. Design of WELD 1 considering shear failure: As in welding, melting of parent metal takes place, so, the yield strength in shear of the
weld will be the yield strength of the mild steel.
The yield strength of the mild steel, max = 115 MPa. [4]
Now, Fmax= 0.707 * s * L * max [4]
Here, s= weld leg size (thickness of weld) = 5 mm
L= Length of weld = 70 mm
Thus, Fmax = 0.707 * 0.005 * 0.07 * 115 * 106
Fmax= 28.4 KN.
Now, keeping the leg size of weld as 5mm and the length of weld as 70 mm, its getting
over designed.
The length of weld is found out by keeping F max as 5KN. The length is coming 12.29 mm.
So, Length of weld1 can be considered as 30mm. Now actual = 47 MPa. So, Factor of
safety = max/actual = 115/47 = 2.44
B. Design of WELD 1 considering tensile failure: The upper half portion of the weld will be in tension and remaining half will be in
compression. So, Fmax= 5 KN.
The tension in the upper part will be F= Fmax/2 = 3.6KN
17
3.1.2 Design of Weld2: A. Design of WELD 2 considering shear failure: We will consider that the leg size of weld is 5mm, we know that max is 115 MPa, and as
we have already considered that Fmax is 5 KN.
So, L= Fmax / (0.707 * s *max)
= 5000/ (0.707*0.005*115*10^6)
= 13 mm
As this weld is more critical so, we will consider L as 30 mm to make it more strong.
B. Design of WELD 1 considering tensile failure: Upper half weld will be in tension and the lower will be in compression.
So, F= Fmax/2= 5000/ 1.414 = 3.6 KN
Actual = 3600 / .5* .005* .03 = 48 MPa. So, the WELD 2 is safe in tension.
3.1.3 Design of support for load end: From the figure 3, this part is exposed only to shear stress. As the specification of the hex
bolt which will penetrate from the hole on the support for the load end is (16A- 17). So,
this means that the nominal diameter of the hex bolt will be 10 mm.
Stress concentration will come in picture here. Here stress concentration factor=
Kt = 1.25: I.e.; max/nominal = 1.25
Here critical section area = ((30-10)*10) mm2 = 200 mm2
Thus, actual = 5000/200 = 25 MPa. So, = actual*Kt= 25*1.25 = 31.25 MPa andmax = 115
MPa. Hence the support for load end is safe in shear.
18
3.2.1 Design of Weld 1: A. Design of WELD 1 considering shear failure: Finding the length of weld,
L= Fmax / (0.707*0.005*115*10^6)
L= 13 mm. So, for increasing the safety the length of weld is considered as 30 mm.
B. Design of WELD 1 considering tensile failure: We will find actual shear stress keeping length of weld as 30 mm.
3.2.2 Design of fulcrum support material: At the weld, the weld length will be 30 mm, so the tapper area where the hole or pitman
pins will be 20 mm. So, the critical area will be ((20-10)*10) = 100 mm2
19
3.5 Design of foot rest: Here the foot rest is mainly exposed to shear stress. So, design for foot rest is done by
considering shear stress.
Critical section = width of the foot rest * average distance where the load is going to rest
on the foot rest.
21
22
Chapter-4
Manufacturing of Mechanical Lever Jack
23
The Mechanical Lever Jack can be manufactured by casting. The pattern is made for
jack and mould is prepared. Then, the metal is poured. Other than casting, it can be made by
welding process.
First of all parts are manufactured by different processes (e.g. Cutting, Drilling,
Grinding, Cutting). Then, different parts of jack are welded. Detailed manufacturing of the
mechanical lever jack is discussed below: -
Name
Description
Manufacturing Process
Material
Foot Rest
Provides support to
steel bar
Cutting, Grinding,
Welding
Mild Steel
Steel Bar
Provides motion to
Large Runner and
Small Runner
Mild Steel
Large
Runner
Cutting, Welding,
Grinding
Mild Steel
Small
Runner
Cutting, Welding,
Grinding
Mild Steel
Pitman arm
Provides linking
motion between large
runner, small runner
and handle
Mild Steel
24
Lifting Pin
Drilling
EN9
Cross Pin
Mild Steel
Spring
Helps in retraction of
pin to its original
position
Spring Steel
10
Handle
Grinding, Welding
Galvanized Iron
4.2 Manufacturing Processes: Welding: Shielded metal arc welding (SMAW) is carried out for welding parts. It is also known
as manual metal arc welding (MMA or MMAW), flux shielded arc welding or informally as
stick welding. It is a manual arc welding process that uses a consumable electrode covered
with a flux to lay the weld.
An electric current, in the form of alternating current from a welding power supply, is
used to form an electric arc between the electrode and the metals to be joined. The work piece
and the electrode melt forming the weld pool that cools to form a joint. As the weld is laid,
the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas
and providing a layer of slag, both of which protect the weld area from atmospheric
contamination.
Because of the versatility of the process and the simplicity of its equipment and
operation, SMAW is chosen for our project manufacturing.
Current(Amp)
111
Voltage(Volt)
8
25
Cutting: Cutting is the separation of a physical object, into two or more portions, through the
application of an acutely directed force. Cutting is a compressive and shearing phenomenon,
and occurs only when the total stress generated by the cutting implement exceeds the ultimate
strength of the material of the object being cut.
The stress generated by a cutting implement is directly proportional to the force with
which it is applied, and inversely proportional to the area of contact. Hence, the smaller the
26
Drilling: Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section
in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed
against the work piece and rotated at rates from hundreds to thousands of revolutions per
minute. This forces the cutting edge against the work piece, cutting off chips from the hole as
it is drilled.
Drilling was one of the most crucial processes as it holds the pins, which in return
hold the Large Runner and Small Runner. Drilling process was completed in different
sections. It is inappropriate to drill a hole directly using a 13mm drill bit directly on to the
work piece. Hence the process was carried out in 3 stages. Firstly, a hole using a 7mm drill
bit, then a 10mm drill bit and finally the required 13mm drill bit. The overall process took
nearly 3hours on machine time which included drilling 30 holes.
27
Grinding: Grinding is an abrasive machining process that uses a grinding wheel as the cutting
tool. Grinding is a subset of cutting, as grinding is a true metal-cutting process.
Each grain of abrasive functions as a microscopic single-point cutting edge and shears
a tiny chip. Surface grinding uses a rotating abrasive wheel to remove material, creating a flat
surface.
For proper welding, it is necessary to have proper grooves and proper surface finish.
The entire surface before welding was properly grinded to have a cleaner surface for welding.
Hand Grinder was used for grinding and for intricate shapes bench grinder was used.
Fig 4.2.7 Grinding Steel Bar before welding the other half of the section
28
Chapter-5
Costing
29
Costing
5.1 Bill of Material: Table 5.1: - Bill of Material
Part
No.
Material
Quantity
Price
110
70
100
(250 X 150 X10)
300
5.
Welding Rods
28
90
6.
Cutter Wheel
15
250
7.
Grinding Wheel
60
100
8.
30
EN9 Rod
9.
100
(500mm)
10.
Scrap Plates
11.
Spring
100
20
20
12.
Total
1320
31
Chapter-6
Summary and Conclusions
32
We have selected Mild Steel as it is machinable and has better weld ability. We have designed
all the elements keeping allowable stresses in mind and designed in the Solid Works for better
understanding of shapes and its manufacturing feasibility. Although a few parts are yet to be
designed, we have a clear idea about how to start manufacturing and will begin soon.
33
Chapter-7
References
34
References
1. Wandering
Tail.
Hi-Lift
Jack
Rebuild
(web).
Available
from:
http://www.wanderingtrail.com/Repairs_Rebuilds/Hilift_Rebuild/Hilift_rebuild.htm
(Accessed 02 March 2016).
2. MACCABEE
ARMS
LTD.
Hi-Lift
Rebuild
(web).
Available
from:
35