Chapter 1

INTRODUCTION
Chapter 1 Introduction
Defination of Hydraulic Jack:-
A hydraulic jack is a device used
to lift heavy loads. The device itself is light, compact and portable,
but is capable of exerting great force. The device pushes liquid
against a piston; pressure is built in the jack's container. The jack
is based on Pascal's law that the pressure of a liquid in a container
is the same at all points.

Introduction:-
A hydraulic jack is a jack that uses a liquid to push
against a piston. This is based on Pascal’s Principle. The principle
states that pressure in a closed container is the same at all points.
If there are two cylinders connected, applying force to the smaller
cylinder will result in the same amount of pressure in the larger
cylinder. However, since the larger cylinder has more area, the
resulting force will be greater. In other words, an increase in area
leads to an increase in force. The greater the difference in size
between the two cylinders, the greater the increase in the force will
be. A hydraulic jack operates based on this two cylinder system.

Pascal’s law :-
Pressure on a confined fluid is transmitted
undiminished and acts with equal force on equal areas and at 90
degrees to the container wall.

A fluid, such as oil, is displaced when either

piston is pushed inward. The small piston, for a given distance of
movement, displaces a smaller amount of volume than the large
piston, which is proportional to the ratio of areas of the heads of the
pistons. Therefore, the small piston must be moved a large distance
to get the large piston to move significantly. The distance the large
piston will move is the distance that the small piston is moved
divided by the ratio of the areas of the heads of the pistons. This is
how energy, in the form of work in this case, is conserved and the
Law of Conservation of Energy is satisfied. Work is force times
distance, and since the force is increased on the larger piston, the
distance the force is applied over must be decreased.

History:-
The Origin Of Hydraulic Jacks Can Be Dated Several
Years Ago When Richard Dudgeon, The Owner And Inventor Of
Hydraulic Jacks, Started A Machine Shop. In The Year 1851, He
Was Granted A Patent For His Hydraulic Jack. In The Year 1855, He
Literally Amazed Onlookers In New York When He Drove From His
Abode To His Place Of Work In A Steam Carriage. It Produced A
Very Weird Noise That Disturbed The Horses And So Its Usage Was
Limited To A Single Street. Richard Made A Claim That His Invention
Had The Power To Carry Near About 10 People On A Single Barrel
Of Anthracite Coal At A Speed Of 14 M.P.H. Dudgeon Deserves A
Special Credit For His Innumerable Inventions Including The Roller
Boiler Tube Expanders, Filter Press Jacks, Pulling Jacks, Heavy
Plate Hydraulic Hole Punches And Various Kinds Of Lifting Jacks.

Features:-
The jack uses compressible fluid, which is forced into a
cylinder by a plunger. Oil is usually used for the liquid because it is
self-lubricating and has stability compared with other liquids. When
the plunger comes up, it pulls the liquid through a check valve
suction pump. When the plunger is lowered again, it sends liquid
through another valve into a cylinder. A ball used for suction in the
cylinder shuts the cylinder and pressure builds up in the cylinder.
The suction valve present in the jack opens at each draw of the
plunger. The discharge valve, which is outside the jack, opens
when oil is pushed into the cylinder. The pressure of the liquid
enables the device to lift heavy loads.

Classification Of Jack:-
Classification Of Jack:-
Mechanical jack:-

Fig 1.1 Mechanical jack

Jackscrews are integral to the Scissor Jack, one of the simplest

kinds of car jacks still used.

A mechanical jack is a device which lifts heavy

equipment. The most common form is a car jack, floor jack or
garage jack which lifts vehicles so that maintenance can be
performed. Car jacks usually use Mechanical advantage to allow a
human to lift a vehicle by manual force alone. More powerful jacks
use hydraulic power to provide more lift over greater distances.
Mechanical jacks are usually rated for a maximum lifting capacity
(for example, 1.5 tons or 3 tons). The jack shown at the right is made
for a modern vehicle and the notch fits into a hard point on a
unibody. Earlier versions have a platform to lift on the vehicles'
frame or axle.

Hydraulic jack:-

Hydraulic jacks are typically used for shop

work, rather than as an emergency jack to be carried with the
vehicle. Use of jacks not designed for a specific vehicle requires
more than the usual care in selecting ground conditions, the
jacking point on the vehicle, and to ensure stability when the jack is
extended. Hydraulic jacks are often used to lift elevators in low and
medium rise buildings.

A hydraulic jack uses a fluid, which is

incompressible, that is forced into a cylinder by a pump plunger. Oil
is used since it is self lubricating and stable. When the plunger pulls
back, it draws oil out of the reservoir through a suction check valve
into the pump chamber. When the plunger moves forward, it pushes
the oil through a discharge check valve into the cylinder. The
suction valve ball is within the chamber and opens with each draw
of the plunger. The discharge valve ball is outside the chamber and
opens when the oil is pushed into the cylinder. At this point the
suction ball within the chamber is forced shut and oil pressure
builds in the cylinder.

In a bottle jack the piston is vertical and directly

supports a bearing pad that contacts the object being lifted. With a
single action piston the lift is somewhat less than twice the
collapsed height of the jack, making it suitable only for vehicles with
a relatively high clearance. For lifting structures such as houses the
hydraulic interconnection of multiple vertical jacks through valves
enables the even distribution of forces while enabling close control
of the lift.

In a floor jack (aka 'trolley jack') a horizontal piston

pushes on the short end of a bellcrank with the long arm providing
the vertical motion to a lifting pad, kept horizontal with a horizontal
linkage. Floor jacks usually include castors and wheels, allowing
compensation for the arc taken by the lifting pad. This mechanism
provide a low profile when collapsed, for easy maneuvering
underneath the vehicle, while allowing considerable extension.

Pneumatic jack:-

A pneumatic jack is a hydraulic jack that is

actuated by compressed air - for example, air from a compressor
instead of human work. This eliminates the need for the user to
actuate the hydraulic mechanism, saving effort and potentially
increasing speed. Sometimes, such jacks are also able to be
operated by the normal hydraulic actuation method, thereby
retaining functionality, even if a source of compressed air is not
available.
Pneumatic jack:-

Fig 1.2 Threaded rod 7" fully extended

Fig 1.3 2.5 ton house jack that stands 24 inches from top to bottom fully
threaded out.

A house jack, also called a screw jack is a

mechanical device primarily used to lift houses from their
foundation. A series of jacks are used and then wood cribbing
temporarily supports the structure. This process is repeated until
the desired height is reached. The house jack can be used for
jacking carrying beams that have settled or for installing new
structural beams. On the top of the jack is a cast iron circular pad
that the 4" × 4" post is resting on. This pad moves independently of
the house jack so that it does not turn as the acme-threaded rod is
turned up with a metal rod. This piece tilts very slightly but not
enough to render the post dangerously out of plumb
Strand jack:-
A strand jack is a specialized hydraulic jack that
grips steel cables often used in concert, strand jacks can lift
hundreds of tons and are used in engineering and construction.

Working Principal:-
The hydraulic jack is a device used for lifting
heavy loads by the application of much smaller force. It is based on
Pascal’s law, which states that intensity of pressure is transmitted
equally in all directions through a mass of fluid at rest.

The working principle of a hydraulic jack may be

explained with the help of Fig. Consider a ram and plunger,
operating in two cylinders of different diameters, which are
interconnected at the bottom, through a chamber, which is filled
with some liquid.

Fig 1.4 Consider a ram and plunger,

Working Of Hydraulic Jack:-
Hydraulic jacks and many other technological
advancements such as automobile brakes and dental chairs work
on the basis of Pascal's Principle, named for Blaise Pascal, who
lived in the seventeenth century. Basically, the principle states that
the pressure in a closed container is the same at all points.
Pressure is described mathematically by a Force divided by Area.
Therefore if you have two cylinders connected together, a small
one and a large one, and apply a small Force to the small cylinder,
this would result in a given pressure. By Pascal's Principle, this
pressure would be the same in the larger cylinder, but since the
larger cylinder has more area, the force emitted by the second
cylinder would be greater. This is represented by rearranging the
pressure formula P = F/A, to F = PA. The pressure stayed the same
in the second cylinder, but Area was increased, resulting in a larger
Force. The greater the differences in the areas of the cylinders, the
greater the potential force output of the big cylinder. A hydraulic
jack is simply two cylinders connected as described above.

An enclosed fluid under pressure exerts that pressure

throughout its volume and against any surface containing it. That's
called 'Pascal's Principle', and allows a hydraulic lift to generate
large amounts of force from the application of a small
Assume a small piston (one square inch area) applies a
weight of 1 lbs. to a confined hydraulic fluid. That provides a
pressure of 1 lbs. per square inch throughout the fluid. If another
larger piston with an area of 10 square inches is in contact with the
fluid, that piston will feel a force of 1 lbs/square inch x 10 square
inches = 10 lbs

Fig 1.5 Working Of Hydraulic Jack:-

So we can apply 1 lbs. to the small piston and get 10 lbs. of force to
lift a heavy object with the large piston. Is this 'getting something
for nothing'? Unfortunately, no. Just as a lever provides more force
near the fulcrum in exchange for more distance further away, the
hydraulic lift merely converts work (force x distance) at the smaller
piston for the SAME work at the larger one. In the example, when
the smaller piston moves a distance of 10 inches it displaces 10
cubic inch of fluid. That 10 cubic inch displaced at the 10 square
inch piston moves it only 1 inch, so a small force and larger distance
has been exchanged for a large force through a smaller distance.
Hydraulic jacks have six main parts. These are the
reservoir, pump, check valve, main cylinder, piston, and release
valve. The reservoir holds hydraulic fluid. A pump will draw the fluid
up and then create pressure on the down stroke as it pushes the
fluid through the check valve. This valve allows the fluid to leave the
reservoir and enter the main cylinder. In the main cylinder, the
piston is forced up as the cylinder is filled with the fluid. When it is
time to release the pressure and allow the piston to return to its
starting position, the release valve is opened. This allows the fluid
to return to the reservoir.
 Shown In Figure;-

Advantages:-
 Safety First:-
Hydraulic jacking System is one of the most safest
mode to erect storage tank, complete work is executed on ground
level preventing risks of accidents. For decades, there has been not
a single report that proves its credibility in being the safest and
most likely method for the storage tank construction. The hydraulic
jack systems has now gained a lot of popularity.
 Easier Inspection:-
Our efficient hydraulic jacking systems needs
various scaffolding and attachments to offer comfortable access
for welding heights.

 No Scaffolding Required:-
Welding inspectors can now perform ultrasonic
as well as several other non destructive tests on welds at ground
level, it allows easier inspection for better quality control.

 Faster Erection:-
The shell plates are erected at ground level in
place of being installed at the height of about 30 feet or more, in
order to save construction time required for the alignment of plates.
The time and manpower needed for lifting the plates to the height is
amputated. Construction work remains unaffected by snow or rain.

 Tank Erection Top Downwards Cuts Construction Time And

Cost Considerably :-
New shell plates are developed at the ground level
in place of being hauled up to about 30 feet heights or more, saving
considerable time desired for alignment of plates. The cumulative
time needed for lifting of men and material to the heights that is
eliminated. Tank construction work stays practically unaffected
from rain or snow, hence most work is performed under the
protection of the tank itself.
Applications:-
 Dismantling of old tanks
 Repair to tank foundation
 Building of field erected storage tanks
 Repair or replacement of tank bottom plate
 Increasing tank capacity by adding shell rings or
courses
 Erection of other circular structures such as
reactor shields in nuclear power stations, etc.
Hydraulic Basics:-

Hydraulics is the science of transmitting force

and/or motion through the medium of a confined liquid. In a
hydraulic device, power is transmitted by pushing on a confined
liquid.Figure 1-1 shows a simple hydraulic device. The transfer of
energy takes place because quantity of liquid is subject to
pressure. To operate liquid-powered systems, the operator should
have a knowledge of the basic nature of liquids. This chapter covers
the properties of liquids and how they act under different
conditions.

Pressure and Force.:-

Pressure is force exerted against a

specific area (force per unit area) expressed in pounds per square
inch (psi). Pressure can cause an expansion, or resistance to
compression, of a fluid that is being squeezed. A fluid is any liquid
or gas (vapor). Force is anything that tends to produce or modify
(push or pull) motion and is expressed in pounds a. Pressure. An
example of pressure is the air (gas) that fills an automobile tire. As
a tire is inflated, more air is squeezed into it than it can hold. The air
inside a tire resists the squeezing by pushing outward on the casing
of the tire. The outward push of the air is pressure.
Equal pressure throughout a confined area is a characteristic of
any pressurized fluid.

Confined liquid is

subject to pressure
 Figure 2.1 Basic hydraulic devices

For example, in an inflated tire, the outward push of the air is

uniform throughout. If it were not, a tire would be pushed into odd
shapes because of its elasticity. There is a major difference
between a gas and a liquid. Liquids are slightly compressible
(Figure 2.1). When a confined liquid is pushed on, pressure builds
up. The pressure is still transmitted equally throughout the
container. The fluid's behavior makes it possible to transmit a push
through pipes,
around corners, and up and down.

D2=F1*D1/F2

Where

F1 = force of the small piston, in pounds

D1 = distance the small piston moves, in
inches
D2 = distance the larger piston moves, in
inches
F2 = force of the larger piston, in pounds

Basic Systems:-

The advantages of hydraulic systems over other methods of power

transmission are

• Simpler design. In most cases, a few pre-engineered components

will replace complicated mechanical linkages.
• Flexibility. Hydraulic components can be located with
considerable flexibility. Pipes and hoses in place of mechanical
elements virtually eliminate location problems.
• Smoothness. Hydraulic systems are smooth and quiet in
operation. Vibration is kept to a minimum.
• Control. Control of a wide range of speed and forces is easily
possible.
• Cost. High efficiency with minimum friction loss keeps the cost of
a power transmission at a minimum.
• Overload protection. Automatic valves guard the system against
a breakdown from overloading.

The main disadvantage of a hydraulic system is maintaining the

precision parts when they are exposed to bad climates and dirty
atmospheres. Protection against rust, corrosion, dirt, oil
deterioration, and other adverse environment is very important.
The following paragraphs discuss several basic hydraulic systems.

Hydraulic Jack:-

In this system a reservoir and a system of valves

has been added to Pascal's hydraulic lever to stroke a small
cylinder or pump continuously and raise a large piston or an
actuator a notch with each stroke. Diagram A shows an intake
stroke. An outlet check valve closes by pressure under a load, and
an inlet check valve opens so that liquid from the reservoir fills the
pumping chamber. Diagram B shows the pump stroking downward.
An inlet check valve closes by pressure and an outlet valve opens.
More liquid is pumped under a large piston to raise it. To lower a
load, a third valve (needle valve) opens, which opens an area under
a large piston to the reservoir. The load then pushes the piston
down and forces the liquid into the reservoir.
 Figure 2-2. Hydraulic jack

Motor-Reversing System:-
Figure 2-2, shows a power-driven
pump operating a reversible rotary motor. A reversing valve directs
fluid to either side of the motor and back to the reservoir. A relief
valve protects the system against excess pressure and can bypass
pump output to the reservoir, if pressure rises too high.

Open-Center System:-
In this system, a control-valve spool must
be open in the center to allow pump flow to pass through the valve
and return to the reservoir.
this system in the neutral position. To operate several functions
simultaneously,
an open-center system must have the correct connections, which
are discussed below. An open-center system is efficient on single
functions but is limited with multiple functions.

The return from the first valve is routed to the inlet of the
second, and so on. In neutral, the oil passes through the valves in
series and returns to the reservoir, as the arrows indicate. When a
control valve is operated, the incoming oil is diverted to the cylinder
that the valve serves. Return liquid from the cylinder is directed
through the return line and on to the next valve. This system is
satisfactory as long as only one valve is operating at a time. When
this happens, the full output of the pump at full system pressure is
available to that function. However, if more than one valve is
operating, the total of the pressures required for each function
cannot exceed the system’s relief setting.

Parts Of Hydraulic Jack:-

 Gland (End Cap)

 Piston Road
 Cylinder
 Base Plate
 Hose Pipe

Parts Of Cylinder:-
Cylinder Barrel:-

The cylinder barrel is mostly a seamless thick

walled forged pipe that must be machined internally. The cylinder barrel is
ground and/or honed internally.

Cylinder Base Or Cap:-

In most hydraulic cylinders, the barrel and the

bottom portion are welded together. This can damage the inside of the barrel if
done poorly. Therefore, some cylinder designs have a screwed or flanged
connection from the cylinder end cap to the barrel. In this type the barrel can
be disassembled and repaired.
Cylinder Head:-

The cylinder head is sometimes connected to the

barrel with a sort of a simple lock. In general, however, the connection is
screwed or flanged. Flange connections are the best, but also the most
expensive. A flange has to be welded to the pipe before machining. The
advantage is that the connection is bolted and always simple to remove. For
larger cylinder sizes, the disconnection of a screw with a diameter of 300 to
600 mm is a huge problem as well as the alignment during mounting.

Piston Rod:-

The piston rod is typically a hard chrome-plated piece of

cold-rolled steel which attaches to the piston and extends from the cylinder
through the rod-end head. In double rod-end cylinders, the actuator has a rod
extending from both sides of the piston and out both ends of the barrel. The
piston rod connects the hydraulic actuator to the machine component doing the
work. This connection can be in the form of a machine thread or a mounting
attachment, such as a rod-clevis or rod-eye. These mounting attachments can
be threaded or welded to the piston rod or, in some cases, they are a machined
part of the rod-end.

Piston Rod Construction:-

The piston rod of an hydraulic cylinder

operates both inside and outside the barrel, and consequently both in and out
of the hydraulic fluid and surrounding atmosphere.

Metallic Coatings:-

Smooth and hard surfaces are desirable on the

outer diameter of the piston rod and slide rings for proper sealing. Corrosion
resistance is also advantageous. A chromium layer may often be applied on the
outer surfaces of these parts. However, chromium layers may be porous,
thereby attracting moisture and eventually causing oxidation. In harsh marine
environments, the steel is often treated with both a nickel layer and a chromium
layer. Often 40 to 150 micrometer thick layers are applied. Sometimes solid
stainless steel rods are used. High quality stainless steel such as AISI 316 may
be used for low stress applications. Other stainless steels such as AISI 431 may
also be used where there are higher stresses, but lower corrosion concerns.
Ceramic Coatings:-
Due to shortcomings of metallic
materials, ceramic coatings were developed. Initially ceramic protection
schemes seemed ideal, but porosity was higher than projected. Recently the
corrosion resistant semi ceramic Lunac2+ coatings were introduced. These
hard coatings are non porous and do not suffer from high brittleness.

Length:-
Piston rods are generally available in lengths which are
cut to suit the application. As the common rods have a soft or mild steel core,
their ends can be welded or machined for a screw thread.

Gland (End Cap):-

The cylinder head is fitted with seals to prevent

the pressurized oil from leaking past the interface between the rod and the head.
This area is called the rod gland. It often has another seal called a rod wiper
which prevents contaminants from entering the cylinder when the extended rod
retracts back into the cylinder. The rod gland also has a rod wear ring. This
wear ring acts as a liner bearing to support the weight of the piston rod and
guides it as it passes back and forth through the rod gland. In some cases,
especially in small hydraulic cylinders, the rod gland and the rod wear ring are
made from a single integral machined part.
 Calculation For design
Distance the larger piston moves

D2=F1*D1/F2

Where

F1 = force of the small piston, in pounds

D1 = distance the small piston moves, in
Inches
D2 = distance the larger piston moves, in
Inches
F2 = force of the larger piston, in pounds

 The definition of fluid pressure is a force per unit

area, or in equation form,

P=F/A

Where P = pressure (N/m2, psi),

F = force (N, lbf), and

A = area (m2, in2).

TO FIND INNER DIAMETER OF CYLINDER TUBE:-

p where, P = total pressure

D = Inner diameter

p = working pressure

TO FIND OUTER DIAMETER OF CYLINDER TUBE:-

We have already a equation =

Where, = working stress

P = working pressure

= outer diameter of cylinder tube

= inner diameter of cylinder tube

= Working stress

THICKNESS OF THE CYLINDER TUBE:-

Tube thickness =
DESIGN OF PISTON

We know that cylinder’s inner diameter is equal to piston’s outer

diameter so piston outer diameter is 60mm . Generally piston’s are
made from MILD STEEL & SUITABLE MATERIAL……

DESIGN OF PISTON ROD

Material strength EN9 = 1750 kg/cm2