Adama

CHAPETR ONE
INTRODUCTION
1.1 Background
Air service jack is a device which lifts heavy equipment. The most common forms of
jacks are car jack, floor jack or service jack which lifts vehicles so that maintenances
can be formed. More powerful jacks are used compressed air power to provide more
lift over greater distances. In air service jack the compressor compresses air pumped
to it and the compressed air pushes the piston inside the compressor that in which
the piston head is connected to the lifting arm of the jack. The lifting arm helps to lift
the part under consideration which needs to be lifted. In the repair and maintenance
of automobiles (car), it is often necessary to raise an automobile to change a tire or
access the underside of the automobile. Accordingly, a variety of car jacks have
been developed for lifting an automobile from a ground surface. Available car
jacks, however, are typically manually operated and therefore require substantial
laborious physical effort on the part of the user. Such jacks present difficulties for
the elderly and handicapped and are especially disadvantageous under adverse
weather conditions.
In light of such inherent disadvantages, commercial automobile repair and

service stations are commonly equipped with large and car lift, wherein such lifts are
raised and lowered via electrically-powered systems. However, due to their
shear size and high costs of purchasing and maintaining electrically-powered car
lifts, such lifts are not available to the average car owner. Such electrical-
powered portable jacks not only remove the arduous task of lifting an
automobile via manually-operated jacks, but further decrease the time needed
to repair the automobile. Such a feature can be especially advantageous when it
is necessary to repair an automobile on the side of a roadway or under other
hazardous conditions.
Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 1

1.2 Objective of the project
 Main objective
The main objective of this design project is to design air service jack by considering
economical, fasting and to be good commercial proposal design doesn’t merely have
to be capable of performing the intended purpose but must be economical cost of
material, manufacturing and maintenance of the jack with 3ton force applied at the
top of the jack resisting any failures.
 Specific objectives
In the air service jack in order to work successfully and properly there are different
mechanism needs to be understandable by the users. The following operating
mechanisms will be specifically designed for the air service jack:
 Lifting mechanism
 Supporting mechanism
 Driving mechanism
 Pressuring mechanism
 Controlling mechanism
 Balancing mechanism
 Reversing mechanism
1.3 Scope and Significance of the project
This project is about the designing of car jack. The types of car jack that will be
designed in this project were Air service jack as it is more reliable and easy to
operate. The scopes of the project were on the designing:
 3 ton maximum lifting capacity of air service jack

 minimum and maximum lifting of 140cm & 460cm, respectively of car jack
by using optimization concept
 Safe, reliable and able to raise and lower the needed height level.

 To develop a car jack that is powered or operated by external human
power.
 Best way of friendly user and lower cost in product development.
 Car jack operated on a flat surface.
 There is no prototype for the designed air service jack.
 The design is based on currently available air jack in the market.
 Only for normal person.
 By describing the manufacturing process, assembly process and
maintenance process, the jack will be designed.
 CAD (Computer Aided Drafting) software will be used to draw the detailed
drawing of each component of the jack with its sectional assembly drawing.
1.4 Statement of the problem
From the general knowledge of design, problem is the key word for improvement
and change of skills. Air service jack is the earliest jack which can operate with the
help of compressed air. The main problem is that it is impossible to lift automobiles
or cars to access them during maintenance underground. In order to helps the user
to maintain their car during suddenly upcoming accidents like changing of flat tire on
journey, to maintain other parts of the car which needs to be lifted to the required
height during the operation of maintenance. And also helps people who may install
snow tires before the winter and remove them in the spring needed to use the jack
perform a job. Women may be able to drive a three-ton truck, but need a
man's help if they must change a tire. Women have a much lighter skeleton that
means, among other things, she can’t pull more forces as well as men and are at
greater risk of skeletal injuries. Moreover, the safety features are also not enough for
operator to operate the present jack. Present car jack do not have a lock or extra
beam to withstand the massive load of the car. The purpose of this project is to
encounter these problems.
1.5 Literature review
Jacks are machine element for lifting heavy loads by applying small force. There are
so many types of jacks. Among them:

Jackscrew
Jackscrews are integral to the scissor jack, one of the simplest kinds of car jack still
used. Scissor car jacks usually use mechanical advantage to allow a human to lift a
vehicle by manual force alone. Earlier versions have a platform to lift on a vehicle's
frame or axle. The electrical energy is used to power up these car jacks to raise and
lower it automatically.
House jack
A house jack, also called a screw jack, is a mechanical device primarily used to lift
buildings from their foundations for repairs or relocation. A series of jacks is 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.
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.
Bottle jack
A bottle jack or whiskey jack is a hydraulic jack which resembles a bottle in shape,
having a cylindrical body and a neck, from which the hydraulic emerges. 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. This type of jack is best used for short vertical lifts.

Blocks may be used to repeat the operation when a greater amount of elevation is
required.
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.
Farm jack
The farm jack is a versatile mechanical tool that can be put to a wide range of uses.
Originally invented sometime around 1905 by P. J. Harrah and sold as the Automatic
Combination Tool, the basic design has remained largely unchanged to this day.
The farm jack is characterized by rugged, simple construction. It comprises a steel

beam with a series of equally spaced holes along its length, and a hand operated
mechanism which can be moved from one end of the beam to the other through the
use of a pair of climbing pins.
The jack's versatility stems from its use for such applications as lifting, winching,
clamping, pulling and pushing. It is this versatility, along with the long travel it offers
and its relative portability, which make the farm jack so popular with off road drivers.
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.
1.6 Methodology for the Design
The process of designing this project, while remaining in specified decision making it
is strongly supported by knowledge of several engineering sciences. In my project I
used the knowledge of mechanism, strength, mechanics, and manufacturing process
etc. The following standard design methodology will be used in the design of the
project.
 Reviewing different literatures: - In today’s time there are a lot of service jacks
were designed and available in the market for the use of the customer
depending on the need. Since this design project depends on the existing
design of air service jack different mechanism of the jack is similar to the
previous one.
 Operating mechanism: - The operating mechanism of the jack will be
illustrated detail in order to make the user to communicate simply with the
service jack. This operating mechanism of the jack will be explained in
operating mechanism part.
 Mathematical analysis:- Through the design process, since mathematical
analysis is the main part of for designing the jack it will be accomplished clearly
using the knowledge of different of mechanism, strength, mechanics,
manufacturing process and etc. for analyzing the forces and stresses of the
service jack.
 Manufacturing process:- In this phase the total process of manufacturing the
parts of the service jack will be discussed based on the selection of the
processes for each part considering the properties they need to have since the
materials properties determines their strength.
 Assembly, maintenance and operation: - After the manufacturing of the jack
the assembly process will be held on. For this reason the general method of
assembly of the parts will be illustrated under this section. The jack will be
maintained through its time of service and operation of the jack will also be
explained under this section.
 Cost analysis: - This section illustrates that the cost analysis of the jack. The
cost analysis will be covered by analyzing the material cost, labour cost and the
standard material selected cost.

CHAPTER TWO
OPERATING MECHANISM
When we say mechanism it means that, is a device designed to transform input

forces and movement into a desired set of output forces and movement and
transforms motion to some desirable pattern and typically develops forces and
transmits power. A machine typically contains mechanisms which are designed to
provide significant forces and transmit significant power. The degree of freedom of
an assembly of links completely predicts its character. If the DOF is positive, it will be
a mechanism and the links will have relative motion. In a mechanism a combination
of rigid and/or flexible bodies connected in such a way to do work and there are
definite constrained relative motions between them.
In the air service jack in order to work successfully and properly there are different
mechanism needs to be designed. This air service jack contains the following main
working mechanism of operating:
 Lifting mechanism
 Supporting mechanism
 Driving mechanism
 Pressuring mechanism
 Controlling mechanism
 Balancing mechanism
 Reversing mechanism
In order to be access the air service jack anyone who is going to use this service jack
will have to be informed or know some of the listed mechanism as discussed below.
2.1 Lifting mechanism

As we have said in the introduction part of this air service jack design, it is used to lift
loads at some maximum value of height and capacity for working purpose. The lifting
mechanism of the air service jack will be operated as the operator pumps the
compressor using the two mechanism of pumping, namely: - using the handle and by
the foot pedal designed for the service jack to pump or compress air in to the
cylinder to lift the load by the power of compressed air. These operations on the jack
will be operated through different mechanism. When the compressed air enters in to
the piston and the cylinder assembly which is power unit of the air service jack it
pushes the piston rod which intern pulls the weight carrier plate which is pinned to
the piston rod with a connecting rod. Using the foot pedal otherwise using the
handle the compressed air enters into the piston cylinder pushing the piston rod
outwards. As the piston rod moves outward, the weight carrier plate will move
upward to its maximum height.
2.2 Supporting mechanism

This mechanism enables that to support the weight which is lifted by the lifting
mechanism to apply purposely its work for the air service jack. The first supporting
mechanism is the weight carrier plates which means, the load will flows through the
pins so that all load on the plate has to be overcome by the compressed air through
the piston rod. Secondly, the parallel
supporting plate or links near the weight
carrier plate which is connected to the
body. The load lifted by the jack will flow
through this plate to the pins and the
walls and finally to the wheels and
ground.
Figure 2.1 The assembly of the power unit, the lifting and the supporting mechanism
2.3 Driving mechanism
Driving mechanism helps us to use the service jack whenever we want to use it
easily. The service jack has four wheels. Two at the front and the left two are at the
back side. The back wheels have two degrees of freedom which translates and
rotates at a time needed for operation at some vertical axis. In another way this
rotation and translation of the back wheels enables the user simply to interact with

the jack in a freedom of any type of motion. The front wheels have only one degrees
of freedom translational motion.
2.4 Pressurizing mechanism

The service jack works depending on the power of compressed air drawn into the
power unit of the jack. There are numerous methods of air compression, positive-
displacement air compressor system is in which compressed and pressurized air is
converted into kinetic energy by forcing air into in a chamber where small volume of
air is stored finally it produces continuous motion of piston. They use one way valves
(one directional control valve) to guide air into a chamber, where the air is
compressed.
Figure 2.2 The assembly of compressor, reversing and pressurizing mechanism
Boyle's law is an experimental gas law which describes how the pressure of a gas
tends to decrease as the volume of a gas increases.
The absolute pressure exerted by a given mass of an ideal gas is inversely

proportional to the volume it occupies if the temperature and amount of gas remain
unchanged within a closed system. If we are dealing with a closed systems in which
no gas enters or leaves we may consider N to be a constant. Furthermore, if we are
not dealing with externally imposed changes of temperature and any changes in
pressure or volume are not so radical as to bring about changes in temperature, we

may consider T also to be a constant. In this case, we may rewrite Boyle's Law
mathematically, Boyle's law can be stated as:
PV=K whereas K=kNT
Where
 P is the pressure of the gas,

 V is the volume of the gas, and
 k is a universal constant.
 N is number of the molecules of the gas
 T is temperature of the gas
The equation states that product of pressure and volume is a constant for a given
mass of confined gas as long as the temperature is constant. For comparing the same
substance under two different sets of condition, the law can be usefully expressed as
P1V1=P1V2
2.5 Controlling mechanism

When we say controlling mechanism it is to tell that the compressed air in the piston
cylinder must stay there until we finish the job to be worked. Once the compressed
air goes into the piston cylinder the two valves of one directional controlling valve
stay closed. When the compressed air comes from the back (from the ball side) it will
compress the spring of the valve and lets in air to the piston cylinder, but not vice
versa because since it is one directional control valve. This is more illustrated on
figure 2.2
2.6 Balancing mechanism

The balancing mechanism helps to protect the service jack from different familiarity
and balancing mechanism is needed. The load must be placed at right angle or
balanced position. And the supporting plate helps to balance the saddle holder from
back and forth movement by connecting with the housing with its one end. We can
understand from figure 2.1 given as shown above on page…..

2.7 Reversing back mechanism
After the jack accomplishes its work it must be placed to its initial position to do so
the air in the piston cylinder must be released and the saddle must be at its
minimum height. In order to implement this operation we need to insert a rod which
has universal joint into the hole on the handle; the mechanism is operated by turning
release knob counter clockwise slowly to reverse back the jack to its minimum
height. The figure 2.2 shows that the operation of that how the jack will be get back
to its initial position using release valve mechanism.

CHAPTER THREE
GEOMETRIC ANALYSIS
3.1 Weight carrier (lifting arm)
Geometric analysis is a mathematical discipline at the interface of
differential geometry and differential equations. It includes both
the use of geometrical methods in the study of partial differential
equations (when it is also known as "geometric PDE"), and the
application of the theory of partial differential equations to
geometry. It incorporates problems involving curves and
surfaces, or domains with curved boundaries, but also the study
of Riemannian manifolds in arbitrary dimension. The calculus of
variations is sometimes regarded as part of geometric analysis,
because differential equations arising from variational principles
have a strong geometric content. Geometric analysis also
includes global analysis, which concerns the study of differential
equations on manifolds, and the relationship between
differential equations and topology. To start the design process
first the analysis of basic length and angles have to be calculated
inconsideration with some assumption. The first analysis is starts
with the geometry of the lever arm.
Figure 3.1 geometry of weight carrier

Where
 y-height for cup
 m-clearance above the wheel
 x-length of pin to the wheel
 l2-minimum height
 l1-maximum length
 H-maximum height
 h-minimum height
 α- angle at which minimum height achieved
 β-angle between horizontal and l2
 Ф-angle between l1 & 12
 Θ-angle at which maximum height achieved
Now we can calculate

(H-y)- (h-y) =Z……………………………………………..eq1
l1sin Θ+l1sin α=Z………………………………………….eq2
By equating eq1 & eq2
(H-y)- (h-y) = l1sin Θ+l1sin α
l1= (H-y)-(h-y)/ (sin Θ+sin α)
Also using the given design information of the design given

below:
 Maximum height= 460mm

 Minimum height= 140mm
 Capacity of the load=3ton (30x103N)
Also,
X-m= l1sin α+h-y
X= l1sin α+h-y-m
Assuming

 Y=80mm let W=l1/l2 =2
 m=25mm
 Θ=60o-70o
 α= 10o-20o
 Ф= 115o
By iterating the values of l1, l2 & X
Table 3.1 iteration for angle and length of weight carrier
Θ Α W L1 L2 X X-l2
60 10 2 307.78 153.89 152.33 -1.55
65 10 2 296.30 148.15 144.60 -9.28
70 10 2 287.42 143.71 138.61 -5.09
60 15 2 284.48 142.24 160.86 18.68
65 15 2 274.64 137.32 15340 16.08
70 15 2 266.99 133.49 147.59 14.10
60 20 2 264.89 132.44 168.03 35.59
65 20 2 256.34 128.17 160.84 32.67
70 20 2 249.60 124.83 154.19 29.36
From the above iteration we can summarize

The first three values with α=10 cannot be taken because the
difference between the X-l2 is negative.
The third three values with α=20 also their X-l2 values has much
differ than the second three values, and the three consecutive
values with α=15o has similarities and less difference so we will
take those values and determine for the horizontal force.
Using sine law we can find the values of the angles β,
Sine law:-
L2 /sin 15=l1 /sin β
From this equation the values of β

β = Sin-1 {(l1/l2) sin15o}
β = Sin-1{(274.64/137.32) sin 15o}
β =31.17o
Ф =180-β –α
Ф = 180-31.17-15 β =31.17o
Ф =1333.83o
Ф =1333.83o
Figure 3.2 analysis of weight carrier dimension
∑MO=0
FH (l2sin β) - FR (l1cos α) = 0
FH = (l1/l2) FR ( cosα/sin β)
By substituting the values the force will be
FH = 111.19KN
From the above analysis for force the three values are the same
and we can take for a design one of them. FH = 111.19KN

3.2 Description of most important parts
1) Housing geometry: - housing is the main parts of the service jack on which the
assembly of all the other parts of are assembled on it.
2) Lever arm (weight carrier):- helps to hold and push load to its needed
position.
3) Saddle: - it is the part which assembled at the top of the holder on the
saddle holder helps to lift the load in the upper direction.
4) Piston rod: - Piston rod is the part of the main part of the power unit of
the jack which assembled with the weight carrier helps to push it.
5) Cylinder:-It is in which the piston rod is assembled and helps to keep the
pressurized air.
6) Saddle holder geometry:-Used to hold the saddle on its own and
connected to the lever arm and supporting plate.
7) Foot pedal geometry: - The foot pedal helps to compress the air in the
compressor by pushing and pulling the piston of the compressor. Used with
the handle interchangeably.
8) Supporting plate geometry:-The supporting plate is used for balancing
mechanism and also to support the saddle and saddle holder assembly by
joining one ends to the housing by pin.
9) Pin geometry: - The pins are used as fasteners at the various joints of the
members. The existence of the jack will depend on the ability of the
pin not to fail under sudden shear, tensional and compressive forces.
Hence, the design of the pin will check all these effects to avoid failure of the
pin.
10) Handle socket: - It is part on which handle is assembled by means of bolt.

11) Base: - It is a part on which the power unit and the compressor are
assembled on it.
12) Spring:- The Spring and its Supporting Members Spring is a flexible
object that is used to store mechanical energy. This device allows
controlled application of force or torque; the storing and release of
energy can be another purpose. The spring is embodied in a sliding
member made of mild steel with the inner part of the cover also coated with
mild steel coating.

CHAPTER FOR
FORCE ANALYSIS
Force analysis can be calculated starting from the cup
4.1 Force analysis of saddle holder

Geometry of the cup looks like
Assuming L=65mm , α= 35o

x= lcos 35=65cos35=53.24mm
y=lsin35=65sin35=37.28mm
θ=55
Case 1: Assume that the force is applied at point ‘a’
∑Mb=0
FL*x-Rax*y-Ray*x=0
30(53.24)-Racos55*37.28-Rasin55*53.24=0
Ra=24.57KN Ra=24.57KN
Rax=Racos55=14.09KN
Ray=Rasin55=20.12KN
∑Fx=0
Rax+Rbx=0
Rbx=-Rax=-14.09KN

∑Fy=0
Ray+Rby=FL
Rby= 30-20.12= 9.88KN
Rb2=Rbx2+Rby2
Rb=17.20KN
Case 2: Assume the force is applied at the middle of the cup Rb=17.20KN
∑Mb=0
FL*(x/2)-Rax*y-Ray*x=0
30(53.24/2)-Racos55*37.28-Rasin55*53.24=0
Ra=12.29KN
Rax=Racos55 = 7.05KN
Ray=Rasin55 = 10.07KN Ra=12.29KN
∑Fx=0
Rax+Rbx=0
Rbx=-Rax= -7.05KN
∑Fy=0
Ray+Rby=FL
Rby= (30-10.07) KN
Rby=19.93KN
Rb2=Rbx2+RbY2
Rb=21.14KN Rb=21.14KN
Case 3: Assume that the force is applied at point ‘b’
At this point the outcome result will be equals to the result at
point ‘a’
Rb=17.20KN Ra=24.57KN
Rax= 14.09KN Ray= 20.12KN
Rby= 9.88KN Rbx =-14.09KN Ra=24.57KN
4.2 Force analysis for weight carrier plate Rb=17.20KN
The lifting arm has the following three critical positions

Θ=65o, θ=0o & θ=15o

Case 1: When θ = 65o
Fp- is force by the piston rod
β1-Is angle that the connecting rod make with the horizontal line
β1 =tan-1 (1-cos31.17/sin31.17+sin35)
β1=7.54o
β1=7.54o
ϓ= 51.29o
ϓ=180-90-7.54-31.17
ϓ= 51.29o

∑Mo=0
Raxl1sinθ + Rayl1cosθ Fpl2sin ϓ=0
Fp= (14.09*274.64*sin65+
20.12*274.64cos65)/137.32
Fp= 42.54KN Fp= 42.54KN
∑Fx=0
Fpcosβ1-Rax-Fox=0
Fox= 42.54cos7.54-14.09
Fox=28.08KN
∑Fy=0
-Fpsinβ1-Ray-Foy=0
Foy=25.7KN
Fp pushes up to 460mm
Fo2= Fox2+Foy2 Fo=38.08KN
Fo=38.08KN
Case 2: when θ=0o

Β1=tan-1(1-cos15/(sin35+sin65))
Β1=1.32o
∑Mo=0
Ray (L1)-Fp (l2sin (180-β1)) =0
Fp=30(274.64)/137.32sin88.68
Fp=60.01KN
∑Fx=0
FPcosβ1-Fox=0
Fox= try to solve again
∑Fy=0
-Fpsinβ1-Ray+Foy=0
Foy=60.01sin1.32+20.12
Foy=21.5KN
Fo2=Fox2+Foy2

When θ=α=15
Β1=tan-1(1-cos35/sin35+sin31.17)
Β1=9.41o Β1=9.41o
∑Mo=0
RayL1cos15-Fpsin80.59L2=0
Fp=58.74KN
Fp=58.74KN
∑Fx=0
Fpcosβ1-Fox=0
Fox=Fpcosβ1
Fox=58.74cos9.41
Fox=57.95KN
∑Fy=0
Fpsin β1+Ray-Foy=0
Foy=58.74sin9.41-20.12
Foy=20.45KN
Fo2=Fox2+Foy2
Fo=61.34KN Fo=61.34KN
4.3 Force analysis for the supporting plate
Rb=Rc since there is no blocking force
Rc=17.02KN
Rb=Rc=17.02KN
4.4 Force analysis of the foot pedal
The free body diagram of the foot pedal is given below

Assume the following parameters
Lp= 450mm Assume
Lc= 50mm Lp= 450mm
Taking moment at point B Lc= 50mm
∑MB=0
FH(Lp)-FpyLc cos45o=0
Fpy= (135*450)/(50cos45)
Fpy=1718.2N
Fpy=Fpsin45
Fp=Fpy/sin45
Fp=1718.2/sin45
Fp=2430N Fp=2430N
∑Fx=0
-Rx-Fpx=0
Rx=-Fpcos45 Rx=-1718.2N
Rx=-1718.2N
∑Fy=0
-FH+Ry+Fpy=0
-135+Ry+1718.2=0
Ry=-1583.8N Ry=-1583.8N
4.5 Force analysis of the handle
The handle geometry will be looks like as shown below. The free
body diagram of the handle will be

Where
LA=handle length
LB=horizontal length from the pin
Lc=vertical length
FH=load applied by human
Fp=force on piston
R=reaction force
Assume that the human force range is between 120N to 150N
Taking the average of it: FH=135N
By taking the consideration of human ranges the handle will be
assumed to be 1000mm
LA=1000mm Assume
Lc=50mm LA=1000mm
LB=100mm Lc=50mm
Taking moment at point ‘O’ as positive LB=100mm
∑Mo=0
135(900)-Fp (Lcsin45)=0
Fp = (135*900)/(50sin45o)
Fp= 3436.54N Fp= 3436.54N
∑Fx=0
R-Fp=0
Rx=3.43KN
Rx=Fp = 3.43KN
∑Fy=0
-Ry+FH=0
Ry=135N
Ry=135N
From the above analysis of force on the handle and the foot
pedal, for the design we need to use the maximum force which
the machine can withstand under working condition.
Since the force from the handle is greater than the foot pedal we
have to use the handle force analysis result parameters.
The force created inside the compressor is the result of the

handle. Next to this the force inside the compressor will be
calculated as below.
From Pascal’s law the pressure created in the compressor is

directly proportional to the force and inversely proportional to
the area of the compressor.
Mathematically, P1=P2 and P=F/A
P1=F1/A1=Fp/A1
Where
dc= diameter of small piston the (compressor)
Lc= length of the piston of the compressor

Assumption
Lc= 150mm
Lc= 150mm
dc= 10mm
dc= 10mm
Ac=πdc2/4 = π(10)2/4= 25πmm2
P1=3.44KN/25πmm2= 43.78Mpa
P1=F2/A2=43.78Mpa
A2=111.97KN/43.78Mpa
A2=2557.56mm2
A2=πDp2/4=2557.56mm2
Dp= 57mm

4.6 Number of stroke
Determination of the number of stroke needs to compress the air
up to 43.78Mpa will be calculated as follow as.
From geometric analysis we have calculated that the length

which the lever arm moves at its bottom. That is
Now
L22+l22=X2
X=20.5 l2
X=20.5(137.32)=194.2mm; stroke length Stroke length
Stroke =V2/V1 X=194.2mm

V2=A2L2, V1=A1L1
Stroke= D2L2/d2L1
Stroke=(572 *194.2)/(102 *150)=42.06
Stroke= 43
Stroke= 43(approximated value)

CHAPETR FIVE
MATREIAL SELECTION
5.1 How to select materials
The selection of a material for this air service jack is one of the most important
decisions. The actual selection of a material, the selection process can be involved
with the evaluation of the many material physical, economical, and processing
parameters. The selected materials are based on the consideration of different
systematic and optimizing approaches important to material properties associated
with the air service jack design, e.g., strength, stiffness, and cost of the materials.
This can be prioritized by using a weighting measure depending on what properties
are more important than others. Next, for each property, by listing all available
materials and ranking them in order to begin with the best material; e.g., for
strength, high-strength steel such as 4340, 4130 steel should be near the top of the
list. For completeness of available materials, this might require a large source of
material data. After performing all the above procedure, manageable amount of
materials would be selected from the top of each list for the design of the air service
jack.
5.2 Factors to be considered in selection of materials

In the material selection of this air service jack design, the following numbers of
factors are considered. The material acquires the desired physical, chemical and
mechanical properties must be applicable of being processed. The best material is
one in which will serve the desired purpose at minimum cost. It is not always easy to
select a material for a machine component, based on the following criteria:
 Availability
 Cost
 Mechanical property
 Manufacturing consideration

5.2.1 Availability
The material should be readily available in that market, in large enough quantities to
meet the requirement. Available materials are selected from the market in order to
solve the problem that affects the designed materials. If there is a shortage of
materials what I have to be select, the process is difficult; due to the above reason
availability is one consideration factor.
5.2.2 Cost
For any application there is a limiting cost beyond which the design cannot go. When
this ultimate exceed I have to be consider another alternative solution or materials.
In cost analysis there are two factors namely:
 Cost of processing the material into finished goods

 Cost of material
It is likely that the cost of the materials must be law but, the processing may involve
costly manufacturing process.
5.2.3 Mechanical properties

Mechanical properties are most important technical factors governing selection of
materials; they include; strength under static & fluctuation loads, elasticity, plasticity,
brittleness and hardness. Designed upon the service conditions and the function
requirement mechanical properties are considered and suitable materials would be
selected.
5.2.4 Manufacturing consideration

For this design project machinability of material is an important consideration in
selection of materials.
The manufacturing processes such as casting, forging, and extrusion, welding, and
governing the selection. Sometimes an expensive material is more economical than
low priced one. In fabricating assemblies of plates and rods welding is become
govern.
5.3 Material selection for main parts of the service jack
5.3.1 Saddle (cup) and saddle holder
It is the top of the jack and load is exerted on it. Due to reputational force is
developed between the saddle and the material loading on it, the saddle can
experience compressive stress. For this reason I choose gray cast iron. The gray cast
iron is due to the fact that carbon is present in the form of free graphite it has low
tensile strength, high compressive strength and no ductility. And it can be machined
easily a good property of gray cast iron is free graphite in its structure acts as a
lubricant. It is very important for that part where sliding contact action is desired.
The gray cast iron is widely used for machine tool bodies, automotive, cylinder block,
head housing, flywheel, pipes and agricultural implement. It can be manufactured by
casting. Material selected for saddle has the following property:
 High compressive stress

 Easily machine able
 No ductility
 Have free graphite
5.3.2 Weight carrier & supporting plate
This links are the main components of the air service jack which connects the two
parts of the jack. The material that used to manufacture of these selection is have
high compressive strength. For these properties I select type of cast iron due to the
following advantages:
 Simple and inexpensive

 Have high compressive strength
 An excellent ability to damp
 More resistance in wear
 Have low notch sensitivity
 Have no bending occurrence from the part

5.3.3 Cylinder
A cylinder which is subjected to a very high internal pressure then the wall of cylinder
which I select is thick because it extremely holds heavy materials. Among the
materials I select to use for the cylinder cast iron. According to the maximum shear
stress theory of failure and tangential stress induced in the cylinder walls from the
above listed material I will use cast iron for that of air cylinder.
The advantage of the selection of the cast iron for the cylinder is:
 The stress assumed to be distributed over the section is not uniform

 The cast iron is hard material to resist the stress that developed radial and
tangential stress with value depend upon the radius of the element.
 It has low cost compared with others.
 It is commercially available
5.3.4 Shaft
A shaft is a rotating machine element which is used to transmit power from one
place to another. The power is delivered to the shaft by some tangential force and
the resultant torque (or twisting moment) set up within the shaft permits the power
to be transferred to various machines linked up to the shaft. These members along
with the forces exerted upon them causes the shaft to bend. In other words, we
may say that a shaft is used for the transmission of torque and bending moment.
The standard sizes of transmission shafts are: 25 mm to 60 mm with 5 mm steps; 60
mm to 110mm with 10 mm steps; 110 mm to 140mm with 15 mm steps; and 140
mm to 500 mm with 20mm steps (Gupta and Khurmi, 2005).
The material used for shafts should have the following properties:
 High strength
 Good machinability
 Low notch sensitivity
 Good heat treatment
 High wear resistance

This shaft transmits power between the source and the machines absorbing
power and carry the jack parts such as handle with its socket, foot pedal, front
wheel and weight carrier. Therefore they are subjected to stresses due to bending
loads. When the shaft is subjected to a twisting moment (or torque) then the
diameter of the shaft may be obtained by using the torsion equation. The materials
used for ordinary shaft carbon steel grades 40C8, 45C8, 10C4, and 50C12.
Table 5.1 Mechanical properties of materials for the parts

Part No Parts Material Designation Yield Ultimate
strength strength
ASJ1 Saddle Cast iron AISI 4140 Q&T 94Mpa 100Mpa

ASJ2 Saddle holder Cast iron AISI 4144 Q&T 655Mpa 758Mpa
ASJ3 Weight carrier Cast iron AISI 4143 Q&T 813Mpa 1260Mpa
ASJ4 Supporting plate Cast iron AISI 4143 Q&T 813Mpa 1260Mpa
ASJ11 Pin Mild steel 180Mpa 260Mpa
ASJ5&6 Power & compressor Cast iron AISI 4143 Q&T 261Mpa 752Mpa
Piston
ASJ7 Block with Cast iron AISI 1020 44Mpa 197Mpa
compressor
ASJ12 Shaft C. steel 40C8 396Mpa 660Mpa
ASJ8 Handle C. Steel FeF250 116Mpa 150Mpa
ASJ9 Foot pedal C. Steel FeF250 116Mpa 150Mpa
ASJ15 Housing C. steel FeF250 116Mpa 150Mpa
12ASJ13 Spring Alloy steel AISI601 827Mpa 689Mpa
&14
ASJ10 Handle socket Cast iron AISI 4144 Q&T 655Mpa 758Mpa
ASJ16 Cylinder Cold drawn AISI 1015 160Mpa 322Mpa

CHAPTER SIX
STRESS ANALYSIS (DETAIL DESIGN)
6.1 Design of saddle
The cup is to be made of cast iron with Sut = 100Mpa
=
C = d/2 = 70/2=35mm, b =70mm M=1050KNmm
M = 30000*35=1050KNmm
∗ ∗
I= = =1.177*106mm4
I =1.177*106mm4
( )∗( )
= =
= 31.197Mpa
= 31.197Mpa
n= = = 3.2 therefore it is effective

.
6.2 Design of saddle holder

Material selected AISI 4140 Q&T
Sut = 758Mpa
σy= 655Mpa
From geometric analysis
X=53mm
Y= 37mm
w=115mm
h=75mm
t=10mm
da=16mm
db=12mm
Point A point B
The stress analysis of the cup will be calculated as follows as by

checking the tearing and bearing stresses
Tearing and bearing stresses are given by

= & σ= ∗
=
Where
F force at the pin
t=thickness
Assume
d= diameter
x=9mm
x= width
db=16mm
x=9mm, db=16mm

= = =505.34Mpa, where factor of safety, n=1.5 = 505.34Mpa
.
. . ( ) =252Mpa
= = =252Mpa
.
Checking for tearing and bearing stresses at point A
Da=12mm
X=20mm
T=10mm
= = =24570N/10*20= 122.85Mpa =122.85Mpa
σ= = 24570/10*16=153.56Mpa σ =153.56Mpa
∗
σbr σbr
σ= + + √3ᴛtr
2 4
By substituting the values we can get
σ1= 303Mpa
σ2= -149.43Mpa
σ1= 303Mpa
ᴛmax = , by substituting the values
σ2= -149.43Mpa
ᴛmax=226.2Mpa
Since σ1 & σ2< σ

ᴛmax< ᴛ , the design is safe!
ᴛmax=226.2Mpa
Checking for tearing and bearing stresses at point B
= = =17200N/10*20= 86Mpa
σbr = ∗
= 17200/10*12=143.35Mpa =86Mpa
σbr σbr σbr =143.35Mpa

σ= + + √3ᴛtr
2 4

by substituting the values we can get
σ1= 237Mpa
σ2= -94Mpa σ1= 237Mpa
ᴛmax = , by substituting the values σ2= -94Mpa
ᴛmax=165.5Mpa
Since σ1 & σ2< σ
ᴛmax=165.5Mpa
6.3 Design of lifting arm (weight carrier)
Moment of inertia
= = −
Substituting the values

h=24mm
t=10mm
Da=16mm
I=5413.34mm4
A=ht-tDa= (24*10-10*16) mm2
A=80mm2
Checking for buckling stress

1
= − ∗
2
Where
= ℎ
C=center half
E=elasticity modulus
L= length of span
Material selected for weight carrier
AISI 4130 Q&T
Sut =1260Mpa
= 813
E=230Gpa
= = =840Mpa, where factor of safety,
.
n=1.5 =840Mpa
. . ( ) =312.7Mpa
= = =312.7Mpa
.
L=274.64mm
. 2
=( ) = 8.22
C=1
E=230Gpa
1
= − ∗
2
= 794.2
= 794.2
Which is less than the value of =840Mpa and the design will be
safe!

 At point A, when θ=65o
= = ,
Since = this implies the force applied to that pin is divided

into two because of geometry of the weight carrier.
Assuming the following values for the weight carrier Assume
x=11mm x=11mm
t=10mm t=10mm
24570 = 111.7
= = 111.7
2 ∗ 10 ∗ 11
= =
2 ∗
= 64.3
24570
= = 64.3
2 ∗ 16 ∗ 10
σbr σbr
σ= + + √3τ
2 4

σ1= 228.3Mpa
σ1= 228.3Mpa
σ2= -164Mpa
σ2= -164Mpa
ᴛmax=196.135Mpa
ᴛmax=196.135Mpa
Since σ1 & σ2< σ

 At point C when θ=15o
F=61.34KN
x=13mm
t=10mm
Dc=20mm
61340
= = 236
2 ∗ 13 ∗ 20
= 236
= =
2 ∗
61340
= = 118
2 ∗ 13 ∗ 20
σbr σbr = 118

σ= + + √3τ
2 4
σ1= 471.8Mpa
σ2= -353.84Mpa
ᴛmax = , by substituting the values σ1= 471.8Mpa
σ2= -353.84Mpa
ᴛmax=413Mpa
Since σ1 & σ2<σ

ᴛmax<ᴛ , the design is safe! ᴛmax=413Mpa
 At point O when θ=65
Fp=42.45KN
X=11mm Assume
Do=16mm X=11mm
Do=16mm
=
42450
= = 192.95
2 ∗ 10 ∗ 11
= = 192.95
2
42450
= = 120.6
2 ∗ 16 ∗ 11
σbr σbr
σ= + + √3τ
2 4 = 120.6
σ1= 399.9Mpa
σ2= -279.3Mpa
ᴛmax=339.6Mpa
Since σ1 & σ2>σ σ1= 399.9Mpa
ᴛmax>ᴛ , the design is not safe! σ2= -279.3Mpa
 In order to make safe the design we have to increase the ᴛmax=339.6Mpa

thickness by inserting into it a shaft.
Assume
Assuming the following parameters
L=95mm
L=95mm Do=16mm
Do=16mm
FL =42.45KN
∑Mo=0, FL*L/2+Mo-Roy*L=0

∑Fy=0
Roy+Ro’y= FL
Boundary conditions are
@x=0, y=0, x=L, y=0
@x=0, θ=0, x=l, θ=0
0≤ ≤
∑Mo=0
-M+Mo− −RoyX=0
Mo=M+ +RoyX
Using quation of elastic curvature

EI =M
EI = Mo- +RoyX
By integrating it we can get

EI = MoX - +Roy + 1
EIy= Mo - +Roy +C1x
From the boundary condition

@x=0, y=0, x=L, y=0

C1=0, substitiing in the first eduation
C2=0, substitiuting in the second equation
Using the second boundary condition
@x=0, θ=0, x=l, θ=0
We can get
4MoL - +2Roy = 0
12M - +2Roy =0
Roy=21.22KN
Mo=187.4Nm Roy=21.22KN
∑Fy=0 Mo=187.4Nm
Roy+Ro’y-FL=0
Ro’y= FL –Roy
Ro’y=21.23KN
Mo’=Mo− + c’yL
The value of Mo’ will be calculated as Ro’y=21.23KN

Mo’=-5.3KNm
4
=
4(187.4 )
=
(10)(16)
= 495.6
> , the design is safe from bending stress.
= 495.6
Now the thickness becomes
t=135mm
x=11mm
=
42450
= = 30.9
125 ∗ 11
= = 30.9
42450 = 21.
= = 21.
125 ∗ 16

σbr σbr
σ= + + √3τ
2 4
σ1= 60.67Mpa σ1= 60.67Mpa
σ2= -41.015Mpa
σ2= -41.015Mpa
ᴛmax=50.84Mpa
Since, σ1 & σ2<σ
ᴛmax<ᴛ , now the design is safe! ᴛmax=50.84Mpa
6.4 Design of supporting plate
W=9mm
L1=137.32mm
X=l1+rb +r1+10
X=137.32+6+6+10
X=159.32mm X=159.32mm
= − 2( )
12 12
10 ∗ 159.32 10 ∗ 12
= − 2( )
12 12
= 336.7 4
A=t*x-t*dp= 10*159.32-2(10*12)

A=1353.2mm2
Material selected for supporting plate
AISI 4130 Q&T Sut =1260Mpa

= 813
E=230Gpa
= = =840Mpa, where factor of safety, n=1.5
. =840Mpa,
. . ( )
= = =312.7Mpa =312.7Mpa
.
2
. 2 = 15.78
=( ) = 15.78
C=1/3
E=230Gpa
1
= − ∗
2
= 396.2
Which is less than the value of =630Mpa and the design will be
= 396.2
safe from buckling stress!
Checking for tearing and bearing stress for supporting plate

Force at θ=65o is
F=Ra=24.54KN
X=7mm Assume
X=7mm
Db=12mm (from geometric)
Db=12mm
= = 204.5
24540
= = 204.5
2 ∗ 7 ∗ 10

=
2
24540 = 102.25
= = 102.25
2 ∗ 12 ∗ 10
σbr σbr
σ= + + √3τ
2 4
σ1= 359Mpa
σ2=-256.73Mpa
σ1= 359Mpa
σ2=-256.73Mpa
ᴛmax=307.86Mpa
Since, σ1 & σ2<σ

ᴛmax<ᴛ , the design is safe from tearing and bearing ᴛmax=307.86Mpa
stresses
6.5 Design of pin

Pin B design and for supporting plate
From selection of standards snap head pin is selected
Hl= head length
D=diameter
Hw=head width
Where Hl=0.7d=12*0.7= 8.4mm

d=12mm

Hw=1.6d=1.6*12= 19.2mm
L=24mm
Material selected for pin design is mild steel with
σul =260Mpa
σy =180Mpa
n=1.2
Procedure to design pins
Relating the maximum shear and yield strength ( ul) in the
Vonmises equation, y= √3* ul
= 3 - p2 = −
√ √
Maximum shear and normal stress becomes zero.

Therefore P = 0
max = = 0.577 where n is the design factor
√
max =125Mpa
=0.577 =125Mpa
.
After getting the maximum shear we can get diameter of the pin
by using the formula.
Τ= , since our force, F = and but =
τ=38.08
A= (6)2 =113.04mm2
The total area of shear must be 2A= 226.08mm2
F=
τ= = 38.08
∗ .
The design is safe since τ< max
Where, F – shear force
ul – shear strength
y - Yield strength
Find the bending stress and crushing stress b =
c =

Where – bending stress
b
c - Crushing stress
t- Minimum thickness
I – moment of inertia
In order to determine the bending moment
Rb
Rb
M= 1 − 2 = ∗ 20 − ∗ 10 = 86 M=86
C= & I=
32
b = 3 & c =
∗ ∗
b = 507.2
32 ∗ 86
b = = 507.2
103 c = 35.84
c = = 35.84
∗ ∗
Pin A design
From selection of standards snap head pin is selected
Hl= head length
D=diameter
Hw=head width

Where Hl=0.7d=16*0.7= 11.2mm
d=16mm
Hw=1.6d=1.6*16= 25.6mm
L=22mm
Material selected for pin design
Mild steel with σul=260Mpa
σy=180Mpa
n=1.2
Procedure to design pins
Relating the maximum shear and yield strength ( ul) in the
Vonmises equation, y= √3* ul
= 3 - p2 = −
√ √
Maximum shear and normal stress becomes zero.
Therefore P = 0
max = = 0.577 where n=1.2 is the design factor
√
=0.577 =125Mpa
.
After getting the maximum shear, determine the normal shear max =125Mpa
stress
τ= , since our force, F = and but =
A= (8)2 =200mm2
The total area of shear must be 2A= 400mm2
F=
τ= = 30.7
∗
τ = 30.7
The design is safe since τ< max

Where, F – shear force
ul – shear strength
y - Yield strength
Find the bending stress and crushing stress
b = =
c =
Where b – bending stress
c - Crushing stress
t- Minimum thickness
I – moment of inertia
In order to determine the bending moment
M= 1 − 2 = ∗ 20 − ∗ 10 = 122.85
M=122.85
C= & I=
32
b = 3 & c =
∗ ∗ b = 24.45
32 ∗ 122.85
b = = 24.45 c = 6.67
83
c = = 6.67
∗ ∗

6.6 Design of the cylinder
This cylinder will house the first piston which will be the
intermittent connector b/n the weight carrier and the second
piston. From the mechanical engineering design book by J.E.
Shigley the stresses acting upon a cylinder are given as follows
H = Hoop stress (circumferential stress)

t = tangential stress = H
r = radial stress
L = longitudinal stress
And the other parameters are given as
d0 = outer diameter
r0 = outer radius
di = inner diameter
ri = inner radius
Pi = internal pressure
P0 = external pressure
The diameter of the larger cylinder is
di = 57mm
d0 = 67mm
And the thickness is t = 5mm
di = 57mm
∗ ∗ ∗ d0 = 67mm
t =
∗ ∗ ∗
r=
∗
L =

ri = di / 2 = 57mm / 2 = 28.5mm ri =28.5mm
Since di = d2 = 57mm
For our cylinder to withstand the pressure applied, an

appropriate thickness must be selected and take a thickness of
5mm
We know that di = 57mm and the thickness t = 5mm
do = 2t + di = 2*5 + 57mm = 67mm
r0 = 33.5mm
r0 = 33.5mm
The safety of our design must be assured. In order to check the
safety we use the maximum strain energy hypothesis
In order to check the safety of the body, principal stresses are

taken as t, L , r
Pi is the internal pressure that pushes the piston rod.
I.e. pi = 43.78Mpa
pi = 43.78Mpa
Po is the pressure applied to induce the returning effect of
compressed air and is induced by the spring effect
ri = 28.5mm
ro = 33.5mm
pi = 43.78Mpa
p0 = 7.175Mpa
p0 = patm + pspring
pi = 43.78Mpa
pspring = = )
( ∗
pspring = 11.76Mpa pspring = 11.76Mpa

patm = 101.325Kpa t = 187.33Mpa
p0 = (101.325 + 11760)Kpa
p0 = 11.86Mpa
Where; p0 = 11.86Mpa
patm. = atmospheric pressure
pspring = pressure from spring
Fspring = force of spring
Pi = internal pressure
∗ ∗ ∗
t= ; since tmax is at r = ri
t = 187.33Mpa
t = 187.33Mpa
2 −
∗ 2− ∗ 2− 2 ∗ 2
r = 2− 2 ; since rmax is at r = ro
r = 155.41Mpa
∗ . ( . )
L = =
( . ) ( . ) r = 155.41Mpa
L =114.71Mpa
By using maximum strain energy theory L =114.71Mpa

( ) ( ) ( ) ^ (1/2)
’=
1 = r= 155.41Mpa
2 = t = 187.33Mpa
3 = L = 114.71Mpa

r = 155.41Mpa
L = 114.71Mpa
( . ) ( . . ) ( . ( )) ^(1/2)
’=
’ = 46.63Mpa
max= 36.31Mpa
187.33Mpa 114.71Mpa)
max = =
’ = 46.63Mpa,
max= 36.31Mpa
For the large cylinder (the power unit) the stresses are
’ = 46.63Mpa, max = 36.31Mpa
The material selected for the power unit construction
AISI 1015 – cold drawn steel,

Sut= 322Mpa
= 160Mpa
Therefore, n = =
’ .
n = 3.43
n = 3.43
Where, y = yield strength
n = safety factor
’ = von misses stress
From shear stress theory
max = 36.31Mpa
max = 36.31Mpa
Therefore, n = = =2.2 the safety factor is n = 2.2.
∗ ∗ .
Therefore, the design of the cylinder is safe.

6.7 Design of piston rod
Design consideration for the piston
 It should have minimum mass maximizing the internal
force
 It should have form an effective gas and oil seeking
 It should provide sufficient bearing area to prevent under
wear
 It should have high speed
 It should have sufficient support for the piston
consideration advantage for selection of material
o Low cost of fabrication
o Good casting characteristics
o High compressive strength
o High resistance in wear
o Has excellent machinability
Where
dp- diameter of piston rod

Pl- length of piston rod
di- internal diameter of cylinder
Do- external diameter of the cylinder
From geometry analysis the internal diameter of the cylinder
di =57mm di =57mm
Pl =192mm Pl =192mm
assume piston length =25mm
 Due to the above consideration the piston rod is made of
mild steel.
max= [1 + sec
W= =
=
4 4
d=D (P/ t ) 0 .5
Material selected is
Sut= 752Mpa
= 261
= = =300.8Mpa, where factor of safety, n=2.5

.
dp =57*(43.78/300.8)
dp= 21.78mm=22mm dp= 22mm
6.8 Design of the compressor (small cylinder)

The appropriate thickness, we select a value of 3.5, because
according to our number of stroke, the air will be cruising at very
high speed and pressure. So the piston cylinder must be able to
withstand this pressure. Assume that the external pressure is
zero.
Assume
t = 3.5mm
t = 3.5mm
do = di + 2(t) = 10+ 2(3.5) = 17mm
ri = 5mm
ri = 5mm
r0 = 8.5mm
r0 = 8.5mm
t = 1+ =90.10Mpa
r = 1− = 43.78Mpa
L = =23.16Mpa
Using maximum strain energy theory

1 = t= 90.10Mpa
1= t= 90.10Mpa
2 = L= 23.16Mpa
2= L= 23.16Mpa
3= r= 43.78Mpa 3 = r= 43.78Mpa
( ) ( ) ( ) ^(1/2)
’=
’ = 66.23Mpa
’ = 66.23Mpa
The material is AISI 1020 – hot rolled steel and for this material at
43.78Mpa the value for y is given by 198.69Mpa.
.
n= = =3
’ .
Applying shear stress theory

. .
max = =
max = 33.47Mpa = 33.47Mpa

max
.
n= = = 2.9
∗ .
Taking the external pressure p0 = patm = 101.325Kpa
∗ ∗ ∗
t = , but we know
that ∗ is zero so it follows

t = 90.1Mpa t = 90.1Mpa
∗ ∗ ∗
r =
r = 46.32Mpa
r = 46.32Mpa
L = = 23.16Mpa
The principal stresses are given as
1 = t= 90.1Mpa
2 = L= 23.16Mpa
3 = r= 46.32Mpa
( ) ( ) ( ) ^(1/2)
’=
’ = 66.23Mpa ’ = 66.23Mpa
.
n= = = 3, so it is safe
.
. .
max = =
max = 33.47Mpa max = 33.47Mpa

.
n= = = 2.9, so it is safe.
∗ .
6.9 Design of piston head
 Large piston head

To design the piston head of the service jack
P = 43.78Mpa P = 43.78Mpa
dp = 57mm
= =2550.4mm2
F = 111970N F = 111970N
= 43.9Mpa
= = = 43.9Mpa
2550.4mm2
Too this specific calculation the shear stress must be taken under
consideration
Ashear = πd2 * l
Ashear = π(3249) * l
The value of l must be determined. And to do this we use the Sy
equation
∗
l=
∗ ∗
Whenever constructing a piston every aspect of the design must

be thoroughly analyzed. And in our design i.e for hydraulic car
jack, we used two pistons and the pistons play a major role, if not
the major role so our assumption of factor of safety for the
design must be very high even up to 15
∗
So, l =
∗ ∗
l= 27.6mm4
 small piston head

Assume nd = 21 and Sy = 340
∗ ∗
l= = = 183.54mm4
∗ ∗ ∗ ∗

6.10 Design of springs
Springs are designed to provide a push, a pull, a twist (torque) or
primarily store energy.
In our design we have considered two springs. And the springs
are positioned at under the cup and with the small piston and
calculations are done on the following pages
The main dimensions to be calculated in the spring design are
1. Wire diameter
2. Mean coil diameter
3. Number of coils
6.10.1 Design of saddle spring
We assumed that fs = 1.5 is used and the following steps must be
accurately followed
Assumptions
Spring index(c) = 8
We used Alloy steel cold drawn spring wire with G = 86Gpa
J (deflection) = 25mm
ρ = 7750
Step 1:- Trial and error diameter = 4mm

D = C*d
D = 8*4mm = 32mm
Step 2:- Find the shear factor KS and calculate the shear in the
coil at the large force
KS = 1 +
KS = 1.0625
. ∗ ∗ . ∗ .
= =
( . )

= 2564 x 106 Pa = 2564 x 106 Pa
Step 3:- Find the ultimate tensile strength of the wire then
torsional yield
= Adb = (4)-0.1822
= 1361.9Mpa = 1361.9Mpa
We obtain A and B from the table found on Shigley
= 0.6
= 0.6*1361.9Mpa= 817.2Mpa
= 817.2Mpa
Step 4:- Safety factor
.
fs= = = 3.18
.
So it is safe
Step 5:- Spring rate
∆
K= =
Assuming that the minimum weight that our jack would lift
without causing damage to the object to be lifted is assumed to
be b/n 1ton and 2.2 ton so the weight we preferred is 1.5 ton.
∆
K= =
=
K = 600N/mm
Step 6:- Number of actually active coils K = 600N/mm
∗ ( ) ∗( . ∗ )
Na = =
∗ ∗ ∗( ) ∗ /
Na = 13.9 Na = 13.9
When we round 13.9 to 14 the spring rate actually becomes

∗ ( ) ∗( . ∗ )
K= =
∗ ∗ ∗( ) ∗
K= 600KN
K = 599.88 = 600KN
Therefore the spring rate doesn’t bring a significant change
Step 7:- Assuming a squared and grooved end and making the
total number of coils
Nt = 16
Nt = Na + 2 = 14 + 2 = 16
Step 8:- The shut height can be determined from
LS =64mm
LS = d (Nt) = 4 (16) = 64mm
Step 9:- Initial definition
.
Y intial = =
Y intial = 0.025mm
Y intial = 0.025mm
Step 10:-Assume dash allowance of 15% of the working
deflection.
= 0.15(25mm)
= 3.75mm
= 3.75mm
Step 11:- Free length
= + + +
= 64 + 3.75 + 25 + 0.025
= 92.77
= 92.77
Step 12:- The deflection to the shut height
= -
= 92.77 – 64
= 28.775
= 28.775
Step 13:- The force at shut height
= K*
= 6000KN * 0.028
= 168 = 168
Step 14:- The shut height stress
∗8∗ ℎ
= 3
0.625∗8∗168∗32
=
43
= 227.3Mpa = 227.3Mpa
Step 15:- The inside an outside coil diameter = 36
= D + d = 32 + 4 = 36mm = 28
= D – d = 32 – 4 = 28mm
Step 16:- The smallest hole and largest pin which should be used
with spring are
Hole min = + 0.03(D) = 36 + 0.03(32) = 32.6mm
Hole min=32.6mm
= - 0.05(D) = 28 – 0.05(32) = 26.4mm
= 26.4
Step 17:- The total mass of the spring
∗ ∗ ∗
M= = =
Step 18:- Pitch

P=6
P=
Ns=6
.
= =6
.
= = = 5.9 = 6
.
The design factor is high b/c the spring is at a point of high

loading. And at that circumstance, it must have a very high
tolerance to wear, tear, and other forces that might bring about
the failure of the spring.

6.10.2 Design of small springs
The diameter of small piston = 10mm
The pressure for the smaller piston is similar to the larger piston.
= =P
Step 1:- d = 17mm

∗
=
∗
∗ ( )∗( ) F=9.9KN
F= = = 9.9KN
( )
= 9.9KN
= 9.9KN
= = 0< < 0.8 , let = 0.5
= *
= 0.5*9.9 = 0.5*9.9
= 4.95KN
Step 2:- =
. .
=
= 2.475KN
= 2.475KN
=
. .
=
= 7.425KN = 7.425KN
Assume that the wire diameter is 3.5mm, c=8

Step 3:- Coil diameter can be calculated as
D = c*d
D = 4.85*3.5 D = 28mm
D = 17mm
Material selection for springs is done from table and for our
design we have selected AISI 1085
= 1.0625
. .
=1+ =1+ = 1.103
.
Where is the direct shear factor
Step 4:- The stress at initial deflection and mean stress is

done as follows = 1875.95
∗ . ∗ ∗ . ∗ . ∗ ∗
= = = 71.68Mpa =5627.86Mpa
( )
∗ ∗ ∗ . ∗ . ∗ ∗
= = =215.5Mpa
( )
Step 5:- The wall factor which is the un stability factor is

calculated as follows.
.
= + = 1.2
= 1.2
= 1.2
Step 6:- Ultimate tensile strength = A*
From table the values are obtained as b = -0.1625 and A =

2153.5Mpa
= 2153.5(3)-0.1625
= 108.1Mpa

= 0.67( ) = 1080.84Mpa
Step 7:-The spring rate is

∆
K= ,
the value of Y is assumed and taken as 3.5mm.
Step 8:- The number of active coil is
∗
K= with G = 81Gpa
. ∗ ∗
∗ ( ) ∗
= = = 4.98 = 5
∗ ∗ . ∗( ) ∗( . )
=5
=5
Step 9:- Assume the spring is squared and grooved end so adding
=7
= +2=7
The shut height is

= 63
=d( ) = 9(7) = 63mm
Step 10:- The initial deflection = = = 6.9mm

.
Step 11:- Assume the clagh allowance is 15% of the initial
= 0.15(3.5) = 0.52mm
Step 12:- The free length is

= + + +
= 63mm + 0.52 + 3.5 + 6.9mm
= 73.92mm
Step 13:- Deflection to the shut length is
= 73.92mm
= - = 73.92 – 63mm = 10.92mm

Step 14:- The force at the shut height is
= - = 73.92 – 63mm = 10.92mm
=K*
= 6.6 * 10.92
= 72.072KN
= 72.072KN
Step 15:- For the shut height safety, f.s must be calculated,
∗ . ∗ ∗ . ∗ . ∗ . ∗
= = = 16.1926
( )
.
= = = 6.69 = 6.69
.
6.11 Design of handle

The material selected for handle design is steel FeE250 with
Sut =150Mpa
Fs =3
From the previous analysis or the pin we found that thickness of
the handle to be 3mm
t=3mm
the outer diameter Do is calculated from the geometry of the
handle given below
Do=Di+2t= DI+6mm
The allowable stress become
= 10.92

150
= = = 50
3
In order to calculate the maximum bending moment on
the handle from the force analysis we have the following FH`=135N
data Ry=135N
FH`=135N
Ry=135N
Length of handle =1000mm
Taking the moment at point B

∑MB=0
M+FH *x=0
M=- FH*`x= -135*900= -121500Nmm
∑Fy=0
V- FH`=0
V= FH`=135N
In order to calculate the outer diameter of the handle
Assumption
 The diameter of the handle is solid due to the use of
another handle inserted through the hole for the specific
calculation only
= , = 50
Where = , =

∗
= = 50 =
Do=29.14=30mm
Do=di+6mm
Di=do-6mm
Di=30mm-6mm
Di=24mm
Check for safe design using shear stress analysis
=
T=F*(1000-900) =135N*900mm= 121500N

121500 ∗ 30/2
= = 22.93
30
64
= 22.93 < 50
This implies that the design is safe from shearing stress, so it is
safe design.
6.12 Design of handle pin (handle socket)

The material selected for pin design is mild steel with the
following parameters
Sut=140mpa
Sshear=100Mpa
fs=2
Bearing pressure intensity=10Mpa
Lp=1.25dp
Therefore
140
= = = 70
2
ℎ 100
= = = 50
2

Where dp=diameter of the pin
Lp=length of the pin
The bearing area of the pin is given by
A=dp*lp we have assumed lp=1.25dp
2
A=1.25dp
The maximum applied (reaction) force at the pin is F=135N
Therefore using the bearing pressure we can calculate the value

of the diameter of the pin, dp
F=A*P
135N=1.25 dp2*10Mpa
dp=3.3mm=4mm
lp=1.25dp= 1.25*4=5mm
Check for safe design
The most possible stress on the pin is shear. Therefore we check

for shearing stress on the pin
135
= = = 5.37
2 2(12.56)
Therefore since < 50 the design of the pin is safe.
6.13 Design of shafts

The material selected for this shaft design 40C8 carbon steel with
Sut =396Mpa
b = 660Mpa
fs=2
Shaft for joining the weight carrier
From force analysis the reaction force at this position is
Fo=61.34KN F=Fo/2

Taking moment at point ‘a’ is zero
∑Ma=0
36F+96F-132Rb=0
Rb =30.67KN
∑Fy=0
Ra + Rb –F-F=0
Ra =30.67KN
Calculating bending moment at point ’c’ and‘d’
Mc= Ra *36= 30.67KN*36mm
Mc =1104.12KNmm
Md= Rb *36=30.67KN*36mm
Md =1104.12KNmm
Using the maximum bending moment
b= , =
Assume the value of = 815
Substituting the values the diameter will be
D=d=23.8mm=24mm

Shaft for the front wheel
Taking moment at point ‘a’ is zero
∑Mc=0
114F-57Rb=0
Rb =15KN
∑Fy=0
Ra + Rb –F=0
Ra =15KN
Calculating bending moment at point ’c’ and‘d’
Ma= Ra *57= 15KN*57mm
Mb =855KNmm
Mc= Rb *36=15KN*36mm
Mc =540KNmm
b= , =
D=d=19.89mm=20mm
Shaft design for the handle and foot pedal assembly
Material selected for shaft from the table ….40C8
carbon steel with Sut =396Mpa, b = 170Mpa

From geometry analysis
L=134mm
Fp=3.44KN
Now taking the moments at point A equal to zero

∑MA=0
67*3440-134RB=0
RB =17200N
∑Fy=0
RA + RB –F=0
RB =1720N
Calculating bending moment at point ’c’
MC= RB*36=1720N*67mm
MC=115240Nmm
b= , =
D=d=24.002mm=24mm

CHAPTER SEVEN
MANUFACTURING PROCESS
Manufacturing of production is an important event that begins with the concept of
product and end with the competitive in the market place. It implies the application
of physical and chemical process for changing the geometric characteristics or
appearance of a given input material to produce parts.
7.1 Casting Operation

After the core is positioned (if one is used) and the two halves of the mold are
clamped together, then casting is performed. Casting consists of pouring,
solidification, and cooling of the cast part. The gating and riser system in the mold
must be designed to deliver liquid metal into the cavity and provide for a sufficient
reservoir of molten metal during solidification shrinkage. Air and gases must be
allowed to escape. One of the hazards during pouring is that the buoyancy of the
molten metal will displace the core. Buoyancy results from the weight of molten
metal being displaced by the core, according to Archimedes’ principle. The force
tending to lift the core is equal to the weight of the displaced liquid less the weight of
the core itself. Expressing the situation in equation form,
Fb=Wm-Wc, Where Fb=buoyancy force, N

mm=weight of molten metal displaced, N
mc=weight of the core, N.
Vc=volume of casting
Weights are determined as the volume of the core multiplied by the respective
densities of the core material (typically sand) and the metal being cast. The density of
a sand core is approximately 1.6 g/cm3. The volume of the parts will be calculated as,
= ℎ
Following solidification and cooling, the sand mold is broken away from the casting
to retrieve the part. The part is then cleaned, gating and riser system are separated,
and sand is removed. The casting is then inspected.

7.1.1 Saddle
The manufacturing process selected for saddle is Low-Pressure type of Casting. In

low-pressure casting, the liquid metal is forced into the cavity under low pressure
approximately 0.1MPa from beneath so that the flow is upward. The advantage of
this approach is that clean molten metal from the center of the ladle is introduced
into the mold, rather than metal that has been exposed to air. Gas porosity and
oxidation defects are thereby minimized and mechanical properties are improved.
7.1.2 Saddle holder
To manufacture the saddle holder Sand casting process is selected, also known as
sand-mold casting, which consists of pouring molten metal into a sand mold,
allowing the metal to solidify, and then breaking up the mold to remove the casting.
The casting must then be cleaned and inspected, and heat treatment is required to
improve metallurgical properties. The cavity in the sand mold is formed by packing
sand around a pattern and then removing the pattern by separating the mold into
two halves. The mold also contains the gating and riser system. In addition, since this
part has holes, a core must be included in the mold. Since the mold is sacrificed to
remove the casting, a new sand mold must be made for each part that is produced.
7.1.3 Piston rod

As pointed piston are typically cast. This process will allows high production
quantities with an ability to vary desired characteristics. By varying the alloying
content, strengths and hardness may be varied according to desired outcomes. Chill
plates could be added to decrease solidification times and also obtains a specified
columnar structure, thus maximizing strengths in a particular direction. In the next
step, this part is gripped by a hydraulic or pneumatic chuck, at which point the
drilling takes place on the piston to make the piston head at a given dimension.
1) Power unit piston

2) Compressor piston

7.1.4 Weight carrier
Since they are the load carrier they need more core strength resistance to
compressive force. In order to get the needed strength i select casting process for
this art manufacturing process. And casting process will be applied as discussed for
the other parts manufacture by casting.
7.1.5 Foot pedal
Since the foot pedal has complicated physical with dimension it is better to
manufacture it with mold cast method. A mold is formed into the geometric shape of
a foot pedal part. Molten metal is then poured into the mold the mold holds foot
pedal in shape as it solidifies. A foot pedal casting is created.
7.1.6 Handle socket

Using mold casting process first, a mold is formed into the geometric shape of the
handle socket. Molten metal is then poured into the mold; the mold holds this
material in shape as it solidifies. A metal casting is created. The molten material is
poured directly into the mold cavity which is exposed to the open environment.
7.1.7 Compressor with block

Gray cast iron is the most versatile of all foundry metals. The high carbon content is
responsible for ease of melting and casting in the foundry and for ease of machining
in subsequent manufacturing. Grey cast iron is the cheapest of the cast materials and
in the plain state it can be casted almost too any size and form. By calculating the
volume of the block with compressor

Table 7.1 volume and weight of parts
Part Part name Quan

Volume Weight(g)
no. tity (mm3)
Molten mass(g) Core mass (g)

ASJ1 Saddle 1 64841 460.4 103.7
ASJ2 Saddle holder 1 75500 536.0 120.8
ASJ3 Weight carrier 2 205500 2918.1 657.6
ASJ5 Power piston 1 32645 231.78 52.23
ASJ6 Compressor piston 1 9490 67.4 15.2
ASJ7 Block with compressor 1 1202130 8535.1 1923.4
ASJ10 Handle socket 1 127260 903.5 203.6
ASJ9 Foot pedal 1 47640 338.244 76.22
7.2 Rolling operation

Metal rolling is one of the most important manufacturing processes in the modern
world. The large majority of all metal products produced today are subject to metal
rolling at one point in their manufacture. Metal rolling is often the first step in
creating raw metal forms. Rolling is most often performed hot.
7.2.1 Housing
To manufacture the part in simple way rolling process is selected. The thickness of
the work is reduced by compressive forces exerted by two opposing rolls. The rolls
rotate to pull and simultaneously squeeze the work between them. For more
improvements of the parts flat rolling process type is selected, which used to reduce
the thickness of a rectangular cross section to a desired thickness. After getting the
desired thickness of the plate work, some of different machining process like as

cutting, by laying out their geometries on the work plate cutting process will be held
on and twist drilling used to drill holes on the parts at a given dimension.
The given data are plate of metal with w=900mm, h=170mm and t=15mm
Assumption
rolls radius=250mm
Coefficient of friction=0.12
Work thickness=10mm
Flow stress, K=275Mpa and n=0.15
Roll speed=50rev/min
The draft attempted in this rolling operation is
Draft= starting thickness – final thickness
d=15-10=5mm
2
dmax= rolls=0.12 *250mm=3.6mm
Since the maximum allowable draft exceeds the attempted reduction, the rolling
operation is feasible. To compute rolling force, we need the contact length Land the
average flow stress Yf.
The contact length is given
= ( − ) = 250(15 − 10) = 50
The true strain experienced by the work in rolling is based on before and after stock
thicknesses. In equation form
15
∈= = 0.4
10
Yf is determined from the true strain:
275 ∗ 0.4 .
= = 208.42
1 + .15
Rolling force is determined from equation
= 208.42 ∗ 170 ∗ 813 = 28.8
Torque required driving each roll is given by
=0.5mm*28.8MN*813mm=1.17*1010Nmm
Power obtained is,
P=2*3.14*50*28.8*106*813mm=7.35*1012Nm/min
7.2.2 Supporting plate

The given data are plate of metal with w=160mm, h=20mm and t=15mm
Assumption
rolls radius=250mm
Coefficient of friction=0.12
Work thickness=10mm
Flow stress, K=275Mpa and n=0.15
Roll speed=50rev/min
The draft attempted in this rolling operation is
Draft= starting thickness – final thickness
d=15-10=5mm
2
dmax= rolls=0.12 *250mm=3.6mm
Since the maximum allowable draft exceeds the attempted reduction, the rolling
operation is feasible.
The contact length is given
= ( − )= 250(15 − 10) = 50
The true strain
∈= = 0.4
Yf is determined from the true strain:

275 ∗ 0.4 .
= = 208.42
1 + .15
Rolling force is determined from equation
= 208.42 ∗ 20 ∗ 160 = 666.95

Torque required driving each roll is given by
=0.5mm*666.95KN*160mm=53.35*106Nmm
Power obtained is,
P=2*3.14*50*53.35*106*160mm=2.68*1012Nm/min
7.3 Machining operation

7.3.1 Housing
1) Drilling operation
The housing have for standard holes used for insertion of shafts, for front wheel
(d=20mm), for foot pedal and handle assembly (d=24mm), for weight carrier
(d=20mm) and for pin (d=12mm). To drill them use the following analysis.
The mean cutting speed for drilling carbon steel is 17.5m/min with feed rate is
0.35mm/rev.
A) For 20mm diameter

17500 /
= = 278.66 /
∗ 20
The feed in turning is generally expressed in mm/rev
fr=Nf
fr= 278.66rev/min*0.35mm/rev= 97.53mm/min
The time to machine is given by
Tm=[10mm/(97.53mm/min)]=0.102min

B) For 24mm diameter
17500 /
= = 232.21 /
∗ 24
fr=Nf
fr= 232.21rev/min*0.35mm/rev= 81.27mm/min
Tm=[10mm/(81.27mm/min)]=0.123min
C) For 12mm diameter

17500 /
= = 464.43 /
∗ 12
fr=Nf
fr= 464.43rev/min*0.35mm/rev=162.55mm/min
Tm=[10mm/(162.55mm/min)]=0.06min.
7.3.2 Supporting plate

A) Drilling operation
The supporting plate has two holes at its end side with 12mm diameter
17500 /
= = 464.43 / .
∗ 12
The feed in turning is generally expressed in mm/rev.
fr=Nf
fr= 464.43rev/min*0.35mm/rev=162.55mm/min.
Tm=[10mm/(162.55mm/min)]=0.06min.
7.3.3 Shafts
A) Front wheel shaft and weight carrier
For simplicity of manufacturing process large diameter of the selected material is
machined on lathe by different process of machining. In order to gets the desired
diameter of the shaft using turning process. In turning, a cutting tool with a single
cutting edge is used to remove material from a rotating work piece to generate a
cylindrical shape. The speed motion in turning is provided by the rotating work part,
and the feed motion is achieved by the cutting tool moving slowly in a direction
parallel to the axis of rotation of the work piece.
1) Bar cutting
Bar cutting is the first step to be carried out on the shaft on reducing the shaft first
stage with power hack saw. It is necessary to determine the machining time will be
taken during bar cutting. The blank diameter of the part is 25mm with length of
139mm and the machining time
( . )
th= = = = 0.098
/
A=circumscribing cross sectional area (mm2)

As=specific cross sectional area (mm2/min)
2) Facing operation
The blank dimension of the part is diameter of 25mm and 139mm in length and the
main dimension is 134mm. The part needs 5mm to be machined with facing to bring
to the main dimension the light lathe machine. The mean cutting speed for 2mm
depth of cut for carbon steel from table …..is 125m/min with feed of 0.3mm/rev and
then spindle speed is
/
, = = 1592.3 /
∗
Where
N=rotational speed
V=cutting speed
Do=original diameter of the part,
fr=Nf, fr= 1592.35rev/min*0.3mm/rev= 477.7mm/min
Tm=2[139mm/(477.7mm/min)]=0.58min.
3) Turning machining time

The turning operation reduces the diameter of the work from its original diameter
Do to Df a final diameter Df, as determined by the depth of cut d:
, d=(Do-Df)/2=2.5mm
The metal to be removed in turning operation is 5mm and 2mm for one passes of
rough cut and 0.5mm for fine cut. The mean cutting speed for 2mm depth of cut for
carbon steel from table …..is 125m/min with feed of 0.3mm/rev
125000 /
= = 1592.3 /
∗ 25
fr=Nf, fr= 1592.35rev/min*0.3mm/rev= 477.7mm/min
, Tm=139mm/ (477.7mm/min)=0.29min.
B) Shaft for handle and foot pedal assembly

1) Bar cutting
The blank diameter of the part is 29mm with length of 139mm and the machining
time
( . )
th= = = = 0.098
/
2) Facing operation
The blank dimension of the part is diameter of 29mm and 139mm in length and the
main dimension is 134mm. The part needs 5mm to be machined with facing to bring
to the main dimension the light lathe machine. The mean cutting speed for 2mm
depth of cut for carbon steel is 125m/min with feed of 0.3mm/rev and then spindle
speed is
/
, = ∗
= 1372.73 /
Depth of cut d would be
, d=(Do-Df)/2=2.5mm
The feed in turning
fr=Nf, fr= 1372.73rev/min*0.3mm/rev=4 11.8mm/min
The time to machine
, Tm=2[139mm/(411.8mm/rev)]=0.674min.
3) Turning machining time
The turning operation reduces the diameter of the work from its original diameter
Do to Df a final diameter Df, as determined by the depth of cut d:
, d=(Do-Df)/2=2.5mm
The metal to be removed in turning operation is 5mm and 2mm for one passes of
rough cut and 0.5mm for fine cut. The mean cutting speed for 2mm depth of cut for
carbon steel from standard table is 125m/min with feed of 0.3mm/rev
125000 /
= = 1372.73 /
∗ 29
fr=Nf, fr= 1372.73 / *0.3mm/rev= 411.8mm/min
Tm=139mm/(411.8mm/min)=0.337min.
7.4 Metal drawing Operation

Metal drawing is a manufacturing process that forms metal work stock by reducing
its cross section. This is accomplished by forcing the work through a mold, (die), of
smaller cross sectional area than the work. This process is very similar to metal
extrusion, the difference being in the application of force. In extrusion the work is
pushed through the die opening, where in drawing it is pulled through.

7.4.1 Cylinder
The pre-material for precision steel tubes is selected, fully killed LD or electrical steel
cast continuously in slabs. It is first checked and then processed into hollow pre-
material tubes. The hollows are cold formed on state of the art drawing benches.
Subsequent heat treatment and passage through high-tech straightening and testing
benches complete the production process into cold drawn precision steel tubes.
7.4.2 Handle
Since metal drawing operations produce round or square shapes, hollow
profiles, particularly hollow round tubes of different lengths, diameters
and wall thicknesses are common in drawing production, and i select
handle of the jack to manufacture with this method. Production of drawn
shapes and hollow tubes is usually performed on a draw bench and would
be classified in the rod and bar category of operations. The specifics of the
metal deformation are important when drawing different cross sections.
When forming a handle a mandrel may not be used. Since its internal
dimensions are not critical. It is often required that hollow tubes hold
certain tolerances on internal diameter and wall thickness. For that
reason, mandrels are often employed.
7.5 Cold working
7.5.1 Spring
Springs are manufacturing by hot or cold working process depends up on

the size of the material the spring index and properties desired. In general
pre- hardened wire should not be used if D/d ≤4 or if d≥1/4in. winding the
spring induces residual stress through bending but these are normal to the
direction of the torsion working stress in coil spring quite frequently in

spring manufacture they are relived after winding by mild thermal
treatment.
7.6 Forging
7.6.1 Pin
To manufacture pin, upsetting type of forging process is selected. Heading or upset
forging is a process by which stock, (typically cylindrical), is upset at its end in order
to increase the cross section of the material in this area. The process is hot, but often
a cold working operation will be held on, which will take advantage of the
strengthening of the material in the region worked. Heading is performed
horizontally, as shown in the diagrams. The impression in the head may be forged in
the punch, the die, or both.

CHAPTER EIGHT
ASSEMBLY AND MAINTANANCE PROCESS
8.1 Safety precautions
 A load must never exceed the rated lifting capacity of the jack.
 Only use the jack on a hard, level surface.
 Use the jack for lifting purposes only. Stay clear of a lifted load. Place
support stands under the axles before working on the vehicle.
 Center the load on the jack saddle. Off-center loads can damage seals and
cause jack failure. Lift only dead weight.
 Do not use blocks or other extenders between the saddle and the load
being lifted. Do not modify the jack or use adapters unless approved or
supplied.
 Lower the jack slowly and carefully while watching the position of the jack
saddle
8.2 Operating instruction

 Position the jack under the vehicle using the manufacturer’s recommended
lifting points on the chassis.
 Close the release valve by shifting the control lever up and clockwise
toward the upper notch. Pump the foot pedal to raise the saddle to the
contact point.
 Check the placement of the jack; the load must be centered on the jack
saddle. Avoid wheel obstructions such as gravel, tools, or uneven expansion
joints. The jack must be free to roll forward during lifting and backward
during lowering. The load could become unstable, or even fall off the
saddle, if the rolling movement of the jack is impaired.
 Finish lifting the vehicle by pumping the handle. Do not attempt to raise the
jack beyond its travel stops.
 Place approved support stands under the vehicle at points that will provide
stable support. Before making repairs on the vehicle, lower it onto the

support stands by unhooking the control lever from the upper notch and
lowering it to the lower notch
8.3 Maintenance process

 The service jack will be cleaned and well lubricated to prevent foreign
matter from entering the system. If the jack has been exposed to rain,
snow, sand, or grit, it must be cleaned before it is used.
 Store the jack in a well-protected area where it will not be exposed to
corrosive vapors, abrasive dust, or any other harmful elements.
 Lubricate rotating and sliding parts at least once per month. Lubricate the
air inlet on the jack.
 Grease the jack once a month using good bearing grease. (These are grease
fittings located on the pivot tube of the weight carrier, the block on the rod
end of the cylinder, and on all four wheels of the jack.)
 Keep warning labels and instructional decals clean and readable. Use a mild
soap solution to wash the external surfaces of the jack.
 Inspect the jack before each use. Take corrective action if any of the
following problems are found
 Cracked or damaged housing
 Excessive wear, bending, or other damage
 Scored or damaged piston rod
 Loose hardware
 Modified or altered equipment
8.4 Assembly process

 Assemble the two handle halves together by depressing the spring-loaded
button on the knurled handle section and inserting the upper handle
section into the lower section. The spring-loaded button should engage
with the hole in the lower handle section.
 Grease the inside of the handle yoke and remove the handle set screw.
 Install the handle assembly in the handle socket until the bottom of the
handle engages with the universal joint assembly.
 Reinstall the handle set screw in the handle socket making sure the screw
secures the handle to the handle socket. Tighten the screw.
8.5 Troubleshooting
1) Jack will not lift load
 The release valve is not closed. Turn the valve clockwise tightly. If this does
not work, remove handle, lubricate handle receptacle and handle end, then
retry.
 Compressor seals may be defective. Clean compressed air passages and
replace seals.
 Make sure jack is on level surface. Open release valve and step on saddle.
Force it to lower as rapidly as possible. Repeat this operation three or four
times. This procedure will thoroughly flush the valves and assure complete
distribution of air.
 Release valve may be held open by dirt on seat. Flush by pulling lifting arm
up and down several times while release valve is open. If necessary, the
release valve may be removed for cleaning the valve and valve seat.
2) Jack will not lift to its full height

 Low on pressurized entering air and may be leakage of compressed air.
 The overload valve is factory adjusted for the jack to lift 3 tons load and
should not be altered.
3) Jack will not lower completely

 Return spring is broken or linkages are binding. Replace spring if broken.
Grease pivot shaft and all lift arm linkages
 It may need lubrication. Clean and oil all moving parts in the lifting arm
mechanism.

4) Jack will not hold load or handle rises
 Discharge ball is not sealing air system. Open the release valve, as required,
to raise and lower the lift arm. Manually raise and lower lift arm.
 The release valve may be held open by dirt on ball seat. When a dirty
release valve or ball seat exists, the jack may lower quickly, causing handle
to fly back with force.

CHAPTER NINE
COST ESTIMATION
9.1 Cost estimation methodology
The main elements of cost are material, labour, energy, tooling and overheads. These
are primarily driven by product and process parameters. The metal and part weight
forms the basis of material cost. Process planning data in terms of
process/equipment used and hours required for each activity forms the basis of
labour cost. Energy cost is estimated based on the weight, yield, pouring
temperature and melting equipment. Tooling cost is the most difficult to estimate,
and a parametric approach has been evolved for this purpose. Overheads are
assigned based on weight. Cost modifiers have been proposed to incorporate the
effect of losses/rejections at different stages of production. They also help in
customizing the program for a specific foundry, and correcting the results for
different types of operation. The total cost is given as the sum of costs corresponding
to material, labour, energy, tooling and overheads.
= + + + +
Other costs related to interest rate, fixed cost, delivery, taxes; duties and premium
can be added. These elements are not considered in the present work, which focuses
only on manufacturing cost driven by product design. Also the energy cost, tooling
cost and overhead cost cannot be analyzed in this project for the jack. For estimation
of costs related to material, labour, and standard selected parts are presented in the
following subsections. The equations are generalized for any currency, that is, the
cost values will be obtained in the same currency.
9.2 Material cost

The material cost involves both direct and indirect materials. Direct materials appear
in the final product whereas indirect materials are essential for production but are
not included in the final product. Moulding sand, dispensable cores, insulating
sleeves, chills etc. are indirect materials. The direct material cost can be determined
from the casting weight. However, the actual amount of metal consumed is more
than the weight of manufactured castings, owing to irrecoverable losses during
melting, pouring and fettling. The basic metal cost equation has been modified to
incorporate these factors. Since rejected castings (defective castings that cannot be
repaired) are re-melted, the factor for rejection is not considered in direct material
cost equation.
Table 9.1 Direct material cost

Part Part qua Type Form Size Unit Birr/kg Cost
no. name ntit specificatio weight(g)
y n
ASJ1 Saddle 1 Gray cast Cast 460.4 41 18.88

iron
ASJ2 Saddle 1 Gray cast Cast 536.05 41 22

holder iron
ASJ3 Weight 2 Gray cast Cast 2918.1 41 119.65

carrier iron
ASJ4 Supporti 2 Carbon Machini (260x20x10 820 38 31.16

ng plate steel ng )mm3
ASJ5 Power 1 Gray cast Cast 224.79 41 9.25

piston iron
ASJ6 Compres 1 Gray cast Cast 67.4 41 2.75

sor iron
piston
ASJ7 Block 1 Gray cast Cast 8535.1 41 349.9

with iron
compres
sor

ASJ8 Handle 1 FeE250 Metal Ф30x1000m 1707.5 28 47.85
drawing m
ASJ9 Foot 1 Gray cast cast 338.244 41 13.86

pedal
ASJ10 Handle 1 Gray cast cast 903.5 41 37.05

socket iron
ASJ11 Pin 6 Mild steel Forging Ф24x192m 681.5 27 18.4

m,
ASJ12 Shaft 3 40C8 Machini Ф25x139m 1976.24 38 75.2

ng m,
Ф29x278m
m,
ASJ13 Saddle 1 AISI4340 Cold 383.00 28 10.7

spring Alloy steel working
ASJ14 Compres 1 AISI 4340 Cold 335.9 28 9.4

sor Alloy steel working
spring
ASJ15 Housing 2 Carbon machinin (900x170x1 36031.5 38 137

steel g 5)mm3
ASJ16 cylinder 1 AISI 1015 Metal 1509.15 22 33.2

drawing
Total 936.25
Indirect materials depend on the process. The moulding sand and core sand
constitute the main element of indirect material cost. The cost of moulding sand
depends on the type of sand (silica, olivine, zircon, sodium silicate, etc.), composition
(amount of binder), mould box size and layout. Core sand cost mainly depends on
the type of sand (represented by the core-making process) and volume of cores. Cost
modifiers for mould rejection, core rejection, casting rejection and sand reclamation
have not considered for this project.
9.3 Labour cost

The labour cost is a function of equipment, labour and time required for various
activities in casting production. This information is contained in the process plan.
Some of the activities such as melting, sand preparation and shakeout, are
performed for a batch. The time per component for these activities has been
calculated based on casting weight, core weight, mould weight and number of
castings, respectively.
Table 9.2 Direct labour cost
No. Operation Time (hr) Rate (birr/hr) Cost (birr)
1 Machining 3.43 19 65.17
2 Rolling 2 18.7 37.4
3 Forging 0.27 17 5
4 Metal drawing 2 14.55 29.1
5 Cold working 3 16.05 48.15
6 Pattern making 33 19.85 655.05
7 Molding, melting, 17 15.67 266.39

finishing.
8 Welding 0.75 16.25 12.18
9 Heat treatment 8 14.07 112.56
Total 1231.00

9.4 Direct cost of standard material
Table 9.3 Direct Standard part selected cost estimation
Part name Specification Quantity Unit price (birr) Total cost(birr)
Bolt M6x1 4 19 76
M8x1 6 24 144
Washer 6mm dia. 4 2.85 11.4
8mm dia. 6 3.26 19.56
22mm dia. 2 4.42 8.84

33mm dia. 2 4.97 9.94
Piston seal 57mm dia. 1 4.75 4.75
17mm dia. 1 2.35 2.35

Gasket 77mm dia. 1 133 133
Caster wheel 33mm dia. 2 57 114

assembly
Front wheel 74mm dia. 2 110 220

assembly
Nut M24x1.5 2 6 12
M16x1.5 2 5 10
DCV assembly (spring 6mm dia. 3 18 54
ball)
Total 819.84
9.5 Total Direct Cost

Table 9.4 Total cost estimation
No. Type Cost(birr)
1 Material cost 936.25
2 Labour cost 1231.00
3 Standard part cost 819.84
Total 2987.09

CHAPTER TEN
CONCLUSION AND RECOMMENDATIONS
10.1 Conclusion
Air service Jacks are the ideal product to push, pull, lift, lower and position loads of
anything from a couple of kilograms to three ton. The need has long existed for an
improved portable jack for automotive vehicles. It is highly desirable that a jack
become available that can be operated at different area for lifting application.
Such a jack should desirably be light enough and be compact enough so that it can be
stored in an automobile, can be lifted driven and carried by most adults to its
position of use, and yet be capable of lifting a wheel of a three ton pound
vehicle off the ground. Further, it should be stable and easily controllable so that
jacking can be done from a position of safety. It should be easily movable either to a
position underneath the axle of the vehicle or some other reinforced support surface
designed to be engaged by a jack.
Thus, the product has been developed considering all the above requirements.
This particular design of air service jack will prove to be beneficial in lifting and
lowering of loads.
10.2 Recommendations
The service jack lifting power will depend on the amount of compressed
air enters to the power unit part, so in order to protect the service jack
from failures it is recommended to check the pumping system every time
before using for application of the service jack.
Since the jack has movable links, within sometime of period maintenance
will recommended. Lubricating the parts of pins, casters and wheels will
helps to improve the service jack operation.

References
 Budynas, Richard G. (2008), Standard Handbook of Machine Design Shigley’s,
8th ed.
 Richard G. Budynas, J. Keith Nisbett. (2008), Mechanical engineering design,
9th Ed.
 Shigley, CharlesR. Mischke(2009), Standard hand book of machine design , 2nd
ed.
 Vinogradov, Oleg (2006), Fundamentals of kinematics and dynamic of
machines and mechanisms , by Oleg Vinogradov. Pp.
 Moran J., Shapiro N.M (2006), Fundamentals of engineering thermodynamics,
5th ed. Wiley press.
 Borgnakke_Sonntag(2003), Fundamentals of Thermodynamics ,6th ed. Team
Tolly printing press.
 Frontmatter(1999), Mechanical Engineering Handbook Ed. Frank Kreith Boca
Raton: CRC Press LLC,
 Crowe, C. T. (Clayton T.) Engineering fluid mechanics, 9th ed.
 Groover, Mikell P, Fundamentals of modern manufacturing: materials,
processes and systems, 4th ed.
 Ullman, D.G. (1997), The Mechanical Design Process, McGraw-Hill.
 McGraw-Hill,( 2005).Advanced Machining Processes.
 Taylan Altan, Gracious,Cold and hot forging : fundamentals and applications .
 Wiley,(2007), Callister Engineering Material 7th ed.
 http//:www.google.com
 http://thelibraryofmanufacturing.com/metal_drawing.html

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CHAPETR ONE

In light of such inherent disadvantages, commercial automobile repair and

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 1

1.3 Scope and Significance of the project

 3 ton maximum lifting capacity of air service jack

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 2

1.4 Statement of the problem

1.5 Literature review

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 3

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 4

The farm jack is characterized by rugged, simple construction. It comprises a steel

1.6 Methodology for the Design

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 6

When we say mechanism it means that, is a device designed to transform input

2.1 Lifting mechanism

2.2 Supporting mechanism

2.3 Driving mechanism

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 8

2.4 Pressurizing mechanism

Figure 2.2 The assembly of compressor, reversing and pressurizing mechanism

The absolute pressure exerted by a given mass of an ideal gas is inversely

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 9

PV=K whereas K=kNT

 P is the pressure of the gas,

2.5 Controlling mechanism

2.6 Balancing mechanism

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 10

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 11

Figure 3.1 geometry of weight carrier

Now we can calculate

(H-y)- (h-y) = l1sin Θ+l1sin α

l1= (H-y)-(h-y)/ (sin Θ+sin α)

Also using the given design information of the design given

 Maximum height= 460mm

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 13

By iterating the values of l1, l2 & X

Table 3.1 iteration for angle and length of weight carrier

From the above iteration we can summarize

Using sine law we can find the values of the angles β,

L2 /sin 15=l1 /sin β

From this equation the values of β

β = Sin-1{(274.64/137.32) sin 15o}

Figure 3.2 analysis of weight carrier dimension

By substituting the values the force will be

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 15

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 16

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 17

4.1 Force analysis of saddle holder

Assuming L=65mm , α= 35o

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 18

The lifting arm has the following three critical positions

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 19

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 20

Case 2: when θ=0o

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 21

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 22

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 23

The force created inside the compressor is the result of the

From Pascal’s law the pressure created in the compressor is

Mathematically, P1=P2 and P=F/A

dc= diameter of small piston the (compressor)

Lc= length of the piston of the compressor

Tesfaye Olana (2014) ADAMA SCINCE AND TECHNOLOGY UNIVERSITY 25