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Table of contents

list of figures ……………..........……………….......................................................... 03

Abstract …………………………………..…………………………………………. 04
Introduction ………………………………..………………………………………... 05
Material selection …………………………..……………………………………….. 05
Cylinder tube ………………………………..……...…………………….…………. 05
Piston rod ……………………………………..……………………………………... 07
The whole other parts ………………………..……………………………………… 08
Calculations …………………………………..……………………………………... 08
Force acting on the cylinder ……………………………........……..……………….. 09
Calculating 𝐹𝑚𝑎𝑥 with MATLAB …………………….………..……………………. 13
Hydraulic cylinder design …………………………………………..………………. 14
References ……………………………………………………………..……………. 16
External links ……………………………………………………………..………… 16
Appendix ……………………………………………………………………..……... 17
2D drawing ………………………………………………………………………..… 18
Redering …………………………………………………………………………..… 19

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list of figures

Figure 1 …………………………………………………………………………….. 06
Figure 2 …………………………………………………………………………….. 07
Figure 3 …………………………………………………………………………….. 09
Figure 4 …………………………………………………………………………….. 09
Figure 5 …………………………………………………………………………..… 10
Figure 6 …………………………………………………………………………….. 11
Figure 7 …………………………………………………………………………….. 12
Figure 8 …………………………………………………………………………….. 13
Figure 9 …………………………………………………………………………….. 16

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Abstract
The goal of this study was to apply the knowledge obtained from studying in the
university and solve the substantial task of creating a design of a hydraulic cylinder in a
scissors lifting platform.
To verify the validity of the theory, the practice work was accomplished. The selection of
the material and calculations of the loads and stresses were performed and explained. As
the result of the work the 3D & 2D models of the hydraulic cylinder was created using
Autodesk inventor.

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Introduction
The most common industrial scissors lifts are actuated by one, two, or three single-acting
hydraulic cylinders. These allow the lift table to lift and lower.
The hydraulic lift was chosen as a subject of the thesis because it is a perfect example of
mechanical engineering field. This mechanism combines a result of several main fields of
engineering and at the same time, it is simple and accessible for understanding. The
construction and load distribution represent statics and strength of material subjects, the
hydraulic cylinder and the control unit involve knowledge of hydraulic systems and
automation. Material science is important for selection of a suitable material as well as
knowledge of 3D modeling.
Also, scissors lift is an integral part of most of the workshops and building objects. The
key advantage of lifts is that they even offer the best way to organize a technological and
industrial process. Besides, almost all lifts give the possibility to change the place of their
installation without much effort, which is important in the frequently changing conditions
in the production process these days.

Material selection
The choice of materials in engineering design is a key factor to engineers. More than
40,000 to 80,000 materials are available to pick from when designing (Ashby, 1992, p. 1).
Therefore, in order to make the best product from the available materials, proper
consideration of what is expected of the design while its function, cost, environmental
implication, ethical consideration should be in mind.

Cylinder tube
The cylinder tube should has as much as possible of these properties:
• Wear resistance
• Corrosion resistance
• Lightweight
• Machinability
• Low cost

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 Figure 1
Having carefully discussed the properties, advantages and disadvantages of the possible
materials, it is only imperative to choose one. Properties of a material such as its density,
young’s modulus, strength and cost define a material (Ashby, 1992 p. 56).
On the above basis, ductile cast iron grade 60-40-18 is chosen as the material for the
cylinder tube production.
Advantages:
• It is very cheap as compared to stainless steel and titanium.
• It has a density lower than that of stainless steel.
• It has a superior surface finish
• Ductile cast iron has a low cost of fabrication
Disadvantages:
• It has limited use in salt water.
• It is difficult to weld and solder
• In acidic environment, ductile cast iron cannot be used.

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Piston rod
The piston & rod should have as much as possible of these properties:
• Ability to withstand high temperatures
• Resistance to crack (fracture toughness)
• Wear resistance
• High stiffness as piston moves toward and forward
• Light weight
• Low cost
• Easily available
• Minimum environmental impact

Figure 2
Nickel-Chromium Alloy Inconel 600 UNS N06600 BS 3075 has excellent corrosion
resistance and good mechanical strength. It has a density of about 8.3-8.5 g/cm3 while a
kilogram cost 14.3-15.8 GBP. Nickel-Chromium alloys have compressive strength of 365-
460 MPa and young’s modulus 150-200 GPa.

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Advantages:
• High tensile strength
• Resistance to a wide range of corrosive media
• Environmentally friendly
• Good weldability, machinability and formability
Disadvantages:
• It is very expensive

The whole other parts

The main interest is made by the legs of the lift, the greatest part of loading is shared
between them and they are a basic element of the assembly. It means that the material of
which they are made has to be capable of maintaining this load. This part is subjected to a
normal force which might cause buckling and shear force which cause bending, which
possibly cause bending deformation or even braking of the part. Then such properties as
strength, hardness, and stiff-ness are needed.
There are also such components as top plates and base plates. The top plates take the load
caused by a weight of lifting goods. The main needed property here is strength and the
selected material is mild steel. The base plates are subjected to the weight of the load and
scissors mechanism itself – cylinder and legs, hence, hardness and stiffness are required.
Ductile cast iron is appropriate for all these parts.

Calculations
The calculations of forces, stresses, and reactions of the structure play the most important
role in the design because on the result of these calculations and its correctness depends
stability, safety and successful work of the whole mechanism. The lifting table is a
dynamic mechanism, but the speed of acting is relatively low, so this fact can be neglected
and this system can be concerned as static. Then only two positions are needed to be
considered, they are the initial position when the lift is lowered and just lying on the floor,
and the highest position, when the mechanism lifted a weight on the highest possible
distance. In these two positions, the highest reactions and internal forces are observed. In
all the other positions the results will be between the two mentioned above.

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Force acting on the cylinder
Lowest position
While calculation it is important to understand the behavior of the structure. For this, the
simplified picture is used to focus on the main acting forces. Here is the free body diagram
on Figure 3

Figure 3
Obviously, whatever is happening inside the system the sum of reactions 𝐷𝑦 and 𝐶𝑦 would
be equal to the weight. Then vertical reactions of D and C are half of the weight of the
main load plus the weight of legs.
W+ 𝑊𝑙𝑒𝑔𝑠
𝐶𝑦 = 𝐷𝑦 = 2

Then the free body diagram is drawn for each leg separately on Figure 4 𝐹𝑦 and 𝐹𝑥 are the
components of F force acting on the pin, it is better to decompose it right now because its
value and direction are not known yet.
𝐿𝑋
Cos α = 𝐿
𝑃𝑋
Cos β = 𝑃

Figure 4

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Then, using the diagram on Figure 3, it is needed to consider a balance of forces in Y and
X directions and also the balance of moments created by the action of forces. It is done
only for AC, but there will be an identical result on DB because dimensions are the same.

Figure 5
Σ𝐹𝑜𝑥 = 0
𝑃𝑥 - 𝐹𝑥 = 0
𝐹𝑥 = P cos β

Σ𝐹𝑜𝑦 = 0
𝑤 𝑊𝑙𝑒𝑔𝑠 𝑊+𝑊𝑙𝑒𝑔𝑠
− 2 + 𝑃𝑦 - 𝐹𝑦 - + =0
2 2

𝐹𝑦 = P sin β

Rotating around point C, CCW is positive direction:

Σ𝑀𝑐 = 0
𝑊𝑙𝑒𝑔𝑠 𝐿 𝑤 𝐿 𝐿 𝐿
. 2 Cos α + . L Cos α - P sin β (2 + a) cos α + 𝐹𝑦 2 Cos α - P cos β (2 + a) sin α + 𝐹𝑥
2 2
𝐿
sin α = 0
2

After simplifying the equation »

𝑤 𝑊𝑙𝑒𝑔𝑠
𝐿 cos 𝛼 ( + )
2 4
P= 𝑎 . sin(𝛼+ 𝛽)

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Highest position
On Figure 6 the free body diagram for the highest position of the lift is shown:

Figure 6

Σ𝑀𝑐 = 0
𝐴𝐵
w . d + 𝑤𝑙𝑒𝑔𝑠 - 𝐷𝑦 . AB = 0
2

𝐷𝑦 = 1.23 w + 0.5 𝑤𝑙𝑒𝑔𝑠

Σ𝐹𝑜𝑦 = 0

𝐷𝑦 - 𝐶𝑦 - 𝑤𝑙𝑒𝑔𝑠 – w = 0

𝐶𝑦 = 0.23 w – 0.5 𝑤𝑙𝑒𝑔𝑠

According to the behavior of the legs: 𝐶𝑦 = - 𝐵𝑦 , 𝐷𝑦 = - 𝐴𝑦 for the free body diagrams of
the legs in the highest position which is shown on Figure 9.8. Cal-culations are done only
for AC, but there will be an identical result on DB because dimensions are the same.

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 Figure 7
Σ𝐹𝑜𝑥 = 0
𝑃𝑥 - 𝐹𝑥 = 0
𝐹𝑥 = P cos β

Σ𝐹𝑜𝑦 = 0
𝑤𝑙𝑒𝑔𝑠
-𝐷𝑦 + 𝑃𝑦 - 𝐹𝑦 - – 𝐶𝑦 = 0
2

𝐹𝑦 = P sin β – 1.46 w – 0.5 𝑤𝑙𝑒𝑔𝑠

Rotating around point C, CCW is positive direction:

Σ𝑀𝑐 = 0
𝑤𝑙𝑒𝑔𝑠 𝐿 𝐿 𝐿 𝐿
. 2 cos α + 𝐷𝑦 L cos α - P sin β (2 + a) cos α + 𝐹𝑦 2 cos α - P cos β (2 + a) sin α + 𝐹𝑥
2
𝐿
sin α = 0
2

After simplifying the equation »

𝑤 𝑊𝑙𝑒𝑔𝑠
𝐿 cos 𝛼 ( + )
2 4
P= 𝑎 . sin(𝛼+ 𝛽)

So, this formula can be used for calculating the force in the cylinder in any position.
The next step now in the calculations is calculating the maximum force on the hydraulic
cylinder which has been calculated using MATLAB.

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M-File
clc;clf;clear;
%A=alpha "angle of links"
%B=Beta " angle of hydraulic cylinder"
A=linspace(5,66,1000);B=linspace(13,72,1000);
Wlegs=80*10;%80 Kgs * 10 (N)
W=1000*10; % 1 Ton * 10 (N)
L=1.3;a=linspace(0.244,0.082,1000);
P=(L*cosd(A).*(W/2+Wlegs/2))./(a.*sind(A+B));
plot(A,P);
xlabel ('Angle(A)');
ylabel ('Force(F_c_y)');
title ('Force & Angle function');
grid on;
Fcy= max(P)

Command window
Fcy =

9.2749e+04

Figure 8

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For the final step and most important in that report, designing the hydraulic cylinder

Hydraulic cylinder design

𝑃𝑚𝑎𝑥 = 20 MPa, 𝐹𝑚𝑎𝑥 = 92749 N

For the piston diameter,
𝜋
𝐹𝐶𝑌 = 4 𝐷2 𝑃𝑚𝑎𝑥
𝜋
92749 = 4 𝐷2 * 20

D = 76.84 ≅ 80 mm

For the thickness of the tube,

Assume thin cylinder
𝑃𝐷 𝑆𝑦
𝜎𝑚𝑎𝑥 = ≤ 𝐹.𝑂.𝑆
2𝑡
20∗80 276
≤
2𝑡 2

t = 6 mm
𝑡 6
check » 𝐷 = 80 = 0.075 < 0.1 OK

For rod,
First, compression:
−𝐹 𝑆𝑦
𝜎𝑐 = ≤ 𝐹.𝑂.𝑆
𝐴
−92749 400
𝜋 2 ≤
𝑑 2
4

d = 24.3 ≅ 25 mm
Second, buckling:
L = 374 mm, C = 2 “fixed hinged”
Assume Euler
𝑃
𝑐𝑟
F = 𝐹.𝑂.𝑆
𝑃𝑐𝑟
92749 = 2

𝑃𝑐𝑟 = 185498 N

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 𝜋
𝐼 𝑑4 𝑑
K = √𝐴 = √64
𝜋 =4
𝑑2
4

𝐿 4𝐿
=
𝐾 𝑑

𝐶𝜋 2 𝐸𝐴
𝑃𝑐𝑟 = 𝐿2
𝐾

𝜋
2∗𝜋 2 ∗160∗103 ∗ 𝑑4
4
185498 = 16∗3742

d = 20.22 mm
check if short or long column »

𝐿∗ 2 𝜋2 𝐶 𝐸 2∗𝜋 2 ∗2∗160∗103
=√ =√ = 125.66
𝐾 𝑆𝑦 400

𝐿 4𝐿 4∗374
𝐾
= 𝑑
= 11.2
= 73.98
𝐿 𝐿∗
< 𝐾 , then use Johnson
𝐾
𝐿
𝑃𝑐𝑟 𝑆𝑦 ∗ 1
= 𝑆𝑦 - ( 𝐾
)2 * 𝐶 𝐸
𝐴 2𝜋
185498 400∗4∗374 2 1
= 400 - ( ) * 2∗160∗103
𝜋 𝑑2 2𝜋𝑑

𝑑𝑟𝑜𝑑 = 25.7 ≅ 26 mm , Take 𝑑𝑟𝑜𝑑 = 28 𝑚𝑚 standards.

For bolts,
Assume the bolts are reused,
𝐹𝑖 = 0.75 𝑆𝑏 𝐴𝑏
𝐹𝑏 = 𝐹𝑖 + K 𝐹𝑒 𝑛𝑓 ≤ 𝑆𝑦 A
𝑃 𝐴𝑐𝑜𝑣𝑒𝑟
𝐹𝑏 = 0.75 𝑆𝑏 𝐴𝑏 + K 𝑛𝑓 ≤ 𝑆𝑦 A
𝑁
𝜋
𝜋 2 20 202 𝜋
0.75*310*4 𝑑𝑏 * + 0.3 * 4
* 2 ≤ 340 * 4 𝑑𝑏 2
𝑁
714.7
≤ 𝑑𝑏 2
𝑁

Assume 𝑑𝑏 = 16 mm "M16",
N = 2.8 ≅ 4 bolts
Check for separation »
Assume hard copper gasket

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Stiffness ”K” = 0.3 from tables
𝐹𝑖 > (1 - K) 𝐹𝑒 𝑛𝑓
𝜋
𝜋 20 202
0.75*310*4 𝑑𝑏 2 > (1 – 0.3) 4
*2
𝑁
770.77
𝑑𝑏 2 > 𝑁

Assume 𝑑𝑏 = 16 mm "M16",
N = 3.01 ≅ 4 bolts
Setting up the bolts in order:

Figure 9

References
- Ashby M.F (1992) Materials Selection in Mechanical Design

External links
- http://www.iron-foundry.com/60-40-18-ductile-iron-400-12-cast-properties.html
- http://www.nickel-alloys.net/nickel_chrome_alloys.html
- https://www.hpalloy.com/Alloys/descriptions/INCONEL600.aspx
- http://www.westfieldfasteners.co.uk/Ref_Strength_Spec.html

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Appendix

Legs of the left: Cast Iron

- yield strength = 355 MPa
Cylinder: Ductile cast iron grade 60-44-18
- yield strength = 276 MPa
Rod and piston: Nickel-Chromium Alloy
- yield strength = 400 MPa
- Young's Modulus = 160 GPa
Top plates and base plates: Ductile cast iron grade 60-44-18
- yield strength = 276 MPa
Bolts and gasket: Medium carbon steel
- Proof strength = 310 MPa
- yield strength = 340 MPa
- Stiffness ”K” = 0.3 - assume hard copper gasket –
Any missing data is calculated from Inventor or MATLAB

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