DESIGN OF ROCK CRUSHER

DIRE DAWA UNIVERSITY

INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICHAL AND

INDUSTRIAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
SOLID MECHANICS AND DESIGN CHAIR
4th year Mechanical Engineering

PROJECT: DESIGN OF ROCK CRUSHER

PREPARED BY:- MINTESNOT TADELE……………………R/1469/09
MEDINA ABDULAH ……………………...R/0442/09
TEBAREK ABDLHAFIZ…………………..R1744/09
BENYAS MOLA……………………………R/0713/09
MEKLIT ABERA…………………………..R/1110/09

Submitted to :AREGA

Submission Date: 30/9/2011

 ACKNOWLEDGMENT

We would like to acknowledge first our classmate students those help us by sharing
designing material like text book and soft copy, and those who share idea with us for what
we are going to do. The other person that we would like to acknowledge is our previous
Machine Elemenet teacher Mr yared seyfu.

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ABSTRACT
This project work deals with a detailed study and design procedure of Impact Rock crusher. A
crusher are one of the main equipment used for reducing large rocks into smaller rock , gravel or
rock dust. They exist in various sizes and capacities which range from 30 tons/hr. to 1000
tons/hr. They can be classified based on the degree to which they can fragment the starting
material and the way they apply forces. Based on the mechanism used crushers are basically of
three types; namely, Cone crusher, Jaw crusher, and Impact Crusher. The main objective is to
design Impact rock crusher it involves the use of impact rather than pressure to crush materials.
The material is held within a cage, with openings of the desired size at the bottom, end or at sides
to allow crushed material to escape through them. Impact stone crusher is used with soft
materials, medium to hard stones and medium hard metallic ores. The principles used for impact
loading is the time for the natural frequency of the body is much greater than with the time for
applying force on materials. Since the hammer is rotating at a very high speed, the time for
which the particles come in contact with the hammer is very small, hence impact loading is
applied. The shaft is considered to be subjected to torsion and bending.

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 TABLE OF CONTENT

TOPIC PAGE
CHAPTER

Impact rock crusher

1. INTRODUCTION……………………………………………………………………………………….6

1.1 Hydraulic bottle jack……………………………………………….……………..…….11

1.2 Definition…………………………………………………………….……..........................11

1.3 Operating principle…………………………………………………..………………….13

1.4 Operating instruction………………………………………………..………………….14

1.5 Input parameter……………………………………………………………………………15

1.6 Main components of hydraulic bottle jack……………..………………………16

1.7 Factor of safety……………………………………………………………………… …….17

1.8 Machine design procedure…………………………………………………………….17

CHAPTER 2

SELLECTION OF HYDRAULIC OIL

2. Introduction…………………………………………………………………………………………..…….19

2.1. Function of hydraulic oil……………………………………………….…………………..………..19

2.2. Composition of hydraulic fluid……………………………………….……………………………20

2.3. Brake fluid………………………………………………………………………..………………..………20

2.4. Biodegradable fluid………………………………………………………..……………………..….…21

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2.5. Selection of hydraulic oil for bottle jack……………………………………..……….22

2.6. How to add oil…………………………….……………………………………………………..22

CHAPTER 3

BOTTLE JACK DESIGN

1. INTRODUCTIN…………………………………………………………………………….23

1.1. Material selection………………………………………………………………23

1.2. Force analysis……………………………………………………………………23

1.3. Pressure distribution……………………………………………………..…..24

1.4. Pressure range selection…………………………………………………….25

1.5. Stress analysis…………………………………………………………………...26

1.5.1. Design of extension screw………………………………………….…26

1.5.2. Design of nut & cup screw……………………………………………..30

i. Design of nut………………………………………………...……..30

ii. Design of cup…………………………………………………..…..31

1.5.3. Design of solid and hollow ram……………………………………..32

i. Design of solid ram………………………………………………...32

ii. Design of hollow ram……………………………………………...35

1.5.4. Design of pump cylinder……………………………………………….38

1.5.5. Design of reservoir…………………………………………..…………..41

1.5.6. Design of plunger & stroke calculation…………………….…….43

i. Design of plunger……………………………….…….………43

ii. Stroke calculation……………………………..…….……….45

1.5.7. Design of top cup, second stage & base………………..…….………..……46

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 i. Design of base……………………………………………………..….46

ii. Design of second stage ram…………………….….………….…47

iii. Design of top cup………………………….………………….……...49

1.5.8. Design of handle, & socket ( for pump, links &pins @ plunger & links)
…………………………………………………………………………….………....51

i. Design of handle & socket for pump…………………….………..….….51

ii. Design of handle socket…………………………….………….………….….52

iii. Design of handle socket pin……………………….………..……….………52

1.5.9. Design of spring for@ discharge valve………………………..…….…………..54

1.5.10. Design of valves………………………………………………………………………..…57

i. Design of boll @ discharge valve………………………..….………..……57

ii. Design of spring for relief valve…………………………………….….…..58

iii. Design of ball for relief valve………………………..……………….….…..60

1.5.11. Design of O-ring seals (for pump piston/cylinder, hollow & solid
ram…………………………………………………………….……………….……………….75

i. O-ring for pump…………………………………………….…………….….…..75

ii. O-ring for hollow ram…………………………….…………………….,,,,,…75

iii. O-ring for solid ram plunger……………………………….……….,,,,,….75

1.5.12. Design of releasing screw……………………………………………...………………75

1.5.13. Design of refilling screw………………………………………..…………………..….75

CHAPTER 4

HOUSING DESIGN FOR HYDRAULIC BOTTLE JACK

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4.1. Introduction …………………………………………………………………………...………….……76

4.2. Function of housing …………………………………………………………………..………….….76

4.3. Material selection for housing……………………………………………………………………77

CHAPTER 5

MANUFACTURING PROCESS……………………………………………………………………....…79

CHAPTER 6

ASSEMBLY AND DISASSEMBLY PROCEDUR………………………………………………..79

Chapter 7

Cost estimationS………………………………………………………………82

6.1. Assembly procedure………………………………………………….………..……………………….83

6.2. Disassembly procedure……………………………………………………..……………….…..…….84

APPENDIX……………………………………………………………………………….……………..…………85

.REFERANCE AND RETERATURE…………………………………………………………..…………..98

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 CHAPTER1

ROCK CURSHER

1. INTRODUCTION
A crusher is a machine designed to reduce large rocks into smaller rocks, gravel,
or rock dust. Crushers may be used to reduce the size, or change the form, of waste
materials so they can be more easily disposed of or to reduce the size of a solid mix of
raw materials (as in rock ore), so that pieces of different composition can be
differentiated. Crushing is the process of transferring a force amplified by mechanical
advantage through a material made of molecules that bond together more strongly, and
resist deformation more, than those in the material being crushed do. Crushing devices
hold material between two parallel or tangent solid surfaces, and apply sufficient force
to bring the surfaces together to generate enough energy within the material being
crushed so that its molecules separate from (fracturing), or change alignment in
relation to (deformation), each other. The earliest crushers were hand-held stones,
where the weight of the stone provided a boost to muscle power, used against a stone
anvil.

Mainly There are three types of rock crusher;

 Jaw crusher

 Cone crusher

 Impact crusher

1.2 Problem statements

The problems that lead us to do this project are:-

 Manually crushing bottle can be time consuming.

 Manually crushing bottle is Labor intensive.
 Often relay on manual crushing bottle which will lead workers to injuries.
 Puts unusual stress on workers

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2.3Objective

2.3.1 General objective

 The general objective of this project is to design rock crusher machine.

2.3.2 Specific objectives

Collecting raw data’s of components of rock crusher machine.

 To model it in 3D solid work model software.

 To determine Crusher Capacity.
 To perform cost estimation
 To determine the efficiency of the current rock crusher system

2.5 Scope of the Project

This project is limited to design rock crusher machine which will be applied on
factory specifically for crushing rock in national ciement.

2.6 Methodology
We are going to use different types of materials and devices in designing this bottle
crusher machine. For each parts of the machines; Body frame, fixed jaw plate, movable jaw
plate, Motors, eccentric shaft and bearing, and materials should be created.

3. LITERATURE REVIEW
A crusher is a machine that is designed to reduce large solid masses of raw material into
smaller portions. Crushing is the process of transferring a force amplified by mechanical
advantage through a material made of molecules that bond together more strongly, and
resist deformation more than those in the material being crushed do. Crushing devices
hold material between two parallel or tangent solid surfaces and apply sufficient force to
bring the surfaces together to generate enough energy within the material being crushed.

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2.7 Material selection
One of the basic factors that affect the choice of a project is the availability of materials,
selection of materials, and the cost of the materials for the design or fabrication of the
project. The materials selection for the design function depends on the following;

 The availability of these materials in our local markets.

 The strength of these materials.
 The cost of these materials.
 The possession of simple mode of the operation .
 The appearance of these materials .
 The ability of these materials to serve the purpose for which the project is intent to
be designed.

2.9 Design consideration

The design engineer has a very large say in the choice of materials. Some of the things they
should consider in the design process are given here.

Strength
The component/structure/product must not fail under the action of expected stresses and
force during its intended life span. Strength can mean many things, tensile, compression,
shear and torsional. The strength can be weakened due to service factors such as corrosion
and fatigue. So there are many things to consider.

Elasticity
The elasticity of a component depends on its modulus and expansion elastic, shear and bulk
modulus along with their relationship with poisons ratio will be found in other modulus
that u should be studying

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Degradation
The material must not become degraded due to service or environmental factors. This will
reduce its intended life span. There are many things that cause a material to degrade such
as corrosion, wear, chemical attack and radiation .

Wear
Wear is a form of degradation due to surface rubbing together. The designer need to
understand Tribology (friction and wear of rubbing surface). It is must to select materials
with suitable, compatibility and wear resistance

Impact resistance
This can be a form of degradation but also affect the strength. It occurs when the surface
becomes damaged due to being struck. This could lead to fatigue failure or to sudden
cracking in the brittle materials. It also affects the visual appearance and may be important
in house hold goods such as work tops and cooker surfaces .

Surface finish
The final treatment of manufactured part is called the finishing process and materials must
be suitable for the process. This is conducted in order to do the following:  Protect the
part from corrosion and other chemical attacks  To produce enhanced physical surface
properties.  To produce an attractive appearance. Here is a list of finishing processes that
might be used.

Weldability
Clearly any structured designed for welding must be suitable for that process and the
weldability of the material is an important consideration. Arc resistance may also be a
consideration.

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Cost
The cost of the product depends on the design and manufacture (processing) as covered in the
preceding work. In addition to cost depend on the following.

Raw material
When more than one material meets required specification, the cheapest material will be
logically chosen and these depend largely on the price of the raw material. For example
when copper is expensive, there is a tendency to make electrical conductors from
aluminum. Even though the cable diameter has to be increased to meet the resistance
criteria. Materials chosen for large scale manufacture might be different to those chosen or
small scale quantities. For small quantities, the material cost is so important .

Storage
The material to be used and the end product may have to be stored and transported so the material
must not degrade whilst in storage. Steel stock, for example should not be stored in the open where a
rain will accelerate rust. If a supplier can reliably supply stock quickly, then you need not bear the cost of
storage.

Availability
Again if more than one material meets the required specification, the final choice of the material may
depend on the availability and the one most readily available would be chosen.

Quantity
The price of materials may well depend on contractual arrangement with discount or quantities and
regularity of orders. The choice of material, all other being equal, is not so important for small
quantities.

2.10 Material selection

Materials science and engineering plays a vital role in this modern age of science and
technology. Various Kinds of materials are used in industry, housing, agriculture,
transportation, etc. to meet the plant and individual requirements. The rapid developments
in the field of quantum theory of solids have opened vast opportunities for better

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understanding and utilization of various materials. The spectacular success in the field of
space is primarily due to the rapid advances in hightemperature and high-strength
materials. The selection of a specific material for a particular use is a very complex process.
However, one can simplify the choice if the details about:

 Operating parameters
 Manufacturing processes
 Functional requirements and
 Cost considerations are known

2.10.1 Factors affecting material selection

The following mechanical and physical properties are very important for the selection of the martial by
using different kind standard such as ASMS

 Strength
 Corrosion resistance
 Resistance to hydraulic attack
 Fracture
 toughness
 Fabric
 ability

A. Strength
The strength of the material are based on the mechanical propriety of the material
that used for the most easy ,fast ,strong and low cost of production .some of the
mechanical properties are (yield strength ,ultimate tensile strength ,creep strength
and rupture strength).
 Yield strength
Yield strength is the region which a material changes from plastic to elastic
deformation. The stress level at which the plastic deformation begins.
 Ultimate tensile strength (UTS)
The ultimate tensile strength (tensile stress) is a measure of the basic strength of
the material .it is the maximum stress that the material will stand and measure by a
standard tensile test.

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  Creep test
Material are often placed in a service at elevated temperature and exposed to static
mechanical stress. Deformation under such circumstance is termed creep .The time
dependent and permanent deformation of material when subjected to a constant
load and stress

B.Corrosion resistance
Corrosion: is partial or complete wearing away, dissolving, or softening of any substance by
chemical or electrochemical reaction with its environment. The term corrosion specifically
applies to the gradual action of natural agents, such as air or salt water, on metals. The stainless
steels are the most frequently used corrosion resistant materials in the chemical industry. To
impart corrosion resistance the chromium content must be above 12 percent, and the higher
the chromium content, the more resistant is the alloy to corrosion in oxidizing conditions. Nickel
is added to improve the corrosion resistance in non-oxidizing environments .

2.11 Major Components part of machine

The jaw crusher machine contains standard and custom components so we are going to select material
for custom component and going to use the same materials for standard component used in the
company. This Jaw Crusher machine project contain the following components. 1. Crusher Frame 2.
Movable Jaw and Fixed Jaw 3. Fly Wheel 4. Eccentric Shaft and Bearing 5. Motor 6. Belt
i) Crusher Frame

Crusher Frame is made of high welding. As a welding structure, it has been designed with every care so
as to ensure that it is capable of resistant to bending stress even when crushing materials of extremely
hard.
ii) Movable Jaw The movable jaw is the main moving part in a jaw crusher. It forms the moving side of
the jaw, while the stationary or fixed jaw forms the other. It achieves its movement through the
eccentric machining of the flywheel shaft. This gives tremendous force to each stroke. Jaw is made of
high quality steel plates and carefully stress relived after welding accurately bored and faced to gauge.
iii) Fixed Jaw The fixed jaw face is opposite the moving jaw face and is statically mounted.

iv) Flywheel Rotational energy is fed into the jaw crusher eccentric shaft by means of a sheave pulley
which usually has multiple V-belt grooves. In addition to turning the pitman eccentric shaft it usually has

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substantial mass to help maintain rotational inertia as the jaw crushes material.
v) Eccentric Shaft and Bearing The pitman is put in motion by the oscillation of an eccentric lobe on a
shaft that goes through the pitman's entire length. The main shaft that rotates and has a large flywheel
mounted on each end. Its eccentric shape moves the moving jaw in and out. Eccentric Shaft is machined
out of Alloy Steel Fitted with anti-friction bearings and is housed in pitman and dust proof housing.
vi) Bearing There are typically four bearings on the eccentric shaft: two on each side of the jaw frame
supporting the shaft and two at each end of the movable jaw. These bearings are typically roller in style
and usually have labyrinth seals and some are lubricated with an oil bath system. Bearings that support
the main shaft. Normally they are spherical tapered roller bearings on an overhead eccentric jaw
crusher.

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 O-ring are torus-shaped seals of circular cross-section made from a variety of
elastomeric and are used in static and dynamic condition.

i. Solid ram

ii. Spring for safety valve

iii. Hollow rams

iv. Cylinder (cylinder ram; just like hollow ram it is subjected to fluid friction,
compressive load, tensile load, buckling and corrosion.

v. plunge cylinder:- again is characteristics is the same as that of ram cylinder

vi. Plunge with plunge rod

vii. NUT

viii. Top-cup with square thread (saddle)

ix. Handle and handle socket

x. Handle socket pins and releasing screws

xi. Base plate

xii. Ball for releasing and safety valve reservoir:- it is all the same character to that of
cylinder.

1.7. FACTOR OF SAFETY

SY=σ cdirect∗c ……………..where sy=yield strength

σ cdirect = direct compressive stress

C= constant

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This constant decides how much more the strength should be as compared to the induced
stress. It assures the safety of machine member from failure and hence is termed as factor
of safety and may be designated as N or F.S.

The right hand side of the above equation is termed as permissible or safe allowable stress,
while left hand is induced stress. F.S may be arbitrary selected as 3 to 5 based on yielding or 5
to 7 based on fracture failure.

1.6. GENERAL MACHINE DESIGN PROCEDURE

It is difficult if not possible to lay down any set rules of procedure for designing machinery.
This situations encountered are too varied to allow this. How ever it is possible to point out
a general procedure which will in the majority cases, prove to be help full to the designer.
This general procedure can be stated in the form of steps as follow.

1. Before starting work on the design of any machine, get thoroughly familiar with
what the machine is intended to accomplish and what special requirements must be
considered.

2. Make free hand sketches of various ways the machine might be constructed at the
same time making any preliminary calculation which might be required to
substantiate your ideas or to establish approximate sizes. Having established what
seams to be feasible construction, make a lay out drawing of the machine paying
particular attention to the necessary details of construction.

3. Analyze the lay out forces, stress etc., & make what ever calculations are necessary
to be certain that the parts will perform satisfactorily.

4. Revise the lay out drawing as necessary for the finished design.

THINGS TO BE CONSIDERED WHILE DESIGNING

i. Proper functioning of designed machine.

ii. Cost.

iii. Ease of manufacture and assembly.

iv. Strength and rigidity of parts.

v. Wear of parts.

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 vi. Ease of service and replacing parts.

vii. Proportion of parts.

DESIGNER SHOULD THINK THE FOLLOWING

 A designer thinks on the drawing board or sketch pad. It is impossible to visualize

all the details of machine with out putting it on paper.

 Sketches should be made large, and enough to picture the construction of the, rather
than merely showing a schematic of operation.

 Drawing should be as complete & detailed as possible. It is only be seeing the

machine pictured in its true size & shape that the designer can make use of his own
judgment. Designing of machine elements involves the fallowing steps;

 Specifying the problem.

 Selection of proper mechanism.

 Analysis of forces.

 Selection of material.

 Selection of F.S.

 Calculation of cross sectional dimensions using basic design

equations.

 Modifying and finalizing dimensions with proper tolerances and

preparing drawing with proper instruction for manufacturing

CHAPTER 2

SELLECTION OF HYDRAULIC OIL

2. INTRODUCTION

Hydraulic fluids, also called hydraulic liquids, are the medium by which power is
transferred in hydraulic machinery. Common hydraulic fluids are based on mineral oil or
water. 

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 Examples; of equipment that might use hydraulic fluids include excavators, brakes, power
steering systems, transmissions, backhoes, garbage trucks, aircraft flight control
systems and industrial machinery.

Hydraulic systems like the ones mentioned above will work most efficiently if the hydraulic
fluid used has low compressibility

A fundamental feature of hydraulic systems is the ability to apply force or torque

multiplication in an easy way, independent of the distance between the input and output,
without the need for mechanical gears or levers, either by altering the effective areas in
two connected cylinders or the effective displacement between a pump and motor. In
normal case hydraulic ratios is combined with a mechanical force or torque ratio for
optimum machine designs, like in boom movements and track drives for an excavator.

Use only good grade hydraulic jack oil. Avoid mixing different types of fluid and never use
break fluid oil, transmission fluid, motor or glycerin. Improper fluid will cause premature
failure of the jack potential for sudden and immediate loss of load.

2.1. FUNCTION OF HYDRAULIC OIL & PROPERTIES;

The primary function of a hydraulic fluid is to convey power. In use, however, there are
other important functions of hydraulic fluid such as protection of the hydraulic machine
components. The table below lists the major functions of a hydraulic fluid and the
properties of a fluid that affect its ability to perform that function

FUCTION Property

 Low compressibility (high bulk modulus)

 Fast air release
Medium for power transfer
 Low foaming tendency
and control

 Low volatility
Medium for heat transfer  Good thermal capacity and conductivity
Sealing Medium  Adequate viscosity and viscosity index

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  Shear stability
 Viscosity for film maintenance
 Low temperature fluidity
 Thermal and oxidative stability
 Hydrolytic stability / water tolerance
Lubricant
 Cleanliness and filterability
 Demulsibility
 Antiwear characteristics

 Corrosion control
 Proper viscosity to minimize internal leakage
Pump efficiency
 High viscosity index
 Fire resistance
Special function  Friction modifications

 Radiation resistance
 Low toxicity when new or decomposed
Environmental impact
 Biodegradability
Functioning life  Material compatibility

2.3. COMPOSITION OF HYDRAULIC OIL

The original hydraulic fluid, dating back to the time of ancient Egypt, was water. Beginning
in the 1920s, mineral oil began to be used more than water as a base stock due to its
inherent lubrication properties and ability to be used at temperatures above the boiling
point of water. Today most hydraulic fluids are based on mineral oil base stocks.

Natural oils such as rapeseed (also called canola oil) are used as base stocks for fluids
where biodegradability and renewable sources are considered important. Other base
stocks are used for specialty applications, such as for fire resistance and extreme
temperature applications. Some examples include: glycol, esters, organophosphate
ester, polyalphaolefin, propylene glycol, and silicone oils.

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Hydraulic fluids can contain a wide range of chemical compounds, including: oils, butanol,
esters, (e.g. phthalates, like DEHP, and adipates, like bis (2-ethylhexyl)
adipose), polyalkylate glycols (PAG), phosphate esters (e.g. tributyl phosphate), silicones,
alkylated aromatic hydrocarbons, polyalphaolefins (PAO) (e.g. poly isobutene), corrosion
inhibitors, etc.

2.4. BIODEGRADABLE HYDRAULIC FLUIDS

Environmentally sensitive applications (e.g. farm tractors and marine dredging) may
benefit from using biodegradable hydraulic fluids based upon rapeseed (Canola) vegetable
oil when there is the risk of an oil spill from a ruptured oil line. Typically these oils are
available as ISO 32, ISO 46, and ISO 68 specification oils. ASTM standards ASTM-D-6006,
Guide for Assessing Biodegradability of Hydraulic Fluids and ASTM-D-6046, Standard
Classification of Hydraulic Fluids for Environmental Impact are relevant .
2.5. BRAKE FLUID

Brake fluid is a subtype of hydraulic fluid with high boiling point, both when new (specified
by the equilibrium boiling point) and after absorption of water vapor (specified by wet
boiling point). Under the heat of braking, both free water and water vapor in a braking
system can boil into a compressible vapor, resulting in brake failure. Glycol-ether based
fluids are hygroscopic, and absorbed moisture will greatly reduce the boiling point over
time. Silicone based fluids are not hygroscopic, but their inferior lubrication is not suitable
for all braking systems.

SAFETY

Because industrial hydraulic systems operate at hundreds to thousands of PSI and

temperatures reaching hundreds of degrees Celsius, severe injuries and death can result
from component failures and care must always be taken when performing maintenance on
hydraulic systems.

2.6. SELLECTION HYDRAULIC OIL FOR HYDRAULIC BOTTLE JACK

A hydraulic bottle jack uses a fluid which is incompressible, that is forced in a cylinder by a
pump plunger. Oil is used since it is self lubricating and stable.

When a plunger pulls back, it draws oil out of the reservoir through the suction check valve
in to the chamber. When the plunger moves fore ward, it pushes the oil through the
discharge check valve into the cylinder.

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The suction valve ball is within the chamber and opens with each draw of the plunger. The
discharge valve ball is out side the chamber and opens, when the oil is pushed in to the
cylinder. At this point the suction ball within the chamber is forced and oil pressure builds
in the cylinder.

Due to the above function and high viscosity high temperature and selected SDT fluid is ATF
(Automatic Transmission Fluid) and designation is AES NO 10, Part number H008& MOBIL
DTE 13

GENERALLY HYDRAULIC OIL IS;

 Used to reduce the friction between the milling surfaces.

 Used to dissipate the heat developed inside the system.

 Used to clean the hydraulic part.

 It prevents parts from corrosion

2.7. HOW TO ADD OIL

 Position the jack on level ground in an up right (vertical) position & fully lower the
saddle.

 Remove filler plug.

 Oil should be filled to the level of the oil filler plug hole. If low add oil as needed.

REPLACING OIL

 Plug hole to drain oil, remove oil filler plug & open release valve.

 Turn jack on its side & drain old oil out through the oil filler.

The fallowing figure shows how to fill oil.

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 CHAPTER 3

BOTTLE JACK DESIGN

1. MATERIAL SELLECTION

Page 22
 PARTS MATERIAL
NO

1 O-RING (SEALING NITRIDE BUTADIENE

2 SOLID RAM Alloy steel,AISI1015

3 SPRING FOR SAFETY VALVE beryllium copper C1720

4 HOLLOW RAMS milled steel ASIM, A487

3.2. FORCE
5 CYLINDER(CYLINDER RAM; Milled steel ASTM , A487
6 PLUNGE CYLINDER Milled steel ASTM , A487
7 PLUNGE WITH PLUNGE ROD Alloy steel, AISI 1002

ANALYSIS
8 NUT malleable cast iron
A) FOR JACK
ASTM,A47
HANDLE AND
9 TOP-CUP WITH SQUARE Gray Cast iron,ASTM60
PUMP FORCE
THREAD (SADDLE)

10 HANDLE AND HANDLE SOCKET Carbon steel,AISI1030

11 HANDLE SOCKET PINS AND Alloy steel ANSI1318

RELEASING SCREWS

12 BASE PLATE Gray cast iron

ASM60
13 BALL FOR RELEASING AND stainless steel AISI 900
SAFTEY VALVE RISERVIOR
14 SCREW Alloy steel AISI 1040
15 HANDLE SOCKET LINK alloy steel ANSI1318

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FIG 1 shows mechanisms of jack handle and pump force

Where Fp........................pin force

FH........................human force (usually it is taken to be (100 to 200)

FF..........................fulcrum force

L............................overall handle length (again most of the time

to be taken (300-500mm))

A ...........................pin to pin length (it also taken (30-50mm))

Using equilibrium condition;

ΣMA =0

(FH x L) – (FF x a) = 0

F h∗L
FF = ............................ (1)
a

2) Σ F y = 0

FF-FP-FH = 0

FP=FF – FH ................................ (2)

*Substitute equation (1) into (2) we have;

FP= FF (1-L/a)…………………………………………. (3)

3.3 PRESSURE DISTRIBUTION

Page 24
By using Pascal’s principles, that is intensity of pressure is transmitted equally in a
directions through a mass of fluid at a plunger.

A force FP is applied to the plunge and a force F R is applied to the rams. Since the force at
two cylinders will be proportional to their respective cross-sectional areas. Pressure is the
same every where it is easy to solve the force applied on ram and plunge

Therefore F =PA= P (πr 2)

But Pram=Pp.......................................Pascal’s principle

Fram Fpunge
<=> = where,
Aram A plunge

Aram =πdr2/4 ………………….. DR = diameter of the ram

π d p2
APlung = ……………………. D p =diameter of the plung
4

Fr Fp
2 2
Since, FR/AR=FP/AP => π d r = π dp
4 4

FR/d r 2= Fp/d p 2

F R=(F p /d p2 )∗d r 2………………………………………….(4)

Page 25
 π D P x DP
But, A P = ..................cylinder bore area (circular area)
4

D P ....................plunge diameter varies (10 to 16mm) it is standard.

From this range let use DP =12mm

π D P x DP
And, therefore A P =
4

And pressure of the pump is given by,

Fp
P pump = where, A p ......plunge cross-sectional area and
Ap

P pump ...........pump pressure

Fp
This implies that P pump = ..................... (5)
Ap

* Using Pascal’s law,

P pump=PPLUNGE = Pram = PCY

Therefore P p = P c Pc=Fc/Ac where Pc=cylinder pressure

Ac =cylinder cross-sectional area

Fc=cylinder force

Fc/Ac = (N/mm2) or Mpa.................................... (5)

3.4. PRESURE RANGE SELECTION

Page 26
Assumption: assume that the internal cylinder diameter and the hollow ram diameter are
equal. Therefore DCR = DHR

Where DCI = internal cylinder diameter

DHR =hollow ram diameter

Let assume that DHR= DCI= 60mm

Therefore Ac =D 2HR/4

Ac = πx602/4 = 2827.43mm2

Hence the minimum pressure to raise the given weight is:-

F 14 x 103 N
PCMIN = where: - F= 14KN........... is the given design force, P CMIN=
Ac 2827.43 mm2
=4.95Mpa

Therefore

PCMIN = 4.95MPa, the internal pressure to be designed should be greater than the minimum
pressure since there are parts to be lifted with this pressure.

Hence PCDESIGN > Pc min=7.07MPa

In order to find the internal design pressure, length of the handle, force of fulcrum, plunge
force and pin to pin length first let us assume the human force and length range for handle.

Assuming Fh = 200N from the range of (100N to 200N)

And L = (300mm to 500mm), assuming, L =450mm

a= (30mm to 50mm, and also assume, a = 40mm

By using equation (1) to equation (2)

F H∗L
FF =
a

200❑∗450
FF =
40

FF = 2250KN

Page 27
 FP=FF – FH

FP= (2250- 200) KN

FP =2050KN

FP (2050 )∗4
PC = == ………… where AP is area of the plunge
A 3.14∗12∗12

PC =18.125MPa

Finally, from the above, Pcylinder must be greater than Pc min=4.95MPa. For this reason the
selected quantities are:-

L = 450 mm, F f = 2250kN, F p = 2050kN

a =40mm, P p = 18.125MPa

3.5. STRESS ANALYSIS

3.5.1 DESIGN OF EXTENSION SCREW

A) DESIGN OF SCREW

We have selected square thread screw. Because of the fallowing reason;

 They can easily manufactured

 They have high efficiency.

 Widely used for transmission of power in either direction.

 They offer less frictional resistance to motion

STEP 1) CALCULATE ALL DIAMETER, PITCH, DEPTH OF THE TREAD

Page 28
Sy = 480Mpa…………………………..yield strength……..from the range of(430-585)

F =14kN………………………………given load

By taking, σ all = 0.65 * Sy = 312Mpa…………………………..

σ all=480Mpa/1.5=320MPa………………………………….FS=1.5

To get core diameter (dc) of the screw

4W F
Σ all = 2 = ………………..F=14KN
ᴨ dc A

4F
dc = (
√ π σ all
)

4∗14000
dc = (
√ π∗312∗106
)= dc =7.5mm

* To be more safe let us take dc =10mm

dc
4
* Pitch of the thread (p) =

10 mm
p=
4

p =2.5mm

p
* h= =1.25mm………………………….depth of screw thread
2

* d b = p + dc =10mm +2.5mm = 12.5mm, where d b = diameter of the screw

* d n = d b + 2(a)…………..where a = 0.25 constant

¿ d n = 12.5mm + 2*(0.25mm) = 13m

* H= 0.5P + a , where H = depth of the nut thread

* H= 0.5 (2.5) + 0.25mm=1.5mm

Page 29
STEP2) DETERMINE CORE AREA OF THE SCREW AND MEAN DIAMETER, HELIX ANGLE,
ANGLE OF FRICTION AND FORCE NEEDED TO RAISE THE LOAD.

ᴨ d c2
¿ Ac = = ……………………………core area of the screw.
4

¿ Ac = ᴨ∗¿ ¿ =

Ac = 78.5mm2

Mean diameter of the screw (dm)

db+dc
DM =
2

12.5 mm+ 10 mm
DM =
2

DM= 11.25mm *

Helix angle ( α):-

p
α
ᴨdm

= tan =

p
α = tan-1
ᴨdm

2.5 mm
α = tan-1
π 11.25 mm

α = 4.050

Frictional angle (β)

* tan β = μ

Page 30
Where (μ) is the coefficient of friction between the thread is equal to 0.125 (for carbon
alloy steel).

β = tan-1μ

β = tan-1 (0.125) =7.1250

When the frictional angle (β) is greater than the helix angle¿) the arrangement is self –
locking. β >α

Therefore this arrangement is self –locking.

** The force required raise the load is given by;

W=F (tanα + β)

W=14KN [(0.0707 + 7.125]

W=100.7KN

*There for the force required raise the load of 14KN is; W=144KN

STEP3) DETERMINE FRICTIONAL TORQUE

FRICTIONAL TORQUE

The torque which resists the frictional force is called frictional torque.

Therefore, thread surface frictional torque;

F∗dm∗tan(α + β)
Tf =
2

Tf = 14000∗11.25∗¿ ¿

14000∗0.10875∗0.0707∗0.125❑
=
1+(0.0707∗.125)

Tf= 88.909Nmm

STEP4) COMPARE WITH DIRECT MAXIMUM AND SHEAR STRESS

*Now let us check the screw for the principal stress on it

Page 31
 4∗F
Direct compressive stress =
ᴨ dc 2

4∗14000
σ cdirect = =178.3MPa
ᴨ 102

Maximum torsional shear stress

τ Max = 16 Tf / ᴨdc 3

τ Max = 16∗88.909∗103 / ᴨ 103

τ Max =45.3MPa

σ c + √ σ c 2+ 4 τ 2
Maximum principal stress =
2

178.3 MPa+ √(178.3 MPa)2 +4 (88.909 MPa)2

σ Max=
2

σ Max =100.7MPa

Since σ max is much less than σ all=320MPa

That is, σ all >σ max

Therefore the screw is safe from crushing.

With efficiency of;

1−sinβ
Efficiency (ῃ)¿
1+ sinβ

1−sin 7.125
=
1+sin 7.125

ῃ =0 .779 =77.9%

STEP4) F INALLY CHECK FOR BUCKLING

Rankin’s formula is applicable for columns, ranging from very long to short ones for this
reason WE use this formula to check buckling.

Page 32
 crushing load
Crippling load = L 2
1+ a( )
K

σ c∗A
Therefore, WCR = L 2 where σ c = crushing stress or yield stress in compression.
1+ a( )
K

A = cross-sectional area of the column

a = Rankine constant

L = Equivalent length of the column

K = radius of gyration.

I
Radius of gyration (K) =
√ A

(ᴨ d 4c /64 )
√
K= ᴨ d 2c
4

K = √ (dc2 )/16

K= dc/4 =10/4 =2.5mm

Let us assume the effective length L is = 80mm

Since a= 1/9000

σc
From; a=
π2E

178.3 MPA
σc
E= = 1
π 2a π 2( )
9000

E=255GPA

W =π 2 EI /L2 …………..Where

I =K2A = 2.52(78.5) mm

Page 33
 I = 490.625mm4

W =π 2 255 GPa( 490.625)/802

WCR=171.7KN

rankine load
Permissible buckling load =
safety factor

PB= WCR/F.S= 171.7/2KN

=85.85KN

**CONCLUSION

Since our load which is 14KN is much less than permissible buckling load, this screw is safe
from buckling

PB > F

3.5.2. DESIGN OF NUT AND CUP SCREW

I. DESIGN OF NUT

TO find number of thread in the nut;

Assume bearing pressure is P= 12MPa…………..from the range of (10 TO 15) MPa.

Nt∗Pbπ ( D 2−D c 2 )
From W=
4

4∗F
Nt=
Pb∗π ¿ ¿

Were ……………………..F=14KN

Page 34
Dm = 11.25mm

Dc=10mm

P=12MPa

There for;

4∗14000 N
Nt= 2 2
12 MPa∗π (11.25 −10 )

NT= 55.95

* Height of the nut is;

H=NT *P =55.5*2.5………………P= Pitch

H=138.75mm

The outer diameter of the nut

DN = 1.5dc

DN = 1.5 x 10mm

DN =15mm

Say DN=20mm

II. DESIGN OF CUP

Maximum diameter of the cup = 2 x dc

Dc = 2 x 10mm = 20mm

Let us assume that thickness of the cup

t = 15mm

Shear area of the cup can be calculated as follows

Area that resists shearing of the cup = ᴨ db * Tc

Page 35
= ᴨ *12.5mm * 15mm

=588.75mm2

The induced shear stress:-

f
τ Indused =
Acup

14000 N
τ = =τ =23.77 MPa
588.75mm 2

**CONCLUSION

Since the induced shear stress is much les than the allowable shear stress.

I.e τ all > τ indused

3.5.3 DESIGN OF SOLLID AND HOLLOW RAM

I) DESIGN OF SOLLID RAM

Because of it is subjected compressive load, fluid friction and corrosion, the selected
material is should be:-

Alloy steel, AISI1015, Stu=420.6MPa, Sy=313.7Mpa

σ =, Sy /2=313.7/2Mpa=156.85

SOLLID RAM

PARAMETERS

Dc=DR=60mm

Pc=18.125MPa

F=14KN

Page 36
CHECK FOR SHEARING AND CRUSHING STRESS

Since the pressure applied on the bottom of the solid ram when it hits the stop of the
second stage ram subjects the neck for shearing and crushing, we have to check for;

Maximum force acting on the neck

ᴨ 2
Fat neck = P cylinder * Ac , where Ac = dc
4

ᴨ 2
Ac = 60
4

Ac = 2827.33mm2

Fat neck = 18.125MPa * 2827.33mm2

Fat neck = 51.25KN

The induced shear force (Ԏinduced)

F at neck
τ= , but A (shear) = π Di * l
Ashear

A (shear) = π 20mm * 15mm = 942mm2

51.25 KN
τ=
942mm 2

τ =54.4MPa

**CONCLUSION

Since τ all > τ induced then this ram is safe from shearing

τ All =0.5*313.7=156.85MPa

The induced crushing stress (σ c)

F @neck π
σc = but A (crushing) = *( Do 2- Di2)
Acrushing 4

Where Do = outer diameter outer diameter of the ram

Page 37
 DI = inner diameter of the ram

π
A (crushing) = *(40 2-202) =1225mm2
4

51.25 KN
σc = = 41.83MPa
1225

**CONCLUSION;

**Since σ all >σ c have our ram is save from crashing

II) CHECK FOR BUCKING

Again using Rankine formula we can check our solid ram from bucking

σ cA
WCR= L 2
1+ Q( )
k

Where WCR…………………………………. crippling load

σ c………………………………………………….Crushing stress on tield stress on compression

A ……………………………………………….. Cross –sectional area of the column

Q ………………………………………………….Rankine constant

L ………………………………………………… equivalent length of the column

K ………………………………………………..least radius of gyration

For carbon steel

1
σ c= 250Mpa and fixture coefficient =
0.25

1
Rankine constant =
9000

Rankine constant for this ram will be:-

1 1
Q= * =0.00044
9000 0.25

Page 38
 And the equivalent length (L) = 95mm

I
Radius of gyration (K) =
√ A

( ᴨdi 4 /64)
√
K= ᴨ d2i
4

K = √ (di2 )/ 4

di 40
K= = = 10mm
4 4

L 2 95 mm 2
[ ] =[ ] = 90.25mm
K 10

Finally the crippling load

σ cA
WCR= L 2 but Ac = π Di2/4 =
1+ Q( )
k

Ac = π40 2/4 = 1256.64mm2

σ cA
WCR = L 2
1+ Q( )
k

250∗1256.64
=
1+ 0.00044∗90.252

WCR = 75.6KN

Rankine load
Permissible buckling load =
S .f

Wcr 75.6
WCR= = WCR= =24.2KN
S.f 3

**CONCLUSION

Page 39
Since the permissible buckling load is much greater than the given load i.e W CR > F = 14KN,
hence the ram is safe from buckling

II. DESIGN OF HOLLOW RAM

Here it is also subjected to fluid friction, compressive load, buckling and corrosion and also
from economic point of view, the selected material is:-

Milled steel ASIM, A487and Sy=90MPa

Material; Mild steel

SY = 90MPa

τ All = 0.5 * SY = 0.5 * 90MPa

=45MPA

σ All = 0.65 * SY = 0.65 *90Mpa = 58.5 MPa

Due to given load, let assuming the hollow ram is thin walled cylinder.

Therefore, from hoop stress (σ h)

Pi∗Di
σh= where ;Pi = internal pressure.
2t

Di = internal diameter

t = hollow ram thickness

Page 40
 Cf = corrosion factor

Therefore Pi =4.95MPa

Di = 40mm

Let us assume that

σ h = σ all = 58.5MPa

Pi∗Di
Therefore, σ h = 2t

Pi∗Di
t=
2σ h

4.95∗40
t=
2∗58.5

t = 1.69mm

*Due to corrosion effect we have to add corrosion factor C f = 1.66mm

Therefore, t actual = 1.69mm + 1.66mm

T actual = 3.35mm

Assuming stop length (L) = 10mm

And Do = Di + 2t = 40mm + (2*3.35)

Do =46.7mm

Most outer diameter of the ram becomes:-

DMO = DO + 2(L) = 46.7 +20 = 66.7mm

I) CHECK FOR SHEAR AND CRUSHING STRESS AT THE STOP (NECK)

Maximum force acting on the neck (stop)

ᴨ∗D MO 2
Fat neck = Pc *Ac but, Ac =
4

Page 41
 ᴨ∗66.72
Ac = . = 3492.8mm2
4

Therefore, Fat neck = 4.95MPa * 3492.8mm2 = 17289N

Induced shear force at neck (stop) is:-

F at neck
τ= where A shear = ᴨ *DO *h
A shear

A shear = ᴨ * 46.7mm * 10mm

A shear =1466.38mm2

17289 N
τ= = 11.7MPa
1466.38mm 2

Crushing stress at neck (stop)

F at neck
σc= where
A crush

ᴨ
A crush = (D 2 –DO2)
4 MO

ᴨ
= (66.72 –46,72) mm2
4

A crush = 1780.38mm2

17289 N
Therefore, σ c = σ = 9.7MPa
1780.38mm 2 = c

**CONCLUSION

**Since the induced shear of the crushing stress are much less than the allowable shear of
normal stress, our hollow ram is safe from this induced stress. i.e,

σ c =9.7MPa <σ all = 58.5Mpa= τ = 11.7MPa < τ all =45MPa

CHECH FOR BUCKLING

Here again the Rankin formula is applicable to check buckling. That is;

Page 42
 σ cA
WCRP = L 2 where WCR = crippling load
1+ Q( )
k

σ c = 320MPa …………….for mild steel crushing stress

1
σc ∗1
Q= 2 = 0.25 = 0.00053………………………rankine constant
Cᴨ E
7500

L= 95mm ……………………………….effective length

I
Radius of gyration (K) =
√ A

K =√ ¿ ¿

D 2Mo −D 2o ¿
K =√ ¿
16

2 2
K = 90.56 −70.56
√ 16

K = 14.3mm

L 2 95 mm 2
[ ] =[ ] = 44.7
K 14.3

ᴨ
And Area (A) = (DM 02 −DO2 )
4

ᴨ
A= (90.56 2−70.562)
4

A =1780.38mm2

320 MPa∗1780.38 mm 2
WCRP =
1+0.00053∗44.7

WCRP= 790.8KN

Page 43
 rankine load
Permissible buckling =
S. f

790.8 N
WCRP = ……………………………………………………………….SF=3
4

WCRP = 197.5KN

**CONCLUSION

** HOLLOW RAM is also safe from buckling. SINCE WCRP >F

3.5.4. DESIGN OF PUMP CYLINDER

Hydraulic pump supply fluid to the components in the system, Pressure in the system
develops in reaction to the load.Just like hollow ram it is subjected to fluid friction,
compressive load tensile load, buckling and corrosion and also from economical point of
view, the selected material is:-

Milled steel ASTM, A487, Sy=90MPa

Page 44
Material: mild steel

SY = 90MPa.

Assume S.F= 2

τ All = 0.5 * SY

=45MPa

σ All = 0.65* SY = 58.5 MPa

THICKNESS OF THE WALL

Again for the same reason which is less internal pressure applied on the cylinder, we can
threat as thin walled cylinder.

Therefore, from hoop stress (σ h)

Pc∗Di
σh = where Pc =18.125 MPa…………cylinder pressure
2t

Pc∗Di
=> t = Di =12mm ………………………..internal diameter of the cylinder
2 σh

σ h =σ all = 58.5 MPa……………………assumption

18.25 MPa∗12 mm
Therefore, t = = 1.86mm
2∗58.5 MPa

To be more safe let us take corrosion factor CF=1.44mm

T actual = t + Cf

T actual = 1.86mm +1.44mm

T actual =3.3

Therefore the outer diameter of the cylinder becomes

Do = Di + 2(tactual)

Do = 12mm + 2*3.3mm= Do = 18.6mm

Page 45
II) CHECK FOR BUCKLING

Therefore, for mild steel;-

σ c = 320MPa ……………..crushing stress.

σc 1 1
Q= 2 = * = 0.00053 where C =the end fixture coefficient
Cᴨ E 0.25 7500

Q = rankine constants

Crippling load

σcA
2
WCR= L where σ c =320MPa
1+ Q( )
k

ᴨ
A= (Do 2−Di2 ) …………..cross-sectional area
4

ᴨ
A= (18.62−122 )
4

A =158.5mm2

Q = 0.00053

L = effective length of the cylinder

I
K=
√ A

K =√ ¿ ¿

2 2
K =√
D −D
o i ¿
¿
16

K= √18.6 2+122 ¿ ¿
16

K = 3.55mm

Page 46
 L 2 60 mm 2
[ ] =[ ] = 293.5
K 3.5 mm

σcA
WCR= L 2
1+ Q( )
k

320∗158.5
WCR=
1+ 0.00053∗293.8

WCR= 43.2KN

buckling load
Permissible buckling load =
S .f

43.4 KN
WCR = 3
… WCR = 14.6KN…………………….. SF=3

**CONCLUSION

Since the permissible buckling load is greater than the fulcrum load (FF=2.25kN) our PUMP
cylinder is safe from buckling.

WCR = 15.46KN > FF=2.25kN

3.4.5. DESIGN OF RESERVIOR

The hydraulic fluid reservoir holds excess hydraulic fluid to accommodate volume changes
from: cylinder extension and contraction, temperature driven expansion and contraction,
and leaks. The reservoir is also designed to aid in separation of air from the fluid and also
work as a heat accumulator to cover losses in the system when peak power is used. Design
engineers are always pressured to reduce the size of hydraulic reservoirs, while equipment
operators always appreciate larger reservoirs. Reservoirs can also help separate dirt and
other particulate from the oil, as the particulate will generally settle to the bottom of the
tank.

Some designs include dynamic flow channels on the fluids return path that allow for a
smaller reservoir.

It is all the same character to that of cylinder and from economical point of view and also
availability, the selected material is:-

Milled steel ASTM, A487 and Sy =90MPa

Page 47
 Figure shows reservoir

Material: mild steel

SY =90 MPa

σ ALL= 0.65* SF= 0.65* 90MPa = 58.5MPa

A. VOLUME DETERMINATION

The volume of the fluid occupied by the ram and the cylinder should be equal to that of the
reservoir volume.

I.e ram volume (VR) = V1 +V2

Where V1 =A1L1

ᴨ
= ¿) * L1 ………………………………L=65mm
4

ᴨ 2
= 60 * 65
4

V1 =183783.17 mm3

V2 = A2L2 …………………………….L1=L2

ᴨ ᴨ
V2 = ¿ * L= ∗90.562 * 65 =418461.6 mm3
4 4

Therefore VRAM = v1 + v2

VRAM =183783.17 + 418461.6 mm3

VRAM =6O1151.8 mm3

Page 48
B) INNER DIAMETER OF THE RESERVIOUR

In order to carry this amount of volume of fluid in the height of the reservoirs volume
should be equal to the volume of the rams.

i.e. VRAM = VRESERVOIR

ᴨ 2
Therefore, VRESERVOIR = (D inner of reservoir - D2outer of the cylinder) * height
4

ᴨ 2
VRESERVOIR = (D i -90.56 2) * 95= Di = 127.5mm
4

To be more safe and reservoir STD let us take Di =130mm

C) THICKNESS OF THE RESRVIOUR

Since only atmospheric pressure is applied on the inside and outside of the reservoir, we
can threat the reservoir us thin walled cylinder.

Therefore from hoop stress (σ h )

Pc∗Di
σh= where, Pc = 1 bar = 105 Pa = 0.1MPa
2t

Pc∗Di
t= ………………….. Di =130mm…..internal diameter of the reservoir.
2σ h

σ h = σ all = 58.5MPa ………..assumption and, t = thickness

0.1 MPa∗130 mm
t= =0.11mm
2∗58.5 MPa

To be more safe let us add corrosion factor CF= 2mm

T actual = t + Cf

T actual = 0.11mm + 2mm =2.11mm

3.5.6 DESIGN OF PLUNGE AND STROKE CALCULATION

1) DESIGN OF PLUNGER

Page 49
Since it has reciprocating motion, it is subjected to fatigue load compressive load, tensile
load, fluid friction and from economic point of view and availability of material the selected
material is :-

Alloy steel, AISI 1002 , Stu=90MPa, SY=46MPa

Material: alloy steel

SY = 40MPa.

Assume, N =2 …………since it is subjected tensile and compressible stress

σ all = 0.65* SY

= 0.65 *40MPa,

σ all = 26Mpa

PLUNGER ROD DIAMETER

In order to determine the plunger rod diameter (D R) from compressive stress (σ c) it can be
Ff
equated as follows. σ c =σ all= …………………………..assumption.
Arod

FR FF
Arod = = ¿¿ = ……………………..Where FR IS Fulcrum force
σ all σ all

4∗F f
DR =
√ ᴨ∗σ all

4∗2250
DR =
√ ᴨ∗26
mm

DR =10.4 mm

Page 50
  CHECK FOR BUCKLING

For alloy steel

σ c = 250MPa …………………….crushing stress

Q = Rankine constants

σc 1 1
Q= 2 = * = 0.00044 where C is fixture constants
Cᴨ E 0.25 9000

And, cross-sectional area Ac;

Ac = ¿ ¿ = 86.4mm2

Active length (L) = 65mm

Radius of gyration (K)

I
K=
√ A

√ ᴨ D4R /64 ¿ ¿ 2
K= ᴨ DR
4

D 2R
K=
√ 16

DR 10.4
K= = =K =2.6mm
4 4

( L/ K )2 = (65 /2.6)2 = 675

Finally the crippling load becomes

σcA
250∗86.4
WCR= L 2=
1+ Q( ) 1+ 0.0004 4∗675
k

WCR= 18KN

Page 51
 Rankine load
Permissible buckling load =
S .f

18 KN
WCR = =…………………………………………………S.f=3
3

WCR = 6KN

**CONCLUSION

Since the permissible buckling load is greater than the fulcrum load (FF =2.25KN) this
plunger road is safe from buckling.

WCR = 6KN> FF =2.25KN

III. STROKE CALCULATION

The Fluid pushes against the face of the piston and produces a force.

F=PA……………………..Full area of piston.

F=P (A-a)…………………on the road.

This force on the load is often less, because of friction between the seals and piston rod and
piston.

Speed; the speed of the piston depends upon the flow rate. The volume per second entering
cylinder must be the change in volume per second.

Q (m3/s) = area *distance moved per second

Q (m3/s) = area* velocity……….full side

Q (m3/s) = (A-a) * volume………….rod side

Finally POWER = volume * F

Number of stroke (N.s) = volume of the ram/volume of the plunge

But v RAM = 601151.8mm3

Page 52
And volume of the plunger =A x H=πdp2/4 x LP

SINCE dp=10.4mm……………………………we assume that LP=100mm

( 10.4 )2∗100
VP=π = 8490mm3
4

(N.s) = 601151.8mm3/ = 8490mm3=∴ (N.s)=7

So in order to raise the load 7 stroke is needed.

3.4.8. DESIGN OF TOP CUP AND BASE

I) DESIGN OF BASE

Fig. base

The base is used to support the jack system and also protect forgive particles from going
into the system .the material used for the basement is most of the time cast iron.

This is b/c of the following reasons:

 It is cheap and easily available

 It can easily resist wear when we compared to steel and

 It is highly resist compressive load.

This base is casted in the molding system and drilled top for fluid comes in and out of the
pump into system and from the system into the reservoir and also from the reservoir into
the pump and so on.

The material is gray cast iron ASTM60 and SY =43Mpa

II) DESIGN OF SECOND STAGE RAM

Page 53
Material specification:- mild steel

SY= 90MPa.

Assume N= 1.25

τ All = 0.5 * SY

=45MPa

σ All= 0.65* SY = 58.5 MPa

Again from the given load and the applied internal pressure, it is possible to assume the
ram cylinder as a thin walled cylinder.

Hence: from hoop stress (σ h)

Pc∗Di
σh= where Pc = 18.125MPa
2t

Di = DMO of the second stage ram

Di = 90.56mm

Assume that σ h = σ all =58.5MPa.

Pc∗Di
σh=
2t

Pc∗Di
t=
2σ h

18.125∗90.56
t=
2∗58.5

t = 14.3mm

To be more safe let us added corrosion factor (CF) = 0.85mm on it.

Therefore, t (actual) = t + CF

t (actual)= 14.3mm + 0.85= t act =15.2mm

1) CHECK FOR THE SHEARING AND CRUSHING STRESS AT THE STOP (NECK)

Page 54
Since the material of the diameter of the ram cylinder is the same as that of the third stage
ram, it is safe from crushing and shearing stress induced on the neck (stop) of the cylinder.

2) CHECK FOR BUCKLING

σcA
.WCR = L 2 ………………………….Crippling load
1+ Q( )
k

But from the text, for mild steel

σ c = 320MPa and

σc 1 1
Q= 2 = * = 0.00053
C ᴨ E 0.25 7500

And cross sectional area of the cylinder becomes

ᴨ
A= (DM 02 −Di2)
4

But DMO =Di + 2t = 90.56mm * 2*(30mm) = 120.6mm

ᴨ
A= (DM 02 −Di2)
4

ᴨ
A= (4435mm 2−2171 mm2) = 2263.44mm2
4

L = 130mm…………………………………………………..…...effective length of the cylinder

I
Radius of gyration (K) =
√ A

K =√ ¿ ¿

2
+ D 2o ¿
K =√
D Mo
¿
16

K= √120.6 2+ 90.562 ¿ ¿
16

K = 37.7mm

Page 55
 130 mm 2
(l/k) 2 = [ ] = 11.89
37.7 mm

FINALLY;

320 MPa∗13571.68 mm2

WCR=
1+0.00053∗11.89

WCR = 1.58 x 106 N

rankine load
Permissible buckling =
S. f

1.58 x 106 N
WCR =
2

WCR = 0.79MN

**CONCLUSION

Since the permissible buckling load is much greater than the given load, which is 20K N,
this ram cylinder is safe from buckling.

WCR = 0.79MN > F=20KN

IV. DESIGN OF TOP CUP

Since it subjected to compressive load the selected material is:-

Gray Cast iron, ASTM60 and SY=86MPa

Material:- GRAY CAST IRON

SY = 86MPa

Assume that S.f = 2

σ All = 0.65* SY = 55.9MPa

Page 56
τ All = 0.5 * SY = 43MPa

I) CHECK FOR SHEARING AT CRITICAL POINTS

F at neck = Pc *Ac…………where Pc = 18.125 MPa……..internal cylinder pressure

ᴨ
Area (Ac) = *( Do 2- Di2)
4

ᴨ
= *(120.62 - 70.562)
4

Ac = 75009mm2

F at neck = 18.125MPa * 75009 mm2

F at neck = 136.288KN

II) INDUCED SHEAR STRESS

F at neck
τ= Where ASH = π Di *L ………..L=20mm
Ashear

ASH = π * 70.56mm * 20mm

ASH= 4396mm2

136.288 KN
τ IN =
4296 mm2

τ IN =31MPa

**CONCLUSSION

Hence the induced shear stress at the critical point is much lower than the allowable shear
stress, our cup is safe.

3.5.8 DESIGN OF HANDLE & SOCKET (FOR PUMP), LINKS, &PINS (AT PLUNGER &LINKS)

I. DESIGN OF HANDLE & SOCKET FOR PUMP

Due to compressive load and tensile load and also bending force on it, the selected material
is:-

Carbon steel, AISI1030, Stu =400MPa and SY=237MPa

Page 57
 I. DESIGN OF HANDLE

FIG. shows handle

Material: Carbon steel

SY=237MPa

τ ALL= 0.65 *SALL= 154MPa

τ ALL= 0.5 * SY = 118.5MPa

To determine the diameter of the handle

Therefore to determine diameter let us calculate it fromτ ALL

Ԏall = (16 TMAX)/ᴨd 3 …………… but TMAX=F*R…………………for R=490mm &

F=200NThen, T=200*490 =98000Nmm

16∗Tmax
d=∛
ᴨ∗Ԏ all

16∗9800
d =∛
ᴨ∗¿ 118.5 MPa

d = 16.14mm=20mm

Page 58
AGAIN FROM MAXIMUM BENDING THEORY

32 Mmax
σ ALL=
ᴨ d3

Where MMAX = 490 mm* 200N

M MAX= 98000N.mm

32∗98000
d=
√ 3

ᴨ∗154

d = 18.64mm to STD value d =20mm

Due to safety from τ all of σ all we have to select the greatest diameter from the above

Therefore d SHAFT = 20mm

I. HANDLE SOCKET

Since it is subjected to compressive, tensile and bending load and also buckling, the
material selected is:-

Alloy steel ANSI1318, SY=70MPa

Figure shows handle socket

Material – Carbon steel, SY = 237MPa

τ ALL= 0.5 * SY =0.5 *237MPa = 118.5MPa

σ ALL = 0.65 * SY = 154MPa

DITERMINATION OF DIAMETER

Again from allowable stresses we can determine the outer diameter of the socket

Page 59
 4∗Ff
σ ALL = where FF= fulcrum force FF=2250N
ᴨ (D 2−d)

D1 …………………………………outer side diameter of the handle socket

d ………………………………… inside side diameter of the handle socket

4 Ff
D1 =
√ ᴨ∗σ all
+d 2

4∗2250
D1 =
√ ᴨ∗154
+ 202

D1 = 20.78mm

And, τ all = (4*FF)/ (ᴨ ( D2-d 2))

4∗2250
D2 =
√ ᴨ∗118.5
+ 202=D2 = 20.59mm

In order to determine the diameter let us check the thickness from the two results,

Therefore t1 = D1 - d = 20.7mm - 20mm = 0.7mm

t2 = D2 – d = 20.6mm – 20mm =0.6mm

This implies that it can be possible to use a material thickness greater than 0.7mm therefore
by adding correction factor Cf =3mm

For convenience it becomes.

D = d + 2(tactual)

D = 20mm + 2*(0.66mm + 3mm)

D = 27.32mm. BUT FROM STD D=30mm

I. HANDLE SOCKET PINS

Hence, it is subjected to torsion shearing compressive load the selected material is:-

Alloy steel ANSI1318, Sy=75MPa.

Page 60
i) FULCRUM PIN

Material: Alloy steel, SY = 75MPa

τall=0.5∗75 MPa=37.5 MPa

DETERMINATION OF THE DIAMETER

PIN

Since the pin is subjected to double shear,

Ff
2τ all = ………………………………..Where Ff=2250N
4 ᴨ d2

Ff
d=
√ 2 ᴨ Ԏ all

2∗2500
d=
√ ᴨ∗37.5

d = 6.18mm, to be more safe and standard let us take d PIN= 10mm

i. PIVOT PIN

Material – Alloy steel, SY= 75 MPa;

τ all= 0.5* SY = 37.5MPa.

DETERMIATION OF THE DIAMETER

Again it subjected to double shear

Fp
τ All =
2 Ashear

Page 61
 Fp
τ All =
2 ᴨ d2

Fp
d=
√ 2 ᴨ Ԏ all

2∗2050
d=
√ ᴨ 37.5

d = 5.9mm

**To be more safe and standard let us take d PIN = 8mm

3.4.10 DESIGN OF SPRING AT DISCHARGE VALVE

Definition;

A spring is an object used to store mechanical energy. A spring are elastic material or
bodies (generally metal) that can ba twisted, pulled or stretched by some force. They can
return to their origional shape when force is removed. In other words it is also termed as a
resilient member. A spring is aflexible element used to exert a force or torque at the same
tostore energy.

Function of spring;

 To provide cushioning, to absorb or to control the energy due to shock & vibration.

 To control motion.

 To measure force.

Page 62
figure shows helical spring

I) MATERIAL for spring material, we have that for discharge valve from text book called
Engineering material Beryllium Copper (C17200)

SY= 860Mpa……………………Fro the range of( 690-860

τ all =0.5 * SY =430MPa

Modulus of elasticity (G) =131GPa

A) DESIGN PROCEDURE

STEP1 CHECK THE SAFETY FACTOR

Assume a wire diameter of d =3mm and spring index C = 5

DM = d * c = 3*5=15mm……….DM, is mean diameter &

DO = DM + d =15+3=18mm …… DO, is out side diameter.

Shear stress factor (Ks), Neglecting effect of curvature

1
Ks = 1 + = 1.1
2C

Maximum shear stress induced

8 W D mean
τ IN= KS *
ᴨ d3

Page 63
Where FA = P X A ……………………………….Axial load

ᴨ d2
And A = assume of the fluid line with d = 4mm
4

ᴨ 42
A= = 12.57mm2
4

N
And P = 18.125 is the cylinder pressure
mm2

N 2
Therefore, W = P X A = 18.125 2 X 12.57mm = 227.6N
mm

8 W D mean
τ IN = KS *
ᴨ d3

8∗227.6∗15
= 1.1 *
ᴨ ¿ 33

τ IN=321.2MPa

Let us check the safety of factor (N)

τ all 430
FS= = = 1.33
τ induced 321.2

***CONCLUSION

Since the safety of factor is greater than one, our discharge spring is safe.

STEP2. CALCULATE SPRING CONSTANT

SPRING CONSTANT (K)

Assume the deflection of the spring (δ) = 2mm

And assume the end details of the spring is square ends

F F W 227.8 N
δ = => K = = = =113.8 * 103 N/m
K δ δ 2∗0.001 m

Number of active length (Na)

Page 64
 d4 G
K= …………………………………C=D/d
8∗D 3m∗Na

d4G G∗δ
Na = 3 =
8∗D m∗K 8∗K∗C 3

131¿ 109∗10−3∗2
Na = = 4.6
8∗113.7∗103∗53

Na = 5

Number of total turn of the spring (Na’)

Na’ = Na + 2 for square end

Na’ = 5 +2 = 7

STEP3. Free length of the spring

We know that free length of the spring

Lf = (Na’ *d) + ( δ) + (0.15 x δ )

=7*20+2+ (0.15*2)

Lf =30.05

Pitch of the spring

Freelength Lf
P= = = 30.05/6 =5.05m
Total number of turn−1 Na ’−1

STEP4 CHECK FOR BUCKLING

The critical load (WCR) that causes buckling may be calculated by using the following
relation

i.e WCR = K*KB *lf where K =spring rate or stiffness of the spring

K=113.8MPa

lf =free length of the spring

Page 65
 lf
KB = Buckling factor that depending up on the ratio =
Dmean

lf 30.05
KB= =¿ = 1.525
Dmean 20

And for built in end spring, μB = 0.71

N
K = 113.8 *103 from the above
m

There fore. WCR= K*KB *lf

N
= 113.8*103 * 0.71 *30.05 *10−3
m

. WCR = 2508.7 N

**CONCLUSION

Since the critical axial load is greater than the applied axial load (W =277.8 N) then this
spring is safe from buckling. WCR = 2508.7 N > W =277.8 N

3.5.10. DESIGN OF VALVES

I. DESIGN OF BALL @ DISCHARGE VALVE

Material due to the application of the fluid friction on it and we have selected stainless steel
and diameter of the ball = mean diameter of the spring

Therefore, DB=D mean =15mm

I. DESIGN SPRING FOR RELIEF VALVE

MATERIAL; this spring is come to in operation, if the jack is over landed to 1KN large than
the designed (require) load.

. Carbon stainless- steel

τ All =for average service = 350 MPa

DESIGN STEPS

Page 66
STEP1; CALCULATE ALL DIAMETER AND PITCH OF SPRING.

Assume for standard wire gauge (SWG) =7, a wire diameter of d = 4.47mm and spring
index C= 5

Mean diameter DM = C x d = 22.35mm

Outer diameter D0 = D + d = 22.35+4.47 mm

D0=26.35mm

Shear stress factor (Ks), neglecting the effect of curvature

Ks = 1 + 1/2c == 1 + ½*5= 1.1

STEP2; CHECK FOR MAXIMUM SHEAR STRESS INDUCED

8 FD
τ Indused= Ks *
ᴨ d3

Where F = P x A ………..applied load

But internal pressure developed will be increase and the applied load also increases by
1KN

I.e W app =F Ram + 1KN =14KN + 1KN = 15KN

D = mean diameter

d = wire diameter

Ks = shear stress factor

Therefore, the internal pressure (P)

Wapp onthe Ram Fapp

P= =
Aram ᴨ (dr)2

15 KN
P= 4* 2 =5.3MPa ………………assume ram diameter is dR= 60mm
ᴨ (60 mm)

ᴨ
Fax= P*A =5.3 * *4.47 2 ……………….assume line diameter dl = 4.47mm
4

Page 67
 Fax=83.14N

τ In = Ks*8*w*D/πd3

= 1.1 * 8 *266N * 22.47mm/π (4mm)3

τ In= 82Mpa

**CONCLUSION

Since the induced shear stress is less than that of allowable shear stress there fore the safe
region and acceptable.

STEP3; DETERMINE SPRING STIFFNESS & FREE LENGTH

Spring rate (k)

Assume deflection of the spring (δ) = 2mm and assume end details of the spring is square
end

K = F/ δ = 83/2=41.5N/mm

Number of active coil (Na)

G∗δ
Na =
8∗k∗C 3

70∗10 9∗2∗10−3
Therefore Na = = 2.4 =>for the sake of safety take
8∗58.25∗5 3

Na = 3

Free length (Lf)

Lf=Na’ *δ +δ +0.15d………………………………….. Na’=NA+2=8 =5*2+2+0.15*2 = 12.3mm

STEP4; USING FREE LENGTH DETERMINE PITCH OF THE SPRING (P)

Lf
P= =>but Na’ =Na +2…………………..for square end
Na−1

= 3+2 = 5

Page 68
 12.3
P= =3.075mm
5−1

B) CHECK FOR BUCKLING

The critical axial load (FCR) that causes buckling may be calculated by using the following
relation

Wcr =k*kB* Lf ………………………….Where k=58.25N/mm

Kb= buckling factor

Lf =free length

Lf 12.3
KB = = =0.55
D 22.24

FCR =41.56N/mm *0.55 *12.3 =281.18N

**CONCLUSION;

Since the critical axial load is greater than that of applied axial load, the spring is safe from
buckling.

III. BALL FOR RELIEF VALVE

Material …..Stain less steel due to application of fluid friction, this material is selected and
diameter of the ball DB = mean diameter of the spring = 22.35mm

II. DESIGN OF SPRING FOR IN TAKE VALVE

Material again from the same text book the spring material is selected.

A. Design procedure

SEP1) Assume that wire diameter, d=2mm and index c=8

STEP2) Mean diameter

D= cd = 8x2 =16mm

STEP3) Outer diameter

Page 69
Do=D + d=16+2=18mm

STEP4) Shear stress factor KS=1+1/2c= 1.0625mm

STEP5) max shear stress that induced

τ Induced =ksx8WD/πd3

Where w =PA…………… the force acting on spring (axial load)

Assume that the fluid in the reservoir is in the atmospheric pressure that is P atm= 1bar.

A =πdl2/4=π* 32/4 =7.03mm2

W=PA = 0.1*12.57 =0.703N

D……………………….mean diameter=16mm

d………………………….wire diameter =2mm

KS………………………….shear stress factor =1.0625

τ Induced =KS*w*D/πd3 = 1.0625**16/π23 =4.78MPa

Since the induced shear stress is less than the allowable stress

The spring is safe and acceptable

STEP6. Spring rate (k)

Assume deflection (δ) =2mm and end detail of the spring is square and k=w/ δ=

K = 0.703/2 = 0.35

STEP7. Number of active turns (Na)

NA=GD/8KC3=3.3 = Na = 4

STEP8. Total turn of the coil (Na’)

Na’=Na+2 …………………………….for square and ground ends

= 4 +2

Na’ = 6

Page 70
STEP9) free length of the spring (Lf)

Lf =Na ’ . δ+ δ+.15 δ

Lf = (6 * 2) + 2 + (0.15 * 2) = 14.3 mm

Pitch =Lf/Na’-1 = 14.3/5= 2.8 mm

A) BALL FOR IN TAKE VALVE

Material due to the same reason as the above the selected material is called stainless steel.

Diameter of the ball

D ball =mean diameter of the spring =16mm

3.4.11 DESIGN OF O - RING SEALS (FOR PUMP PISTON /CYLINDER, HOLLOW RAM&
SOLID RAM PLUNGER

O-ring are torus-shaped seals of circular cross-section made from a variety of elastomeric
and are used in static and dynamic condition.

Material Nitride Butadiene (class A)

And we have selected from compatible for different purpose.

I. O - RING FOR PUMP PISTON /CYLINDER

O-ring piston with diameter of; D=12mm

I. O - RING FOR HOLLOW RAM

Dmo=90.56mm

II. O - RING SOLID RAM PLUNGER

O-ring of plunger with d=10.4mm

Page 71
 3.4.12 DESIGN OF THE RELEASING SCREW

Material alloy steel, ANSI1318, Sy=75MPa

The selected STD screw M6

3.4.13 DESIGN OF REFILING SCREW;

Material:-alloy steel and the selected STD screw is M3.

CHAPTER 4

HOUSING DESIGN

4.1 INTRODUCTION

Housing encloses and supports the machine parts. It is most commonly made of cast iron or
cast steel although welding is also used as a means of fabrication.

Design of housing begins when the other elements of a mechanism have been designed in
every detail. Housing is just one of the components of the, as a shell is an integral part of a
tortoises skeleton. Housing is almost always the biggest part of a mechanism. It is usually
made as a closed box, so that the rest parts are mounted inside it. In this respect the
housing also serves as a guard.

4.2. FUNCTION OF HOUSING

SERVING AS AGUARD; Housing isolates a mechanism from the surrounding to create

conditions inside that are confortable for the mechanism. On the other hand, the housing
isolates surrounding, including personal, from the mechanism. So that we are protected
from hearing the noise and from being sprinkled with hot oil; besides we can’t easily put
our finger into it.

Page 72
The housing is an assembly basis for the rest of parts and unit of the mechanism. There for
it should meet some obligatory requirement;

Because mechanism is assembled inside the housing, the latter must be designed so as to
enable assembly operation and the control of parameters to be checked after assembly. i,e
the housing should have;

 Parting or sufficiently sized openings that enables convenient assembly &

 Control of the mechanism.

 Dimensions should be accuracy.

 Material should be;

 Heat resistance

 Ability to clump noise and vibration.

 Low weight

 Ability to with stand aggressive environment such as; sea water & others which can
be achieved on any material by suitable coating.

ALIGNMENT OF PIECES AND SHAPES OF HOUSING

Means must be provided to get the various pieces of the housings to line up properly when
the machine is assembled. This lining up cannot be done by the bolts which hold the
housing together since these bolts cannot be very accurately located them selves. Because
of this, and to aid assembly, the holes through which the bolts pass are considerably larger
than the bolts completely incapable of accurately aligning the housing parts.

SUPPORTING THE HOUSING

The housing, which commonly supports the machine parts, must itself be supported on a
floor or foundation surface. This is generally accomplished by forming a base as part of the
housing. The base is on only one piece of the housing and the housing should be designed
with this in mind. If more than one piece of the housing were extended downward to rest
on the floor or foundation, difficulty would be encountered in trying to get the bottom
surfaces of the pieces to line up together. Hence the base should be made of one piece
wherever possible.

Page 73
4.3 MATERIAL SELLECTION FOR HOUSING

Because housings are intricated shaped, they are mostly cast.

Gray cast iron;

 it has good castability & machinability,

 corrosion resistance,

 good wear resistance (b/c it is impregrated with graphite)

Page 74
 CHAPTER 5

MANUFUCTURING PROCESS

A. FOR THE PLUNGER OF THE PUMP.

STEPS;

I. First select with the appropriate diameter.

II. Then face and turn the work piece according to the dimensions.

III. Make internal groove for O-ring with the required thickness and depth.

IV. Finally with the precise finishing machine make finishing.

B. FOR SOLID RAM:

-STEPS;

I. Initially select the blank (work piece) with the required dimension and faces the
work piece by using lathe machine for the required and exact dimension

II. Secondly drill the internal blind with the required dimension (diameter) by using
lathe machine with out missing the center

III. Finally :- steep turn the external part of the solid ram and finishing process with
high surface finishes required so that use precise surface finish machine .

C. FOR HOLLOW RAM

STEPS;

Page 75
 I. Make the blank by casting with a dimension of the nearest to the exact dimension
and bore and turn the internal and external part by using lathe machine.

II. Make groove for the O-ring seal with the appropriate dimension.

III. Make some finishing with précised surface.

IV. Finish material or machine like internal and external grinding machine.

B. FOR THE BASE PLATE

STEPS;

I. By using casting process make the lower base plate blanks which is suitable for
machining

II. Correct the casting blank for the appropriate dimensions.

III. Drill the upper surface for the fluid passage to the required diameter and make
thread for releasing screw with 1mm pitch.

IV. Make thread the upper inner surface to tight the cylinder and the reservoir with a
metallic thread engagement part with 1mm pitch by using lathe machine.

V. Finally make the necessary surface finish.

E) FOR EXTENSION SCREW:-

STEPS;

I. Select the blank (work piece) with a required dimension and by using lathe machine
face and turn for the required dimension.

II. Chamfer the lower part of the screw by 45° for easy of losing.

III. Make a thread with a square thread by using the appropriate pitch and use milling
machine for easiness, when using indenting to this thread, use the appropriate pitch.

IV. Finally use the necessary fining by using surface finishing machine

F) FOR THE HANDLE

The handle is made from the round bar.

Page 76
STEPS;

I. Turn the round bar and face with the required specification.

II. Make to some length knurling for good griping ability.

III. Finally make the required surface finish. It is usually made by extrusion process.

G) FOR THE SOCKET

STEPS;

I. The socket is made from socket metal of the required thickness.

II. Cut the sheet metal with the correct lay out by using cutter machines.

III. Drill the socket metal for pin connection with a drilling machine.

IV. Roll the sheet metal with accurate dimension.

H) FOR THE CYLINDER OF THE PUMP

STEPS;

I. Prepare hollow round bar with the required dimension.

II. Bore the round bar by using lathe machine to the required diameter.

III. Make thread by using lathe machine on the lower part of it.

IV. And make hexagonal head by using milling machine on the upper part of it.

V. Finally make the necessary finishing.

I) FOR RAM CYLINDER

STEPS;

I. Make the blank by casting with the nearest dimension that enables as to make the
exact dimension bore and turn the dimension by using lathe machine with the
required dimension.

II. Make the groove for O-ring seal with the appropriate depth with by using lathe
machine on the top inner surface of the cylinder.

Page 77
III. Make precise surface finishing by using surface grinding machine.

IV. Finally on the lower part and on the upper part make a thread for thigh ting with
the top cup and base plate

J) FOR OCTAGONAL TOP CUP

STEPS;

I. By using casting process make the top cup handle which is suitable for machining.

II. Make some correction the casting for the appropriate dimension.

III. Next make a thread at the lower and upper inner surface to tighten the cylinder and
the reservoir with a metallic thread arrangement part with 1mm pitch by using
lathe machine

IV. Finally make necessary surface finishing process.

K) O-RING:-

O - Ring seal made from rubber compound by the process vocalizations.

First make mold for the vocalizations process then, insert the compound on it.

L) FOR THE RESERVIOR

STEPS;

I. The reservoir can be manufactured from the sheet metal with the appropriate
thickness.

II. First prepare a sheet metal with appropriate thickness, width and height. Then, roll
the sheet metal by using rolling machine.

III. Next weld the rolled metal using welding machine .then make thread at the lower
part and the make groove at the lower and upper inner surface to the required
length, width and height.

IV. Finally make a necessary surface finish

M) LINK: - can be manufactured by using sheet metal with the appropriate length and
thickness.

Page 78
  First cut a sheet metal in a strip then drill at the required position for pin
connection.

 Finally bond with the required dimension.

N) SPRING;

If spring is of small diameter & the wire diameter is also small then the spring is normally
manufactured by cold drawn processes through mangle. How ever for a spring having large
coil diameter & large coil diameter one has to go for manufactured by hot process. First one
has to heat the wire & then use proper mangle to wind the coil.

CHAPTER 6

ASSEMBLY AND DISASSEMBLY PROCESS

The jack assembly is portable , self contained unit with a single speed manually operated
pump at the lift unit consisting of three rams and on extension screw or cased within an
anchored cylinder mounted on the base .A stamped shell enclosed the ram and cylinder to
form the fluid reservoir.

6.1 ASSEMBLY PROCEDURE

The following steps will help us to assemble the hydraulic bottle jack.

i. First put all components of HBJ in order pair and identify the dimension of all
components.

ii. Put the base on the on the flat table.

iii. Assemble the cylinder with the base together with the base plate.

iv. Assemble the reservoir to base together with sealing part.

v. Insert O-ring and seal of nut to piston.

vi. Assemble piston to the piston.

vii. Assemble nut to piston.

Page 79
viii. Insert adjusting screw and adjusting screw socket to piston road to get ram.

ix. Assemble O-ring (pump, plunger).

x. Assemble plunger, spring bolt, short pin, link plate, and swing socket.

xi. Assemble oil fill plug, pin, release valve seal, boll, and spring with base.

xii. Install rubber handle holder onto the top nut & slide down ward until it rests upon
the reservoir of the jack.

xiii. FINALLY assemble the handle section by lining up the spring detent in the rubber
grip section with the slot in the other section.

6.2 DISASSEMBLY PROCEDURE

Steps;

1. Clean table (keep the work area clean and well it)

2. Use manuals

3. Open the jack base.

4. Drain the hydraulic oil.

5. Open the bottle jack unit.

6. Safely over load the check valve.

7. Disassemble the plunger.

8. Clean the bottle jack unit passage ways.

9. Release the valves (O-ring).

10. Check valves & safety over load valve.

11. Disassemble the ram seal.

You can refer the fallowing diagram

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 Chapter 7

Cost estimations

Cost estimation is include the analysis of the cost material ,cost of manufacturing, cost of
standard materials available in market like bearing, bearing house, block support and etc. and
cost of manufacturing.

5.3.1 Cost of materials

The cost of materials are bought and sold in kilogram. And every parts of the design may vary
differ by their mass and specification of the material. The formula of cost analysis is;

Total cost = [direct material cost]+[direct labor cost]+[direct expense]+

[Overhead cost manufacturing]+ [administrative OHC]

1 direct material cost

A) Pump cylinder
- Material specification= mild steel
- Density = 7850 kg/m3
- Diameter= 20 mm= 0.02m
- Height=600mm=0.6m

π D2 × L π ( 20 mm ) 2 ×600 mm
Volume( V )= = =0.0001884 m3
4 4

We know that the shaft material is steel and the density of steel is 7850 Kg/m3

ρ=m/V Where m is mass of material

V is volume of the material

m=ρ∗V =7850 kg/m3∗0.0001884=1.47kg

Then we know for 1kg mild steel the cost is 120 in Ethiopian birr.

1kg=120 birr

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 1.4784kg=x x=177.36birr

B) Ram cylinder

- Material specification=mild steel

- Density=ρ=7850kg/m3

- Volume of ram is already calculated= 585,979.3 mm3=0.000585m3

Then:

ρ=m/V

m=ρ∗V =7850 kg/m3∗0.000585=4.59kg

And we know that 1kg=120birr

4.59 kg=x x=550birr

c) Top cup

- Material specification= grey cast iron

- Diameter= 90.56mm

- Thickness= 19mm

- Density= 7300

π D2 × L π ( 91mm ) 2 ×19 mm
Volume( V )= = =0.000483 m3
4 4

ρ=m/V

m=ρ∗V =7300 kg/m3∗0.000483=3.52kg

We know that 1kg of cast iron is around 200 birr, then

1kg = 200 birr

3.52kg =x x=704birr

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 d) Plunger

- Material specification=mild steel

- Density=ρ=7850kg/m3

- Length =65mm

- Diameter =12.12 mm

π D2 × L π ( 12.12 mm ) 2× 65 mm
Volume( V )= = =0.0000749 m3
4 4

We know that the shaft material is steel and the density of steel is 7850 Kg/m3

ρ=m/V Where m is mass of material

V is volume of the material

m=ρ∗V =7850 kg/m3∗0.0000749=0.059kg

Then we know for 1kg mild steel the cost is 120 in Ethiopian birr.

1kg=120 birr

0.059kg=x x=70.86birr

e) Reservoir

- Material specification=mild steel

- Density=ρ=7850kg/m3

Ram volume= Reservoir volume, then the cost of material will be the same 550 birr

f) O-ring

- Material specification = grey cast iron

I) for hollow ram

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 - Diameter =91mm

- Thickness= 3mm

π D2 × L π ( 91mm ) 2 ×3 mm
Volume( V )= = =0.000078 m 3
4 4

We know that the material is grey cast iron and the density of steel is 7300 Kg/m3

ρ=m/V Where m is mass of material

V is volume of the material

m=ρ∗V =7300 kg/m3∗0.0000749=0.056kg

We know that 1kg cast iron is 200 birr;

1 kg= 200 birr

0.056kg=x x=11birr

With the same procedure :

II) For solid ram x= 13 birr

III) For the pump piston x=12 birr

gd) Handle

- Material specification= carbon steel

- Diameter= 20mm

-length= 65mm

π D2 × L π ( 20 mm ) 2 ×65 mm
Volume( V )= = =0.0002041 m3
4 4

m=ρ∗V =7850 kg/m3∗0.0002041=1.602kg

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Then 1kg=120 birr

1.602kg=x x=192.24 with the same procedure the other parts are listed below.

2.Direct labor cost ( DLC ): - is the cost of technicians/machinist that operates the materials into
the required shape or designed. Office workers and the person who see the finished material is
not theDLC. For the labors the birr is paid by hours they stay/done. Man
power rate=salary /working hours=salary/8 Hrs . per day∗22 days salary is average of all the
machinist say 1601 and lastly it comes ¿ 9.1 birr in1 hour in the shops. To finish the given shaft
48hrs.and

The total cost of labor is=9.1∗48=436.8 birr

3. Direct expense cost : - is the cost of the covered material example box for embracing bullet,
wood pattern, nail, and etc. assume there is no direct expense in our design.

I. Manufacturing overhead cost ( Mfg OHC)is indirect cost like cost of machine
depreciation, cost of materials used for our machine that operates our work pieces like
rag, coolant (grease, oil and) and etc. Manufacturing overhead cost is always greater or
equal to the direct labor cost.
Mfg OHC=1.23 DLC =1.23∗436.8=537.264 birr
The total cost (T c) of the shaft is the summation of above calculated birr

And the total cost will be summarized below.

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No material name specifications material selected total

cost

1 pump cylinder D=20mm ,l=60mm miled steel 177.36

3
2 ram cylinder V ram=585,979.3mm miled steel 550

3 top cup D=90.56mm, t=19mm grey cast iron 740

4 plunger D=12.12mm, l= 65mm milled steel 70.8

3
5 reservoir V reservoir=585,979.3mm milled steel 550
6
O-ring specification on their diameter grey cast iron 36

and thickness

7 handle d=20mm, l=300 carbon steel 192.24

8 nut n=20, d= 12, h=20mm, Dc=8mm malleable cast iron 20

9 spring n=7, l=30.05, p=5.05 beryllium copper 23

10 screw Dc=8mm, h=1,25 alloy steel 40

11 pin Dc=8mm and with their alloy steel 12

structure

12 handle socket link depending on their handle design alloy steel 15

13 base plate depending on their overall grey cast iron 45

design

14 ball depending on the ton lifting stainless steel 19

capacity

total sum=2490.4

APPENDIX

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TABLE1. STANDARED WIRE GUAGE (SWG) NUMBER & CORRESPANDING DIAMETER OF
SPRING WIRE

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 REFERANCE AND LITERATURE

1. Text book of machine design, by R.H KHURMI & J.N

2. Omega

3. Machine elements life and design, by; B.M. KLEBANOV, DAVID M.BARLOM
&FREDREC E. NYOSTROM

4. Design of existing car jack by; MOHAMED AFIQ BIN MOHAMUD FAUZI.

5. How to select the correct hydraulic oil for your machine by; BRENDAN CASEY.

6. Text book of material science. By; CALLISTER.

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