1.

Introduction

Hydraulic bottle jack is portable device which is used for vertical

lifting of axles of vehicles, aircraft or other rolling equipment for the purpose of
changing or repairing tires, wheels, springs or related parts and also for checking
some mechanical system of vehicle.

The jack assembly unit mainly consisting of:-

 Manually operated pump

 Two rams ( pistons )
 An extension screw
 Cylinder mounted on the base
 A shell encloses the rams & cylinder to form the fluid
reservoir
 Valve and e.t.c

Manually-Operated Pump used in hydraulic bottle jack is a

plunger type reciprocating pump. The pumping chamber of this type of pumps
are surrounded by one-way valves, so that the hydraulic fluid only move in from
the low pressure side i.e. suction side and out from the high pressure side i.e.
discharge side. There fore, this type of pump is used to converts mechanical energy
to hydraulic energy in the form of flow.

This pump consists of: - 1. Plunger

2. Cylinder
3. O-ring (seal)

Valves: - the simplest type of valve are used in hydraulic jack which are used to
control the transfer of hydraulic energy through the system by controlling the
fluid flow direction by moving the valve stem ( ball ) against or away from valve
seat. used to control the pressure requirement of the system.

The jack consists of the following type of valves: - 1.Intake valve

2. Discrage valve and
 3. Pressure release valve

Rams (Actuating Pistons):- rams are used to converts hydraulic energy in to

mechanical energy in the form of linear motion. This mechanical energy is used to
perform the lifting work (mechanism).Therefore, the rams are used as a force
multiplying device.

Tank (Reservoir):- The type of tank used in hydraulic jack is pressurized tank
with filler screw; this type of tank is sealed from the atmosphere, keeping dirt and
humidity out of the tank. The internal pressure also forces oil towards the pump,
avoiding pump cavitations. The filler screw is used to check reservoir (tank) for
proper fluid content and if fluid level is low, we add up to correct level through the
filler by removing the filler screw.

2. Operating principle of the jack

When the handle of the pump is moved up word (up word stroke) the ball of
intake valve is unseat against (away) from valve seat and fluid is drown from the
reservoir (tank) through the pipe in to the plunger cylinder. On the downward
stroke (pressure stroke) of the handle of the pump, fluid pressure seats the ball of
intake valve and unseats the ball of the discharge valve, forcing pressure to the
rams (pistons) cylinder. Then continued operation of the pump will create
sufficient pressure and raise the first stage ram (piston) until it hits the stop of the
second stage ram. With additional pressure, the second stage ram will be raised
until it hits the stop of the cylinder. When the pressure release valve is opened,
pressure is released through unseat ball of the pressure is release valve and fluid
returns to the reservoir, then the rams will be collapsed by the load.

Remark:- When an over load applied to the jack, excessive pressure is created
thought the system, but this pressure does not lift this load, due to
this the handle of the pump suddenly become hard & can not
perform pumping stroke, so we have to select other jack.

2.1 Lifting procedure of a load by using jack

-First, Tighten( close ) the pressure release valve properly
-Then, put the jack base on a firm and reasonably level footing. If necessary, place
a plate under the jack to provide a solid footing.
-Then, position the jack under load. If necessary, raise the extension screw to
desired height but not exceeding 2/.3 of its height.
-Finally, operate the handle of the pump in smooth and long strokes until the jack
has lifted the load.
Caution
If the handle of the pump become hard and the jack stops lifting load before the
rams (piston) are fully extended or before load is raised, when this happens, use
a jack with greater capacity to lift the load.
2.2 Lowering Procedure of a load by using Jack
-First, open the pressure release valve slowly until the jack begins to lower. The
rate of descent of the load is controlled by the degree of opening of the pressure
release valve.
-Then, the rams (piston) will be collapsed most of the way by the load, lower the
extension screw and press rams flush by the hand.
-Finally, Re-tighten the pressure release valve.
3. Force Analysis

Using lever rule

Let= Fp-Force on the pin
FH-Human force on pump handles (range from 150 to 200 N)
FF-Fulcrum (plunger) force
L- The length of pump handle, assume 300-500mm
L-Pin to pin length, assume 30-50mm

f
f
f
f

►by using equilibrium equations, we can find the value of Fp & FF

→ ∑Fy=0

FF -FP -FH=0 ► FP = FF – FH ---------------------Eqn. 1

→∑MA = 0
FH * L –FF * l =0 ►FF = (FH * L) / l --------------Eqn.2
►Assume FH=200N
L=400mm
L=40mm
►FF = (200 * 400) / 40 =2000N
►FP=FF –FH=2000-200=1800N
The Pressure created by the pump (PP)
►PP = FF /AP Where
AP = π (DP) 2 /4 AP =Area of the plunger
Let, assume DP =14mm DP =Diameter of the plunger (10-16mm)
AP = π (14)2 /4 = 153.86 mm2 = 154mm2
PP=FF /AP = 200N / (154x10-3) m2 =12.99Mpa
=13Mpa
►By considering Pascal’s law (pp0rinciples) ,we can specified the area of the
cylinder of the piston.
Pascal’s law states that:-
The pressure force applied to confined liquid is transmitted equally in all
directions. I.e. the pressure in the hydraulic fluid is the same every where in the
system but the force at the cylinders will be proportional to their respective cross-
sectional area.

P=F/A
According to Pascal’s principles
PP= PC= W Where
AC PC= Pressure in the cylinder
13x106Pa = 10.5x103 ASR = Area of the solid RAM
AC PP = The pressure created by the PUMP
ASR= 10.5 x 103 W = Capacity = 10.5KM
13 x 106
ASR= 10500 x 10-6
13
ASR = 807.69mm2
≈ 808mm2
AC= π DCI2 - But DSR = DHR1
4 Where x
DSR= Diameter of Solid RAM
DHR = Inner Diameter of Hollow RAM
DSR2 = 4AC
π
DSR = 4 x 208 = 32.08
3.14
DSR= DHRi ≈ 32mm

4. Material Selection
& Stress Analysis
for each parts of JACK
4.1 Material selection & stress Analysis for the Extension screw with square
threaded.
4.1.1 Material Selection
The material, I selected for the Extension screw is Gray cast Iron because, Gray
cast Iron has the following properties :-
 High resistance to wear
 High fluidity at casting temperature
 Cheap =
 Excellent bearing & damping properties
 Excellent mach inability and it is available in
the market
 Type of Gray cast Iron. I used is = ASTM30, δy = 130Mpa

4.1.2 Stress Analysis

Assume the safety factor for this Extension screw is n=4
 δall = δy = 130Mpa = 32.5Mpa
n 4
1. Core diameter of screw under compression,
dc = 4WB Where
π δall dc= core diameter
dc= 4x 10.5x 103x 1.25 W= load
3.14x 32.5x 106 δall= allowable stress
B= over load factor= 1.25
dc= 22mm

2. Torque to raise the load and over come friction between nut and screw.
Ts= ½ wdm ton ( α +Ø)

Where
dm= men diameter of screw
dm= (do + dc)/2
From table P1 & P2, Proportions of square threads
Do= 26mm Where
c.d= 2 do= Major diameter of screw
P= 5 (type normal) cd= Common difference
µ= 0.20 P= Pitch
Ø= Friction angle
µ= coefficient of friction
α= Helix angle

 dm= do+dc = 26+22 =24mm

 2 2
 Ø= tan-1(µ)= tan-1(0.20)= 11.31º
 α = tan-1 P = tan-1 5 = 3.8º
π dm 3.14x24
 Ts= ½x 10.5x 103x 24 tan (3.8 + 11.31)
Ts = 34x 103Nmm = 34Nm

3. It satisfies condition for self locking because,

Ø>α
11.31 º > 3.8 º

4. Checking the screw for the principal stress due to the load.

 Direct compressive stress = W = W = 4W

Ascrew πdc2 πdc2
4
= 4x(10.5x 10-3) = 27.6MPa
3.14x(22x10 )
-3 2

 Maximum torsional shear stress = 16Ts = 16 x 34

π(dc)3 3.14x(22x10-3)3
= 16.27mpa

 Bending stress due to eccentricity = 32M

π (dc)3
M= W x eccentricity
Eccentricity = 5mm, Minimum
M= 10.5x103x5x10-3 = 52.5Nm
=
32(52.5) = 50.25Mpa
3.14x (22x10-3)
 Maximum principal stress = δc + δc2 +4  2
2
= 27.6+2(27.6)2 +4(16.27)2
2
= 32Mpa
 Che cking, the extension screw will buckle or not.
Buckling: - is made of failure in which large deformation of a member
results due to unstability that arises from compressive loads.
This Buckling failure can be analysised by using rankine Gorden formula.
 Our active length of the screw (l)= 35mm
 dc= 22mm
 The end fixture coefficient = 0.25
  The Rankin constant 300N/mm2 & 1
7500
 The Rankin constant for the screw = 1 = 1
7500x0.25 1875
 The Rankin load for the screw = fc Ac
1+1 1
a k
 fc = 300N/mm2
 Ac= πdc2 = 3.14 (22)2 = 379.94mm2
4 4
 1 = 1 = 0.0005
a 1875
 l , K =I/A , I= πdc4 = 3.14 (22)4 = 11493.19mm4
K 64 64
K = 11493.19 = 5.5mm
379.94

 l = 35 = 40.49
K 5.5
 The Rankin load for the screw = 300x 379.94 = 111720.22N
1+.00005 (40.49)
 The permissible buckling load = 111720 = 27,930N
4
 The loading capacity of the Jack is less than the permissible buckling load
i.e., 10,500N < 27,930N,
 Therefore, our screw is safe.

For Nut
 Number of threads, from bearing consideration.
i= 4W Where
π(do -dc )Pb
2 2
i= No of threads
i= 4x10.5x103 Pb= allowable beering pressure from
3.14((26x10-3)2-(22x10-3)2)x12x106 table P3 & Assume =12 Mpa

i = 5.8
≈ 6 threads
 Length of nut = i x Pitch = 6x5 = 30mm
 The outer Diameter of the nut (Do) = 4W + dc2
π δall
= 4x10.5x103 + (22x10-3)2
3.14x 32.5x10.6
≈ 28mm
For the cup
 Maximum diameter of the cup, Assume = 1.5x do
 = 1.5x26 = 39
≈ 40mm
 Thickness of the cup, Assume = t= 10mm
 Area that Resists shearing of cup = πdo.t
= 3.14x26x10
= 816.4mm2

 The induced shear stress = W

Ac

= 10.5x1000 = 12.86MPa
816.4mm2

4.2 Material Selection &

Stress Analysis for
Solid Ram (Piston)
4.2.1Material Selection
The Material I, selected for the solid Ram (Piston) is Alloy steel because, Alloy
steel has the following properties:-
 High strength, harden ability, & resistance.
 High creep, & wear resistance.
 Generally, It has a good mechanical property
 Type of Alloy steel, I used is AISI 1015, δy =313.7Mpa

4.2.2Stress Analysis
 Assume the safety factor for this solid ram = n=3
δall = δy = 313.7Mpa = 104.57Mpa
n 3
Checking, the solid Ram will buckle or not , by using Rankine garden formula
 Our active length of the solid Ram (l) =61
 Diameter of the solid ram = DSR = 32mm
  The end fixture coefficient = 0.25
 The Rankin constant for solid Ram = 1 = 1

7500x0.25 1875
 The Rankin load for the solid Ram= fc Ac
1+1 (l/k)2
a
 fc = 300N/mm 2

 ASR= πdSR2 = 3.14 (32)2 = 803.84mm2

4 4
 1 = 1 = 0.0005
a 1875
 l , K= I/A , I= πdSR4 = 3.14 (32)4 = 51445.76mm4
K 64 64
K = 51445.76 = 8mm
803.84
 l = 61 = 58.141
K 8
 The Rankin load for the solid ram = 300x 803.84 = 234339.63N
1+0.0005 (58.141)
 The permissible buckling load = 234339.63 = 78,113.2N
3
 The loading capacity of the Jack is less than the permissible buckling load
i.e., 10,500N < 78,113.2N,
 Therefore, our solid ram (piston) is safe.

4.3 Material Selection & stress

Analysis for Hallow Ram (Piston)
4.3.1 Material Selection
The Material I, selected for the Hallow Ram (Piston) is Alloy steel because, Alloy
steel has the following properties:-
 High strength, harden ability, & toughness.
 High creep, & wear resistance.
 Generally, It has a good mechanical property
 Type of Alloy steel, I used is AISI 1015, δy =313.7Mpa

4.3.2 Stress Analysis

 Assume the safety factor for this hallow ram = n =2
 δall = δy = 313.7Mpa = 156.85Mpa
n 2
►From force analysis calculation result;-
PC =13Mpa
DSR=DHRI =32mm Where
-DSR =Diameter of solid ram
-DHRI= Inner diameter of hallow
ram
►Assume the hallow ram as thin walled pressure cylinder, D ≥20
t
by using Hoop stress equation, we can get the thickness of the cylinder

δall = PcD= 13Mpa x 32mm = 1.33mm

2t 2 x 156.85
► D ≥20 = 32 ≥ 20 =24 ≥ 20, it satisfies thin cylinder rule.
t 1.33
-But for safety , t=2mm
Outer diameter of the hallow ram ( DHRO) can be
DHRO=DHRI + 2t = 32 + 2( 2 ) =32 +4 =36mm
Assume Diameter of flange parts on Hallow ram = 44mm
Checking, the hallow Ram will buckle or not , by using Rankine garden formula
 Our active length of the hallow Ram (l) =114mm
 Diameter of the hallow ram = DHRI = 32mm
DHRO=36mm
 The end fixture coefficient = 0.25
 The Rankin constant for hallow Ram = 1 = 1
7500x0.25 1875
 The Rankin load for the hallow Ram= fc Ac
1+1 (l/k)2
a
 Fc = 300N/mm 2

 AHR=( πdHRO2 - πdHRI2 )= 3.14 ( 362 - 322 ) = 213.52mm2

4 4 4
 1 = 1 = 0.0005
a 1875
 l , K= I/A , I= π (dHRO4 –DHRI4 ) = 3.14 (364 - 324) = 30960.40mm4
K 64 64
K= I/A = 30960.4 = 12.04mm
213.52
 l = 114 = 89.65
K 12.04
 The Rankin load for the hallow ram = 300x 213.52 = 61,307.87N
1+0.0005 (89.65)
 The permissible buckling load = 61,307.87 = 30,653.94N
 2
 The loading capacity of the Jack is less than the permissible buckling
load .i.e., 10,500N < 30,653.94N,
 Therefore, our Hallow ram is safe.

4.4 Material Selection &

4.5 Stress Analysis for the
cylinder.
4.5.1 Material Selection
The material, I selected for the cylinder is Low Alloy steel, because, Low
Alloy steel has the following properties:-
 Good strength & ductility
 Cheep & available in the market
 Good mechanical properties and most of the time pipes, Tubes and
cylinders are manufactured from low Alloy Steel.
 Type of Low Alloy steel, I used is SA-210, δy = 276Mpa

4.5.2 Stress Analysis

 Assume the safety factor for this cylinder=n=2

 δall = δy = 276Mpa = 138Mpa
n 2
 Inner Diameter of the cylinder = Diameter of flanged parts on Hallow
ram
= 44mm
 Assume the cylinder as thin walled pressure cylinder, D > 20,
t
 By using hoop stress equation, we can get the thickness of the cylinder.
 δall = PcD
2t
t = PcD = 13Mpa x 44mm = 2.07mm
2 δall 2 x 138 Mpa
 D > 20,  44 = 21.23 > 20, It satisfies thin cylinder Rule
t 2.07
 But for safety, t ≈ 3mm
 Outer Diameter of the cylinder can be
Dco = Dci + 2 (t) = 44 +2 (3) = 44+6 = 50mm
Checking, the cylinder will buckle or not, by using Rankine – Gordan formula.
 Our active length of the cylinder (l)=105mm
 Diameter of the cylinder = Dci = 44mm
Dco = 50mm
 The end fixture coefficient = 0.25
 The Rankin constant = 300N/mm2 & 1/7500
 The Rankin constant for the cylinder = 1 = 1
7500x0.25 1875

 The Rankin load for the cylinder = fc Ac

1+ 1 [l/k]2
a
 fc = 300N/mm2
 AC= π (dCO2 - DCI 2 ) = 3.14 (502 -442) = 442.74mm2
4 4
 1 = 1 = 0.0005
a 1875
 l , K= I/A , I= π (dCO4 – dCI4) = 3.14 (504-444) = 122749.67mm4
K 64 64
K= I/A = 122749.67 = 16.65mm
442.74
 l = 105 = 39.77
K 16.65
 The Rankin load for the cylinder = 300 x 442.74 = 130,232.33N
1 + 0.0005(39.77)
 Permissible buckling load = 130,232.33 = 65,116.17N
2
 The loading capacity of the jack is less than the permissible buckling load i.e.
10,500 N < 65,116.17N
  There fore, our cylinder is safe.

4.6Material Selection &

volume calculation for
the Reservoir.
4.6.1 Material Selection

The material, I selected for the reservoir is carbon steel because, carbon steel has
the following properties
 Ductile
 Strong
 Machinable & available in the market
 Most of the time tank & Reservoir are Manufacture from
carbon steel.
 Type of carbon steel, I used is SA-106, δy = 207Mpa

4.6.2 Volume Calculation for the Reservoir

 Volume of Hallow Ram (Vl) = π D2HRo . H.E.H.R

4
 Outer Diameter of Hallow Ram = 44
 Effective Height of the Hallow ram = 114mm
V1 = 3.14 x (44)2 x 114 = 173,252.64mm3
4

 Volume of solid Ram (V2)= π D2SR . H.E.S.R

4
 Diameter of the solid Ram = 32mm
 Effective height of the solid Ram = 61mm
V2 = 3.14 x (32)2 x 61 = 49,034.24mm3
4
 Total Volume occupied by the Rams (V) = V1 +V2
V= 173,252.64,+ 49,034.24 = 222,286.88mm3
 Assume the Height of the fluid occupies the reservoir is up to the filling screw
& Assume the height is = 85mm
 In order to find the Diameter of the Reservoir at the height of 85mm, we can
follow the following procedures.
 Volume of Reservoir = Volume of occupies by the Rams
π (DR2 - D2co) H fluid level = 222,286.88mm3
4

3.14 x (DR2-502) x 85 = 222286.88

4
DR = 222286.88 X 4 + (502)
3.14 x 85

= 5908 =76.86mm
Inner diameter of the Reservoir is =77mm
Outer Diameter of the reservoir is =83mm, by assuming the thickness of the
reservoir t=3mm

4.6.3 Quantity of fluid required

The quantity of fluid to be required to fill the reservoir is=222286.88 x 10-9 x 1000
liters
=0.222liters
≈0.25litres
4.6 Material Selection & stress Analysis for the cylinder of pump.
4.6.1 Material Selection
The material, I selected for the cylinder is Low Alloy steel, because, Low
Alloy steel has the following properties:-
 Good strength & ductility
 Cheep & available in the market
 Good mechanical properties and most of the time pipes, Tubes and
cylinders are manufactured from low Alloy Steel.
 Type of Low Alloy steel, I used is SA-209 δy = 95Mpa
4.6.2 Stress Analysis
 Assume the safety factor for this cylinder=n=2
 δall = δy = 95 Mpa = 47.5Mpa
n 2
  Inner Diameter of the cylinder = 14mm
 Assume the cylinder as thin walled pressure cylinder, D > 20,
t
 By using hoop stress equation, we can get the thickness of the cylinder.
 δall = PpD
2t
t = PpD = 13Mpa x 14mm = 1.9mm
2 δall 2 x 47.5Mpa
t ≈ 2mm
 Outer Diameter of the cylinder of the pump can be
Dco = Dci + 2 (t) = 14 +2 (2) = 14+4 = 18mm
► When the lever is on upward stroke, Assume, the lever make an angle of θ =600
from stationary position.
►X is the distance move by the plunger in up ward & down ward stroke
The value of X can be X= 40mm x sin600 =34.64
x ≈35mm
Checking, the cylinder will buckle or not, by using Rankine – Gordan formula.
 Our active length of the cylinder (l)=45mm
 Diameter of the cylinder = Dci = 14mm
Dco = 18mm
 The end fixture coefficient = 0.25
 The Rankin constant = 300N/mm2 & 1/7500
 The Rankin constant for the cylinder = 1 = 1
7500x0.25 1875

 The Rankin load for the cylinder = fc Ac

1+ 1 [ l/k]2
a
 fc = 300N/mm 2

 AC= π (dCO2 - DCI 2 ) = 3.14 (182 -142) = 100.48mm2

4 4
 1 = 1 = 0.0005
a 1875
 I , I= π (dCO4 – dCI4) = 3.14 (184-144) = 3265.6mm4
K 64 64
K= I/A = 3265.6 = 5.70mm
100.48
 l = 45 = 62.33
K 5.70
 The Rankin load for the cylinder = 300 x 100.48 = 29,232.95N
1 + 0.0005(62.33)
 Permissible buckling load = 29,232.95 = 14,616.48N
 2
 The fulcrum ( plunger ) force is less than the permissible buckling load i.e.
2000 N < 14,616.48N
 There fore, our cylinder is safe.

4.7 Material Selection &

stress Analysis for plunger
of pumps.
4.7.1 Material Selection
The material, I selected for the plunger is Low Alloy medium carbon steel,
because, Low Alloy medium carbon steel has the following properties:-
 Strong & hard
 Heat treatable
 Good mechanical properties
 The basic alloying elements are Cr,Mo& Ni
 Type of Low Alloy medium carbon steel, I used is SA-369 δy = 207Mpa
4.7.2 Stress Analysis
 Assume the safety factor for this plunger=n=2
From Compressive Stress (δc )
δc = FF Where
APR FF =Fulcrum (plunger) force
APR=Area of plunger rod
 APR= π dPR2
4
δc= δall = δy = 207Mpa = 103.5Mpa
n 2
δc= δall = 4FF
π dPR2
DPR= 4FF = 4 x 2000 =4.96mm
π δall 3.14 x 103.5
For safety,Assume DPR= 12mm

 Checking, the plunger will buckle or not, by using Rankine – Gordan

formula.
 Our active length of the plunger rod (l)=41mm
  Diameter of the plunger = DPR = 12mm
 The end fixture coefficient = 0.25
 The Rankin constant = 300N/mm2 & 1/7500
 The Rankin constant for the plunger rod = 1 = 1
7500x0.25 1875

 The Rankin load for the plunger rod = fc Ac

1+ 1 [l/k]2
a
 fc = 300N/mm 2

 AC= π (dPR2 ) = 3.14 (122 ) = 113.04mm2

4 4
 1 = 1 = 0.0005
a 1875
 l, I= π (dPR4 ) = 3.14 (124) = 1017.36mm4
K 64 64
K= I/A = 1017.36 = 3mm
113.04
 l = 41 = 186.79
K 3
 The Rankin load for the plunger = 300 x 113.04 = 31,026.53N
1 + 0.0005(186.79)
 Permissible buckling load = 31,026.53 = 15,513.66N
2
 The fulcrum ( plunger ) force is less than the permissible buckling load i.e.
2000 N < 15,513.66N
 There fore, our plunger rod is safe.
4.8 Calculation of No. of Stroke required to lift the load up to maximum lifting
height
No. of stroke =Volume of Hallow Rom (V1) + Volume of solid ram (V2)
Volume of the Pump
 = π D2HRo . H.E.H.R + π D2HRo . H.E.H.R
4 4 4
π DP2 .
Hplunger
4
= 3.14 x (44)2 x 114 + 3.14 x (32)2 x 61
4 4 4
3.14 x (14) X 35mm
2

= 173,252.64 + 49,034.24 = 222,286.88

5,385.10 5,385.10
= 41.28

 Therefore, No of stroke Required to lift a load up to maximum lifting Height is

= 42 Stroke
+

4.9 Material Selection &

Stress Analysis for the
Upper Plate (housing)
4.9.1 Material; Selection
The material, I selected for the upper plate (housing) is ductile cost Iron because,
Ductile cost Iron has the following properties:-
 High ductility
 Good fatigue strength
 Good wear & shock resistance
 Type of Ductile cast Iron, I used is, Ductile Iron 60-40-18, δy= 324Mpa

4.9.2 Stress Analysis

 Assume the safety factor is n = 2
 δall = 324 = 162 Mpa
2
 Thickness of the plate = t = CD P
δall
t= 0.54 X 50 13Mpa C=0.54
162Mpa P=13Mpa
t= 7.65mm
 Therefore, for safety the critical point of the plate, assume the thickness t =
10mm
 Shear checking at critical height = h = 15mm
 F = Pc. A = 13Mpa [π/4 (502 - 362)]
= 12,286.82N
 Shear stress = F/A = F = 12,286.82 = 5.22Mpa
πDH 3.14 X 50 X 15

 all (allowable shear stress) = 0.4δy

= 0.4 X 324 = 129.6Mpa
 The calculated shear stress is less than the allowable shear stress, there fore,
our upper plate (Housing) is safe.

4.10 Material Selection

for the Base plate
The Material, I selected for the base plate is Gray cast Iron, because, most of the
time base structures are manufactured from Gray cast Iron & it has the following
properties:-
 High resistance to wear
 High fluidity at casting temperature
 Cheap
 Excellent mach inability
 Excellent bearing & damping properties
 It is available in the market
 Type of Gray cast Iron, I used is = ASTM 30, δy = 130Mpa

4.11 Material
Selection & stress
 Analysis for the
handle of the PUMP.

 The material I selected for the handle is carbon steel.

 Type of carbon steel, I used is SA-106, δy =207Mpa
 Assume the safety factor for this handle is n =2
 δall = δy = 207 = 103.5Mpa
n 2

 all = 0.40δy = 0.40 (207) = 82.8Mpa

 By using singularity function, we can find the shear force (V) & the
Bending moment of the Handle.
 Low of Singularity functions
(x-a) n = (x-a) n, for X > a
0, for x<a

For SHEAR FORCE (V)

V= -200 <x-0>º + 2000< X – 360>º - 1800<x – 400>º-)
 at X = o, V = -200N
 at X = 360, V = -200+2000= 1800N
 at X = 400, V = -200 + 20 – 1800 = 0 N
For Bending Moment (BM)
V= - 200<X -0> + 2000 < X – 360> -1800 < X- 400>
 at X = o , M= 0 Nmm
 at X = 360, M = -72000 Nmm
 at X = 400mm, M = -80000 + 80000 = 0 Nmm
I. The free body diagram of the force

II. The shear force Diagram

III. The Bending moment Diagram
 There fore our Tmax = 1800 Nmm
Mmax = 72000 Nmm
 The Diameter of the Handle we can get by analyzing the normal & shear
stress.
Shear stress  = V/A
 all = 4V = d = 4V = 4 X 1800 = 5.26mm
πd2 πall 3.14 X 82.8
Normal Stress
δall = 32M =d = 32 m = 32 X 72000 = 19.20mm
πd3 π δall 3.144 X 103.5

 Therefore, Diameter of the handle is D = 20mm

4.12 Material
Selection & stress
Analysis for the
socket of the
handle.
 The Material, I selected for the socket of the handle is carbon steel.
 Type of carbon steel, I used is SA -106, δy = 207Mpa
 Assume the safety factor for this socket is n = 2
  δ all = δy = 207 = 103.5Mpa
2 2
 all = 0.40δy = 0.40(207) = 82.8Mpa
For shear stress
all= FF = 4FF
A π(D2-d2) Where
-FF=Fulcrum force
(D2-d2) =4FF -D =Outer diameter of the socket
π all -d=Inner diameter of the socket

D2 =4FF + d2
π all

D2 =4 x 2000 + (20)2 =430.770mm2

3.14 x 82.8
D=20.76mm , t=20.76-20= t=0.76mm

For Normal Stress

δ all = FF = 4FF
A π(D2-d2)

D2 =4FF + d2 =4 x 2000 + (20)2 =424.62mm2

π δ all 3.14 x 103.5

D=20.61mm, t=20.61-20 =t= 0.61

For safety, we can use a material thickness greater than 0.76mm, therefore, we can
use 2mm thick material

4.13 Material Selection

& stress Analysis for the
pins at the plunger & link
4.13.1 Pin at the plunger
:-this pin is used to retain the plunger relative to the handle socket
►The material, I selected is alloy steel, Type AISI 1015, δ y=313.7Mpa
►Assume the safety factor is n=3
δ all =δ y = 313.7 =104.57 Mpa
n 3
 all =0.40 δ y = 0.4 ( 313.7) = 125.48 Mpa

For Shear Stress consideration

The pin is subjected to double shear
all= FF = 2FF
2A πd2

d = 2FF = 2x 2000 =3.19mm

π all 3.14 x 125.48

For Bending Stress consideration

Z = M where Z=π d3
δ all 32
M=Fl
π d3 = Fx d x 1.5 4
32 4 x δ all Usual proportion of l/d =1-2
Assume l/d = 1.5 =l=1.5d
d = 2000 x 32 x 1.5 =8.55mm
4 x 104.57 x 3.14
d = 8.55 mm

For Bearing Stress Consideration

F=(lxd)Pb Assume l/d=2
F =2d2 Pb l=2d
d2 = F AssumePpb =15N/mm2
2Pb
d = 2000 = 8.16
2 x 15
Therefore, the diameter of the pin at the plunger is 8mm & its length =1.5 x 8= 12
mm

4.13.2 Pin at the link

:-this pin is used to retain the link relative to the handle socket
►The material, I selected is alloy steel, Type AISI 1015, δ y=313.7Mpa
►Assume the safety factor is n=3
δ all =δ y = 313.7 =104.57 Mpa
n 3
all =0.40 δ y = 0.4 ( 313.7) = 125.48 Mpa

For Shear Stress consideration

The pin is subjected to double shear
all= Fp = 2Fp
2A πd2

d = 2Fp = 2x 1800 =3.02mm

π all 3.14 x 125.48
For Bending Stress consideration

Z = M where Z=π d3
δ all 32
M=Fl
π d = Fx d x 1.5
3
4
32 4 x δ all Usual proportion of l/d =1-2
Assume l/d = 1.5 =l=1.5d
d = 1800 x 32 x 1.5 =8.11mm
4 x 104.57 x 3.14
d = 8.11 mm

For Bearing Stress Consideration

F=(lxd)Pb Assume l/d=2
F =2d2 Pb l=2d
d2 = F Assume pb =15N/mm2
2Pb
d = 1800 = 7.75mm
2 x 15
Therefore, the diameter of the pin at the link is 8mm & its length =1.5 x 8= 12mm

4.14 Material Selection

& Stress Analysis for the
link
 The material, I selected for the link is carbon steel.
 Type of carbon, steel, I used is SA-106, δy= 207Mpa
 Assume the safety factor for this link is n=3
 δall= δy = 207 = 69Mpa
n 3
 Width of link = 2 dpin = 2x8 = 16mm

 Thickness of link = t = width of link (usual proportion)

5
T = 16 = 3.2
5
T ≈ 3mm
  The length of link we need is l = 64mm
 Area = A = l x w = 16 x 64 = 1024mm2
 Stress due to buckling tendency
δ = R1 [ 1 + a (l/k)2]
a= 1 = 0.00016
6250
R1= load along link axis = 1800N

K = I/A , I= hb3 b/c Rectangular type

12
I = 64 x (16)3 = 21845.33 mm4
12
A = l x w = 64 x 16 = 1024 mm2
K = 21845.33 = 21.33 = 4.62mm
1024
l = 64 = 191.90
K 4.62

δ= 1800 [ 1 + 0.00016 (191.90)] = 1.81Mpa

1024mm2

 Therefore, the δall of the material, I selected is greater than stress due to
buckling tendency i.e ( 69 Mpa > 1.81 Mpa), so Our link is safe from buckling
b/c buckling can be occure when we select a material with δall < 1.81Mpa

4.15 Design&
Material Selection
for Springs
4.15.1 Spring at the Discharge Value
 Type of material – Cold drown carbon steel
 G = 86Gpa
 Type of spring is helical compression spring.

Designing Procedures
1. Assume d = 2mm Where
C=6 d=wire diameter
2. C = D/d C=spring index
D = 2 x 6 = 12mm D= main coil diameter
3. Ks = 1 + 1 = 1 + 1 = 1 + 1 = 1.083 KS=stress concentration factor
2c 2(6) 12  =maximum shear stress
4.  = Ks 8F D F= the factor acting on the
spring
πd3
 Assume the Diameter of the fluid line = 4mm
P = F/A = F = PA
 The force acting on the spring = P. A fluid line
F = 13Mpa x π x (4 x 10 -3)2 = 13 x 106 x 3.14 x 16 x 10-6 = 163.28N
4 4
 = (1.83) x 8 x 163.28 x 12 x 10 = 675.794Mpa
-3

3.14 x (2 x 10-3)3
5. all = 0.67 δult
δult = Adb = 1753.3 (2)-0.1822 = 1545.28Mpa
all = 0.67 (1545.28Mpa)
all=1035.34 Mpa
6. Safety factor =n= all =1035.34 =1.53
 675.79
Therefore our spring is Safe & acceptable.
7. The spring rate (K)
►Assume the deflection of the spring (Y)=5mm
►Assume the end details of the spring is Square & ground ends.
K= F = 163.28 =32656N/m
Y 5 x10-3
8. Number of active coils (Na)
K= d4G
8D3Na
Na= d4G = (2X10-3)4 x 86 x109 = 3.04 ≈ 4
8D3Na 8(12 x 10-3)3 x 32656
9. Number of coils ( Nt)
 Nt=Na+2 =4+2= 6
10. The slot height (Ls)
Ls=d x Nt =2x6=12mm
Ls=12mm
11. Free length of the spring (Lf)
Lf =Y + Ls = 5+12 =17mm
Lf =17mm
12.The Pitch is =Free length of the spring = Lf =17mm =2.8 ≈3
Number of the coil Nt 6
4.15.2 Spring at the Intake Valve
 Type of material – Cold drown carbon steel
G = 86Gpa
 Type of spring is helical compression spring.

Designing Procedures
1. Assume d = 1.5mm Where
C=5 d=wire diameter
1. C = D/d C=spring index
D = 1.5 x 5 = 7.5mm D= main coil diameter
3. Ks = 1 + 1 = 1 + 1 = 1 + 1 = 1.1 KS=stress concentration factor
2c 2(5) 10  =maximum shear stress
4. = Ks 8F D F= the factor acting on the spring
πd3
Assume the Diameter of the fluid line = 4mm
Assume the Suction force created by the pump which compresses the intake valve
spring =Fsuction=100N
 = (1.1) x 8 x 100 x 7.5 x 10-3 = 622.79Mpa
3.14 x (1.5 x 10-3)3
5. all = 0.67 δult
δult = Adb = 1753.3 (1.5)-0.1822 = 1628.44Mpa
all = 0.67 (1628.44Mpa)
all=1091.06Mpa
6. Safety factor =n= all =1091.06 =1.75
 675.79
Therefore our spring is Safe & acceptable.
7. The spring rate (K)
►Assume the deflection of the spring (Y)=3mm
►Assume the end details of the spring is Square & ground ends.
K= F = 100.00 =33333.33N/m
Y 3x10-3
8. Number of active coils (Na)
K= d4G
8D3Na
Na= d4G = (1.5X10-3)4 x 86 x109 = 3.87 ≈ 4
8D3Na 8(7.5 x 10-3)3 x 33333.33
9. Number of coils ( Nt)
Nt=Na+2 =4+2= 6
10. The slot height (Ls)
Ls=d x Nt =1.5x6=9mm
Ls=9mm
11. Free length of the spring (Lf)
Lf =Y + Ls = 3+9 =12mm
Lf =12mm
12.The Pitch is =Free length of the spring = Lf =12mm =2
Number of the coil Nt 6

4.16 Designation&
material Selection
for O-Ring seals
For the plunger of
the pump
 The material of the 0 – ring can be made from
Teflon (polytetrafluoro ethylene), class D.
 Plunger Diameter = 14mm from standard table d1=13.5
d2 = 2.4

For the flange of the hallow ram

 The material of the 0 – ring can be made from
Teflon (polytetrafluoro ethylene), class D.
 Hallow Ram flange diameter = 44mm from standard table d1=43.8mm
d2=4.1

For the Solid ram

 The material of the O- ring can be made from
Teflon (polytetrafluoro ethylene), class D.
 Solid ram diameter = 32mm
 From standard table = d1 = 31.2
d2 = 4.7

For the Upper plate

 The material of the O- ring can be made from
Teflon (polytetrafluoro ethylene), class D.
 Inner diameter of Upper plate = 36mm
 From standard table = d1 = 27.8
d2 = 4.3

4.17 Selection of
Hydrulic Fluid
 The fluid in hydraulic Jack is used to transmit energy as the fluid is
pumped through the system because liquids are virtually incompressible.
 The other functions of hydraulic fluids are to provide lubrication for move
parts, and to protect components from rust and corrosion.
  It is important to use a fluid with the proper fluid viscosity in order to
avoid the problems that may occur if the wrong fluid is used.
 It the fluid is to thin, it can cause:-
 Increase in internal & external leakage
 Pump slippage
 Reduction in system pressure
 Excessive component wear from
inadequate lubrication
 If the fluid is too thick, it may result in :-
 Increase in internal friction
 More power required for operation.
 Therefore, in order to avoid the above described problem it is better to use
a medium fluid viscosity with a grade 20 or grade 30.

5 Manufacturing
Process
5.1 For Extension Screw
 Select a blank (a work piece) with admission of Ø 50mm x 50mm
 Face the work piece up to the required dimensions & shape by using Lathe
machine & by following the part drawing
 Chamfer the lower part of the screw
 Threading with square thread engagement & 5mm pitch.
 Indexing the top part of the screw by using milling machine.
 Finally, make necessary finishing by using different machine

5.2 For Solid Ram

 Select a blank (a work piece) with a dimension of Ø = 35m x 130mm
 Face the work piece according to the dimension & shape on the part
drawing by using Lathe machine.
  Drill the center to the required dimension on the part drawing by using
drilling machine.
 Chamfer the internal end and treaded with tread engagement with screw
specification.
 Finally, make a groove for the O–ring seal seat & good surface finishing by
using lathe machine.

5.3 For the Hallow Ram

 The hallow ram can be manufactured by centrifugal casting with inner
diameter of 26mm & outer diameter of 45mm
 Face the outer surface according to the dimension & shape on the part
drawing by using Lathe machine.
 Bore the inner surface according to the dimension & shape on the part
drawing by using Lathe machine.
 Finally, make a groove for the O – ring seal seat at the flange of the ram &
make a necessary surface finishing by using Lathe machine

5.4 For Ram Cylinder

 The ram cylinder can be manufactured by centrifugal casting with inner
diameter of 42mm outer diameter of 52mm.
 Face the outer surface & bore the inner surface according to the dimension
& shape on the part drawing by using Lathe machine.
 Thread the upper & Lower, outer surface of the cylinder with metric
thread engagement with 1mm pitch.
 Finally, make a necessary surface finish.

5.5 For Upper Plate (Housing)

 The upper plate an be manufactured by sand casting
 Correct the casted plate to appropriate dimension on the part drawing.
 Thread the lower inner surface to light the cylinder & the reservoir with
metric tread engagement part tool with 1mm pith by using Lathe machine.
 Finally, make a necessary surface finish.

5.6 For Reservoir

 The Reservoir can be manufactured by centrifugal casting with inner
diameter of 76mm & outer diameter of 84mm
  Face the outer surface & bore the inner surface according to the dimension
on the part drawing by using Lathe machine.
 Thread the outer surface of upper & lower of the reservoir with metric
thread engagement with 1mm pitch.
 Finally, make a necessary surface finish.

5.7 For the Base Plate

 Select a blank (a work piece) with a dimension of 160 x 125mm
 Face the work piece according to the dimension & shape of the part by
using milling machine.
 Drill the oil port & the spring seat by using drilling machine.
 Close unnecessary hole by pouring molten metal.
 Finally, make a necessary surface finish.

5.8 For Plunger of the Pump

 Select a blank with Ø 16mm x 65mm
 Face the work piece according to the dimension & shop on the part
drawing by using Lathe machine.
 Male a groove for O – ring seal seat at the plunger.
 Make a hole at the rod for pin passage.

5.9 For the Handle

 The Handle can be manufactured from a metal rod with Ø 22 x 405mm
 Finally turn the rod by using Lathe machine to the Ø 20mm x 400mm.

5.10 For the Socket

 The socket can be manufactured by rolling sheet metal.

5.11 For the Cylinder of the Pump

 Select a blank with Ø 20mm x 50mm
 Face the outer surface up to a given dimensions on the part drawing by
using Lathe machine.
 Drill the center by using different drill bit diameter for some step.
 Bore the cylinder to the accurately given dimensions & shop on part
drawing by using Lathe machine.
  Finally, thread the outer lower surface of the cylinder with metric thread
engagement with 1mm pitch.

5.12 For Link

 The link can be manufacture from 3mm thick sheet metal.

5.13 O - Ring Seal

 O- Ring seal can be manufactured by using Die.

5.14 Pressure Release Value.

 The pressure release value can be manufactured by casting & face the work
piece according to the dimension & shape on the part drawing by using
Lathe machine.
 Finally, thread the surface with metric thread engagement part tool with
1mm pitch by using Lathe machine.

6. Operational Troubles, Probable Cause & Remedy.

S.No Trouble Probable Cause Remedy

1 Rams (pistons) do Restriction in fluid suction passage
not lift a load when Pressure release valve is
pump is operated. completely closed
No fluid or low fluid level.
2 Rams (pistons) do Low fluid level
not travel to full
Height Leaking discharge valve
Pressure release valve leaks
Dissemble and remove restriction.
not Seat release valve securely.
Fill with proper fluid to required
level.
Fill with proper fluid to the
required level
Disassemble and replace ball of
discharge valve
Replace ball of release value of
 repair valve seat
Oil leak Lower load and check for oil
leaks.
3 Pump operates with Defectise on O – ring of the Disassemble & replace, the
difficulty or not at plunger of the pump. damaged O –Ring
all.
4 Rams (Pistons) raise Leaking discharge valve. Disassemble & replace ball of
and fall on each discharge valve.
stroke. Pressure release valve slightly open Turn pressure release valve to
seat tightly.
5 Rams (Pistons) will Word rams have jammed. Use another jack to remove the
not lower load from the jack, and replace
the rams.

To Trouble Shoot the above described trouble we have to the following Dis-
Asseblig & Assembling procedures.

6.1 Disassembling Procedures.

A. Remove handle (22)
B. Remove the filler screw (23)
C. Pour reservoir fluid in to another container
D. Remove the pin(24) & links (25)
E. Remove pump cylinder (16) from the base plate
F. Remove the plunger (15) from the pump cylinder
G. Remove the extension screw (1)
H. Remove the upper plate (4)
I. Remove the reservoir (8)
J. Remove the second sage ram (3)
K. Remove the first stage ram (2)
L. Remove the cylinder (7)
M. Remove the Screw plug (19) of discharge value
N. Remove the spring (18) & ball (11) of discharge value
O. Remove the screw plug (21) of suction value
P. Remove the spring (20) & ball (12) of suction value
Q. Finally, Remove the pressure release value (10) from the base plate (9)
6.2 Assembling Procedures
 The Assembling procedures of parts of the Jack are in the opposite direction
of the disassembling procedures. i.e. from Q to A

derso bazie