Hydraulic Bottle Jack Final Design-1 PDF

UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICALENGINEERING
Machine design project 2
Section two
TITLE:-DESIGN
DESIGN OF HYDRAULIC BOTTLE JACK
GROUP MEMBERS NAME: ID
1. Mekuriyaw Agegnehu……………....................0771/07
Agegnehu……………..
2. Gebre kidan Arega………………………………0491/07
3. Demewoz Demeke………………………………0300/07
4. Kibikab Wubie …………………………………0662/07
5. Mequanint Adane………………………………0795/07
6. Saleamlak Tamrat ………………………………0051/08
Submitted to-INS: Misgana

MisganawAbebaw.
Submitted Date: 14/10/2009E.C.

14/10
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Acknowledgement
We would like to give glory to our instructor Mr. Misganaw Abebaw becase he gives an advice
how to do this design and support by adding extra time to finish the design. secondly we would
like to acknowledge for fourth year mechanical students those who give us some related design
samples as reference and help us by sharing designing material like text book, and those who
share idea with us for what we are going to do.
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ABSTRACT
Hydraulic bottle jack is a device that uses force to lift heavy loads in built lifting and safety
arrangements. Hydraulic bottle jack system is attached to automobile vehicle on front. Some repairs
without lifting externally drop the hydraulic bottle jack with a single button. For heavy vehicles like truck,
lorry etc., it will be easy to remove and fix the tire in case of inflated and by operating the motor in single
switch. Bottle jack components are designed based on same procedure that is from start to end, design of
Piston Rod ,Extension screw ,Head of the reservoir ,Main cylinder ,Reservoir cylinder ,Links ,Plunger
,Basement ,Pump handle and O- Ring. And the objective of this design project is to design a
hydraulic bottle jack with a high performance to lift range 20cm, load 6 ton, Operating pressure
25Mpa and Man effort put on the handle is 20 KG.
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List of figure page
Figure 1 piston inside the cylinder ................................................................................................. 6
Figure 2 piston head ....................................................................................................................... 7
Figure 3 Cap .................................................................................................................................... 8
Figure 5 Pumping cylinder .............................................................................................................. 9
Figure 6 Reservoir cylinder ............................................................................................................. 9
Figure 7 cover plate ...................................................................................................................... 10
Figure 8 Link ................................................................................................................................. 11
Figure 9 Geometric analysis bottel jack ....................................................................................... 29
Figure 10 pump piston .................................................................................................................. 32
figure 12 diagram of pascal lo ....................................................................................................... 34
Figure 13 telescopic cylinder ....................................................................................................... 37
figure 14 Piston Rod ..................................................................................................................... 41
Figure 16 Piston Head ................................................................................................................... 46
Figure 17 diameter of the cap....................................................................................................... 49
Figure 18 tangential stresses diagram .......................................................................................... 51
Figure 19 main cylinder................................................................................................................. 55
Figure 20 cylinder.......................................................................................................................... 57
Figure 21 reservoir cylinder ......................................................................................................... 59
Figure 22 Cover Plate .................................................................................................................. 61
Figure 23 threated part ................................................................................................................ 62
Figure 24 diameter of socket ....................................................................................................... 64
Figure 25 Pin Joint Mechanism ................................................................................................... 65
Figure 26 joint Pin and Plunger .................................................................................................... 67
Figure 27 Pump handle ................................................................................................................. 68
Figure 28 Pump handle ................................................................................................................. 69
Figure 29 Plunger ......................................................................................................................... 74
Figure 31 tear ............................................................................................................................... 76
Figure 32 pump handle ................................................................................................................. 77
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List of table page
Table 1 mechanical properties of the piston material ................................................................... 7
Table 2 iteration result of piston ................................................................................................. 39
Table 3 iteration result of piston .................................................................................................. 39
Table 4 mechanical properties of the piston material. ................................................................ 45
Table 7 Standard Spring Table ...................................................................................................... 82
Table 6 properties of metal ......................................................................................................... 50
Table 8 O-ring Standard Table ...................................................................................................... 85
Table 9 O-ring Standard ............................................................................................................... 86
Table 10 Standard Pin Table ........................................................................................................ 88
table 11 pipe size ........................................................................................................................ 89
Table 12 Troubleshooting Table .................................................................................................. 99
Table 13 Result of Piston Rod ..................................................................................................... 101
Table 14 Result of Main Cylinder ................................................................................................ 101
Table 15 Result of Telescopic Cylinder ....................................................................................... 101
Table 16 Result of Pumping Cylinder ......................................................................................... 102
Table 17 Result of Reservoir Cylinder ......................................................................................... 102
Table 18 Result of Cover Plate .................................................................................................... 102
Table 19 Result of Handle Socket ............................................................................................... 103
Table 20 Result of Plunger .......................................................................................................... 103
Table 21 Result of Pump Handle ................................................................................................. 103
Table 22 Result of Link ................................................................................................................ 104
Table 23 Result of Basement ...................................................................................................... 104
Table 24 Result of O-ring selection ............................................................................................. 104
Table 25 Result of Spring selection ............................................................................................. 104
Table 26 Result of Pin selection .................................................................................................. 105
Table 27 Result of Valve Selection .............................................................................................. 105
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Contents Page
CHAPTER ONE ............................................................................................................................. 1
1.1 INTRODUCTION .................................................................................................................... 1
1.1.2 Definition of Hydraulic Jacks ............................................................................................ 2
1.1.3 Background of Hydraulic Bottle Jacks............................................................................... 3
1.1.4 Classification of Hydraulic Jacks ....................................................................................... 5
1.1.5 Components of hydraulic Bottle jack ................................................................................. 6
1.1.6 Working Principle ............................................................................................................ 13
1.1 7 Objective .......................................................................................................................... 15
1.1.8 Design Methodology ........................................................................................................ 17
1.1.8 sTATEMENT OF PROBLEM ........................................................................................ 22
1.1.9 Limitation of study ........................................................................................................... 23
Chapter two ............................................................................................................................... 24
2.1 Journals and literature review ................................................................................................. 24
CHAPTER THREE ...................................................................................................................... 29
3.1. DETAILED DESIGN ........................................................................................................ 29
3.1.2 Design of Piston Rod........................................................................................................ 40
3.1.3 Design for Buckling ......................................................................................................... 44
3.1.4 Design of Piston Head ...................................................................................................... 45
3.1.5 Design of Cap ................................................................................................................... 46
3.4.6 Design of main cylinder ................................................................................................... 50
3.1.8 Design of Pump handle .................................................................................................... 69
3.1.9 Design of the Plunger ....................................................................................................... 74
3.1.10 Design of the link ........................................................................................................... 77
3.1.11 Design of the Basement.................................................................................................. 79
3.1.12 Cost Analysis.................................................................................................................. 90
3.1.13 Manufacturing Process and Maintenance ...................................................................... 94
CHAPTER FOUR ....................................................................................................................... 100
4.1 Result and Discussion ........................................................................................................... 100
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4.1.2 Results of Geometrical Analysis .................................................................................... 100
Recommendation ........................................................................................................................ 106
Conclusion .................................................................................................................................. 107
Reference .................................................................................................................................... 108
vi University of Gondar Institute Of Technology Design Project

CHAPTER ONE
1.1 INTRODUCTION
Hydraulic jacks are typically used for shop work, rather than as an emergency jack to be carried
with the vehicle. Use of jacks not designed for a specific vehicle requires more than the usual
care in selecting ground conditions, the jacking point on the vehicle, and to ensure stability when
the jack is extended. Hydraulic jacks are often used to lift elevators in low and medium rise
buildings.
A hydraulic jack uses a fluid, which is incompressible, that is forced into a cylinder by a pump
plunger. Oil is used since it is self lubricating and stable. When the plunger pulls back, it draws
oil out of the reservoir through a suction check valve into the pump chamber. When the plunger
moves forward, it pushes the oil through a discharge check valve into the cylinder. The suction
valve ball is within the chamber and opens with each draw of the plunger. The discharge valve
ball is outside the chamber and opens when the oil is pushed into the cylinder. At this point the
suction ball within the chamber is forced shut and oil pressure builds in the cylinder.
In a bottle jack the piston is vertical and directly supports a bearing pad that contacts the object
being lifted. With a single action piston the lift is somewhat less than twice the collapsed height
of the jack, making it suitable only for vehicles with a relatively high clearance. For lifting
structures such as houses the hydraulic interconnection of multiple vertical jacks through valves
enables the even distribution of forces while enabling close control of the lift.
In a floor jack (aka 'trolley jack') a horizontal piston pushes on the short end of a bell crank, with
the long arm providing the vertical motion to a lifting pad, kept horizontal with a horizontal
linkage. Floor jacks usually include castors and wheels, allowing compensation for the arc taken
by the lifting pad.
Mechanism provides a low profile when collapsed, for easy maneuvering underneath the vehicle,
while allowing considerable extension.
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This project, which is concerned the course Machine Design Project two. This is a second
design project out of two main projects that are given during the semester coverage of the course.
This second project is mainly concerned with the design steps or procedures and considerations
of hydraulic bottle jack design. The project requirement is to select suitable material, geometric,
force and stress analysis for each component of hydraulic bottle jack.
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 rams and cylinder to form the fluid
reservoir.
The hydraulic jack is one of the simplest forms of a fluid power system. By moving the handle of
a small device, an individual can lift a load weighing several tons. A small initial force exerted
on the handle is transmitted by a fluid to a much larger area. The operation of hydraulic jack
depends on Pascal‘s law. This states that when a fluid is at rest in a closed vessel and if a certain
pressure is applied at any point the pressure will be transmitted equally in all direction.
1.1.2 Definition of Hydraulic Jacks

A jack is a device that uses force to lift heavy loads. The primary mechanism with which force is
applied varies, depending on the specific type of jack, but is typically a screw thread or a
hydraulic cylinder. [9]
A hydraulic jack is a jack that uses a liquid to push against a piston.Jacks employ a screw
thread or hydraulic cylinder to apply very high linear forces. This is based on Pascal’s Principle.
The principle states that pressure in a closed container is the same at all points. If there are two
cylinders connected, applying force to the smaller cylinder will result in the same amount of
pressure in the larger cylinder. Car jacks usually use mechanical advantage to allow a human to
lift a vehicle by manual force alone. More powerful jacks use hydraulic power to provide
more lift over greater distance. The mechanical advantage is the factor by which a mechanism
multiplies the force or torque applied to it.
An automotive jack is a device used to raise all or part of a vehicle into the air in order to
facilitate repairs. Most people are familiar with the basic auto jack that was still included as
standard equipment with most new cars. These days, fewer people than ever have had to use a

car jack. This is due to the continuing improvements in modern tires that have made “getting a
flat” rare. Even so, people who like to rotate their tires themselves or who may install
snow tires before the winter and remove them in the spring need to use a jack to perform the job.
Hydraulic bottle jacks are typically used for shop work & other. They are used to lift
vehicles and other loads. Use of jacks not designed for a specific vehicle requires more than the
usual care in selecting ground condition, the jacking point on the vehicle and ensuring stability
when the jack is fully extended. The goal of this project is to generate some conceptual design of
a hydraulic bottle jack, select the best and design its components. Finally, proposing a safe,
costly and reliable hydraulic bottle jack. [9]
1.1.3 Background of Hydraulic Bottle Jacks

Bottle jacks became popular in the early 1900s when the automobile industry began to take off.
Also called hand jacks, bottle jacks provided an easy way for an individual to lift up a vehicle for
roadside inspection or service. Their resemblance to milk bottles earned bottle jacks their
name—today, they range in size and weight to offer a lifting capability ranging from one
hundred to several tons. Bottle jacks feature a vertical shaft, which supports a platform (called a
bearing pad) that directly bears the weight of the object as it is lifted.[10]
Although they are most commonly used in the automobile industry (1.5 to 5 ton jacks are
frequently used to lift cars), bottle jacks have other uses as well. In the medical industry they can
be used in hydraulic stretchers and patient lifts. In industrial applications, they can be found as
pipe benders used in plumbing, as cable slicers for electrical projects, and as material lifts within
warehouses. Their ability to lift heavy loads plays a big role in enabling the repair of large
agricultural machinery and in many construction operations. Bottle jacks can be secured within a
frame, mounted on a beam, or simply used as they are for easier jack transportation.
As the automobile became a major part of American Life in the early part of the 20th Century the
Automobile Service Industry boomed alongside of it. And while the bottle/hand jack worked fine
for lifting a vehicle off the ground they quite often required the inconvenience of crawling under
the car to set up, then, with their limited lifting stroke, sometimes necessitated jacking, securing
on stands, repositioning and jacking again - both going up and coming down - a pain in the
BUTT to be sure.[11]

The origin of hydraulic jacks can be dated several years ago when Richard Dudgeon, the owner
and inventor of hydraulic jacks, started a machine shop. In the year 1851, he was granted a patent
for his hydraulic jack. In the year 1855, he literally amazed onlookers in New York when he
drove from his abode to his place of work in a steam carriage. It produced a very weird noise that
disturbed the horses and so its usage was limited to a single street. Richard made a claim that his
invention had the power to carry near about 10 people on a single barrel of anthracite coal at a
speed of 14 m.p.h. Dudgeon deserves a special credit for his innumerable inventions including
the roller boiler tube expanders, filter press jacks, pulling jacks, heavy plate hydraulic hole
punches and various kinds of lifting jacks.
First, there's the original 'alligator' - About 4 1/2 feet long, a foot wide, 8 inches high with a
handle rising at the back to about chest level. The hydraulic jack was in the back third and the
main lifting arm took up the front two thirds. The original cast iron beasts weighed in at close to
two hundred pounds but became lighter in the 50's. This configuration is still very much with us
today, to confined primarily to the heavy duty side of the aisle for working on trucks,
recreational vehicles and big rigs in 4 to 10 ton capacities. 20 ton jacks ARE made but are rather
rare.
Somewhere in the late 30's some other clever fellow came along with a new design for a
'compact' jack only about three feet long and a tiny bit less capacity than the alligators - from 2
tons down to 1 tons. The hydraulic unit was squeezed into the back 1/4 of the frame and the
lifting arm took up the remaining 3/4's of the chassis - it'll never work, the old timers scoffed!
They were wrong and grudgingly, through the 50's the 'compact' short chassis jack took over the
industry. An added plus of the shortly was its removable handle and lighter weight (a tad under
100 pounds) which allowed for a new portability.[11]
Now a day, Hydraulic jacks are widely used all across the globe. They have a lot of
relevance in the present era, as they have made an incredible contribution in making our life
much more comfortable than it was before.

1.1.4 Classification of Hydraulic Jacks
According to the source of power
 Manually operated jack (hand or pedal operated).

 Power operated jack (pump is used)
According to the lift of ram
 High lift hydraulic Jack

 Medium lift hydraulic Jack
 Low lift hydraulic Jack
According to the arrangement of cylinder
 Vertical hydraulic Jack

 Horizontal hydraulic Jack
 Inclined hydraulic Jack
According to the number of cylinders
 Single cylinder hydraulic Jack

 Multi cylinder hydraulic Jack
According to the construction
 Hydraulic Service /Floor /jacks:

 Hydraulic Bottle jacks:
 Trolley jack

1.1.5 Components of hydraulic Bottle jack
Piston Rod
The piston rod design of a hydraulic cylinder is highly stressed and therefore it should be
able to resist the bending and the compressive force that it may encounter during it operation
without buckling. The piston should design in such a way that it is able to support a given load
without experiencing a sudden change in its configuration.
Configuration of the piston rod (ram)
The piston rod selected for this jack is solid rod since screw extension is needed.
Head of the piston inside the cylinder
The head should be designed in such a way that:
 The seal should be well mounted to it and completely prevented leakage of the oil.
 The head of the piston should be slightly extended radially (wide) so that the seal will
not be squeezed and bind when the load is lowered.
 There should be small clearance (usually 2mm) between the head and the walls of the
cylinder to minimize wear due to friction.
Figure 1 piston inside the cylinder [13]
Piston Head.
It is the upper part of piston. Used to protect some dest particles and other extra things.I can use
the mechanical properties of the piston material.
Table 1 mechanical properties of the piston materia
Material Selected Steel 3 % Ni, 0.4%C

Yield strength 1035 MPa
Shear strength 620MPa
Modulus of elasticity 207MPa
The head of the piston is taken as a uniform circular flat plate. The pressure of the oil acts
upon the plate uniformly.
Design Analysis
Now the following equation can be applied to find head the piston thickness.
Fig 4.7: Piston Head
Figure 2 piston head [13]
Cap
The cap is upper part of the piston rod on which the load is placed. It is the only part of
the whole jack which is physical contact with the profile of the load.
The upper profile of the cap should be designed in such a way that the load will not
translate (slide) horizontally during operation, thus the geometrical shape of the upper plate of
the cap should be carefully selected and it must be able to grip the load in a fixed horizontal
position.

I have selected the profile of the piston cap as follows
Figure 3 Cap[13]
Main cylinder
The basic function of the hydraulic cylinder is to

convert fluid power in to linear mechanical lift force.
In doing so, the cylinder is subjected to internal
pressure of the fluid (oil) thus it is critical part of the
jack and needs through the design. Since the internal
pressure should be high enough to sustain the load,
then the cylinder must be heavy cylinder which is expected to be thick to sustain the pressure.
Figure 4 Main cylinder[13]
Design of Telescopic cylinder
The telescopic cylinders are evaluated in the same war and the main cylinder since both are
subjected to the same internal pressure. For this part material should be Good mechanical
property It is strong and ductile Good in mach inability Good surface finish High corrosion
resistant Is light in weight, these minimize the weight of the jack Availability and low cost

Pumping cylinder
The pumping cylinder is small in size when compared to the other cylinder but is subjected to the
same pressure. Still the analysis will be the same with the previous procedures of cylinder
design
Figure 5 Pumping cylinder[13]
Reservoir cylinder
The reservoir must be a stable non relative material. It is not subjected to any type of stress
except when the cover plates are tight ended. However the stress resulted from this tight ended
can be neglected since it many not bring significant effect.
Figure 6 Reservoir cylinder[13]
As explained the reservoir only stores the oil and is not subjected to any severe stress. Thus any
type of iron used in pipe manufacture can be selected as reservoirs cylinder material but its inner
walls are chromium plated to prevent any chemical attached and rust.

cover plate
Actually the cover plate is not directly subjected to the pressure of the oil other type of reaction
force due to the loading. But since it is screwed into the main cylinder remarkable shearing many
occur on the threads.
Figure 7 cover plate[13]
Pump handle socket

As previously explained the pump handle socket transmits force from handle to pump plunger of
pump the socket is hollow in shaped and contains plates with holes that use as connecting
mechanism of the socket and the link and the plunger.
Pump handle
The force distribution on the handle and its dimensions were carefully design in the geometry
analysis. The size of the handle is selected so that the operator can easily manageable. Also we
have selected a hollow handle so as to save material. Thus, the handle can be generally viewed as
a hallow rod with inner and outer rod.
Plunger
The plunger is rod like structure found in the pump piston.
Material Selection
Mostly piston rods are made of high tensile materials finished and hardened with chromium
plating to provide resistance of corrosion.

Link
The link is connected to the base by pin joint. There are two links used to connect the socket and
the base.
Figure 8 Link [12]
Basement
The base contains threaded parts for mounting cylinder, pump and release valve. It also contains
check valves to control the flow of the oil and flow line. The overall area of the base should be
designed in such a way that it will not sink to the ground during lifting operation.
Material Selection
O-ring
In a static application there is no relative motion between parts of the groove which contact the
O-Ring. Small amounts of movement, caused by thermal expansion, vibration, bolt stretch or O-
Ring response to fluid pressure, do not alter the static definition. Static seals are often
categorized according to the direction in which compression is applied to the O-Ring cross-
section. There are two basic directions of compression: axial and radial. There are also
applications which combine both axial and radial compression (crush seals)
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 seatused to control the pressure requirement of the
system. The jack consists of Intake valve, Discharge valve and Pressure release valve.
L

Material selection
Many factors have to be considered when selecting engineering materials, but for chemical
process plant the overriding consideration is usually the ability to resist corrosion. The process
designer will be responsible for recommending materials that will be suitable for the process
conditions. We must also consider the requirements of the mechanical design properties; the
materials selected must have sufficient strength and be easily worked. The most economical
material that gives satisfied both process, this will be the material that gives the lowest cost over
the working life of the plant, allowing for maintenance and replacement. Other factors, such as
product contamination and process safety must also be considered. [4]
The most important characteristics to be considered when selecting a material of constructions

are:
A. Mechanical properties:
Include the following properties.
 Strength:- Tensile strength required
 Stiffness: - The material should have high Elastic modulus (Young’s
modulus).
 Toughness: - Fracture resistance needed.
 Hardness: - high wear resistance required.
N.B: Also the material fatigue and creep resistances are needed.
B. The effect of high and low temperature on the mechanical properties.

C. Corrosion resistance
D. Any special properties required such as thermal conductivity, electrical résistance, and
magnetic properties.
E. Case of fabrication: forming, welding, casting etc.
F. Availability in standard sizes: plates, sections, tubes etc.
G. Cost of the material

One of the most widely used steel for general purpose in the construction of bottle jack is SA-
283, Grade C. This steel has good ductility and forms welds and machines easily. It is also one of
the most economical steel suitable for bottele jack.
Now, many new series of materials like low alloy, high alloy steels, high temperature and low
temperature materials are available which can be selected to suit the requirement of every
individual need of process industry.
The important materials generally accepted for construction of bottle jack are indicated here.
Metals used are generally divided into three groups based on market cost as:-
1. Low cost: - for example: Cast iron, Cast carbon and low alloy steel, wrought carbon and
low alloy steel.
2. Medium cost: - for example: High alloy steel (12%chromium and above), Aluminum,
Nickel, Copper and their alloys, Lead.
3. High cost: - for example: platinum, Tantalum, Zirconium, Titanium silver.
Materials mentioned (2 & 3) groups are sometimes used in the form of cladding or bonding for
materials in group (1). Also, use non-metallic lining such as rubber, plastics, etc.
Vessels with formed heads are commonly fabricated from low carbon steel wherever corrosion
and temperature considerations will permit its use because of the low cost, high strength, ease of
fabrication and general availability of mild steel. Low and high alloy steel and non-ferrous
metals are used for special service.[4]
Generally, material selection process is very important for hydraulic bottle jack design.
Therefore the designer must give more emphasis for this process.
1.1.6 Working Principle

The actual working of hydraulic system that lifts the car takes place by single press of
the button provided on dashboard. When the switch is turned on the motor starts running which
is powered by a battery already available in the car. This motor facilitates the flow of oil which is
pressurized by the pump provided. This pressurized oil id then directed to the control unit
which in turn directs the flow. Distribution of the pressurized oil is controlled by a switch on
the dashboard. As the oil proceeds into the hydraulic cylinder, it exerts a certain amount of

pressure on the plunger or the ram inside the cylinder. This exerted pressure of the oil is
converted into a linear force which in turn causes the plunger in the cylinder to move out of the
cylinder. Thus ultimately the exerted pressure of the oil is converted into linear motion of the
plunger. As the plunger downwards out of the cylinder linearly, after a definite travel of the
plunger in the downward direction and once it touches the ground it starts lifting the car.[11]
Once the car is lifted to a desired height the tires can be changed. It is the specialty of a simple
hydraulic jack that it possesses a self-locking system i.e. once the car is lifted to a certain height
and even if the power to the jack is cut off the jack can still hold the entire part of car that is
lifted by it. And thus, the driver can easily change the tire.
Once the tire is changed, now the concern is to release the pressure in the jack which is in the
form of pressurized oil. Thus a relief valve is provided on the jack for this purpose. But
since it is impossible to actuate this valve manually when this jack is installed on the chassis,
this valve is then provided on the dashboard of the car in form of a switch which controls the
relief valve provided on the control unit of the system. Once the relief valve is opened the oil in
the cylinder which has lost its pressure energy, starts returning to the control unit. Once
the oil starts returning the control unit then sends the accumulated oil back to the oil sump. And
in this way the entire system efficiently works.
When we see the advantages of hydraulic systems are as below [9]
 Simpler design. In most cases, a few pre-engineered components will replace

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

 It requires simple maintenance cares
 The moving parts of this system are cooled by the oil itself used. Thus this project does
not requireany cooling arrangements.
 Checking and cleaning are easy.
 Repairing is easy.
 Replacement of parts is easy.
 The loaded light vehicles can be easily lifted.
 Manual power not required.
 Handling is easy.
 No Oil wastage. and also
The possible disadvantages of this invention may bias below, but if compare with effective it is
negligible [9]
 Elements of hydraulic system to be applied in the car have to be machined to a high

degree of precision which increases the manufacturing cost of the system.
 Leakage of hydraulic oil during its flow in the system causes heavy pressure drop or may
not lift car.
 In cold climate hydraulic oil freezes.
 The main disadvantage of a hydraulic system is maintaining the precision parts when
they are exposed to badclimates and dirty atmospheres.
 Protection against rust, corrosion,
 Dirt, oil deterioration, and other adverse environment are very important.
1.1 7 Objective
Main Objective
The major objective of this design project is to design a hydraulic bottle jack with a high
performance to
 lift range 20cm
 load 6 ton and
 Operating pressure 25Mpa AND
 Man effort put on the handle 20 KG.

Specific Objective
 Designing of Piston Head.
 Designing of rod and cap.
 Designing of main cylinder.
 Designing of telescopic cylinder.
 Designing of pumping cylinder and Plunger.
 Designing of reservoir cylinder and cover plate.
 Designing of links and basement..
 Designing of pump handle, springs and pump handle socket.
 Designing of pins O- ring & valves.
 Preparing each component of the hydraulic bottle jack and the assembly
drawing.
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. [13]
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 &
cannot perform pumping stroke, so we have to select other jack.
Lifting procedure of a load by using jack [1]
 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.
Lowering Procedure of a load by using Jack [1]
 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.
1.1.8 Design Methodology
Design of components
Geometry Analysis:-Under the geometry analysis I determined maximum and minimum height,
number of strokes, basement thickness, handle length and so on by using mathematical methods
and numerical iteration methods.
Steps of Geometrical analysis:
 The first step that use to start the analysis is take nice and reasonable assumptions of
tb(basement thickness), b(different between cap and main cylinder), tp(thickness of piston
head),tc(the sum of thicknesses of main and telescopic cylinder) and hmin(minimum height).

 The next step is determination of h1, h2, h3 and hmaxby mathematical and geometrical
approach.
 After the two steps take the following considerations to drive 4 major formulas:
 Case 1: when the plunger (pump piston) is at its lowest position.
By using this consideration I develop expression for R 2 by using equilibrium
method.
2= ∗ ( + )/( ∗ cos ) − − − − − ( )
 Case 2: when the plunger (pump piston) is at its maximum position.
By using this consideration I can develop expression for hA by using
mathematical geometry.
hA = X ∗ sinθ − − − − − −(ii)
 Case 3: Considering Pascal’s law of the fluid (oil) in the cylinders of the jack.
By using this consideration I develop expression for R 2 by using Pascal’s law.
R2 = 9kn ∗ (dA /d ) − − − − − − − − − − (iii)
 Case 4: considering volume relations of cylinders
By using this consideration I develop expression for n by using volume
relations of main, telescopic and pump cylinders.
πd1 πd2
(1.005h1 − tc) + (h2 + tc − q)
V1 + V2 4 ∗ 4 ∗
n= = − − − −(iv)
VA πdA
4 ∗ hA
 After the development 4 major equations, I take assumptions for some parameters like d2, d1,
dp, L and the load applied on the handle by the operator.
 After the above those steps I take iteration of the major formulas with different numerical
values and tabulate results. After that I take the proper and reasonable values.
Stress Analysis:-Under stress analysis I check whether the stresses are not the cause for failure
by generating factor of safety and by using failure formulas.

1. Piston Rod:-
 Draw the free body diagram
 Select the proper material with reasons
 Check failure due to compressive stress
≤ 11
∗ √12
 Check failure due to crushing
>
 And the above conditions are satisfied the design is safe.

2. Piston head:-
 Generate factor of safety and find the allowable stress.
 Then find the thickness of the head.
3. Cap:-
 Next find the allowable shear stress
 Next find the factor of safety
 Also consider the crushing stress

 Thus the above all are safe the design is also safe.
4. Main cylinder:

 Next find the radial and hoop stress and check either maximum normal stress
theory, or maximum shear stress theory.
 Next find thickness of the cylinder by using Bernie’s equation.
+ (1 − ) ∗
= ∗ −1
2 − (1 + ) ∗
 Side by side find the pitch and thread length.

5. Telescopic cylinder
 Generate factor of safety to find the tangential stress
 Then find the thickness by using Bernie’s equation.
+ (1 − ) ∗
= ∗ −1
2 − (1 + ) ∗
6. Pumping cylinder
 First find tangential and radial stresses.
 Generate factor of safety
 And find the allowable stress
 Check the stresses are safe
 After that find the thickness
7. Reservoir cylinder
 First find tangential and radial stresses.
 And find the allowable stress
 Check the stresses are safe
 Find the volume
 After that find the thickness
8. Cover plate
 Find the dimensions of the cover plate that remains undetermined
9. Pump handle socket
 Check the tensile failure
 Also check the shear failure
 Thus both conditions are satisfy the design is safe
10. Pump handle socket
 Find the BMD and SFD of the handle
 Generate factor of safety and find allowable stress
 Find handle thickness
11. Plunger
 Find allowable stress
 And find the diameter of the hole
 Find the height of the plunger.

12. Link
 Generate facto of safety
 And find the thickness of the link
 Find shear allowable
 Check the following condition full fill. < 40
13. Basement
 Generate facto of safety
 And find the thickness of the base
 Find the length and width of the basement.
Other components like pins, springs, valves and seals are selected form standard table for
appropriate dimensions and force value.
Force Analysis: this analysis part is simultaneously calculated in the stress and geometric
analysis.
1.1.8 sTATEMENT OF PROBLEM

Now a days in this country, the most available jacks are manually powered, we found out that
these manual hydraulic jacks were very difficult to be used by our farmers especially the
female ones because of the strength and energy needed to operate it making it to be time
consuming; furthermore, in scenarios of these manual hydraulic jack malfunctioning and
subsequently the collapse of the machine under maintenance could lead to musculoskeletal
disorders, injuries of the neck, back and shoulder. Thus, to overcome this problem of
drudgery, musculoskeletal disorders, injuries, increase timeliness and efficiency in the farm

while changing tires and carrying out some other maintenance works beneath the tractor
prompted the design of a remote controlled motorized hydraulic jack for tractors.
1.1.9 Limitation of study

When we design horizontal pressure vessel there is a limitation we do not consider some
Factors around economical area and others; thus limitations are
i. We are design but we do not manufacture because some design are complex to
manufacture
ii. We do not consider economical costs to manufacture
iii. How much customers want such kinds of product after manufacture and
iv. There is difference understanding between the designer and reader therefore problem
is occurring during manufacture.

Chapter two
2.1 Journals and literature review

An inbuilt lifting and safety arrangements for a Four Wheeler with a hydraulic bottle jack system
is attached to automobile vehicle on front and rear part of the chassis. During puncture or some
repairs without lifting externally drop the hydraulic bottle jack with a single button. For heavy
vehicles like truck, lorry etc., it will be easy to remove and fix the tyre in case of inflated. In this
paper, we are fixed a mechanism to lift the vehicles for the four sides and by operating the motor
in single switch. The hydraulic jack is operated by a cam which works under the mechanism of
single slider crank chain. It consists of one sliding pair and three turning pair, the lever is
connected with a return spring rod. Force applied to the piston is 10 times lesser than the weight
lifted. [11]
The device is accomplished of exerting great force. It thrust the liquid against a piston; pressure
is reinforced in the jack's container. Based on Pascal's law that the pressure of a liquid in a
container is the same at all points. It control the equipment consists of hydraulic jacks with cam
operated using the electrical power of motor. The pumping rod is present at the center. Motor
shaft is coupled with cam. Battery is operated by a motor,the motor is connected with cam. It is
rotated with the specified rpm, the cam is connected to a hydraulic bottle jack when the
continuous rotation of the cam the circular motion is converted to a reciprocating motions that
reciprocating motion used to step up the bottle jack. The link is connected with the bottle jack is
used to rise the arm. This arm connected to spring shaft is lower down and lift the vehicles. [11]
Rajmohan G 1, Jazim Haris2, Mohamed Shafin K2, Sabah Salam K2, Santhosh Kumar S2
Assistant Professor, Department of Mechanical Engineering, Dhaanish Ahmed College of
Engineering Copyright to IJAREEIE 10. 15662/ijareeie. 2015.0403072 page 1436
Bottle jacks are versatile because their horizontal position makes it possible to place them in
tight spots and provides good leverage (fig.1a). Bottle jacks have proven useful in search and
rescue missions following earthquake damage. As a result, bottle jacks are standard equipment in
firehouses and for search and rescue teams. They are also used for elevating, thrusting, weighing,

or forcing requirements. The base of bottle jacks is welded for strength. All models of bottle
jacks are capable of working in erect, angled, or horizontal positions
Then to minimize this problem follow the following procedure
1. Before operating the jack you must purge its hydraulic circuit in order to eliminate any
possible air in the System.
2. To purge the system open the release valve, turning it anti-clockwise. Then with the aid of the
lever operate The pump several times.
3. Close the release valve with the lever in a clockwise direction until it is fully closed.
4. The jack is setup for use.
5. To lower the jack, turn the release valve very tardily in an counter clockwise direction.
6. Always keep the jack in erect position, with the ram, extension screw and pump retracted after
use.
7. If you require operating the jack in a horizontal manner the pump should be located on the
lower side of the jack. [9]
International Journal of Advanced Research in Electrical, Electronics and Instrumentation
Engineering (An ISO 3297: 2007 Certified Organization) Vol. 4, Issue 3, March 2015 page
1438
BOTTLE JACKS became popular in the early 1900s when the automobile industry began to
take off. Also called hand jacks, bottle jacks provided an easy way for an individual to lift up a
vehicle for roadside inspection or service. Their resemblance to milk bottles earned bottle jacks
their name today. [5]
weight to offer a lifting capability ranging from one hundred to several tons. Bottle jacks feature
a vertical shaft, which supports a platform (called a bearing pad) that directly bears the weight of
the object as it is lifted. Although they are most commonly used in the automobile industry (1.5
to 5 ton jacks are frequently used to lift cars), bottle jacks have other uses as well. In the medical
industry they can be used in hydraulic stretchers and patient lifts. In industrial applications, they
can be found as pipe benders used in plumbing, as cable slicers for electrical projects, and as
material lifts within warehouses. Their ability to lift heavy loads plays a big role in enabling the
repair of large agricultural machinery and in many construction operations. Bottle jacks can be

secured within a frame, mounted on a beam, or simply used as they are for easier jack
transportation.
Hydraulic jack works on the principle of ―Pascal‘s lawǁ. When the handle is operated, the
plunger reciprocates then the oil from the reservoir is sucked into the plunger cylinder during
upward stroke of the plunger through the suction valve. The oil in the plunger cylinder is
delivered into the ram cylinder during the downward stroke of the plunger through the delivery
valve. This pressurized oil lifts the load up, which is placed on top plate of the ram. After the
work is completed the pressure in the ram cylinder is released by unscrewing the lowering screw
thus the pressure releases and the ram is lowered, then the oil is rushed into the reservoir.it
consists of plunger cylinder on one side and ram cylinder on the other side. These two cylinders
are mounted on base which is made of mild steel. Plunger cylinder consists of plunger which is
used to build up the pressure by operating the handle. Plunger cylinder consists of two non-return
valves i.e. one for suction and other for delivery. Ram cylinder consists of ram which lifts the
load. The ram cylinder connected to delivery valve of plunger cylinder. It is also consists of
lowering screw this is nothing but a hand operated valve used for releasing the pressure in the
ram cylinder for get down the load. [5]
aMechanical Engineering Department professor @ Sreyas Institute of Engineering &

Technology, Nagole, Hyderabad-500068, bStudent,Mechanical Engineering department,
Sreyas Institute of Engineering & TechnologyNagole, JNTUH, Hyderabad-500068, INDIA
International organization of Scientific Research 16 | P a g e
A hydraulic jack is a device that uses a liquid to push against a piston. This is based on Pascal’s
Principle. The principle states that pressure in a closed container is the same at all points. If there
are two cylinders connected, applying force to the smaller cylinder will result in the same
amount of pressure in the larger cylinder. However, since the lager cylinder has more area, the
resulting force will be greater. In other words, an increase in area leads to an increase in force.
The greater the difference in size between the two cylinders, the greater the increase in the force
will be. A hydraulic jack operates on this two cylinder system (Muchnik, 2007). Many trends
(screw or hydraulics) have gone down around the lifting applications in the automobile

workshops. Increasing the mechanical advantage of doing work remains the objective of these
developments. [10]
These jacks have outweighed conventional screw jacks that were in use at some point in time.
They consist of two cylinders joined together. It works on the principle of Pascal's law which
suggests that when there is an increase in pressure at any point in a container of fluid, there is an
equal increase in pressure at every other point in the container (Muchnik, 2007).
The origin of hydraulic jacks can be dated several years ago when Richard Dudgeon, the owner
and inventor of hydraulic jacks, started a machine shop. In the year 1851, he was granted a patent
for his hydraulic jack. In the year 1855, he literally amazed onlookers in New York when he
drove from his abode to his place of work in a steam carriage. It produced a very weird noise that
disturbed the horses and so its usage was limited to a single street. Richard made a claim that his
invention had the power to carry near about 10 people on a single barrel of anthracite coal at a
speed of 14 m.p.h. Dudgeon deserves a special credit for his innumerable inventions including
the roller boiler tube expanders, filter press jacks, pulling jacks, heavy plate hydraulic hole
punches and various kinds of lifting jacks. [10]
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 02 Issue: 07 | Oct-2015 www.irjet.net p-ISSN: 2395-0072
This project will build a prototype of a remote controlled system for a hydraulic jack with 30 ton
maximum lifting capacity that could be used in lifting
The advent of the industrial revolution which saw the major transition in the history of
manufacturing and engineering processes nurtured the acquisition of great momentum in
technological and economical advancement. “For the first time in history, the living standards of
the masses of ordinary people have begun to undergo sustained growth. Nothing remotely like
the economical behavior has happened before” (Lucas, 2002). The first cranes are thought to
have been developed by ancient Egyptian, Greek and Roman builders. Some think it was dated
as far back as the 6th century. [13]
All of these cultures developed strong skills in construction - as evidenced by the buildings they
created that still exist today. These early cranes would have used animal or man power to lift
weight. Larger cranes would have a human-powered treadmill. Fast-forward to the medieval era,
and technology in lifting equipment had not progressed, although cranes, hoists and other

equipment were in limited use in warehouses and mills. As the industrial revolution progressed,
technology improved. Whereas equipment had always been made largely of wood, stronger
materials such as steel began to be used. There was also a move away from human powered
devices, to those which harnessed new-found technologies and fuels. Steam powered cranes for
example, were introduced, especially for work on railways. Progress was slow though: cranes
powered by treadmill and hand winches continued to be used throughout the nineteenth century
and beyond (Coulton, 2004).
It’s therefore obvious that Lifting technology really didn't emerge until the start of the Industrial
Revolution in approximately 1812. Incremental stages that increased productivity were Steam
Engines, followed by the Combustion Engine, followed by Hydraulics and Electrical Motors,
and now magnetic levitation is a science incorporated into the newest high-speed trains. [7]
Engr. Mrs. G. U. Asonye , Department of Agricultural and Bioresource Engineering, Federal

University of Technology, Owerri, Imo State, Nigeria © 2015, IRJET ISO 9001:2008 Certified
Journal Page 1225

CHAPTER THREE
3.1. DETAILED DESIGN
For this design the following data’s are given:
Parameter Values
Load 6 ton(60KN)
Operating pressure 25Mpa
Lift range 20cm
Man effort 20 kg
Geometric analysis
Figure 9 Geometric analysis bottel jack [2]
Considering that the above sketch can be taken as a model to a particular hydraulic
bottle jack with the given parameters the dimensions analysis of the given drawing
(sketch) can be computes and interpreted as follows.

Important points about the geometry analysis of this jack are:
All vertical displacements force distribution over the detail parts of the jack
including any reaction forces diameters clearances are tube determines.
To find the above listed parameters, geometrical relationships between heights

pressure and forces balance and the essential clearance are very important
In addition to the above relations (which have finite number of equations which
relate the parameters) certain assumptions of values are needed to complete the
geometry.
Finally we can use numerical method (typically the iteration approach) to find the
unknown parameters
Assumptions
Once again consider the above sketch of the given jack. The head thickness of the
piston rod actually these parameters should have tube determined after design
analysis of the piston cap but we can assume some standard value to the thickness
since it may help to find the other parameters.
Let the thickness be, =
The unthreaded portion height of the cover plate, =
The thickness of the base and its components is the height of the jack below the
bottom part of the reservoir cylinder but the minimum value of these parameters
be, =
The thickness of the combined sum value of the thickness of the value has
determined, = .
Also assume the minimum height of the jack, =
Now h1, ℎ2 and ℎ3 (at labeled in the sketch) can be found as follows:
Considering the minimum left height of the jack. = 190

= ℎ1 + + +
190 = ℎ1 + 50 + 30 + 25
ℎ1 = 85
When the release valve is opened the telescopic cylinder comes down and we
assume that its upper margin will come just below upper margin of the cover plate
this leads to the following height relationship.
ℎ1 + = ℎ2 +
ℎ2 = ℎ1 + − = 85 + 30 − 20 = 95
Considering the maximum lift height of the jack
= + 150 = 190 + 200 = 390
Then we can find ℎ3 in terms of ℎ1, h2 and as follows
= ℎ1 + ℎ2 + ℎ3 +
ℎ3 = 390 − 85 − 95 − 50 = 160
As it can be seen from the sketch h 3 is not the height of the piston (instead) it is
portion of the height at the piston.
ℎ (ℎ ℎ ) = ℎ3 +
Dimensions of the handle & socket and force analysis
Hydraulic systems which use positive displacement input output device required
force analysis hydraulic bottle jack one of these systems which require force
analysis.
Variation in length and points of supports on this jack handle gives various outputs
thus iteration for acceptable range of length will be important.
Case 1: when the plunger (pump piston) is at its lowest position.

Figure 10 pump piston
Lowest Position of Socket
Let F- the force that the operator applies on the handle.
R 1 - reaction force between the link and the socket which is vertical
R 2 - reaction force between the plunger and the socket plate
Now in order the handle socket to be at equilibrium the forces and moments should
be balance as follows. This equation is valid only when the handle is horizontal.
∑ =0, 2= 1+ ∑ =0, 2( ) − ( + )
X+L
R2 = ∗F
X
When the handle is deflected by an angle then R 2 becomes
∑ =0, 2 ∗ cos ( ) − ∗( + )
2= ∗ ( + )/( ∗ cos ) − − − − − (1)
Case 2: when the plunger (pump piston) is at its maximum position.

This happens when the operator up strokes (moves the handle making is make some
specified angle with the horizontal) the handle. This case can be shown
diagrammatically as follows
Let h A - the distance through which the piston in the moves
- The angle (maximum angle) through which the handle moves with the
horizontal.
Now the rise ha is given by:
=ℎ /
hA = X ∗ sinθ − − − − − −(2)
figure 11 pump piston

Fig 4.3: Maximum Position of Socket

Case 3
Considering Pascal’s law of the fluid (oil) in the cylinders of the jack.
Let W is the load acting on the piston
R 2 be the fore acting on the plunger (actuator piston).
Then = 1∗ 1 ,
Where, P 1 = pressure required in the fluid required to hold the piston in equilibrium
A 1 =is the base area of telescopic cylinder.
Consider that both pistons move up and down with uniform velocity. The force due
to mass (which is negligible compared to the load) is not considered.
2= 2∗ 2
From Pascal’s law P 1 =P 2
= , R2 = 60kN ∗ (dA /d ) − − − − − − − − − − (3)

Case 4: considering volume relations of cylinders
In order to bring the piston to its maximum possible position the actuator cylinder
must be moved ‘n’ limits up and down. In other words ‘n’ is called the number of
strokes needed to reach the maximum lift height.
Volume of cylinder filled to move piston = n (volume of actuator cylinder moved by

the
Actuating piston)
1+ 2= ∗
Hence,
1+ 2
=
Where, V 1 = Volume of main cylinder
V 2 = Volume of telescopic cylinder

occupied by the oil
V A = Volume of the actuating cylinder

when the plunger moves up to its maximum possible position Let the main cylinder
(oscillating) cylinder is mounted in the base to a depth of about its height above the
base then the total volume of the main cylinder filled with the oil becomes.
V 1 = Volume of main cylinder
1= ℎ ℎ ∗
1 1
1= ∗ (ℎ + 0.005ℎ1 − )= ∗ (1.005ℎ1 − )
4 4
V 2 = Volume of telescopic cylinder occupied by the oil

2 2
2= ∗ℎ ℎ ℎ = ∗ (ℎ2 + − )
4 4
V A = Volume of the actuating cylinder when the plunger moves up to its maximum
possible position.
= ℎ ℎ ∗
= ∗ℎ
4
Thus, the number of strokes that the operator has to perform (repeat) to fully raise
the piston
1+ 2
=
Substitute the values of V 1 , V 2 and V A .
1 2
(1.005ℎ1 − ) + (ℎ2 + − )
1+ 2 4 ∗ 4 ∗
= = − − − −(4)
∗ℎ
4
Now we have got the four equations containing the unknown parameters of the
geometry. The four equations are summarized as follows:
Equation 1: 2= ∗ ( + )/( ∗ cos )
Equation 2: ℎ = ∗
Equation 3: 2 = 60 ∗( / )
Equation 4:
1 2
(1.005ℎ1 − ) + (ℎ2 + − )
4 ∗ 4 ∗
=
∗ℎ
4

In the above four equation the only known parameters are h 1 =85mm, h 2 =95mm and
t c =20mm. thus, numerical methods typically iteration and assumption of values will
be helpful to solve the equations since the number of unknowns are larger than the
number of equations.
Helpful Assumptions
Diameter of the telescopic cylinder d 2 :- the diameter of the piston ram can be found
by considering the crushing strength of the material selected but for this part
equation analysis we can take some minimum values of the diameter of the piston
which have to be checked later. Let it be d p =25mm.
If diameter of telescopic cylinder is d 2 then,
Figure 13 telescopic cylinder [7]
2= +2∗( )+2∗( ℎ ℎ & ℎ )
d2= 25 + 2 ∗ 5 + 2 ∗ (2 ) = 39 ( ℎ )
Diameter of the main (isolating) cylinder d 1 :-
1= 2+2∗ ( ℎ ℎ ℎ )
=5
1 = 39 + 2 ∗ 5 = 49 ( ℎ )

The range of the force that a man (operator) can apply on the handle.
Let the range of the force vary from 250-450 Newton.
Length of the handle and the socket:-
Let the length of the handle, L be vary from 500 – 700mm.
Let the length of the socket between the holes of the joint ‘X’ be vary from 50-
60mm.
Portion of piston heights that remains in the telescopic cylinder when maximum
height is reached q. let the value be 50mm.
Now let the operator wants to apply a force of 350N (averagely) on the handle the
iteration will proceed as follows with an objective of finding the possible number of
strokes to practically raise the piston up to the indicated maximum lift height.
Thus,
Equation 1: R2 = 350kN ∗ (X + L)/(X ∗ cos θ)
Equation 2: hA = X ∗ sinθ
Equation 3: dA = d2√( )
Equation 4:
1 ∗ (1.005 ∗ 85 − 20) + 2 ∗ (95 + 20 − 50) 65.425( 1 ) + 65 2

= =
∗ℎ ( ∗ℎ )
Now we select ‘3’ cases to iterate and to find the unknown results. The iteration
result is tabulated below.
Table 4.2: Iteration Result
Case 1: where L=500 mm

Table 2 iteration result of piston [2]
Known Assumed Values Calculated Values

Values
h1 h2 F,(KN) L X d1 d2 Θ Eqn Eqn2 Eqn3 Eqn4
(mm) (mm) (mm) (mm) (mm) (mm) (Degree 1 (mm) (mm) (no)
) (KN)
85 95 350 500 50 49 39 30 4.45 25 10.6 91
85 95 350 500 55 49 39 35 4.31 31.5 10.4 75
85 95 350 500 60 49 39 40 4.26 38.6 10.3 62
Case 2: where L=600mm
Table 3 iteration result of piston[2]

Values
) (KN)
85 95 350 600 50 49 39 30 5.25 25 11.5 77
85 95 350 600 55 49 39 35 5.08 31.5 11.3 63
85 95 350 600 60 49 39 40 5.02 38.5 11.2 53

Case 3: where L=700 mm=

Values
) (KN)
85 95 350 700 50 49 39 30 6.06 25 12.3 67
85 95 350 700 55 49 39 35 5.86 31.5 12.2 54
85 95 350 700 60 49 39 40 5.78 38.5 12.1 45
Then the preceding design analysis of each part will be depending on valves of
parameters obtained from case 3 and 3 rd iteration because of the value of number of
stroke is smaller than all other iterations.
3.1.2 Design of Piston Rod

The piston rod design of a hydraulic cylinder is highly stressed and therefore it
should be able to resist the bending and the compressive force that it may encounter
during it operation without buckling. The piston should design in such a way that it
is able to support a given load without experiencing a sudden change in its
configuration.
Configuration of the piston rod (ram)
The piston rod selected for this jack is solid rod since screw extension is needed.
Head of the piston inside the cylinder
The head should be designed in such a way that:
The seal should be well mounted to it and completely prevented leakage of the oil.
The head of the piston should be slightly extended radially (wide) so that the seal
will not be squeezed and bind when the load is lowered.

There should be small clearance (usually 2mm) between the
head and the walls of the cylinder to minimize wear due to
friction.
The height of the piston rod including its head and cup is
ℎ =ℎ + = 160 + 50 = 210
But when the jack is at the minimum lift of height, the total
height of the jack assembly above the base of the main
(isolating) cylinders is:
ℎ = ℎ + 0.05 ∗ ℎ + + = 85 + 85 ∗ 0.05 + 30 + 25 =
140.4 ≅ 140 .
figure 14 Piston Rod [8]
This total height have to be completely occupied by the piston so that all the oil in
the main cylinder will return back to the reservoir when the load is lowered thus to
satisfy this total height of the piston should be adjusted, that ℎ =140mm.
Material Selection
Mostly piston rods are made of high tensile materials finished and hardened with
chromium plating to provide resistance of corrosion. Stainless steel is also used as a
rod material due to its excellent anti-corrosive property.
We have the following material selected as piston rod material:

Table 4 piston rod material[3]
Material Selected Steel 3 % Ni,

0.4%C
Modulus of 207MPa
elasticity
We have selected this material due to the reason:
High compressive strength to support the load. Due to its appreciable hardness.
Give good surface finish. Relatively low cost to other grades of steel.
Design Analysis
The piston rod may fail in two ways:
Failure due to compressive stress (crushing)
Failure due to instability (buckling)
The cross section of the rod or critical loading should be calculated after
considering whether it is stressed rod or column. This consideration could be
checked by the following approach.
If the length of the rod to least cross actuation dimension ratio is less than or equals
to 11. Then the piston rod is considered as stressed otherwise considered as a
column.

Mathematically,
≤ 11, ℎ
≥ 11,
Also since the piston is round shaped d can be substituted by × √12,
= ( / )
Where,
K is the slenderness ratio.
×
( )=
64
∗
( ℎ )=
4
Then, substitute the values
≤ 11, → ≤ 11 √12 , → ≤ 40,

∗ √12
Thus,
√((( ∗ )/64)/(( ∗ )/4)) = /4
=
4
Therefore, take =25mm (from geometry analysis) and L= 140mm.
140
≤ 40 → 22.4 ≤ 40, Short column type
25/4
Thus, the piston is short and will fail due to compressive stress Crushing and
Buckling.

Design for Crushing.
= 25
= 60
=3
Next find the allowable stress,
1035
= = = 345
3
On the other hand,
= → 345 =
25
∗ 4 ∗ 4
= 169.351
This is greater than that of working load, > → 169.351 > 60 the design is
safe.
3.1.3 Design for Buckling

First find the length of piston without length of cup head.
= 140 − ( −5 ) = 140 − (25 − 5) = 120
Assume considered a solid short column then considering J.B Johnson’s equations
for buckling I have:
= ∗ (1 − /(4 ∗ ∗ ∗ ∗( / ) ))
Where, = ∗ = ∗ = 490.87
25
= = = 6.25
4 4

120
= = 24
5
= 1035 MPa
= 2, ℎ
= 207
Substitute numerical value
1035
= 409.87 ∗ 1035 1− = 424.2
4∗2∗ ∗ 207 ∗ (24)
This is greater than that of working load, > → 424.2 > 60 the design is safe.
3.1.4 Design of Piston Head

We have selected the material for the head such that the piston rod and its head are
the same material thus, we can use the previous mechanical properties of the piston
material.
Table 4 mechanical properties of the piston material.[2]

0.4%C
Modulus of 207MPa
elasticity
The head of the piston is taken as a uniform circu
lar flat plate. The pressure of the oil acts upon the plate uniformly.

Design Analysis
Now the following equation can be applied to find the piston head thickness.
Figure 16 Piston Head[2]
1035
= = = 345
3
60000
= = = = 50.22
2 39
∗ 4 ∗ 4
= 0.433 ∗ ( / ) = 0.433 ∗ 25 ∗ (50.22 /345 ) = 4.13 ≅4
3.1.5 Design of Cap

The cap is upper part of the piston rod on which the load is placed. It is the only
part of the whole jack which is physical contact with the profile of the load.
The upper profile of the cap should be designed in such a way that the load will not
translate (slide) horizontally during operation, thus the geometrical shape of the
upper plate of the cap should be carefully selected and it must be able to grip the
load in a fixed horizontal position.

We have selected the profile of the piston cap as follows
Material selection for the cap
Since the cap is in directing contact the load it has to be hard enough to contain it
and should not be easily failing due to the direct high compressive stress and this
depends on the correct selection of the material for the cap. Also local availability
and cost are also determinant factor for selection.
Considering all these things and the other factors we have selected the following
material and its mechanical property for the cap.

0.4%C
Modulus of 207MPa
elasticity
Design Analysis
The cap of the piston is subjected to high compressive stress of the load. Now
considering shearing of the cap at the joint with the piston rod we have.
60
= = = = 30.5
∗ ∗ ∗ 25 ∗ 25
Where: − ℎ

− ℎ ℎ
ℎ ℎ ℎ
And, find the factor of safety:
620
= → 30.5 = → = 20
Therefore this indicates that the thickness assumed (t p ) is safe.
Also consider crushing stress of each extended rectangular shapes on the upper
surface of the cap we have the following analysis:
Thus the compression stress is:
Where: −
Let we need n such structure on the upper surface of the cap to minimize sliding of
the loading.
Figure A- square end geometrical shape at the middle of the
Surface let these are 4 in number.
Figure B- rectangular geometry shapes (half of the above shapes) at the profile of
the cap. Let these are 8 in number.
Assume there will be 8 square shaped extended surfaces.

= =
∗
60000 1035
= = → = 12.03 ≅ 12
∗8 20
The next task is determining the diameter of the cap.
FBD
Cap Multi-View
Figure 17 diameter of the cap
Then find the Total Tearing area of the cap:
25
= 4∗ ∗ 2∗ − = 8 ∗ 25 ∗ − = 100 ∗ − 25
4 4 4 4
Next by using allowable shear find d c
W
τ =
100mm ∗ d − 25
60000
30.5 = → = 31.81 ≅ 32
100 ∗ − 25

3.4.6 Design of main cylinder
The basic function of the hydraulic cylinder is to convert fluid power in to linear
mechanical lift force. In doing so, the cylinder is subjected to internal pressure of
the fluid (oil) thus it is critical part of the jack and needs through the design. Since
the internal pressure should be high enough to sustain the load, then the cylinder
must be heavy cylinder which is expected to be thick to sustain the press
Main Cylinder
Material selection
Both cost and drawn materials can be selected as cylinder material for hydraulic
bottle jack but the most frequently selected material is called drawn deep polished
low carbon steel with relatively high stress values.
But due to the following two reasons I have selected the stainless steel, with
mechanical properties given below, as cylinder materials the reasons are:
Manufacturing feasibility
Local availability
Table 6 properties of metal [11]
Material Selected Stainless Steel

Yield strength 520MPa
Ultimate strength 860MPa
Modulus of 190GPa
elasticity
Modulus of rigidity 75GPa

Design Analysis
In hydraulic cylinder design the wall thickness it is closed so that the stress at the
working pressure (P) is less than the yield strength of the wall. Stress over the
selection of the walls cannot be assumed to be uniformly distributed. The walls
develop both tangential and radial stresses with values which depend up on the
radius.
First find the thickness and pressure of the walls by using lame’s equation as
follows. The cylinder is subjected to for radial and tangential stress ( & )
respectively.
In the next we present the effects of radial and tangential

stresses diagrammatically.
A)
B)
Figure 18 tangential stresses diagram[9]
For tangential and radial stress equations given below:
= ∗ 1− And = ∗ 1+
Known boundary conditions
For radial stress
= =
= =
For tangential stress
= =
= =
Substitute values and we get the following:
: =− =0
2
= ∗ 1+ =
− −
Now we can select different approaches (maximum normal stress theory, maximum
shear stress theory or maximum strain theory) to evaluate the failure of the
cylinder.
Considering the maximum tangential stress and follow the maximum strain theory
we get the following equation called Bernie’s equation.
+ (1 − ) ∗
= × −1
2 − (1 + ) ∗
Find the known values:
= = .
= 208 , take N= 2.5
Next find P i :
= = ∗
= 50.22 ,
= 0.3,
Substitute values and = 6.06 ≅6

Threads on the main cylinder
The main cylinder is screwed into the base to 0.05h 1 depth the over plate is also
screwed on the upper part of the cylinder to a depth of r, thus the main cylinder is
threaded in the both its ends.
Threads on the outer surface can be made on lathe machine of the cylinder is
prepared by casting. Standard selected M-82 and core diameter is 44mm.
Length of threaded part on the cylinder is
= 0.05 × ℎ = 0.05 × 85 = 4.25
The lower part is subjected to compression stress due to radial stress in the
cylinders
×
= = =
ℎ × ×
Let as find the unknown parameter, take N=3
520
= = = 173
2
39
= × = × = 1194.5 2
4 4
A1= × = × = 1885.7 2
P=50.22MPa
Substitute numerical value
50.22 × 1194.5
= = 260 → = 4.5 ≅ 5
1885.7 ×
The pitch thread length is
4.25
ℎ= = = 0.85
5

Thread length for the upper thread
If there is excess fluid in the reservoir and the mechanic pumps more than
maximum number of strokes, shearing of threads many occurs.
= = 75 , take N=2
60 60
= = = = 75
ℎ ℎ 0.85
2 ×
( 2 × × ) × 44
→ =8
Thread length is = ℎ∗ = 0.85 × 8 = 6.8 ≅ 7mm

Design of Telescopic cylinder
Figure 19 main cylinder
The telescopic cylinders are evaluated in the same war and the main cylinder since
both are subjected to the same internal pressure.
Material selection
The selection criteria are:
 Good mechanical property

 It is strong and ductile
 Good in machinability
 Good surface finish

 High corrosion resistant
 Is light in weight, these minimize the weight of the jack
 Availability and low cost
Thus we select the following
Material Selected Steel 0.6% carbon

(quenched)
Yield strength 515MPa Telescopic Cylinder
Modulus of 207GPa
elasticity
Design analysis
The objective of the design analysis is to find the thickness of the telescopic
cylinder based on the Bernie’s equation the analysis is the same with the previous
design of the main cylinder, the only parameters changed here are the diameter and
the tangential stress that is d 2 =39mm and n= 3
+ (1 − ) ∗
= ∗ −1
2 − (1 + ) ∗
Find the known values:
= = = 171.6 , take N= 3
Next find P i :
60000
= = = 50.22
∗ 39
4
= 0.3,
Substitute values and = 7.69 ≅8
Design of the pumping cylinder

The pumping cylinder is small in size when compared to the other cylinder but is
subjected to the same pressure = 50.22 still the analysis will be the same with
the previous procedures of cylinder design.
Figure 20 cylinder
Piston Rod
From geometry analysis of equation (3) = d2 (R2/60 × 10 ) = 39 ×
(5780/60 ∗ 10 )
12.1 ≅ 12mm
Material for pumping cylinder

The material that we select for the pumping cylinder satisfies the following
selection criteria’s.
Availability
Corrosion resistance and chemical stability
Manufacturing feasibility
Material Selected 0.6% carbon steel

(quenched)
Modulus of 207GPa
elasticity
Design Analysis
The pumping cylinder is subjected to be the tangential and radial stresses.
Tangential stress ( )
( 2 )
= ∗ 1+
− 2 (2 ∗ )
Where: − inner diameter
−Outer diameter
− Fluid pressure
r - Print of maximum pressure
The maximum pressure occurs at r=
Thus,

+ 2
= ∗ , = 12 & = 50.22
− 2
Also
515
= = = 171.6
3
Substitute numerical value,
+ 12
171.6 = 50.22 ∗ → = 16.2 ≅ 16
− 12
Thus thickness of the cylinder is
− 16 − 12
= = =2 , ℎ 5 .
2 2
Design of the reservoir cylinder
The reservoir must be a stable non relative material. It is not subjected to any type
of stress except when the cover plates are tight ended. However the stress resulted
from this tight ended can be neglected since it many not bring significant effect.
Figure 21 reservoir cylinder [9]

Reservoir Cylinder
Material selection
As explained the reservoir only stores the oil and is not subjected to any severe
stress. Thus any type of iron used in pipe manufacture can be selected as reservoirs
cylinder material but its inner walls are chromium plated to prevent any chemical
attached and rust.

Modulus of 190GPa
elasticity
Design Analysis
The oil that fills the main cylinder and the telescopic cylinder comes from the
reservoir cylinder thus we can find the diameter of the reservoir cylinder
considering volume relationships.
Also the reservoir can fill only up to the oil feeder hole, thus only portion of the
reservoir cylinder below the oil feeder hole is considered. Let the oil feeder hole is
located at ‘T’ mm unit below that height (upper) level of the reservoir, also let the
portion of the reservoir above the oil feeder hole be 45% of the total volume thus:
= 0.15 ∗ ℎ = 0.15 ∗ 85 = 12.75
= ℎ
= +
From the geometry analysis

( ∗ )
= ∗ (ℎ ∗ 0.15)
4
( ∗ )
= ∗ (85) = 160,287.9
4
( ∗ )
= ∗ (95) = 11,3486.1
4
Substitute numerical values and
= 165
As we have explained above the reservoir just only stress the oil and its thickness is
independent of the load since the pressurized fluid (oil) is preventing from going
the safe just select
=6
3.1.7 Design of the cover plate
Actually the cover plate is not directly subjected to the pressure of the oil other
type of reaction force due to the loading. But since it is screwed into the main
cylinder remarkable shearing
many occur on the
threads.
Figure 22 Cover Plate [13]

Material Selection

Modulus of 190GPa
elasticity
Thus material is frequently used in nut manufacturing.
Design Analysis
The threated part of the cover plates was already design during main cylinder thread
part design analysis thus =7
Let us go deep in to the profile of the threaded in the cover plate.
Figure 23 threated part [11]
If we choose at 60 o threaded then we have:
60 0.85
tan = → = = 0.736 ≅ 1
2 2 2 ∗ tan 30

Let us find the following diameters:
= ℎ ℎ = 49 + (2 ∗ 7) = 63
= ℎ ℎ = 165
= ℎ ℎ = 165 + 10 = 175
= + 2 ∗ 8 = 39 + 16 = 55
Thus,
2 = − = 175 − 55 = 120
= 60
Let the inner seal is located 10mm below the upper surface the plate a=20mm. the
thickness of the seal to be selected from standard tables.
b=30mm from geometry analysis
b’=25mm any value greater than 2t s but less than b.
Design of Pump handle socket
As previously explained the pump handle socket transmits force from handle to
pump plunger of pump the socket is hollow in shaped and contains plates with holes
that use as connecting mechanism of the socket and the link and the plunger.
Material Selected
The material that selected for the pump handle socket is tabulated below with its
property.

(quenched)
Modulus of 207GPa
elasticity
Design Analysis
The objective of the design is to find the value of the parameters shown in the
sketch above. From the handle design, outer diameter of handle = 20 inner
diameter of socket is
= +2∗( ) = 20 + (2 × 1) = 22
Figure 24 diameter of socket [11]
Consider the following diagram to show the force exerted on the plates part of the
socket, each hole is subjected to shearing and crushing stress.

Let us take the pin joint mechanism for the link and the plate and magnify it as
follows
Figure 25 Pin Joint Mechanism [12]
Generally the following types of failure occur in the pin joint mechanism shown
above.
Tensile Failure of the plate
As R 1 pulls the plates down ward the upper parts of the socket also pulls it with an
equal’s amount of force upward. The cross-sectional area of the plates is, = ×
then the allowable tensile strength of the material is:
tensile force R
allowable tensile strength (σ ) = =
cross sectional area π∗d
a ∗l − 4
The critical area will be considered during failure analysis. The following types of
model forces also occur in the joint connection.
Transvers failure of the pin
Compressive bearing failure between the pin and the hole
Now let us come back to the first mode failure type, let =5 , = 13
Thus,

= 50 − + 7 = 36.5 . Factor of safety 3
Also, = = 171.67
R2=R1+F,@Design of piston rod R1=R2-F =5480-350=5430N=5.43KN
Next find the diameter of the hole by equating both equations
5.43
171.67 = → = 6.52 ≅ 7
∗
5 ∗ 13 − 4
Shear Failure of the plate (clevis due to tear out)
The length of the shear is
= −
Also the tear out area is:-
= ×( − )
The shear stress is:
=
× −7
Take factor of safety 3.
515
= = = 85.83
2×3 2×3
Next find the length of the shear by equating both equations
5.43
85.83 = → = 19.65 ≅ 20
5× −7

Now let me take the pin joint between the
socket and the plunger and magnify it as
follows. FBD becomes
Figure 26 joint Pin and Plunger [11]
Magnified joint Pin and Plunger
Tensile stress on the socket plate, then the value of ‘Z’
Z = 2 ∗ a + d + clerance
And the value of ‘r’ is:
=( − )/2 = (20 − 7)/2 = 6.5
Let the factor of safety is 3 for the crushing strength then the compressive stress is
= = = =
2∗ ∗ 3
Let =5
5780 515
= = 3.37 → ≅4
2∗5∗ 3
Next find the thickness of the socket

Figure 27 Pump handle
= 6.5 + 60 + 5 = 71.5
Handle and S
Next find the moment from point ‘O’ beam diagram
∗ (700 + 7) 707
= = 350 ∗ = 3.46
71.5 71.5
Also find the value of shear allowable
3.46
= =
∗
Substitute numerical value,
3.46
85.83 = → = 0.56 ℎ 1
∗ 71.5
∴ ℎ = 22 + 2 ∗ 1 = 24

3.1.8 Design of Pump handle
The force distribution on the handle and its dimensions were carefully design in the
geometry analysis. The size of the handle is selected so that the operator can easily
manageable. Also we have selected a hollow handle so as to save material. Thus,
the handle can be generally viewed as a hallow rod with inner and outer rod.
The cross sectional of the handle can be represented by the

t he following diagram.
:C
ro
Figure 28 Pump handle
Material Selection
The handle should have to fulfill the following criteria’s:
Should be hard
Should be not brittle
Good resistance to corrosion and rust (for long working life)
Ease of manufacturability

Therefor the selected material is:
Material Selected Steel 3 % Ni, 0.4%C

Modulus of elasticity 207MPa
Design Analysis
Generally the force distribution over the handle can be represented as follows:
:
F
The values specified above were taken from the iteration result of the geometry
analysis the value of R 2 is not constant since it is dependent on the angle by
which the handle is rotated therefor it must be resolve with respect to .
Then,
=0 → 5780 − 350 = 5.43
Also the cross sectional area of the handle is assumed to be constant. As it easily
can be seen the handle is subjected to bending force and it should be designed for

bending strength. Belo the BMD and SFD are presented as follows:
By taking each section (x-x) and ((y-y) we can find maximum bending moment and
shear force.
By taking section (x-x):
∑ = 0, 1 + (− ) = 0, 1= =5430N
∑ = 0, (R1× 0)-(M× ) = 0
Mx=0…………….(1)

@ x=60mm , M=0
By taking section (y-y):
∑ = 0, 1 − 2 + = 0, 5430 − 5780 + = 0, = 5780 − 5430 = 350
∑ = 0. R1× 60 + = × ( − 60)
M= × ( − 60) -R1× 60………………(2)
@ x=60, M= -R1× 60
= -5430× 60 = −325800
=-325.8KN.mm
@ x=700, M=0
Therefore the maximum bending moment of the pump handle is:

M=-325.8KN.mm
: BMD & SFD
The bending moment diagram shows that the maximum bending occurs at the pump.
Thus the strength equation is
= ∗
Where, =
= ℎ ℎ
The modulus of section of circular cross section is, since the handle is hallow:

−
= ∗
32
Also we can express Z by using thickness of the handle:
( ) −( −2∗ ) (20) − (20 − 2 ∗ )

= ∗ = ∗
32 32 20
From the BMD maximum bending value is 325.8kNmm, also take N=3 thus,
= = 345 ,
Then, substitute numerical value
= ∗
(20) − (20 − 2 ∗ )
325.8 = 345 ∗ ∗
32 20
=6
3.1.9 Design of the Plunger

The plunger is rod like structure found in the pump piston.
Material Selection
Figure 29 Plunger [8]
Mostly piston rods are made of high tensile materials finished and hardened with
chromium plating to provide resistance
: Plunger of corrosion. Stainless steel is also used as a
rod material due to its excellent anti-corrosive property.

We have the following material selected as piston rod material:

0.4%C
Modulus of 207MPa
elasticity
We have selected this material due to the reason:
High compressive strength to support the load.
Due to its appreciable hardness.
Give good surface finish.
Relatively low cost to other grades of steel.
Design Analysis
Forces on the plunger are compression forces due to shear force in the hole. If the
length of ℎ is larger relative to its diameter then the force may cause buckling. Let
me take factor of safety is 3.
Now find the plunger head thickness ( ) by using the following equations. First
fin the allowable stress. And take = 15 also ℎ =4
1035 1035
= = = 345
3
424.2
= 0.433 × × = 0.433 × 15 × = 7.2 ≅ 7
345

Next find tearing of the plunger at the hole due to vertical reaction of force. First
find the allowable stress:
5.78
= = = 345
There are two possible shear areas as shown in the figure.
Thus, the area of the tear is
= − ∗ +
4 4 2
Figure 31 tear [11]
Then find the value of
5780
= = = 345 → = 4.6
4∗
≅5
Thus, area of tear become
= 0.5 × (3 + ) :Shear Areas of the Plunger

Substitute in the above equation
5780
= = = 345 → = 30
0.5 × (3 + )
Therefore, the height of the plunger is
ℎ =ℎ + + +2 + = 38 + 4 + 30 + 2 × 7 + 1 = 87
3.1.10 Design of the link

The link is connected to the base by pin joint. There are two links used to connect
the socket and the base.
Figure 32 pump handle [5]
Material selection
The material that selected for the pump handle socket is tabulated below with its
property.

(quenched)
Modulus of 207GPa
elasticity
Design Analysis
Let the least cross section of the link is square of side, the link (each link) is
subjected to the tensile compressive stress due to reaction force R 1 =5430N,
=7
Thus,
( /2) (5430 /2)

= =
Where, = ℎ = × , = =
Let me use factor of safety of 3,
515 5430
= = = 171.6 = → = 5.6 ≅ 6
3
Considering tearing of the clevis of the link the shear stress can be follows as:
( /2)
=
Next find ,
−7
=2× × − = 2×6× =6 − 42
2 2 2
Thus,

515 2715
= → = 12.27 ≅ 12
6 6 − 42
If the link is not to buckle < 40 , where k=slenderness ratio
Let us find the value of k,
( + ) 6+6
12 12
= = = = 0.54
( + ) 6+6
Now check the condition,
< 40 → < 21.6 Therefore it is suitable.

.
3.1.11 Design of the Basement

The base contains threaded parts for mounting cylinder, pump and release valve. It
also contains check valves to control the flow of the oil and flow line. The overall
area of the base should be designed in such a way that it will not sink to the ground
during lifting operation.
Material Selection
Considering carbon content, machinability corrosion resistance strength I have

selected mild still for base material. Its property tabulated below;

Material Selected steel (Annealed &
Hardened )
Yield strength 294.8MPa
tensile strength 394.0 MPa
HB 111
Modulus of 207GPa
elasticity
Design analysis
The minimum thickness of the base is found using the following formula:
Let factor of safety be taken 3
Thus,
294.98
= = = 98.33
3
424.2
= ∗ = 0.4 ∗ 49 ∗ = 40.2 ≅ 40
98.33
Where, =
= ℎ ℎ
= 0.4
Base dimensional Area
In order to find the dimension of base environmental factor should have to be

considered. That is where the jack should be used for example if the ground in
which the case wheel is to be changes is soft than the jack may sink to the ground

up on lifting in such cases the base area of the jack is preferred to be large. The
width of the . since Calculate as follows:
= ℎ1 + 2 + +2 +
+ ℎ
= 85 + 2 × 6 + 38 + 2 × 5 + 50 + 2 × 20 = 235
Since h1 in horizontal position equal to vertical position=85mm
Also the length of the base is L b.
= + = 60 + 165 = 225
N.B. the numbers in the above formula are those found in the design of cylinders,
pumps and also the spaces between each design part is considered.
Components selected from standard tables
Compressive Spring selection:
The main function of springs in a hydraulic bottle jack is to apply forces on the
valves so that the flow of the oil is controlled. The valves also exerted an equal
amount of force on the springs.

Material Selection
Materials for springs should have High fatigue resistance, High ductility, High
resilience Creep made from resistance. Generally, we select oil tempered carbon
steel containing 0.6-0.7% carbon and 0.6- 1% of manganese.We selected the
following parameters for from standards books:
Table 7 Standard Spring Table

Result Table
O.D Free I.D Rate Max Max Solid Wire Total

(mm) length (mm) (N/mm) Deflection Load Length Diameter Coils
(mm) (mm) (N) (mm) (mm)
6.10 9.7 3.8 32 1.8 57 6.6 1.1 5.75
O-ring selection:
All O-Ring sealing applications can be classified as either static or dynamic.
Static seals
In a static application there is no relative motion between parts of the groove which
contact the O-Ring. Small amounts of movement, caused by thermal expansion,
vibration, bolt stretch or O-Ring response to fluid pressure, do not alter the static
definition. Static seals are often categorized according to the direction in which
compression is applied to the O-Ring cross-section. There are two basic directions
of compression: axial and radial. There are also applications which combine both
axial and radial compression (crush seals).
Static axial seals
In this application the compression is on the top and bottom of the O-Ring, which is
similar to a flat gasket. Static axial seals are typically utilized in face seal
applications, as illustrated in the figure below.
This application means that the compression is between the inside diameter and the
outside diameter of the O-Ring. Typical static radial seals are cap seals and plug
seals.
In dynamic sealing applications there is relative movement between the parts of the
groove, which is O-Rings
: Staticare subject
radial seal to a sliding action against the surface. This
motion causes difficulties that cause design problems different from those of static
seals. For the great majority of dynamic applications, O-Rings are squeezed radially

and are subjected to reciprocating motion, either intermittent or continuous, or, less
frequently, to an intermittent rotary or oscillating motion.
Reciprocating seals
In this type of application, there is a relative reciprocating (back and forth) motion
along the shaft axis between the inner and outer elements of the groove. O-Rings
used in reciprocating applications are called piston or rod seals.
Oscillating seals
In this application, the inner and outer components of the groove move in an arc
: Oscillating seals
around the axis of the shaft, first in one direction and then in the opposite direction,
usually intermittently, with no more than a few turns in each direction. The most
common application for oscillating O-Ring seals is in valves.
Selected Standards
O-ring install between
Piston head and Telescopic cylinder.
Cover plate and Telescopic cylinder.
Cover plate and reservoir.
We select the following standard:

Table 8 O-ring Standard Table[8]

Selection result
Cross section Inside diameter Tolerance

5 mm 5 mm ±0.15 mm
O-ring install between
Plunger and Pump cylinder.
We select the following standard:
Table 9 O-ring Standard [8]

Selection result

1 mm 1.15 mm ±0.08 mm
Pin selection: There are three pins in the whole assembly one used to connect
plunger and socket two pins used to connect the link and the socket. Those pins are
subjected to double shear.
Material selection:
Malleable cast iron with the following material properties can be subjected as pin
material.
Material Selected ASTM A602

tensile strength 621 MPa
Selected Standards
We select standards from Holo – Krom Technical Handbook. We select two type of
pins based on their nominal diameter for 9mm and 4mm. the result presented below.
Figure 33 pins [6]

Table 10 Standard Pin Table [5]
Selection result
No of pins Nominal size A B C R LS

1 pin 4mm 4.009mm 3.9m 0.9mm 0.4mm 4.5mm
2 pins 10mm 10.012mm 9.8mm 1.4mm 0.6mm 6.0mm
Valve Selection: There are two check and one release valves are available in this
jack. I select standard from Catalogs of Valves. The selected results are present
below.

Selected Standard
We select universal low pressure check valve base on nominal diameter of the pipe.
The Universal Low Pressure (U3) check valve is a one piece body machined from
bar stock and is designed for minimum pressure drop. The valve has a light weight
compact design that provides maintenance-free dependable service.
table 11 pipe size [8]

3.1.12 Cost Analysis
In this topic we discussed about manufacturing cost of the jack including labor
cost, power and 20% contingency. We use standard cost data for calculating the
price.
Purchasing cost
In this topic only the purchasing cost of materials are listed below.
Piston Rod:
Density of low alloy steel=7850
= × = × × × = 7850 × × 19.5 × 140
= 1.31
Then from our data the cost of steel per Kg is 29.92ETB. Thus the total cost is:
× = 1.31 × 29.92 = 39.2ETB
Cover plate:
= × = 7850 × × (87.5 ) ×1 = 0.188
Then from our data the cost of steel per Kg is 29.92 ETB. Thus the total cost is:
× = 0.188 × 29.92 = 5.65ETB
Main cylinder:
= ∗ = 7850 × 89.25 × × 24.5 = 1.32

Then from our data the cost of stainless steel per Kg is 91.52 ETB. Thus the total
cost is:
× = 1.69 × 91.52 = 120.89ETB
Telescopic cylinder:
= × = 7850 × 115 × × (19.5 ) = 1.07
× = 1.07 × 29.92 = 98.7ETB
Reservoir cylinder:
= × = 7850 × 85 × × (87.5 ) = 16.04
Then from our data the cost of stainless steel per Kg is 91.52 ETB. Thus the total
cost is:
× = 16.04 × 91.52 = 1468ETB
Links:
= × = 7850 × 12 × 80.95 ×6 = 0.045kg
× = 0.045 × 29.92 = 1.36ETB

Plunger:
= × = 7850 × 87 × × (8 ) = 0.137
× = 0.013 × 29.92 = 4.15ETB
Basement:
= × = 7850 × 235 × 225 × 40 = 16.6
× = 16.6 × 29.92 = 496.7
Pump handle:
= × = 7850 × 500 × × (10 ) = 1.23
∗ = 1.23 ∗ 29.92 = 36.8ETB
O- Rings: The cost of one O-ring is 0.01-0.1 $ multiply this by 20 we get 0.2-2
ETB.
Seal for 1mm inside diameter: the cost of one seal is 0.01 $ multiply this by 20 we
get 0.2 ETB. Thus we desired four gaskets the cost is 0.8 ETB.

Seal for 5mm inside diameter: the cost of one seal is 0.1 $ multiply this by 20 we
get 2 ETB. Thus I desired six gaskets the cost is 12 ETB.
Thus, the total cost of flange is: 0.8 ETB + 12 ETB = 12.80 ETB
Valves: The cost of one valve is 1$ multiply this by 20 we get 20 ETB. Thus I
desired four gaskets the cost is 20 ETB.
Pins: The cost of one valve is 2$ multiply this by 20 we get 40 ETB. Thus I desired
three gaskets the cost is 60 ETB.
Springs The cost of one spring is 2$ multiply this by 20 we get 40 ETB. Thus I
desired three gaskets the cost is 60 ETB.
Therefore, Total purchasing cost is:
39.2 ETB + 5.65ETB + 120.89 ETB + 1468 ETB + 1.3ETB + 98.7ETB + 4.15 ETB
+ 36.8ETB + 496.7ETB + 2 ETB + 12.8ETB + 20ETB + 60 ETB
= 2,426.25 ETB
Manufacturing cost
In this topic the manufacturing cost listed below.
Power cost: ≈ 1000 ETB
For labor salary: ≈ 2000 ETB
1000ETB + 2000ETB = 3000ETB
Therefore, the total cost of this design is = 2426.25 ETB + 3000 ETB = .
Also the total cost of the design with 20% contingency is:
20
5426.25ETB + 5426.25ETB × = .
100

3.1.13 Manufacturing Process and Maintenance
Process equipment is fabricated by a number of well-established methods such as
fusion welding, casting, forging, machining, brazing and soldering and sheet metal
forming. Each method has certain advantages for particular types of equipment.
However, fusion welding is the most important method. The size, shape, service and
material properties of the equipment all may influence the selection of the
fabrication method.
Methods of fabrication
Piston Rod and Cap: To manufacture the piston rod and cap I recommend the
following steps. Select a blank (a work piece) with a dimension of Ø = 34mm x
140mm. 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.
Main Cylinder: The main cylinder can be manufactured by centrifugal casting with
inner diameter of 44mm outer diameter of 54mm. 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.
Telescopic Cylinder:The Telescopic cylinder can be manufactured by centrifugal

casting with inner diameter of 34mm & outer diameter of 54mm for bottom part and
46mm outer diameter and 20 mm inner diameter for upper part. 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.

Pumping Cylinder: The main cylinder can be manufactured by centrifugal casting
with inner diameter of 15mm outer diameter of 23mm. 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.
Reservoir Cylinder: The Reservoir can be manufactured by centrifugal casting

with inner diameter of 103.05mm & outer diameter of 113.05mm with 15mm oil
feeder hole. 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.
Cover Plate: The upper plate can 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.
Pump handle socket: The socket can be manufactured by sand casting. Correct the
casted plate to appropriate dimension on the part drawing. Prepare two holes with 9
and 4 mm to connect the socket with plunger and pin. Finally, make a necessary
surface finish.
Handle: The Handle can be manufactured from a metal rod with Ø 24 x 454mm.
Finally turn the rod by using Lathe machine to the Ø 20mm x 400mm.
Plunger: Select a blank with Ø 15mm x 76mm. Face the work piece according to
the dimension & shop on the part drawing by using Lathe machine. Make a groove
for O – ring seal seat at the plunger. Make a hole at the rod for pin passage.
Link: The link can be manufacture from 4mm thick sheet metal by cutting and
machining processes.
Base Plate: Select a blank (a work piece) with a dimension of 174x 160mm with
thickness of 45mm. 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.
O - Ring Seal: O- Ring seal can be manufactured by using Die.
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.
Maintenance
What Kind of Oil Goes in a Bottle Jack?
A bottle jack is made of steel and can vary in weight according to size. The smallest
jack is a few pounds, while the 100 ton jack weighs greater than 200 pounds. In
order to maintain the seals as long as possible, the operator should use jack stands
and keep the machine away from paint thinners, acids, heat, alcohol and pet urine.
A bottle jack requires hydraulic oil. This type of oil is a liquid lubricant used to
send power throughout hydraulic systems. Hydraulic oil provides good lubrication,
protects from rust and oxidation and has low foaming characteristics. The stuff
packaged as hydraulic jack oil is low viscosity. A lot of tractor hydraulics and some
heavier earthmoving stuff use hydraulic oil that’s essentially the same viscosity as
10W motor oil. Jack oil looks about the same. The main thing is DON'T use brake
fluids as hydraulic fluid because Brake fluid contains alcohol, which is harmful to
the seals when we use this fluid over and over the seals become tear and have jelly
like behavior.

ADDING OIL
Position the jack on level ground in an upright (vertical) position and fully lower
the saddle.
Remove oil filler plug
Oil should be filled to the level of the oil filler plug hole. If low, add oil as needed.
REPLACING OIL
To drain oil, remove oil filler plug and open release valve.
Turn jack on its side and drain old oil out through the oil filler plug hole
Refill with new oil through the oil filler plug hole. DO NOT allow dirt or other
foreign material to enter the hydraulic system when filling.
After refilling, remove any air from the hydraulic system by opening the release
valve and rapidly pumping the jack handle several times.
Replace the oil filler plug.
LUBRICATION
Put grease into fitting on base using a grease gun and lubricate lifting arm spindle
with oil every 3 months.
PREVENTING RUST
Check ram and pump plunger every few months for any signs of rust or corrosion.
Clean as needed by wiping with an oily cloth.
When not in use, ALWAYS store jack with saddle and pump plunger lowered all the
way down.
Inspection

Visual inspection shall be made before each use the jack by checking for abnormal
conditions, such as cracked welds, leaks, and damaged, loose, or missing parts.
Other inspections shall be made per product operating instructions.
Each jack shall be inspected immediately if the device is believed to have been
subjected to an abnormal load or shock.
Safety
Study, understand, and follow all instructions provided with and on this device
before use.
Do not exceed rated capacity.
This is a lifting device only.
After lifting, immediately transfer the load to appropriately rated vehicle stands.
Use only on hard, level surface.
Lift only on areas of the vehicle as specified by the vehicle manufacturer.
No alterations shall be made to this device.
Only attachments and/or adapters supplied by the manufacturer shall be used.
Failure to heed these markings may result in personal injury and/or property
damage.
To avoid crushing and related injuries:
• Never work on, under, or around a load supported only by a hydraulic jack
• Read, understand and follow all printed materials provided with and on this jack.
• Immediately support the lifted load with appropriately rated jack stands.
• Use ONLY on vehicles whose lift points are compatible with the saddle of this
jack. Incompatibility may result in structural damage to the vehicle and/or jack.

• Chock each un-lifted tire in both directions.
• Be alert and sober when servicing a vehicle! Never operate this equipment when
under the influence of drugs or alcohol.
• DO NOT use this device to lift, level, lower, support, adjustor otherwise move a
house, mobile home, travel trailer, camper, or building structure of any type, size,
or configuration.
Troubleshooting
Table 12 Troubleshooting Table [3]

CHAPTER FOUR
4.1 Result and Discussion

In this topic we discussed about Results and conclusions with short and precise
description.
4.1.2 Results of Geometrical Analysis

Generally, the geometry analysis of the Hydraulic bottle jack can be summarized as
follows:
Maximum lift height (H max ) - 390mm.
Minimum lift height (H min ) - 190 mm.
Height of reservoir cylinder above the base (h 1 ) - 85mm.
Height of telescopic cylinder above the main cylinder (h 2 ) - 95mm.
Length of socket between pin connections (X) - 60mm.
Length of the handle up to the plunger pin connections from the left (L) - 700mm.
Applied force operator force (F) - 350N.
Diameter of telescopic Cylinder (d 2 ) – 39mm
Diameter of main Cylinder (d 1 ) – 49mm
Angle that the handle makes with the horizontal for maximum
Position of the plunger ( )- 40 o
Diameter of the pump (Actuator) cylinder (d A ) – 12.1mm ≅ 12mm.
Maximum rise of the plunger (h A )- 38.5mm ≅ 39mm
Vertical plunger pin reaction force (R 2 ) – 5780N.
Number of strokes – 45 times.

Table 13 Result of Piston Rod
Height 140mm
Material Type Steel 312 % Ni,
0.4%C
critical load 169.35KN
t head 4mm
Diameter of the 32mm
cap
Table 14 Result of Main Cylinder
Height 95 mm
Material Type Stainless Steel
critical load 169.35 KN
Thickness 6mm
Diameter 49mm
Allowable shear 75MPa
Critical stress 260MPa
Table 15 Result of Telescopic Cylinder
Height 95 mm
Material Type Steel 0.6% C, Quenched
Thickness 8mm
Diameter 39mm
Critical stress 171.6MPa

Table 16 Result of Pumping Cylinder
Height 43 mm
Thickness 5mm
Diameter 39mm
Table 17 Result of Reservoir Cylinder
Height 85mm
Thickness 6mm
Diameter 165mm
Thickness 7mm
Table 18 Result of Cover Plate
A 20mm
B 30mm
C 60mm
D 25mm
Thickness 4mm
Diameter outer 175mm
Diameter inner 165mm
Thickness 7mm

Table 19 Result of Handle Socket

Diameter outer 22mm
as 5mm
bs 36.5mm
ls 13mm
Thickness 7mm
Table 20 Result of Plunger
Material Type Steel 312 % Ni, 0.4%C

Height 87mm
Diameter outer 8mm
Thickness 5mm
Allowable stress 171.6MPa
Table 21 Result of Pump Handle
Material Type Steel 312 % Ni, 0.4%C

Height 700mm
BM ma x 325800N.mm
Diameter outer 20mm
Thickness 6mm
Allowable stress 345MPa

Table 22 Result of Link

Height 80.95mm
Diameter of the hole 12mm
Thickness 6mm
Table 23 Result of Basement

Length 225mm
Width 235mm
Thickness 40mm
Table 24 Result of O-ring selection

5 mm 5 mm ±0.15 mm
1 mm 1.15 mm ±0.08 mm
Table 25 Result of Spring selection
O.D Free I.D Rate Max Max Solid Wire Total

(mm) length (mm) (N/mm) Deflection Load Length Diameter Coils
(mm) (mm) (N) (mm) (mm)
6.10 9.7 3.8 32 1.8 57 6.6 1.1 5.75

Table 26 Result of Pin selection
No of pins Nominal size A B C R LS

1 pin 4mm 4.009mm 3.9m 0.9mm 0.4mm 4.5mm
2 pins 10mm 10.012mm 9.8mm 1.4mm 0.6mm 6.0mm
Table 27 Result of Valve Selection
Nominal Size code A Hex size B C Orifice

pipe size diameter
3/8 C 2.16 13/16 3/8 NPT 0.348

Recommendation
The design progress was good and it is mandatory to mechanical engineer
students but due some factors like exam, other course projects we are loss time.
Therefore the given time to finish the design was very short compared to the
hugeness of the design. So, we recommended for the future the time allowed should
be enough to finish the design.
There was a shortage of reference materials due to this from the design we have
not full description of bottel jack components figures, tables and others. therefore
we recommended that at least full reference book must be present.

Conclusion
The Hydraulic Bottle Jack is successfully designed so that it with stand all the
mechanical stresses acting on it. The jack is analyzed under various conditions of
operation. All forces are carried according to strength and geometry analysis. The
jack also with stand the external load with the help of internal fluid at working
conditions. The stresses in above-mentioned conditions are found out and thickness
of various parts is selected such that the stresses produced in each member are
within the maximum allowable range. All the selected have been successfully
verified and hence the design of the jack is safe.

Reference
1. Mechanical Engineering, Shigley’s Mechanical Engineering Design, Budynas
– Nisbett, Eighth Edition.
2. Mechanical Design an Integrated Approach, Ansel C. Ugural.
3. International Check valve standard book
4. Coulson and Richardson mechanical design equipment
5. International Pin standard book
6. International Spring standard book
7. International Check valve standard book
8. International O-ring standard book
9. http://alibaba.com
10. http://answers.yahoo.com/question/
11. http://www.linkdin slideshear.org/
12. http://wikipidia/
13. http://www.google.com

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UNIVERSITY OF GONDAR

Submitted to-INS: Misgana

Submitted Date: 14/10/2009E.C.

i University of Gondar Institute Of Technology Design Project

i University of Gondar Institute Of Technology Design Project

ii University of Gondar Institute Of Technology Design Project

iii University of Gondar Institute Of Technology Design Project

iv University of Gondar Institute Of Technology Design Project

v University of Gondar Institute Of Technology Design Project

vi University of Gondar Institute Of Technology Design Project

1 University of Gondar Institute Of Technology Design Project

1.1.2 Definition of Hydraulic Jacks

2 University of Gondar Institute Of Technology Design Project

1.1.3 Background of Hydraulic Bottle Jacks

3 University of Gondar Institute Of Technology Design Project

4 University of Gondar Institute Of Technology Design Project

 Manually operated jack (hand or pedal operated).

According to the lift of ram

 High lift hydraulic Jack

According to the arrangement of cylinder

 Vertical hydraulic Jack

According to the number of cylinders

 Single cylinder hydraulic Jack

According to the construction

 Hydraulic Service /Floor /jacks:

5 University of Gondar Institute Of Technology Design Project

Configuration of the piston rod (ram)

Head of the piston inside the cylinder

The head should be designed in such a way that:

Figure 1 piston inside the cylinder [13]

Material Selected Steel 3 % Ni, 0.4%C

Fig 4.7: Piston Head

Figure 2 piston head [13]

7 University of Gondar Institute Of Technology Design Project

The basic function of the hydraulic cylinder is to

Design of Telescopic cylinder

8 University of Gondar Institute Of Technology Design Project

Figure 5 Pumping cylinder[13]

Figure 6 Reservoir cylinder[13]

9 University of Gondar Institute Of Technology Design Project

Figure 7 cover plate[13]

Pump handle socket

The plunger is rod like structure found in the pump piston.

10 University of Gondar Institute Of Technology Design Project

Figure 8 Link [12]

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The most important characteristics to be considered when selecting a material of constructions

B. The effect of high and low temperature on the mechanical properties.

12 University of Gondar Institute Of Technology Design Project

1.1.6 Working Principle

13 University of Gondar Institute Of Technology Design Project

When we see the advantages of hydraulic systems are as below [9]

 Simpler design. In most cases, a few pre-engineered components will replace

14 University of Gondar Institute Of Technology Design Project

 Elements of hydraulic system to be applied in the car have to be machined to a high

15 University of Gondar Institute Of Technology Design Project

Lifting procedure of a load by using jack [1]

 First, Tighten (close) the pressure release valve properly

16 University of Gondar Institute Of Technology Design Project

Lowering Procedure of a load by using Jack [1]

1.1.8 Design Methodology

Steps of Geometrical analysis:

17 University of Gondar Institute Of Technology Design Project