A PROJECT REPORT ON

DESIGN AND FABRICATION OF MINI HYDRAULIC JACK

Submitted in partial fulfillment of the requirements

For the award of the degree

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

SUBMITTED BY

RAVI AKASH MURTI

(202015510)

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DEPARTMENT OF MECHANICAL ENGINEERING

SIKKIM MANIPAL INSTITUTE OF TECHNOLOGY

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Design & Fabrication of Mini Hydraulic Jack

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ABSTRACT

Here we study the fabrication of a mini hydraulic jack that uses hydraulic power to operate the
jack in vertical movement. Our system consists of a smartly designed hydraulic jack that is
capable of lifting relatively heavy weights as compared to its size. The system consists of a
lifting jack mechanism made out of light weight but strong materials. This mechanism is then
powered by a syringe in a way as to achieve the most weight lifting mechanism as compared to
its size. The system consists of a bed mounted on top of the mechanism where the car or weight
to be lifted is to be placed.

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INTRODUCTION

The term hydraulics, which is derived from the Greek word for water, originally referred to the
study of the physical characteristics of still and moving water. Although it is primarily concerned
with liquid motion, use has expanded its meaning to include the behaviour of all liquids.
Hydraulics examines how liquids behave in tanks and pipes, discusses their characteristics, and
considers how to make use of these characteristics. Although modern hydraulics is
comparatively new, many hydraulic principles and their applications were known to the ancients.
Ancient inhabitants of Egypt, Persia, India, and China transported water along channels for
domestic use and agriculture while utilising dams and sluice gates to regulate the flow. TheThe
ancient Cretans had an elaborate plumbing system. Archimedes studied the laws of floating and
submerged bodies. The Romans constructed aqueducts to carry water to their cities. Torricelli,
French physicist, Edme Mariotte, Daniel Bernoulli both performed experiments to examine the
components of force in the discharge of water via tiny holes in the sides of tanks and short
pipelines. The fundamental law of hydraulics was discovered during this time by French scientist
Blasé Pascal. The Pascal's law, which asserts that an increase in surface pressure of a confined
fluid is transferred undiminished throughout the confined vessel or system, is the foundation of
hydraulic jacks.

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HYDRAULIC JACK
It is a hand-operated hydraulic lift that has a brief stroke. There may be a portable hydraulic jack
available. For ease and maintenance, cars are routinely elevated in this way. additionally to
replace the damaged wheels. The hydraulic jack is one of the simplest examples of a fluid power
system. By moving the handle of a small apparatus, one can hoist a large object that weights
many tonnes. A fluid disperses the handle's initial, rather little force over a much wider area. The
functioning of hydraulic jacks is based on Pascal's law, which states that pressure will be
transmitted equally when a fluid is at rest in a closed vessel and a certain pressure is applied at
any location. A portable hydraulic jack might be available. This is frequently used to elevate cars
for convenience and maintenance. additionally for changing the damaged wheels. One of the
simplest types of a fluid power system is the hydraulic jack. An individual may raise a heavy
object that weighs many tonnes by turning the handle of a little device. A fluid transfers a tiny
initial force applied to the handle to a significantly larger region. Pascal's law, which states that
when a fluid is at rest in a closed vessel and a particular pressure is applied at any point, the
pressure will be transmitted equally in all directions, is what drives the working of hydraulic
jacks. Mechanical advantage is obtained by a practical application of Pascal‘s law of
transmission of fluid pressure. Two pistons of different sizes operate inside two cylinders
suitably connected with a pipe so that pressure in each is the same. If ‘P’ is the pressure and ‘A 1’

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‘A2’ are the cross sectional area of cylinder 1 and 2 respectively, then a force ‘F 1’ applied to the
smaller plunger will lift the load (W).

Here,

P= pressure of the fluid

A1 = small cylinder area

A2= larger cylinder area

F1 = force acting on smaller plunger

W = load lifted

If the volume of liquid is constant. The displacement of large piston will be proportionate to
smaller plunger.

WORKING OF HYDRAULIC JACK

The basis for hydraulic jack operation is Pascal's law. The plunger reciprocates as the handle is
moved, sucking oil into the plunger cylinder during the upward stroke of the plunger through the
suction valve and into the reservoir. The delivery valve moves oil from the plunger cylinder into

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the ram cylinder as the plunger descends. By means of this pressured oil, the weight, which is
situated on the top plate of the ram, is elevated. Once the task has been completed, the lowering
screw is unscrewed to release the pressure in the ram cylinder, allowing the ram to be lowered
and the oil to be pumped into the reservoir. On one side, it has a ram cylinder, and on the other, a
plunger cylinder. steel. Plunger cylinder consists of plunger which is used to build up the
pressure by making use of the handle. Two non-return valves, one for suction and the other for
delivery, make up the plunger cylinder. The ram in the ram cylinder lifts the weight. The
delivery valve of the plunger cylinder is connected to the ram cylinder. Additionally, it includes
a lowering screw, which is nothing more than a manually operated valve used to release pressure
from the ram cylinder in order to lower the load.

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USES

 Automotive. Automotive manufacturing and repair facilities utilize hydraulic jacks to

raise and lower vehicles with a high degree of precision and control. These devices allow
operators to inspect and work on the vehicle’s undercarriage.
 Construction. Within the construction industry, workers rely on hydraulic jacks to lift
heavy loads, such as pieces of construction material, equipment, or entire structures.
Other forms of these devices also feature in equipment such as forklifts and bulldozers,
and in elevators systems in low- and medium-rise buildings.
 Material Handling & Lifting. Hydraulic jacks find use in many material handling
applications. For example, in industrial warehouses and facilities, hydraulic pallet jacks
allow operators to lift and transport materials and equipment stacked on pallets.

 Railroad & Transportation. In the railroad and transportation industries, hydraulic

jacks enable workers to raise and lower rails for placement on the track system.

 Mining. Large chunks of rock can present a major obstacle to mining processes.
Hydraulic jacks allow a safe, controlled method of moving large pieces of rock or other
debris.

 Agriculture. Hydraulic jacks are used in a number of agricultural machines, such as

tractors, to raise and lower tools and equipment to the proper working height.

 Marine. Hydraulic jacks facilitate the construction of ships and are used to load large
components onto finished boats and ships.

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 Aerospace. Similar to their use in marine applications, hydraulic jacks are employed in
construction and loading operations.

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LITERATURE REVIEW

P.S. Rana et al. (2012)

In this study work, the authors propose the use of integrated automated jacks for four-wheelers,
which have jacks on both sides of the car and which can be conveniently actuated by pressing a
button on the dashboard. This jack is specifically made to address the challenges experienced by
women and senior folks who find it challenging to manually operate the jack.

Mohammed Abuzaid et al. (2013)

The inbuilt hydraulic jack mechanism that is attached to an automobile vehicle's front and rear
parts of the chassis is the topic of this research paper. An automobile's front suspension is
situated centrally, between the front wheels, with a hydraulic jack for the front suspension.
Additionally, a hydraulic rear suspension jack is mounted centrally to the car's rear suspension,
between the back wheels. The front and rear automobile jack outlets are connected to a
pressurised fluid reservoir tank that powers the mechanism.
Mayank Agrawal et al. (2018)
This essay examines the advantages of an integrated hydraulic jack system over a conventional
mechanical jack system. By examining the design of the prototype, it is possible to see that the
design of the built-in hydraulic jack is also investigated and adjusted to the necessary extent. The
car's dash board contains buttons that make it simple to operate the hydraulic jack system that is
built into the vehicle. The vehicle's chassis will receive the jack. The reason for choosing this
system over a traditional mechanical system is that it produces more power and is more
straightforward to construct than a traditional design. Given that hydraulic oil cannot be
compressed, its lifting capacity is higher than that of a pneumatic system, which runs on air.

Parth M. Patel et al. (2013)

This study explains the automatic hydraulic jack mechanism's implementation within a four-
wheeler. The battery will provide power to the jack. Therefore, to change a flat tyre, all that is
required is to press a button, and the car's built-in jack will lift the vehicle.

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METHODOLOGY

Fabrication is a significant sector of the economy that entails the cutting, shaping, and
assembling of materials to create desired structures. And while different fabrication businesses
employ a variety of methods, the majority rely on the three fundamental operations of cutting,
bending, and assembly.
1) Cutting
Cutting is the initial step in fabrication. The metal fabrication company will cut one or more
pieces of raw metal throughout this procedure to be used in the production of a new metal
structure or product. But cutting metal needs specialised equipment, whether it's steel,
aluminium, iron, or any other common form of metal. Torches are used by some metal
production companies, whereas CNC machines with lasers or water jets are used by others.
When done, the business will have clean, suitable-sized sheets or sections of metal to work with.

2) Bending
Metal fabrication businesses must bend the raw metal after cutting it. After cutting metal, there
are numerous ways to bend it. Some businesses that fabricate metal shape the metal sheets or
sections using a hammer. Hammering can be carried out manually or mechanically (power
hammering). But lately, a lot of metal fabrication businesses have started bending their metal
with press brakes. When activated, this large industrial device automatically presses metal sheets
and pieces into a particular shape. The metal is simply clamped between a punch die and forced
into the required shape.

3) Assembling
The third and final process of metal fabrication is assembling. As the name suggests, this process
involves assembling the metal sheet or sections into the desired finished product. Assembling is
typically performed via welding, though other steps may be included in the process as well. In
addition to welding, for example, metal fabrication companies may crimp seams, apply screws or
other fasteners, and apply glue. After assembling the metal, the company will finalize the
product before shipping and selling it to its customers.

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Metal fabrication is a driving force behind the country’s ever-growing manufacturing sector.
Although there are countless machines and techniques used by metal fabrication companies,
must rely on a three-step process that consists of cutting, bending and assembling. These three
processes allow metal fabrication companies to transform raw metal materials into new products.

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DESIGN CONSIDERATION

Several structural design considerations should be taken into account for economical and
efficient manufacturing. Many of these apply to other joining methods, and all apply to both
subassemblies and the complete structure.

1. The product should be capable of being manufactured locally.

2. The attachment should be made with inexpensive materials and processes.

3. It should satisfy low-income populations' fundamental demand for mechanical power and be
affordable and available to them.

4. It must be easy to produce, use, maintain, and repair.

5. It ought to serve a variety of functions, including powering tiny equipment utilised in rural
business as well as diverse agricultural implements.

6. It should make use of resources and expertise that are close by. common steel items like
plates, rods, and angle iron, and flat stock that are locally available should be used. Standard
tools used in machine shops such as hacksaw, files, punches, taps & dies; medium duty welder;
drill press; small lathe and milling machine should be adequate to fabricate the parts needed for
the dual-purpose bicycle.

7. It should make use of standard parts wherever possible.

8. The device should adapt easily No permanent structural modification should be made

9. Excessive weight should be avoided, as durability is a prime consideration.

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DESIGN PROCEDURE

1. Definition of problem

2. Synthesis

3. Analysis of forces

4. Selection of material

5. Determination of mode of failure

6. Selection of factor of safety

7. Determination of dimensions

8. Modification of dimensions

9. Preparation of drawings

10. Preparation of design report

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DESIGN CONSIDERATIONS

● Strength

● Rigidity

● Reliability

● Safety

● Cost

● Weight

● Ergonomics

● Aesthetics

● Manufacturing considerations

● Assembly considerations

● Conformance to standards

● Friction and wear

● Life

● Vibrations

● Thermal considerations

● Lubrication

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● Maintenance

● Flexibility

● Size and shape

● Stiffness

● Corrosion

● Noise

● Environmental considerations

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AESTHETIC CONSIDERATIONS IN DESIGN
• A product's appearance serves as an external representation of its quality and serves as its initial
point of contact with a user.

• The study of aesthetics is the study of the rules for appreciating beauty. It concerns how the
product appears.

ASPECTS OF AESTHETIC DESIGN

● Form(shape)

● Symmetry and shape

● Continuity

● Variety

● Proportion

● Noise

● Contrast

● Impression and purpose

● Style

● Material and surface finish

● Tolerance

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ERGONOMICS CONSIDERATIONS IN DESIGN
• Ergonomics is defined as the study of the man - machine - working environment relationship

• It aims at decreasing the physical and mental stresses to the user

• Areas covered under ergonomics

• Communication between man (user) and machine

• Working environment

• Human anatomy and posture while using the machine

• Energy expenditure in hand and foot operations

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MANUFACTURING CONSIDERATIONS IN DESIGN

● Minimum total number of parts in a product

● Minimum variety of parts

● Use standard parts

● Use modular design

● Design parts to be multifunctional

● Design parts for multiple use

● Select least costly material

● Design parts for ease of manufacture

● Shape the parts for minimizing the operations

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STANDARDIZATION
• It is the process of establishing the set of norms to which a specified set of characteristics of a
component or a product should conform

• Example: Standardizing the shaft consists of specifying the set of shaft diameters and material

Objectives of standardization

• To make the interchangeability of the components possible

• To make the mass production of components easier

Objectives of the project

1. To cater to the issue of competition in the mechanical industry the need for automation is
assessed by all the industry.

2. To identify the key policy avenues considered to be appropriate to meet the challenge of
sustainable manufacturing and packaging industry for the future.

3. To provide alternatives for industries aiming toward reducing human effort and improvement
in material handling systems by implementing automation.

4. Sustainable and practical automation solutions for the future industrial environment.

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MECHANICAL PROPERTIES OF MATERIALS

● Strength

● Stiffness/Rigidity

● Elasticity

● Plasticity

● Ductility

● Brittleness

● Malleability

● Toughness

● Machinability

● Resilience

● Creep

● Fatigue

● Hardness

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Objective Of Work

 To study ergonomics and problems of project.

 To develop some concepts based on their needs.
 Different projects analysis and it's type and it's major uses.
 To achieve comfort and easy response concepts that satisfying most of the needs and
which gives more suitable and also economical.
 To develop model of those concept.
 To evaluate the CAD model in real environment.

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AESTHETIC

Consideration of the product's appearance, also referred to as its aesthetics, is another crucial
factor in any product design. The aesthetic appeal of this product significantly helps to meet
customer needs. Numerous aesthetic factors, including social appeal, colour, dimension, cushion
material, etc., were taken into account in the proposed chair design. In Table X, a number of
aesthetic concerns about the proposed chair's demands for students are noted and briefly
explained.

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DESIGN DRAWING AND PICTURES

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COMPONENTS

Syringe
Pipe
Lifting frame
Base Frame (Bed)
Supporting frame
Joints & screws

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PARTS DESCRIPTION

We have used syringe as plunger.

Material used-
Base plate – acrylic – 150mm x 250mm, thickness – 6mm
Top plate – acrylic – 80mm x 180mm, thickness – 6mm
Screw – M6 for all the joints
Arms – MS plate 2mm thickness – 15mm x 180mm

Base Frame (Bed)

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Base plate – acrylic – 150mm x 250mm, thickness – 6mm

The base frame is the base to fix pantograph frames. It supports the fixed part of the frame and is
mounted on supporting insulators of pantographs. Base frames are usually made of profile steel,
plates through extrusion, or steel tubes through splicing or castings and profile steel through
splicing.

Lifting Frame

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Top plate – acrylic – 80mm x 180mm, thickness – 6mm
Lifting frame is used as a supporting frame that carry the load on it which is in direct contact
with load.

Syringe

Syringe is used as a device used to inject fluids into or withdraw them from something (such as
the body or its cavities).

Linkage (Arms)

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A mechanical linkage is an assembly of systems connected to manage forces and movement. The
movement of a body, or link, is studied using geometry so the link is considered to be rigid. The
connections between links are modelled as providing ideal movement, pure rotation or sliding for
example, and are called joints.

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FABRICATION PROCESS

A set of operations using a raw material, typically metal sheets and other flat materials, result in
a finished end product. For almost any firm to operate efficiently, create the equipment they
need, make items, etc., metal fabrication is essential. As you can see, it is a very varied industry
that keeps the entire planet running.
Fabrication is the process of manufacturing flat materials to adhere to preset shapes, such as
sheet metal. The procedure starts with sheet metal that is no thicker than a quarter inch. At this
thickness, sheet metal and other flat materials are sufficiently flexible to assume different shapes.
Fabricators use this metal to mould the sheet to a desired shape. This is done via cutting,
stamping, shaping, folding, and welding. Another related activity is custom fabrication, which is
the creation of brand-new, one-of-a-kind parts using inventive combinations of several
procedures.
All of this work is done by metal fabricators, highly skilled individuals who are trained to cut
and shape metal with the surgical accuracy of a surgeon. The majority of the time, these
fabricators run their businesses out of sizable manufacturing plants or specialised fabrication
facilities. The shops themselves come in a wide range and offer specialised fabrication for the IT
and medical industries in addition to traditional fabrication services.
Sheet metal and other flat materials fabrication may require additional parts to be added during
the process, including but not limited to.

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WORKING

The hydraulic brake is a type of braking mechanism that uses a brake fluid, typically ethylene
glycol (contained in the reservoir), to transfer pressure from the controlling unit (the master
cylinder) to the actual brake mechanism, which is typically at or near the wheel of the vehicle, in
order to stop or slow down a moving body. A hydraulic jack is a device that generates force by
pressurising fluids. These devices consist of a straightforward cylinder and piston system.
Whenever either piston is pushed inward, a fluid, such as oil, is displaced.

Any device that compresses under the influence of hydraulic pressure is referred to as a
hydraulic jack. This project makes use of

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ADVANTAGES

 Hydraulic jack generally suffers from less damage due to hard parts rubbing together.
 They use fluid to transfer energy, resulting in 100% efficiency as fluids used are
incompressible in nature.
 They are simple in Design.
 By applying small force, up to 4-10 Tons of load can be lifted.
 The technological ease you get while
 The process utilizes minimal effort vitality source
 Large machines outlines are not required on the procedure

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RESULTS

Successfully we achieved the desired result by using “Design and Fabrication of Mini Hydraulic
Jack” that uses hydraulic power to operate the jack in vertical movement.

Let,

F1 = Force applied on smaller plunger

F2 = Output Force (Ram side)

A1 = Surface area of piston (Plunger side)

A2 = Surface area of piston (Ram side)

Now, since the interacting fluid is incompressible fluid, the pressure inside the system will
remain constant.

i.e. P1 = P2 =P ….(1)

Force
we know, P=
Area

From eq. (1),

F1 F2
=
A1 A2

Suppose, D2 = 4D1

Then,

A2
∴ F 2=F 1
A1

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 2
π (D¿¿ 2)
∴ F 2=F 1 ¿
4 π 2
( D1 )
4
2
16(D¿ ¿1)
∴ F 2=F 1 ¿
(D¿¿ 1)2 ¿

∴ F 2=16 F 1

i.e., Output force F2 will be 16 times input force F1.

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CONCLUSIONS
Mild steel, acrylic material, liquid water, screws, and bolts are used to construct a reliable
hydraulic jack lifting mechanism. Marking, cutting, assembling, and connecting operations were
used throughout fabrication.
This project's work has been tested, and it has performed as expected. The dimensions of the
loads that were lifted were set by their manufacturers' standards.

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FUTURE SCOPE

This project's arrangement of an integrated hydraulic jack system is made for heavy-loaded
trucks, but with a few minor adjustments to the current project, this arrangement might also be
widely employed in the future for heavy vehicles.

We can find the thing using an ultrasonic sensor. Pneumatic systems can take the role of
hydraulic systems.

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REFERENCES

[1] M.M. Noor, K. Kadirgama and M.M. Rahman, Analysis Of Auto Car Jack, National
Conference in Mechanical Engineering Research and Postgraduate Students, FKM Conference
Hall, UMP, Kuantan, Pahang, Malaysia, 26-27 May 2010, 198-203.

[2] Mohd Abuzaid, Mohd Hasnain, Shabaj Alam, Sohail Khan and Surendra Agarwal, Inbuilt
Hydraulic jack in Automobile vehicles, International Journal of Innovations in Engineering and
Technology, 2(2),2013,76-84.

[3] Tarachand G. Lokhande, Ashwin S. Chatpalliwar and Amar A. Bhoyar, Optimizing

Efficiency of Square Threaded Mechanical Screw Jack by Varying Helix Angle, International
Journal of Modern Engineering Research,.2(1), 2012, 504-508.

[4] P.S. Rana, P.H. Belge, N.A. Nagrare, C.A. Padwad, P.R. Daga, K.B. Deshbhratar and N.K.
Mandavgade, European Journal of Applied Engineering and Scientific Research, 1 (4),
2012,167-172.

[5] Prashant Kumar Srivastav, Vipin Kumar Pandey, Shailesh Kumar Maurya, Ajit Tiwari,
Jawed Rafiq and S.K. Dwivedi, Highly Efficient Motorized Screw Jack, International Journal of
Computational Engineering Research, 3(5), 2013, 35-41.

[6] A. S. Akinwonmi and A. Mohammed, Modification of the Existing Design of a Car Jack,
Journal of Emerging Trends in Engineering and Applied Sciences, 3 (4), 2012, 581-588.

[7] J.J. Ferreira, M.G. Boocock and M.I. Gray, Review of the risks associated with pushing and
pulling heavy loads (Health and Safety Laboratory Broad Lane Sheffield S3 7HQ, 2004).

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