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Design of New Hydraulic Jack-Biped Jack

Article · January 2013

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B. Ramesh Ayyasamy Elayaperumal

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 Design of New Hydraulic Jack- Biped Jack
B.Ramesh1, P.Venkateshwaran2, Dr.A.Elayaperumal3
1
Associate Professor, Dept. of Mechanical Engg., St.Joseph’s College of Engineering,
Chennai-600 119, India, rameshphd2010@yahoo.in
2
U.G Student, Dept. of Mechanical Engg., St.Joseph’s College of Engineering,
Chennai-600 119, India, vineethvenkat@yahoo.in
3
Associate Professor, Dept. of Mechanical Engg., College of Engineering Guindy, Anna University,
Chennai-600 025, India, ep_mal@yahoo.com

Abstract: The heavy motor vehicles use screw jack to lift the vehicle axle for replacing the worn out wheel. This requires considerable
human energy and a lot of time. The Biped Jack has been developed to reduce human energy and time, considerably.

Keywords: Link, Lever, Buckling; Double acting double rod cylinder, Direction control valve.

d2 = 50

I. INTRODUCTION

t1 = 17

l1 = 184
Creating a plan or drawings for a product using
intellectual ability and scientific knowledge is called design.

l2 = 16.5
The Biped Jack has its name because it seems to have two i i
d1 = 33

legs. The Biped Jack lifts the axle of the vehicle using Fig. 1. Pin Fig. 2. Pin
hydraulic (oil) energy. Here the main function is taken by
links, which acts as levers and increase in the height of Diameter of the pin rod = d1
levers makes the axle to elevate from the ground. The Diameter of the piston rod = d = d1
increase in the height of levers is aided by double acting Diameter of the pin head = d2 = 1.5 d1
double rod hydraulic cylinder. Thickness of pin head = t1 = 0.5 d1
The Biped Jack has eight links and eight levers Load to be lifted = P = 100 kN = 1,00,000 N = 10,000 kg =
with the pin as fulcrum. Four links form a leg. The Biped 10 ton
Jack is kept always ready, so that, when there is a need to Length of pin=l1=t1+4t2+t+ t 3 +l2=5.5 d1
replace the worn-out wheel, it is simply assembled to the 2
wheel axle by means of taper pin and operated. Here, an oil Distance of tapered hole from one end of the pin rod = l2 =
truck of weight 6800 kg. without load and 16300 kg. with 0.5 d1
load is taken. The Biped Jack is designed for a capacity of Thickness of eye end in the link = t2 = 0.75 d1
10 tons. Higher end tool, Pro/E 2001 is used for modeling Thickness of eye end in piston rod, axle and base = t = 1.25
and mechanism development. All the parts of the Biped d1
Jack are made of high tensile cast steel CS 125. Thickness of collar = t3 = 0.5 d1
Yield strength = σy = 1020 N/mm2 (min).
II. DESIGN OF PIN

In static loading, load is applied gradually and

after the application, load does not vary with time. [σc] = 1020 = 510 N/mm2. Permissible shear stress =
Or, load may vary slowly so that it cannot come under 2
dynamic or impact loading. For steel or ductile materials [τ] = [σ c ] (Eq. 2.3)
subjected to static type of load, the factor of safety is 1.5 – 2 2
based on σy. = 510 = 255 N/mm2
Permissible tensile stress = 2
[σt] = σ y (Eq. 2.1) In the following failure analysis, the axial force is equated
FOS to the resistance to failure.
= 1020 = 510 N/mm2. Permissible crushing stress = [σc]
2 A. Failure of pin rod in tension
= σy (Eq. 2.2) The maximum load subjected by the piston rod =
FOS P1 = 195.47 kN

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
 P1 = π d 2 [σ t ] (Eq. 2.4)
4 = [49.3 x 103[(18/3) + 18 + (30/2)]] – [[(195.47 x 103)/2]
π [30/4]] = 1189687.5 Nmm
195.47 x 103 = d2 x 510
4 Section modulus = Z = π d 13 (Eq. 2.8)
32
∴ d = 22.1 mm.
Let d = 24 mm. The other dimensions of the pin
are obtained by using the proportions. P2

t2
t2
3
d1 = d = 24 mm, d2 = 36 mm ,
t = 30 mm, t1 = 12 mm, t2 = 18 mm, t3 = 12 mm, l1 =
P1
2

132 mm , l2 = 12 mm.

t
P1
2

Since the dimensions are fixed by proportions, we calculate

t2
3

t2
P2

the induced stresses and check them against the permissible

values. Fig. 4a. Distribution of load on the pin

B. Failure of the Pin by shear

P2

t2
t2
3
P1
2

t
P1
2

t2
3

t2
P2

Fig. 4b. Distribution of load on the pin

Fig. 3. Area resisting shear Taking maximum bending moment,

The maximum load subjected by pin = Maximum induced bending (tensile) stress = σ t = M 2
Z
P1 = 4 x π d12 τ (Eq. 2.5) (Eq. 2.9)
4 =[1189687.5]/[(π/32) 243] = 876.6 N/mm2
195.47 x 103 = π x 242 x τ σt = 876.6 N/mm2 > [σt] = 510 N/mm2
∴ Induced shear stress = τ = 108.02 N/mm2 ∴ The design is not satisfactory.
τ = 108.02 N/mm2 < [τ] = 255 N/mm2 Increase the value of d1. Let d1 = 33 mm. The other
∴ The design is satisfactory. dimensions of the pin are obtained by using the proportions.
d1 = d = 33 mm, t1 = 16.5 ≈ 17 mm l1 = 184 mm,
C. Failure of the pin by bending d2 = 49.5 ≈ 50 mm, t2 = 24.75 ≈ 25 mm, l2 = 16.5 mm, t =
In actual practice, the pin is loose in the eyes 41.25 ≈ 42 mm, t3 = 16.5 ≈ 17 mm
attached to leg in order to permit angular movement of one The maximum load subjected by pin =
with respect to the other. Therefore, the pin is subjected to
π
bending in addition to shearing. By making the diameter of P1 = 4 x d12 τ (Eq. 2.10)
pin equal to the diameter of the piston rod (i.e., d = d1), a 4
margin of strength is provided to allow for the bending of i.e., 195.47 x 103 = 4 x [π /4] x 332 x τ
the pin. Since, the stress due to bending is taken into ∴ τ = 57.14 N/mm2
account, it is assumed that the load on the pin is uniformly τ = 57.14 N/mm2 < [τ] = 255 N/mm2
distributed along the middle portion (i.e., the eye ends ∴ The design is satisfactory.
attached to piston rod, axle and base) and varies uniformly M1 = P2 [(t2/3) + (t/2) ] - [ P1/2 ] [ t/4 ] (Eq.2.11)
over the eye ends attached to leg. = [49.3 x 103 [(25/3) + (42/2)]] – [[(195.47 x 103) / 2] [42
Thus, in the eye ends attached to leg, a load P2 acts / 4]]=419915.83 Nmm
M2 = P2 [ (t2/3) + t2 + (t/2) ] - [P1 / 2] [t / 4] (Eq. 2.12)
through a distance of t 2 from the inner edge and the = [49.3 x 103 [(25/3) + 25 + (42 / 2)]] – [[(195.47 x 103) / 2]
3
[42 / 4]] =1652415.83Nmm.
bending moment will be maximum at the centre of the pin.
Taking maximum bending moment,
The bending moment is calculated as follows:
Maximum induced bending (tensile) stress =
M1 = P2 [(t2/3) + (t/2)] - [P1/2] [t/4] (Eq. 2.6)
σt = M2 / Z (Eq.2.13)
= [49.3 x 103[(18/3) + (30/2)]] – [[(195.47 x 103)/2]
=[1652415.83]/[(π/32) 333] = 468.36 N/mm2σt = 468.36
[30/4]] = 302287.5 Nmm
N/mm2 < [σt] = 510 N/mm2
M2 = P2 [(t2/3) + t2 + (t/2)] - [P1/2] [t/4] (Eq. 2.7)
∴ The design is satisfactory.

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
 Diameter of the tapered hole in pin on other side = Diameter
III. DESIGN OF COLLAR of the tapered hole in inner diameter of the collar at other
end d8=8.07 mm
Diameter of the tapered hole in outer diameter of the collar
at other end = d7 = 7.9 mm

V. DESIGN OF BUSH

Fig. 5. Collar

Inner diameter of collar = d3 = d1 = 33 mm

Outer diameter of collar = d4 = 1.5 d1= 49.5 ≈ 50 mm
Thickness of collar = t3 = 0.5 d1 = 16.5 ≈ 17 mm
Radial distance of tapered hole from one face of the collar = Fig. 8. Bush
t
l 3 = 3 = 8.5 mm A 3 mm thick phosphor bronze or gun metal or
2 brass bush is pressed into the eye ends as a bearing so that
the renewal becomes simple when wear occurs. The collar
IV. DESIGN OF TAPER PIN is not provided with bush because after sufficient service,
the collar has to be replaced due to wear on the profile.

3
33
=
d1

39
t = 42
Fig. 6. Taper pin
Fig. 9a. Bush
Taper ratio = 1:50 The following bush is pressed into the eye ends in piston
Length of the taper pin = l4 = 1.8 d1 = 59.4 mm ≈ 60 mm rod, axle and base.
Diameter of the taper pin at one end = d5 = 0.25 d1 = 8.25
mm ≈ 9 mm. =
33
d1
d = 8.07

39
d = 7.9
d = 8.9

d = 8.73

d = 7.8
7
10

6
8
9
d =9

t2 = 25
5

d = 33
1

d = 50
4
i h
Fig. 9b. Bush
l = 60
4

Fig. 7. Taper pin

VI. DESIGN OF EYE END IN PISTON ROD
Taper = [[Diameter at the larger end] – [Diameter at the
Inner diameter of the eye end =
smaller end]]/ Distance between the two ends (Eq.
d11 = d1 + 6 = 39 mm.
4.1)
Outer diameter of the eye end =
d12 = 2 d1 = 66 mm.
1/50 = [9 – d6] / 60 ∴ d6 = 7.8 mm
Thickness of the eye = t = 42 mm
1/50 = [9 – d7] / 55 ∴ d7 = 7.9 mm
Dimensions of the square end = 1.1 d1 = 37 x 37 x 10 mm
1/50 = [9 – d8] / 46.5 ∴ d8 = 8.07 mm
Length of the octagonal end = l5 = 1.2 d1 = 39.6 ≈ 40 mm
1/50 = [9– d9] / 13.5 ∴ d9 = 8.73 mm
1/50 = [9 – d10] / 5 ∴ d10 = 8.9 mm Length of the eye = l6 = d12 + 10 + l5=83 mm
i.e., 2
Diameter of the taper pin at the other end=d6=7.8 mm
Diameter of the tapered hole in
Outer diameter of the collar at one end=d10=8.9 mm
Diameter of the tapered hole in pin on one side = Diameter
of the tapered hole in inner diameter of the collar at one
end=d9=8.73 mm
Fig. 10. Eye end in piston rod

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
 P = 2 [(d12 – d11)/2] t τ (Eq. 7.2)
A. Failure of the eye end in tension i.e., 100 x 103 = [66 – 39] 42 x τ
The max. load subjected by eye end = ∴ Induced shear stress = τ = 88.18 N/mm2
P1 = (d12 - d11) t σt (Eq. 6.1) τ = 88.18 N/mm2 < [τ] = 255 N/mm2
i.e.,195.47 x103 = [66-39]42 x σt ∴ The design is satisfactory.
∴ Induced tensile stress =σt = 172.37 N/mm2
σt = 172.37 N/mm2 < [σt] = 510 N/mm2 C. Failure of eye end in crushing
∴ The design is satisfactory. P = d11 t σc (Eq. 7.3)
i.e., 100 x 103 = 39 x 42 x σc
B. Failure of eye end in shear ∴ Induced crushing stress = σc =61.05 N/mm2
⎡ [d − d11 ] ⎤ σc = 61.05 N/mm2 < [σc] = 510 N/mm2
P1 = 2 ⎢ 12 x t ⎥ τ (Eq. 6.2) ∴ The design is satisfactory.
⎣ 2 ⎦
3
i.e.,195.47 x 10 = (66-39)42 x τ VIII. DESIGN OF BASE
∴ Induced shear stress = τ = 172.37 N/mm2
τ = 172.37 N/mm2 < [τ] = 255 N/mm2
∴ The design is satisfactory. d12
=
66

39
=
d11
l7 = 65
C. Failure of eye end in crushing

t4 = 20
t

20
eye l8 = 200

Fig.14. Base Fig. 15. Base

d11

Pin Let, Length of the base = l8 = 200 mm

Breadth of the base = l9 = 150 mm
Fig. 11. Area resisting crushing Thickness of the base = t4
Assume the base is simply supported at its ends and a
P1 = d11 t σc (Eq. 6.3) concentrated load of P acts at its centre.
i.e., 195.47 x 103 = 39 x 42 x σc Therefore, maximum bending moment =
∴ Induced crushing stress = σc = 119.33 N/mm2
σc = 119.33 N/mm2 < [σc] = 510 N/mm2 M = Pl8 (Eq. 8.1)
∴ The design is satisfactory. 4
Moment of resistance for a rectangular section M =
VII. DESIGN OF EYE END IN AXLE AND BASE 1
f bd 2 (Eq. 8.2)
6
Where, f = maximum stress offered by the base section.
d13 = 130 t = 42

Equating maximum bending moment to moment of

l7 = 65

39
=
20

d11

resistance,
pl8 1 1
= fbd 2 = [σ c ] l9 t 42 (Eq. 8.3)
6
=6

4 6 6
d12

Fig.12. Eye end in Fig.13. Eye end in 3

axle and base axle and base i.e., 100 x 10 x 200 = 1 x 510 x 150 x t 42
4 6
Inner diameter of the eye end = d11 = 39 mm ∴ t4 = 19.8 mm ≈ 20 mm.
Outer diameter of the eye end = d12 = 66 mm
Breadth of the eye end = breadth of the axle = d13 = 130 mm
Thickness of the eye = t = 42 mm IX. DESIGN OF LEG
Let, length of the eye = l7 = 65 mm
2

l13 = 92
d11 = 39
d12 = 66

A. Failure of eye end in tension

l12

t6 = 3

P = [d12 – d11] t σt (Eq. 7.1)

l11 = 276

i.e., 100 x 103 = (66 – 39) 42 x σt

∴ Induced tensile stress = σt = 88.18 N/mm2 t5 = 15
l12 = 61

σt = 88.18 N/mm2 < [σt] = 510 N/mm2 Fig.16. Half Fig.17. Two links
∴ The design is satisfactory. of the leg forming half of the leg

B. Failure of eye end in shear Thickness of plate joining the two links = t6 = 3 mm

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
Distance between the axis of the eye end and 1). Euler’s formula 2). Johnson’s Parabolic formula and 3).
t Rankine formula.
plate=l12=1.2d1+ = 60.6 ≈ 61 mm
2 Euler’s formula
Distance between the axis of the two links = l13 = 2 t2 + t =
92 mm. nπ 2 EI L
Pc = for > 120 (steels) (Eq. 9.4)
2
L K
A. Design of eye end in the link Where,
Pc = buckling load, N
t2 = 25

d12
=
66

d11 =
39
n = co-efficient of end condition.
L = equivalent length of link, mm
K = radius of gyration, mm
E = young’s modulus, N/mm2
l11 = 276

t5 = 15
l10 = 30
I = moment of Inertia = AK2, mm4
A = area of cross section, mm2
Pc nπ 2 E
Now, buckling stress = =
Fig. 18. Link A ⎛ L ⎞2
⎜ ⎟
Breadth of the link = l10 ⎝K⎠
Thickness of the link = t5 n =1 (both ends of the link are hinged).
Length of the link = l11 The buckling stress for a column cannot be more
Inner diameter of the eye end = d11 = 39 mm than the crushing stress of the column material. Therefore,
Outer diameter of the eye end = d12 = 66 mm equating buckling stress to crushing stress we get,
Thickness of the eye end in the link = L
510= 1x π x 2.1 x 10 ∴
2 5
t2 = 25 mm = 63.75 < 120
⎛L⎞
2 K
1) Failure of the eye end in tension ⎜ ⎟
The maximum load subjected by the link = P2 = ⎝K⎠
49.3 kN ∴ Euler’s formula is not valid here.
P2 = [d12 - d11] t2 σt (Eq. 9.1)
i.e., 49.3 x 103 = [66 – 39] 25 x σt Johnson’s parabolic formula
∴ Induced tensile stress = σt = 73.04 N/mm2 σ y ⎛ L ⎞2 L
σt = 73.04 N/mm2 < [σt ] = 510 N/mm2 Pc = Aσ y [1 − ⎜ ⎟ ] for < 120 (steels)
4 nπ 2 E ⎝ K ⎠ K
∴ The design is satisfactory. (Eq. 9.5)
2) Failure of the eye end in shear
Pc ⎡ σ y ⎛ L ⎞2 ⎤
[d − d11 ] ⎤ τ
P2 = 2 ⎡ 12 (Eq. 9.2) ∴ = σ y ⎢1 − ⎜ ⎟ ⎥
⎣⎢ 4nπ E ⎝ K ⎠ ⎦⎥
t2 ⎥ 2
⎢ 2
A
⎣ ⎦
i.e., 49.3 x 103 = [66 – 39] 25 x τ ⎡ 1020 ⎛L⎞ ⎤
2
i.e.,510= 1020 ⎢1 − ⎜ ⎟ ⎥
∴ Induced shear stress = τ = 73.04 N/mm2 ⎢⎣ 4 x1xπ x 2.1x10 ⎝ K ⎠ ⎥⎦
2 5

τ = 73.04 N/mm2 < [τ] = 255 N/mm2

∴ The design is satisfactory. L
∴ = 63.75 < 120
K
3) Failure of the eye end in crushing ∴ Johnson’s parabolic formula is valid here.
P2 = d11 t2 σc (Eq. 9.3)
i.e., 49.3 x 103 = 39 x 25 x σc Rankine formula
∴ Induced crushing stress= σc = 50.56 N/mm2
σc = 50.56 N/mm2 < [σc] = 510 N/mm2
Aσ yc
∴ The design is satisfactory. Pc=
2
for 60 <
L
< 120 (Eq. 9.6)
⎡L⎤ K
B. Failure analysis of link 1+ C ⎢ ⎥
⎣K ⎦
According to the proportions, l11 > 2 l12 = 122 mm.
Where,
The link is subjected to axial compressive force. So, it is
σ yc = yield point stress in compression ≈ σy for steel
treated as a column in failure analysis. The three formulas
used for failure analysis of column are:

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
 σ yc 1 (Eq. 9.7)
C = Rankine constant = x Now,
π E n
2
3
Now, t 5 l10
σy IXX = (Eq.9.9)
Pc
= 12
A σy 1⎡L⎤ 2
= (15 x 303)/12 = 33750 mm4
1+ x
π 2 E n ⎢⎣ K ⎥⎦ 3
l10 t 5
i.e, 510 = 1020 IYY = (Eq. 9.10)
1020 1⎡ L ⎤
2 12
1+[ 2 = (30 x 153)/12 = 8437.5 mm4
π x 2.1 x 10 1 ⎢⎣ K ⎥⎦ ]
5 x
IYY < IXX
L ∴ Buckling takes place in Y-Y direction.
∴ = 45.1 < 60 IYY = AK2 (9.11) ∴ K = sqrt[8437.5 /
K
(15 x 30)] = 4.33 mm
∴ Rankine’s formula is not valid here.
In order to have the link equally strong in both the W.K.T. L = 63.75 ∴ L = 276 mm
planes of buckling, Pc (X-axis) = Pc (Y-axis) K
i.e., ⎡ σy AL2 ⎤ ⎡ σy AL2 ⎤ Since, both ends of the link are hinged,
Aσ y ⎢1 − x ⎥ = Aσ y ⎢1 − x ⎥
⎣ 4x1xπ x E I xx ⎦
2
⎢⎣ 4 x1x π x E I yy ⎥⎦
2 Actual length of the link = Effective length of the link
i.e., l11 = L = 276 mm > 122 mm
t5 The stress induced due to axial loading =
Y
P2
σt = (Eq. 9.12)
X X t 5 l10
l10

Y = 49.3 x 103/(15 x 30) = 109.56 N/mm2

Fig. 19. Section of the link σt = 109.56 N/mm2 < [σt] = 510 N/mm2
∴ The design is satisfactory.
2 2 Now, Johnson’s buckling load =
i.e., L = L
Pc=15x30x1020 ⎡1 − 1020 2 ⎤ P = 229.49
⎢ 4 x1xπ 2 x 2.1x10 5 [63.75] ⎥
I xx I yy c
⎣ ⎦
About X-X , L = l11, for both ends free to turn.
kN
l11 Maximum safe working load =
About Y-Y, L = , for both ends fixed. In the direction of
2 P3 = Pc (Eq. 9.13)
the axes of these pins, however, it may be considered as FOS
having fixed ends. Where, FOS = 3 - 4
4 1 ∴ P3 = 229.49 / 3 = 76.5 kN
l112 l112 / 4 12 l112 3 l112 = 2 => P2 = 49.3 kN < P3 = 76.5 kN
∴ = ie , = 2
t 5 l103 l10 t 53 t 5 l10
3
l10 t 53 l10 t 5 ∴ The design is satisfactory.
12 12
2 1
= X. DESIGN OF WELDING
l10 t 5
P Axle

i.e., l10 = 2 t5
150

Stresses due to axial loading

Tensile stress induced = t = 42
10

P (Eq. 9.8)
σt = 2
l10 t 5 P

Fig. 20. T-joint

Compressive stress induced = σc = σt .
Here, l10 = 2 t5
Here, double transverse fillet weld is used to weld
∴ σt = 49.3 x 103 / (2 x t52), [σt] ≥ σt the eye ends with the axles of the vehicle. The load acts at
∴ 510 ≥ 24.65 x 103 / t52 right angles to the weld. The type of joint is T-joint. In a
∴ t5 ≥ 6.95 mm typical oil truck two eye ends should be welded suitably in
Let t5 = 15 mm
each of the two axles.
∴ l10 = 30 mm The maximum load to be lifted = P = 100 kN

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
Leg (or) size of the weld = h X1
100 KN
X

Throat thickness = t7 = 0.765 h

Minimum area of the weld = A =
Throat area = t7 d13
98.6 KN

Ø1 Ø

Y1

Length of the weld = d13 = 130 mm

Y1

Allowable shear stress for mild steel coated electrodes for Fig. 23. Elements of Load
steady load = [τ] = 95 N/mm2
Now, P = 1.65 h x d13 x [τ] (10.1) X /2
i.e., 100 x 103 = 1.65 x h x 130 x 95 ∴ Y1 = 1 (Eq. 11.1)
cos θ 1
∴ h = 4.91 ≈ 5 mm
The fillet size should be greater than the minimum = [100 x 103 / 2] / cos 59.53 = 98.6 KN
recommended values to reduce stress concentration effects. X /2
∴ Y1 = (Eq. 11.2)
∴ Let, h = 10 mm cosθ
∴ A = t7 d13 (Eq. 10.2)
= 0.765 h d13 = 0.765 x 10 x 130 = 994.5 mm2 i.e., 98.6 = X /( 2 cos 30.47 )
The minimum area of the weld is taken because the stress is ∴ X = 169.97 KN
maximum at the minimum area. i.e., Tensile load acting on the piston rod = 169.97 KN
Design of New Hydraulic Jack- Biped Jack
Tensile load acting on each link = 98.6 / 2 = 49.3 kN
0.
76
5

5
h

XII.DESIGN OF HYDRAULIC CYLINDER

67.5

h=10

Fig. 21. Enlarged view of the fillet

Since the weld is weaker than the plate due to slag

and blowholes, therefore the weld is given a reinforcement,
which may be taken as 10% of the plate thickness. Here the
reinforcement is 4.2 ≈ 5 mm. Fig. 24a. Double acting double rod hydraulic cylinder

XI. DESIGN OF FORCES ACTING ON EACH 10 4 6

4

ELEMENT OF THE BIPED JACK 18 5

AO = [460 – ( 65 + 65 + 20 + 10 + 20 )] / 2
33

125

= 280 / 2 = 140 mm 10

∴ BO = sqrt (2762 – 1402) = 237.86≈238 mm 143

5
100 KN
Fig. 24b. Section of double acting double rod hydraulic
130 cylinder
A. Piston
65

98.6
Ø

KN
3°
9.5

140

238
=5

98.6
1
Ø

169.97 KN KN 169.97 KN
Ø = 30.47°

O
B
Ø

169.97 KN D
460
Ø

169.97 KN

276
Ø

c Fig. 25. Piston

wood
65

130
Ground level
20

200
Pressure required in the hydraulic cylinder =
10

20

Fig. 22. p= Load (Eq. 12.1)

Bottom position of biped jack Effective area
Let, the standard piston diameter = d14 = 125 mm
∴ tan θ = AO / BO = 140/ 238 ∴ θ Let the coefficient of sliding friction be 0.15
0
= 30.47
θ1 = 90 – θ = 90 – 30.47 = 59.530
∴ p = [169.97 x 103 + (0.15 x 169.97 x 103)] / π(62.52 –
16.52) = 17.12 N/mm2
The external herringbone gear pump can develop pressure
from 4 N/mm2 to 30 N/mm2. The hydraulic circuit should

51
International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
be analyzed using Bernoulli’s equation and the pressure = (π / 64) 334 = 58213.76 mm4
loss due to friction and hydraulic devices should be found. I = AK2 (Eq.12.6)
Therefore, pressure developed by the external herringbone ∴ K = I / A = 58213.76 / (π x 16.52)
2

gear pump = ∴ K = 8.25 mm

p1 = p + pressure loss (Eq. 12.2) ∴ L / K = 46.5 / 8.25 = 5.64 < 120
∴ Johnson’s parabolic formula is used.
Thickness of Piston = Johnson’s buckling load
3 pd142 σ y ⎛ L ⎞2 (Eq. 12.7)
t8 = mm (Eq. 12.3) Pc = Aσ y [1 − ⎜ ⎟ ]
16[σ t ] 4nπ 2 E ⎝ K ⎠
= sqrt[ (3 x 17.12 x 1252) / 16 x 510 ] = π x 16.52 x 1020[1- [[1020 / (4 x 4 x π2 x 2.1 x
= 9.92≈10 mm 105)][5.64]2]] = 871.55 kN
Maximum safe working load =
B. Failure analysis of Piston rod Buckling load
P4 = (Eq. 12.8)
FOS
Where FOS = 3 – 4
∴ P4 = 871.55 / 3 = 290.52 kN
P1 = 195.47 kN < P4 = 290.52 kN
∴ The design is satisfactory.
Tensile stress induced on Piston rod =
Fig 26. Piston rod σt = (195.47 x 103) / (π x 16.52) (Eq. 12.9)
= 228.54 N/mm2
Let, Total length of the Piston rod = l14 = 62 + 10 + 31 + 40 σt= 228.54 N/mm2 < [σt] = 510 N/mm2
= 143 mm ∴ The design is satisfactory.
Where, Actual length of the Piston rod = l15 = 62 + 31 = 93
mm
Thickness of the Piston = t8 = 10 mm , Clearance = 31
mm C. Cylinder Barrel
Length of the threaded end = l5 = 40 mm While piston is moving with some acceleration, if
the valve is closed to stop the motion, the cylinder has to
40 310 face an additional pressure along with the main working
66
=

pressure. The sum of these two pressures is known as the

2
d1

surge pressure. The surge pressure causes the sudden

39

476
mechanical expansion of the cylinder barrel. The stresses
=
d11

43

Fig 27. Eye ends in piston rod may be well within the design limits for ultimate strength.
b
Radial pressure = px = − a (Eq. 12.10) Hoop stress =
Both ends of the Piston rod are fixed. x2
∴ Effective length = L = l15 / 2 = 93 / 2 = 46.5 mm b
Co-efficient of end condition = n = 4 fx = +a (Eq. 12.11)
Stroke length of the cylinder = x2
[l − clearance] Let, surge pressure =
l16 = 15 x 2 (12.4) p2 =2 p = 2 x 17.12 = 34.24 N/mm2 = px
2
At x = 62.5,
∴ l16= [(93 – 31) / 2] x sqrt(2)=43.84≈44 mm
34.24 = b – a (Eq. 12.12)
62.5 2
510 =
b +a (Eq. 12.13)
62.5 2
Solving Equations (12.12) and (12.13) we get,
Fig. 28. Stroke length of the cylinder 2b
= 544.24
62.5 2
The Piston rod is subjected to axial compressive ∴ b = 1062968.75 & a = 237.88
force. So it is treated as a column in failure analysis. At x = r15, px = 0
Moment of inertia = ∴ [1062968.75 / r152] - 237.88 = 0 ∴ r15 =
I = π d4 (Eq. 12.5) 66.85 ≈ 67 mm∴ Thickness of cylinder barrel = t9 = 67 –
64 62.5 = 4.5 ≈ 5 mm.

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
 Let the velocity of oil entering the cylinder be 3.5
D. Flow rate of oil in the hydraulic cylinder m/s.
Say we want to lift the axle of the vehicle in 10 Area of the retract port = [Flow rate into the cylinder /
seconds, then, Velocity of oil entering the cylinder] (Eq. 12.18)
Flow rate of oil in the hydraulic cylinder = [(3.014 x 10-3) / (3.5 x 60)]
= [Effective area of the piston] x [Velocity of the piston] ∴ Inner radius of the retract ports
(Eq. 12.14) =2.14 x 10-3 m ≈ 2 mm
= π (0.06252 - 0.01652) x [0.044/(10/60)] ∴ Inner diameter of the retract ports = 4 mm.
= 3.014 x10-3 m3/min. Area of the extend port
It is usual to select a pump with a capacity about 10% = [(2 x 3.014 x 10-3) / (3.5 x 60)]
higher than required to make an allowance for the reduction ∴ Inner radius of the extend port
in volumetric efficiency with wear. = 3.02 x 10-3 m ≈ 3 mm.
∴ Volume of oil delivered by the pump = ∴ Inner diameter of the extend port = 6 mm.
Q = 2 [3.014 x 10-3] 1.1
= 6.63 x 10-3 m3/min = 6.63 lit/min. XIII. DESIGN OF SCREW FASTENERS
The external herringbone gear pump’s delivery ranges from
0.25 x 10-3 The piston rod and the eye are screw fastened.
m3/min to 760 x 10-3 m3/min. Single start thread is used. The thread designation is M 33.
From standard tables, for M 33, Pitch = 3.5 mm, Major or
E. Extend and retract velocity of Piston nominal diameter of octagonal end and piston rod = d = 33
Flow rate in cylinder = [Effective area of piston] x mm, Effective or pitch diameter of octagonal end and piston
[Retract velocity of piston] (Eq. 12.15) rod = dp= 30.727 mm, Minor or core diameter of piston rod
i.e., 3.014 x 10-3 = π [0.06252 - 0.01652] x Retract velocity. = dc= 28.706 mm, Minor or core diameter of octagonal end
∴ Retract velocity of the piston = 0.264 m/min < 8 m/min = dc= 29.211 mm,
∴ The cylinder need not be cushioned. Depth of thread (piston rod) = 2.147 mm,
Flow rate in cylinder = [Effective area of piston] x [Extend Maximum depth of engagement = 1.894 mm,
velocity of piston] (Eq. 12.16) Stress area = 694 mm2
i.e., 3.014 x 10-3 = π x 0.06252 x extend velocity.∴ Extend Now, Threaded length = l5 = 40 mm,
velocity of the piston = 0.246 m/min. Initial tension in the piston rod =
Retract time of the piston = 10 seconds πd c 2
Extend time of the piston = [stroke length / extend velocity] Pi = σt (Eq. 13.1)
(Eq. 12.17) 4
= [0.044 / 0.246] 60 = 10.73 seconds. Where, σt = stress setup in the piston rod, dc = core
diameter of piston rod.
F. Ports of the cylinder Let the fasteners be not fluid tight
∴ Pi = 1420 d (Eq. 13.2)
= 1420 x 33 = 46860 N
Threaded length = Number of threads x Pitch
∴ σt = Pi x 4 (Eq. 13.3)
(Eq. 13.6)
πdc 2 i.e., 40 = No. of threads x 3.5 ∴ Number of
= 46860 [4 / (π x 28.7062)] = 72.41 N/mm2 . threads = 11.43 ≈ 12.
σy
Permissible stress of the material = (Eq. 13.4)
FOS B. Piston rod and piston
Where, FOS = 3 - 4 A small piston is generally screwed on the
∴ Permissible stress = (1020/3) = 340 N/mm2 threaded end of a piston rod. The end of the rod is slightly
Since the piston rod is initially stressed, riveted to prevent it from unscrewing.
Permissible stress= 340–72.41=267.59 N/mm2 The maximum load subjected by piston rod = P1
Maximum safe tensile load = π
d c [σ t ]
2
= (Eq. 13.7)
P5 = permissible stress x stress area (Eq. 13.5) 4
= 267.59 x 694 = 185.71 kN. Where, dc = minor diameter of piston rod.
The tensile load subjected by fasteners = P1 = 195.47 kN. π
P1 = 195.47 kN > P5 = 185.71 kN . i.e., 195.47 × 103 =
2
d c x 510 ∴ dc = 22.1
Values of induced loads 10% greater than the permissible 4
values are acceptable. mm
∴ The design is satisfactory.

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
From standard tables, let the thread designation be M 33. Flow area = [Discharge / Velocity] (Eq. 14.1) = [2 x 3.014
For M 33, Pitch = 3.5 mm, Major or nominal diameter of x 10-3] / 60 = 10.05 x 10-5 m2
piston rod and piston = d = 33 mm, ∴ Inner diameter of the hose = sqrt[(10.05x 10-5 x 4) / π ] =
Effective or pitch diameter of piston rod and piston = 0.01131 m=11.31mm≈11 mm.
30.727 mm, From the standard tables, a 15 mm nominal size hose of
Minor or core diameter of piston rod = SAE number 100R2 is available which has a minimum
dc= 28.706 mm, bursting pressure of 77.4 N/mm2. So, it will be suitable for
Minor or core diameter of piston = suction and return lines.
dc= 29.211 mm,
Depth of thread (piston rod) = 2.147 mm, B. Pressure lines
Maximum depth of engagement = 1.894 mm, Let the velocity of oil be 3.5 m/s
Stress area = 694 mm2. Flow area = [Discharge / Velocity] (Eq. 14.2)
Now, Threaded length = t8 = 10 mm = [2 x 3.014 x 10-3] / [3.5 x 60]
Initial tension in the piston rod = = 2.871 x 10-5 m2.
π ∴ Inner dia. of the hose= sqrt[(2.871 x 10-5 x 4) / π ] = 6.1
Pi = d c 2 σ t (Eq. 13.8)
4 x 10-3 m ≈ 6 mm
Where, σt = stress setup in the piston rod. From the standard tables, a 9 mm nominal size hose of SAE
dc = core diameter of piston rod. number 100R2 is available which has a minimum bursting
Let the fasteners be not fluid tight. pressure of 112.2 N/mm2. So it will be suitable for
∴ Pi = 1420 d (Eq. 13.9) pressure lines.
= 1420 × 33 = 46860 N
XV. POWER RATING OF THE MOTOR
∴ σt = P x 4 (Eq. 13.10)
πd c 2
i
Power rating of the motor required to run the gear
2
= 46860 [4 / (π x 28.706 )] = 72.41 N/mm2. pump =
Permissible stress of the material p1Q
N= kW (Eq. 15.1)
= σ y (Eq. 13.11) 6 x10 4 η mη v
FOS Where,
Where, FOS = 3 – 4 p1 = pressure developed by the pump, N/m2,
∴ Permissible stress = 1020 = 340 N/mm2 Q = volume of oil delivered by the pump, m3/min,
3 ηm = co-efficient of mechanical efficiency of the pump;
Since the piston rod is initially stressed, generally ηm = 0.7 – 0.9,
Permissible stress = 340 -72.41 = 267.59 N/mm2 ηv = co-efficient of volumetric efficiency of the pump
Maximum safe tensile load = (leakage losses);
P6 = Permissible stress × stress area (Eq. 13.12) generally ηv = 0.7 - 0.8
= 267.59 × 694 = 185.71 kN. ∴ N = [17.12 x 106 x 6.63 x 10-3] / [6 x 104 x 0.8 x 0.75] =
The tensile load subjected by fasteners = P1 = 195.47 kN > 3.15 kW = 4.23 HP
P6 = 185.71 kN.
Values of induced loads 10% greater than the permissible XVI. DESIGN OF RESERVOIR
values are acceptable.
∴ The design is satisfactory. Capacity of reservoir = 3 x [volume of oil
Threaded length = No. of threads × pitch (Eq. 13.13) delivered by the pump / min] (Eq. 16.1)
i.e., 10 = No. of threads × 3.5, = 3 x 6.63 x 10-3 = 0.01989 m3 = 19.89 litre.
∴ No. of threads = 2.86 ≈ 3. Let the reservoir be a square section with side = a and
height = 2 a
XIV. DESIGN OF HOSES ∴ a x a x 2 a = 0.01989 m3
∴ a = 0.2151 m = 215.1 mm ≈ 215 mm
It is desirable to keep the fluid flow to be laminar ∴ Side of the square section = a = 215 mm
and for pressure drops to be minimal. This can be achieved Height of the reservoir = 2 a = 430 mm.
by keeping the fluid velocities low. The suitable velocity
range for suction and return lines is 0.6 to 1.2 m/s and for XVII. LIFT OF BIPED JACK
pressure lines is 2.1 to 4.6 m/s.

A. Suction and return lines

Let the velocity of oil be 1 m/s.

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
 A
Filter capacity per minute ≥ 2x [pump rated flow per
minute] (Eq. 19.1)
A
27
6
=
1 x [reservoir’s capacity in litre] (Eq. 19.2)

196.32
276
3
140
whichever is greater.

45.3
30.47
∴ Filter capacity per minute = 0.01326 m3

4°
°

B 238
O B 194 O
C. Compound relief valve
Fig. 29. Biped Jack in bottom and top position. The relief valve should be set for maximum
working pressure [p1] + 10%. Therefore, the compound
AO = sqrt[2762 – 1942] = 196.32 mm relief valve is set for 18.83 N/mm2.

∴ Lift = [2 x 196.32] – [2 x 140] = 112.64 mm ≈ 113 mm. D. Shut - off valve

Since, the bottom portion of the Biped Jack goes only 10 The manually operated shut-off valves are
mm down, the axle of the vehicle will be lifted up by = included to enable the load part of the system, just hydraulic
[113/2] + [(113/2) – 10] cylinder, to be isolated from the pump part and likewise to
= 56.5 + 46.5 = 103 mm. isolate the pressure indicator.
∴ The worn-out wheel will be lifted up by 103 mm from
the ground. XX. WORKING PRINCIPLE OF BIPED JACK

XVIII. DESIGN OF HYDRAULIC CIRCUIT OF

BIPED JACK

Double
P1 P1 acting
double rod
cylinder

Manuallyoperatedshut off
A B valve
4- way3position
pistontypeDCV Fig. 31a. Biped Jack
P T
Pressure
Flowcontrol valvewithintegral check
indicator
The Biped Jack is assembled to the axle of the vehicle
compound
relief valve by means of taper pin. The taper pin is used to readily
M
Motor
External gear pump
assemble and disassemble the Biped Jack. The hoses are
Filter connected to the hydraulic cylinder and the gear pump is
Reservoir started.
Fig. 30. Hydraulic circuit of Biped Jack

XIX. SPECIFICATIONS OF HYDRAULIC COMPONENTS

A. Hydraulic fluid
The oil used in hydraulic device must have a high
viscosity to keep down leakage losses. When the working
pressure is between 7 to 17.5 N/mm2 the oil viscosity
should be between 0.65–1 cm2/s. When the working
pressure is greater than 17.5 N/mm2 the oil viscosity should
be between 1 - 2 cm2/s. Mineral oils of correct viscosity
will work satisfactorily with most pumps, provided the oil is
clean. MS (most severe) engine type oil provides increased
hydraulic system life due to better lubricity. This is due to
the antiwear additives. This improved lubricity also
provides wear resistance for the heavily loaded hydraulic
components such as pumps and valves.
B. Filter
Since the working pressure is greater than 13.5
N/mm2, 25: m filtration can be selected.
Fig. 31b. Biped Jack
When there is a need to replace the worn-out wheel, the
Biped Jack is assembled to the axle of the vehicle by means
of taper pin. The taper pin is used to readily assemble and
disassemble the Biped Jack. The hoses are connected to the
hydraulic cylinder and the external herringbone gear pump
is started. When the four-way valve is in its spring-centered
position (tandem design) the cylinder is hydraulically
locked. Also the pump is unloaded back to the reservoir at
essentially atmospheric pressure.
When the four-way valve is actuated into the flow
path configuration of the left envelope, the cylinder is

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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
 retracted against its load force P1 as oil flows from port P
through port A. Also, oil in the blank end of the cylinder is
free to flow back to the reservoir via the four-way valve
from port B through port T. Note that the cylinder could
not retract if this oil were not allowed to leave the blank end
of the cylinder. When the four-way valve is deactivated, the
spring-centered envelope prevails, and the cylinder is once
again hydraulically locked. Now, the axle has been
sufficiently lifted and we can do the repairing wizard i.e.,
replacing the worn-out wheel.
Fig. 32. Bottom position of Biped Jack
After the worn-out wheel has been replaced, the four-
way valve is actuated into the flow path configuration of the
right envelope and the cylinder extends as oil flows form
port P through port B. Oil in the rod end of the cylinder is
free to flow back to the reservoir via the four-way valve
from port A through port T. At the ends of the stroke, there
is no system demand for oil. Thus, the pump flow goes
through the relief valve at its pressure-level setting unless
the four-way valve is deactivated. In any event, the system
is protected from any cylinder over loads.
The check valve prevents the load (if it becomes
excessive) from extending the cylinder while it is being
retracted using the left envelope flow path configuration.
The gear pump is stopped. The hoses are disconnected from
the hydraulic cylinder and the Biped Jack is disassembled
from the axle of the vehicle.
XXI. RESULTS AND DISCUSSIONS
The Biped Jack can be readily assembled and
disassembled by means of taper pin. Using hydraulic (oil)
energy, it lifts the worn-out wheel by 103 mm from the
ground. The time taken to lift is 10 seconds and thus the
Biped Jack saves considerable human energy and precious
time. Here the Biped Jack is designed to lift load up to10
tons and it can be designed for any load.
The cost of the vehicle will be a bit higher. But for a
customer who buys a heavy motor vehicle for many lakhs,
the raise in cost will not disturb him, considering the
advantages of this setup.
The pressure required in the hydraulic cylinder is 17.12
N/mm2 i.e., 171.2 bar and the power rating of the motor
required to run the external herringbone gear pump is 3.15
kW i.e., 4.23 H.P.
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International Journal of Advance Research in Science and Engineering- IJARSE, Vol-1, Iss-2
View publication stats
The Biped Jack in its bottom position has the following
dimensions:
Width = 54.2 cm, Height = 39.8 cm.
The double acting double rod hydraulic cylinder has the
following dimensions: Internal diameter = 12.5 cm, Internal
length = 16 cm, Thickness = 5 mm, Stroke length = 4.4 cm.
The heavy motor vehicle has an oil reservoir (13.75 or 14.5
litre) for the purpose of cooling the engine. This can be
designed to Biped Jack requirement (19.89 litre) so that it
serves for dual purpose.
Among the three types of design viz., Adaptive design,
Development design and New design, the Biped Jack comes
under development design.
The Biped Jack has been developed from Toggle Jack.
In Biped Jack: the bolts and nuts of Toggle Jack has been
replaced by knuckle joints; the lead screw of Toggle Jack
has been replaced by double acting double rod hydraulic
cylinder. Toggle Jack can be used to lift load up to 3 tons
but Biped Jack can be used to lift any load.
So far, double acting double rod hydraulic cylinder has
been designed with only one piston and two ports. But here,
to suit the Biped Jack requirement the hydraulic cylinder
has been designed with two pistons and three ports (two
retract ports and one extend port).
Also so far, the hydraulic cylinder has been used
directly to lift the load. But in Biped Jack, the hydraulic
cylinder has been used indirectly to lift the load i.e., the
increase in the height of levers, which makes the axle to
elevate from the ground, is aided by double acting double
rod hydraulic cylinder.
Thus, by correlating the facts already known (analytical
and experiments), the design of Biped Jack has been
developed.
REFERNCES
1. Prabhu T.J. (1999), ‘Design of Transmission Elements’.
2. Prabhu T.J. (1999), ‘Fundamentals of Machine Design’.
3. P.S.G. Design Data Book (1995).
4. Gopalakrishna K.R. (1998), ’Machine Drawing’, Subhas
Publications.
5. Bhatt N.D. and Panchal V.M. (1996), ‘Machine Drawing’,
Charotar Publishing House.
6. Khurmi R.S. and Gupta J.K. (2003), ‘Machine Design’,
Eurasia Publishing House (pvt.) Ltd.
7. Ramamrutham S. and Narayan R. (1998), ‘Strength of
Materials’, Dhanpat Rai Publishing Co.
8. Anthony Esposito (Fourth Edition), ‘Fluid Power With
Applications’, Prentice-Hall International Inc.
9. Srinivasan R., ’Hydraulic and Pneumatic Controls’, Vijay
Nicole Imprints (pvt.) Ltd.
10. Bolton W. (1997), ‘Pneumatic and Hydraulic Systems’,
Butter Worth - Heinemann.
11. Sen G.C. and Bhattacharya A. (2002), ‘Principles of Machine
Tools’, New Central Book Agency (pvt.) Ltd.
12. Mehta N.K. (2003) , ‘Machine Tool Design and Numerical
Control’, Tata Mc Graw-Hill.