DEBRE BERHAN UNIVERSITY

INISTITUTE OF TECHNOLOGY
COLLEGE OF ENGINEERING
Department of mechanical engineering
Machine design project 2
Hydraulic service jack

Group member ID No

1. Yoseph worku ..………………………………………………...3343/11

2. Yayeh kassegn …………………………………………………..2598/11
3. Michael yitages ………………………………………………….3646/11
4. Reta Beyene……………………………………....................3038/11
5. Debele Tulu ……………………………………....................3386/11
6. Yohannes G/medhin…………………………………………..1046/10

Submission date; 21/09/2013 e.c

Submitted to Mr
1 Introduction
A hydraulic jack is a jack 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 larger 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 based on this two cylinder system.

Hydraulic services jack are typically used for workshop. They are used to lift
vehicle and other loads. Used of jack not designed for specific vehicle require
more than the usual cag 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 hydraulic
service jack, select the best and design its component and finally proposing a
safe, costly and reliable hydraulic service jack.
1.1 Background of the study

Before the invention of weight lifting device such as screw jack, hydraulic jack, crane, etc.,
the early man applies a crude way of lifting objects to great heights with ropes and rollers,
which was mostly applied in the construction area, where, it was used to raise mortar
(cement, sand & water).

The virtues of using a screw as a machine, essentially an inclined plane wound round a
cylinder, was first demonstrated by Archimedes in 200BC with his device used for pumping
water.
There is evidence of the use of screws in the Ancient Roman world but it was the great
Leonardoda Vinci, in the late 1400s, who first demonstrated the use of a screw jack for lifting
loads. Leonardo’s design used a threaded worm gear, supported on bearings, that rotated by
the turning of a worm shaft to drive a lifting screw to move the load - instantly recognizable
as the principle we use today. We can’t be sure of the intended application of his invention,
but it seems to have been relegated to the history books, along with the helicopter and tank,
for almost four centuries.
It is not until the late 1800s that we have evidence of the product being developed further. In
the industrial revolution of the late 18th and 19th centuries came the first use of screws in
machine tools, via English inventors such as John Wilkinson and Henry Causley The most
notable inventor in mechanical engineering from the early 1800s was undoubtedly the
mechanical genius Joseph Whitworth, who recognized the need for precision had become as
important in industry as the provision of power .A screw jack that has a built-in motor is now
referred to as a linear actuator but is essentially still a screw jack.

Whitworth’s have become internationally famous for their precision and quality, and
dominated the market from the 1850th. Inspired young engineers began to put whit worth’s
machine tools to new uses. During the early 1880th in Coati cook, a small town near Quebec,
a 24-year-old inventor named Frank Henry Sleeper designed a lifting jack. Like da Vinci’s
jack, it was a technological innovation because it was based on the principle of the ball
bearing for supportinga load and transferred rotary motion, through gearing and screw, in to
linear motion for moving the load. The device was efficient, reliable and easy to operate. It
was used in the construction of bridges, but mostly by the railroad industry, where it was
able to left locomotives and railway care. Arthur Osmoses Norton spotted the potential for
sleeper’s design and in 1886th hired the young man and purchased the patent and then Norton
jack was born. Over the coming years the famous Norton jack were manufactured at plants in
Boston, Coati cook, Moline and Illinois.

Meanwhile, in Alleghany County near Pittsburgh in 1883, an enterprising Mississippi river

boat captain named Josiah Barrett had an idea for a ratchet jack that would pull barges
together to form a tow. The idea was based on the familiar lever and fulcrum principle and he
needed someone to manufacture it. That person was Samuel Duff, proprietor of a machine
shop. Together they created the Duff Manufacturing Company, which by 1890 had developed
new applications for the original Barrett jack and extended the product line to seven models
in varying capacities.

After the industrial revolution, with the advent of Machine, the Machine Shop was also faced
with the challenge of load lifting, because of the bulkiness of some Machine parts. The
Machine Shop deals with various components made of metal, rubber, ceramics, polymers,
etc., assembled mechanically to move people and goods from one place to the other. Because
of the interface between the Machine and human lives, there is need for standardization of its
component parts toimprove its performance and efficiency and to reduce failure. For this
reason, care has to betaken during production and assembly of its component parts. Many
tools and equipment used in the Machine Shop are designed to help the personnel working
in a production facility. Othertools are produced to help the operators of the machine. Such
tools include the lifting device, generally called jack.
1.1.1 Definition of hydraulic jack

A hydraulic jack is a device used to liftheavy loads. The device itself is light, compact and
portable, but is capable of exerting great force. The device pushes liquid against a piston;
pressure is built in the jack's container. The jack is based on Pascal's law that the pressure of a
liquid in a container is the same at all points.

1.1.2 Classification of jack:-

1. Mechanical jack

A mechanical jack is a device, which lifts heavy equipment. Themost common form is a car jack,
floor jack or garage jack which lifts vehicles so that maintenance can be performed. Car jacks
usually use Mechanical advantage toallow a human to lift a vehicle by manual force alone. More
powerful jacks use hydraulic power to provide more lift over greater distances. Mechanical jacks are
usually rated for a maximum lifting capacity (for example, 1.5 tons or 3 tons). The jack shown at the
right is made for a modern vehicle and the notch fits into a hard point on a unibody. Earlier versions
have a platform to lift on the vehicles' frame oraxle.

2 . Hydraulic jack

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, thatis 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 thecylinder. 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 suitableonly for vehicles with a relatively high clearance. For
lifting structures such as houses the hydraulic interconnection of multiple vertical jacks through
valvesenables the even distribution of forces while enabling close control of the lift.
In a floor jack (aka 'trolley jack') a horizontal piston pushes onthe 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.This mechanism provides a low profile when collapsed, for easy
maneuveringunderneath the vehicle, while allowing considerable extension

Pneumatic jack

A pneumatic jack is a hydraulic jack that is actuated bycompressed air - for example, air from a
compressor instead of human work. This eliminates the need for the user to actuate the hydraulic
mechanism, saving effort and potentially increasing speed. Sometimes, such jacks can also be
operated by the normal hydraulic actuation method, thereby retaining functionality,even if a source
of compressed air is not available.
 Fig. Threaded rod 7" fully extended
A house jack, also called a screw jack is a mechanicaldevice primarily used to lift houses from
their foundation. A series of jacks are used and then wood cribbing temporarily supports the
structure. This process is repeated until the desired height is reached. The house jack can be used
for jacking carrying beams that have settled or for installing new structural beams. On the top of
the jack is a cast iron circular pad that the 4" × 4" post is resting on. This pad moves
independently of the house jack so that it does not turn as the acme-threaded rod is
turned up with a metal rod. This piece tilts very slightly but not enough to render the post
dangerously out of plumb
1.1.3 Application area of Hydraulic jack
 An hydraulic jack is preferable on the following area
 Bridge lifting system
 Heavy weight lifting system
 Synchronous System
 Low profile area
 Automotive industry
 Construction industry
 Weight test system
 Rope tension system
1.1.4 Advantage and limitation
 The followings are the advantages of Hydraulic jack
 It occupies less space
 They are also less likely to am due to rust I the screw thread
  It is highly effective with heavy loads
 It lifts load with the minimum of effort
 It is easier to use
 It is bit lighter than screw jacks
 The followings are the disadvantages of hydraulic jack
 It is susceptible to failure if the oil seals are worn out, this can cause serious problem
 It has relatively low speed
 Hydraulic oil can emit unpleasant odor when become too warm to overuse
 It can overheat fairly quick
 Hydraulic oil leak can cause soil and water pollution

1.2 Problem Statement

Mechanical jack requires more effort moreover not suitable for uneven surfaces. It
require more power consumption also maintenance is quite high as well as suitable for
small capacity and required skilled labour. The purpose of this project is to modify the
design of existing car jack in terms of its functionality and also human factor consideration
General idea of the project is to minimize the human effort while operating the jack. To
provide an inbuilt hydraulic jacking system that is directly and permanently incorporated
into the vehicle frame in such a way as to prevent the additional risk of damage.

Design and develop the model of vehicle which will have the vehicle safety system of
Automatic hydraulic jack for 4 wheeler which helps for automatic and hydraulic system.

Also fabricate the model of the same which would able to show the characteristic of
system and working accordingly to need.
1.3 OBJECTIVE

1.3.1 General objective

 To improve the designing of hydraulic service jack for good quality lifting system.

1.3.2 Specific objective

 To design a good qualitative of hydraulic lifting.

 To satisfy the need of customer.
 To improve method of designing system.
 Enable to be skillful real engineer.
 To make a good problem solver when it arise.
 Reducing the cost to satisfy society needs.
 To lift heavy thing easily with a minimum human force
 To utilize machine designing facilities.
 To make a productive manufactures.
 To make a good project designer.
 To avoid challenger of lifting cars.
 To make very easily to our performance
1.4 Scopes

This project is about the designing and fabricating hydraulic service the type of hydraulic jack
that we were used in this project were hydraulic service car jack, as it is more reliable and easy
to operate in order to develop new concept of weight lifting system, we do some research in
order to optimize human power the concept that will be used in this product were replacing the
long arm of car jack with leg pad.
1.5, METHODOLOGY

START

Selection of hydraulic service jack standard overview

Problem definition

Literature

Material selection

Calculation of geometry analysis

Calculation of its loaded

Checking to ensure the design is safe

Draw assembly of hydraulic service jack

END

1
 Chapter Two
LITERATURE REVIEW
2.1 P.S. Rana et al. (2012)
[2]In this research paper they have come up with the idea of Integrated Jacks for 4-wheelers.
This jack is designed to overcome the difficulties faced by the senior citizens and ladies
who find it
difficult to manually operate the jack.
2.2 Mohammed Abuzaid et al. (2013)
[3]In this research paper they have focused on an inbuilt hydraulic jack system which is
attached to automobile vehicle on front and rear part of the chassis. There is a front
suspension hydraulic jack that is mounted centrally to the front suspension of an automobile
between its front wheels.
There is also a rear suspension hydraulic jack that is mounted centrally to the rear
suspension of the automobile between its rear wheels. The system operates from a
compressed fluid reservoir tank that has connections for the front and rear car jack outlets.
2.4 Mayank Agrawal et al. (2018)
[4]This paper represents a study over in- built hydraulic jack system and shows its benefits
over traditional mechanical jack system. The design of inbuilt hydraulic jack is also studied
and modified to require extent which can be seen by analyzing design of prototype. An
Inbuilt hydraulic jack
system can be easily operated by buttons provided on the dash board of the vehicle. The
jack will be installed on chassis of the vehicle. The motive behind using this system instead
of a conventional mechanical system is the more power produced by the system and simple
in design as
compared to a conventional design. As the hydraulic oil is incompressible so the lifting
capacity is more in comparison with the pneumatic system which operates on air which is
compressible.
Material selection
Part Material Sy L 𝜏max K G

Pins pin AISI 1010 hot 180Mpa 60- 57.93Mpa 8

1 rolled steel 200mm
pin AISI 1020 hot 210Mpa 65- 60.585Mpa 8
2 rolled steel 200mm

pin AISI 1035 hot 270Mpa 45- 59.92Mpa 5.56

3 rolled steel 200mm

pin AISI 1045 hot 310Mpa 35- 65.4Mpa 4.5

4 rolled steel 160mm
pin AISI 1060 hot 270Mpa 35- 32.456Mpa 4.5
5 rolled steel 160mm
large cylinder AISI 1015 cold 320Mpa 56.95Mpa
drawn steel
small cylinder AISI 1020 cold 280Mpa 132.92Mpa
drawn steel
Cup cast iron 310Mpa

rigid body cast iron 270Mpa 0.258

Spring cold drawn spring 86Gpa
wire

small spring AISI 1085 86Gpa

3
Design Analysis
Car jack given variables
Hmax (maximum lifting height)…………………………………560mm
Hmin (minimum lifting height)…………………………………150mm
Force to be lifted ……………………………………………500kg
Geometry of jack

Geometry of load of car jack

hma
h

=560-35
=525

=150-35

=115

Δh =560-150
Δh =410

5
`

Δh = l1 sinc + l1sinα

Sum of moment at point zero is zero

To find the value of l1 and l2 , the values of α and β have to be assumed.

Therefore , assumption from table

=θ = 60 80

β = 20 to 30

6
From table

β l1 l2 C1 L

20 60
21 65
22 70 2.4775 258.69 104.518
23 75 2.3358 255.58 108.480
24 80 2.2460 252.819 112.43
25 85 2.1445 249.51 116.379 220.479 104.096 171.607
26 90 2.0503 246.773 120.335

From the given table above we choose the following data

β= 24

θ =65

l1= 258.940

l2= 120.420

Therefore

l = 116.379 + 2(1− 95) =l =117.85

ℎ L

65 24 2.246 258.940 120.420 220.32 99.1 168.806

7
`

2.1.Force analysis

The force to weight ratio read from the table 15 is

=2.246

F = 2.246 * 5KN

F = 11230N

The force should be minimized by a service factor K so take service factor to be

F2=1.2

F 2= K * F

F2=1.2*11230N

F2=13,476N

We know that pressure is given by

,
𝐹 13476
P =𝐴=20Mpa = 𝐴

,
The area will be, A= 0.675*10-3

3.0. DESIGN OF HANDLE

8
 11230
= 6095 = 1.84
An average person can apply a force b/n 150N to 250N

In the figure above in order to multiply the force two pistons must be used as shown in the
figure

9
`

F P A1 d1 d2 A2
89,190 20Mpa 4.45*10-3 23.83 91.169 5.34*10-3
80,856 20Mpa 4.042*10-3 0.0735 0.0824 4.85*10 -3

=angle of deflection

= length of connecting link

= length which the small piston rod moves (stroke length of small piston)

l’

l’ = 37.22

∅ l’ (mm)

40 40 27.3616

40 50 33.8094

40 60 40

40 70 45.886

10
 l1 =40

∅=70°

l’ = 45.886

Calculating for the small and larger cylinder

V1 = A1 * l’

V1 = 247.3mm2 * 37.22

V1= 9204.506

The ratio of the volume of the larger cylinder to the smaller cylinder is known as number of
strokes .
𝑣2
S =100mm=9204.506

V2 =S*V1

V2= 920,450.6

CHAPTER FOUR
4.0. FORCE ANALYSIS OF PINS

For safe design the supporting bar b/n pin2- pin3 and b/n pin5 – pin4 is parallel and also the bar
b/n pin2-pin5 and pin3-pin4 are parallel.

Assume; the dimensions b/n pin3 and pin 4 is 44mm x 44mm

CASE 1
When the weight is applied directly to pin 3 in the cup sitting or saddle

11
`

ƩFx = 0 , i.e F3x = F4x = 0

ƩFy = 0
F3y = W = 5KN but F4y = 0

CASE 2

Assume the weight shifts to the right by 20mm

ƩFx = 0
ƩF3x= -ƩF4x

ƩFy = 0

12
F3y + F4y = W

The moment at point 3 is zero

ƩM3 = 0

F4y * 44 – F4x * 44 – W*20 =0

5𝐾𝑁∗20
F4y – F4x= = 2.27 KN
44

F4y – F4x = 2.27 KN, but tan =

2.27KN
F4y = -1.98KN

F4X = F4y – 2.27

F4X= -1.98-2.27

F4X =-4.25 KN

F4 = (1.982+ 4.252)

F4 = 4.689 KN

Since F5x = -F4x

F5X = -4.689 KN

F3y + F4y+ W, F3y = w-F4y

F3y = 5KN – (- 1.98KN)

13
`

F3y = 6.98KN

F=√4.6892 + 6.982

F3 = 8.408

The force analysis on the pins which is placed on the bar in three cases

CASE 1

When the bar is at the initial position i.e l3 is horizontal.

In this case there is no spring effect in pin3

ƩFx = 0

F2x = F + F3x = 74.25 + 4.689 =78.939 KN

F2x = 78.939 KN

ƩFy = 0

F2y=F3y=6.98KN

F=√6.982 + 78.942

F2 =79.24KN

CASE 2

When l2 becomes horizontal

In this case, the spring has its own effect in pin3 the figure is shown as

14
Assume that the horizontal distance b/n the tip of pin3 and the origin of the spring is 70mm

α=90−(24+65) = 90 – 89 = 10

Hm is given in the first instance of the calculation

We can find hm by using

Hm = 1sin 𝛾+ h’min

Hm = 258 (sin65) + 150mm

383.82
Hm = = 192
2

70
=tan-1 (192)
=20.030

15
`

ƩFx = 0

F3sin + F4x + F3x = 0

F4x + F3x = 0.597KN

ƩFy = 0

F3y + F4y = W + F3cos

F3y + F4y = 5KN+ 1.9083KN

F3y + F4y = 6.908KN

Ʃmoment at pin 3 is zero

Ʃ M3 = 0 = 44F4y – 44F4x – 20(W) = 0

20
F4y – F4x = 44* 5 = 2.27KN

F4y – F4x = 2.27KN

NOTE: when l1 becomes horizontal also the supporting bar becomes horizontal so there is
vertical component of force in pin4 b/c of this the moment equation becomes

-F4X= 2.27KN

F4y = 0

F4 =

F4 = 2.27KN

From the above equation

F4x + F3x = 0.597KN

F3x= 0.597 – F4x

F3x = 0.597-(-2.27)

F3x = 2.867KN

16
F3y + F4y = 5KN, But we know that F4y is zero

F3 =

= 7.48KN

17
`

18
G – 𝛾= 30

=90 – 30 = 60

Y = l2cos + l1sin

Y = 120cos60 + 258.94sin65

Y = 294.6

= 90 – 𝛾 = 90 – 65 = 25

l1sin = l1sin 𝛾 * sin25

l1sin =258.44(sin65)(sin25)

l1sin = 99.17

As calculated the distance from pin 1 to to the ground is 150mm

Length from the ground perpendicular fine passing through pin 3 = 73

The angle b/n the spring and perpendicular line is

19
`

ƩFx = 0

F3x+ F4x = Fssin

At this point the force of the spring is increased from the previous positions. So we assumed
that let the force of spring is 3KN

F3X + F4x = 3 * sin8.659

F3x + F4x = 0.4863

ƩFy = 0

F3y + F4y = FScos + W

F3y + F4y= 3.5cos8.659 + 5KN

F3y + F4y=7.96KN

Se take, F3y + F4y= 6.98

Ʃmoments at point 3 is zero

F4y*44 – F4x*44 – W*20 = 0

=tan 𝛾

F4y = F4x* tan 𝛾

20
 =F4x * tan(65)

F4y =F4x *(2.1445)

F4x*44 + 2.1445F4x*44 = W*20

F4x = 5 ∗20/44∗2.1445

F4x = 1059.79

Then F4y= 2.1445* 1059.79

= 2272.72N

F3x + F4y = 0.526

F3x = 0.526 – F4x

= 0.526 - 1059.79

= 1059.26

F3y + F4y = 6.98

F3y = 6.98 – F4y

F3y = 6.98 – 2.27

F3y= 4.708

F3 =

F3 = √ 1.0592 + 4.7082

= 4.83

To find the force on pin 2 first find the angle of inclination of the piston rod

= 𝛾 +β

21
`

= 65 + 24

= 89

=60

The X = hmax – l3sin

= 560 – 294.29sin90

= 560 – 294.29

X = 34mm

= 180 - -θ

= 180 – 90 – 65

= 250

22
23
`

(L′2) =X2 + 294.282 – 2(X)*294.282

(L′2) = (34)2 + (294.28)2

(L′2) =296.23

Tan = X/296.23 .

α= tan-1(34/296.23

α= 6.5475

This is the angle of inclination of the force

After having determined the angle we can calculate the force on pin 2 by using

ƩFx = 0

F2x – F3X - Fcos = 0

F2x = Fcos + F3x

= 11230cos6.547 + 1093.26

=12235.89

F2y = F3y - Fsin

= 4708 – 11230sin6.5475

= -3425.3

Conclusion

F2 =

=√12235.892+3425.32

=12.705KN

PIN 1 = 11.230KN

PIN 2 = 12.705KN

PIN 3 = 8.408KN

24
PIN 4 = 4.689KN

PIN 5 = 4.689KN

CONCLUSION

Select the maximum force at each pin amongst the three positions ; i.e when the plate is
horizontal and plate at maximum position

5.0. DESIGN OF PIN

25
`

5.1. GEOMETRY OF THE BELL CRANK

-For pin design if we get the inner diameter we can get the other parameters such as length of
pin head, diameter of small hole, etc. because pin 5 are standards

The procedure of pin design is as follows

1) Relating the maximum shear and yield strength (sy ) in the von mises equation , Sy
*Ssy

Maximum shear and normal stress becomes zero . therefore p = 0

where nd is the design factor

2) after getting the maximum shear we can get diameter of the pin by using the formula.

τmax = 4V/3A , but A=πr2

τmax=

d1 = , but V = where, V – shear force

Ssy– shear strength

Sy - yield strength

26
3) After determining the diameter find the bending stress and crashing stress

𝜎b=MC/I = 32M/πd3

𝜎c

Where 𝜎 b – bending stress

𝜎 c - crashing stress t-

minimum thickness

I – moment of inertia

4) The final thing is checking the factor of safety and finding the other parameters from
standard table

nb = sy/ 𝜎c

nc = sy/ 𝜎c mostly pins are made from steel or

mild steel

5.2.DESIGN OF PIN 3

F =49.9KN

27
`

t = 0.006m

Assuming the thickness of the bar is 6mm and 10mm

28
M = *29 - *20 =223.68

For safe design the safety factor should be greater than 1.5 , i.e n b 1.5 Let

Sy = 270Mpa

nd =2.6

𝜏max = 59.92Mpa

so we prefer this material for pin 3

AISI 1035 hot rolled steel which has a Sy of 270Mpa

k =5.56 D = 33

d1 = 8 d2 = 5

R=1

29
`

C=4 l = 45-200mm e

=2

Reference Design of agricultural machinery

5.3.DESIGN OF PIN 4

The maximum applied force is F=

Assume the thickness of the bar is 6mm and 8mm , t = 0.008mm

.

V=

V = 14.09KN

= 0.577

M = (43 – 35)

Let Sy = 310Mpa nd=2.75

nb=max=65.4Mpa

30
for pin 4 we prefer a material of AISI 1045 – Hot rolled steel , Sy = 310Mpa the parameters

are

d1 = 16mm l1 = 6 D= 25

R =0.6 d2 =4 l = 35 –160mm

C =3

K = 4.5

All the dimensions are in mm For pin

4, Sy = 310Mpa

l = 35 – 160mm

nb = 1.579

5.4. DESIGN OF PIN 5

For pin 5 instead of using one long pin we wanted to use two short pins , in order to minimize
the cost . because we are using two pins , the applied on pin 5 must be divided by two.
Therefore ,
.

F =

F = 14.09KN
.

V=

V = 14.09

31
`

M = *16 - *4

Assume that the thickness of the bar is 8mm each t =

0.008m

d1 =

Let Sy = 290 Mpa b =

nd = 2.6 nb =

max = 64.358Mpa

d=

N.B the above is not safe

Let Sy = 279Mpa b =

Nd = 6.4 nb = max =

32.456 c =

d= nc =

for pin 5 we prefer a material of AISI 1060 – Hot rolled steel – Sy = 270Mpa
32
 d1 =16 k = 4.5 D=

25 l1 = 6

d2 =4 R = 0.6 C = 3 l = 35 – 160mm e =1.6 all dimensions are in mm

for pin 5 Sy = 270Mpa , d1 = 16mm , l = 35 – 160mm , nb = 1.856

5.5.DESIGN OF PIN 1

Assume that let the thickness of the bar is 10mm each one of the piston rod diameter is 34mm

The maximum force applied at pin 1 is F = 67.380KN V = =

V = 33.69 t= 0.01m

M = ( 28 – 23 )

M = 168.45KN

Let Sy = 210Mpa b =

nd =2.4 nb =

33
`

max = 50.487Mpa c =

d = 30 nc = let Sy =

180Mpa b =

nb =2 n b max

=57.93 c = d = 30mm

nc =

For pin 1 we prefer a material of AISI 1010 – Hot rolled steel Sy = 180Mpa

d1 = 30mm k=8

D =44 l1 = 10

d2 =8 R=1

C =4 l = 60 – 200mm e =4

All dimensions are in mm

For pin 1 : Sy = 180Mpa , d1 = 30mm , l1 = 60 – 200mm , nb = 3.433

5.6. DESIGN OF PIN 2

Assume that the thickness of the bar is 8 and 10mm and the distance b/n the bar is 32 , 34 ,
34mm from pin head to pin tail

The maximum force applied at pin 2 is given as F = 74.066KN V= =

37.033KN t = 0.008

= 0.577

34
 d=

M = *43 - *39 = (43 – 39) = M = 148.13KN

Let, Sy = 210Mpa b =

nb = 2 nb =

max = 60.585Mpa c =

d1 = 33 nc =

For pin 2 we prefer a material of AISI 1020 – Hot rolled steel Sy = 210Mpa

The parameters are

Sy = 210Mpa k=8

d1 = 33 l1 = 10 d2 = 8

R=1

D = 47 l = 65 - 200

C = 4 e = 2 all dimensions are

in mm

35
`

for pin 2 , Sy=210Mpa

d1 = 33mm l=

65 – 200mm nb =

4.76

6.0. DESIGN OF CYLINDER

6.1. DESIGN OF LARGE CYLINDER

This cylinder will house the first piston which will be the intermittent connector b/n the handle
second piston

From the mechanical engineering design book by J.E. Shigley the stresses acting upon a

cylinder are given as as follows H = Hoop stress ( circumferential stress ) t = tangential stress

= H r = radial stress

L = longitudinal stress

And the other parameters are given as d0 =

outer diameter r0 = outer radius di = inner

diameter ri = inner radius

Pi = internal pressure

P0 = external pressure

The diameter of the larger cylinder is di =

73.5mm d0 = 83.5mm

And the thickness is t = 5mm

36
 r

ri = di / 2 = 73.5mm / 2 = 36.75mm since di = d2

= 73.5mm

For our cylinder to withstand the pressure applied , an appropriate thickness must be selected
and take a thickness of 5mm we know that di = 73.5mm and the thickness t = 5mm do = 2t + di =
2*5 + 73.5mm = 83.5mm r0 = 41.75mm

The safety of our design must be assured. In order to check the safety we use the maximum
strain energy hypothesis

In order to check the safety of the body principal stresses are taken as t , L , r

Piis the internal pressure that pushes the piston rod i.e p i = 17Mpa

Po is the pressure applied to induce the returning effect of fluid and is inuced by the spring

effect ri = 36.75mm ro = 41.75mm pi = 20Mpa p0 = 7.175Mpa

p0 = patm + pspring
pi = 17Mpa

pspring

pspring = 7074.19Kpa

patm = 101.3254Kpa p0=101.325+7074.19

p0 = 7175.515Kpa where ;

patm = atmospheric pressure

pspring = pressure from spring

37
`

Fspring = force of spring

Pi = internal pressure

;since tmax is at r = ri

t = 93.909Mpa,tension

r ; since rmax is at r = ri

r = -20Mpa , compression

L =68.818Mpa

By using maximum strain energy theory

𝛿 1= 𝛿 r = -20Mpa

𝛿 2=𝛿 t = 93.909Mpa

𝛿3 =𝛿 L = 68.818 Mpa

𝛿t = 93.909 Mpa

𝛿r = -20Mpa

𝛿L = 68.818Mpa

𝛿’ = 103.667Mpa

For the large cylinder the stresses are

𝛿’ = 103.66Mpa , 𝜏max = 56.95Mpa

For AISI 1015 – cold drawn steel , Sy = 320Mpa

38
Therefore, n =
n = 3.086

Where, Sy = yield strength

n = safety factor

𝛿’ = von misses stress

From shear stress theory

𝜏max =

𝜏max = 56.95Mpa

Therefore , n = . The safety factor is n = 2.809. Therefore, the design

of the cylinder is safe.

7.0. DESIGN OF SMALL CYLINDERS

Assume that the external pressure is zero

Diagram

The appropriate thickness , we select a value of 3.5 , because according to our number of stroke
, the fluid will be cruising at very high speed and pressure. So the piston cylinder must be able
to withstand this pressure.

t = 3.5mm
do = di + 2(t) = 82.4mm + 2(3.5) = 89.4mm ri =
41.2mm
r0 = 44.7mm

39
`

Using maximum strain energy theory

𝛿 1= 𝛿 t= 245.84Mpa

𝛿 2= 𝛿 L= 112.9Mpa

𝛿 3= 𝛿 r= -20Mpa

𝛿’ = 230.2Mpa

The material is AISI 1020 – hot rolled steel and for this material at 20Mpa the value for y is
given by 245.8. we got this from the internet ME.COM.

applying shear stress theory

𝜏max = 132.92Mpa

n=

Taking the external pressure p0 = patm = 101.325Kpa

𝛿t , but we know that ∗ is zero so it follows

𝛿 t = 245.84Mpa

𝛿r

𝛿 r = -20Mpa

40
 𝛿L= = 112.9Mpa

The principal stresses are given as

𝛿 = 𝛿 t= 245.84Mpa

𝛿 = 𝛿 L= 112.9Mpa

𝛿 = 𝛿 r= -20Mpa

𝛿’ = 230.2Mpa

n= =1.2
So it is safe

𝜏max = 132.92Mpa

n=

so it is safe.

41
`

17.0. DESIGN OF RESERVOIR

The reservoir is where the necessary fluid for the piston to function on is stored at.

= 82.4 + 3.5

= 85.9mm

The load needs to be raised safely on in order to do this the volume of the reservoir must be 1.4
times the volume of the cylinder.

42
Rom the sample paper that we got the standard thickness for b/n 120 and 130 is 9mm.

Therefore the outer diameter of the reservoir becomes 142.6mm

In the reservoir there is internal and external pressure ;

t = 8.3Mpa

𝛿r

𝛿r = -1001.4Mpa

43
`

𝛿 = 3.7178Mpa

Using the maximum strain theory for this design

Due to lack of material selection table further calculations on the factor of safety could not be
done.

44
 RESULT

Geometry

hmax=560

hmin=150

lifting height=410

stroke=S=100

V1= 9204.50.6

V2= 920,450.6

Force analysis on pins

PIN 1 = 11.230KN

PIN 2 = 12.705KN

PIN 3 = 8.408KN
PIN 4 = 4.689KN

PIN 5 = 4.689KN

For pin 1 : Sy = 180Mpa , d1 = 30mm ,

l1 = 60 – 200mm , nb = 3.433

for pin 2 , Sy=210Mpa

d1 = 33mm l=

65 – 200mm nb =

4.76

for pin 3, Sy of 270Mpa

k =5.56 D = 33

d1 = 8 d2 = 5

R=1

45
`

C=4 l = 45-200mm e
=2

pin 4, Sy = 310Mpa

d1 = 16mm

l = 35 – 160mm

nb = 1.579

pin 5 Sy = 270Mpa , d1 = 16mm , l = 35 – 160mm , nb = 1.856

LARGE CYLINDER

di = 73.5mm, t = 5mm do= 83.5mm, r0 = 41.75mm

Sy = 320Mpa

𝛿’ = 103.66Mpa , 𝜏max = 56.95Mpa

n = 2.809

SMALL CYLINDER

t = 3.5mm
do = di + 2(t) = 82.4mm + 2(3.5) = 89.4mm ri =
41.2mm
r0 = 44.7mm
𝜏max = 132.92Mpa

Sy = 280Mpa

𝛿 t= 245.84Mpa

n=1.2

DESIGN OF SADDLE

d = 0.0178m

A = 9.954 x 10-4

P = F/2 = 5/2 = 2.5KN

e = 0.04 , c = 1 , = 0.04

46
E= 207Gpa , K = 1

Sy = 90Mpa

DESIGN OF CUP

H=99.1

L=60

Sy= 310Mpa

𝛿 b =93.3Mpa

n=3.3

DESIGN OF smaller piston

L = 0.0707m

C=1

E = 207Gpa ( steel )

Sy = 390Mpa, d = 11.83mm

DESIGN OF parallel link

pcr – 117.2KW

h – 0.009m

E – 207Gpa
C= 1, l=0.258

Sy = 270Mpa, b = 0.0714m

DESIGN OF large piston

P = 20Mpa

dpistonrod = 0.0735

Api = 0.00405m2

DESIGN OF small pin diameter = 0.012m

47
`

Conclusion

This project aims to design a hydraulic service jack that can lift 500kg with a stroke of
100mm. It consists the introduction, material selection, literature review, and mostly the
design analysis sections. It focuses on the paper (the difficulties that might occur on the
prototype haven’t been examined) this is not our best but our first project. it was made
to introduce us to the machine design project field.

48
Reference

[1] Mechanism of material 1st edition Ferdinand p,reer

[2] Mechanism of material 1,E.J Hansen,3rd edition Shigley ‘s mechanical
engineering design ,8th edition
[3] Machine design an integrated approach,Ansel C.Upugal
[4] A Textbook machine design ,R.S kharmi,14th edition
[5] Mechanical design ,Peler child,2ndedition
[6] Machine design, an integrated approach,Robert L.Norton 3rdedition
[7] Machine and mechanism, applied kinematics analysis David H.Maggazak
[8] Design of machinery, an introduction to the synthesis and analysis of
mechanism ,Robert L.Norton 2nd edition
[9] Braver wheel an caster catalogue
[10] Silvolite supersedes catalog 2007
[11] ASME CODE AND STANDARD
[12] Fastener handbook ,Black fastener
[13] ASTM International standards catalog,2009
[14] Washers 2012 catalog, Baler and washer, special and shine
[15] Hydraulic cylinder, general catalog

49
`

Assembly of the jack

50