CHAPTER 4

DESIGN CALCULATION AND FABRICATION PROCESS OF MOTORIZED

HYDRAULIC JACK

4.1. Calculation of Motor Torque

Model -MY2016Z2
Output Power, Pm -250 W
Voltage -24V DC

Speed of motor, Nm -338 r.p.m

Motor torque can be calculated by using Equation 3.1.

2  N m  m
m =
60
60  250
m 
2  338

=7.06 N-m

4.2. Calculation for a Gear Drive

A single stage speed reducer to actuate a motor from 250W electric motor

running at 338 r.p.m. This operates intermittent or 3 hours per day.

Type of gear - Spur gear

Material - Alloy Steel

Pressure angle, ϕ - 20° full depth invoute

Transmit power, P - 250 W

Number of teeth of pinion, Np -9

Number of teeth of gear, Ng - 46

Pitch circle diameter of pinion, Dp -3mm

Face width, b -18 m

 47

4.2.1 Calculation of Velocity Ratio and Rotation Speed of Gear

The velocity ratio of gear drive can be calculated by using Equation 3.2.
Tg
V.R =
Tp

46
=
9
=5.11  5
The output rotation speed of gear can be calculated by using Equation 3.2.
Np
Ng =
V.R
338

5
 67.6  68

= 68 r.p.m

4.2.2. Calculation of Center Distance between Two Parallel Shaft

The module can be determined by using Equation 3.4.
Dp
m
Tp

27
 = 3 mm
9
Pitch diameter of gear can compute by using Equation 3.5.
Dg
m=
Tg

= 3×46 =138 mm

Center distance between two parallel shaft can be calculated by using

Equation 3.4.
Dp  Dg
x
2
27  138

2

= 82.5 mm
 48

4.2.3. Dynamic Tooth Load for a Gear Drive

The dynamic effects which become more severe as the pitch line velocity
increases. Thus the design will be based upon the gear. Both the pinion and gear are
made of the same material, then pinion is the weaker. So design will be based upon
the pinion.
The pitch line velocity of the pinion can be calculated by using Equation 3.8.
  Dp  N p
v=
60
  27  10 3  338
=
60
= 0.478 m/s
Assuming steady load conditions and Intermittent or 3 hours per day, the
service factor (Cs) from table 3.1 is given by Cs = 0.8.
The steady transmitted load can be calculated by using Equation 3.7.
P
WT =  Cs
v
250
=  0.8
0.478
= 418.41 N
From table 3.2, at carefully cut gears
m = 3 mm, Tooth error = 0.025
From table 3.3 is given deformation factor, C = 285 N/mm
The dynamic load can be calculated by using Equation 3.6.
21vb.C  WT 
WD = WT 
21v  b.C  WT

21  0.47818  285  418.41

= 418.41 
21  0.478  18  285  418.41
= 1077.32 N

4.2.4. Static Tooth Load for a Gear Drive

By checking the gears for forces, Lewis Form Factor (y) for Spur Gear with
load at tip of tooth can calculate by using Equation 3.10.
0.912
y  0.154 

 49

0.912
= 0.154 
9
= 0.052
From table 3.4, σe = 525 MPa
Static tooth load is computed by using Equation 3.11.
Ws   e  b    m  y

 525 18    3  0.052

= 4631.33 N
W s > WD
Therefore the design is safe.

4.2.5. Wear Tooth Load for a Gear Drive

Ratio factor for external spur gear can be calculated by
2  V.R
Q
V.R  1
25
Q
5 1
= 1.67
From table 3.5,
K = 1372 KN/m2
By checking the maximum tooth for satisfactory wear of gear can be
computed by using Equation 3.11.
Ww  D p  b  Q  K

Ww  27  18  1.67  1372  10-3

= 1113.54 N

W w > WD

Therefore the design is safe.

4.3. Torque for Flywheel

The flywheel torque can be calculated by using Equation 3.12. Gear is
connected to flywheel with shaft. So rotation speed of gear is same with flywheel
speed.
 50

2  N f  f
m =
60
250  60
f =
2  68

= 35.11 N-m

4.4. Calculation of Inner Diameter of Hydraulic Cylinder

The inner diameter of hydraulic cylinder for five tons lifting capacity

hydraulic jack can be calculated by using Equation 3.13.

Assume, P = 70 Mpa (700 bar)

Know,

1 ton = 1000 kg

1 kg force = 9.81 N

W =  D i2  
4
W
D i2 =


4
5000  9.81
=

 70  10 6
4
Di = 0.03 m

= 30 mm

4.5. Calculation of Wall Thickness of Hydraulic Cylinder

Wall thickness of hydraulic cylinder for five tons lifting capacity hydraulic

jack can be calculated by using Equation 3.14. Since the material used for making

hydraulic cylinder is mild steel. The tensile stress of mild steel is 400 MPa.

Di   t   
t =   1
2  t   
 51

30  400  70 
=   1
2  400  70 

= 2.9 mm
So, the wall thickness of hydraulic cylinder is 3 mm.

4.6. Calculation of Hydraulic Jack

The required specifications of hydraulic jack for design and analysis are given

as follow.

Working pressure, P - 70 MPa

Weight to be lifted, W - 4000 Kg

Inner diameter of cylinder, Di - 30 mm

Inner diameter of plunger, dp - 10.5 mm

Length of fulcrum, L’ - 25 mm
Length of lever, L - 365 mm
Distance move by weight, Ld - 115 mm
Diameter of flywheel, Df - 100 mm

4.6.1. Calculation for Force Applied on the Plunger

Force applied on the plunger can be calculated by using Equation 3.17.
F
W= 2
 Di2
dp

4000  9.81
F= 
 10.5  10 3 
2

30 10  -3 2

= 4806.9 N

4.6.2. Calculation for Force Applied on the End of Lever

Force applied on the end of lever can compute by using Equation 3.19.
L
F = F 
L
25
F = 4806.9 
365
 52

= 329.23 N

4.6.3. Calculation for Plunger Displacement

Plunger displacement can be calculated by using Equation 3.20.

L L
=
Df L p

25
Lp =  100
365

= 6.84 mm

4.6.4. Calculation for Number of Stroke Perform by Plunger

Total volume of liquid displaced can be calculated by using Equation 3.22.


VT =  D i2  L d
4

 30   115
2
=
4
= 81.28  103 mm 3

Total volume of liquid displaced per stroke by plunger will be computed by

using Equation 3.23.


Vp =  d 2p  L p
4

 10.5  6.84
2
=
4
= 592.27 mm3

Number of stroke perform by plunger is obtained by using Equation 3.24.

VT
n=
Vp

81.28  103
=
592.27
= 137.23
 137
 53

4.6.5. Calculation for Time Taken by Weight

Time taken to lift four tones can be determined by using Equation 3.25.
n
T=
Nf

137
=
68

= 2.01 minutes

4.6.6. Calculation for Work Done by the Press

Work done by the press per second can be determined by using Equation 2.26.
W  Ld
Wd =
Tt  60

4000  9.81  115  10-3

Wd =
2.01 60

= 37.41 Nm/s

Table 4.1. Calculation Result for Motorized Hydraulic Jack

Particular Items Symbols Results

Motor torque Tm 7.06 N-m

Flywheel torque Tf 35.11 N-m

Inner diameter hydraulic cylinder Di 30 mm

Wall thickness of hydraulic cylinder t 3 mm

Force applied on plunger F 4806.9 N

Force applied on lever F 329.23 N

Plunger displacement Lp 6.84 mm

Number stroke perform by plunger n 137

Time taken by weight T 2.01 minutes

Work done by the press Wd 37.41 Nm/s

 54

Table 4.2.Calculation Result of Gear Drive for Motorized Hydraulic Jack

Particular Items Symbols Results

Velocity ratio V.R 5
Output speed of gear Ng 68 r.p.m
Center distance x 82.5 mm
Transmitted load WT 418.41 N
Dynamic tooth load WD 1077.32 N
Static tooth load Ws 4631.33 N
Wear tooth load Ww 1113.54 N