GROUP 9 2004

Acknowledgement
We would like to acknowledge first our classmate students those help us by sharing
designing material like text book, and those who share idea with us for what we are going to
do. The other but the one who is the great man that we would like to acknowledge is our
previous teacher Engineer abel. Because, He help us by giving the soft copy which
somewhat good for designing purpose

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TABLE OF CONTENT

TITLE PAGE

UNIT ONE

1.1 Introduction ………………………………………………………………..……………….4

1.2 Hydraulic Ram and Plunger……..……………………………………………..4

1.3Description……………………………………………………………………………..4

1.4Operating………………………………………………………………………………..5

1.5Operating preparation……………………………………………………………..6

1.6Pressure Distribution…………………………………….…………………………7

UNIT TWO

2.1Force Analysis……………………………………….…………………………………8

2.1.1For jack handle and pump force………………………………………….8

2.1.2Pressure range selection…………………………………………………….10

UNIT THREE

3.1Material Selection……………………………..……………………………………...11

3.2Stress Analysis…………………………..………………………………………….....14

3.2.1Top-Cup with a Square Thread……………………..………………..………14

3.2.2 Solid Ram………………………………………………………………….………..20

3.2.3 Second Stage Ram………………………………………………….…….……...22

3.2.4 Reservior…………………………………………………………………………....26

3.2.5 Plunger Cylinder……………………………………………..……………………30

3.2.6 Plunger with Plunger Rod……………………………………………………...33

3.2.7 Octagonal Head Top Plate……………………………………………….……...35

3.2.8 Handle…………………………………………………………………………..………36

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3.2 .9 Handle Socket……………………………………………………………………….38

3.2.10 Handle Socket Pins…………………………………………………………........38

3.2.11 Spring Design for Check Valves……………………………………............39

3.2.12 Design of the Base…………………………………………………………………47

3.2.13 Design of the Releasing Screw……………………………………………….47

3.2.14Design of Refilling Screw……………………………………………………......47

3.2.15Design of Retainer…………………………………………………………………47

3.2.16Design of Sealing………………………………………………………………......48

UNIT FOUR

4.1Manufacturing Process………………………………………………………………48

Appendix………………………………………………………………………………….…………53

References……………………………………………………………………………57

UINIT ONE

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1.1 Introduction
Jacks are portable hand operated devices for rising and lowering
loads through short distance. There are three types in common uses, screw
jacks, rack and lever jacks, and hydraulic jack. Bell-bottom screw jack are
available in capacitive to 2 tons and a lifting range to ( 1-4)in. the screw is
rated by a bar inserted in holes in the screw head or by a ratchet cover
fitted to the head .Gear drive jacks will lift up to 50 tones. A lever
mechanism turns a bevel pinion, on internal thread between the gear rises
and the non- rotating screw rack and lever jacks consists of a cast steel or
malleable iron housing in which the lever pivots. The rack toothed bar
passes through the hollow housing the load may be lifted eigher on the top
or ending from the bottom of the bar. The lever paule may be biased either
to rise to lower the bar. Hydraulic jack can be classified in to three based on
the application of the jack that are:- hydraulic service jack, session
hydraulic jack and hydraulic bottle jack. From these hydraulic jacks, the
bottle hydraulic jack as consists of a cylinder, a piston and lever operated
pump and their capacities is to up to 50 tones and lifting height is up to
22in. Large hydraulic jack may be provided with two pumps.

1.2 HYDRAOLIC RAM AND PLUNGER

A hydraulic ram (hydraulic jack, hydraulic press, fluid press etc) is
a force multiplying devices. A force FP is applied to plunge and a use full
force Fv appears at the ram. Even though the pressure in the hydraulic fluid
is the same every where the orse at the two cylinders will be proportional
their respective cross-sectional areas.

1.3 DESCRIPTION
The jack assembly is portable, self contained unit with a
single speed manually operated pump at the lift unit consisting of
three rams and on extension screw or cased within an anchored
cylinder mounted on the base .A stamped shell enclosed the rams
and cylinder to form the fluid reservoir.
1.4 OPERATING

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When the handle is moved upward, ball (A) is seated and

fluid is drawn from the reservoir through the screen into the
valve assembly. From there fluid enters the plunger cylinder as it
indicated by the section symbol. (vent and filler screw must be
open to allow fluid to flow).other down ward stroke of the handle
or pressure stroke ,fluid pressure to the master cylinder.
Continued operation of the pump will create sufficient pressure to
rise the first stage ram. Until it hits the stop of the second stage
ram with the additional pressure. The second stage ram will be
raised until it hits the stop of the third stage ram. If the pressure is
still continued, the third stage ram will be raised to the full height
of lift until it hits the stop of the cylinder. At the end of the travel
of the rams or with an over load applied to the jack. Excessive
pressure from the continued pump unseats ball (B) and flied is by
passed to the reservoir (with this occurs the handle will suddenly
drop or go soft during the pumping stoke). If the releasing screw
is opened pressure is released through unseated ball (C) and fluid
to the reservoir.

1.5 OPERATING PREPARATION

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When placing the jack in service, apply a light film of

lubricating oil, on outer bearing surface of ram. Wipe away any
excess of oil to prevent accumulation of dust and grit on ram
surfaces. Open the releasing screw slightly and collapse rams until
flush remove vent and five screws to check reservoir for proper
fluid content. If oil level is low, add correct fluid.
NOTE:- always fill reservoir with fresh, clean oil in case of
emergency operation flush jack with clean hydraulic oil and refill
reservoir. In order to get numbers of rams, thickness of neck, and
achieving minimum and maximum height to required amount the
following procedure have to follow.
H max−H min
A) Number of rams = H min

Where H Tmax - H Tmin = 320mm...................given

Assume, that H Tmax = 420mm and

H Tmin= 100mm

But in order to get N rams base height and cap height must be
subtracted from the given value above.
Assuming that, base height =25mm
And, cap height =10mm
=> H min = H min total - Bheight - C height
H min = 320mm – 25mm -10mm
= 285mm
And, H max = H Tmax- Bheight - C height
H max = 420mm – 25mm – 10mm
= 385mm
( H max – H min )
Therefore:-Nrams = H min
( 385 mm – 285 mm )
= 285 mm

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Nrams= 0.351

Since Nrams should be whole number then, Nrams = 1

B) THICKNESS OF NECK
Since l= H min=285mm, therefore l=y+2t
( H max – H min )
But, y= 2
=
( 385 mm – 285 mm )
y= 2
y = 50mm
( 285 mm – 5 0 mm )
=> t = 2
t = 117.5mm

C) CHECKING
H max = H min +2y
= 285mm +2(50mm)
H max = 385mm therefore the analysis is correct.
1.6 PRESSURE DISTRIBUTION
By using Pascal’s principles, that is intensity of pressure is
transmitted equally in a directions through a mass of fluid at rest.

The force at two cylinders will be proportional to their

respective cross-sectional areas. A force Fp is applied to the

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plunge and a force Fr is applied to the rams. Since the pressure is

the same every where it is easy to solve the force applied on ram
and plunge.
Therefore F =PA=P(πr 2)
But Pram=Pplunge.......................................Pascal principle
F ram Fp l unge
Aram = A plunge where, Aram =πdrxdr/4
dr =diameter of the ram
Aplunge =πdpxdp/4
dp =diameter of the plunge
Fr Fp
2 2
Since Fr/Ar=Fp/Ap => π d r = π dp
4 4
Fr/d r 2= Fp/d p 2

UNIT TWO

2.1FORCE ANALYSIS
2.1.1 FOR JACK HANDLE AND PUMP FORCE
where Fp............pin force
Fh............human force (usually it is taken to be (100 to
200N)
Ff.............fulcrum force
L..............overall handle length (again most of the time it
has to be taken (300-500mm))
l................pin to pin length (it also taken (30-50mm))

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Using equilibrium condition i.e

1) ΣMA =0
(Fh x L) – (Ff x l) = 0
F h∗L
Ff = l
............................(1)
2) ΣFy = 0
Ff-Fp-Fh = 0
Fp=Ff - Fh...........................(2)
and pressure of the pump is given by ,
Fp
P pump =A p
Where, Ap......plunge cross-sectional area and
P pump ...........pump pressure
π DP2
But, A P= ..................cylinder bore area (circular area)
4
D P ....................plunge diameter varies (10 to 16mm) it is
standard.
From this range let use Dp =10mm
π DP2
And, therefore AP = 4
=π*0.01m2/4
=7.85*10-5 m2=78.5 mm2
Fp
This implies that P pump = A p .....................(3)
Using Pascal’s law,
P pump= Pplunge = Pram = Pcylinde
Therefore Pp= Pc => Pc=Fc/Ac
Where Pc=cylinder pressure
Ac=cylinder cross-sectional area
Fc=cylinder force
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=> Fc/Ac(N/mm2) or MPa............................(4)

2.2.2 PRESURE RANGE SELECTION
Assumption:- assume that the interval cylinder diameter and
the hollow ram diameter are equal. Therefore Dci = Dhr
Where Dci = internal cylinder diameter
Dhr =hollow ram diameter
 let assume that Dci = Dhr= 60mm
Therefore Ac =πDhr2/4
Ac = π(60mm)2/4
= 2827.43mm2
Hence the minimum pressure to raise the given weight is:-
W
Pcmin = Ac
Where:- W= 20,000N=20KN........... is the given design weight
20 x 103 N
Pcmin = 2827.43 mm2
= 7.07MPa
Therefore Pcmin = 7.07MPa, the internal pressure to be designed
should be greater than the minimum pressure since there are
parts to be lifted with this pressure.
Hence Pcdesign > Pc min=7.07MPa
In order to fit the internal design pressure, length of the
handle, force of fulcrum plunge force and pin to pin length first
let us assume the human force and length range for handle.
Assuming Fh = 150N from the range of (100N to 200N)
And L = (300mm to 500mm), assuming, L =500mm
l = (30mm to 50mm), and also assume l = 30mm
by using equation (1) to equation (4)
 l(mm) L(mm) Ff(N) Fp(N) Pp(MPa)
30 500 2500 2350 29.94

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Finally, from the above, Pcylinder must be greater than Pc min=

7.07MPa. For this reason the selected quantities are:-
L = 500mm, Ff = 2500N, F p = 2350N

L =30mm, Pp = 29.94MPa,

UNIT THREE

3.1 MATERIAL SELECTION

 O-RING (SEALING) :-
O-ring are torus-shaped seals of circular cross-section
made from a variety of elastomeric and are used in static and
dynamic condition.
Material:-the ring shall be made out of the following 4 classes
of material.
O-ring size Diameter(mm) Location Width (mm)
006 to 045 20 Pump piston 1.77±0.07
110 to 163 60 Second piston 2.6±0.07
rod
006 to 045 40 First piston 1.778±0.07
rod
006 to 045 35 Top of second 1.77±0.07
piston

 SOLID RAM:-
Because of it is subjected compressive load, fluid friction
and corrosion, the selected material is should be :-
Alloy
steel,AISI1015,Stu=420.6MPa,Sy=313.7MPa.
 SPRING FOR SAFETY VALVE :-

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Hence, it is selected from spring material. for this reason it

is selected from spring material table .

 HOLLOW RAMS:-
Here it is also subjected to fluid friction, compressive load,
buckling and corrosion and also from economic point of view, the
selected material is:-
Milled steel ASIM, A487and Sy=90MPa

 CYLINDER(CYLINDER RAM):-
Just like hollow ram it is subjected to fluid friction,
compressive load, tensile load, buckling and corrosion and also
from economical point of view, the selected material is:-
Milled steel ASTM, A487,Sy=90MPa
 PLUNGE CYLINDER
Again its characteristics is the same as that of ram cylinder
and from economic point of view and availability of material the
selected material is:-
Milled steel ASTM, A487,Sy=90MPa

 PLUNGE WITH PLUNGE ROD:-

Since it has reciprocating motion ,it is subjected to fatigue
load ,compressive load , tensile load ,fluid friction and from
economic point of view and availability of material the selected
material is :-
Alloy steel,AISI 1002 , Stu=90MPa ,Sy=46MPa
 OCTOGONAL HEAD TOP PLATE :-
Since it is only subjected to compressive load ,so that
the selected material is:-
Malleable cast iron ASTM,A47 with Stu=345MPa ,and
Sy=224MPa.
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 TOP-CUP WITH SQUARE THREAD:-

Since it subjected to compressive load the selected material
is:-
Gray Cast iron,ASTM60 and Sy=86MPa.
 HANDLE AND HANDLE SOCKET:-
For this, due to compressive load and tensile load and
also bending force on it, the selected material is:-
Carbon steel,AISI1030,Stu=400MPa and Sy=237MPa.
 HANDLE SOCKET PINS AND RELEASING SCREWS:-
Hence, it is subjected to torsion shearing compressive
load the selected material is:-
Alloy steel ANSI1318,Sy=75MPa.
 HANDLE SOCKET LINK :-
Since it is subjected to compressive, tensile and
bending load and also buckling ,the material selected is:-
Alloy steel ANSI1318,Sy=70MPa.
 BASE PLATE :-
Since it is only subjected to compressive load the selected
material is:-
Gray cast iron ASM60 with Stu=431MPa, Scu=1293MPa.
 BALL FOR RELEASING AND SAFTEY VALVE:-
Since it is safety materials from the pressure to be
developed and it is always contact to fluid friction and corrosion
the selected material is:-
Stainless steel AISI 900 and Sy = 200MPa.
 RISERVIOR
It is all the same character to that of cylinder and from
economical point of view and also availability ,the selected
material is :-
Milled steel ASTM, A487 and Sy =90MPa
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3.2 STRESS ANALYSIS

3.2.1 TOP-CUP WITH A SQUARE THREAD

A) FOR SCREW

Sy = 482Mpa

W = 20kN

By taking, σall =0.65 * Sy = 313.3Mpa

So that, to get core diameter (dc) of the screw

4W F
σall= 2 =
A
ᴨ dc

4W
√
dc = (
ᴨ σ all
)

4∗20,000
√
dc = (
ᴨ 313.3∗106
)

dc =15.98mm

To be more safe let me take dc =20mm

dc
Pitch of the thread (p) = 4 ………………………………square thread

20 mm
p= 4

p =5mm

p
h = 2 =2.5mm ………………………….depth of screw thread

d b = p + dc =20mm +5mm = 25mm, where d b = diameter of the screw

d n = d b + 2(a) where a = 0.25mm constant

d n = 25mm + 2*(0.25mm) = 25.5mm

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h= 0.5P + a , where h= depth of the nut thread

=0.5*5mm+0.25mm

H= 2.75mm

ᴨ d c2
Ac = π = …………………………………core area of the screw.
4

Ac = π ᴨ ¿ ¿ = 314mm2

Ac = 314mm2

Mean diameter of the screw (dm)

db+dc
dm = 2

25 mm+20 mm
dm = 2

= 22.5mm

helix angle ( α ):-

p
tan α = ᴨ dm

p 5 mm
α = tan-1 = tan-1 ᴨ 22.5 mm
ᴨ dm

α = 4.050

Frictional angle (β)

Where (μ) is the coefficient of friction between the thread is equal to 0.125
(for carbon alloy steel).

tan β = μ

β = tan -1μ

β = tan-1 (0.125) =7.1250

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When the frictional angle (β) is greater than the helix angle ¿) the
arrangement is self –locking

Therefore this arrangement is self –locking.

FRICTIONAL TORQUE

The torque which resists the frictional force is called frictional torque.

Therefore, thread surface frictional torque

W∗dm∗tan (α + β )
Tf =
2

20,000 N∗22.5 mm∗tan( 4.05+7.125)

=
2

Tf =44.45N.m

Now let us check the screw for the principal stress on it

4∗W
Direct compressive stress =
ᴨ dc 2

4∗20,000 N
σ cdirect = =200MPa
ᴨ (20 mm)2

Maximum Tortional shear stress

τmax= 16 Tf / ᴨ dc 3

= 16∗44.45∗103 Nmm/(ᴨ 20 mm)3

τmax =88.9MPa

σ c + √ σ c 2 + 4 τ Ԏ2
Maximum principal stress =
2

200 MPa+ √ (200 MPa)2 + 4( 8 8.9 MPa)2

σ max =
2

σ max = 233.8MPa

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Since σ max is much less than σ all

that is σ all >σ max

233.3MPa < 313.3MPa

Therefore the screw is safe from crushing

CHECK FOR BUCKLING

Rankine’s formula is applicable for columns, ranging from very long

to short ones for this reason I use this formula to check buckling.

crus hing load

Crippling load = L 2
1+Q( )
K

σ c∗A
Therefore, WGr = 1+ Q( L )2 where σ c = crushing stress or yield stress
K
in compression.

A = cross-sectional area of the column

Q = rankine constant

L = Equivalent length of the column

K = less radius of gyration.

Take the following design data From machine design book page
“607“, table 16.3 for material ,carbon steel

σ c = 250Mpa

And fixture coefficient = 0.25

1 1
Rankine constant (Q) = 9000 * 0.25

=0.00044

And assuming equivalent or effective length of the screw (L) =80mm

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I
Radius of gyration (K) =
√ A

(ᴨ d 4c /64 )
√
K= ᴨ d 2c = √ (dc2 )/4
4

dc 20 mm
K= 2= 2

K = 10mm

L 2 80 2
[ ] = [ ] = 64
K 10
A=πdc2/4=π*(20mm)2/4
=314mm 2
σ c∗A
Therefore Wcr = 1+ Q( L )2
K

250∗314
= 1+ 0.00044∗64

= 76.35KN

rankine load
Permissible buckling load = safety ¿!

W cr
= s.f

76.35 KN
= 1.25

= 16KN

Since our load which is 61.08KN is much less than permissible buckling
load, this screw is safe from buckling.

B) FOR A NUT

Bearing Area for thread = (π/4) (db 2– dc 2)

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A b = (π/4) (d 2 – dc 2)

Ab = (π/4) (252 – 202)

A b = 177mm2

Minimum number of thread in the nut

W
NT = 10 Ab

20 x 10 3
NT =
10 x 177

NT= 11.29

NT =12

The outer diameter of the nut

DN = 1.5dc

DN = 1.5 x 20mm

DN =30mm

C) FOR THE CUP

Maximum diameter of the cup = 2 x dc

Dc = 2 x 20mm = 40mm

Let us assume that thickness of the cup

t c = 30mm

Shear area of the cup can be calculated as follows

area that resists shearing of the cup = ᴨ db * tc

= ᴨ 25mm * 30mm

A cup=750mm2

The induced shear stress:-

W
τ indused = A cup

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20000
= 750

τindused =26.67MPa

Since the indused shear stress is much less than the allowable shear stress.

i.e σ all > τindused

313.3MPa > 26.67MPa

3.2.2 SOLID RAM

Material:- alloy steel

Sy = 313.7 MPa

F .S = 4 ………………..assumption
τ all = 0.4* Sy

= 0.4 * 313.7 MPa

= 125.48MPa

σall = 0.65 * Sy = 203.905 MPa

Capacity W = 20,000 N=20KN

i) CHECK FOR SHEARING AND CUSHING STRESS

Since the pressure applied on the bottom of the solid ram when it hits
the stop of the second stage ram subjects the neck for shearing and
crushing, we have to check it.

Maximum force acting on the neck

Fat neck = P cylinder * Ac ,

Where Ac = π dc 2/4

Ac = π (60 mm)2/4

A c = 2827.33mm2

Fat neck = 29.94MPa * 2827.33mm2

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Fat neck = 84.65KN

The induced shear force (τinduced)

F at neck
τ = As h ear but Ashear = π Di * t

A shear = π* 40mm * 15mm = 1884.95mm2

84.6 5 KN
τ=
1884.95mm 2

τ =44.882MPa

Since σ all > τ induced then this ram is safe from shearing

313.3Pa > 44.882MPa

The induced crushing stress (σ c)

T @ neck π
σc =
Acrus hing
but Acrushing = 4 *( Do 2- Di2)
Where Do = outer diameter outer diameter of the ram
Di = inner diameter of the ram
π
A crushing = 4 *(40 2-302) =1570.8mm2

84.6 KN
σc = = 53.86MPa
1570.8 mm2

Since σ all > σ c have our ram is save from crashing

313.3MPa > 53.86MPa

ii) Check for Bucking

Again using Rankine formula we can check our solid ram from bucking
σ cA
WCr = 1+ Q( L )2
k

Where Wcr = crippling load

σ c=Crushing stress on tield stress on compression

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A = Cross –sectional area of the column

Q = Rankine constant

L = equivalent length of the column

K = least radius of gyration

From machine design textbook, Gupta , page 542, table 16.3, I have take
that the Rankine constant, crushing stress and fixture coefficient as
follows:-

 For carbon steel

1
σ c = 250Mpa and fixture coefficient =
0.25
1
Rankine constant = 9000
Rankine constant for this ram will be :-

1 1
Q = 9000 * 0.25 =0.00044

And the equivalent length (L) = 95mm

I
Radius of gyration (K) =
A√
(ᴨ di 4 /64 )
√
K= ᴨ d 2i = √ (di2 )/ 4
4

di 40
K = 4 = 4 mm = 10mm

L 2 95 mm 2
[ ] =[ ] = 90.25mm
K 10

Finally the crippling load

σ cA
Wcr = 1+ Q( L )2 but Ac = π Di2/4 = π( 40 mm)2/4
k

Ac = 1256.64 mm2

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σ cA
Wcr = L 2
1+ Q( )
k

250∗1256.64
=
1+ 0.00044∗90.252

WGr= 302.16KN
Rankine load
Permissible buckling load = S .f

Wcr
W Grp= S.f

302.16
W Grp = 1.25
= 241.73KN

Since the permissible buckling load is much greater than the given load
i.e WGr > W = 20KN, hence the ram is safer from buckling.

3.3.3 SECOND STAGE RAM

Material:- Mild steel

Sy = 90MPa
σ all = 0.5 * Sy = 0.5 * 90MPa

= 45MPA
σ all = 0.65 * Sy = 0.65 *90MPa

= 58.5 MPa

Due to given load, assuming the hollow ram is thin walled cylinder.

Therefore, From hoop stress (σ h )

Pi∗Di
σh = where Pi = internal pressure
2t

Di = internal diameter

t = hollow ram thickness

Cf = corrosion factor

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Therefore Pi = 29.94MPa

Di = 60mm

Let us assume that

σ h = σ all = 58.5MPa

Pi∗Di
Therefore, σ h = 2t

Pi∗Di
t = 2σ h

22.94∗60
t = 2∗58.5

t = 11.76mm

Due to corrosion effect we have to add corrosion factor C f =

1.66mm

Therefore, tactual = 11.76mm + 1.66mm

tactual = 13.42mm

Assuming stop length ( L) = 10mm

And Do = Di + 2t = 60mm + (2*11.42)mm

Do =66.84mm

Most outer diameter of the ram becomes :-

DMO = DO + 2(L) = 66.84mm +20mm

= 86.84mm

I ) CHECK FOR SHEAR AND CRUSHING STRESS AT THE STOP (NECK)

Maximum force acting on the neck (stop)

ᴨ∗D MO2
Fat neck = Pc *Ac but, Ac = π
4

ᴨ∗(86.84 mm)2
Ac = π = 5919.83mm2
4

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Therefore, Fat neck = 29.94MPa *5919.83 mm2 = 177.24KN

Induced shear force at neck (stop) is:-

F at neck
τ = A shear where Ashear = π ᴨ *DO *h

A shear = π ᴨ * 66.84mm * 10mm

A shear =2098.8mm2
177.24 KN
τ= 2098.8 mm2 = 103.4168MPa

Crushing stress at neck (stop)

F at neck
σc =
A crush
where Acrush = (π/4)(DMO2 –DO2 )

= (π/4)(86.84 2 –66.842 )mm2

Acrush = 2412.8mm2
177.24 K N
Therefore, σ c = 2412.8 mm2

σ c = 73.46MPa

Since the induced shear of the crushing stress are much less than the
allowable shear of normal stress, our hollow ram is safe from this induced
stress.

ii) CHECK FOR BUCKLING

Here again the Rankine formula is applicable to check buckling, that is

σ cA
Wcr = 1+ Q( L )2 where Wcr = crippling load
k

σ c = 320MPa …………….for mild steel crushing stress

1
σc ∗1
Q= 2 = 0.25 = 0.00053………………………rankine constant
Cᴨ E
7500

L= 95mm ……………………………….effective length

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 GROUP 9 2004

I
Radius of gyration (K) =
√ A
K =√ ¿ ¿

2
+ D 2o ¿
K =√
D Mo
¿
16

(86.84 2+66.84 2)
K=
√ 16

K = 27.39mm

L 2 95 mm 2
[ ] =[ ] = 34.7
K 27.39 mm

And Area (A) = ( π /4 )(DM 02−DO 2)

A = ( π /4 )(86.842−66.842 )

A = 2412.8mm2

320 MPa∗2412.8 mm2

WGr =
1+0.00053∗34.7

WGr = 0.76 x 106N

rankine load
Permissible buckling = S. f

0.76 x 106 N
W Grp =
1.25

W Grp = 606.6KN

Since the permissible buckling load is much greater than the given
load, which is 20KN, this second stage ram is also safe from buckling.

3.3.4 RESERVIOR

Material:- mild steel

Sy =90 MPa

Since the reservoir is much less loaded let us take S.f = 2

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 GROUP 9 2004
σ all =0.65* Sy = 0.65* 90MPa = 58.5MPa

i) VOLUME CALCULATION

And the volume of the fluid occupied by the ram and the cylinder
should be equal to that of the reservoir volume.

i.e ram volume (VR ) = V1 +V2

Where V1 =A1h1

= ( π /4 )¿) * h1

= ( π /4 )602 * 65

V1 =183,783.17 mm3

V2 = A2h2

V2 = ( π /4 )¿ * h2 = ( π /4 )∗86.84 2 * 65mm

=384,788.9mm 3

Therefore VRam = v1 + v2

= 568,572.1mm3

ii) INNER DIAMETER OF THE RESERVIOUR

In order to carry this amount of volume of fluid in the height of h=95mm

the reservoirs volume should be equal to the volume of the rams.

i.e. VRam = Vreservoir

therefor,

Vreservoir =(π/4)( D2inner of reservoir - D2outer of the cylinder ) * height

Vreservoir =(π/4)( D2i - 86.84 2) * 95mm

D 2i - (86.84 mm)2 = 7624.2mm2

Di = 132.15mm

To be more safe and reservoir STD let us take Di =140mm

iii) THICKNESS OF THE RESRVIOUR

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 GROUP 9 2004

Since only atmospheric pressure is applied on the inside and outside

of the reservoir, we can threat the reservoir us thin walled cylinder.

Therefore from hoop stress (σ h )

Pc∗Di
σh =
2t
where, Pc = 1 bar = 105 Pa = 0.1MPa

Pc∗Di
=> t = 2 σ h Di =140mm…..internal diameter

of the reservoir.
σ h = σ all = 58.5MPa ………..assumption and ,
t = thickness

0.1 MPa∗140 mm
t = 2∗58.5 MPa
= 0.12mm

To be more safe let us add corrosion factor Cf = 1.9mm

tacual = t + Cf

tacual = 0.12mm + 1.9mm =2.02mm

3.3.5 RAM CYLINDER

Material specification:- mild steel

Sy = 90MPa.

Assume S.f = 1.25

σ all = 0.5 * Sy

=45MPa
σ all = 0.65* Sy

= 58.5 MPa

Again from the given load and the applied internal pressure , it is
possible to assume the ram cylinder as a thin walled cylinder.

Hence: from hoop stress (σ h)

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 GROUP 9 2004
Pc∗Di
σh = where Pc = 29.94MPa
2t

Di = DMO of the second stage ram

 Di = 86.84mm
Assume that σ h = σ all =58.5MPa.
Pc∗Di
σh =
2t

Pc∗Di
t = 2σ h

29.94∗86.84
t= 2∗58.5

t = 22.22mm

To be more safe let us added corrosion factor (Cf ) = 0.85mm on it.

Therefore, tactual = t + Cf

tactual = 29.15mm + 0.85mm

tactual =23.07mm

i) Check for the Shearing and Crushing Stress at the Stop (Neck)

Since the material of the diameter of the ram cylinder is the same as
that of the third stage ram, it is safe from crushing and shearing stress
induced on the neck (stop) of the cylinder.

ii) Check for Buckling

Again from the same text called GUPTA, I used Rankine formula of
buckling.
σcA
WGr = 1+ Q( L )2 ………………………….Crippling load
k

But from the text, for mild steel

σ c = 320MPa and

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 GROUP 9 2004
σc 1 1
Q= 2 = 0.25 * 7500 = 0.00053
Cᴨ E

And cross sectional area of the cylinder becomes

ᴨ 2 2
A = 4 (DM 0 −Di )

But DMO =Di + 2t = 86.84mm + 2*(30mm) = 146.84mm

A = ( π /4 )(DM 02−Di2 )

A = ( π /4 )¿ = 11,006.33mm2

L = 130mm…………..effective length of the cylinder

I
Radius of gyration (K) =
√ A

K =√ ¿ ¿

2
+ D2o ¿
K =√
D Mo
¿
16

2
K = (146.84 ¿ 2+86.84 ) ¿
√ ¿
16

K = 42.65mm

L 2 130 mm 2
[ ] =[ ] = 3.05
K 42.65 mm

FINALLY

320 MPa∗11006.3 mm 2
WGr =
1+ 0.00053∗3.05

WGr =3.52 x 106N

rankine load
Permissible buckling = S. f

3.52 x 10 6 N
W Grp =
1.25

W Grp = 2.81MN
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 GROUP 9 2004

Since the permissible buckling load is much greater than the given
load, which is 20K N, this ram cylinder is safe from buckling.

3.3.5 PLUNGER CYLINDER

Material:- Milled steel

Sy = 90MPa

Assume S.f =1.25 …since the cylinder is subjected to compression load and
the tensile load we have to take higher safety factor.
σ all = 0.5 * Sy = 45MPa

σ all = 0.65* Sy

= 58.5 MPa

i) THICKNESS OF THE WALL

Again for the same reason which is less internal pressure applied on
the cylinde, we can threat as thin walled cylinder.

Therefore, from hoop stress (σ h )

Pc∗Di
σh = where P c =29.94 MPa…………cylinder pressure
2t

Pc∗Di
=> t = 2 σ Di =10mm ……internal diameter of
h

the cylinder
σ h=σ all = 58.5 MPa………assumption

29.94 MPa∗10 mm
Therefore, t = 2∗58.5 MPa
= 2.56mm

to be more safe let us take corrosion factor Cf =1.44mm

tacual = t + Cf

tacual = 2.56mm +1.44mm

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 GROUP 9 2004

tacual = 4mm

Therefore the outer diameter of the cylinder becomes

Do = Di + 2(tacual)

Do = 10mm + 2*4mm

Do = 18mm

ii) CHECK FOR BUCKLING

From the same text book which is GUPTA, I used rankine formula and
take constants.

Therefore, for mild steel;-

σ c = 320MPa ……………..crushing stress.

σc 1 1
Q= 2 = 0.25 * 7500 = 0.00053
Cᴨ E

where C =the end fixture coefficient

Q = rankine constants

Crippling load
σcA
WGr = 1+ Q( L )2 where σ c =320MPa
k

A = ( π /4 )(Do2 −Di2) …………..cross-sectional area

A = ( π /4 )(182−102 )

A =175.95mm 2

Q = 0.00053

L = effective length of the the cylinder

I
K=
√ A
=√ ¿ ¿

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 GROUP 9 2004
2
+ D 2i ¿
K =√
D o
¿
16

K= √18 2+10 2 ¿ ¿
16

K = 6.02mm

L 2 70 mm 2
[ ] =[ ] = 135.21
K 6.02 mm

σcA
Wcr = 1+ Q( L )2
k

320∗175.95
Wcr = 1+ 0.00053∗135.21

Wcr = 52.54KN
buckling load
Permissible buckling load = S .f

52.54 KN
WGrp = 1.25

= 42.03KN

Since the permissible buckling load is greater than the fulcrum load (F f
= 2.5kN) our plunger cylinder is safe from buckling.

3.3.6 PLUNGER WITH PLUNGER ROD

Material:-alloy steel

Sy = 40MPa.

Assume, S.f =2 …………since it is subjected tensile and compressible

stress
σ all = 0.65* Sy

= 0.65 *40MPa
σ all= 26MPa

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 GROUP 9 2004

i) PLUNGER ROD DIAMETER

In order to determine the plunger rod diameter (DR) from compressive

stress (σ c) it can be equated as follows.
Ff
σ c =σ all = …………………………..assumption.
Arod

Ff Ff
Arod = σ all = π ¿ ¿ = σ all

4∗F f
DR =
√ π ᴨ∗σ all

4∗2500
DR =
√ᴨ π∗26
mm

DR =11mm

ii )CHECK FOR BUCKLING

Again from the same text book GUPTA, by applying the Rankine
formula

For alloy steel

σ c = 250MPa …………………….crushing stress

Q = Rankine constants
σc 1 1
Q= 2 = 0.25 * 9000 = 0.00044 where C is fixture constants
Cᴨ E

And, cross-sectional area Ac

Ac = π ¿ ¿ = 95mm2

Active length (L) = 70mm

I
Radius of gyration (K) K =
√ A

√ ᴨ D 4R /64 ¿ ¿ 2
ᴨ D 2R = D R
K=
4 √ 16

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 GROUP 9 2004
DR 11
K= = 4
4

K =2.75mm

( L/ K )2 = (70/2.75)2 = 648

Finally the crippling load becomes

σcA
WGr = 1+ Q( L )2
k

250∗95
= 1+ 0.0004 4∗648

WGr = 18.5KN
Rankine load
Permissible buckling load = S .f

18.5 KN
W Gr = 2

W Gr = 9.25KN

Since the permissible buckling load is greater than the fulcrum load
(Ff =2.5KN) this plunger road is safe from buckling.

3.3.7 OCTAGONAL HEAD TOP PLATE

Material:- Alloy steel

Sy = 382MPa

Assume that S.f = 2 since the load on the top plate is very low
σ all = 0.65* Sy = 248.3MPa

τall = 0.5 * Sy = 191MPa

i)CHECK FOR SHEARING AT CRITICAL POINTS

F at neck = Pc *Ac where Pc = 29.94MPa internal cylinder

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 GROUP 9 2004

pressure

Area (A c ) = (π/4) ( Do2 - Di2)

= (π/4) ( 1402 – 86.84 2)

A c = 9,466.2 mm2

F at neck = 29.94MPa * 9,466.2 mm2

F at neck = 283.42KN

INDUCED SHEAR STRESS

F at neck
τ = Ashear where Ashear = π* Di *h

A shear = π*86.84mm * 22mm

A shear = 6000mm2
283.42 KN
τinduced =
6 000 mm 2

τinduced =47.24MPa

Hence the induced shear stress at the critical point is much lower
than the allowable shear stress, our plate is safe.

3.3.8 HANDLE

Material:- Carbon steel

S y =237MPa

Sall = 0.65 *Sy = 154MPa

σ all = 0.5 * Sy = 118.5MPa

i) DETERMINATION OF DIAMETER

From the above diagram (Fig.1) maximum Torque is moment can

be seen

Therefore to determine diameter let us calculate it from σ all or Sall

Sall = (16 Tmax)/πd 3

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 GROUP 9 2004
16∗Tmax
d = ∛ ᴨ π∗Ԏ σ all

16∗150∗470
d =∛ π ᴨ∗154.5

d = 13.25mm

32 Mmax
and, σall =
ᴨ d3

Where Mmax = 470 mm* 150N

Mmax = 70500N.mm

32∗70500
d =3
√ ᴨ π∗118.5

d =18.23mm to STD value d =20mm

Due to safety from Sall of σall we have to select the greatest diameter from
the above

Therefore dshaft = 20mm

3.3.8 HANDLE SOCKET

Material – Carbon steel, Sy = 237MPa

τ all = 0.5 * Sy =0.5 *237MPa = 118.5MPa

σ all = 0.65 * Sy = 154MPa

i) DITERMINATION OF DIAMETER

Again from allowable stresses we can determine the outer diameter of the
socket
4∗Ff
σ all = 2 where Ff = fulcrum force
ᴨ (D 2−d )

D1 = outer side diameter of the handle socket

d = inside side diameter of the handle socket

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 GROUP 9 2004

4 Ff
D1 =
√ ᴨ σ all
+d 2

4∗2500
D1 =
√ ᴨ 1 54
+ 202

D1 = 21.56mm

And, τall =(4*Ff)/(π( D2-d 2))

4∗2500
D2 =
√ ᴨ π∗118.5
+202

D2 = 20.66mm

In order to determine the diameter let us check the thickness from the
two result.

Therefore t1 = D1 - d = 20.56mm - 20mm = 0.56mm

t2 = D2 – d = 20.66mm – 0.66mm =0.66mm

This implies that it can be possible to use a material thickness greater than
0.66mm therefore by adding correction factor Cf =2.34mm for convenience
it becomes.

D = d + 2(Aactual)

D = 20mm + 2*(0.66mm + 2.34mm)

D = 26mm

3.3.9 HANDLE SOCKET PINS

i) FULCRUM PIN

Material:-Alloy steel, Sy = 75MPa

σ all =0.5*75MPa=37.5MPa

A) DETERMINATION OF THE DIAMETER

Since the pin is subjected to double shear

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 GROUP 9 2004
Ff
σ all =
2 ᴨ d2

Ff
d=
√ 2∗σ all

2500
d=
√ 2∗37.5

d = 5.77mm, to be more safe and standard let us take d pin = 8mm

ii) PIVOT PIN

Material – Alloy steel, Sy = 75MPa;

σ all = 0.5* Sy = 37.5MPa.

A) DETERMIATION OF THE DIAMETER

Again it subjected to double shear

Fp
σ all =
2 Ashear

Fp
σ all =
2 ᴨ d2

Fp
d=
√ 2 ᴨ Ԏ∗σ all

2350
d=
√ 2∗ᴨ 37.5

d = 3.16mm

To be more safe and standard let us take dpin = 6mm

3.3.10 SPRING DESIGN FOR CHECK VALVES

I) MATERIAL for spring material, we have that for discharge valve from text
book called Engineering material Berilium Copper (C17200)

Sy = 1172MPa
σ all =0.5 * Sy =586MPa

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 GROUP 9 2004

Modulus of elasticity (G) =131GPa

A DESIGN PROCEDURE

Assume a wire diameter of d =4mm and spring index C = 5

Dmean = d * c =20mm

Douter = Dmean + d =22mm

Shear stress factor (Ks), Neglecting effect of curviture

1
Ks = 1 + 2C = 1.1

Maximum shear stress induced

8 W D mean
σ induced = ks *
ᴨ d3

Where W = P X A ……………………………….Axial load

ᴨ d2
And A = assume of the fluid line with d = 4mm
4

ᴨ 42
A =π = 12.57mm2
4

N
And P = 29.94 is the cylinder pressure
mm2

N
Therefore, W = P X A = 29.94 X 12.57mm2 = 376.3N
mm2

8 W D mean
σ induced = ks *
ᴨ d3

8∗376. 3∗20
= 1.1 *
ᴨ 43

σ induced = 329. 22MPa

Let us check the safety of factor (S.f)

Ԏall 586
S .f = Ԏ = 329.22 = 1.78
induced

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 GROUP 9 2004

Since the safety of factor is greater than one ,our discharge spring is
safe and acceptable.

SPRING CONSTANT (K)

Assume the deflection of the spring (d) = 2mm

And assume the end details of the spring is square ends

F F W 376 N
δ = K => K = ᵟ δ = ᵟ δ = 2∗0.001 m =188 * 103 N/m

Number of active length (Na)

d4 G
K=
8∗D 3m∗Na

d4G G∗d
 Na = 3 =
8∗D m∗K 8∗K∗C 3

¿ 10∗¿9 2∗10−3
Na = 131 ¿ = 1.57
8∗188∗103∗53

Na = 2

Number of total turn of the spring (Na’)

Na’ = Na + 2 for square end

Na’ = 2 +2 = 4

Free length of the spring

We know that free length of the spring

lf = (Na’ *d) +( δ) + (0.15 x d)

=(4*2+2+2*0.15)mm

=10.3mm

Pitch of the spring

Freelength Lf
P = Total number of turn−1 = Na ’−1 = 10.3/(4-1)=3.43mm

CHECK FOR BUCKLING

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 GROUP 9 2004

The critical load (Wcr) that causes buckling may be calculated by using the
following relation

i.e Wcr = K*KB *lf where K =spring rateor stiffness of the spring
W
= f

l f =free length of the spring

KB = Buckling factor that depending up on the the

lf
ratio Dmean

KB, From the table for

lf 10 .3
KB= Dmean =¿ 20 =0.515

And for built in end spring, μB = 0.71

N
K = 188 *103 m from the above

Therefore. Wcr = K*KB *lf

N
= 188* 103 m * 0.515 *10.3 *10−3 m

= 997.25N

Since the critical axial load is greater than the applied axial load (W = 376.3
N) then this spring is safe from buckling

C) BALL FOR DISCHARGE VALVE

Material due to the application of the fluid friction on it. i have selected
stainless steel and diameter of the ball = mean diameter of the spring

Therefore, Db =Dmean =20mm

ii) SPRING FOR RELIEF VALVE

This spring is come to in operation, if the jack is over landed to 1KN large
than the designed (require) load.

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 GROUP 9 2004

Material from the spring material, we have selected that for relief valve
from text book called GUPTA .i.e. carbon stainless- steel (BISA)
σ all =for average service = 364 MPa

G = 44 GPa

A) DESIGN PROCEDURE

Assume a will diameter of d = 4mm and spring index C= 5

Mean diameter D = C x d = 20mm

outer diameter D0 = D + d = 22mm

shear stress factor (ks), neglecting the effect of curvature

Ks = 1 + 1/2c = 1.1

Maximum shear stress induced

8 WD
τindused = Ks *
ᴨ d3

Where W = P x A ………..applied load

But internal pressure developed will be increase and the applied load also
increases by 1KN

i.e W app =FRam + 1KN =20KN + 1KN = 21KN

D = mean diameter

d = wire diameter

Ks = shear stress factor

Therefore, the internal pressure (P)

Wapp onthe Ram 4∗Wapp
P= =
Aram π ᴨ (dr )2

21 KN
P= 4* = 7.43MPa ………assume ram diameter is dr = 60mm
ᴨ π (60 mm)2

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πᴨ
Waxial = P*A = 7.43MPa* 4 *( 4 mm)2 ……….assume line diameter dl = 4mm

Waxial =93.32N

τindussed = ks*8*w*D/πd3

= 1.1 * 8 *93.32N * 10mm/π(4mm) 3

τindussed = 48.85MPa

Since the induced shear stress is less than that of allowable shear
stress therefore the is to safe region and acceptable.

Spring rate (k)

Assume deflection of the spring (δ) =2mm and assume end details of the
spring is square end

K =W/ δ= 93.32/ 2 = 46.66 *103N/m

Number of active coil (Na)

G∗d
Na =
8∗k∗C 3

44∗10 9∗2∗10−3
Therefore Na = =1.88 =>for the sace of safety take Na =2
8∗46.66∗103∗53

Number of total turn of the spring (Na’)

Na’ = Na + 2 for square end

Na’ = 2 +2 = 4

Free length (Lf)

Lf=Na’ δ +δ +0.15d

=(4*2+2+0.15*2)mm = 10.3mm

9. Pitch of the spring (p)

Lf
P= =>but Na’ =Na +2…………………..for square end
Na−1

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 GROUP 9 2004

= 2+2 = 4
10.3
P = 4−1 =3.43mm

B) Check for buckling

The critical axial load( Wcr) that causes buckling may be calculated by
using the following relation

Wcr =k*kB* Lf
lf 10.3
KB for KB= Dmean = 20
=0.515

And for spring in end spring KB = 0.515 k =46.66kN/m

Wcr =46.66kN/m *0.515 *0.01033 =248.23N

Since the critical axial load is greater than that of applied axial load , the
spring is safe from buckling .

C) Ball for relief valve

Material …..stainless steel due to application of fluid friction , this material

is selected And diameter of the ball Db = mean diameter of the spring =
20mm and G=35GPa.

iii)Design of spring for intake valve

material again from the same text book the spring material is selected .

A) Design procedure
1) Assume that wire diameter =d=1mm and index c=10
2) Mean diameter =D=c*d=(10x1)mm=10mm
3) Outer diameter Do=D + d=(10+1)mm=11mm
4) Shear stress factor ks=1+1/2c= 1.05mm
neglecting the effect of curvature
5) Max shear stress that induced
τinduced =ks*8*WD/πd3
Where W =P*A…………… the force acting on spring (axial load)

Assume that the fluid in the reservoir is in the atmospheric pressure

that is Patm= 1bar
BOTTLE HYDROLIC JACK DESIGN Page 45
 GROUP 9 2004

And assume diameter of the line to be dl=4mm

A =πdl2/4=π* 42/4 =12.57mm2

W=PA = 0.1MPa*12.57mm 2 =1.257N

D……………………….mean diameter=20mm

d………………………...wire diameter =1mm

ks………………………….shear stress factor =1.05

τinduced =ks*w*D/πd3 = 1.05*1.257*20/π13

=33.6MPa

since the induced shear stress is less than the allowable stress

the spring is safe and acceptable

6. Spring rate (k)

Assume deflection (δ) =2mm and end detail of the spring is square and
k=w/ δ=1.257/2

K = 0.6285*103N/m

7. Number of active turn (Na)

G∗d
Na =
8∗k∗C 3

35∗10 9∗1∗10−3
= = 6.96
8∗0.6285∗10 3

Na = 7

8. Total turn of the coil(Na’)

Na’=Na+2 …………………………….for square and ground ends

= 7 +2

Na’ = 9

8)Free length of the spring (Lf)

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 GROUP 9 2004
Lf =Na ’ . δ+ δ+0 .15 d

Lf = (9 * 2) + 2 + (0.15 * 2) = 20.3 mm

Pitch =Lf/Na’-1 = 20.3/8 = 2.5 mm

B)Check for buckling

Wcr=k x kB X Lf ……………………………….critical axial load

From the table of STD,for Lf/D=20.3/10 =2.03 , and built in end spring

Kb=.72 k=0.6285 * 103N/m

Lf = 20.3mm

Wcr= Kb * k *Lf

= 0.72 * 0.6285 * 103 * 20.3 = 9.19KN

Since critical axial load is greater t than the applied axial load which is
(1.25N)

The spring is safe from buckling.

C)Ball for intake valve

Material due to the same reason as the above the selected material is called
stainless steel
Diameter of the ball
Dball =mean diameter of the spring
Db =D=10mm
3.3.12Design of the base
The base is used to support the jack system and also protect forgive
particles from going into the system .the material used for the basement is
most of the time cast iron. this is b/c of the following reasons: it is cheap
and easily available, it can easily resist wear when we compared to steel
and it is highly resist compressive load .this base is casted in the molding
system and drilled top for fluid comes in and out of the pump into system
and from the system into the reservoir and also from the reservoir into the
pump and so on.
The material is gray cast iron ASTM60 and Sy =43MPa.

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 GROUP 9 2004

3.3.13 DESIGN OF THE RELEASING SCREW

Material alloy steel, ANSI1318, Sy=75MPa

The selected STD screw M8
3.3.14 DESIGN OF REFILING SCREW
Material:-alloy steel and the selected STD screw is M4 and this screw is
hollow due to the passage of atm .pressure.

3.3.15DESIGN OF RETAINER

Material:-alloy steel and from standard and compatible selected t=2mm

3.3.16 DESIGN OF SEALINGS
Material Nitride Butadiene (class A)
And we have selected from compatible for different purpose

UNIT FOUR

4.1MANUFACTURING PROCESS

A) FOR THE PLUNGER OF THE PUMP

First select with the appropriate diameter, then face and turn the
work piece according to the dimensions. Make internal groove for O-
ring with the required thickness and depth. Finally with the precise
finishing machine make finishing.

B)For Solid Ram : -

Initially select the blank (work piece) with the required
dimension and faces the work piece by using lathe machine for
the required and exact dimension
Secondly drill the internal blind with the required dimension
(diameter) by using lathe machine without missing the center

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 GROUP 9 2004

Finally :- steep turn the external part of the solid ram and
finishing process with high surface finishes required so that use
precise surface finish machine .

C) FOR HOLLOW RAM

Make the blank by casting with a dimension of the nearest to the
exact dimension and bore and turn the internal and external part
by using lathe machine. Make groove for the O-ring seal with the
appropriate dimension. Make some finishing with précised
surface finish material or machine like internal and external
grinding machine.
D) For the base plate

By using casting process make the lower base plate blanks which is
suitable for machining

Correct the casting blank for the appropriate dimensions. Drill the
upper surface for the fluid passage to the required diameter and
make thread for releasing screw with 1mm pitch. Make thread the
upper inner surface to tight the cylinder and the reservoir with a
metallic thread engagement part with 1mm pitch by using lathe
machine. Finally make the necessary surface finish.

E) For Extension Screw :-

select the blank (work piece) with a required dimension and by
using lathe machine face and turn for the required dimension .
And then chamfer the lower part of the screw by 45o for easy of
losing and hitghching Thirdly ,make a thread with a square
thread by using the appropriate pitch and use milling machine for
easiness , when using indenting to this thread , use the
appropriate pitch . Finally use the necessary fining by using
surface finishing machine
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F) FOR THE HANDLE

The handle is made from the round bar turn the round bar and face
with the required specification. Make to some length knurling for
good griping ability. Finally make the required surface finish

G) FOR THE SOCKET

The socket is made from socket metal of the required thickness cut
the sheet metal with the correct lay out by using cutter machines
drill the socket metal for pin connection with a drilling machine .roll
the sheet metal with accurate dimension.

H) FOR THE CYLINDER OF THE PUMP

Prepare hollow round bar with the required dimension. Bore the
round bar by using lathe machine to the required diameter. Make
thread by using lathe machine on the lower part of it. And make
hexagonal head b y using milling machine on the upper part of it
.finally make the necessary finishing.

I) FOR RAM CYLINDER

Make the blank by casting with the nearest dimension that enables
as to make the exact dimension bore and turn the dimension by
using lathe machine with the required dimension. Make the groove
for O-ring seal with the appropriate depth with by using lathe
machine on the top inner surface of the cylinder. Make precise
surface finishing by using surfase grinding machine. Finally on the
lower part and on the upper part make a thread for thigh ting with
the top cup and base plate

J) FOR OCTAGONAL TOP CUP

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By using casting process make the top cup handle which is suitable
for machining. Make some correction the casting for the appropriate
dimension .next make a thread at the lower and upper inner surface
to tighten the cylinder and the reservoir with a metallic thread
arrangement part with 1mm pitch by using lathe machine. Finally
make necessary surface finishing process.

K) O-RING:- o-ring seal made from rubber compound by the process

vocalizations. First make mold for the vocalizations process then,
insert the compound on it.

L) FOR THE RESERVIOR

The reservoir can be manufactured from the sheet metal with the
appropriate thickness. First prepare a sheet metal with appropriate
thickness, width and height. Then, roll the sheet metal by using
rolling machine. Next weld the rolled metal using welding machine
.then make thread at the lower part and the make groove at the
lower and upper inner surface to the required length, width and
height. Finally make a necessary surface finish

M) LINK: - can be manufactured by using sheet metal with the

appropriate length and thickness. First cut a sheet metal in a strip
then drill at the required position for pin connection. Finally bond
with the required dimension.

9) HYDRAULIC SELECTION AND STROKE CALCULATION

A) Hydraulic selection

The hydraulic oil has the following function:-

-It used to reduce the friction b/n the milling surface.

-it used to dissipate the heat developed inside the system

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-it used to clean the hydraulic part

-it prevents the parts from corrosion and so on

Due to the above function and high viscosity at high temperature the
selected STD fluid is called ATF (automatic transmission fluid) and its
designation is as follows

AES-NO10 Part number H008

B) Stroke calculation

In order to get the maximum height of the jack, how many strokes
are needed can be calculated as follow

Number of stroke = volume of the ram/volume of the plunge

But vram =v1+v2 = 847240.415mm3

And volume of the plunger =AxH=πdp2/4xlp = 4712.4mm3

Number of stroke = 847240.415mm3/ 4712.4mm3

= 18

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APPENDIX

TABLE.1

TABLE .2

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References
 Text Book of Machine Design, Gupta
 Text Book of Engineering Material
 Dudly a.pease,basic fluid power(1965)
 V.b bhandari, design of machine element, 2nd
edition, 2007.

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