UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
INTERNSHIP FINAL REPORT

PROJECT TITLE: HYDROULIC SHOPE CRANE

HOISTING COMPANY AMHARA METAL INDUSTRY AND MACHINE
TECHNOLOGY DEVELOPMENT ENTERPRIS (AMIMTDE)

ID
PREPARED BY_ HAILEMICHAEL GASHAW 4563/08
MOGESSIE SISAY 4746/08
SICHALEW MEHARI 4875/08

`
ADVISOR_ MR. NETSANET
 Declaration
This report documentation is fourth-year mechanical engineering students that have taken the
internship experience in Amhara Metal Industry and Machine Technology
DevelopmentEnterprise (AMIMTDE). From a period ofFebruary 24/02/2019 to 10/06/2019
under the guidance of Mr. Solomon (company supervisor).
To certify that work is original and compiled according to the internship report writing guide
line given by the industry linkage office of the institute.

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 Acknowledgment
First of all we would like to thank the almighty God for his unforgettable help in all direction.
We express my thankfulness to God for his blessing and guidance throughout my entire
training. We would like to express our profound to Amhara metal industry and machine
technologydevelopment enterprise which is willing to accept our internship program, for
valuable guidanceand providing necessary facilities and source during this internship
program.

We would like to tanks for university of Gondar for providing such kind of an opportunity
for students to apply their understanding in practical knowledge and improve theoretical
knowledge.
Next to this we give great altitude for our academic advisor MR Netsanet and our for
company advisors.

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 Executive summery
Internship is the program in which the students improve their practical skill in the field. The
main goal of the internship program is to develop the student’s practical skill. With this
internship program, we are able to learn the techniques relevant to our profession as well as
practical work.
This report includes the brief history of the Amhara Metal Industry and Machine Technology
Development Enterprise (AMIMTDE) and its main product as well as its main customers and
the main goal of the company. The report also includes the organizational structure and its
work flow. Finally, we try to do the project in order to solve the problems of the company

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Table of Contents
Declaration........................................................................................................................................i
Acknowledgment..............................................................................................................................ii
Executive summery.........................................................................................................................iii
Chapter one..........................................................................................................................................1
1.1 Background of the hoisting company........................................................................................1
1.2 Enterprise Mission, Vision, Values and Duties and Responsibilities.....................................2
1.2.1 Vision...................................................................................................................................2
1.2.2 Major values........................................................................................................................2
1.3 Objectives of the enterprise.......................................................................................................3
1.4 Shops present in the company..................................................................................................3
1.4.1 Machine shop......................................................................................................................3
1.4.2Sheet metal work shop.........................................................................................................4
1.4.3Welding work shop..............................................................................................................4
1.4.4Foundry shop.......................................................................................................................4
1.4.5Assembly work shop............................................................................................................5
1.5 Product of the company............................................................................................................5
1.6 Main costumer or end users......................................................................................................6
1.7Organizational structure............................................................................................................7
1.8Work Flow...................................................................................................................................8
Chapter two.........................................................................................................................................9
2.1 Internship experience and overall benefits..............................................................................9
2.2 Engineering methods, tools and techniques we used...............................................................9
2.2.1 Methods...............................................................................................................................9
2.2.2Tools used.............................................................................................................................9
2.3Challenges and Problems.........................................................................................................10
2.4 Measure to overcome this challenge and problems...............................................................11
2.5 Overall benefits we gain from internship...............................................................................11
2.5.1 Improving Practical skills................................................................................................12
2.5.2 Upgrading theoretical knowledge....................................................................................12
2.5.3 Improving team playing skills..........................................................................................12
2.5.4 Improving leadership skills..............................................................................................12
2.5.6 Understanding how to be entrepreneurship skills..........................................................13
2.5.7 Improving interpersonal communication skills..............................................................14

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 2.6 Conclusion................................................................................................................................14
2.7 Recommendation.....................................................................................................................15
Chapter three.....................................................................................................................................16
3.1 Summary of the project...........................................................................................................16
3.2 Problem Statement..................................................................................................................16
3.3 Objectives.................................................................................................................................17
3.3.1 General Objectives............................................................................................................17
3.3.2 Specific Objectives............................................................................................................17
3.3.3 Constraints and Design objectives...................................................................................17
3.4 Methodology.............................................................................................................................18
3.5.1 Analysis of Mechanism frame..........................................................................................21
3.5.2 Analysis of Boom Reaction...................................................................................................25
3.6 Material Selection....................................................................................................................27
3.7 Design Analysis the Parts........................................................................................................28
3.7.1 Design of vertical column.................................................................................................28
3.7.2 Design of Boom.................................................................................................................29
3.7.3Fork Analysis.....................................................................................................................31
3.7.4 Design of base plate...........................................................................................................33
3.7.5 Design of long ram hydraulic jack.......................................................................................34
3.7.6Material Selection..................................................................................................................39
3.7.7 Design of Solid Ram..........................................................................................................41
3.7.8 Design of ram Cylinder....................................................................................................43
3.7.9 Design of reservoir............................................................................................................45
3.7.10 Design of plunger cylinder.............................................................................................46
3.7.11 Design of plunger rod.........................................................................................................47
3.7.12 Design of octagonal head top plate................................................................................48
3.7.13 Design of handle..............................................................................................................49
3.7.14 Design of Handle socket..................................................................................................49
3.7.15 Design of handle socket pins..........................................................................................50
3.7.16 Spring design for relief valve.........................................................................................53
3.7.17 Spring design for intake valve........................................................................................55
4.7.17Design of retainer..............................................................................................................57
3.7.18 Design of sealing..............................................................................................................57
3.7.19 Design of the base............................................................................................................57
3.7.20 Design of the releasing screw.........................................................................................57
3.7.21 Design of relieving screw................................................................................................57

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 3.8 Caster wheel selection..............................................................................................................58
Ram.....................................................................................................................................................64
Reservoir.............................................................................................................................................64
Plunger cylinder..................................................................................................................................64
Plunger rod..........................................................................................................................................64
Handle.................................................................................................................................................64
Chapter four......................................................................................................................................65
4.1 Conclusion................................................................................................................................65
4.2 Recommendations....................................................................................................................66
References..........................................................................................................................................67

List of figure
Figure 1 machine shop.............................................................................................................................................4
Figure 2 welding shop..............................................................................................................................................4
Figure 3 foundry shop..............................................................................................................................................5
Figure 4 assembly work shop...................................................................................................................................5
Figure 5 product of company...................................................................................................................................6
Figure 6 challenge and problem............................................................................................................................11
Figure 7 Basic “A” frame gantry hoist (LK Goodwin 2012).................................................................................18
Figure 8 Rose Float gantry hoist, no support of the compression flange..............................................................19
Figure 9 Caster wheel 1650 lbs. capacity (Grainger 2012)..................................................................................20
Figure 10 Jet 2-ton trolley (CPO Jet Tools 2013).................................................................................................20
Figure 11 Jet 3.2-ton hoist (CPO Jet Tools 2013)..................................................................................................20
Figure 12Overall Dimensioning of the hydraulic fork lift ....................................................................................21
Figure 13Mechanism Iteration Elements...............................................................................................................22
Figure 14 vertical column......................................................................................................................................29
Figure 15 boom.....................................................................................................................................................31
Figure 16 fork.........................................................................................................................................................33
Figure 17 base plate...............................................................................................................................................33
Figure 18Working Principle of hydraulic Jack......................................................................................................35
Figure 19Pascal’s Law...........................................................................................................................................36
Figure 20Simplified hydraulic jack........................................................................................................................37
Figure 21 hydraulic jack.........................................................................................................................................58
Figure 22 caster wheel...........................................................................................................................................59
Figure 23 hydraulic shop crane assembly.............................................................................................................63

List of table
Table 1 iteration 1..................................................................................................................................................23
Table 2 iteration 2..................................................................................................................................................23
Table 3 iteration 3..................................................................................................................................................24
Table 4 iteration 4..................................................................................................................................................35
Table 5 Safety coefficients of caster for different usage conditions......................................................................59

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 NOTATION
P = Pitch of the screw
d = Mean diameter of the screw
B = Angle of inclination of the link with the horizontal
= Helix angle
T = Total torque required to rotate the screw
P = Effort applied at the circumference of the screw to lift the load
W = Load to be lifted
= Coefficient of friction between the screw and nut
= tan where is the friction angle
Wcr = Critical load
= Yield stress
= Shearing permissible stress
= Tensile permissible stress
L = Length of screw
K = Least radius of gyration
E = Modulus of elasticity
n = Number of threads in engagement
dc = Core or root diameter of the screw
do = Outer or major diameter of the nut screw
d = Mean diameter of screw
pb = The bearing pressure on the threads
Fs = Factor of safety
K = Radius of gyration
I = Moment of inertia

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 Chapterone

1.1 Background of the hoisting company

The Amhara Metal Industry and Machine Technology Development Enterprise (hereinafter
called “AMIMTDE) is an autonomous government development enterprise established by the
Council of Regional Government on November 28, 2004 with the regulation Number
127/2014 intending to create and build up one strong metal engineering centers in the region
which carries out the tasks of manufacturing and commercializing metal and machine
technology products so as to alleviate impediments in technology supply and utilization
within the manufacturing industry and agricultural sector.

To realize the technological development in the Region, AMIMTDE has premeditated to

work with researchers and industrial partners. It works in collaboration with the research
centers, colleges and universities in order to advance the knowledge in a particular field or to
improve the given technology one step ahead. It also provides an integrated industrial
development support, training and counseling service for those private investors,
cooperatives, micro and small-scale enterprises and other stakeholders engaged in the
technology development sectors.

AMIMTDE works focusing on copping and adapting appropriate technologies. Evaluating

each technology for technical merit, commercial opportunity and state of appropriateness, it
implements the design development, production of prototypes and then harvesting it,
consecutively, for those feasible and selected technologies. The mass production operation
for verified technologies will be carried out through outsourcing and own capacity. The large
amount of production is intended to be manufactured through outsourcing with critical follow
up and quality control process, how each part of the technology is performed per proposed
functionality regarding capable of being made economical and to be attractive for the targeted
consumers.

In the long run when its technical and financial capacity increases, AMIMTDE will
participate on heavy and advanced technologies. Hence, on the current situation, its operation
is limited to the light and medium scale metal and machine technologies under metal
engineering division. Based on this direction, to increase production and productivity all over

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the region the enterprise is working focusing on seven metal manufacturing sub programs.
Thus are;

1. General Equipment manufacturing sub program,

2. Agricultural machinery manufacturing sub program,
3. Food processing and packaging materials manufacturing sub program,
4. Main machinery parts manufacturing sub program,
5. Construction equipment manufacturing sub program,
6. Transportation of manufacturing Equipment sub program
7. Environmental protection equipment manufacturing sub program.

In addition to these technology programs, the Enterprise will participate in shade construction
of steel structure, plant installation and maintenance services, consulting and training,
commissioning and preparing machine specifications based on customer requests.

The enterprise comes to operation since the 4th quarter of 2008 EFY after Bahir Darand
Kombolchacitybranches of Agricultural Mechanization Research Centers have been
transferred into the enterprise by the regional government decision on December 1,
2008EFY. The human and material resources in the two mechanizations used as an engine to
start its technology development in the existing workshops. Moreover, these workshops are
used to capacitate the skills of engineers and produce prototypes that are going to be used in
the new manufacturing factories besides to generating revenues.

The enterprise is now found on project implementation phase. Four factories, such as,
General flexible manufacturing factory, foundry plant and transformer maintenance plant at
Bahir Dar site, and farm implement factory at Kombolcha site, are on construction process.

1. Related to the organizational structure, the enterprise on the top is managed and
supervised by the Board. The Chief Executives, there are the General Manager, and
the two Deputy General Managers. Under these Chief Executives, there are five Core
Processes, two Manufacturing units and five Support Processes. The number of
permitted man- power for the organizational structure is 480 which may increase
along with the growth and expansion of the enterprise in the future.

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1.2 Enterprise Mission, Vision, Values and Duties and Responsibilities

Maintain, produce market and import metal and machine technology to market the world's
largest technology and manufacturing industries which will challenge the agricultural and
industrial technologies of the world and ensure stable institutional growth.
1.2.1 Vision

 be one of Africa's top 10 technological capabilities by 2017

1.2.2 Major values

While all ethical codes are preserved, we focus on the following values.

 We are passionate about our customers.

 Our employees are the heart of our business

 We are committed to deliver exceptional values.

 Profitability is the core of our business.

 We build trust and act with honesty

 We believe in working together as a team and as a partner.

 We never stop learning and growing.

 We respect the environment

1.3 Objectives of the enterprise

The General objective of the enterprise is to full fill the gaps of technology requirement
among

 Manufacturing Industry,
 Agriculture Sector, Micro and Small enterprise in terms of product and service.

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1.4 Shops present in the company

1.4.1 Machine shop

A machine shop is a room, building or company where machining is done. In a machine shop
machinist use machine tools and cutting tools to make parts, usually a metal. The production
can consist of cutting, shaping, drilling, finishing, and other process.

The machine tools typically include metal lathes, milling machines, grinding machines etc.
The products in the company’s machine shop include worm and

Worm gears, screws, shafts,

Figure 1 machine shop

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1.4.2Sheet metal work shop

It deals with working of thin sheets with hand tools and simple machines into various cutting
forms by cutting, forming into shapes, bending, rolling etc. Machines in sheet metal shop are
hydraulic shearing machines, bending machines, rolling machines etc. In sheet metal shop
different shapes by bending, rolling and shearing the sheet metal.
1.4.3Welding work shop

Welding shop is a place where joining activities are done. Welding involves localized
coalescence or joining together of two metallic parts at their faying surfaces. The faying
surfaces are the part surfaces in contact or close proximity that are to be joined. Welding is
usually performed on parts made of the same metal, but some welding operations can be used
to join dissimilar metals. Welding provides a permanent joint. The welded parts become a
single entity.

Figure 2 welding shop

1.4.4Foundry shop

A wood shop is a shop where machining of wood can be performed. In our company, the
machines present in the wood shop are band saw machine, jointer machine etc. In this shop,
the company produce different patterns for the purpose of casting in order to reverse the
machine components according to the customer questions.

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 Figure 3 foundry shop

1.4.5Assembly work shop

Mechanical assembly uses various methods to mechanically attach two (or more) parts
together. In most cases, the method involves the use of discrete hardware component called
fasteners, which are added to the parts during the assembly operation.

In our company’s assembly shop, assembling and finishing activities are performing. For
example: painting, assembling of car bodies etc.

Figure 4 assembly work shop

1.5 Product of the company

Amhara National Regional State Metal Industry and Machine Technology Development
Enterprise were established to meet the gap of technology requirement among Manufacturing
Industry, Agriculture Sector, Micro and Small enterprise in terms of product and service.
Generally, the products of the company are not constant, because the products are mainly
depending on the needs of the customers. Currently the company produce different product

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based on reverse engineering techniques. Such technique is important for developing country
to produce different spare part and machine components.

The main current products of the company are:

 Industry park shade

 Car parking and shade

 Fish feed pelletizer machine

 Pipe bender

 Manual bar cuter

 Seed cleaner

 Screw type lift table truck without hydraulic pump

 Thresher machine

 Pressure vessel

 Concert level

Different equipment’s for building an industry park

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 Figure 5 product of company

1.6 Main costumer or end users

The company supplies its products to the local markets at reasonable price striving to satisfy
the requirements of its customers. The above products that produced in the company are
selling to local customers. For example

 Industry park shade

 car parking and shade for Amhara regional state administration

office
 mixer and fish feed pelletizer machine for Bahir Dar University
 Agricultural machineries for rural society like maize Sheller.
 Different Industry parks colon, beam and its part

1.7Organizational structure

Board of Director

General Manager xv
 Law Services
Deputy Manager Audit ICT Planning
Service

Deputy Manager
Marketing Deputy Manager
Exposure and
purchasing
Technology Quality Control
process
Development and assessment Purchasing
and Marketing process procurement, Human
preparation Preparation for finance and resource
marketing property
Agricultural development coordinator management
design Coordinator process

Product sales
Industrial development Finance
coordinator
design coordinator coordinator

Purchasing
Biophysical economic Industrial input coordinator
research coordinator purchasing
coordinator
Property
Marketing preparation Management
coordinator coordinator
Product specific factory
General
Workshop
Metal product and
Wood shop machine coordinator
coordinator

Assembly coordinator

Electrical and electronics coordinator

Machine Installation

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1.8Work Flow

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 Chapter two
2.1 Internship experience and overall benefits

Internship program is very nice program to introduce student with the real world.
participating in this program makes us to know what the working environment looks like,
helps to introduce ourselves with the industry’s enables us to know the practical way of what
we learn, enables us to get awareness for the task that wait us after graduation, etc. are the
important of internship for all of us.

2.2 Engineering methods, tools and techniques we used

Methods, tool & techniques are vital to the success of any project.

2.2.1 Methods
Method is way of doing something in a systematic way. Here “systematic” implies an orderly
logical sequence of steps or task. Technique is a specific approach to efficiently accomplish a
task in a manner that may not be immediately obvious. In this section, all work tasks are
performed according the standard instruction manuals formulated by Company. And these
guidelines contain many mechanical engineering methods and techniques. Among these
methods we try to list some of them below:

Some of the mechanical engineering techniques and methods are:

 Safety: All mechanics and cleaners in this section wear a standard

safety shoe which can hold high load that might cause damage to foot
fingers. The company also provides a standard work wearing and
putting a rule that all mechanics should wear at work with gloves.
Also, each mechanics have their own table and box for putting their
own work tools.
 Cleaning: For a good service and maintenance a good cleaning is
needed from engineering point of view.

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2.2.2Tools used

Tools used in AMIMTDE during our intern program are:

 Hand tools

 Pullers

 Trolley

Hand tools: as we know in many local garages there are so many hand tools to repair and
maintain machine and vehicle, and this equipment’s are called by not their English names
rather most mechanics use Italian names

Pliers: are so many pliers in garage and each has their own purpose some of them are listed
below

 Combined pliers

 Snap ring pliers

 Single nose pliers

2.3Challenges and Problems

There are different problems that have been faced during machine operation installation,
those are

 There are challenges and problems we have been facing while

performing our work tasks. Some of the employers are not willing to
work with us.
 There are some machines which are placed outside the workshop that are
exposed to the sun and rain which cause corrosion and other defects.
 Also manufactured products are staying outside the shop are exposed for
weather condition and dust until the customer buys them.
 In the store the raw materials, tools or equipment’s are not arranged
orderly i.e. kaizen is not applied. There were some staffs that were
blocking the existing profiles of the factory due to miss understanding of
the intern ship programs

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  There has no technological machine or lifts to move equipment’s and
machines to arrange in its position
 There is lack of coordinator in the installation team, this leads to change
the idea and take more time to decide where this machine has been sets

Figure 6 challenge and problem

2.4 Measure to overcome this challenge and problems

 We try to communicate to the employer, team leader and

monitor in order to working together.
 For the machines which are placed outside the work shop, we
tell to the manager to prepare temporary sheds.
 We discus to the manager to apply kaizen for disordered
materials and give training about kaizen for company
employees.
 Even though there were very few factory workers who hide the
company profile, we approached smoothly to other volunteer
workers to get the required information.

2.5 Overall benefits we gain from internship

In these four months internship experience, we have got much skills, knowledge and higher
confidence about many things. Generally, we have got such benefits in terms of:

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  Improving Practical skills
 Upgrading theoretical knowledge
 Improving team playing skills
 Improving leadership skills
 Understanding about work ethics related issues
 Understanding how to be entrepreneurship skills
 Improving interpersonal communication skills
2.5.1 Improving Practical skills

During our internship time we have been trying just to know new things in order to get new
practical knowledge. In machine installation, we gain that how machine is installing and
different installation requirement to prevent the machine from any failure.

We have been familiar for solid work software and design and modeling of different machine
part using solid work. This is the base to design any machine and prepare flow chart for
manufacture process.

In addition to this we know that how one machine can be design using solid work and prepare
drafting of the component using solid work software.
2.5.2 Upgrading theoretical knowledge

In internship program we have get the opportunity to apply our theoretical knowledge in real
world environments. Frankly speaking, our theoretical knowledge got strengthen more by
those practical techniques invested on this internship.

This internship period was a good filed to read about real world problems how to solve it in
engineering departments. Therefore, we gained the following essential things:

 Creative and logical approach to solving problems

 Clearly understand different machine devices working principle and mechanism
 Understand and practice how machine are design and manufacture
 Able to apply our basic knowledge to design and modeling of screw type lift table
truck without hydraulic pump.

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2.5.3 Improving team playing skills
Team work, especially for engineers is important and involves in every piece of task. Thus,
gaining good team playing skill has been essential for effective completion of the given task.
As team member someone contribute a lot in many ways to improve individual
communicative knowledge of solving the existing problem. Because of these team members
we can improve the following attributes:

 Ability of problem identification for solving those problems

 Selecting the most appropriate method to solve the existing problem.
 Generating or forwarding flexible permissions to solve the problems raised.
 A good decision maker.
2.5.4 Improving leadership skills.

A person who is in the position of leadership should be smart enough to manage those
individuals whom he/she is leading Leadership is a skill to guide, control and monitor people.
This shows that we take a lot of experiences from their leading. They control each employee
in their day to day activities. That means we got the chance to saw the strength and weakness
of each leader. We have gained the following benefits which improved our leadership skills:

 Committed to the work

 Understanding others idea
 Peaceful with others
 Upgrading with knowledge etc.

2.5.5 Understanding about work ethics related issues

Ethics is a branch of philosophy that defines morality and determines the meaning and
rational justification of the right way to live, correct values as well as correct ways of treating
others. As workers wear made to specialize in different fields, specific codes of conduct were
expected from each worker. Ethical work conduct enables me to posses’ appropriate
behaviors in our work and so as to develop proper relationships with co-workers and it helps
us to create good relationships.

By working in this company, we also gain understanding about industrial psychology which
is a very important tool for the success of the company:

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  Punctuality
 Office disciplines
 Reliability
 Honesty
 Cooperative
 Good leadership
 Self confidence

2.5.6 Understanding how to be entrepreneurship skills

Entrepreneurship can be defined as the process of involving the creation of new enterprises
and that the entrepreneur is the founder. The major characteristics of entrepreneurs that we
have been observed in this internship include the following:

 Self-confident multi-skilled
 Results-orientated
 A risk-taker
 Total commitment.

The most important skills we gained from this internship include:

 Provides work experience in a field of interest.

 Provides a "real life" experience with a short-term commitment.
 Strengthens background in field of choice.
 Creates the potential for future work with the company.
 Develop our communication skills.
 Deal with real life people (human interaction).
 Acquire problem solving skills and how to assess and analyze situations
correctly.
2.5.7 Improving interpersonal communication skills

During the internship period we recognized that team work is necessary for a given task to
be an accomplished early and qualitatively. Individuals often learn different things from
colleagues’ through communication. For any individual’s communication is an important
way of learning, which can be defined formally as the act, process, or experience of gaining
knowledge or skills. Communication and the subsequent learning help individual especially

xxiii
engineers more allow them to gain new professional knowledge and abilities. Good
communication is the life hood of the engineering profession. Even though, it takes many
forms, such as speaking, writing and listening, it has the following usage:

 To exchange new ideas and knowledge with the other

 Improve to build up self confidence
 It improves our speaking and listening skills
 Improve relationships with the other

2.6 Conclusion
This internship report contains the overall experiences that gain from the internship program.
Concluded that the program is very good to know the real-world life and work way
comparing with class study subjects.

The internship was successful by acquiring sufficient knowledge and practical skills. Here
during this period (as an intern) the hosting company satisfied with the activities of our
performance spatially theoretical understanding in every moment.

On the internship period, have understood so many skills that was the job environment and
what it meant to be a worker, what and why ethics we need to have at the work place and
outside. It was also very effective in developing team playing, interpersonal and leadership
skills.

Generally, get satisfactory knowledge and more benefited at internship period. This
internship program is real, necessary and important to Mechanical engineering students

2.7 Recommendation

Recommendation for Amhara metal industry and machine technology development enterprise
Amhara metal industry and machine technology development enterprise is a well establish
and develop different machines and parking. However, we would like to recommend it based
on our observation while we were conducting the internship program. Thus,
recommendations are as follow:

 The company should be ready for internship students by preparing project tasks and
motivations to achieve this internship program.

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  There is no research and development department, this cause the workers to have less
sense to upgrade their knowledge and improve this company
 The company worker is considered that internship students are not perform any task
and they are not known in the company
 The company must be managed and arrange the time to do different task in rotation,
rather than perform single task during internship period

Chapter three
3.1 Summary of the project

This project presents the design of hydraulic lifting machine. It is driven by small human
power. The main component of hydraulic lift is hydraulic jack, metal structure such as post,

xxv
boom, base, support, and fork also for machine raise up for needed height we use jack. In
AMIMTDE we design manually operated hydraulic forklift to raise and transport plate,
welding product of the shop to the assembly shop and transport to factory product store.

This project designed for

 To save time, money and space

 To easily operate and maintain
 To decrease number of educated workers on one
operation

 The product should be light enough to easily move

around.

 The product must have minimal cost.

3.2 Problem Statement

Ethiopia’s aspiration to be among the world’s industrialized nation may not be met unless
adequate and endogenous workshop equipment is deployed to supplement imported ones in
all its maintenance and production shops. The number of forklift vehicles imported in to
Ethiopia is growing annually. Repair and maintenance of these forklift vehicles are regular
and must take place for their continued operation. This informs the reason for the ever-
increasing number of such as welding, Sheet metal, machine automobile repair shops in the
country. Most shops however are grossly unequipped for proper handling and job execution
in the shops. So, in order to keep up with this increasing number of forklift vehicles, proper
material handling equipment’s should be used in each and every shop to reduce the
manpower and working time, providing safe operations to increase the efficiency and quality
of repair and maintenance process.

Handling of heavy objects is a daily activity in most machine shops, welding and fabrication
workshops and with the consistent maintenance need to mount heavy objects in machines,
overhaul motor vehicle engines once in a while, handling of such heavy objects or engine
has become a major problem in operational/automobile workshops, occasioning
musculoskeletal injuries at most times where humans directly handle the carriage and
installation of the vehicle engines and axles. That machining, welding and fabrication and
auto mechanics work are laborious is a common saying born from the fact that most carriage

xxvi
and handling jobs in most workshops are purely manually executed. Motor vehicle repair and
maintenance often require the lifting of the entire vehicle or sub-assembly part of it or the
lifting up and down of its heavy components. Also, in other industries and welding shops,
there are items and repairs which need the employment of shop cranes. The lack of shop
crane utilization in our industries and automobile repair shops not only leads to injury and
accident but also to poor repair and maintenance. There are however few shops who have
shop cranes. These shop cranes are imported at exorbitant cost and as such not within the
reach of most operational/automobile workshops. In recognition of this need, this project
intends to design and develop a made in Ethiopia, affordable shop crane.

3.3 Objectives
3.3.1 General Objectives
 The general objective of the intern ship project is to design and produce portable and
moveable lifting crane to lift heavy loads that is beyond the capacity of human being
applying only small force in the production machine shop, Design and analysis of safe
and reliable hydraulic shop crane for a 2ton load.

3.3.2 Specific Objectives

 To design analytically the portable lifting machines lifts slightly heavy objects that
can’t be carried by single worker
 To design a product that is easily maintained by the user if it’s needed and with as few
parts as possible
 To minimize cost expenditure for fuel that is made for operating fork lift in
transporting every component in the production shop
 Specifically, in bus production factory to minimizes wastage of time due to each
station should wait for a single crane for lifting
 To produce the working prototype of portable, moveable crane for the production
shop
 Finally, to documentation of internship project

3.3.3 Constraints and Design objectives

 The design must be able to lift a 2ton load.
 The boom must be long enough to reach and support the load.
 The crane must be foldable, to save floor space will not in use.
 The hoist must be tall enough to reach into standard size cars and trucks.

xxvii
  The product must be able to move through a specified range of operating heights.
 The product should be light enough to easily move around.
 The product must have minimal cost.
 The hoist must be durable.
 The design must be able to be produced easily and with as few parts as possible.

Business plan must be prepared for the designed hydraulic shop crane

3.4 Methodology

The methodology incorporated in design and development of portable crane in the production
shop of AMIMTDE Industry is indicated as follows;

 Data source identification, collection and analyze;

Observation in different shops such as; Welding shop, Sheet metal shopetc.…….

 Development of suitable system configuration

It should have moveable wheel attached base, hydraulic link, basic vertical column, and
connections

 Design analysis of each components of the portable crane.

 Development of working crane condition in solid work application.

LITERATURE REVIEW

LK Goodwin CO. is a material handling Equipment Company that sells many types of
hoist’s and cranes for certain applications. Looking through their list of portable hoists, a 2
ton has a cost around $2500 for a non - adjusting height crane and would have an equivalent
rating to the one being designed. These hoists come with casters but the trolley and chain
hoist must be purchased separately. Below is an example of a basic portable gantry hoist
design.

xxviii
 Figure 7 Basic “A” frame gantry hoist (LK Goodwin 2012)

This design is relatively easy to assemble while it is lying down but would most likely require
two people to stand up. Using two people to stand up the hoist after assembly seems to be an
unavoidable factor in the design. The Cal Poly Rose Float club has a gantry hoist (3 ton
Capacity) which was quickly examined to get a different idea of how the column and frame
could be designed. After looking at the frame it was easy to see that the legs were designed
poorly; they were built with 3”X6”X3/16” rectangular tube which is strong but the “A” frame
design means the legs will start deflect due to the resolving bending moment and the
rectangular tube was oriented to bend about its weaker axis seen in Figure 2. This also allows
for someone to be underneath the frame when it could potentially fail making it a severe
safety hazard. The hoist beam is an S15X42.9 and spans around 26ft without support of the
compression flange making its Lb.value 26ft as shown in Figure 2. Adding support (drawn in
Figure 2) would reduce the travel of the trolley slightly but would improve the overall safety
of the design by reducing the beam’s Lb. value. This is a very long length to span without
supporting the compression flange and using the AISC Steel Manual page 3-82 the beam’s
Lp=4.41ft and Lr=16.8ft. Since Lb.>Lr the critical force Fcr was calculated and found to be
15,100 lbswhich means the 3 ton capacity is allowable.

xxix
 Figure 8 Rose Float gantry hoist, no support of the compression flange

Grainger has a large selection of casters with a wide range of load bearing capacities.
Grainger Item # 1NVT6 is a swivel caster with a rating of 1650lbs/caster making it a possible
choice for this design. Using four casters would be able to hold 6600lbs which would satisfy
the assumed 2 ton desired load capacity.

Figure 9 Caster wheel 1650 lbs. capacity (Grainger 2012)

They run about $66/caster which seems typical for casters above 1500lbs. The caster wheels
will be the limiting factor for this hoist and they will determine the load capacity that will be
printed on the side. The trolley chosen was a JET 2 ton manual trolley; this trolley is meant
for beams from 4-8 in width. The hoist is designed for 4000 lbs so the 2 ton trolley will meet
the capacity required for the design and will be compatible with the hoist since they are the

same brand.

xxx
 Figure 10 Jet 2-ton trolley (CPO Jet Tools 2013)

The AISC Steel manual will be the book used to help calculate the maximum load the beam
available can handle and how much the beam will deflect with the assumed load on it. The
compression flange is the main factor to design around when using a beam whether it is an
“S” or “I” beam. This can also be used for the column calculations to find what point load
will cause the columns to buckle. Shigley’s Mechanical Engineering Design book shows how
to calculate the loads on the beam supports and gussets along with the Mohr’s circle to
find the max shear and normal stresses. This will help find the Factor of Safety for the frame
of this design.

Figure 11 Jet 3.2-ton hoist (CPO Jet Tools 2013)

3.5 Design Analysis

3.5.1 Analysis of Mechanism frame
To start analyzing the mechanism, first let us give overall dimension to the crane. But from
our specification, the maximum height of the crane tip from the base structure while carrying
a load of 2ton is given to be two meters. Since the load is very heavy, the post should be
strong enough to support the load. If it is a simple vertical frame, it might not be able to
support the load required adequately, but if an inclined post with supporting vertical structure
was chosen, the support will be much stronger and more reliable. Thus, an inclined post was
chosen over the vertical.

xxxi
 Figure 12Overall Dimensioning of the hydraulic fork lift

Now, assuming the inclination of this post from the base structure to be, 75o and its length to
be 1.25 meter, we can determine how much of height it provides to the total vertical height of
the crane by using trigonometric relations as follows.

¿>1.25 m ×sin 75=1.207 m

Thus, the other 0.793m should have to be provided by the boom structure in order to achieve
the maximum vertical height, which is 2 meters.

Therefore, let us determine the length ‘L’, by assuming the fulcrum length, r 1=0.2m and the
angle of inclination of this fulcrum from the horizontal at the specified maximum height to
be, θ=50°. Now using trigonometric relation,

r 1 sinθ+ Lsinω=0.793 m

0.793 m−r 1 sinθ

Now solving for L , L= , but [ ω=90−θ ]
sinω

0.7926 m−r 1 sinθ 0.7926 m−(0.2× sin 50)

L= =
sin ( 90−θ ) sin ( 90−50 )

xxxii
L=0.995m ≅ 1 m.

Now that the boom length has been determined, we can decide the best extended length of
hydraulic ram by iterating the values r2, r3, r4 and r5.

Assumed value ranges for the variables

 r 2=[900 mm−1100 mm]

 r 3=[60 mm−90 mm]
 r 4 =[300 mm−500 mm]
 r 5=[30 mm−50 mm]

Figure 13Mechanism Iteration Elements

Therefore, let us determine the equation for the

extended length of the hydraulic ram using
trigonometric relations as follows.

i. Determine length ‘a’ from triangle ‘1O5’.

We know that, r 1=200 mm∧θ=50°

But, β 1=θ+ 90° +15 °=50 ° +90 ° +15 °

xxxiii
 β 1=155 ˚

Appling trigonometric relation for two sides and the angle between them known to the
triangle,

r 2 sin β 1
tan β 2=
r 1−r 2 cos β 1

r 2 sin β 1
β 2=tan
−1
( r 1−r 2 cos β 1 )
r 2 sin 155 °
β 2=tan
−1
( 200−r 2 cos 155 ° )
Table 1 iteration 1

r2 900mm 1000mm 1100mm

β 1(°) 155 155 155

β 2(°) 20.53 20.91 21.22

From the iteration table we select: β =21.22° and length of r2=1100mm

β 3=180 °−( β 1 + β 2 )

β 3=180°−( 155 ° +21.22 ° )

β 3=3.78 °

Applying cosine law to the triangle,

a=√ r 12+ r 22−2 r 1 r 2 cos β 1

a=1284.05 mm

ii. Determine length ‘b’ from triangle ‘125’

xxxiv
Now that we have calculated the length ‘a’ we can solve the next triangle to find the rest of
the angles and the length ‘b’.

Two angles and the angle between them known

r 3 × sin ( 90+ β 3 )
tan β 4 =
a−r 3 cos ( 90+ β 3 )
Table 2 iteration 2

r3 60 mm 75 mm 90 mm

β 3(°) 3.78 3.78 3.78

β 4(°) 2.66 3.32 3.98

From the iteration table select r 3 and β 4 90 mm , 3.98° respectively

Then

β 5=180 °−¿ )

β 5=¿82.24°

Now, applying sine law to the triangle,

b r
= 3
sin ⁡( 90+ β3 ) sin β 4

r 3 × sin(90+ β 3 )
b=
sin β 4

b =1293.85mm

iii. Determine length ‘c’ from triangle ‘543’.

Applying Pythagoras theorem to the

triangle,

C=√ r 42 +r 52

r5
sin β 6=
c

xxxv
β 6=sin−1 ( rc )
5

β 7=−β 6 +90

Table 3 iteration 3

r4(mm) 300 300 300 400 400 400 500 500 500

r5(mm) 30 40 50 30 40 50 30 40 50

c(mm) 301.50 302.65 304.14 401.12 401.99 403.11 500.90 501.60 502.49

β 6(°) 5.71 7.59 9.46 4.29 5.71 7.13 3.43 4.57 5.71

According to the iteration, from the above we select

r 4 = 300 mm

r 5 =40 mm

c =302.65mm

β 6=7.59°

so, β 7=82.41 °

iv. Determine extended

length of the

hydraulic ram
( Lext )

from triangle ‘235’.

γ 1=α −( β 4+ β6 ) ,

but α= β2 +90 °

α =¿111.22°

xxxvi
γ 1=90 ° + β 2−( β 4 + β6 )

γ 1=97.78 °

Appling the trigonometric relation for two sides and the angle between them known to the
triangle,

b ×sin γ 1
tan γ 2=
c−bc osγ 1

γ 2=¿ 69.5°

γ 3=12.72 °

by cosine law:

Lext 2=c 2+ b2–2cbcosγ 1

Lex =1368.608mm

3.5.2 Analysis of Boom Reaction

From our specification the maximum height to be achieved while carrying a 2ton load has
already been decided to be 2m, thus the weight load (W) will be,

xxxvii
W =mg=2000 Kg∗9.81m/ s2=19620 N .

Taking moment about point A,

i.e. Σ M A =0 ,

[(−F c∗cosϕ)∗(0.2−0.04 )]+ [(−F c∗sinϕ)∗0.3 ] + [(−Wcosθ )∗0.2 ]+ [ Wsinθ∗1 ] =0

But from our Iteration we know the values of angle ϕ and θ to be 61.94° and 50 °
respectively.

Inserting back this value in the above moment equation,

−F c∗0.34−2522.3+15029.8=0

F c =36786.76 N

Take the summation of forces along the x-axis

i.e. Σ F x =0 ,

−Fpin x + F c cosϕ – Wcosθ=0

Fpin x =F c cosϕ−Wcosθ=36786.76 ×cos 61.94 °−19620 ×cos 50 °

Fpin x =4692.85 .16 N .

Take the summation of forces along the y-axis,

i.e. Σ F x =0 ,

−Fpin y + F c sinϕ – Wsinθ=0

Fpin y =F c sinϕ – Wsinθ=36786.76× sin 61.94 °−19620 ×sin 50 °

Fpin y =17432.88 N .

Therefore, the resultant pin reaction force, Fpin will be,

xxxviii
Fpin=√ Fpin x 2+ Fpin y 2=√ 4692.852❑+17432.882

Fpin=18053.48 N

The angle,ψ of this resultant force from the x axis can be found as follows,

Fpin x 4692.85
tanψ = = =0.269
Fpin y 17432.88

ψ=tan−1 ( 0.269 )

ψ=15.06 o

Since we are designing the equipment for various capacities, let us now determine the

1
maximum possible length of the boom for 1 ton. From our 2ton analysis we have already
2
determined the maximum force applied by the hydraulic ram to be, F c =65828.91 N .

W 1=mg=1500 Kg× 9.81 m/ s2=14.715 kN

Taking moment about point A,

i.e. Σ M A =0 ,

[(−F c∗cosϕ)∗(0.2−0.04 )]+ [(F c∗sinϕ)∗0.3 ]+ [(W 1 cosθ)∗0.2 ]−[ W 1 sinθ∗L1 ]=0

Now solving the equation for L1,

L1 =
[(F c∗cosϕ)∗( 0.2−0.04)] + [(W 1 cosθ)∗0.2 ]+ [ ( Fc ∗sinϕ)∗0.3 ]
W 1 sinθ

But we know the values of angle ϕ and θ to be 61.29° and 50° respectively.

Inserting back this value in the above equation,

L1=¿ ¿

L1=1.28 m

xxxix
Following the same procedure, we can again determine the maximum possible length of the

1
boom for 1ton and ton to be L2=1.83 m∧L3=3.5 m respectively.
2

3.6 Material Selection

Material selection is a means of selecting material that best suited for the member of machine
to be designed. As a designer material selection should be done carefully in order to design
each component that will serve till the end of service life. The basic considerations done in
selecting materials are; Strength, Machinability, Toughness, Ductility, Hardness…etc.

for each components of the crane.

 Material for vertical column (Post)

Load that the vertical column subjected to is compressive, and material for the column is
selected to be cast iron, because it has low cost, good casting, and high compressive stress. It
is primarily made of carbon and iron with carbon content of 1.7% to 4.5%

 Material for the boom and base plate

Since the load applied on these components is high the material used to make these
components should be strong and hard, thus the best material suited for is steel which has
carbon content of up to 1.5% which results in an increased strength and hardness.

 Material for Bolt

The material for the bolt is subjected to tensile and shearing stress and mild steel best fit the
criteria to resist these stresses and is selected as a material for bolt.

 Material for the Pins

In our project pins are subjected to tensile and shearing. The material selected for the pin
should be ductile and we have selected mild steel

xl
3.7 Design Analysis the Parts
3.7.1 Design of vertical column

Vertical column is modeled as a strut or short compression member thus it is exposed to a

compressive stress and this stress is the sum of simple stress component and flexural
(bending) components [2].

σc =Pvc/A(1+ec/k)
Therefore: c=0.15m/2, e=1.6m
The column cross section subjected to compression stress is

The area of column cross section A= [(0.15×0.13) - (0.116×0.136)]m^2

= 3.724×10^-3m^2
• Moment of Inertia
Iyy = [0.13×(0.15)3−(0.116 × ( 0.136 )3)¿/12
−5
=1.22×10 m 4

Ixx=[0.15×(0.13)3−¿ /12

−6
=9.77×10 m 4

xli
NOTE: Buckling always occurs about the axis having minimum radius of gyration or least
moment of inertia, therefore in our case buckling occur along horizontal direction (Ixx).

K=
√ Ixx = 0.977 × 10−5 ×103
√
A 3.724

=5.12×10−2 m

σc =Pvc/A(1+ec/k)

m
P =2000Kg× 9.81
s2

=19620N =19.62KN

PVC=P/cos15°=20312.32 N=20.31 KN

0.075
A(1+ec/k) =3.724×10
−3
(1+1.6 × 0.0512 )
0.075
σ c=20312.32N/3.724×10
−3
(1+1.6 × 0.0512 )
σ c = 736.013MPa

→ Referring to text book of machine design by KHURMI and GUPTA, the maximum value
of crushing stress (c) that will develop in cast iron is given to be 400MPa to 1000Mpa. Since
the induced compressive stress due to the applied load is not greater than the maximum
crushing stress developed in the cast iron. Therefore the vertical column is designed safe.

xlii
 Figure 14 vertical column

3.7.2 Design of Boom

Boom analysis
The boom is the support beam that is used to raise and lower the load to a desired height. It is
very similar to a lever arm with the fulcrum placed at one end. Within the boom is the pinned
pivot point, the pinned cylinder point, the pinned lift point, and an extendable arm. The
pinned pivot point is the attachment point between the boom and the post. It acts as the
‘fulcrum’ on a lever arm. The pinned cylinder point is the point of attachment for the
hydraulic cylinder. It acts as the ‘force’ on a lever arm. The pinned lift point is the point that
the load is attached to. It is the point where the ‘load’ is applied on a lever arm.

The boom design of the assembly is what holds the weight being lifted. It must be structurally
sound to lift, maneuver, and withhold any extra forces that may be factors while the machine
is in use. From here, the weight will be pushed, lifted, lowered, and swung around. Since the
beam will be used for hoisting objects, it needs a mechanism to fix itself to the lifted objects.

A load of 2ton was placed on the right end. The points where the hydraulic cylinder would be
placed was fixed in the y-direction, and the pinned end that attaches to the post was
constrained in all directions

The boom is modeled as simply supported beam, and it is subjected to a bending stress due to
bending moment developed at the fixed end where it is pinned with the vertical column.

Where:

xliii
  Z = section modulus
 M = Bending Moment at point
 b = Bending stress

Since the boom is hollow rectangular cross section, the area of boom to which the effect of
load P induces the stress is:

A=1m(0.12m-0.108m) =0.012m^2

 Moment of Inertia

Ixx=1(0.12¿ 3 ×0.108 ¿/12

=1.55524×10−5 m4
 Distance from neutral axis extreme fiber (c), is;
c = 0.12/2m =0.06m

Section Module(z)

Z = I/c, 0.000015552m 4 /0.06m

Z = 0.0002592m^3

Bending Moment M is;

M=P× L , L=length of boom

M=19.62KN ×1 m=19.62 KNm

M
σb = = 19.62KNm/0.0002592m^3
Z

induced bending stress (σ ) = 75694444.44N/m^2 = 75.6944MPa

xliv
NOTE: The material selected for the boom is standard steel Fe E-520-Indian standard
designation, and it has a minimum yield stress of 520Mpa and the allowable bending stress is;

𝞂b = Sy/n

n = factor of safety – which is assumed to be 4

𝞂b = 520MPa/4

= 130MPa

Since the allowable bending stress developed is greater than the induced bending stress due to
the load applied, then the boom is designed safe.

Figure 15 boom

3.7.3Fork Analysis

Forklift loading parts are responsible for picking up the load and carry it during the
transportation. In this process, there are two kinds of failure: sudden fracture due to the heavy
load and fatigue fracture due to the vibration caused by uneven ground during the
transportation. We will do stress analysis targeting both conditions the maximum loading
capacity of this forklift is 2000kg.So we will apply 2000kg external load to carry all analysis
here. Forks Stress Analysis this section covers both the static and dynamic (due to fatigue)
analyses of the forks.

For the static analysis, we already got the result that the maximum loading capacity of this
forklift is 2000kg. 2000kg convert to force is about 19620N. There are three forks and the
structure are symmetrical, so each one of them will carry 33.3% of the force, which is 6540N

xlv
Since the top of the fork will be attached to a bar from support frame, so we will fix the top of
the fork as its boundary condition,
3.7.3.1Stability Triangle & Tipping over

The most important consideration when designing a forklift is the safety issue, while the
crane is doing the loading and moving. The forklift’s stability system consists of 3 points of
contact: 2 front wheels and the center of the rear axle for a 4-wheel forklift, or the rear steer
wheel on 3- caster. Without these 3 points of contact, the forklift could not even safely sit on
an uneven ground

700 ×550 ×100 over all dimension of fork in cm

Case 1: By considering fork as a cantilever beam with point loading.

Fig. 9Deflection on fork by point load

W=6540N by point load, 𝑀𝑥 = −𝑊 ×𝐿 =6540N× 0.7 m =4578Nm Deflection,

𝑦𝑚𝑎𝑥 = 𝑊𝐿^3/ 3𝐸𝐼 =4578× (0.7) ^3 /3× 2.1 × 10^5(16 × 6540^3 /12)=2.0048×10−14m

xlvi
Case 2: By considering fork as a cantilever beam with uniform distributed load

UDL

Fig. 10 Deflection on fork by UDL

Now 𝑀𝑥 = −𝑊×𝐿 = 6540N× 0.7m =4578Nm

5 3
Deflection, 𝑦𝑚𝑎𝑥 =𝑊𝐿4 /8𝐸𝐼=6540× 0.74 /(8 ×2.1 × 10 ( 16 × 0.7 ) 12)=0.00204mm.
❑

Figure 16 fork

3.7.4Design of base plate

Base plate /Truck serve as a base for carrying all the weight of the proposed design project. In
additional it carries the load by all the components of the crane It is composed of four bars
and each of them is modeled as a beam.

xlvii
Bar 1 and Bar 2 are side bars on which the center connecting bar is supported over. And the
other is end bar which is provided at the back end of the two side bars to give extra strength.

To know the stress developed in these components first we should know the all loads applied
and let’s first calculate all the masses of all the other components.

Figure 17 base plate

3.7.5Design of long ram hydraulic jack

Introduction
Hydraulics: The word hydraulics is based on the Greek word for water, and originally
covered the study of the physical behavior of water at rest and in motion.

Hydraulic jack is work based on the Pascal’s law which states that increase in pressure on the
surface of a confined fluid is transmitted undiminished throughout the confined vessel or
system. Hydraulic cylinder or also known as linear hydraulic motor is a mechanical actuator
that is used to give a unidirectional force through a unidirectional stroke. Design of hydraulic
cylinder consists of design of cylinder, design of piston rod, hinged pin, design of flat end
cover design of piston,
Working Principle of Hydraulic Jack

Hydraulic jack works on the principle of Pascal’slaw. A small initial force exerted on the
handle is transmitted by a fluid to a much larger area. When the handle is operated, the
plunger reciprocates then the oil from the reservoir is sucked into the plunger cylinder during
upward stroke of the plunger through the suction valve. The oil in the plunger cylinder is
delivered into the ram cylinder during the downward stroke of the plunger through the
delivery valve. This pressurized oil lifts the load up, which is placed on top plate of the ram.
After the work is completed the pressure in the ram cylinder is released by unscrewing the
lowering screw thus the pressure releases and the ram is lowered, then the oil is rushed into

xlviii
the reservoir. It consists of plunger cylinder on one side and ram cylinder on the other side.
These two cylinders are mounted on base which is made of mild steel. Plunger cylinder
consists of two non-return valves i.e. one for suction and other for delivery. Ram cylinder
consists of ram which lifts the load. The ram cylinder connected to delivery valve of plunger
cylinder. It is also consisting of lowering screw this is nothing but a hand operated valve used
for releasing the pressure in the ram cylinder for get down the load.

Figure 18Working Principle of hydraulic Jack

Design of Ram
In order to get numbers of rams and thickness of neck, for achieving minimum and maximum
height required, the following procedure has to be followed.

A) Number of rams

xlix
Table 4 iteration 4

, H Tmax 1410mm 1460mm 1520mm 1570mm

H Tmin 700mm 750mm 800mm 850mm

N rams 1.136≈ 2 1.05≈ 2 0.993≈ 1 0.92≈ 1

From our previous work we have already determined that, maximum and minimum height
achieved to be, H Tmax =1410 mm∧H Tmin=700 mm respectively. But in order to get number of
ram’s base height and cap height must be subtracted from the given value above.

Assuming that, base height = 50mm and, cap height =25mm

H min = H min total - Bheight - C height= 700mm – 50mm - 25mm

H min = 625mm and

H max = H max total - Bheight - C height= 1410mm – 50mm - 25mm

H max = 1335mm

Therefore,

( H max – H min ) ( 1335mm – 625 mm )

N rams = = =1.136
H min 625 mm

Since N rams should be a whole number then, N rams =2.

But if the number of rams is going to be 2, the cost and time of manufacturing the hydraulic
system will increase, thus we have to choose other dimensions from the Iteration table to get
number of ram equal or less than 1.

Now choosing, H Tmax =1520 mm∧H Tmin=800 mm

H min = H min total - Bheight - C height= 800mm – 50mm - 25mm

l
 H min = 725mm and

H max = H max total - Bheight - C height= 1520mm – 50mm - 25mm

H max = 1445mm

Therefore,

( H max – H min ) ( 1445mm – 725 mm )

N rams = = =0.993
H min 725 mm

Since N rams should be a whole number then, N rams =1.

B Thickness of Neck

( H max – H min ) ( 1445 mm – 725 mm )

But, y= = =360 mm
2 2

( 725 mm – 360 mm )
t= =182.5 mm
2

Since,l=H min =725 mm, thereforel= y +2 t

C) Checking

H max =H min + 2 y=725mm+ 2(360 mm)

H max =1445 mm , Therfor the analysis is correct.

li
Pressure distribution

Figure 19Pascal’s Law

Force analysis for jack handle and pump force

By using Pascal’s law which states that when a fluid is at rest in a closed vessel and if a
certain pressure is applied at any point the pressure will be transmitted equally in all direction

The force at two cylinders will be proportional to their respective cross-sectional areas. A
force F p is applied to the plunge and a force Fr is applied to the rams. Since the pressure is
the same everywhere, it is easy to solve the force applied on the ram and plunge.

Therefore, F=PA=P (π r 2 )

But Pram =P plunge ............................ Pascal principle

F ram F plunge
=
A ram A plunge

π d r2
Where, Aram = , d r=diameter of the ram
4

π d p2
A plunge = ,d p =diameter of the plunge
4

lii
 Figure 20Simplified hydraulic jack

Where, F p
is pin force,

F his the normal human effort (usually it is taken to be (100 to 200N), in this case take 150N.

F f is the fulcrum force

Lis the overall length of the handle (most of the time it ranges from 300 to 500mm), in this
case let us take500mm?

lis pin to pin length (most of the time it ranges form 30-50mm), in this case take 30mm.

 Using equilibrium condition i.e.

1) Take the summation of moment about point A,

liii
i.e. Σ M A =0

( F h x L ) – ( F f x l )=0

F h∗L
Ff= .................... … ....(1)
l

2) Take summation of all the forces along the y-axis,

i.e. Σ F y =0

F f −F p−F h=0

F p=F f −F h .. . .........................(2)

Now substituting equation (1) in equation (2), we get the following relation for F p,

F p= ( F ∗L
h
l
−F ) =F (
L−l
l )
h h

The values of F h, L andlhave already been determined to be 150N, 0.5m, and 0.03m
respectively. Therefor inserting back this value in the above equation, we can find the value
of F p∧F f as follows.

F p=150 N∗ ( 0.50−0.03
0.03 )
=2350 N

F h∗L 150∗0.5
Ff= = =2500 N
l 0.03

Thus, we can determine the cylinder pressure, Pcylinder as follows,

From Pascal’s law, Pcylinder =P ram=P plunge

F plunge
P plunge =
A plunge

Where F p is the pin force, which has already been calculated to be F p=2350 N .

π d P2
And A p is the plunge cross-sectional area and it is given by, A plunge =
4

liv
But d P is the plunge diameter, which most of the time ranges from 10 to 16mm. From this
range let us take, d P=12 mm.

π d P 2 π∗0.012 −4 2
And, therefore A P= = =0.7854 ×10 m
4 4

F plunge 2500 N
A P=78.54 mm2 P plunge = = =31.63 MPa
A plunge 78.54 mm2

Therefore, the pressure in the cylinder will be, Pcylin=Pram =P plun =31.63 MPa.

We have already calculated the maximum force applied to the hydraulic jack to be,
F c =36786.76Nbut the hydraulic jack is the heart of our lifting mechanism. That means, if the
hydraulic jack fails to supply the required amount of pressure, then the whole system will
fail. Therefore it has to be designed with good factor of safety to ensure good reliability of the
product. Therefore, factor of safety=2, so 4ton hydraulic ram will be designed. That means,
the maximum weight force applied to our jack is 4000× 9.81=39240 N

i.e. F r=39240 N .

Now the diameter of the ram cylinder,d r can be determined as follows,

Fr Fp
¿> 2
=
dr d p2

F r∗d p2 39240∗0.012
dr=
√ Fp
=
√ 2500
=0.0396 m

d r =39.6 mm, ≈ 40

π d r 2 π × 402 2
Therefore, Ar = = =1256.63 mm
4 4

Hence the minimum pressure to raise the given weight is:

Fc 36786.76 N
Pmin = = =29.27 MPa
A r 1256.63 mm2

lv
Since the cylinder pressure designed is greater than the minimum pressure, the load will
surely be lifted. i.e. Pcylinder > Pmin, 31.63 MPa>29.27 MPa

3.7.6Material 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 rod 2.6±0.07

006 to 045 40 First piston rod 1.778±0.07

006 to 045 35 Top of second piston 1.77±0.07

 Solid ram,

Because of it is subjected compressive load, fluid friction and corrosion, the selected material
is should be strong:

Alloy steel, AISI1015 Stu =420.6 MPa , S y =313.7 MPa.

 Spring for safety valve,

Hence, it is selected from spring material. For this case it is selected from spring material
table.

 Hollow ram,

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 S y =90 MPa.

 Ram cylinder,

lvi
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, S y =90 MPa

 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, S y =90 MPa.

 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 =90 MPa , S y=46 MPa

 Octagonal head top plate,

Since it is only subjected to compressive load, so that the selected material is: -

Malleable cast iron ASTM, A47 with Stu =345 MPa ,∧S y =224 MPa .

 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 =400 MPa∧S y =237 MPa .

 Handle socket pins and Releasing screw

Hence, it is subjected to torsion shearing compressive load the selected material is:

Alloy steel ANSI1318, S y =75 MPa .

lvii
  Handle socket link,

Since it is subjected to compressive, tensile and bending load and also buckling, the material
selected is:

Alloy steel ANSI1318, S y =70 MPa .

 Base plate,

Since it is only subjected to compressive load the selected material is:

Gray cast iron ASM60 with Stu =431 MPa , S cu =1293 MPa .

 Ball for releasing and safety 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 S y =200 MPa .

 Reservoir,

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 S y =90 MPa

3.7.7Design of Solid Ram

Material: - Alloy steel, S y =313.7 MPa , Assume F . S=4

τ all=0.4∗S y =0.4∗313.7 MPa=125.48 MPa

σ all=0.65∗S y =203.905 MPa

Maximum Load, W =39240 N

i) Check for shearing and crushing stress

Since the pressure applied on the bottom of the solid ram when it hits the top of the ram
cylinder subjects the neck to shearing, we have to check whether it is safe or not.

lviii
Maximum force acting on the neck, F neck=Pcylinder × A r

π d r 2 π × 402 2
But,Pcylinder =31.63 MPa∧A r = = =1256.63 mm
4 4

F neck=31.63 MPa ×1256.63 mm2=39747.43 N

F neck
The induced shear force, τ induced =
A shear

But A shear =π d r∗t=π∗40 mm∗15 mm=1884.95 mm2

39747.43 N
τ induced = =21.01 Mp a
1884.96 mm 2

Since τ all >τ induced then this ram is safe from shearing, i.e. 125.48 MPa>21.01 Mpa

ii) Check for Bucking

σc A
W Cr =
Using Rankineformula, we can check our solid ram for buckling, L 2 where,
1+Q( )
k
W Cr =crippling load

σ c =Crushing stress ontield stress on compression

A = Cross –sectional area of the column

Q = Rankine constant

L = equivalent length of the column

K = least radius of gyration

We have taken Rankine constant, crushing stress and fixture coefficient as follows:

1 1
 For carbon steel, σ c =250 Mpa and Fixture coefficient = Rankine constant =
0.25 9000
1
∗1
9000
Rankine constant for this ram will be ; Q= =0.00044∧¿
0.25

lix
The equivalent length(L)=650 mm

(π d i4 /64 )
Radius of gyration , K=
√ √
I
A
=
¿¿
¿

K=11.75 mm

L 2 700 mm 2
[ ] =[ ] = 3549.12
K 11.75 mm

σc A
W cr =
Finally, the crippling load, L 2
1+Q( )
k

But Ac = πDi2/4 = π( 40 mm)2/4 = 1256.64 mm2

σc A 250∗1256.64
W cr = 2
= =169321.50 N
L 1+0.00044∗4225
1+Q( )
k

Rankine load
Permissible buckling load ¿
S. f

Wcr 169321.50 N
W Grp = = =135457.2 N
S. f 1.25

Since the permissible buckling load is much greater than the given load,

i.e.W Grp >W =39240 N , hence the ram is safer from buckling

3.7.8Design of ram Cylinder

It is a cylinder in which produces a slide way to the ram. The ram cylinder is made up of mild
steel with density of 7.868 gm/cc. It is mounted on the base plate.

Material; Mild steel, S y =90 MPa

τ all=0.5∗S y =0.5∗90 MPa=45 MPa

σ all=0.65∗S y =0.65∗90 MPa=58.5 MPa

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

Pi∗Dr
Therefore, from hoop stress, σ h=
2t

Where, Pi=Internal pressure

Di=Internal diameter

t=Hollow ram thickness

C f =Corrosion factor

But Pi=31.64 MPa ,∧D r =40 mm

Let us assume that, σ h=σ all =58.5 MPa

Pi∗Dr
Therefore,σ h=σ all =
2t

Pi × D i 31.83∗40
t= = =10.88 mm
2σ h 2∗58.5

Due to corrosion effect we have to add corrosion factor, C f =1.66 mm

Therefore, t actual=10.88 mm+ 1.66 mm

t actual=12.54 mm

Assuming stop length, L=10 mmand,

D o =D r +2 t=40 mm+(2∗12.54) mm

Do =65.08 mm

Most outer diameter of the ram becomes;

D MO=D O + (2 × L ) =65.08 mm+20 mm=85.08 mm

i) Check for shear and crushing stress at the stop (neck)

lxi
Maximum force acting on the neck (stop), F neck =Pcylinder × A cylinder

D MO2 2
( 85.08 mm ) 2
But, Ac =π =π =5685.12 mm
4 4

Therefore, F neck=31.83 MPa ×5685.12 mm2=180690 N

Fneck
Induced shear force at neck (stop),τ =
A shear

Where, A shear =π × DO ×h=π∗65.08 mm∗15 mm

A shear =3066.82 mm2

180960 N
τ= =59 MPa
3066.82 mm2

F neck
Crushing stress at neck (stop),σ c =
A crush

π 2 2 π 2 2
Where, Acrush = (D MO – D O )= (85.08 – 65.08 )
4 4

Acrush =2452.95 mm2

134731.34 N
Therefore, σ c = =54.93 MPa
2452.95 mm2

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.

Check for buckling

σ cA
W cr =
Here again the Rankine formula is applicable to check buckling, that is, L 2
1+Q( )
k
where, W cr =crippling load

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

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

L=650 mm ……………………………effective length

π
Radius of gyration, K= I
A √
=
64
π
√
( D MO4 −DO4 )
( D 2−DO 2)
4 MO

D MO2−D O2 85.08 2−65.082

 K=
√
2
16
=

2
√ 16
=6.8 mm

L 650 mm
 [ ] =[ ] =9114.4 and
K 6.8 mm
π π
 Area, A=
4
( ()
D MO 4−D O 4 ) =
4
( 85.082−65.08 2) =2358.7 mm2

320 MPa∗2358.7 mm 2
 W Gr = =129106 N
1+0.00053∗9144.4

rankine load
Permissible buckling =
S. f

129106 N
W Grp = =103283 N
1.25

Since the permissible buckling load is much greater than the given load, which is 78480N,
this ram cylinder is also safe from buckling.

3.7.9Design of reservoir

Material; Mild steel, S y =90 MPa

Since the reservoir is much less loaded let us take factor of safety, F . S=2

τ all=0.5∗S y =0.5∗90=45 MPa

σ all=0.65∗S y =0.65∗90 MPa=58.5 MPa

i) Volume calculation

lxiii
The volume of the fluid occupied by the ram and the cylinder should be equal to that of the
reservoir volume,

π 2 π 2
Where,V ram = Ar h= × D ×hr = × 40 × 650
4 4

V ram =816814.1 mm3

i) Inner diameter of the reservoir

In order to carry this amount of volume of fluid in the height of 650mm, the reservoirs
volume should be equal to the volume of the rams.

i.e.V ram =V reservoir =816814.1 mm3

Therefore,

π
V reservoir = ( D2inner of reservoir −D 2outer of reservoir ) ×height
4

π
816814.1 mm3= ( D 2inner of reservoir −85.082 )× 650 mm
4

Di=94 mm

To be safe, from reservoir standard, let us take Di=96 mm

i) Thickness of the reservoir

Since only atmospheric pressure is applied on the inside and outside of the reservoir, we can
threat the reservoir us thin walled cylinder.

Pc∗Di
Therefore, from hoop stress, σ h=
2t

Where, Pc = 1 bar = 105 Pa = 0.1MPa

Pc∗Di
=>t= ,
2 σh

But internal diameter of the reservoir, Di=100 mm

lxiv
 Now assuming, σ h=σ all =58.5 MPa

0.1 MPa∗100 mm
t= =0.085 mm
2∗58.5 MPa

To be safer, let us add corrosion factor, C f =2mm

t actual=t+C f

t actual=0.085+2=2.085 mm

Therefore, thickness of the reservoir will be,t actual ≅ 2.00 mm

Do =Di+ 2t actual =96 mm+(2∗2) mm

Do =100 mm
3.7.10Design of plunger cylinder

The plunger cylinder is made up of mild steel and is mounted on the base plate. It provides
slide way to the plunger in order to build up the pressure.

Material; Mild steel, S y =90 MPa

Since the cylinder is subjected to compression load and the tensile load, we have to take
higher safety factor, thus let us take, F . S=2

τ all=0.5∗S y =0.5∗90=45 MPa

σ all=0.65∗S y =0.65∗90 MPa=58.5 MPa

i) Thickness of the wall

Since less internal pressure is applied on the cylinder, we can treat it as thin walled cylinder.

Pi∗Di
Therefore, from hoop stress, σ h=
2t

Where, Pi=Internal pressure

Di=Internal diameter

lxv
t=Hollow ram thickness

C f =Corrosion factor

But Pi=31.83 MPa ,∧Di =10 mm

Let us assume that, σ h=σ all =58.5 MPa

Pi∗Di
σ h=σ all =
2t

Pi × D i 31.83∗10
Therefore, t= = =2.72 mm
2σ h 2∗58.5

To be safer, let us take corrosion factor, C f =1.44 mm

t actual=t+C f

t actual=2.72+1.44=4.16 mm

Therefore, the outer diameter of the cylinder becomes,

D o =D i+ 2t actual =10+ ( 2× 4.16 )=18.32 mm

ii) Check for buckling

σ cA
W cr =
Here again the Rankine formula is applicable to check buckling, that is, L 2
1+Q( )
k
where, W cr =crippling load

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

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

L=50 mm ……………………………effective length

lxvi
 π
Radius of gyration, K= I
A √
=
64
π
4
( √
( DO 4−Di4 )

DO2−Di2
2 2
D O −D i )

18.322 −102
 K=
16√ =
16 √ =3.84 mm

L 2 50 mm 2
 [ ] =[ ] = 169.54 and
K 3.84 mm
π π
 Area, A= ( D O2−D i2 ) = ( 18.322 −102 )=185.06 mm2
4 4
320 MPa∗185.06 mm 2
 W Gr = =59.22 kN
1+0.00053∗169.54

rankine load
Permissible buckling =
S. f

59.22 kN
W Grp = =47.38 kN
1.25

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

3.7.11Design of plunger rod

Material; Alloy steel, S y =40 MPa

Since the plunger rod is subjected to tensile and compressive stress, let us take safety factor
of, F . S=2.

τ all=0.5∗S y =0.5∗40 MPa=20 MPa

σ all=0.65∗S y =0.65∗40 MPa=26 MPa

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.
A rod

lxvii
 Ff π 2 Ff
Arod = => Drod =
σ all 4 σ all

4∗F f 4∗2500
Drod =
√ π ×σ all√=
π∗26
=11.06 mm

ii) Check for buckling

σ cA
W cr =
Here again the Rankine formula is applicable to check buckling, that is, L 2
1+Q( )
k
where, W cr =crippling load

σ c =250 MPa ……………….……. Alloy steel crushing stress

1
∗1
σc 0.25 ………………………rankine constant
Q= = =0.00044
2
Cᴨ E 9000

L=50 mm ……………………………effective length

π
Radius of gyration, K= I
A
=
64
π
4
√ ( √
( Drod 4 )
2
D Orod )

Drod 2 Drod
 K=
√ 16
=
4
=2.76 mm

L 2 50 mm 2
 [ ] =[ ] = 328.18 and
K 2.76 mm

π 2 π 2 2
 Area, A= × D rod = × D rod =96.07 mm
4 4

250 MPa∗96.07 mm 2
W Gr = =20423.62 N
1+0.00044∗400

rankine load
Permissible buckling =
S. f

20423.62 N
W Grp = =16338.90 N
1.25

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

3.7.12Design of octagonal head top plate

Material; Alloy steel, S y =382 MPa

Since the load on the top plate is very low, let us take factor of safety,F . S=2

τ all=0.5∗S y =0.5∗382 MPa=191 MPa

σ all=0.65∗S y =0.65∗382 MPa=248.3 MPa

i) Check for shearing at critical points

Maximum force acting on the neck (stop), F neck =Pcylinder × A cylinder

π π
But, Pcylinder =31.63 MPa∧A c = ( D 2 −Di2)= 4 ( 96 2−85.082 )=1553.3mm 2
4 O

Therefore, F neck=31.69 MPa ×1553.3 mm2=49433.2 N

Fneck
i) Induced shear force at neck (stop),τ =
A shear

Where, A shear =π × Di × h=π∗96 mm∗22 mm

A shear =6635.50 mm2

49433.2 N
τ= =7.45 MPa
6635.04 mm2

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

3.7.13Design of handle

Material; Carbon steel, S y =237 MPa

Since the load on the top plate is very low, let us take factor of safety,F . S=2

τ all=0.5∗S y =0.5∗237 MPa=118.5 MPa

lxix
σ all=0.65∗S y =0.65∗237 MPa=154.5 MPa

Determination of diameter

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

16
Let us determine diameter from allowabletensilestrength, σ all = T max
π d3

16∗T max 3 16∗150∗470

Now solving for the diameter, d shaft =
√
3

π∗σ all √
=
π∗154.5
=13.25 mm∧,

32
From allowableshearstrength we have, τ all= M max
π d3

Where , M max =470 mm∗150 N =70500 Nmm

32∗70500
Now solving for the diameter, d shaft =
√
3

π∗118.5
=18.23 mm

Taking the closest standard diameter,d=20 mm

Due to safety from the two diameters, we have to select the largest diameter.

Therefore, d shaft =20 mm, is selected.

3.7.14Design of Handle socket

Material; Carbon steel, S y =237 MPa

Since the load on the top plate is very low, let us take factor of safety,F . S=2

τ all=0.5∗S y =0.5∗237 MPa=118.5 MPa

σ all=0.65∗S y =0.65∗237 MPa=154.5 MPa

Determination of diameter.

From allowable stresses we can determine the outer diameter of the socket.

4∗F f
σ all=
π ( D2−d2 )

lxx
Where,

F f = fulcrum force,

D1 = outer side diameter of the handle socket,

d = inside side diameter of the handle socket

4 × Ff 4∗2500
D1 =
√ π ×σ all √
+d 2=
π∗1 54
+202=20.51 mm

4 Ff 2 2
And, τ all= ( D 2 −d )
π

4∗2500
D 2=
√ π∗118.5
+202 =20.66 mm

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

Therefore, t 1=D1−d =20.51mm−20 mm=0.51 mm

t 2=D 2 – d=20.66 mm – 20 mm=0.66 mm

This implies that it can be possible to use a material thickness greater than 0.66mm therefore
by adding correction factor, C f =2mm for convenience it becomes.

D=d+ 2t actual =20 mm+2∗(0.66 mm+2 mm)

D=25.32mm ≈ 26 mm
3.7.15Design of handle socket pins

Fulcrum pin

Material; Alloy steel, S y =75 MPa

Since the load on the top plate is very low, let us take factor of safety,F . S=2

τ all=0.5∗S y =0.5∗75 MPa=37.5 MPa

σ all=0.65∗S y =0.65∗75 MPa=48.75 MPa

lxxi
Determination of the diameter,

Ff Ff
Since the pin is subjected to double shear, σ all= =
2 A shear 2 π d pin2

Ff 2500
Now solving for the diameter,d pin =
√ 2∗τ all√=
2∗37.5
=5.77 mm

To be safe, take from standard let us take, d pin =8 mm

Pivot pin

Material; Alloy steel, S y =75 MPa

Since the load on the top plate is very low, let us take factor of safety,F . S=2

τ all=0.5∗S y =0.5∗75 MPa=37.5 MPa

σ all=0.65∗S y =0.65∗75 MPa=48.75 MPa

Determination of the diameter,

Fp Fp
The pin is subjected to a double shear,σ all= =
2 A shear 2 π d pin2

Fp 2350
Now solving for the diameter,d pin =
√ 2∗τ all√=
2∗37.5
=5.59 mm

To be safe take from standard let us take, d pin =6 mm

Spring design for check valves

Spring material; Copper C17200, S y =1172 MPa

τ all=0.5∗S y =0.5∗1172MPa=586 MPa

σ all=0.65∗S y =0.65∗1172 MPa=761.8 MPa

Modulus of elasticity, G=131 GPa

Design procedure

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

D mean=d × c=20 mm

Douter =D mean+ d=24 mm

Shear stress factor (Ks),

1
Neglecting effect of curvature, K s =1+ =1.1
2C

Maximum shear stress induced,

8W D mean
τ induced =Ks×
ᴨ d3

Where, W =P× A ……………………………Axial load

Assume the diameter of the fluid line to be, d=4 mm

d2 42 2
A=π =π =12.57 mm And P=22.11 MPa ,is the cylinder pressure,
4 4

Therefore, W =P× A = 22.11 MPa ×12.57 mm 2 = 277.84N

8 W D mean 1.1∗8∗277.84∗20
τ induced =K s × 3
=
ᴨd ᴨ 43

τ induced =243.21 Mpa

Check for safety factor (F.S)

τ all 586
F.S = = = 2.4
τ induced 243.21

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

Spring constant (K)

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

lxxiii
 F F W 277.84 N
δ= => K= = = =138920 N /m
K δ δ 0.002 m

Number of active length (Na)

d4 G
K=
8∗D 3m∗Na

d4G G∗d 131 ¿ 109∗2∗10−3

 Na= = = =1.88
8∗D 3m∗K 8∗K∗C 3 8∗138920∗53

Since it must be a whole number we take, Na =2

Number of total turns of the spring (Na’),

N a ’=N a +2 , for square end

N a ’=2+2=4

Free length of the spring (l f ),

We know that free length of the spring,l f =( N a ’∗d)+δ +(0.15 x d)

¿ ( 4 ×2 ) +2+ ( 0.15 ×2 ) mm=10.3mm

Pitch of the spring (P),

Free length Lf 10.3

P= = = =3.43 mm
Total number of turn−1 Na ’−1 4−1

Check for buckling,

The critical load (W cr ) that causes buckling can be calculated by using the following

Where,

W
K=spring rate∨stiffness of the spring=
f

lxxiv
l f =free length of the sp ring

lf
K B=Buckling factor that depending up on the ratio ,
Dmean

lf 10.3
K B ,¿ the table for K B= = =0.515=¿
D mean 20

For built ∈end spring , μ B=0.71

K=200 kN /m ,

N
Therefore from the above, W cr =K × K B ×l f = 139820 * 0.515 *10.3 *10−3 m
m

=>W cr =741.67 N

Since the critical axial load is greater than the applied axial load (W = 400N) then this spring
is safe from buckling.

Ball for discharge valve

Due to the application of the fluid friction on it. We have selected stainless steel and diameter
of the ball = mean diameter of the spring

Therefore, D b =D mean=8 mm
3.7.16 Spring design for relief valve

Spring material; Carbon stainless- steel (BISA), S y =728 MPa

τ all=0.5∗S y =0.5∗728 MPa=364 MPa

σ all=0.65∗S y =0.65∗1172 MPa=473.2 MPa

Modulus of elasticity, G=44 GPa

This spring comes to operation, if the jack is over loaded to 1kN larger than the designed
(require) load.

Design procedure

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

D mean=d × c=20 mm

Douter =D mean+ d=24 mm

Shear stress factor (Ks),

1
Neglecting effect of curvature, K s =1+ =1.1
2C

Maximum shear stress induced,

8W D mean
τ induced =Ks×
ᴨ d3

Where, W =P× A ………………………………. Axial load

But internal pressure developed will increase and the applied load also increases by 1kN.

i.e.W app =F ram + 1kN =39620 N +1000 N=40620 N

WappontheRam 4∗Wapp
Therefore, the internal pressure, P = =
Aram π (dr )2

4∗40620 N
P= =23.41 MPa ………since ram diameter is, d r =47 mm
π ( 47 mm )2

Assume the diameter of the fluid line to be, d=4 mm

d2 42 2
A=π =π =12.57 mm andP=23.41 MPa ,is the cylinder pressure,
4 4

Therefore, W axial =P × A = 23.41 MPa× 12.57 mm2 = 294.30N

8 W D mean 1.1∗8∗294.30∗20
τ induced =K s × 3
= τ induced =257.62 Mpa
ᴨd π × 43

Check for safety factor (F.S)

τ all 364
F.S = = = 1.41
τ induced 257.62

lxxvi
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 (δ )=2 mm and the end details of the spring is square
ends.

F F W 294.3 N
δ= => K= = = =147150 N /m
K δ δ 0.002 m

Number of active length (Na)

d4 G
K=
8∗D 3m∗Na

d4G G∗d 44 ¿ 109∗2∗10−3

 Na = 3 = = =0.59
8∗D m∗K 8∗K∗C 3 8∗147.15∗103∗53

Since it must be a whole number we take, Na =1

Number of total turn of the spring (Na’),

N a ’=N a +2 , for square end

N a ’=1+2=3

Free length of the spring (l f ),

We know that free length of the spring,l f =( N a ’∗d)+δ +(0.15 x d)

¿ ( 3 ×2 ) +2+ ( 0.15 ×2 ) mm=8.3 mm

Pitch of the spring (P),

Free length Lf 8.3

P= = = =4.15 mm
Total number of turn−1 Na ’−1 3−1

Check for buckling,

The critical load (W cr ) that causes buckling can be calculated by using the following relation,
i.e. W cr =K × K B ×l f ,

lxxvii
Where,

W
K=spring rate∨stiffness of the spring=
f

l f =free length of the spring

lf
K B=Buckling factor that depending up on the ratio ,
Dmean

lf 8.3
K B ,¿ the table for K B= = =0.415∧¿
D mean 20

For built ∈end spring , K B=0.415 ,

N
Therefore, from the above, W cr =K × K B ×l f = 147150 * * 0.415 *8.3 *10−3 m
m

=>W cr =¿ 506.86N

Since the critical axial load is greater than the applied axial load then this spring is safe from
buckling.

Ball for relief valve

Due to application of fluid friction, stainless steel is selected, and diameter of the ball is equal
to the mean diameter of the spring.

i.e. Db= mean diameter of the spring = 10mm.

3.7.17 Spring design for intake valve

Spring material; Copper C17200, S y =1172 MPa

τ all=0.5∗S y =0.5∗1172 MPa=586 MPa

σ all=0.65∗S y =0.65∗1172 MPa=761.8 MPa

Modulus of elasticity, G=35 GPa

Design procedure

lxxviii
Assume a wire diameter of, d=1mm and spring index,C=10

D mean=d × c=10 mm

Douter =D mean+ d=11mm

Shear stress factor (Ks),

1
Neglecting effect of curvature, K s =1+ =1.05
2C

Maximum shear stress induced,

8W D mean
τ induced =Ks×
ᴨ d3

Where, W =P× A ………………………………. Axial load

Assume that the fluid in the reservoir is in the atmospheric pressure, that is Patm =1 ¯¿ and the
diameter of the fluid line to be, d 1=4 mm

d 12 42 2
A=π =π =12.57 mm ∧P=0.1 MPa,
4 4

Therefore, W =P× A = 0.1 MPa ×12.57 mm2 = 1.257N

8 W D mean 8∗1.257∗10
τ induced =K s × 3
=1.1× =35.21 Mpa
ᴨd π ×13

Since the induced shear stress is less than the allowable stress the spring is safe and
acceptable.

Spring constant (K)

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

F F W 1.257 N
δ= => K= = = =628.5 N /m
K δ δ 0.002 m

lxxix
Number of active length (Na)

d4 G
K=
8∗D 3m∗Na

d4G G∗d 35 ¿ 109∗1∗10−3

 Na = = = =6.96
8∗D 3m∗K 8∗K∗C 3 8∗628.5∗103

Since it must be a whole number we take, Na =7

Number of total turns of the spring (Na’),

N a ’=N a +2 , for square end

N a ’=7+2=9

Free length of the spring (l f ),

We know that free length of the spring,l f =( N a ’∗d)+δ +(0.15 x d)

¿ ( 9 ×1 ) +2+ ( 0.15 ×1 ) mm=11.15 mm

Pitch of the spring (P),

Free length Lf 11.15

P= = = =1.39 mm
Total number of turn−1 Na ’−1 9−1

Check for buckling,

The critical load (W cr ) that causes buckling can be calculated by using the following relation,
i.e. W cr =K × K B ×l f ,

Where,

W
K=spring rate∨stiffness of the spring=
f

l f =free length of the spring

lxxx
 lf
K B=Buck ling factor that depending up onthe ratio ,
D mean

lf 11.15
K B ,¿ the table for K B= = =1.11∧¿
Dmean 10

For build ∈end spring , K B =1.11 K=628.5 N /m ,

N
Therefore, from the above, W cr =K × K B ×l f = 628.5 * 1.11 *11.15*10−3 m
m

=>W cr =7.78 N

Since critical axial load is greater than the applied axial load which is (1.257N), the spring is
safe from buckling.

Ball for intake valve

Due to application of fluid friction, stainless steel is selected, and diameter of the ball is equal
to the mean diameter of the spring.

i.e. D b= mean diameter of the spring = 10mm.

4.7.17Design of retainer

We selected standard and compatible retainer having a thickness of 2mm.

3.7.18Design of sealing

We selected standard and compatible, Nitride Butadiene (class A) sealing.

3.7.19Design of the base

The base is used to support the jack system and also protect foreign particles from going into
the system. The material used for the basement is most of the time cast iron. This is because
of the following reasons:

 It is cheap and easily available,

 It can easily resist wear when we compared to steel, and
 It is highly resisting compressive load.

lxxxi
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.

Therefore, the material selected is; Gray cast iron ASTM60 and S y =43 MPa

τ all=0.5∗S y =0.5∗43 MPa=21.5 MPa

σ all=0.65∗S y =0.65∗43 MPa=27.95 MPa

3.7.20Design of the releasing screw

Material; Alloy steel, ANSI1318, S y =75 MPa

τ all=0.5∗S y =0.5∗75 MPa=35.7 MPa

σ all=0.65∗S y =0.65∗75 MPa=48.75 MPa

The selected standard screw is M8.

3.7.21Design of relieving screw

Material; Alloy steel, ANSI1318, S y =75 MPa

τ all=0.5∗S y =0.5∗75 MPa=35.7 MPa

σ all=0.65∗S y =0.65∗75 MPa=48.75 MPa

The selected standard screw is M4 and this screw is hollow due to the passage of atmospheric
pressure.
Hydraulic oil 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
 It used to clean the hydraulic part
 It prevents the parts from corrosion and so on

lxxxii
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

Stroke calculation

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

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

ButV ram =816814.1 mm3

π d p2 3
And volume of the plunger ¿ AxH = x l p =18086.5 mm
4

Number of stroke=816814.1mm 3 /18086.5 mm3 =45 strokes

Figure 21 hydraulic jack

3.8 Caster wheel selection

Load calculation per caster or wheel

Selection of the wheel depends on the load we are going to pick by the lifting machine. The
first step is to determine properly the load on each wheel or caster, according to project and

lxxxiii
utilization conditions of the equipment where they will be mounted. Avoiding exceed load
bearing capacity limits of casters and wheels shown in the catalog is important to get the best
product performance. The formula below enables load calculation over each caster or wheel,
considering some of the most important factors.

C= ( PE+6PMC ) S=( PE+2000

6
Kg
) ×1.5=523.25 kg
Where

C=Load per caster∨wheel ( kg )

PE=Equipment , cart∨structure weight ( kg )

PMC=Maximumload weight ¿ be carried ( kg )

N=Number of casters∨wheels

S=Safety coefficient

The value of safety coefficient S must be between 1.0 and 2.0, depending on application
conditions.

Table 5Safety coefficients of caster for different usage conditions

Safety Coefficient, S Usage Conditions

1.0 Almost static load

1.33 Frequent utilization, handling on flat floors

1.5 Frequent utilization, handling on irregular floors

2.0 Sever utilization, speeds above 10Km/h, with solid or liquid

loads, or requiring stepping over obstacles.

lxxxiv
 Figure 22 caster wheel

Environmental conditions

The second step is to evaluate the caster or wheel working environment conditions, such as
maximum and minimum temperatures and the presence of chemicals that may cause
contaminations. Casters with stainless steel rigs offer an excellent durability in wet
environments with chemically aggressive products. But here in this case there is no need to
consider extreme conditions so we assumed room temperature.

Floor conditions

It is fundamental to make an analysis of floor type and conditions. Identify floor irregularities
and obstacle presence. One must choose the most adequate wheel material in order to not
damage the floor, with resistance to aggressive surfaces or impacts and easily stepping over
obstacles. In order to reduce noise level and vibrations during handling, select soft casters and
wheels with springs.

Wheel bearings

We jump now to the third step which is to select the ideal wheel bearing. Wheels can be
delivered with five different wheel bearings, which exert a great influence in their
performance.
They are: plain bearing, nylon socket, bronze socket, roller bearing and ball bearing. For light
duty loads and low handling requirements, the plain bearing or nylon socket wheels are the
most suitable, providing an excellent cost-benefit ratio. Those with bronze socket must be

lxxxv
used in very wet conditions or extreme temperatures. Roller bearings are indicated for
medium and light duty loads they make handling of manual traction equipment easier with a
low cost. Ball bearings provide easier handling for all load ranges, higher resistance and
durability. They must be always used in equipment subject to severe utilization, with
mechanical traction and higher speeds. Supplied with a guard with grease nipple, or two
guards with permanent lubrication. In case of highly severe applications, high loads and
speeds, where radial and axial efforts are present, we can supply wheels with tapered rollers
upon request.

Taking into consideration the above information a caster with the following specification has
been chosen, also taking into consideration the availability of the wheels in our country, we
select the Rubber wheel with aluminum core with part number RAR-620. This has the
diameter of 100-250mm and the capacity of carrying from 180-550kg of mass.

Masses of vertical column:

Length 1250mm so,

 Volume vertical column

V = A× L=[ ( 150× 130 ) mm−( 136 ×116 ) mm 1250 mm ]

¿4655000mm^3

V = 0.004655m^3

Since the material for the vertical column is made from cast iron, the mass density of cast
iron is 7250kg/m 3.

m
ρ= ,m= ρ× v
v

¿ 7250 Kg/m3 ×0.00455 m3=¿ 33.748Kg

m = 33.745kg, mass of Vertical column

lxxxvi
Mass of Boom:

 The volume of the boom is

V = A× L=[ ( 1200× 1200 ) mm−( 1060 ×1060 ) mm ] ( 1003.2mm )
¿ 3164001.21 mm3=0.003164 m 3so,

The boom is made of standard steel, and the mass density of steel is 7850kg/m3

m
ρ= ,m= ρ× v
v

m¿ 7850 kg /m 3 ×0.003164 m 3 =24.837Kg

Mass of vertical column support:

V = A *h

= [(60*70)−( 52∗62)¿ 1200

=0.0006048m^3

The material for the support is selected to be cast iron, which have mass density of
7250kg/m3.

Density = m/v, m = 7250*0.0006048

Mass (m) = 4.4 kg

Mass of Fork

V = l*w*h =(700 ×550 ×100 ¿ m m3 =38500000 mm3 =0.0385m^3

Since the material for crane hook is wrought iron, which have mass density of 7780kg/m3,

m
ρ= ,m= ρ× v=7780 kg /m 3 ×0.0385m^3=29.9kg
v

So, we have 3 fork mf=3*29.9=89.85kg

lxxxvii
The mass of other components like hydraulic tank with the fluid, hydraulic cylinder, pin,
bolts with nut, all in one are estimated to be 25kg.Additionally the design is proposed to lift a
load of 2000kgand the total mass applied on the base plate is,

Mtotal= 33.745kg+24.837kg+4.4kg+25kg+2000kg+89.85kg

=2177.83kg

Pt = Mt*g = 2177.88kg*9.81m/s^2

=21364.51N = 21.392KN

Due to the load Pthe bar is subjected to equal bending moment at both end of the plate. At
both end there are two reaction forces to encounter the bending of beam due to the load
applied. And these are equals to half the load applied.

R = 19.62KN/2 = 9.81KN

A = (200×80)- (193×73)mm^2 = 1900mm^2 = 0.0019m^2

Section Modules

Z = (200×80^3 – 186×66^3) ¿ 5.69 ×10−5 m 3

• Moment at the two ends of bar

520 N
M = Z¿ σ = we use factor of safety 3,σ =173.3 N /mm 2
mm 2

M ¿ 5.69 ×10−5 m3 × 173.3 N /mm2=9862.67 Nm

M = P*L/2 so, 9862.67Nm*2 = 19620N*L

lxxxviii
L = 1.0053m

The material selected for the center bar of the base plate is standard steel of Indian standard
designation FeE520, having yield strength of 520N/mm2. Taking the factor of safety equals
3.

Sy 520 173.33 N
Σ= = =
n 3 m m2

Since the induced stress is less than the ultimate bending stress, then the bar is designed
safely.

Figure 23 hydraulic shop crane assembly

lxxxix
Result
Component value
Vertical column t=7mm
h=1250mm
boom W=120mm
L=1000MM
T=6mm
fork L=700mm
Base plate L=1250mm
Ram Do=85.08mm
T=10.88mm
Reservoir Di=96mm
tact=2.085mm
Hydraulic jack Plunger cylinder Di=10mm
tact=4.16mm
Plunger rod Dr=11.06mm

Handle Dh=20mm

xc
 Chapter four
4.1Conclusion

The Hydraulic Crane we have designed has the following final specifications;

 Strong metal frame construction

 4 ton long hydraulic lifting jack
 4 position adjustable jibe
 Rated load = 2 ton
 Lifting height = 0 – 2360mm
 Easy to erect
 Folds for easy storage
 6 strong castor wheels for ease of movement
 1800 x 1040 x 2382mm (W x D x H)
In order to insure safe operation once fabrication is completed, it is necessary to test this
hoisting before full operation. It should be tested to insure structural soundness. The hoist
should be put through normal cyclic loadings witha few irregular load cases.
A regular load case scenario would be lifting garage equipment’s, such as the workshop
beam, diesel engineor tractor transmission, onto the back of the pickup car. To simulate an
irregular load, a heavy classaid should be positioned so the hoist cannot lift vertically, such as
close to the wall. This will test the effects of a forwardand twisting load. During transfer, it is
important that the load is lifted to the lowest level possible, moved to its desired location,and
raised up at that point. Moving a load at a high height is very unsafe and NOT recommended.

xci
The load should not belowered at a high rate. A smooth controlled drop is recommended.
This may be practiced with a lighter load before using the hydraulic shop crane on heavy
equipment. All pins need to be installed before operation.if the hoist passes these tests,
normal operation may resume. However, if a failure were to occur, further investigation must
be done before further operation or repairs are made. Investigation may include material
analysis, failure analysis, further FEA, and/or weld failure analysis. It is up to the operator to
keep this hoist in top shape.

4.2 Recommendations

In order to keep up with this increasing number of workshop product, this hydraulic shop
crane material handling equipment should be used in each and every shop to reduce the
manpower and working time, providing safe operations to increase the efficiency and
quality of repair and maintenance process in recognition of this need, this project has
successfully designed and developed a made in Ethiopia, affordable shop crane to meet the
required objectives The hydraulic crane involves analysis of forces acting in various member
of the crane structure, analysis of the links mechanism, determination of pressure developed
in the actuator at maximum load, and material selection lifting device capable of hoisting
2tonat 2m length has been designed for proper handling and job execution in the shops.
Engineering analysis has been performed on the hydraulic shop crane. The design is both
structurally sound and manufacturable.

xcii
 References

[1] R. C. Hibbeler, Mechanics of Materials, Boston: Pearson Prentice Hall,

2011.
[2] R.S. Khurmi and J.K. Gupta, A text book of machine design, New Delhi:
Eurasia Publishing House, 2005.
[3] G. M. Maitra, Handbook of Gear Design, New Delhi: McGraw Hill
Publishing, 2001.
[4] S. Timoshenko, Strength of Materials, Toronto: D. Van Nostrand Company,
Inc, 1998.
[5] BISHOFTU AUTOMOTIVE INDUSTRY design of hydraulic workshop crane

xciii