Adama University School of Engineering and Inforamation Technology Bottle Jack Design Design of Hydraulic Bottle Jack

Bottle Jack Design 2010
ADAMA UNIVERSITY
SCHOOL OF ENGINEERING AND INFORAMATION
TECHNOLOGY
Bottle Jack Design
DESIGN OF HYDRAULIC BOTTLE JACK
[
Designed by :-
1. Abebe Defaru………………………………………………….R/0235/00
2. Alemu Kebede………………………………………………….R/0250/00
3. Babey Bezabih…………………………………………………..R/0287/00
Submitted to Girma G/wold (MSc)

Submission Date 24/ 06/2010
1
Acknowledgement
we would like to acknowledge first our classmate students those help us by sharing
designing material like text book, and those who share idea with us for what we are going to
do. The other but the one who is the great man that we would like to acknowledge is our
previous teacher Ato Elias . because, he help us by giving the soft copy which some what good
for designing purpose.
2
TABLE OF CONTENT
TITLE PAGE
Introduction …………………………………………………………………………………………………………………………1
Hydraulic Ram and Plunger……………………………………………………………………………… . 1
1. Description………………………………………………………………………………………………2
2. Operating…………………………………………………………………………………………………2
3. Operating preparation………………………………………………………………………………2
4. Pressure Distribution……………………………………………………………………………….4
5. Force Analysis………………………………………………………………………………………….5
6. Material Selection…………………………………………………………………………………….6
7. Stress Analysis………………………………………………………………………………………...9
7.1 Top-Cup with a Square Thread………………………………………………………..….9
7.2 Solid Ram………………………………………………………………………………….….15
7.3 Second Stage Ram……………………………………………………………………….…..18
7.4 Reservior…………………………………………………………………………………………24
7.5 Plunger Cylinder…………………………………………………………………………….26
7.6 Plunger with Plunger Rod………………………………………………………………28
7.7 Octagonal Head Top Plate…………………………………………………………30
7.8 Handle…………………………………………………………………………………….31
7 .8 Handle Socket……………………………………………………………………….34
7.9 Handle Socket Pins…………………………………………………………………34
7.10 Spring Design for Check Valves……………………………………………35
7.11 Design of the Base………………………………………………………………….43
7.12 Design of the Releasing Screw……………………………………………….43
7.13Design of Refilling Screw…………………………………………………………43
7.14Design of Retainer…………………………………………………………………43
3
7.15Design of Sealing……………………………………………………………………….43
8. Manufacturing Process……………………………………………………………………….43
Appendix………………………………………………………………………………………………..47
References………………………………………………………………………………………………51
4
Introduction
Jacks are portable hand operated devices for rising and lowering loads through short
distance. There are three types in common uses , screw jacks, rack and lever jacks, and
hydraulic jack. Bell-bottom screw jack are available in capacitve to 2 tons and a lifting
range to ( 1-4)in. the screw is rated by a bar inserted in holes in the screw head or by a
ratchet cover fitted to the head .Gear drive jacks will lift up to 50 tonnes. A lever
mechanism turns a bevel pinion , on internal thread between the the gear rises and the
non- rotating screw rack and lever jacks consists of a cast steel or malleable iron housing in
which the lever pivots . the rack toothed bar passes through the hollow housing the load
may be lifted eigher on the top or ending from the bottom of the bar. The lever paule may
be biased either to rise to lower the bar. Hydroulic jack can be classified in to three based
on the application of the jack that are:- hydraulic service jack, session hydraulic jack and
hydraulic bottle jack. From these hydraulic jacks, the bottle hydraulic jack as consists of a
cylinder, a piston and lever operated pump and their capacities is to up to 50 tones and
lifting height is up to 22in. Large hydraulic jack may be provided with two pumps.
HYDRAOLIC RAM AND PLUNGER
A hydraulic ram (hydraulic jack, hydraulic press, fluid press etc) is a force multiplying
devices. A force FP is applied to plunge and a usefull force Fv appears at the ram.
Eventhough the pressure in the hydraulic fluid is the same every where the orse at the two
cylinders will be proportional their respective cross-sectional areas.
5
1) DESCRIPTION
The jack assembly is portable , self contained unit with a single speed manually operated
pump at the lift unit consisting of three rams and on extension screw or cased within an
anchored cylinder mounted on the base .A stamped shell enclosed the rams and cylinder to
form the fluid reservoir.
2) OPERATING
When the handle is moved upward, ball(A) is seated and fluid is drawn from the reservoir
through the screen into the valve assembly. From there fluid enters the plunger cylinder as
it indicated by the section symbol. (vant and filler screw must be open to allow fluid to
flow).other down ward stroke of the handle or pressure stroke ,fluid pressure to the
master cylinder. Continued operation of the pump will creat sufficient pressure to rise the
first stage ram. Until it hits the stop of the second stage ram with the additional pressure.
The second stage ram will be rised until it hits the stop of the third stage ram . if the
pressure is still continued, the third stage ram will be rised to the full height of lift until it
hits the stop of the cylinder. At the end of the travel of the rams or with an over load
applied to the jack. Excessive pressure from the continued pump unseats ball (B) and flied
is by passed to the reservoir (with this occurs the handle will suddenly drop or go soft
during the pumping stoke). If the releasing screw is opened pressure is released through
un seated ball (C) and fluid to the reservoir.
3) OPERATING PREPARATION
When placing the jack in service, apply a light film of lubricating oil , on outer bearing
surface of ram. Wipe away any excess of oil to prevent accumulation of dust and grit on ram
surfaces. Open the releasing screw slightly and collapse rams until flush remove vent and
five screw to check reservoir for prope fluid content. If oil level is low, add correct fluid .
NOTE :- always fill reservoir with fresh, clean oil in case of emergency operation flush jack
with clean hydraulic oil and refill reservoir.
6
in order to get numbers of rams, thickness of neck ,and achieving minimum and
maximum height to required amount the following procedure have to followed.
A) number of rams =
where - = 130mm.....................given
assume, that = 260mm and
= 130mm
but in order to get N rams base height and cap height must be subtracted from the given
value above.
Assuming that, base height =25mm
And, cap height =10mm
=> = - -
= 130mm – 25mm -10mm

= 95mm
And, = - -
=> = 260mm – 25mm – 10mm

= 225mm
Therefore:-
Nrams =
= 1.4
Since Nrams should be whole number then, Nrams = 2
B) THICKNESS OF NECK
Since l= =95mm, therefore l=y+2t
But, y= =
7
y=
y = 65mm
=> t =
t = 15mm
C) CHECKING
= +2y
= 95mm +2(65mm)
= 225mm therefore the analysis is correct.
4.PRESSURE DISTRIBUTION
by using Pascal’s principles, that is intensity of pressure is transmitted equally in a
directions through a mass of fluid at rest.
The force at two cylinders will be proportional to their respective cross-sectional areas. A
force Fp is applied to the plunge and a force Fr is applied to the rams. Since the pressure is
the same every where it is easy to solve the force applied on ram and plunge.
therefore F =PA=P(π )
but Pram=Pplunge.......................................pascals principle
<=> = where ,Aram =πdrxdr/4
dr=diameter of the ram

Aplunge =πdpxdp/4
8
dp =diameter of the plunge

since Fr/Ar=Fp/Ap => =
Fr/ = Fp/
5 FORCE ANALYSIS
5.1 FOR JACK HANDLE AND PUMP FORCE
where Fp................pin force

Fh.......................human force (usually it is taken to be (100 to 200)
Ff......................fulcrum force
L.........................overall handle length (again most of the time it has
to be taken (300-500mm))
l............................pin to pin length (it also taken (30-50mm))
using equilibrem condition i.e
I) ΣMA =0
=> (Ff x L) – (Ff x l) = 0
=> Ff = ............................(1)
2) ΣFy = 0
=> Ff-Fp-Fh = 0
=> Fp=Ff - Fh................................(2)
and pressure of the pump is given by ,

= where ,Ap......plunge cross-sectional area and
9
...........pump pressure
But , = ..................cylinder bore area (circular area)
....................plunge diameter varies (10 to 16mm) it is standard.

from this range let use Dp=10mm
and, therefore =
this implies that = .....................(3)
using Pascal’s law ,

= Pplunge = Pram = Pcylinder
therefore Pp= Pc => Pc=Fc/Ac where Pc=cylinder pressure

Ac =cylinder cross-sectional area
Fc=cylinder force
=> Fc/Ac(N/mm2) or Mpa....................................(4)
5.2 PRESURE RANGE SELECTION

Assumption :- assume that the interval cylinder diameter and the hollow ram diameter are
equal. Therefore Dci = Dhr
where Dci = internal cylinder diameter
Dhr =hollow ram diameter
 let assume that Dci = Dhr= 60mm

therefore Ac =πDhrxDhr/4
Ac = πx60mmx60mm/4
= 2827.43
Hence the minimum pressure to raise the given weight is:-
Pcmin = where :- W= 6 x x 9.81 = 58.86 x ........... is the given design weight
Pcmin =
= 20.82MPa
10
therefore
Pcmin = 20.82MPa , the internal pressure to be designed should be greater than the
minimum pressure since there are parts to be lifted with this pressure.
Hence Pcdesign > Pc min=20.82MPa
in order to fit the internal design pressure ,length of the handle ,force of fulcrum plunge
force and pin to pin length first let us assume the human force and length range for handle.
assuming Fh = 150N from the range of (100N to 200N)
and L =(300mm to 500mm) ,assuming , L =500mm
l = (30mm to 50mm) ,and also assume l = 30mm
by using equation (1) to equation (4)
 l(mm) Ff(N) Fp(N) Pp(MPa)
30 2500 2350 29.92
finally, from the above , must be greater than Pc min=20.82MPa. For this reason the
selected quantities are :-
L = 500mm , = 2500N, = 2350N
L =30mm, = 29.92MPa,
6.MATERIAL SELECTION
O-RING (SEALING) :-
O-ring are torus-shaped seals of circular cross-section made from a variety of
elastomeric and are used in static and dynamic condition.
Material :-the ring shall be made out of the following 4 classes of material.
SOLID RAM:-
Because of it is subjected compressive load, fluid friction and corrosion, the selected
material is should be :-
11
Alloy steel,AISI1015,Stu=420.6MPa,Sy=313.7MPa.
SPRING FOR SAFETY VALVE :-
Hence, it is selected from spring material. for this reason it is selected from
spring material table .
 HOLLOW RAMS:-
Here it is also subjected to fluid friction ,compressive load ,buckling and corrosion and
also from economic point of view, the selected material is :-
Milled steel ASIM, A487and Sy=90MPa
CYLINDER(CYLINDER RAM):-
just like hollow ram it is subjected to fluid friction, compressive load ,tensile load ,
buckling and corrosion and also from economical point of view ,the selected material is:-
Milled steel ASTM , A487,Sy=90MPa
PLUNGE CYLINDER:- again its characteristics is the same as that of ram cylinder and
from economic point of view and availability of material the selected material is :-
Milled steel ASTM , A487,Sy=90MPa
PLUNGE WITH PLUNGE ROD:-

Since it has reciprocating motion ,it is subjected to fatigue load ,compressive
load , tensile load ,fluid friction and from economic point of view and availability of
material the selected material is :-
Alloy steel,AISI 1002 , Stu=90MPa ,Sy=46MPa
OCTOGONAL HEAD TOP PLATE :-
since it is only subjected to compressive load ,so that the selected material is:-
malleable cast iron ASTM,A47 with Stu=345MPa ,and Sy=224MPa.
TOP-CUP WITH SQUARE THREAD:-
Since it subjected to compressive load the selected material is:-
Gray Cast iron,ASTM60 and Sy=86MPa.
HANDLE AND HANDLE SOCKET:-
For this ,due to compressive load and tensile load and also bending
force on it, the selected material is:-
12
Carbon steel,AISI1030,Stu=400MPa and Sy=237MPa.

HANDLE SOCKET PINS AND RELEASING SCREWS:-
Hence, it is subjected to torsion shearing compressive load the selected material is:-
Alloy steel ANSI1318,Sy=75MPa.
 HANDLE SOCKET LINK :-
Since it is subjected to compressive, tensile and bending load and also
buckling ,the material selected is:-
alloy steel ANSI1318,Sy=70MPa.
BASE PLATE :-
Since it is only subjected to compressive load the selected material is:-
Gray cast iron ASM60 with Stu=431MPa, Scu=1293MPa.
BALL FOR RELEASING AND SAFTEY VALVE:-
Since it is safety materials from the pressure to be developed and it is
always contact to fluid friction and corrosion the selected material is:-
stainless steel AISI 900 and Sy = 200MPa.
 RISERVIOR:- it is all the same character to that of cylinder and from economical
point of view and also availability ,the selected material is :-
Milled steel ASTM, A487 and Sy =90MPa
7 ) STRESS ANALYSIS
7.1 TOP-CUP WITH A SQUARE THREAD
A) FOR SCREW
Sy = 482Mpa
W = 58.86kN
By taking , σall =0.65 * Sy = 313.3Mpa
So that, to get core diameter (dc) of the screw
σall= =
13
=15.5mm
To be more safe let me take dc =20mm
Pitch of the thread (p) = ……………………………………………………………square thread
p=
p =5mm
h= =2.5mm ………………………….depth of screw thread
= p + dc =20mm +5mm = 25mm , where = diameter of the screw
= + 2(a) where a = 0.25 constant
= 25mm + 2*(0.25mm) = 25.5mm
H= 0.5P + a , where H = depth of the nut thread
H= 2.75mm
= = …………………………………core area of the screw.
= =
= 314.16mm2
Mean diameter of the screw (dm)
14
dm =
dm =
= 22.5mm
helix angle ( ):-
tan =
= tan-1
= tan-1
= 4.050
Frictional angle (β)
Where (μ) is the coefficient of friction between the thread is equal to 0.125 ( for carbon
alloy steel).
tan β = μ
β = tan-1μ
β = tan-1 (0.125) =7.1250
when the frictional angle (β) is greater than the helix angle ) the arrangement is self –
locking
therefore this arrangement is self –locking
FRICTIONAL TORQUE
The torque which resists the frictional force is called frictional torque.
15
Therefore, thread surface frictional torque = Tf =
Tf =
=130.8N.m
Now let us check the screw for the principal stress on it
Direct compressive stress =
= =187.36MPa
Maximum Tortional shear stress
Ԏmax =
Ԏmax =
Ԏmax =83.3MPa
Maximum principal stress =
max =
max = 219.1MPa
Since max is much less than all
that is all > max
therefore the screw is safe from crushing
CHECK FOR BUCKLING
Rankine’s formula is applicable for columns, ranging from very long to short ones for this
reason I use this formula to check buckling.
16
cripping load =
Therefore , WGr = where = crushing stress or yield stress in compression.
A = cross-sectional area of the column
Q = rankine constant
L = Equivalent length of the column
K = less radius of gyration .
Take the following design data From machine design book page “607“, table 16.3 for
material ,carbon steel
= 250Mpa
And fixture coefficient = 0.25
Rankine constant (Q) = *
=0.00044
And assuming equivalent or effective length of the screw (L) =80mm
Radius of gyration (K) =
K=
K=
K=
K= = 10mm
17
= = 64
Therefore Wcr =
=76.35KN
Permissible buckling load =
= 61.08KN
Since our load which is 58.86KN is much less than permissible buckling load, this screw is
safe from buckling.
B ) FOR A NUT
Bearing Area for thread = ( – )
Ab = ( – )
Ab = ( – )
Ab = 177mm
Minimum number of thread in the nut
NT =
18
NT =
NT = 33.25
The outer diameter of the nut
DN = 1.5dc
DN = 1.5 x 20mm
DN =30mm
C ) FOR THE CUP
Maximum diameter of the cup = 2 x dc
Dc = 2 x 20mm = 40mm
Let us assume that thickness of the cup
t = 30mm
shear area of the cup can be calculated as follows
area that resists shearing of the cup = db * tc
= *25mm * 30mm
=2356.19mm2
the induced shear stress :-
Ԏindused =
Ԏindused =25MPa
Since the indused shear stress is much les than the allowable shear stress.
i.e Ԏall > Ԏindused
19
7.2 SOLID RAM
Material :- alloy steel
Sy = 313.7 MPa
F .S = 4 ………………..assumption
Ԏall = 0.4* Sy
= 0.4 * 313.7 MPa
= 125.48MPa
σall = 0.65 * Sy = 203.905 MPa
Capacity = W = 58860 N
CHECK FOR SHEARING AND CRUSHING STRESS
Since the pressure applied on the bottom of the solid ram when it hits the stop of the
second stage ram subjects the neck for shearing and crushing, we have to check it.
Figure
Maximum force acting on the neck
Fat neck = P cylinder * Ac , where Ac =
Ac =
Ac = 2827.33mm2
Fat neck = 29.92MPa * 2827.33mm2
Fat neck = 84.6KN
The induced shear force (Ԏinduced )
Ԏ= but Ashear = π Di * t
20
Ashear = π 40mm * 15mm = 1884.95mm2
Ԏ =
Ԏ =44.882MPa
Since Ԏall > Ԏinduced then this ram is safe from shearing
The induced crushing stress ( c)
c= but Acrushing = *( - )
Where Do = outer diameter outer diameter of the ram

Di = inner diameter of the ram
Acrushing = *( - ) =1570.8
c = = 53.86MPa
> c have our ram is save from crashing
ii) Check for Bucking
Again using Rankine formula we can check our solid ram from bucking
WCr =
Where Wcr = crippling load
c=Crushing stress on tield stress on compression
A = Cross –sectional area of the column
Q = Rankine constant
L = equivalent length of the column
K = least radius of gyration
From machine design textbook, Gupta , page 542, table 16.3, I have take that the Rankine
constant, crushing stress and fixture coefficient as follows:-
21
 For carbon steel

c = 250Mpa and fixture coefficient =
Rankine constant =
Rankine constant for this ram will be :-
Q= * =0.00044
And the equivalent length (L ) = 95mm
K=
K=
K= = = 10mm
= = 90.25mm
Finally the crippling load
Wcr = but Ac = π /4 =
Ac = π /4 = 1256.64
Wcr =
WGr = 302.16KN
WGrp =
22
WGrp = = 241.73KN
Since the permissible buckling load is much greater than the given load i.e WGr > W =
58.86KN , hence the ram is safer from buckling
7.3 SECOND STAGE RAM
Material :- Mild steel
Sy = 90MPa
Ԏall = 0.5 * Sy = 0.5 * 90MPa
= 45MPA
all = 0.65 * Sy = 0.65 *90MPa
= 58.5 MPa
Due to given load, assuming the hollow ram is thin walled cylinder.
Therefore , From hoop stress ( h)
h = where Pi = internal pressure
Di = internal diameter
t = hollow ram thickness
Cf = corrosion factor
Therefore Pi = 29.92MPa
Di = 40mm
Let us assume that
h = all = 58.5MPa
Therefore, h =
23
t=
t=
t = 15.34mm
due to corrosion effect we have to add corrosion factor Cf = 1.66mm
therefore, tactual = 15.34mm + 1.66mm
tactual = 17mm
assuming stop length ( L) = 10mm
and Do = Di + 2t = 60mm +(2*17)
Do =94mm
most outer diameter of the ram becomes :-
DMO = DO + 2(L) = 94 +20 = 114mm
I ) CHECK FOR SHEAR AND CRUSHING STRESS AT THE STOP (NECK)
Maximum force acting on the neck (stop)
Fat neck = Pc *Ac but, Ac =
= Ac = = 10207.03mm2
Therefore , Fat neck = 29.99MPa * 10207.03mm2 = 305.4KN
Induced shear force at neck (stop) is:-
Ԏ= where Ashear = *DO *h
Ashear = * 94mm * 10mm
Ashear =2953.097mm2
24
Ԏ= = 103.4168MPa
Crushing stress at neck (stop)
c = where
Acrush = (DMO2 –DO2 )
= (1142 –942 )mm2
Acrush = 3267.256mm2
Therefore , c =
c = 93.473MPa
Since the induced shear of the crushing stress are much less than the allowable shear of
normal stress, our hollow ram is safe from this induced stress.
ii ) CHECK FOR BUCKLING
Here again the Rankine formula is applicable to check buckling . that is
Wcr = where Wcr = crippling load
c = 320MPa …………….for mild steel crushing stress
Q= = = 0.00053………………………rankine constant
L= 95mm ……………………………….effective length
K=
K=
25
K =
K = 16.1245mm
= = 34.7
And Area (A)=
A=
A = 3267.256mm2
WGr =
WGr = 1.0266 x N
Permissible buckling =
WGrp =
WGrp = 821.3KN
Since the permissible buckling load is much greater than the given load, which is 58860N,
this second stage ram is also safe from buckling.
7.5 RAM CYLINDER
Material specification :- mild steel
Sy = 90MPa.
Assume S.f = 1.25
Ԏall = 0.5 * Sy
26
=45MPa
all = 0.65* Sy
= 58.5 MPa
Again from the given load and the applied internal pressure , it is possible to assume the
ram cylinder as a thin walled cylinder.
Hence : from hoop stress ( h)
h = where Pc = 29.92MPa
Di = DMO of the second stage ram
 Di = 114mm
Assume that h = all =58.5MPa.
h =
t=
t=
t = 29.15mm
to be more safe let us added corrosion factor (Cf ) = 0.85mm on it.
Therefore , tactual = t + Cf
tactual = 29.15mm + 0.85
tactual =30mm
i ) Check for the Shearing and Crushing Stress at the Stop (Neck)
since the material of the diameter of the ram cylinder is the same as that of the third stage
ram, it is safe from crushing and shearing stress induced on the neck (stop) of the cylinder.
ii Check for Buckling
again from the same text called GUPTA, I used Rankine formula of buckling.
27
WGr = ………………………….Crippling load
But from the text, for mild steel
= 320MPa and
Q= = * = 0.00053
And cross sectional area of the cylinder becomes
A=
But DMO =Di + 2t = 114mm * 2*(30mm) = 174mm
A=
A= = 13571.68
L = 130mm…………..effective length of the cylinder
K=
K=
K =
K = 52mm
= = 6.25
FINALLY
WGr =
28
WGr = 4.33 x N
Permissible buckling =
WGrp =
WGrp = 3.463MPa
Since the permissible buckling load is much greater than the given load, which is 58860 N ,
this ram cylinder is safe from buckling .
7.4 RESERVIOR
Material:- mild steel
Sy =90 MPa
Since the reservoir is much less loaded let us take S.f = 2
all = 0.65* Sy = 0.65* 90MPa = 58.5MPa
i VOLUME CALCULATION
and the volume of the fluid occupied by the ram and the cylinder should be equal to that of
the reservoir volume.
i.e ram volume (VR ) = V1 +V2
where V1 =A1h1
= ) * h1
= * 65
V1 =183783.17 mm3
V2 = A2h2
V2 = * h2 = * 65 =663457.24 mm3
Therefore VRam = v1 + v2
29
= 847240.415mm3
ii ) INNER DIAMETER OF THE RESERVIOUR
In order to carry this amount of volume of fluid in the height of …………… the reservoirs
volume should be equal to the volume of the rams.
i.e. VRam = Vreservoir =
therefore , Vreservoir = ( D2inner of reservoir - D2outer of the cylinder ) * height
Vreservoir = ( D2i - ) * 95
D2i - = 11355.16mm2
Di = 204mm
To be more safe and reservoir STD let us take Di =210mm
iii ) THICKNESS OF THE RESRVIOUR
Since only atmospheric pressure is applied on the inside and outside of the reservoir , we
can threat the reservoir us thin walled cylinder.
Therefore from hoop stress ( h)
h = where, Pc = 1 bar = Pa = 0.1MPa
=> t = Di =210mm…..internal diameter of the reservoir.
h = all = 58.5MPa ………..assumption and , t = thickness
t = = 0.18mm
to be more safe let us add corrosion factor Cf = 1.9mm
tacual = t + Cf
tacual = 0.18mm + 1.9mm =2mm
30
7.5 PLUNGER CYLINDER
Material :- Milled steel
Sy = 90MPa
Assume S.f =1.25 …since the cylinder is subjected to compression load and the tensile load
we have to take higher safety factor.
Ԏall = 0.5 * Sy = 45MPa
all = 0.65* Sy
= 58.5 MPa
i) THICKNESS OF THE WALL
Again for the same reason which is less internal pressure applied on the cylinder ,we can
threat as thin walled cylinder.
Therefore , from hoop stress( h)
= where Pc =29.92 MPa…………cylinder pressure
=> t = Di =10mm ………………………..internal diameter of the cylinder
= all = 58.5 MPa……………………assumption
Therefore , t = = 2.56mm
to be more safe let us take corrosion factor Cf =1.44mm
tacual = t + Cf
tacual = 2.56mm +1.44mm
tacual = 4mm
therefore the outer diameter of the cylinder becomes
31
Do = Di + 2(tacual)
Do = 10mm + 2*4mm
Do = 18mm
ii ) CHECK FOR BUCKLING
From the same text book which is GUPTA ,I used rankine formula and take constants.
Therefore, for mild steel;-
c = 320MPa ……………..crushing stress.
Q= = * = 0.00053 where C =the end fixture coefficient
Q = rankine constants
crippling load
WGr = where =320MPa
A= …………..cross-sectional area
A=
A =175.95mm2
Q = 0.00053
L = effective length of the the cylinder
K=
K=
K=
32
K =
K = 6.02mm
= = 135.21
Wcr =
Wcr =
Wcr = 52.54KN
WGrp =
= 42.03KN
Since the permissible buckling load is greater than the fulcrum load (Ff = 2.5kN ) our
plunger cylinder is safe from buckling.
7.6 PLUNGER WITH PLUNGER ROD
Material :- alloy steel
Sy = 40MPa.
Assume , S.f =2 …………since it is subjected tensile and compressible stress
all = 0.65* Sy
= 0.65 *40MPa
all = 26MPa
i ) PLUNGER ROD DIAMETER
33
In order to determine the plunger rod diameter (DR ) from compressive stress (ᵟc ) it can
be equated as follows. c = all = …………………………..assumption.
Arod = = =
DR =
DR = mm
DR =8 mm
ii )CHECK FOR BUCKLING
Again from the same text book GUPTA, by applying the Rankine formula
For alloy steel
c= 250MPa …………………….crushing stress
Q = Rankine constants
Q= = * = 0.00044 where C is fixture constants
And, cross-sectional area Ac
Ac = = 50.27mm2
Active length ( L) = 70mm
Radius of gyration (K) K =
K=
34
K=
K= =
K =2mm
= = 1225
Finally the crippling load becomes

WGr =
WGr = 22.8KN
WGr =
WGr = 11.4KN
Since the permissible buckling load is greater than the fulcrum load (Ff =2.5KN) this
plunger road is safe from buckling.
7.7 OCTAGONAL HEAD TOP PLATE
Material :- Alloy steel
Sy = 382MPa
Assume that S.f = 2 since the load on the top plate is very low
all = 0.65* Sy = 248.3MPa
Ԏall = 0.5 * Sy = 191MPa
i)CHECK FOR SHEARING AT CRITICAL POINTS
35
F at neck = Pc *Ac where Pc = 29.92 MPa internal cylinder pressure
Area (Ac ) = *( - )
= *( - )
Ac = 27696.3 mm2
F at neck = 29.92MPa * 27696.3 mm2
F at neck = 828.67KN
figure
INDUCED SHEAR STRESS
Ԏ= where Ashear = π Di *h
Ashear = π * 94mm * 22mm
Ashear = 6496.81
Ԏinduced =
Ԏinduced =127.55MPa
Hence the induced shear stress at the critical point is much lower than the allowable shear
stress, our plate is safe.
7.8 HANDLE
Material :- Carbon steel
Sy =237MPa Figure
Sall = 0.65 *Sy = 154MPa
Ԏall = 0.5 * Sy = 118.5MPa
i) DETERMINATION OF DIAMETER
36
 From moment diagram
From the above diagram maximum Torque is moment can be seen
Therefore to determine diameter let us calculate it from Ԏall or fall
Ԏall = (16 Tmax)/ᴨ
d=
d=
d = 14.47mm
and, σall =
where Mmax = 470 mm* 150N
Mmax = 70500N.mm
d=
d = 14.247mm to STD value d =20mm
37
Due to safety from Ԏall of σall we have to select the greatest diameter from the above
Therefore dshaft = 20mm
7 .8 HANDLE SOCKET
Material – Carbon steel, Sy = 237MPa
Ԏall = 0.5 * Sy =0.5 *237MPa = 118.5MPa
all = 0.65 * Sy = 154MPa
i) DITERMINATION OF DIAMETER
Again from allowable stresses we can determine the outer diameter of the socket
all = where Ff = fulcrum force
D1 = outer side diameter of the handle socket
d = inside side diameter of the handle socket
D1 =
D1 =
D1 = 20.51mm
And , Ԏall =(4*Ff)/(ᴨ ( - ))
D2 =
D2 = 20.66
In order to determine the diameter let us check the thickness from the two result
Therefore t1 = D1 - d = 20.51mm - 20mm = 0.51mm
t2 = D2 – d = 20.66mm – 0.66mm
38
this implies that it can be possible to use a material thickness greater than 0.66mm
therefore by adding correction factor Cf =2.34mm
for convenience it becomes.
D = d + 2(Aactual )
D = 20mm + 2*(0.66mm + 2.34mm)
D = 26mm
7.9 HANDLE SOCKET PINS
i) FULCRUM PIN
material :- Alloy steel , Sy = 75MPa
A) DETERMINATION OF THE DIAMETER
Since the pin is subjected to double shear
Ԏall =
d=
d=
d = 3.25mm , to be more safe and standard let us take dpin = 8mm
ii) PIVOT PIN
Material – Alloy steel , Sy = 75MPa ; Ԏall = 0.5* Sy = 37.5MPa.
A) DETERMIATION OF THE DIAMETER
Again it subjected to double shear
Ԏall =
Ԏall =
39
d=
d=
d = 3.16mm
to be more safe and standard let us take dpin = 6mm
7.10 SPRING DESIGN FOR CHECK VALVES
I ) MATERIAL for spring material, we have that for discharge valve from text book called
Engineering material Berilium Copper (C17200)
Sy = 1172MPa
Ԏall =0.5 * Sy =586MPa
Modulus of elasticity (G) =131GPa
A DESIGN PROCEDURE
Assume a wire diameter of d =4mm and spring index C = 5
Dmean = d * c =20mm
Douter = Dmean + d =22mm
Shear stress factor (Ks) , Neglecting effect of curviture
Ks = 1 + = 1.1
Maximum shear stress induced
Ԏinduced = ks *
Where W = P X A ……………………………….Axial load
And A = assume of the fluid line with d = 4mm
A= = 12.57mm2
40
And P = 29.92 is the cylinder pressure
Therefore , W = P X A = 29.92 X 12.57mm2 = 376.2N
Ԏinduced = ks *
= 1.1 *
Ԏinduced = 329. 22MPa
Let us check the safety of factor (S.f)
S .f = = = 1.78
Since the safety of factor is greater than one ,our discharge spring is safe and acceptable.
SPRING CONSTANT (K)
Assume the deflection of the spring (d) = 2mm
And assume the end details of the spring is square ends
ᵟ = => K = = = =188 * 103 N/m
Number of active length (Na)
K=
 Na = =
Na = = 2.78
Na = 3
Number of total turn of the spring (Na’)
Na’ = Na + 2 for square end
41
Na’ = 3 +2 = 5
Free length of the spring
We know that free length of the spring
lf = (Na’ *d) +( ᵟ) + (0.15 x ᵟ )
pitch of the spring
P= = =3
DRAWING OF THE SPRING
CHECK FOR BUCKLING
The critical load (Wcr) that causes buckling may be calculated by using the following
relation
i.e Wcr = K*KB *lf where K =spring rateor stiffness of the spring
lf =free length of the spring
KB = Buckling factor that depending up on the the ratio
KB ,From the table for
= 0.615
And for built in end spring, μB = 0.71
42
K = 188 * from the above
Therefore . Wcr = K*KB *lf
= 188* * 0.71 *12.3 *
= 1641.804 N
Since the critical axial load is greater than the applied axial load (W = 376.1 N) then this
spring is safe from buckling
C) BALL FOR DISCHARGE VALVE
Material due to the application of the fluid friction on it.i have selected stainless steel and
diameter of the ball = mean diameter of the spring
Therefore ,Db =Dmean =20mm
ii) SPRING FOR RELIEF VALVE
This spring is come to in operation ,if the jack is over landed to 1KN large than the designed
(require) load .
Material from the spring material , we have selected that for relief valve from text book
called GUPTA .i.e. carbon stainless- steel (BISA)
Ԏall =for average service = 364 MPa
G = 44 GPa
A) DESIGN PROCEDURE
Assume a will diameter of d = 4mm and spring index C= 5
Mean diameter D = C x d = 20mm
outer diameter D0 = D + d = 22mm
shear stress factor (ks), neglecting the effect of curvature
Ks = 1 + 1/2c = 1.05
Maximum shear stress induced

43
Ԏindused = Ks *
Where W = P x A ………..applied load
But internal pressure developed will be increase and the applied load also increases by
1KN
i.e W app =FRam + 1KN =58.86KN + 1KN = 59.86KN
D = mean diameter
d = wire diameter
Ks = shear stress factor
Therefore , the internal pressure (P)
P = =
P= 4* ………………assume ram diameter is dr = 60mm
Waxial = P*A = 21.17 * * ……………….assume line diameter dl = 4mm
Waxial =266N
Ԏindussed = ks*8*w*D/πd3
= 1.1 * 8 *266N * 10mm/π(4mm)3
Ԏindussed = 116.42MPa
Since the induced shear stress is less than that of allowable shear stress therefore the is to
safe region and acceptable.
Spring rate (k)
Assume deflection of the spring (δ) =2mm and assume end details of the spring is square
end
K = 266/ 2 = 133 *103N/m
44
Number of active coil (Na)
Na =
Therefore Na = = 0.6 =>for the sace of safety take Na = 1
Free length (Lf)
Lf=Na’ δ =+δ +0.15d
=3*2+2+0.15*2 = 8.3mm
9. Pitch of the spring (p)
P= =>but Na’ =Na +2…………………..for square end
= 1+2 = 3
P= =4.15mm
B) Check for buckling
The critical axial load( Wcr) that causes buckling may be calculated by using the following
relation
Wcr =k*kB*
KB for = =0.415
And for spring in end spring KB = 0.72 k = 133kN/m
Wcr =133kN/m *0.72 *0.0083 =783.77N
Since the critical axial load is greater than that of applied axial load , the spring is safe from
buckling .
C) Ball for relief valve
Material …..stainless steel due to application of fluid friction , this material is selected And
diameter of the ball Db = mean diameter of the spring = 20mm
iii)Design of spring for intake valve
45
material again from the same text book the spring material is selected .
A) Design procedure
1)assume that wire diameter =d=1mm and index c=10
2) mean diameter =D=cd=10x1=10mm
3) outer diameter Do=D+d=10+1=11mm
4)shear stress factor ks=1+1/2c= 1.05mm
neglecting the effect of curvature
5)max shear stress that induced
Τinduced =ksx8WD/πd3
Where w .PA…………… the force acting on spring (axial load)
Assume that the fluid in the reservoir is in the atmospheric pressure that is Patm=
1bar
And assume diameter of the line to be dl=4mm
A =πdl2/4=π* 42/4 =12.57mm2
W=PA = 0.1*12.57 =1.257N
D……………………….mean diameter=20mm
d………………………….wire diameter =1mm
ks………………………….shear stress factor =1.05
τinduced =ks*w*D/πd3 = 1.05*1.257*20/π13
=33.6MPa
since the induced shear stress is less than the allowable stress
the spring is safe and acceptable
6. spring rate (k)
Assume deflection (δ) =2mm and end detail of the spring is square and k=w/ δ=
K = 1.257/2 = 0.6285
7. number of active turn (Na)
Na =
46
= = 6.96
Na = 7
8. total turn of the coil(Na’)
Na’=Na+2 …………………………….for square and ground ends
= 7 +2
Na’ = 9
8)free length of the spring (Lf)
Lf = (9 * 2) + 2 + (0.15 * 2) = 20.3 mm
Pitch =Lf/Na’-1 = 20.3/8 = 2.5 mm
B)check for buckling
Wcr=k x kB X Lf ……………………………….critical axial load
From the table of STD,for Lf/D=20.3/10 =2.03 , and built in end spring
Kb=.72 k=0.6285 * N/m
Lf = 20.3mm
Wcr= Kb * k *Lf
= 0.72 * 0.6285 * * 20.3 = 9.19
Since critical axial load is greater t than the applied axial load which is (1.25N)
The spring is safe from buckling.
C)Ball for intake valve

Material due to the same reason as the above the selected material is called stainless steel
Diameter of the ball
Dball =mean diameter of the spring
Db =D=10mm
47
7.11 Design of the base

The base is used to support the jack system and also protect forgive particles from going
into the system .the material used for the basement is most of the time cast iron . this is b/c
of the following reasons : it is cheap and easily available , it can easily resist wear when we
compared to steel and it is highly resist compressive load .this base is casted in the molding
system and drilled top for fluid comes in and out of the pump into system and from the
system into the reservior and also from the reservoir into the pump and so on.
The material is gray cast iron ASTM60 and Sy =43MPa.
7.12 DESIGN OF THE RELEASING SCREW
Material alloy steel ,ANSI1318 ,Sy=75MPa

The selected STD screw M8
7.13 DESIGN OF REFILING SCREW
Material :-alloy steel and the selected STD screw is M4 and this screw is hollow due to the
passage of atm .pressure.
7.14DESIGN OF RETAINER
Material :-alloy steel and from standard and compatible selected t=2mm
7.15 DESIGN OF SEALINGS
Material Nitride Butadiene (class A)
And we have selected from compatible for different purpose
8 MANUFACTURING PROCESS
A) FOR THE PLUNGER OF THE PUMP
First select with the appropriate diameter, then face and turn the work piece according to the
dimensions. Make internal groove for O-ring with the required thickness and depth. Finally with
the precise finishing machine make finishing.
B)For Solid Ram : -
48
initially select the blank (work piece) with the required dimension and faces the work
piece by using lathe machine for the required and exact dimension
Secondly drill the internal blind with the required dimension (diameter) by using lathe
machine with out missing the center
Finally :- steep turn the external part of the solid ram and finishing process with high
surface finishes required so that use precise surface finish machine .
C) FOR HOLLOW RAM
Make the blank by casting with a dimension of the nearest to the exact dimension and bore
and turn the internal and external part by using lathe machine. Make groove for the O-ring
seal with the appropriate dimension. Make some finishing with précised surface finish
material or machine like internal and external grinding machine.
D) For the base plate
By using casting process make the lower base plate blanks which is suitable for machining
Correct the casting blank for the appropriate dimensions. Drill the upper surface for the fluid
passage to the required diameter and make thread for releasing screw with 1mm pitch. Make
thread the upper inner surface to tight the cylinder and the reservoir with a metallic thread
engagement part with 1mm pitch by using lathe machine. Finally make the necessary surface
finish.
E) For Extension Screw :-

select the blank (work piece) with a required dimension and by using lathe machine face
and turn for the required dimension . And then chamfer the lower part of the screw by 45o
for easy of losing and hitghching Thirdly ,make a thread with a square thread by using the
appropriate pitch and use milling machine for easiness , when using indenting to this
thread , use the appropriate pitch . Finally use the necessary fining by using surface
finishing machine
F) FOR THE HANDLE
The handle is made from the round bar turn the round bar and face with the required
specification. Make to some length knurling for good griping ability. Finally make the required
surface finish
G) FOR THE SOCKET
49
The socket is made from socket metal of the required thickness cut the sheet metal with the
correct lay out by using cutter machines drill the socket metal for pin connection with a drilling
machine .roll the sheet metal with accurate dimension.
H) FOR THE CYLINDER OF THE PUMP
Prepare hollow round bar with the required dimension. Bore the round bar by using lathe
machine to the required diameter. Make thread by using lathe machine on the lower part of it.
And make hexagonal head b y using milling machine on the upper part of it .finally make the
necessary finishing.
I) FOR RAM CYLINDER
Make the blank by casting with the nearest dimension that enables as to make the exact
dimension bore and turn the dimension by using lathe machine with the required dimension.
Make the groove for O-ring seal with the appropriate depth with by using lathe machine on the
top inner surface of the cylinder. Make precise surface finishing by using surfase grinding
machine. finally on the lower part and on the upper part make a thread for thigh ting with the
top cup and base plate
J) FOR OCTAGONAL TOP CUP
By using casting process make the top cup handle which is suitable for machining. Make some
correction the casting for the appropriate dimension .next make a thread at the lower and
upper inner surface to tighten the cylinder and the reservoir with a metallic thread
arrangement part with 1mm pitch by using lathe machine. Finally make necessary surface
finishing process.
K) O-RING:- o-ring seal made from rubber compound by the process vocalizations. First make
mold for the vocalizations process then, insert the compound on it.
L) FOR THE RESERVIOR
The reservoir can be manufactured from the sheet metal with the appropriate thickness. First
prepare a sheet metal with appropriate thickness, width and height. Then, roll the sheet metal
by using rolling machine. Next weld the rolled metal using welding machine .then make thread
at the lower part and the make groove at the lower and upper inner surface to the required
length, width and height. Finally make a necessary surface finish
50
M) LINK: - can be manufactured by using sheet metal with the appropriate length and
thickness. First cut a sheet metal in a strip then drill at the required position for pin connection.
Finally bond with the required dimension.
9) HYDRAULIC SELECTION AND STROKE CALCULATION
A) Hydraulic selection
The hydraulic oil has the following function:-
-It used to reduce the friction b/n the milling surface.
-it used to dissipate the heat developed inside the system
-it used to clean the hydraulic part
-it prevents the parts from corrosion and so on
Due to the above function and high viscosity at high temperature the selected STD fluid is called
ATF (automatic transmission fluid) and its designation is as follows
AES-NO10 Part number H008
B) Stroke calculation
In order to get the maximum height of the jack, how many strokes are needed can be
calculated as follow
Number of stroke = volume of the ram/volume of the plunge
But vram =v1+v2 = 847240.415mm3
And volume of the plunger =AxH=πdp2/4xlp = 4712.4mm3
Number of stroke = 847240.415mm3/ 4712.4mm3
= 18
51
APPENDIX
TABLE.1
TABLE .2
52
53
54
55
References
Text Book of Machine Design, Gupta
Text Book of Engineering Material
WWW. We papers /papers /9399/tasksheet
56

Adama University School of Engineering and Inforamation Technology Bottle Jack Design Design of Hydraulic Bottle Jack

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Bottle Jack Design 2010

Bottle Jack Design

DESIGN OF HYDRAULIC BOTTLE JACK

Submitted to Girma G/wold (MSc)

Hydraulic Ram and Plunger……………………………………………………………………………… . 1

7.1 Top-Cup with a Square Thread………………………………………………………..….9

7.2 Solid Ram………………………………………………………………………………….….15

7.3 Second Stage Ram……………………………………………………………………….…..18

7.5 Plunger Cylinder…………………………………………………………………………….26

7.6 Plunger with Plunger Rod………………………………………………………………28

7.7 Octagonal Head Top Plate…………………………………………………………30

7.9 Handle Socket Pins…………………………………………………………………34

7.10 Spring Design for Check Valves……………………………………………35

7.11 Design of the Base………………………………………………………………….43

7.12 Design of the Releasing Screw……………………………………………….43

7.13Design of Refilling Screw…………………………………………………………43

HYDRAOLIC RAM AND PLUNGER

= 130mm – 25mm -10mm

=> = 260mm – 25mm – 10mm

Since Nrams should be whole number then, Nrams = 2

dr=diameter of the ram

dp =diameter of the plunge

5.1 FOR JACK HANDLE AND PUMP FORCE

where Fp................pin force

and pressure of the pump is given by ,

But , = ..................cylinder bore area (circular area)

....................plunge diameter varies (10 to 16mm) it is standard.

this implies that = .....................(3)

using Pascal’s law ,

therefore Pp= Pc => Pc=Fc/Ac where Pc=cylinder pressure

5.2 PRESURE RANGE SELECTION

 let assume that Dci = Dhr= 60mm

PLUNGE WITH PLUNGE ROD:-

Carbon steel,AISI1030,Stu=400MPa and Sy=237MPa.

7.1 TOP-CUP WITH A SQUARE THREAD

By taking , σall =0.65 * Sy = 313.3Mpa

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

To be more safe let me take dc =20mm

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

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

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

= + 2(a) where a = 0.25 constant

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

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

= = …………………………………core area of the screw.

Mean diameter of the screw (dm)

helix angle ( ):-

Frictional angle (β)

β = tan-1 (0.125) =7.1250

therefore this arrangement is self –locking

Therefore, thread surface frictional torque = Tf =

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

Direct compressive stress =

Maximum Tortional shear stress

Maximum principal stress =

Since max is much less than all

that is all > max

therefore the screw is safe from crushing

CHECK FOR BUCKLING

Therefore , WGr = where = crushing stress or yield stress in compression.

A = cross-sectional area of the column

L = Equivalent length of the column

Ԏ= where Ashear = DO h