University of Gondar

University of Gondar
Institute of technology
Department of Mechanical
Engineering
Hydraulic car jack
Project 2
Name I.D
1. Getachew Tsgehanns……………………………..4507/08
2. Hagos Tsehaye….………………………………....4549/08
HAYDRAULIC BOTTLE CAR JACK 04/10/2010
Abstract
This project deals with design and fabrication as well as cost analysis of hydraulic bottle car
lifting attachment with the help of hydraulic cylinder. The project deals also the working
principle and application of hydraulic bottle jack. The working principle of a hydraulic bottle
jack is explained with the help of figure. Consider a ram and plunger, operating in two cylinders
of different diameters, which are interconnected at the bottom, through a chamber, which is filled
with some liquid. Lifting the car in any problem case like replacing wheel, & when tire is
puncture it is not easy. For this type of operations we need heavy force. In the case of tire
puncture or replacing wheels lift the car is more important part. This time we use traditional
ways to lift the tire. In that case a physically handicapped person, ladies person or aged person
not lifts the tire easily. They require more time and also require more force to lift the tire.
Hydraulic jack system is more useful for this type of problems. The application of Pascal’s law
is also discussed in the project because of its main role in the working principle of the hydraulic
bottle jack.
GECH & HAGOS I

ACKNOWLEDGEMENTS
First we would like to thank to our almighty God who help us at all things. Next we
acknowledge the help and guidance we have received from a numerous people during the course
of our stay at University of Gondar. Our instructor, Mr.Kirubel Aweke for providing us with
energy, enthusiasm, insight to work on this interesting design project and for all comments given
during the design. Moreover, I would like to express my heartfelt and sincere for their priceless
guidance and support during my final year. Furthermore, we also would like to thank our senior
students who give references and motivate us during the project. Not forgetting our fellow
friends who gave us a lot of ideas, contributing in our development of the design. Which we also
learnt the importance of team working.
GECH & HAGOS II

Contents Page
Abstract............................................................................................................................................1
ACKNOWLEDGEMENTS.............................................................................................................2
CHAPTER ONE..............................................................................................................................4
INTRODUCTION...........................................................................................................................4
1.1 overview of the project..........................................................................................................4
1.2 Definition of Hydraulic Jacks................................................................................................5
Classification of jack...............................................................................................................6
Classification of Hydraulic Jacks............................................................................................8
Strand jack:............................................................................................................................11
According to the source of power..........................................................................................11
According to the lift of ram...................................................................................................11
According to the arrangement of cylinder.............................................................................12
According to the number of cylinders...................................................................................12
According to the construction................................................................................................12
1.4 Components of hydraulic Bottle jack..................................................................................12
1.5 Hydraulic fluid.....................................................................................................................14
1.6 Material used and its property.............................................................................................14
1.7 Hydraulic Basics..................................................................................................................16
1.8 Pascal's Law.........................................................................................................................16
1.9 Hydraulic Systems...............................................................................................................17
1.10 Hydraulic Pressure, Force, and Motion.............................................................................17
1.11 Working Principle..............................................................................................................18
1.12 Advantages and disadvantages of hydraulic bottle jack....................................................19
1.12.1Advantages..................................................................................................................19
1.12.2 Disadvantages.............................................................................................................20
1.13 Historical Background of Hydraulic bottle Jacks..............................................................21
1.14 Problem Statement.............................................................................................................21
1.15 OBJECTIVE......................................................................................................................22
1.15.1 Main objective............................................................................................................22
GECH & HAGOS III

1.15.2Specific objective.........................................................................................................22
1.16 METHODOLOGY............................................................................................................23
1.17 Problem specification........................................................................................................23
1.18 Design of parts...................................................................................................................23
1.19 Scope and Limitation of the Project..................................................................................27
1.19.1 Scope of the project....................................................................................................27
1.19.2 Limitation of the project.............................................................................................27
CHAPTER TWO...........................................................................................................................29
LITERATURE REVIEW..............................................................................................................29
CHAPTER THREE.......................................................................................................................31
DETAILDESIGN AND DISCUSSION........................................................................................31
3.1 Introduction..........................................................................................................................31
3.1.1. Givens of the design....................................................................................................31
Actuating piston)........................................................................................................................36
3.3. STRESS ANALYSIS.........................................................................................................42
3.3.1 Design of Piston Rod....................................................................................................42
3.3.2 Design of Piston Head..................................................................................................46
3.3.3. Design of Cap..............................................................................................................47
3.3.4. Design of main cylinder...............................................................................................51
3.3.5. Design of Telescopic cylinder.....................................................................................54
3.3.6. Design of the pumping cylinder..................................................................................56
3.3.7. Design of the reservoir cylinder..................................................................................58
3.3.8. Design of the cover plate.............................................................................................60
3.3.9. Design of Pump handle socket....................................................................................61
3.3.10. Design of Pump handle..............................................................................................65
3.3.11. Design of the Plunger................................................................................................68
3.3.12. Design of the link.......................................................................................................70
3.3.13. Design of the Basement.............................................................................................72
3.4. Components selected from standard tables-3.....................................................................73
3.4.1. O-ring selection:..........................................................................................................73
CHAPTER FOUR.........................................................................................................................80
Manufacturing Process and Maintenance......................................................................................80
4.1 Introduction..........................................................................................................................80
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4.2 Methods of fabrication.........................................................................................................80

4.3. Maintenance........................................................................................................................82
4.3.1. Oil in a Bottle Jack......................................................................................................82
4.3.2. Adding oil....................................................................................................................82
4.3.3. Replacing oil................................................................................................................82
4.4. Lubrication..........................................................................................................................83
4.5. Preventing rust....................................................................................................................83
4.6. Inspection............................................................................................................................83
4.7. Safety..................................................................................................................................83
4.8. Troubleshooting..................................................................................................................85
CHAPTER–FIVE..........................................................................................................................86
Cost Analysis.................................................................................................................................86
5.1 Purchasing cost....................................................................................................................86
CHAPTR SIX................................................................................................................................89
Result and Discussion....................................................................................................................89
6.1 Introduction..........................................................................................................................89
6.2 Results of Geometrical Analysis.........................................................................................89
6.3 Results of Stress Analysis...................................................................................................90
CHAPTER SEVEN.......................................................................................................................94
Conclusion and Recommendation.................................................................................................94
7.1 Conclusion:..........................................................................................................................94
Recommendation:......................................................................................................................94
Reference...................................................................................................................................95
Appendix........................................................................................................................................96
GECH & HAGOS V

List of figure PAGE
Figure 1 solid representation of Hydraulic bottle jack....................................................................8

Figure 2 Mechanical jack...............................................................................................................10
Figure 3 hydraulic bottle car jack..................................................................................................11
Figure 4 Hydraulic car jacks..........................................................................................................12
Figure 5 hydraulic bottle car jack..................................................................................................12
Figure 6 floor hydraulic jack........................................................................................................13
Figure 7Pneumatic jack.................................................................................................................14
Figure 8 components of hydraulic bottle car jack.........................................................................16
Figure 9 components of hydraulic car jack....................................................................................17
Figure 10 Pascal law......................................................................................................................20
Figure 11 working principle of hydraulic car jack........................................................................22
Figure 12 Lowest Position of Socket............................................................................................37
Figure 13Maximum Position of Socket.........................................................................................38
Figure 14 Pascal’s law of the fluid................................................................................................38
Figure 15 The main and telescopic cylinder..................................................................................40
Figure 16 Head of the piston.........................................................................................................42
Figure 17 Piston Rod.....................................................................................................................46
Figure 18Piston Head....................................................................................................................50
Figure 19 2D and3D model of cap................................................................................................51
Figure 20 Cap Surface Models......................................................................................................52
Figure 21 free body diagram of cup..............................................................................................53
Figure 22 Main Cylinder...............................................................................................................54
Figure 23Tangential and Radial Stresses.......................................................................................55
Figure 24Telescopic Cylinder........................................................................................................58
Figure 25 pumping cylinder...........................................................................................................59
Figure 26 Reservoir Cylinder........................................................................................................61
Figure 27 Cover Plate....................................................................................................................63
Figure 28 Magnified Pin and Plunger joint...................................................................................67
Figure 29 Handle and Socket beam diagram.................................................................................68
Figure 30 Force Distribution of Handle.........................................................................................69
Figure 31BMD & SFD..................................................................................................................70
Figure 32Plunger...........................................................................................................................71
GECH & HAGOS VI

Figure 33 Link Multi-View...........................................................................................................74

Figure 34Static axial seal...............................................................................................................77
Figure 35 Static radial seal............................................................................................................77
Figure 36 Reciprocating seals........................................................................................................78
Figure 37 Oscillating seals.............................................................................................................79
Figure 38 O-ring Standard 1..........................................................................................................79
Figure 39 animation image of bottle hydraulic car jack................................................................82
Figure 40 Safety Picture 1.............................................................................................................87
Figure 41Safety Picture 2.............................................................................................................87
Figure 42Safety Picture 3.............................................................................................................88
List of table
Table page
Table 1 given specification Table..................................................................................................28
Table 2 Iteration tables..................................................................................................................37
Table 3 material selection for piston rod.......................................................................................41
Table 4 Mechanical properties of piston material.........................................................................43
Table 5 Mechanical properties for cap..........................................................................................45
Table 6 Material selection for telescopic cylinder.........................................................................52
Table 7 Material selection of pump cylinder.................................................................................54
Table 8 Material selection for reservoir.........................................................................................56
Table 9 Material selection for cover plate.....................................................................................57
Table 10Material selection for pump handle socket......................................................................59
Table 11 Material selection for plunger........................................................................................66
Table 12 Troubleshooting Table....................................................................................................82
Table 13 Results of the analysis....................................................................................................87
GECH & HAGOS VII

CHAPTER ONE
INTRODUCTION
1.1 overview of the project
A hydraulic jack is a jack that uses a liquid to push against a piston. Jacks employ a screw thread
or hydraulic cylinder to apply very high linear forces. This is based on Pascal’s Principle. The
principle states that pressure in a closed container is the same at all points. If there are two
cylinders connected, applying force to the smaller cylinder will result in the same amount of
pressure in the larger cylinder. Car jacks usually use mechanical advantage to allow a human to
lift a vehicle by manual force alone. More powerful jacks use hydraulic power to provide
more lift over greater distance. The mechanical advantage is the factor by which a mechanism
multiplies the force or torque applied to it.
An automotive jack is a device used to raise all or part of a vehicle into the air in order to
facilitate repairs. Most people are familiar with the basic auto jack that was still included as
standard equipment with most new cars. These days, fewer people than ever have had to use a
car jack. This is due to the continuing improvements in modern tires that have made “getting a
flat” rare. Even so, people who like to rotate their tires themselves or who may install
snow tires before the winter and remove them in the spring need to use a jack to perform the job.
Hydraulic bottle jacks are typically used for shop work & other. They are used to lift
vehicles and other loads. Use of jacks not designed for a specific vehicle requires more than the
usual care in selecting ground condition, the jacking point on the vehicle and ensuring stability
when the jack is fully extended.
The goal of this project is to generate some conceptual design of a hydraulic bottle jack,
select the best and design its components. Finally, proposing a safe, costly and reliable hydraulic
bottle jack.
GECH & HAGOS 1

1.2 Definition of Hydraulic Jacks

A jack is a device that uses force to lift heavy loads. The primary mechanism with which force is
applied varies, depending on the specific type of jack, but is typically a screw thread or a hydraulic
cylinder. Jacks can be categorized based on the type of force they employ:
 Mechanical jacks: such as car jacks and house jacks, lift heavy equipment and are rated
based on lifting capacity (for example, the number of tons they can lift)
 Hydraulic jacks: tend to be stronger and can lift heavier loads higher, and include bottle
jacks and floor/service/ jacks.
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. Use has broadened its meaning to include the
behavior of all liquids, although it is primarily concerned with the motion of liquids. Hydraulics
includes the manner in which liquids act in tanks and pipes, deals with their properties, and explores
ways to take advantage of these properties.
Figure 1 solid representation of Hydraulic bottle jack
GECH & HAGOS 2

Hydraulic jack is a short stroke hydraulic lift which is fed from hand pump. The hydraulic jack may
be portable. This is extensively used for lifting automobiles usually to facilitate and repair for
replacing the punctured wheels.
Although the modern development of hydraulics is comparatively recent, the ancients were familiar
with many hydraulic principles and their applications. The Egyptians and the ancient people of
Persia, India, and China conveyed water along channels for irrigation and domestic purposes, using
dams and sluice gates to control the flow. The ancient Cretans had an elaborate plumbing system.
Archimedes studied the laws of floating and submerged bodies. The Romans constructed aqueducts
to carry water to their cities. Torricelli, French physicist, Edme Mariette, and later, Daniel Bernoulli
conducted experiments to study the elements of force in the discharge of water through small
openings in the sides of tanks and through short pipes. During the same period, Blasé Pascal, a
French scientist, discovered the fundamental law for the science of hydraulics.
The hydraulic jack is perhaps one of the simplest forms of a fluid power system. By moving the
handle of a small device, an individual can lift a load weighing several tons. A small initial force
exerted on the handle is transmitted by a fluid to a much larger area. The operation of hydraulic jack
depends on Pascal‘s law. This 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.
Classification of jack
Jacks are classified into two common types. These are Hydraulic and Mechanical jacks.
Mechanical jacks: A mechanical jack is a device which lifts heavy equipment. The most common
form is a car jack, floor jack or garage jack which lifts vehicles so that maintenance can be
performed. Car jacks usually use Mechanical advantage to allow a human to lift a vehicle by manual
force alone. More powerful jacks use hydraulic power to provide more lift over greater distances.
Mechanical jacks are usually rated for a maximum lifting capacity (for example, 1.5 tons or 3 tons).
Such as car jacks and house jacks, lift heavy equipment and are rated based on lifting capacity (for
example, the number of tons they can lift)
GECH & HAGOS 3

Figure 2 Mechanical jack
Hydraulic jacks: tend to be stronger and can lift heavier loads higher, and include bottle jacks and
floor/service/ jacks Hydraulic jacks are typically used for shop work, rather than as an emergency
jack to be carried with the vehicle. Use of jacks not designed for a specific vehicle requires more than
the usual care in selecting ground conditions, the jacking point on the vehicle, and to ensure stability
when the jack is extended. Hydraulic jacks are often used to lift elevators in low and medium rise
buildings.
GECH & HAGOS 4

Figure 3 hydraulic bottle car jack
Classification of Hydraulic Jacks

Two common types of hydraulic jacks include BOTTLE JACKS & FLOOR JACKS.
GECH & HAGOS 5

Figure 4 Hydraulic car jacks

I. BOTTLE JACKS
BOTTLE JACKS also called hand jacks, bottle jacks provided an easy way for an individual to
lift up a vehice for roadside inspection or service. Their resemblance to milk bottles earned bottle
jacks their name—today, they range in size and weight to offer a lifting capability ranging from
one hundred to several tons. Bottle jacks feature a vertical shaft, which supports a platform
(called a bearing pad) that directly bears the weight of the object as it is lifted. Although they are
most commonly used in the automobile industry (1.5 to 5 ton jacks are frequently used to lift
cars), bottle jacks have other uses as well. In the medical industry they can be used in hydraulic
stretchers and patient lifts.
GECH & HAGOS 6

Figure 5 hydraulic bottle car jack
II. FLOOR JACKS
Unlike bottle jack shafts, the shaft in a floor jacks is horizontal—the shaft pushes on a
crank that connects to a lifting pad, which is then lifted horizontally. Floor jacks typically
provide a greater range of vertical lift than bottle jacks, and are available in two sizes.
The original jack is about four feet long, a foot wide, and weights around 200 pounds—
they can lift 4-10 tons. A more compact model was later made, which is about three feet
in length, and can lift 11/2 tons. Although mini jack are also produced, they are not a
recognized standard type of floor jack. Typically, one of the first two sizes should be
used.
Figure 6 floor hydraulic jack
GECH & HAGOS 7

Hydraulic jack is also classified as pneumatic jack and strand jack. These jacks are discussed
below.
A) Pneumatic jack:-
A pneumatic jack is a hydraulic jack that is actuated by compressed air - for example, air
from a compressor instead of human work. This eliminates the need for the user to actuate
the hydraulic mechanism, saving effort and potentially increasing speed. Sometimes, such
jacks are also able to be operated by the normal hydraulic actuation method, thereby retaining
functionality, even if a source of compressed air is not available.
Figure 7Pneumatic jack

Strand jack:
A strand jack is a specialized hydraulic jack that grips steel cables often used in concert, strand jacks
can lift hundreds of tons and are used in engineering and construction.
Hydraulic car jack is further classified as follow
According to the source of power

 manually operated jack (hand or pedal operated).
GECH & HAGOS 8

 Power operated jack (pump is used)
According to the lift of ram

 High lift hydraulic Jack
 Medium lift hydraulic Jack
 Low lift hydraulic Jack
According to the arrangement of cylinder

 Vertical hydraulic Jack
 Horizontal hydraulic Jack
 inclined hydraulic Jack
According to the number of cylinders

 Single cylinder hydraulic Jack
 Multi cylinder hydraulic Jack
According to the construction

 Hydraulic Service / Floor /jacks:
 Hydraulic Bottle jacks:
 Trolley jack
1.4 Components of hydraulic Bottle jack

A typical hydraulic Bottle jack consists if the following basic machine element components:
The jack assembly unit mainly consisting of:-
Piston Rod: Piston rods or rams are used to converts hydraulic energy in to mechanical energy in the
form of linear motion. This mechanical energy is used to perform the lifting work
(mechanism).Therefore, the rams are used as a force multiplying device.
Cover plate: This part used to enclose the reservoir and main cylinder. It used to keep the oil from
dirt and environmental hazards.
Main cylinder: This part is used to enclose the reservoir and main cylinder. It used to keep the oil
from dirt and environmental hazards.
GECH & HAGOS 9

Telescopic cylinder: This part is used to increase the height of the jack. Used as extension cylinder.
Reservoir cylinder: This part is used to hold the working fluid of the jack.
Links: There is two links in the hydraulic bottle jack. Those links used to hold the socket with the
basement.
Plunger: Plungers are used to transfer operator load to the fluid with the form of pressure.
Basement: This part used to hold all parts of the jack and used as a cellar.
Pump handle: This part used to transfer operator load to the socket and plunger of the jack.
O- Rings: An O-ring, also known as a packing, or a tori joint, is a mechanical gasket in the shape of
a torus; it is a loop of elastomer with a round cross-section, designed to be seated in a groove and
compressed during assembly between two or more parts, creating a sealant the interface.
Valves: the simplest type of valve are used in hydraulic jack which are used to control the transfer of
hydraulic energy through the system by controlling the fluid flow direction by moving the valve stem
(ball) against or away from valve seat used to control the pressure requirement of the system. The
jack consists of Intake valve, Discharge valve and Pressure release valve.
Figure 8 components of hydraulic bottle car jack
GECH & HAGOS 10

Figure 9 components of hydraulic car jack
1.5 Hydraulic fluid

It also known as tractor fluid, hydraulic fluid is the life of the hydraulic circuit. It is usually
petroleum oil with various additives. Some hydraulic machines require fire resistant fluids,
depending on their applications. In some factories where food is prepared, water is used as a working
fluid for health and safety reasons.
In addition to transferring energy, hydraulic fluid needs to lubricate components, suspend
contaminants and metal filings for transport to the filter, and to function well to several hundred
degrees Fahrenheit or Celsius.
1.6 Material used and its property

The material selected must be have sufficient strength and be easily worked. The most economical
material that satisfy both process and mechanical requirement should be selected. Many factors have
to be considered when selecting engineering materials, but for lifting process the over riding
consideration is usually Tensile strength, Elastic modulus, Yield strength, Fracture resistance and
GECH & HAGOS 11

Creep resistance. The process designer will be responsible for recommending materials that will be
suitable for the process conditions. we must also consider the requirements of the mechanical design
properties; the materials selected must have sufficient strength and be easily worked. The most
economical material that gives satisfied both process, this will be the material that gives the lowest
cost over the working life of the plant, allowing for maintenance and replacement. Other factors,
such as product contamination and process safety must also be considered.
The most important characteristics to be considered when selecting a material of constructions are:
A. Mechanical properties:
Include the following properties.
 Strength:- Tensile strength required
 Stiffness: - The material should have high Elastic modulus (Young’s modulus).
 Toughness: - Fracture resistance needed.
 Hardness: - high wear resistance required.
N.B: Also the material fatigue and creep resistances are needed.
B. The effect of high and low temperature on the mechanical properties.
C. Corrosion resistance
D. Any special properties required such as thermal conductivity, electrical résistance, and magnetic
properties.
E. Case of fabrication: forming, welding, casting etc.
F. Availability in standard sizes: plates, sections, tubes etc.
G. Cost of the material
One of the most widely used steel for general purpose in the construction of hydraulic bottle jack is
ASTM, Grade 30 cast iron. This steel has good ductility and forms welds and machines easily. It is
also one of the most economical steel suitable for hydraulic jacks. It use to construct saddle, saddle
holder, arm and so on.
GECH & HAGOS 12

Another material is AISI 1045 carbon steel is most widely used construction of connecting rods, pins,
piston rods and so on. Also AISI 1040 carbon steel used to construct cylinders and the like.
Now, many new series of materials like low alloy, high alloy steels, high temperature and low
temperature materials are available which can be selected to suit the requirement of every individual
need of process industry.
The important materials generally accepted for construction of jacks are indicated here. Metals used
are generally divided into three groups based on market cost as:-
1. Low cost: - for example: Cast iron, Cast carbon and low alloy steel, wrought carbon and low alloy
steel.
2. Medium cost: - for example: High alloy steel (12%chromium and above), Aluminum, Nickel,
Copper and their alloys, Lead.
3. High cost: - for example: platinum, Tantalum, Zirconium, Titanium silver.
Materials mentioned (2 & 3) groups are sometimes used in the form of cladding or bonding for
materials in group (1). Also, use non-metallic lining such as rubber, plastics, etc.
Jacks are commonly fabricated from cast iron wherever strength, fracture considerations will permit
its use because of the low cost, high strength, ease of fabrication and general availability of mild
steel. Low and high alloy steel and non-ferrous metals are used for special service.
Generally, material selection process is very important for hydraulic service jack design. Therefor the
designer must give more emphasis for this process.
1.7 Hydraulic Basics

Hydraulics is the science of transmitting force or motion through the medium of a confined liquid. In
a hydraulic device, power is transmitted by pushing on a confined liquid. The transfer of energy takes
place because a quantity of liquid is subject to pressure. To operate liquid-powered systems, the
operator should have knowledge of the basic nature of liquids.
1.8 Pascal's Law

Blasé Pascal formulated the basic law of hydraulics in the mid 17 thcentury. He discovered that
pressure exerted on a fluid acts equally in all directions. His law states that pressure in a confined
fluid is trans-mitted undiminished in every direction and acts with equal force on equal areas and at
right angle to a container's walls.
GECH & HAGOS 13

Figure 10 Pascal law
1.9 Hydraulic Systems

A hydraulic system contains and confines a liquid in such a way that it uses the laws governing
liquids to transmit power and do work and. components of a hydraulic system that store and
condition the fluid. The oil reservoir (sump or tank) usually serves as a storehouse and a fluid
conditioner. Filters strainers and magnetic plugs condition the fluid by removing harmful impurities
that could clog passages and damage parts. Heat exchanges or coolers often are used to keep the oil
temperature within safe limits and prevent deterioration of the oil. Accumulators, though technically
sources of stored energy, act as fluid storehouses.
1.10 Hydraulic Pressure, Force, and Motion

Although the force available to do work is increased by using a larger piston in one cylinder, the total
movement of the larger piston is less than that of the smaller one. When output force increases,
output motion decreases. If the 10-square-inch input piston moves 2 inches as it applies 50psi to the
100-square-inch output piston, that output piston will move only 0.2 inch as it applies 5000 pounds
GECH & HAGOS 14

of output force. The ratio of input motion to output motion is the ratio of the input piston area to the
output piston area, and you can use this simple equation to calculate it: The result from dividing the
area of the input piston (A1) by the area of the output piston is multiplied by the stroke of the input
piston or (A1 ÷ A2) × S (the input stroke) = M (the output stroke) or 10 square inches (input piston)
100 square inches (output piston) =110× 2 inches (input stroke) =0.2 inch output motion If the output
piston is larger than the input piston, it exerts more force but travels a shorter distance. The opposite
also is true. If the output piston is smaller than the input piston, it exerts less force but travels a
longer distance. Apply the equation to the 5-squareinch output piston: 10 square inches (input piston)
5 square inches (output piston) =21× 2 inches (input stroke) =4.0
1.11 Working Principle

The actual working of hydraulic system that lifts the car takes place by single press of the button
provided on dashboard. When the switch is turned on the motor starts running which is powered by a
battery already available in the car. This motor facilitates the flow of oil which is pressurized by the
pump provided. This pressurized oil id then directed to the control unit which in turn directs the flow.
Distribution of the pressurized oil is controlled by a switch on the dashboard. As the oil proceeds into
the hydraulic cylinder, it exerts a certain amount of pressure on the plunger or the ram inside the
cylinder. This exerted pressure of the oil is converted into a linear force which in turn causes the
plunger in the cylinder to move out of the cylinder. Thus ultimately the exerted pressure of the oil is
converted into linear motion of the plunger. As the plunger downwards out of the cylinder linearly,
after a definite travel of the plunger in the downward direction and once it touches the ground it starts
lifting the car.
Once the car is lifted to a desired height the tires can be changed. It is the specialty of a simple
hydraulic jack that it possesses a self-locking system i.e. once the car is lifted to a certain height and
even if the power to the jack is cut off the jack can still hold the entire part of car that is lifted by it.
And thus, the driver can easily change the tire.
Once the tire is changed, now the concern is to release the pressure in the jack which is in the form of
pressurized oil. Thus a relief valve is provided on the jack for this purpose. But since it is impossible
to actuate this valve manually when this jack is installed on the chassis, this valve is then provided on
the dashboard of the car in form of a switch which controls the relief valve provided on the control
unit of the system. Once the relief valve is opened the oil in the cylinder which has lost its pressure
GECH & HAGOS 15

energy, starts returning to the control unit. Once the oil starts returning the control unit then sends the
accumulated oil back to the oil sump. And in this way the entire system efficiently works.
Figure 11 working principle of hydraulic car jack
1.12 Advantages and disadvantages of hydraulic bottle jack

1.12.1Advantages
• Simpler design. In most cases, a few pre-engineered components will replace complicated
mechanical linkages.
• Flexibility. Hydraulic components can be located with considerable flexibility. Pipes and hoses in
place of mechanical elements virtually eliminate location problems.
• Smoothness. Hydraulic systems are smooth and quietin operation. Vibration is kept to a minimum
control.
• Control of a wide range of speed and forces is easily possible.
GECH & HAGOS 16

• Cost. High efficiency with minimum friction loss keeps the cost of a power transmission at a
minimum.
• Overload protection. Automatic valves guard the system against a breakdown from overloading.
• It requires simple maintenance cares
• The moving parts of this system are cooled by the oil itself used. Thus this project does not require
any cooling arrangements.
• Checking and cleaning are easy.
• Repairing is easy.
• Replacement of parts is easy.
• The loaded light vehicles can be easily lifted.
• Manual power not required.
• Handling is easy.
• No Oil wastage.
1.12.2 Disadvantages
• Elements of hydraulic system to be applied in the car have to be machined to a high degree of
precision which increases the manufacturing cost of the system.
• Leakage of hydraulic oil during its flow in the system causes heavy pressure drop or may not lift
car.
• In cold climate hydraulic oil freezes.

The main disadvantage of a hydraulic system is maintaining the precision parts when they are
exposed to bad climates and dirty atmospheres.
• Protection against rust, corrosion,
• Dirt, oil deterioration, and other adverse environment are very important.
Lifting procedure of a load by using jack
-First, Tighten (close) the pressure release valve properly
GECH & HAGOS 17

-Then, put the jack base on a firm and reasonably level footing. If necessary, place a plate under the
jack to provide a solid footing.
-Then, position the jack under load. If necessary, raise the extension screw to desired height but not
exceeding 2/3 of its height.
-Finally, operate the handle of the pump in smooth and long strokes until the jack has lifted the load.
Caution: - If the handle of the pump become hard and the jack stops lifting load before the rams
(piston) are fully extended or before load is raised, when this happens, use a jack with greater
capacity to lift the load.
Lowering Procedure of a load by using Jack
-First, open the pressure release valve slowly until the jack begins to lower. The rate of descent of the
load is controlled by the degree of opening of the pressure release valve.
-Then, the rams (piston) will be collapsed most of the way by the load, lower the extension screw and
press rams flush by the hand.
-Finally, Re-tighten the pressure release valve.
1.13 Historical Background of Hydraulic bottle Jacks

As the automobile became a major part of American Life in the early part of the 20 th Century the
Automobile Service Industry boomed alongside of it. And while the bottle/hand jack worked fine for
lifting a vehicle off the ground they quite often required the inconvenience of crawling under the car
to set up, then, with their limited lifting stroke, sometimes necessitated jacking, securing on stands,
repositioning and jacking again - both going up and coming down - a pain in the BUTT to be sure he
origin of hydraulic jacks can be dated several years ago when Richard Dudgeon, the owner and
inventor of hydraulic jacks, started a machine shop. In the year 1851, he was granted a patent for his
hydraulic jack. In the year 1855, he literally amazed onlookers in New York when he drove from his
abode to his place of work in a steam carriage. It produced a very weird noise that disturbed the
horses and so its usage was limited to a single street. Richard made a claim that his invention had the
power to carry near about 10 people on a single barrel of anthracite coal at a speed of 14 m.p.h.
Dudgeon deserves a special credit for his innumerable inventions including the roller boiler tube
expanders, filter press jacks, pulling jacks, heavy plate hydraulic hole punches and various kinds of
lifting jacks.
GECH & HAGOS 18

Now a day, Hydraulic jacks are widely used all across the globe. They have a lot of relevance in the
present era, as they have made an incredible contribution in making our life much more comfortable
than it was before.
1.14 Problem Statement

In our Country, most of the cars were equipped with many different jacks. We found that many
of the car jacks were requires much Energy from the person to rotate the jack, this condition is
difficult to be used by women’s and elderly people. For this reason, we are initiated to design a
mechanical bottle hydraulic jack which is simple and flexible to operate by human hands.
1.15 OBJECTIVE
1.15.1Main objective
The main objective of this project is to design a hydraulic bottle jack having capacity load of 6 ton,
operating pressure of 25MPa, lift range of 20 cm and man effort on handle of 20 Kg with good
performance, long lived, and high quality.
1.15.2 Specific objective

Specifically, we would like to design each of the main components of the hydraulic bottle jack with
their design procedure.
1. Design of extension screw and its Cup
2. Design of ram
3. Design of cylinder
4. Design of reservoir and its head
5. Design of valves
6. Design of basement of jack
7. Design of pump (small) cylinder
8. Design 0f plunger
10. Design of handle and handle socket
11. Design of nut type head cylinder
GECH & HAGOS 19

12. Design of O-rings seals
13. Design of pin

14. Design of link
1.16 METHODOLOGY
In this Hydraulic bottle jack design project we follow so many steps. These steps are very important
for us to design this equipment.
Before start to design the hydraulic bottle jack we have to search and refer information and collect
data on related topic about hydraulic bottle jack. These data collection are very important input for
easy design process.
Before start to design the pressure vessel we have to search and refer information on related topic.
This information may be obtained from different source. Such as:
 Different journals and books,
 By interviewing professional persons,
 Using internet access
 Referring previously worked documents etc…

These data will make our starting better to finish by overcoming the problems.
1.17 Problem specification

As we have seen before in data collection step, after we observe different sources, we can determine
what problem is happened and what mistake is made by the designer in his work.
We can also determine the cause of the failure (mistake). Whether it is Material selection error or
Extreme internal and external factors or Designer error or analytical error and so on this specification
of problem will help us to avoid repeating of problem that was made before by somebody else. It also
lead us to design advanced component than before. Generally, it help us to design and produce better
product, which meet interest of customer.
1.18 Design of parts

Geometry Analysis:-Under the geometry analysis we determined maximum and minimum height,
number of strokes, basement thickness, handle length and so on by using mathematical methods and
numerical iteration methods.
GECH & HAGOS 20

Steps of Geometrical analysis:

The first step that use to start the analysis is take nice and reasonable assumptions of t b (basement
thickness), b (different between cap and main cylinder), t p (thickness of piston head), t c (the sum of
thicknesses of main and telescopic cylinder) and h min (minimum height).The next step is
determination of lcy, lre, lro and hmax by mathematical and geometrical approach. After the two steps
take the following considerations to drive 4 major formulas:
Case 1: when the plunger (pump piston) is at its lowest position.
By using this consideration I develop expression for R 2 by using equilibrium method.
R2=F∗(X+L)/ (X∗cosθ) −−−−−(i)
Case 2: when the plunger (pump piston) is at its maximum position.
By using this consideration I can develop expression for h A by using mathematical geometry
hA=X∗sinθ−−−−−−(ii)
Case 3: Considering Pascal’s law of the fluid (oil) in the cylinders of the jack.
By using this consideration I develop expression for R 2 by using Pascal’s law.
R2=50kn ∗ (dA2/d2) −−−−−−−−−− (iii)
Stress Analysis: - Under stress analysis I check whether the stresses are not the cause for failure by
generating factor of safety and by using failure formulas.
1. Piston Rod:
 Draw the free body diagram
 Select the proper material with reasons
 Check failure due to compressive stress
𝐿𝐾∗√12≤11
 Check failure due to crushing
𝑊𝑐𝑟>𝑊
 And the above conditions are satisfied the design is safe.
2. Piston head:
 Draw the free body diagram

 Generate factor of safety and find the allowable stress.
 Then find the thickness of the head.
3. Cap:
GECH & HAGOS 21


 Next find the allowable shear stress
τall =WAt
 Next find the factor of safety
τall=τyn
 Also consider the crushing stress
 Thus the above all are safe the design is also safe.
4. Main cylinder:

 Next find the radial and hoop stress and check either maximum normal stress theory, or
maximum shear stress theory.
 Next find thickness of the cylinder by using Bernie’s equation.
t = Dci2 [√σall+Pσall−P −1]
 Side by side find the pitch and thread length.
5. Pumping cylinder
 First find tangential and radial stresses.
 Generate factor of safety
 And find the allowable stress
 Check the stresses are safe
 After that find the thickness of the pump cylinder by using Bernie’s equation.
t = Dci2 [√σall+Pσall−P −1]

6. Reservoir cylinder
GECH & HAGOS 22

 First find tangential and radial stresses.
 And find the allowable stress
 Check the stresses are safe
 Find the volume
 After that find the thickness
7. Pump handle socket
 Check the tensile failure
 Also check the shear failure
 Thus both conditions are satisfy the design is safe
8. Pump handle

 Find the BMD and SFD of the handle
 Generate factor of safety and find allowable stress
 Find handle thickness
9. Plunger

 Find allowable stress
GECH & HAGOS 23

 And find the diameter of the hole

 Find the height of the plunger
 Check the buckling due to critical load.
10. Link

 Generate facto of safety
 And find the thickness of the link
 Find shear allowable
 Check the following condition full fill.
11. Basement

 Generate facto of safety
 And find the thickness of the base
Other components like pins, springs, valves and seals are selected form standard table for appropriate
dimensions and force value.
Force Analysis: this analysis part is simultaneously calculated in the stress and geometric analysis
finally the part and assembly drawing is done using software clearly.
1.19 Scope and Limitation of the Project

1.19.1 Scope of the project
This project is about the designing and fabricating the car jack. The types of car jack that was used in
this project were hydraulic bottle car jack as it is more reliable and easy to operate. The scopes of the
design were on the designing of hydraulic bottle car jack which can lift a load of 60KN by expecting
maximum lifting capacity than this to overcome any additional load of car due to different factors by
using optimization concept. The concept that will be used in this product is the long arm method.
GECH & HAGOS 24

This Project Standard and Specification covers requirements governing the classification, design,
fabrication, of hydraulic bottle jack, taking into consideration all internal and external design and
working fluid.
1.19.2 Limitation of the project

The limitation of this project is time and the type of hydraulic bottle jack we have made the project is
wide and with time being a factor it was too wide to go through all the major topics, so we had to do
the project from a general view. And the variety of failures were also a big factor. Since there was no
sufficient time, the vast range of application, type, material, failure, etc…it has been a limitation to
the project. Since there was lack of source and the internet connection was weak, we could not get
the journals and books needed. Another minor factor was the different type of conclusions that we
got from the books. The books had lots of different information thus making it hard for us to choose
and bring a flow of words.
GECH & HAGOS 25

CHAPTER TWO
LITERATURE REVIEW
N.K. Mandavgade (2012) –studied that Automobile hydraulic jack can be easily operated by a single
push button provided on the dash board. The jack will be installed on both the sides of chassis
according to the weight distributions of the car. The system operates on hydraulic drive which
consists of three main parts: hydraulic pump, driven by hand force, hydraulic cylinder to lift the
vehicle. The car gets lifted and load gets distributed on three point i.e., plunger or ram of hydraulic
cylinder and two tires opposite to side which is lifted.
Dr. Ramachandra C G, Krishna Pavana, Shivraj Shet and Venugopal Reddy, Virupaxappa B (2013)
– have presented that whenever any vehicles undergo a tyre failure, it becomes a very cumbersome
task for the person to lift the vehicle from the ground level and lot of manual effort is required even
though a jack is used.
Musa Nicholas, Abodunrin Tosin Oladipo Sarafadeen (2016) - have studied that in order to mitigate
the problems associated with the use of a single jack and other lifting devices to raise cars completely
off the ground to effect repairs.
P. S. Borkar, S. V. Sontakke, R. R. Dorwe, A. B. Ganorkar, S. P. Lokhande (2015)-have studied
application of pressurized air to produce mechanical motion. Hydraulic bottle jack is a fabricated
model which when installed in four wheeler, will ease in the problems arising in the conventional
operated jack.
Balkeshwar Singh, Anil Kumar Mishra.(2015) - This research paper analyzes the modification of the
existing hydraulic screw jack by incorporating an hand force in the screw in order to make load
lifting easier. In this modified design, the power screw is rotated by connecting motor through
universal coupling, plugged to theautomobile for the prime mover, which transmits its rotating speed
to the power screw to be rotated with required speed reduction and increased torque to drive the
power screw.
Mohammed Siddique Ahmed, MohdRiyazUddin ,Faraz Ur Rehman Azhar, Md Shaffi ( 2014 )- A jack
is a device that uses force to lift heavy loads. The primary mechanism with which force is applied
varies, depending on the specific type of jack, but is typically a screw thread or a hydraulic cylinder.
GECH & HAGOS 26

Jacks can be categorized based on the type of force they employ: mechanical or hydraulic.
Mechanical jacks, such as car jacks and house jacks, lift heavy equipment and are rated based on
GECH & HAGOS 27

Lifting capacity (for example, the number of tons they can lift). Hydraulic jack tend to be stronger
and can lift heavier loads higher, and include bottle jacks and floor jacks . [8]
We conclude that the system operates on hydraulic drive which consists of three main parts:
hydraulic pump, driven by hand force, hydraulic cylinder to lift the vehicle. The car gets lifted and
load gets distributed on three point i.e., plunger or ram of hydraulic cylinder and two tires opposite to
side which is lifted. Hydraulic bottle jack is a fabricated model which when installed in four wheeler,
will ease in the problems arising in the conventional operated jack. Hydraulic jack tend to be stronger
and can lift heavier loads higher, and include bottle jacks and floor jacks .
GECH & HAGOS 28

CHAPTER THREE
DETAILDESIGN AND DISCUSSION

3.1 Introduction
Under this chapter we try to describe the Geometrical analysis, Force analysis and
strength analysis of the Hydraulic bottle jack.
3.1.1. Givens of the design

For this design the following data’s are given:
Table 1 given specification Table
Design of hydraulic car jack
Parameters Value Unit
Load 10 Ton
Operating pressure 35 MPa
Lift range 30 Cm
Man effort put on the handle 30 Kg
Geometry Analysis
GECH & HAGOS 29

Figure 6: Assembly of Hydraulic Jack
Considering that the above sketch can be taken as a model to a particular

hydraulic bottle jack with the given parameters the dimensions analysis of the given
drawing (sketch) can be computes and interpreted as follows. important points about the
geometry analysis of this jack are:
• All vertical displacements force distribution over the detail parts of the jack
including any reaction forces diameters clearances are tube determines.
• To find the above listed parameters, geometrical relationships between heights

pressure and forces balance and the essential clearance are very important
• In addition to the above relations (which have finite number of equations which
relate the parameters) certain assumptions of values are needed to complete the eometry.
• Finally we can use numerical method (typically the iteration approach) to find the
unknown parameters
Assumptions
Once again consider the above sketch of the given jack. The head thickness of the piston
rod actually these parameters should have tube determined after design analysis of the
piston cap but we can assume some standard value to the thickness since it may help to
find the other parameters.
 Let the thickness be, tp=30mm.

 The unthreaded portion height of the cover plate, b=40mm.
 The thickness of the base and its components is the height of the jack below the
bottom part of the reservoir cylinder but the minimum value of these parameters be,
tb=60mm.
 The thickness of the combined sum value of the thickness of the value has
determined, tc= 20mm.
 Also assume the minimum height of the jack, Hmin=300mm.
GECH & HAGOS 30

Now h1, h2 and h3 (at labeled in the sketch) can be found as follows:
 Considering the minimum left height of the jack. Hmin=300mm.

𝐻𝑚𝑖𝑛 = ℎ1 + 𝑡𝑏 + 𝑏 + 𝑡𝑝
300 = ℎ1 + 60 + 40 + 30
ℎ1 = 170𝑚𝑚
When the release valve is opened the telescopic cylinder comes down and we assume that
its upper margin will come just below upper margin of the cover plate this leads to the
following height relationship.
ℎ1 + 𝑏 = ℎ2 + 𝑡𝑐
ℎ2 = ℎ1 + 𝑏 − 𝑡𝑐 = 170 + 40 − 24 = 186𝑚𝑚
Considering the maximum lift height of the jack Hmax
𝐻𝑚𝑎𝑥 = 𝐻𝑚𝑖𝑛 + 200𝑚𝑚 = 300 + 300 = 600𝑚𝑚
Then we can find h3 in terms of h1, h2 and tb as follows
𝐻𝑚𝑎𝑥 = ℎ1 + ℎ2 + ℎ3 + 𝑡𝑏
ℎ3= 600 − 170 − 186 – 60
= 184𝑚𝑚
As it can be seen from the sketch h 3 is not the height of the piston (instead) it is portion of
the height at the piston.
ℎ(ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑝𝑖𝑠𝑡𝑜𝑛) = ℎ3 + 𝑞
Dimensions of the handle & socket and force analysis
GECH & HAGOS 31

Hydraulic systems which use positive displacement input output device required force analysis
hydraulic bottle jack one of these systems which require force analysis. variation in length and
points of supports on this jack handle gives various outputs thus iteration for acceptable range of
length will be important.
Case 1: when the plunger (pump piston) is at its lowest position.
Figure 12 Lowest Position of Socket.

Let F- the force that the operator applies on the handle.
R1- reaction force between the link and the socket which is vertical
R2- reaction force between the plunger and the socket plate
 Now in order the handle socket to be at equilibrium the forces and moments should be
balance as follows. This equation is valid only when the handle is horizontal.
∑𝐹=0 𝑅2 = 𝑅1 + 𝐹 ∑ 𝑀𝐴 = 0 𝑅2(𝑋) − 𝐹(𝑋 + 𝐿)
• When the handle is deflected by an angle then R2 becomes

(FBD Diag.)
∑ 𝑀𝐴 = 0, 𝑅2 ∗ cos θ (X) − F ∗ (X + L)
Case 2: when the plunger (pump piston) is at its maximum position. this happens when the
operator up strokes (moves the handle making is make some specified angle with the horizontal)
GECH & HAGOS 32

the handle. This case can be shown diagrammatically as follows Let h A- the distance through
which the piston in the moves
𝜃- The angle (maximum angle) through which the handle moves with the horizontal. now the
rise ha is given by: 𝑠𝑖𝑛𝜃 = ℎ𝐴/𝑋
hA = X ∗ sinθ
Figure 13Maximum Position of Socket
Figure 14 Pascal’s law of the fluid
GECH & HAGOS 33

Case 3: Considering Pascal’s law of the fluid (oil) in the cylinders of the jack.
Let: W is the load acting on the piston

R2 be the fore acting on the plunger (actuator piston).
Then 𝑊 = 𝑃1 ∗ 𝐴1,
Where, P1= pressure required in the fluid required to hold the piston in
equilibrium
A1=is the base area of telescopic cylinder.
Consider that both pistons move up and down with uniform velocity. The force due to mass
(which is negligible compared to the load) is not considered.
𝑅2 = 𝑃2 ∗ 𝐴2
From Pascal’s law P1=P2

W1/A1=R2/A2, R2=W1× (d22/d21)=10KN × ( d22/d21)
Case 4: considering volume relations of cylinders
In order to bring the piston to its maximum possible position the actuator cylinder must be
moved
‘n’ limits up and down. In other words ‘n’ is called the number of strokes needed to reach the
maximum lift height.
Volume of cylinder filled to move piston = n (volume of actuator cylinder moved by the
Actuating piston)
𝑉1 + 𝑉2 = 𝑛 ∗ 𝑉𝐴
Thus,
GECH & HAGOS 34

Where, V1= Volume of main cylinder

V2= Volume of telescopic cylinder occupied by the oil
V A= Volume of the actuating cylinder when the plunger moves up to its maximum
possible position
Let the main cylinder (oscillating) cylinder is mounted in the base to a depth of about
its height above the base then the total volume of the main cylinder filled with the oil becomes.
• V1= Volume of main cylinder is given by the equation:
𝑉1 = ℎ𝑒𝑖𝑔ℎ𝑡 ∗ 𝐴𝑏𝑎𝑠𝑒
• V2= Volume of telescopic cylinder occupied by the oil is also given by:
Figure 15 the main and telescopic cylinder
• VA= Volume of the actuating cylinder when the plunger moves up to its maximum
possible position.
𝑉𝐴 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑠𝑡𝑟𝑜𝑘𝑒 ∗ 𝐴𝑏𝑎𝑠𝑒
GECH & HAGOS 35

Thus, the number of strokes that the operator has to perform (repeat) to fully raise the piston
Substitute the values of V1, V2 and VA.
Now we have got the four equations containing the unknown parameters of the geometry. The
four equations are summarized as follows:
Equation 1: 𝑅2 = 𝐹 ∗ (𝑋 + 𝐿)/(𝑋 ∗ cos 𝜃)
Equation 2: ℎ𝐴 = 𝑋 ∗ 𝑠𝑖𝑛𝜃
Equation 3: 𝑅2 = 10𝐾𝑁 ∗ (𝑑22/𝑑2)
Equation 4:
In the above four equation the only known parameters are h 1=170mm, h2=184mm
and tc=24mm. thus, numerical methods typically iteration and assumption of values will be
helpful to solve the equations since the number of unknowns are larger than the number of
equations.
Helpful Assumptions
Diameter of the telescopic cylinder d2:- the diameter of the piston ram can be found by
considering the crushing strength of the material selected but for this part equation analysis we
GECH & HAGOS 36

can take some minimum values of the diameter of the piston which have to be checked later. Let
it be dp=30mm.
If diameter of telescopic cylinder is d2 then,
Figure 16 Head of the piston
d2 = dp + 2 ∗ (tl) + 2 ∗ (clearance between the head & the cylinder wall)

d2= 30 + 2 ∗ 8 + 2 ∗ (2) = 50mm (Internal diameter of the telescopic cylinder)
• Diameter of the main (isolating) cylinder
d1:- d1 = d2 + 2 ∗ w (lower head width of the telescopic cylinder)
GECH & HAGOS 37

Let w = 8mm
d1 = 50 + 2 ∗ 8 = 66mm (Internal diameter of the main cylinder)
• The range of the force that a man (operator) can apply on the handle.
Let the range of the force is up to 300N.
• Length of the handle and the socket:-
Let the length of the handle, L be vary from 600 –650mm.
Let the length of the socket between the holes of the joint ‘X’ be vary from 70-80mm.
• Portion of piston heights that remains in the telescopic cylinder when maximum
height is reached q. let the value be 60mm.
The applied man effort on the handle is given to be 30Kg (approximately 300N)
and the iteration will proceed as follows with an objective of finding the possible
number of strokes to practically raise the piston up to the indicated maximum lift
height.
Thus,
Equation 1: 𝑅2 = 300 ∗ (𝑋 + 𝐿)/(𝑋 ∗ cos 𝜃)

Equation 2: ℎ𝐴 = 𝑋 ∗ 𝑠𝑖𝑛𝜃
Equation 3:
Equation 4:
Now we select ‘2’ cases to iterate and to find the unknown results. The iteration result is
tabulated below.
Table 2 Iteration tables

Case 1: Where L=600 mm
GECH & HAGOS 38

Known Assumed Values Calculated Value s

Values
h1 h2 F L X d1 d2 Θ Eqn1 Eqn2 Eqn3 Eqn4

(m (mm) (mm) (mm) (mm) (mm) (Degree) (KN) (mm) (mm) (no)
,(KN
m)
)
108 120 200 600 50 48 38 30 3.00 25 26.87 16
108 120 200 600 55 48 38 35 2.91 31.55 26.46 13
108 120 200 600 60 48 38 40 2.87 38.57 26.28 11
Case 2: Where L=650 mm
Calculated
Known Values Assumed Values Values
h1 h2 F, L X Eqn1 Eqn2 Eqn3 Eqn4

d1 d2 Θ
(mm) (mm) (mm) (mm) (Degree) (KN) (mm) (mm)
(mm) (mm)
(KN) (no)
108 120 200 650 50 48 38 30 3.23 25 27.89 15
108 120 200 650 55 48 38 35 3.13 31.55 27.45 13
108 120 200 650 60 48 38 40 3.09 38.57 27.27 10
GECH & HAGOS 39

Then the preceding design analysis of each part will be depending on values of parameters
obtained from case 2 and 3rd iteration because of the value of number of stroke is smaller
than all other iterations.
3.3. STRESS ANALYSIS

3.3.1 Design of Piston Rod
The piston rod design of a hydraulic cylinder is highly stressed and therefore it
should be able to resist the bending and the compressive force that it may encounter
during it operation without buckling. The piston should design in such a way that it is able
to support a given load without experiencing a sudden change in its configuration.
• Configuration of the piston rod (ram)
The piston rod selected for this jack is solid rod since screw extension is needed.
• Head of the piston inside the cylinder
The head should be designed in such a way that:

• The seal should be well mounted to it and completely prevented leakage of the
oil.
• The head of the piston should be slightly extended radially (wide) so that the seal
will not be squeezed and bind when the load is lowered.
• There should be small clearance (usually 2mm) between the head and the walls of
the cylinder to minimize wear due to friction.
The height of the piston rod including its head and cup is
ℎ𝑝 = ℎ3 + 𝑞 = 184 + 60 = 244𝑚𝑚
But, when the jack is at the minimum lift of height, the total
height of the jack assembly above the base of the main
(isolating) cylinders is:
GECH & HAGOS 40

ℎ𝑝 = ℎ1 + 0.05 ∗ ℎ1 + 𝑏 + 𝑡𝑝 = 170 + 170 ∗ 0.05 + 40 + 30
ℎ𝑝 = 248.5 ≈ 248mm.
This total height have to be completely occupied by the piston so that all the oil in
the main cylinder will return back to the reservoir when the load is lowered thus to satisfy
this total height of the piston should be adjusted, that hp=248mm.
Figure 17 Piston Rod
Material Selection
Mostly piston rods are made of high tensile materials finished and hardened with
chromium plating to provide resistance of corrosion. Stainless steel is also used as a rod
material due to its excellent anti-corrosive property.
We have the following material selected as piston rod material:

Material Selected Steel 312% Ni,
0.4%C
Yield strength 1035 Mpa
GECH & HAGOS 41

Shear strength 620Mpa

Modulus of elasticity 207Mpa
Table 3 material selection for piston rod
We have selected this material due to the reason:
 High compressive strength to support the

load.
 Due to its appreciable hardness.
 Give good surface finish.
 Relatively low cost to other grades of steel.
Design Analysis
The piston rod may fail in two ways:
• Failure due to compressive stress (crushing)

• Failure due to instability (buckling)
The cross section of the rod or critical loading should be calculated after
considering whether it is stressed rod or column. This consideration could be checked by
the following approach.
If the length of the rod to least cross actuation dimension ratio is less than or equals to 11.
Then the piston rod is considered as stressed otherwise considered as a column.
Mathematically,
Also since the piston is round shaped, ‘d’ can be substituted by 𝐾 ∗ √12,
Where,
K is the slenderness ratio.
GECH & HAGOS 42

Substitute values
Thus,
Therefore, take 𝑑𝑝=30mm (from geometry analysis) and L= ℎ𝑝 = 248mm.
248/(30/4)≤40=33.06≤40, (short colomn type)
Thus, the piston is short and will fail due to compressive stress Crushing and Buckling.
Design for Crushing
Next find the allowable stress,
On the other hand,
This is greater than that of working load, 𝑊𝑐𝑟 > 𝑊 → 156.08𝐾𝑁 > 60𝐾𝑁, the design is safe.
Design for Buckling

First find the length of piston without length of cup head.
𝑙𝑤𝑐 = 248 − (𝑡𝑝 − 8𝑚𝑚) = 248 − (30 − 8) = 226𝑚𝑚
GECH & HAGOS 43

Assume considered a solid short column then considering J.B Johnson’s equations for
buckling we have:
𝑾𝒄𝒓 = 𝑨𝒄𝒓 ∗ 𝝈𝒚(𝟏 − 𝝈𝒚/(𝟒 ∗ 𝒄 ∗ 𝝅𝟐 ∗ 𝑬 ∗ (𝒍𝒘𝒄/𝑲)𝟐))
Where,
𝜎𝑦 = 1035 MPa
𝑐 = 2, 𝑓𝑜𝑟 𝑜𝑛𝑒 𝑒𝑛𝑑 𝑓𝑖𝑥𝑒𝑑 𝑎𝑛𝑑 𝑜𝑡ℎ𝑒𝑟 𝑝𝑖𝑣𝑜𝑡𝑒𝑑
𝐸 = 207𝐺𝑃𝑎
Substitute numerical value
This is greater than that of working load, 𝑊𝑐𝑟 > 𝑊 → 729.98𝐾𝑁 > 100𝐾𝑁, the design is safe.
3.3.2 Design of Piston Head

We have selected the material for the head such that the piston rod and its head are the same
material thus, we can use the previous mechanical properties of the piston material.
0.4%C
Table 4 Mechanical properties of piston material
The head of the piston is taken as a uniform circular flat plate. The pressure of the oil acts
upon the plate uniformly.
GECH & HAGOS 44

Design Analysis
Figure 18Piston Head
3.3.3. Design of Cap

The cap is upper part of the piston rod on which the load is placed. It is the only part of the
whole jack which is physical contact with the profile of the load.
The upper profile of the cap should be designed in such a way that the load will not
translate (slide) horizontally during operation, thus the geometrical shape of the upper
plate of the cap should be carefully selected and it must be able to grip the load in a fixed
horizontal position. We have selected the profile of the piston cap as follows
GECH & HAGOS 45

Figure 19 2D and 3D model of cap

Material selection for the cap
Since the cap is in directing contact the load it has to be hard enough to contain it and
should not be easily failing due to the direct high compressive stress and this depends on
the correct selection of the material for the cap. Also local availability and cost are also
determinant factor for selection.
Considering all these things and the other factors we have selected the following material and its
mechanical property for the cap.

0.4%C
Table 5 Mechanical properties for cap
Design Analysis
The cap of the piston is subjected to high compressive stress of the load. Now considering
shearing of the cap at the joint with the piston rod I have.
Where: 𝜏𝑎𝑙𝑙 − 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠
GECH & HAGOS 46

𝑊 − 𝑔𝑖𝑣𝑒𝑛 𝑙𝑜𝑎𝑑
𝐴𝑠 − 𝑆ℎ𝑒𝑎𝑟𝑖𝑛𝑔 𝑎𝑟𝑒𝑎 𝑒𝑞𝑢𝑎𝑙 𝑤𝑖𝑡ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑜𝑓 𝑡ℎ𝑒 𝑝𝑖𝑠𝑡𝑜𝑛 𝑎𝑛𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑎𝑝.
And, find the factor of safety:
Therefore this indicates that the thickness assumed (tp) is safe.
Also consider crushing stress of each extended rectangular shapes on the upper surface of the
cap we have the following analysis:
Thus the compression stress is:
Where: 𝜎𝑐 − 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠

𝑊 − 𝑔𝑖𝑣𝑒𝑛 𝑙𝑜𝑎𝑑
𝐴𝑐 − 𝐶𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝐴𝑟𝑒𝑎
Let we need n such structure on the upper surface of the cap to minimize sliding of the loading.
Figure A- square end geometrical shape at the middle of the

Surface let these are 4 in number.
Figure B- rectangular geometry shapes (half of the above shapes) at the profile of the cap.
Let these are 8 in number.
GECH & HAGOS 47

Figure 20 Cap Surface Models
Assume there will be 8 square shaped extended surfaces.
The next task is determining the diameter of the cap. FBD
Figure 21 free body

diagram of cup
GECH & HAGOS 48

Then find the Total Tearing area of the cap:
Next by using allowable shear find dc
3.3.4. Design of main cylinder

The basic function of the hydraulic cylinder is to convert fluid power in to linear
mechanical lift force. In doing so, the cylinder is subjected to internal pressure of the fluid
(oil) thus it is critical part of the jack and needs through the design. Since the internal
pressure should be high enough to sustain the load, then the cylinder must be heavy
cylinder which is expected to be thick to sustain the pressure.
Figure 22 Main Cylinder

Material selection
Both cost and drawn materials can be selected as cylinder material for hydraulic bottle
jack but the most frequently selected material is called drawn deep polished low carbon
GECH & HAGOS 49

steel with relatively high stress values. But due to the following two reasons we have
selected the stainless steel, with mechanical properties given below, as cylinder materials
the reasons are:
 Manufacturing feasibility
 Local availability
Material Selected Stainless Steel
Yield strength 520Mpa
Ultimate strength 860Mpa
Modulus of elasticity 190GPa
Modulus of rigidity 75GPa
Design Analysis
In hydraulic cylinder design the wall thickness it is closed so that the stress at the working
pressure (P) is less than the yield strength of the wall. Stress over the selection of the walls
cannot be assumed to be uniformly distributed. The walls develop both tangential and radial
stresses with values which depend up on the radius.
First find the thickness and pressure of the walls by using lame’s equation as follows. The
cylinder is subjected to for radial and tangential stress (𝜎𝑟 & 𝜎𝑡) respectively.
In the next we present the effects of radial and tangential stresses diagrammatically.
A) B)
GECH & HAGOS 50

Figure 23Tangential and Radial Stresses
And Known boundary conditions
For radial stress
𝜎𝑟𝑚𝑎𝑥 = 𝑟 = 𝑟𝑖
𝜎𝑟𝑚𝑖𝑛 = 𝑟 = 𝑟𝑜
For tangential stress
𝜎𝑡𝑚𝑎𝑥 = 𝑟 = 𝑟𝑖
𝜎𝑡𝑚𝑖𝑛 = 𝑟 = 𝑟𝑜
Substitute values and I get the following:
𝐹𝑜𝑟 𝑟𝑎𝑑𝑖𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠: 𝜎𝑟𝑚𝑎𝑥 = −𝑃 𝜎𝑟𝑚𝑖𝑛 = 0
Now we can select different approaches (maximum normal stress theory, maximum shear stress
theory or maximum strain theory) to evaluate the failure of the cylinder.
Considering the maximum tangential stress and follow the maximum strain theory we get the
following equation called Bernie’s equation.
Find the known values:
• , take N= 3
• Next find Pi:
, FBD
GECH & HAGOS 51

• 𝜇 = 0.3, 𝑓𝑜𝑟 𝑚𝑜𝑠𝑡 𝑚𝑒𝑡𝑎𝑙𝑠

Substitute values and 𝑡 = 5.5𝑚𝑚 ≅ 6𝑚𝑚
Threads on the main cylinder
The main cylinder is screwed into the base to 0.05h1 depth the over plate is also screwed
on the upper part of the cylinder to a depth of r, thus the main cylinder is threaded in the
both its ends.
Threads on the outer surface can be made on lathe machine of the cylinder is prepared by
casting. Standard selected M-82 and core diameter is 48mm.
Length of threaded part on the cylinder is

𝐿 = 0.05 ∗ ℎ1 = 0.05 ∗ 170 = 8.5𝑚𝑚
The lower part is subjected to compression stress due to radial stress in the cylinders
Let as find the unknown parameters
• A
P=25Mpa
Substitute numerical value
The pitch thread length is
Thread length for the upper thread

If there is excess fluid in the reservoir and the mechanic pumps more than maximum number of
strokes, shearing of threads many occurs.
GECH & HAGOS 52

For safe design, take n=6

Thread length is 𝑟 = 𝑃𝑖𝑡𝑐ℎ ∗ 𝑛 = 0.9 ∗ 6 = 5.4 ≅ 6
3.3.5. Design of Telescopic cylinder

The telescopic cylinders are evaluated in the same war and the main cylinder since both are
subjected to the same internal pressure.
Figure 24 Telescopic Cylinder

Material selection
The selection criteria are:
• Good mechanical property

• It is strong and ductile
• Good in machinability
• Good surface finish
• High corrosion resistant
• Is light in weight, these minimize the weight of the jack
GECH & HAGOS 53

• Availability and low cost

Thus we select the following
Material Selected Steel 0.6% carbon

(quenched)
Table 6 Material selection for telescopic cylinder
Design analysis
The objective of the design analysis is to find the thickness of the telescopic cylinder based
on the Bernie’s equation the analysis is the same with the previous design of the main
cylinder, the only parameters changed here are the diameter and the tangential stress that is
d2=38mm and n= 2.5
Find the known values:
• , take N= 2.5
• Next find Pi:
•
Substitute values and 𝑡 = 6.12𝑚𝑚 ≅ 6𝑚𝑚
GECH & HAGOS 54

3.3.6. Design of the pumping cylinder

The pumping cylinder is small in size when compared to the other cylinder but is
subjected to the same pressure P=52.9MPa still the analysis will be the same with the
previous procedures of cylinder design.
Figure 25 pumping cylinder
From geometry analysis
Material for pumping cylinder

The material that we select for the pumping cylinder satisfies the following selection criteria’s.
• Availability
• Corrosion resistance and chemical stability
• Manufacturing feasibility
Material Selected 0.6% carbon steel

(quenched)
Table 7 Material selection of pump cylinder
GECH & HAGOS 55

Design Analysis
The pumping cylinder is subjected to be the tangential and radial stresses.
Tangential stress (𝜎𝑡)
Equation 8
Where: 𝑑𝐴 − inner diameter

𝑑𝐴𝑜 −Outer diameter
𝑃𝑖 − Fluid pressure
r - Print of maximum pressure
The maximum pressure occurs at r=
Thus,
Also,
Substitute numerical value,
Thus thickness of the cylinder is
3.3.7. Design of the reservoir cylinder

The reservoir must be a stable non relative material. It is not subjected to any type of stress
except when the cover plates are tight ended. However the stress resulted from this tight
ended can be neglected since it many not bring significant effect.
GECH & HAGOS 56

Figure 26 Reservoir Cylinder

Material selection
As explained the reservoir only stores the oil and is not subjected to any severe stress.
Thus any type of iron used in pipe manufacture can be selected as reservoirs cylinder
material but its inner walls are chromium plated to prevent any chemical attached and rust.

Table 8 Material selection for reservoir

Design Analysis
The oil that fills the main cylinder and the telescopic cylinder comes from the reservoir cylinder
thus we can find the diameter of the reservoir cylinder considering volume relationships.
Also the reservoir can fill only up to the oil feeder hole, thus only portion of the reservoir
cylinder below the oil feeder hole is considered. Let the oil feeder hole is located at ‘T’
mm unit below that height (upper) level of the reservoir, also let the portion of the
reservoir above the oil feeder hole be 45% of the total volume thus:
𝑇 = 0.15 ∗ ℎ1 = 0.15 ∗ 108𝑚𝑚 = 16.2𝑚𝑚
GECH & HAGOS 57

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑟𝑒𝑠𝑒𝑟𝑣𝑖𝑜𝑟 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑤𝑜 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟𝑠

𝑉𝑟 = 𝑉1 + 𝑉2
From the geometry analysis
Substitute numerical values and

𝑑𝑟 = 103.05𝑚𝑚
As we have explained above the reservoir just only stress the oil and its thickness is
independent of the load since the pressurized fluid (oil) is preventing from going the safe
just select
𝑡𝑟 = 5𝑚𝑚
3.3.8. Design of the cover plate

Actually the cover plate is not directly subjected to the pressure of the oil other type of
reaction force due to the loading. But since it is screwed into the main cylinder remarkable
shearing many occur on the threads.
Figure 27 Cover Plate
GECH & HAGOS 58

Material Selection
Table 9 Material selection for cover plate
Thus material is frequently used in nut manufacturing.
Design Analysis
The threated part of the cover plates was already design during main cylinder thread part design
analysis thus r= 6mm.
Let us go deep in to the profile of the threaded in the cover plate.
If we choose at 60o threaded then we have:
Let us find the following diameters:

𝑑𝑜 = 𝑡ℎ𝑒 𝑜𝑢𝑡𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑖𝑛 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 48 + (2 ∗ 6) = 60𝑚𝑚
GECH & HAGOS 59

𝑑𝑟𝑖 = 𝑡ℎ𝑒 𝑖𝑛𝑛𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑒𝑠𝑒𝑟𝑣𝑜𝑖𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 103.05𝑚𝑚

𝑑𝑟𝑜 = 𝑡ℎ𝑒 𝑜𝑢𝑡𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑟𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑒𝑠𝑒𝑟𝑣𝑜𝑖𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 103.05 + 10𝑚𝑚 = 113.05𝑚𝑚
𝑑𝑐𝑜 = 𝑑𝑐𝑖 + 2 ∗ 8 = 38 + 16 = 52𝑚𝑚
Thus,
2𝐶 = 𝑑𝑟𝑜 − 𝑑𝑐𝑜 = 113.05 − 50
𝐶 = 31.525 ≅ 32𝑚𝑚
Let the inner seal is located 10mm below the upper surface the plate a=15mm. the
thickness of the seal to be selected from standard tables.
b=30mm from geometry analysis b’=10mm

any value greater than 2ts but less than b.
3.3.9. Design of Pump handle socket

As previously explained the pump handle socket transmits force from handle to pump
plunger of pump the socket is hollow in shaped and contains plates with holes that use as
connecting mechanism of the socket and the link and the plunger.
Material Selected
The material that selected for the pump handle socket is tabulated below with its property.

(quenched)
Table 10Material selection for pump handle socket
Design Analysis
The objective of the design is to find the value of the parameters shown in the sketch below.
From the handle design, outer diameter of handle 𝑑𝑜 = 24𝑚𝑚 inner diameter of socket is
𝑑𝑖𝑠 = 𝑑𝑜 + 2 ∗ (𝑐𝑙𝑒𝑟𝑎𝑛𝑐𝑒) = 24𝑚𝑚 + (2 ∗ 0.5)= 25𝑚𝑚

Consider the following diagram to show the force exerted on the plates part of the socket, each
hole is subjected to shearing and crushing stress.
GECH & HAGOS 60

Let us take the pin

joint mechanism for the link and the plate and magnify it as follows
Generally the following types of failure occur in the pin joint mechanism shown above.
• Tensile Failure of the plate

As R1 pulls the plates down ward the upper parts of the socket also pulls it with an equal’s
amount of force upward. The cross-sectional area of the plates is, 𝐴𝑠 = 𝑎𝑠 ∗ 𝑙𝑠, then the
allowable tensile strength of the material is:
The critical area will be considered during failure analysis. The following types of model forces
also occur in the joint connection.
• Transvers failure of the pin

• Compressive bearing failure between the pin and the hole
Now let us come back to the first mode failure type, let 𝑎𝑠 = 7.2𝑚𝑚, = 22.8𝑚𝑚
Thus,
GECH & HAGOS 61

. Factor of safety 3
Also,
Next find the diameter of the hole by equating both equations
• Shear Failure of the plate (clevis due to tear out)
The length of the shear is
𝐿𝑠 = 𝑙𝑝 − 𝑑ℎ𝑜𝑙𝑒, 𝐿 Lp  37.2mm
Also the tear out area is:-
𝐴𝑡 = 7.2 ∗ (𝑙𝑝 − 𝑑ℎ𝑜𝑙𝑒) = 159.84mm2 the shear stress is:
Take factor of safety 3.
Next find the length of the shear by equating both equations
Now let us take the pin joint between the socket and the plunger and magnify it as
follows.
FBD
GECH & HAGOS 62

Figure 28 Magnified Pin and Plunger joint

Tensile stress on the socket plate, then the value of ‘Z’
𝑍 = 2 ∗ 𝑎𝑠 + 𝑑𝑝𝑙 + 𝑐𝑙𝑒𝑟𝑎𝑛𝑐𝑒
And the value of ‘r’ is:

𝑟 = (𝑙𝑝 − 𝑑ℎ𝑜𝑙𝑒)/2 = (37.2 − 15)/2 = 11.1𝑚𝑚
Let the factor of safety is 3 for the crushing strength then the compressive stress is
Let 𝑎𝑠 = 6𝑚𝑚
Next find the thickness of the socket
Figure 29 Handle and Socket beam diagram
𝐿𝑠 = 22.8 + 60 + 7.2 = 90𝑚𝑚

Next find the moment from point ‘O’
Also find the value of shear allowable
GECH & HAGOS 63

Substitute numerical value,
∴ 𝑡ℎ𝑒 𝑜𝑢𝑡𝑒𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑠 = 25 + 2 ∗ 1 = 27𝑚𝑚

3.3.10. Design of Pump handle
The force distribution on the handle and its dimensions were carefully design in the
geometry analysis. The size of the handle is selected so that the operator can easily
manageable. Also we have selected a hollow handle so as to save material. Thus, the
handle can be generally viewed as a hallow rod with inner and outer rod.
The cross sectional of the handle can be represented by the following diagram.
Material Selection
The handle should have to fulfill the following criteria’s:
• Should be hard
• Should be not brittle
• Good resistance to corrosion and rust (for long working
life)
• Ease of manufacturability Therefor the selected material is:
Material Selected Steel % Ni, 0.4%C

GECH & HAGOS 64

Design Analysis
Generally the force distribution over the handle can be represented as follows:
Figure 30 Force Distribution of Handle

The values specified above were taken from the iteration result of the geometry analysis
the value of R2 is not constant since it is dependent on the angle by which the handle is
rotated therefor it must be resolve with respect to .
Then, ∑ 𝐹𝑦 = 0 → 6𝐾𝑁 − 200𝑁 = 5.8𝐾𝑁
Also the cross sectional area of the handle is assumed to be constant. As it easily can be
seen the handle is subjected to bending force and it should be designed for bending
strength. Belo the BMD and SFD are presented as follows:
Figure 31 BMD & SFD
GECH & HAGOS 65

The bending moment diagram shows that the maximum bending occurs at the pump. Thus the
strength equation is
𝑀𝑏 = 𝜎𝑎𝑙𝑙 ∗ 𝑍
Where, 𝑀𝑏 = 𝑀𝑜𝑚𝑒𝑛𝑡 𝑜𝑓 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑒𝑛𝑑𝑖𝑛𝑔

𝜎𝑎𝑙𝑙 = 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠
𝑍 = 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 ℎ𝑎𝑛𝑑𝑙𝑒
The modulus of section of circular cross section is, since the handle is hallow:
Equation
Also we can express Z by using thickness of the handle:
From the BMD maximum bending value is 259KN.mm, also take n=3.5 thus,
Then, substitute numerical value
3.3.11. Design of the Plunger.

The plunger is rod like structure found in the pump piston.
Material Selection
Mostly piston rods are made of high tensile materials finished and hardened with
chromium plating to provide resistance of corrosion. Stainless steel is also used as a rod
material due to its excellent anti-corrosive property.
GECH & HAGOS 66

Figure 32Plunger
We have the following material selected as piston rod material:

0.4%C
Table 11 Material selection for plunger
We have selected this material due to the reason: o High
compressive strength to support the load.
 Due to its appreciable hardness.

 Give good surface finish.
 Relatively low cost to other grades of steel.
Design Analysis
Forces on the plunger are compression forces due to shear force in the hole. If the length
of hp is larger relative to its diameter then the force may cause buckling. Let me take factor
of safety is 3.
GECH & HAGOS 67

Now find the plunger head thickness (tpe) by using the following equations. First fin the
allowable stress. And take dA =18mm also dhole =15mm
Next find tearing of the plunger at the hole due to vertical reaction of force. First find the
allowable stress:
There are two possible shear areas as shown in the
figure. Thus, the area of the tear is
Then find the value of 𝑑𝑝𝑙
→ 𝑑𝑝𝑙 = 8.73𝑚𝑚 ≈ 9𝑚𝑚. We take d=22mm.
Thus, area of tear become,
𝐴𝑡𝑒𝑎𝑟 = 10.58 ∗ (3 + 𝑒)
GECH & HAGOS 68

Substitute in the above equation
Therefore, the height of the plunger is

ℎ𝑝 = ℎ𝐴 + 𝑑ℎ𝑜𝑙𝑒 + 𝑒 + 2𝑡𝑝𝑒 + 𝑡𝑠 = 2 + 6 + 43 + 20 + 5 = 76𝑚𝑚
3.3.12. Design of the link

The link is connected to the base by pin joint. There are two links used to connect the socket
and the base.
Figure 33 Link Multi-View

Material selection
The material that selected for the pump handle socket is tabulated below with its property.
(quenched)
GECH & HAGOS 69

Design Analysis
Let the least cross section of the link is square of side, the link (each link) is subjected to the
tensile compressive stress due to reaction force R1 =2.166KN, 𝑑ℎ𝑜𝑙𝑒 = 15𝑚𝑚
Thus,
Where, 𝐴𝑐𝑟 = 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑖𝑛𝑘 = 𝑡𝑙1 + 𝑡𝑙2 , 𝑡𝑙1 = 𝑡𝑙2 = 𝑡𝑙
𝐴𝑐𝑟 = 𝑡𝑙2
Let us use factor of safety of 2.5,
Considering tearing of the clevis of the link the shear stress can be follows as:
Next find Atear,
Thus,
If the link is not to buckle , where k=slenderness

ratio Let us find the value of k,
Now check the condition,
0.
GECH & HAGOS 70

3.3.13. Design of the Basement

The base contains threaded parts for mounting cylinder, pump and release valve. It also
contains check valves to control the flow of the oil and flow line. The overall area of the
base should be designed in such a way that it will not sink to the ground during lifting
operation.
Material Selection
Considering carbon content, machinability corrosion resistance strength we have selected mild
still for base material. Its property tabulated below;
Material Selected steel (Annealed & Hardened )

Yield strength 294.8Mpa
tensile strength 394.0 Mpa
HB 111
Design analysis
The minimum thickness of the base is found using the following formula:
Let factor of safety be taken 2.5
Thus,
Where, 𝜎𝑎𝑙𝑙 = 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠

𝑑2 = 𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑟𝑒 𝑜𝑓 𝑙𝑎𝑟𝑔𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 𝑖𝑛 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑤𝑖𝑡ℎ
𝑡ℎ𝑒 𝑏𝑎𝑠𝑒 𝑐 = 0.4 𝑓𝑜𝑟 𝑚𝑖𝑙𝑑 𝑠𝑡𝑒𝑒𝑙
Base dimensional Area
In order to find the dimension of base environmental factor should have to be considered.
That is where the jack should be used for example if the ground in which the case wheel is
to be changes is soft than the jack may sink to the ground up on lifting in such cases the
base area of the jack is preferred to be large. The width of the wb Calculate as follows:
GECH & HAGOS 71

𝑤𝑏 = 10 + 30 + 44 + 10 + 15 + 50 + 4.65 + 10 = 173.65 ≅ 174𝑚𝑚

Also the length of the base is Lb
𝐿𝑏 = 60 + 110 = 160𝑚𝑚
N.B. the numbers in the above formula are those found in the design of cylinders, pumps and
also the spaces between each design part is considered.
3.4. Components selected from standard tables-3

3.4.1. O-ring selection:
All O-Ring sealing applications can be classified as either static or dynamic.
Static seals
In a static application there is no relative motion between parts of the groove which
contact the O-Ring. Small amounts of movement, caused by thermal expansion, vibration,
bolt stretch or O-Ring response to fluid pressure, do not alter the static definition. Static
seals are often categorized according to the direction in which compression is applied to
the O-Ring cross section. There are two basic directions of compression: axial and radial.
There are also applications which combine both axial and radial compression (crush seals).
Static axial seals

In this application the compression is on the top and bottom of the O-Ring, which is
similar to a flat gasket. Static axial seals are typically utilized in face seal applications, as
illustrated in the figure below.
GECH & HAGOS 72

Figure 34 Static axial seal

Static radial seals
This application means that the compression is between the inside diameter and the outside
diameter of the O-Ring. Typical static radial seals are cap seals and plug seals.
Figure 35 Static radial seal

Dynamic seals
In dynamic sealing applications there is relative movement between the parts of the
groove, i. e. O-Rings are subject to a sliding action against the surface. This motion causes
difficulties that cause design problems different from those of static seals. For the great
majority of dynamic applications, O-Rings are squeezed radially and are subjected to
reciprocating motion, either intermittent or continuous, or, less frequently, to an
intermittent rotary or oscillating motion.
Reciprocating seals
In this type of application, there is a relative reciprocating (back and forth) motion
along the shaft axis between the inner and outer elements of the groove. O-Rings used in
reciprocating applications are called piston or rod seals.
GECH & HAGOS 73

Figure 36 Reciprocating seals

Oscillating seals
In this application, the inner and outer components of the groove move in an arc
around the axis of the shaft, first in one direction and then in the opposite direction,
usually intermittently, with no more than a few turns in each direction. The most common
application for oscillating O-Ring seals is in valves.
Figure 37 Oscillating seals

Selected Standards
A. O-ring install between
• Piston head and Telescopic cylinder.

• Cover plate and Telescopic cylinder.
• Cover plate and reservoir.
We select the following standard:
GECH & HAGOS 74

Figure 38 O-ring Standard 1
Selection result
Cross section Inside diameter Tolerance

5 mm 5 mm ±0.15 mm
B. O-ring install between
• Plunger and Pump cylinder.

We select the following standard:
GECH & HAGOS 75

Selection result

1 mm 1.15 mm ±0.08 mm
1. Pin selection: There are three pins in the whole assembly one used to
connect plunger and socket two pins used to connect the link and the socket. Those
pins are subjected to double shear.
Material selection: Malleable cast iron with the following material properties can be
subjected as pin material.
Material Selected ASTM A602
tensile strength 621 Mpa
Selected Standards
We select standards from Holo – Krom Technical Handbook. We select two type of pins based
on their nominal diameter for 9mm and 4mm. the result presented below.
GECH & HAGOS 76

Selection result
No of pins Nominal size A B C R LS

1 pin 4mm 4.009mm 3.9m 0.9mm 0.4mm 4.5mm
2 pins 10mm 10.012mm 9.8mm 1.4mm 0.6mm 6.0mm
2. Valve Selection: There are two check and one release valves are available
in this jack. We select standard from Catalogs of Valves. The selected results are
present below.
Selected Standards
We select universal low pressure check valve base on nominal diameter of the
pipe. The Universal Low Pressure (U3) check valve is a one piece body machined from
bar stock and is designed for minimum pressure drop. The valve has a light weight
compact design that provides maintenance-free dependable service.
GECH & HAGOS 77

Figure 39 animation image of bottle hydraulic car jack
CHAPTER FOUR
Manufacturing Process and Maintenance

4.1 Introduction
Process equipment is fabricated by a number of well-established methods such as
fusion welding, casting, forging, machining, brazing and soldering and sheet metal
GECH & HAGOS 78

forming. Each method has certain advantages for particular types of equipment. However,
fusion welding is the most important method. The size, shape, service and material
properties of the equipment all may influence the selection of the fabrication method.
4.2 Methods of fabrication

• Piston Rod and Cap: To manufacture the piston rod and cap we recommend the
following steps. Select a blank (a work piece) with a dimension of Ø = 50mm x
248mm. Face the work piece according to the dimension & shape on the part
drawing by using lathe machine. Drill the center to the required dimension on the
part drawing by using drilling machine. Chamfer the internal end and treaded with
tread engagement with screw specification. Finally, make a groove for the O–ring
seal seat & good surface finishing by using lathe machine.
• Main Cylinder: The main cylinder can be manufactured by centrifugal casting

with inner diameter of 66mm outer diameter of 60mm. Face the outer surface & bore
the inner surface according to the dimension & shape on the part drawing by using
Lathe machine. Thread the upper & Lower, outer surface of the cylinder with metric
thread engagement with 1mm pitch. Finally, make a necessary surface finish.
• Telescopic Cylinder: The Telescopic cylinder can be manufactured by centrifugal

casting with inner diameter of 50mm & outer diameter of mm for bottom part and
46mm outer diameter and 20 mm inner diameter for upper part. Face the outer
surface according to the dimension & shape on the part drawing by using Lathe
machine. Bore the inner surface according to the dimension & shape on the part
drawing by using Lathe machine. Finally, make a groove for the O – ring seal seat at
the flange of the ram & make a necessary surface finishing by using Lathe machine.
• Pumping Cylinder: The main cylinder can be manufactured by centrifugal casting

with inner diameter of 15mm outer diameter of 23mm. Face the outer surface & bore
the inner surface according to the dimension & shape on the part drawing by using
Lathe machine.
Thread the upper & Lower, outer surface of the cylinder with metric thread engagement
with 1mm pitch. Finally, make a necessary surface finish.
GECH & HAGOS 79

• Reservoir Cylinder: The Reservoir can be manufactured by centrifugal casting

with inner diameter of 103.05mm & outer diameter of 113.05mm with 15mm oil
feeder hole. Face the outer surface & bore the inner surface according to the
dimension on the part drawing by using Lathe machine. Thread the outer surface of
upper & lower of the reservoir with metric thread engagement with 1mm pitch.
Finally, make a necessary surface finish.
• Cover Plate: The upper plate can be manufactured by sand casting. Correct the
casted plate to appropriate dimension on the part drawing. Thread the lower inner
surface to light the cylinder & the reservoir with metric tread engagement part tool
with 1mm pith by using Lathe machine. Finally, make a necessary surface finish.
• Pump handle socket: The socket can be manufactured by sand casting. Correct
the casted plate to appropriate dimension on the part drawing. Prepare two holes with
9 and 4 mm to connect the socket with plunger and pin. Finally, make a necessary
surface finish.
• Handle: The Handle can be manufactured from a metal rod with Ø 24 x 454mm.
Finally turn the rod by using Lathe machine to the Ø 20mm x 400mm.
• Plunger: Select a blank with Ø 15mm x 76mm. Face the work piece according to
the dimension & shop on the part drawing by using Lathe machine. Make a groove
for O – ring seal seat at the plunger. Make a hole at the rod for pin passage.
• Link: The link can be manufacture from 4mm thick sheet metal by cutting and
machining processes.
• Base Plate: Select a blank (a work piece) with a dimension of 174x 160mm with
thickness of 45mm. Face the work piece according to the dimension & shape of the
part by using milling machine. Drill the oil port & the spring seat by using drilling
machine. Close unnecessary hole by pouring molten metal. Finally, make a necessary
surface finish.
• O - Ring Seal: O- Ring seal can be manufactured by using Die.

• Pressure Release Value: The pressure release value can be manufactured by
casting & face the work piece according to the dimension & shape on the part
GECH & HAGOS 80

drawing by using Lathe machine. Finally, thread the surface with metric thread
engagement part tool with 1mm pitch by using Lathe machine.
4.3. Maintenance
4.3.1. Oil in a Bottle Jack
A bottle jack is made of steel and can vary in weight according to size. The
smallest jack is a few pounds, while the 100 ton jack weighs greater than 200 pounds. In
order to maintain the seals as long as possible, the operator should use jack stands and
keep the machine away from paint thinners, acids, heat, alcohol and pet urine.
A bottle jack requires hydraulic oil. This type of oil is a liquid lubricant used to
send power throughout hydraulic systems. Hydraulic oil provides good lubrication,
protects from rust and oxidation and has low foaming characteristics. The stuff packaged
as hydraulic jack oil is low viscosity. A lot of tractor hydraulics and some heavier
earthmoving stuff use hydraulic oil that’s essentially the same viscosity as 10W motor oil.
Jack oil looks about the same. The main thing is DON'T use brake fluids as hydraulic fluid
because Brake fluid contains alcohol, which is harmful to the seals when we use this fluid
over and over the seals become tear and have jelly like behavior.
4.3.2. Adding oil

• Position the jack on level ground in an upright (vertical) position and fully lower
the saddle.
• Remove oil filler plug.

• Oil should be filled to the level of the oil filler plug hole. If low, add oil as
needed.
4.3.3. Replacing oil
• To drain oil, remove oil filler plug and open release valve.
• Turn jack on its side and drain old oil out through the oil filler plug hole
• Refill with new oil through the oil filler plug hole. DO NOT allow dirt or other
foreign material to enter the hydraulic system when filling.
GECH & HAGOS 81

• After refilling, remove any air from the hydraulic system by opening the release
valve and rapidly pumping the jack handle several times.
• Replace the oil filler plug.
4.4. Lubrication
• Put grease into fitting on base using a grease gun and lubricate lifting arm spindle
with oil every 3 months.
4.5. Preventing rust

• Check ram and pump plunger every few months for any signs of rust or
corrosion. Clean as needed by wiping with an oily cloth.
• When not in use, ALWAYS store jack with saddle and pump plunger
lowered all the way down.
4.6. Inspection
1. Visual inspection shall be made before each use the jack by checking for
abnormal conditions, such as cracked welds, leaks, and damaged, loose, or missing
parts.
2. Other inspections shall be made per product operating instructions.

3. Each jack shall be inspected immediately if the device is believed to have been
subjected to an abnormal load or shock.
4.7. Safety
1. Study, understand, and follow all instructions provided with and on this device
before use.
2. Do not exceed rated capacity.
3. This is a lifting device only.
4. After lifting, immediately transfer the load to appropriately rated vehicle stands.
5. Use only on hard, level surface.
6. Lift only on areas of the vehicle as specified by the vehicle manufacturer.
7. No alterations shall be made to this device.
8. Only attachments and/or adapters supplied by the manufacturer shall be used.
GECH & HAGOS 82

9. Failure to heed these markings may result in personal injury and/or property
damage.
To avoid crushing and related injuries:
• Never work on, under, or around a load supported only by a hydraulic jack.
Figure 40 Safety Picture 1

• Read, understand and follow all printed materials provided with and on this jack.
• Immediately support the lifted load with appropriately rated jack stands.
Figure 41Safety Picture 2
• Use ONLY on vehicles whose lift points are compatible with the saddle of this jack.
Incompatibility may result in structural damage to the vehicle and/or jack.
• Chock each un-lifted tire in both directions.
GECH & HAGOS 83

Figure 42Safety Picture 3
• Be alert and sober when servicing a vehicle! Never operate this equipment when under
the influence of drugs or alcohol.
• DO NOT use this device to lift, level, lower, support, adjustor otherwise move a house,
mobile home, travel trailer, camper, or building structure of any type, size, or configuration.
4.8. Troubleshooting
Table 12 Troubleshooting Table
CHAPTER–FIVE
Cost Analysis
Now we can discuss about manufacturing cost of the jack including labour cost, power and 15%
contingency. We use standard cost data for calculating the price.
5.1 Purchasing cost
In this topic only the purchasing cost of materials are listed below.
GECH & HAGOS 84

 Piston Rod:
2
mass ofrod =ρ∗v=7300∗2∗40∗π ¿ 16 =1.643 Kg
Then from our data the cost of steel per Kg is 29.92 ETB. Thus the total cost is:
mass∗cost ETB
=1.643 Kg∗29.92 =49.18 ETB
Kg Kg
 Extension screw
2
mass ofrod =ρ∗v=7300∗2∗80∗π∗13 =0.62 Kg
mass∗cost ETB
=0.62 Kg∗29.92 =18.55 ETB
Kg Kg
 Head of the reservoir:
mass ofhead=ρ∗v =7850∗2∗148∗π ¿ 542=21.28 Kg

Then from our data the cost of mild steel per Kg is 29.92 ETB. Thus the total cost is:
mass∗cost ETB
=21.28 Kg∗29.92 =636.88 ETB
Kg Kg
 Main cylinder:
2
mass ofplate =ρ∗v=7850∗2∗156∗π ¿27.5∗¿ =5.818 Kg ¿
Then from our data the cost of stainless steel per Kg is 91.52 ETB. Thus the total cost is:
mass∗cost ETB
=5.818 Kg∗91.52 =532.54 ETB
Kg Kg
 Reservoir cylinder:
2
mass ofplate =ρ∗v=7850∗2∗148∗π ¿ 28 =5.72 Kg
Then from our data the cost of mild steel per Kg is 91.52 ETB. Thus the total cost is:
mass∗cost ETB
=5.72 Kg∗91.52 =523.77 ETB
Kg Kg
 Links:
mass ofplate =ρ∗v=7850∗100∗4.125∗16.5=0.053 Kg
GECH & HAGOS 85

mass∗cost ETB
=0.053 Kg∗29.92 =1.59 ETB
Kg Kg
 Plunger:
mass ofplate =ρ∗v=7850∗57.1∗π ¿ 102=0.281 Kg
mass∗cost ETB
=0.281 Kg∗29.92 =8.42 ETB
Kg Kg
 Basement:
mass ofplate =ρ∗v=7850∗40∗60∗120=9=2.26 Kg
mass∗cost ETB
=2.26 Kg∗29.92 =67.6 ETB
Kg Kg
 Pump handle:
mass ofplate =ρ∗v=7850∗120∗π ¿ 222=2.86 Kg

mass∗cost ETB
=2.86 Kg∗29.92 =85.7 ETB
Kg Kg
 O- Rings: The cost of one O-ring is 0.01-0.1 $ multiply this by 20 we get 0.2-2 ETB.
 Seal for 1mm inside diameter: the cost of one seal is 0.01 $ multiply this by 20
we get 0.2 ETB. Thus we desired four gaskets the cost is 0.8 ETB.
 Seal for 5mm inside diameter: the cost of one seal is 0.1 $ multiply this by 20
we get 2 ETB. Thus we desired six gaskets the cost is 12 ETB.
Thus, the total cost of flange is: 0.8 ETB +12 ETB=12.80 ETB
 Valves: The cost of one valve is 1$ multiply this by 20 we get 20 ETB. Thus we desired
four gaskets the cost is 20 ETB.
 Pins: The cost of one valve is 2$ multiply this by 20 we get 40 ETB. Thus we desired
three gaskets the cost is 60 ETB.
GECH & HAGOS 86

Therefore, Total purchasing cost is:

49.18 ETB+18.55 ETB+ 636.88 ETB+532.54 ETB+523.77 ETB+1.59 ETB +8.42 ETB+ 67.6 ETB+85.7 ETB+12.8
6.1. Manufacturing cost

In this topic the manufacturing cost listed below.
 Power cost: ≈ 540 ETB
 For labour salary: ≈ 650 ETB
540 ETB+ 6500 ETB =1190 ETB
∴ thetotal cost of this designis=1997.19 ETB +1190 ETB
3187.19 ETB
Also the total cost of the design with 15% contingency is:
(
3187.19 ETB+ 3187.19
ETB∗15
100 )
=3665.35 ETB
CHAPTR SIX
Result and Discussion

6.1 Introduction
In this topic I discussed about Results and conclusions with short and precise description.
6.2 Results of Geometrical Analysis
Generally, the geometry analysis of the Hydraulic bottle jack can be summarized as follows:
 Maximum lift height (Hmax) - 330 mm.
 Minimum lift height (Hmin) - 180 mm.
 Height of reservoir cylinder above the base (h1) - 90mm.
 Height of telescopic cylinder above the main cylinder (h2) - 100mm.
GECH & HAGOS 87

 Length of socket between pin connections (X) - 50mm.

 Length of the handle up to the plunger pin connections from the left (L) - 650mm.
 Applied force operator force (F) - 300N.
 Diameter of telescopic Cylinder (d2) – 34mm
 Diameter of main Cylinder (d1) – 44mm
 Angle that the handle makes with the horizontal for maximum
Position of the plunger ( )- 40o
 Diameter of the pump (Actuator) cylinder (dA) – 11.26mm 12mm.
 Maximum rise of the plunger (hA)- 32.14mm ≅ 33mm  Vertical plunger pin reaction
force (R2) – 5.48KN.
 Number of strokes – 59 times.
6.3 Results of Stress Analysis.

Table 13 Results of the analysis
1. Piston Rod:
Height 140mm
Material Type Steel 312% Ni, 0.4%C
critical load 108.38 KN
thead 4mm
Diameter of the cap 25mm
2. Main Cylinder
GECH & HAGOS 88

Height 94.5 mm
Material Type Stainless Steel
critical load 108.38 KN
Thickness 5mm
Diameter 44mm
Allowable shear 75MPa
Critical stress 260MPa
3. Telescopic cylinder
Height 115 mm
Material Type Steel 0.6% C, Quenched
Thickness 6mm
Diameter 34mm
4. Pumping cylinder
Height 43 mm
Thickness 4mm
Diameter 15mm
5. Reservoir Cylinder
Height 90mm
Thickness 4mm
Diameter 103.05
GECH & HAGOS 89

Thickness 5mm
6. Cover Plate
a 15mm
b 25mm
c 32mm
b’ 10mm
Thickness 4mm
Diameter outer 113.05
Diameter inner 103.05
Thickness 8mm
7. Handle Socket
Diameter outer 21mm
as 6mm
bs 50mm
ls 14mm
Thickness 8mm
Critical stress 171.67MPa
8. Plunger
height 76mm
Diameter outer 8mm
Thickness 5mm
GECH & HAGOS 90

Allowable stress 345MPa
9. Pump Handle
height 650mm
BMmax 259 KN.mm
Diameter outer 20
Thickness 4mm
Allowable stress 295.71MPa
10. Link
height 80.95mm
Diameter of the hole 23.03mm
Thickness 4mm
Allowable stress 206MPa
11. Basement
length 160mm
width 174mm
Thickness 45mm
Allowable stress 117.992MPa
12. O-ring selection

5 mm 5 mm ±0.15 mm
1 mm 1.15 mm ±0.08 mm
GECH & HAGOS 91

13. Spring selection

O.D Free I.D Rate Max Max Solid Wire Total
(mm) length (mm) (N/mm) Deflection Load Length Diameter Coils
(mm) (mm) (N) (mm) (mm)

6.10 9.7 3.8 32 1.8 57 6.6 1.1 5.75
14. Pin selection

No of pins Nominal size A B C R LS
1 pin 4mm 4.009mm 3.9m 0.9mm 0.4mm 4.5mm
2 pins 10mm 10.012mm 9.8mm 1.4mm 0.6mm 6.0mm
15. Valve Selection

Nominal pipe Size code A Hex size B C Orifice
size diameter
3/8 C 2.16 13/16 3/8 NPT 0.348
CHAPTER SEVEN
Conclusion and Recommendation

7.1 Conclusion:
The Hydraulic Bottle Jack is successfully designed so that it with stand all the
mechanical stress acting on it. The jack is analyzed under various conditions of operation.
All forces are carried according to strength and geometry analysis. The jack also can carry
the external load with the help of internal fluid at working conditions. The stresses in
above-mentioned conditions are found out and thickness of various parts is selected such
that the stresses produced in each member are within the maximum allowable range.
Proper selection of working fluid during maintenance is stated and replacing also
presented this minimizes the effect of corrosion which is a problem that makes the jack
GECH & HAGOS 92

will be fail. Also the maximum lifting range for maintenance is achieved. All the selected
have been successfully verified and hence the design of the jack is safe.
Recommendation:
The design progress was decent, but the given time to finish the design was very
short compared to the hugeness of the design. So, we recommended for the future the time
allowed should be enough to finish the design.
Reference
1. How Hydraulic Jacks Work, 25 March, 2014:
http://www.thomasnet.com/articles/materialshandling/how-hydraulic-jacks-work
2. http://cotsncots.com/faq-general.html
3. http:// www.lib.uiowa.edu/scua/bai/hydraul.html
4. http://EzineArticles.com/886634
5. Mechanical Engineering, Shigley’s Mechanical Engineering Design, Budynas – Nisbett,
Eighth Edition.
6. Mechanical Design an Integrated Approach, Ansel C. Ugural.

7. International Check valve standard book
8. International Pin standard book
GECH & HAGOS 93

9. International Spring standard book

10. International Check valve standard book
11. International O-ring standard book
12. http://alibaba.com
13. http://answers.yahoo.com/question/
14. http://www.nationalboard.org/
15. http://wikipidia/
http://www.google.com
Appendix
GECH & HAGOS 94

GECH & HAGOS 95

Table 5: Standard Pin Table
GECH & HAGOS 96

Table 4: O -Ring Standard Table 2
GECH & HAGOS 97

Table 6: Standard Valve Table
Table 6: Standard Valve Table
GECH & HAGOS 98

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GECH & HAGOS III

GECH & HAGOS IV

4.2 Methods of fabrication.........................................................................................................80

GECH & HAGOS V

List of figure PAGE

Figure 1 solid representation of Hydraulic bottle jack....................................................................8

GECH & HAGOS VI

Figure 33 Link Multi-View...........................................................................................................74

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GECH & HAGOS 1

1.2 Definition of Hydraulic Jacks

Figure 1 solid representation of Hydraulic bottle jack

GECH & HAGOS 2

GECH & HAGOS 3

Figure 2 Mechanical jack

GECH & HAGOS 4

Figure 3 hydraulic bottle car jack

Classification of Hydraulic Jacks

GECH & HAGOS 5

Figure 4 Hydraulic car jacks

GECH & HAGOS 6

Figure 5 hydraulic bottle car jack

II. FLOOR JACKS

Figure 6 floor hydraulic jack

GECH & HAGOS 7

Figure 7Pneumatic jack

According to the source of power

GECH & HAGOS 8

 Power operated jack (pump is used)

According to the lift of ram

 Medium lift hydraulic Jack

 Low lift hydraulic Jack

According to the arrangement of cylinder

 Horizontal hydraulic Jack

 inclined hydraulic Jack

According to the number of cylinders

 Multi cylinder hydraulic Jack

According to the construction

1.4 Components of hydraulic Bottle jack

GECH & HAGOS 9

Figure 8 components of hydraulic bottle car jack

GECH & HAGOS 10

Figure 9 components of hydraulic car jack

1.5 Hydraulic fluid

1.6 Material used and its property

GECH & HAGOS 11

 Toughness: - Fracture resistance needed.

 Hardness: - high wear resistance required.

E. Case of fabrication: forming, welding, casting etc.

F. Availability in standard sizes: plates, sections, tubes etc.

G. Cost of the material

GECH & HAGOS 12

3. High cost: - for example: platinum, Tantalum, Zirconium, Titanium silver.

1.7 Hydraulic Basics