Desea Debelo Project

Table of Contents
ABSTRACT................................................................................................5
NOMENCLUTURE......................................................................................6
PARAMETER............................................................................................6
UNIT ONE................................................................................................7
INTRODUCTION........................................................................................7
PROBLEM STATEMENT...............................................................................7
CHAPTER TWO.........................................................................................7
OPERATING MECHANISM............................................................................7
Lifting mechanism........................................................................................................ 8
Driving mechanism....................................................................................................... 8
Supporting mechanism................................................................................................... 8
Controlling mechanism.................................................................................................. 9
Balancing mechanism.................................................................................................... 9
OBJECTIVES OF SERVICE JACK..................................................................10
GENERAL OBJECTIVES............................................................................................ 10
SPECIFIC OBJECTIVES............................................................................................. 10
BACK GROUND.......................................................................................10
LITERATURE REVIEW..............................................................................11
BOTTLE JACK......................................................................................................... 11
FLOOR JACK........................................................................................................... 11
HOUSE JACK........................................................................................................... 11
HYDRAULIC JACK................................................................................................... 11
CHAPTER THREE.....................................................................................12
METHEODOLOGY OF THIS PROJECT............................................................12
Operating mechanism............................................................................................ 12
MANUFACTURIG PROCESS................................................................................... 12
MATHEMATICAL ANALYSIS........................................................................12
COST ANALYSIS...................................................................................................... 12
DATA COLLECTION................................................................................................. 12
Scope...................................................................................................................... 12
EXPECTED OUT COME............................................................................................. 13
CONCEPTUAL DESIGN OF THIS PROJECT......................................................13
MATERIAL SELECTION.............................................................................13
FACTORS TO BE CONSIDERED IN SELECTION OF MATERIAL..............................13
Cost........................................................................................................................ 14
Mechanical properties..................................................................................14
Manufacturing consideration..........................................................................14
MATERIAL SELECTION FOR THE MAIN SERVICE JACK .....................................14
Material selection for the saddle..................................................................................... 14
Material selection for the cylinder................................................................................... 15
Shaft.....................................................................................................15
UNIT FOUR.............................................................................................15
GEOMETRIC ANALYSIS.............................................................................15
TABLE -1................................................................................................................. 16
UNIT FIVE..............................................................................................18
FORCE ANALYSIS....................................................................................18
TABLE -2................................................................................................................. 20
Force analysis for the arms......................................................................................... 22
Force analyze for the rods for every arms we have two linking rods connecting rods..................23
Force analysis of hydraulic system...............................................................................24
Strength analysis........................................................................................................ 24
Strength analysis for the saddle...................................................................................... 25
check for the shear strength............................................................................25
STRENGTH ANALYSIS FOR ARM..................................................................28
STRENGTH ANALYSIS FOR THE CONNECTING LINKING RODS............................32
Material AISI carbon steel............................................................................................. 32
Strength of analysis for the pins...................................................................................... 32
DESIGN OF HELICAL EXTENSION SPRING.................................................................35
........................................................................................................... 36
Design for the front wheel
DESIGN FOR THE OIL RESERVIOR ..................................................................................38

STANDARD MACHINE ELEMENT ...................................................................................39
DESIGN OF BOLT ............................................................................................................... 39
................................................................................................................ 40
DESIGN OF PINS
UNIVERSAL JOINT LOAD

.........................................................................................41
COMPRESSION SPRING
..........................................................................................41
EXTENSION SPRING ............................................................................................41
APENDIX - A........................................................................................................... 42
APENDIX-B............................................................................................................. 42
APENDIX -C............................................................................................................ 43
APENDIX -D............................................................................................43
PROJECT SCHADULE PLAN........................................................................43
TABLE -3................................................................................................................. 43
BUDGET DES CRIPTION.............................................................................44
CONCULUSION........................................................................................44
RECOMANDETION...................................................................................44
REFERENCE...........................................................................................45
ACKNOWLEDGEMENT
I would like to express our deep rooted thanks and appreciating instructor Mr. Robsan over
project adviser for their design project subject matter comment and my friend who helped me
when I needed consultation throughout the design process. I would also like to thank learning
Process for that he made great effort for the success of this design project. Next I would like to
express my particular thanks to God. These whole design and manufacturing process of the
design of project end also for help recommendation. Lastly to acknowledgement the book of
machine design, second who was our side fill the completion this project.
ABSTRACT
This project focuses on complete analysis to the design of service jack. 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. 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 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 .the purpose of design of service jack is to modify
the design of the existing car jack in terms of its functionality and also human consideration. In
this project there are many alternatives of hydraulic service jack were proposed and one is
selected on the basis of several design consideration. So that geometric analysis, force analysis,
and strength analysis are conducted for this design.
The working principle of service jack is the basic principle to lift heavy loads, the moderately
heavy loads and large vehicles, oil is purred in to the oil reservoir via the oil vent, the motion of
linking rods result in an upward motion of the saddle and the arms .So that the focused of this
project to complete the design analysis of hydraulic service jack.
.
NOMENCLUTURE
max= maximum s h ear styress

H = Hoop stress (circumferential stress)

t = tangential stress
min=minimum s h ear stress
=coefficient of friction
=angle between horizontal and length
=angle at which minimum height
= angle at which maximum height
all =allowable shear stress
b =bending stress
I=moment of inertia
PARAMETER
d0 = outer diameter
r0 = outer radius
di = inner diameter
A=area of the piston
t =thickness of the of material

K=spring,
L=maximum length
I= moment of inertia
P=pivot of the distance
S=stroke
b=base unit distance
UNIT ONE
INTRODUCTION
jack is a device that uses force to lift heavy loads and apply great forces. 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 or hydraulic. It 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. The service 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.
Their ability to lift heavy loads plays a big role in enabling the repair of large agricultural
machinery and in many construction operations. Service jacks can be secured within a frame,
mounted on a beam, or simply used as they are for easier jack transportation. the goal of this
project is to generate some conceptual design of hydraulic service jack and finally proposing a
safe, and reliable hydraulic service jack.
PROBLEM STATEMENT
From the general knowledge of design, problem is the key word for improvement and change of
skills. In order to helps the user to maintain their car during suddenly upcoming accidents like
changing of flat tire on journey, to maintain other parts of the car which needs to be lifted to the
required height during the operation of maintenance. And also helps people who may install
snow tires before the winter and remove them in the spring needed to use the jack perform a job.
Present car jack do not have a lock or extra beam to withstand the massive load of the car.
The purpose of this project is to encounter these problems.
The another problem of this project is problem of impact on customer such like
Affecting safety of customer

Dissatisfaction of customer
CHAPTER TWO
OPERATING MECHANISM
Operating mechanism is a device designed to transform input forces and movement into a
desired set of output forces and movement and transforms motion to some desirable pattern and
typically develops forces and transmits power. A machine typically contains mechanisms which
are designed to provide significant forces and transmit significant power. The degree of freedom
of an assembly of links completely predicts its character
A service jack in order to work successfully and properly there are different mechanism needs to
be designed .This a service jack contains the following main working mechanism of operating.
Lifting mechanism
As we have said in the introduction part of this service jack design, it is used to lift loads at some
maximum value of height and capacity for working purpose. The lifting mechanism of the
service jack will be operated as the operator pumps the compressor using the two mechanism of
pumping, namely: - using the handle and by the foot pedal designed for the service jack to pump
or compress in to the .These operations on the jack .will be operated through different
mechanism. When the compressed fluid enters in to the piston and the cylinder assembly which
is power unit of the a service jack it pushes the piston rod which intern pulls the weight carrier
plate which is pinned to the piston rod with a connecting rod. Using the foot pedal otherwise
using the handle the compressed fluid enters into the piston cylinder pushing the piston rod
outwards. As the piston rod moves outward, the weight carrier plate will move upward to its
maximum height.
Driving mechanism
Driving mechanism helps us to use the service jack whenever we want to use it easily. The
service jack has four wheels. Two at the front and the left two are at the back side. The back
wheels have two degrees of freedom which translates and rotates at a time needed for operation
at some vertical axis. In another way this rotation and translation of the back wheels enables the
user simply to interact with the jack in a freedom of any type
Supporting mechanism
This mechanism enables that to support the weight which is lifted by the lifting mechanism to
apply purposely its work for the oil service jack. The first supporting mechanism is the weight
carrier plates which means, the load will flows through the pins so that all load on the plate has
to be overcome by the compressed oil through the piston rod. Secondly, the parallel supporting
plate or links near the weight carrier plate which is connected to the body. The load lifted by the
jack will flow through this plate to the pins and the walls and finally to the wheels and ground.
Controlling mechanism
When we say controlling mechanism it is to tell that the compressed oil in the piston cylinder
must stay there until we finish the job to be worked. Once the compressed oil goes into the piston
cylinder the two valves of one directional controlling valve stay closed. When the compressed oil
comes from the back (from the ball side) it will compress the spring of the valve and lets in oil to
the piston cylinder, but not vice versa because since it is one directional control valve.
Balancing mechanism
The balancing mechanism helps to protect the service jack from different familiarity and
balancing mechanism is needed. The load must be placed at right angle or balanced position. And
the supporting plate helps to balance the saddle holder from back and forth movement by
connecting with the housing with its one end.
OBJECTIVES OF SERVICE JACK
GENERAL OBJECTIVES
The main objective of this design project is to design of service jack by considering economical,
fasting and to be good commercial proposal design doesnt merely have to be capable of
performing the intended purpose but must be economical cost of material, manufacturing and
maintenance of the jack with 1ton force applied at the top of the jack resisting any failures. The
owner and operator shall be aware that use and repair of this product may require special skills
and knowledge.
SPECIFIC OBJECTIVES
In the service jack in order to work successfully and properly there are different mechanism
needs to be understandable by the users. The following operating mechanisms will be
specifically designed for the service jack.
Lifting mechanism
Driving mechanism
Balancing mechanism
BACK GROUND
Hydraulic floor jack is the bought it new during the 1970s. It began to leak down a little a few
months ago. The lift arm no longer rises when the handle is pumped up and down. It is able to
pull the lift arm up by hand and it settled slowly enough that it could make a photo with the arm
partially raised.
Their ability to lift heavy loads plays a big role in enabling the repair of large agricultural
machinery and in many construction operations. Bottle jacks can be secured within a frame,
mounted on a beam, or simply used as they are for easier jack transportation. Do not uses if
broken, bent, cracked, or damaged parts are noted. Any jack that appears damaged in any way,
operates abnormally or is missing parts shall be removed from service immediately and the
manufacturer notified. If you suspect that the jack was subjected to a shock load, immediately
discontinue use until the jack has been checked by a factory authorized service center and
contact distributor or manufacturer for list of Authorized Service Centers. It is recommended
that an annual inspection be done by qualified personnel. Replace worn or damaged parts with
Hein-Werner Authorized Replacement Parts only. Labels and owners manuals are available
from manufacturer.
Finally, one day, the lift arm would not rise at all. If filling with fluid and purging air from the
system do not restore function, there is probably internal leakage, even though fluid is not
leaking from the jack. From what I have read, forty years of service is a reasonable time for a
hydraulic jack to operate before it needs a rebuild.
LITERATURE REVIEW
Jacks are machine element for lifting heavy loads by applying small force. There are so many
types of jacks. Among them;
BOTTLE JACK
A bottle jack or whiskey jack is a hydraulic jack which resembles a bottle in shape, having a
cylindrical body and a neck, from which the hydraulic emerges. In a bottle jack the piston is
vertical and directly supports a bearing pad that contacts the object being lifted. With a single
action piston the lift is somewhat less than twice the collapsed height of the jack, making it
suitable only for vehicles with a relatively high clearance. For lifting structures such as houses
the hydraulic interconnection of multiple vertical jacks through valves enables the even
distribution of forces while enabling close control of the lift. This type of jack is best used for
short vertical lifts.
FLOOR JACK
Unlike bottle jack shafts, the shaft in a floor jacks is horizontalthe 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 should be used.
HOUSE JACK
A house jack, also called a screw jack, is a mechanical device primarily used to lift buildings
from their foundations for repairs or relocation. A series of jacks is used and then wood cribbing
temporarily supports the structure. This process is repeated until the desired height is reached.
The house jack can be used for jacking carrying beams that have settled or for installing new
structural beams.
HYDRAULIC JACK
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.
CHAPTER THREE
METHEODOLOGY OF THIS PROJECT

The process of designing this project, while remaining in specified decision making it is strongly
supported by knowledge of several engineering sciences. In my project I used the knowledge of
mechanism, strength, mechanics, and manufacturing process and the following standard
methodology will be used in the design of this project.
Operating mechanism: - is the mechanism of the jack will be illustrated detail in order to
make the user to communicate simply with service jack
MANUFACTURIG PROCESS
In this phase the total process of manufacturing the parts of the service jack will be discussed
based on the selection of the processes for each part considering the properties they need to have
since the materials properties determines their strength.
MATHEMATICAL ANALYSIS
Through the design process, since mathematical analysis is the main part of for designing the
jack it will be accomplished clearly using the knowledge of different of mechanism, strength,
mechanics, manufacturing process a, geometric analysis, analyzing the forces and stresses of the
service jack.
COST ANALYSIS
This section illustrates that the cost analysis of the jack. The cost analysis will be covered by
analyzing the material cost, labour cost and the standard material selected cost.
DATA COLLECTION
The are many source of this project specially website such like http//:www.com,standard hand
book of machine design shingly and mechanical engineering design, 5th edition.
Scope
This project is about the designing and fabricating of service jack, in the type of car jack that we
were used in this project because hydraulic jack is more reliable and easy to operate. The scope
of this project is on the designing of 1 ton maximum lifting capacity of the car jack by using the
concept.
EXPECTED OUT COME
The final advantage of this project is it use in the identical replacement parts refer to
attached product and use of unauthorized part.
Service jack are design to lift, not support, rated capacity loads consisting of one end of a
vehicle and after lifting the, load must be supported by a pair of appropriately rated jack
stands.
CONCEPTUAL DESIGN OF THIS PROJECT
Our design of my project service jack is a device which lifts heavy equipment
and the most common service jack are vehicles that can be formed. In this case
the roll of service jack is to release valve closed, an upward stroke of the jack
handle draws oil from the reservoir tank into the plunger cavity.
For the alternatives of the hydraulic oil service jack were proposed and one is
selected on the bases of several design consideration.
Identify all the sought function.
To obtain suitable solution.
MATERIAL SELECTION
The selection of a material for this oil service jack is one of the most important decisions. The
actual selection of a material, the selection process can be involved with the evaluation of the
many material physical, economical, and processing parameters. The selected materials are based
on the consideration of different systematic and optimizing approaches important to material
properties associate with the air service jack design, strength, stiffness, and cost of the materials.
This can be prioritized by using a weighting measure depending on what properties are more
important than others. Next, for each property, by listing all available Materials and ranking them
in order to begin with the best material; e.g., for Strength, high-strength steel such as AISI 1045
carbon steel, ASTM grade 30 cast iron, AISI carbon steel and hard drawn wire should be near the
top of the list. For completeness of available materials, this might require a large source of
Material data. After performing all the above procedure, manageable amount of materials would
be selected from the top of each list for the design of the oil service jack.
FACTORS TO BE CONSIDERED IN SELECTION OF MATERIAL

The material selection of the service jack design is the following numbers of factors are
considered and the material acquires the desired physical and mechanical properties must be
applicable of being processed. The best material is one in which will serve the desired purpose at
minimum cost. It is not always easy to select a material for a machine component, based on the
following process.
Availability
Cost
Mechanical property
Manufacturing consideration
Cost
For any application there is a limiting cost beyond which the design cannot go. When this
ultimate exceed I have to be consider another alternative solution or materials. In cost analysis
there are two factors namely:
Cost of processing the material into finished goods

Cost of material
Mechanical properties
Mechanical properties are most important technical factors governing selection of
Materials; they include; strength under static & fluctuation loads, elasticity, plasticity, brittleness
and hardness. Designed upon the service conditions and the function requirement mechanical
properties are considered and suitable materials would be selected.
Manufacturing consideration
For this design project mach inability of material is an important consideration in
Selection of materials. The manufacturing processes such as casting, forging, and extrusion,
welding, and governing the selection. Sometimes an expensive material is more economical than
low priced one.
MATERIAL SELECTION FOR THE MAIN SERVICE JACK .
Material selection for the saddle

It is the top of the jack and load is exerted on it. Due to reputational force is developed between
the saddle and the material loading on it, the saddle can
Experience compressive stress. For this reason I choose gray cast iron. The gray cast iron is due
to the fact that carbon is present in the form of free graphite it has low tensile strength, high
compressive strength and no ductility. And it can be machined easily a good property of gray cast
iron is free graphite in its structure acts as a lubricant. It is very important for that part where
sliding contact action is desired.
The gray cast iron is widely used for machine tool bodies, automotive, cylinder block, head
housing, flywheel, pipes and agricultural implement. It can be manufactured by casting. Material
selected for saddle has the following property:
High compressive stress
Easily machine able
No ductility
Have free graphite
Material selection for the cylinder

A cylinder which is subjected to a very high internal pressure then the wall of cylinder which I
select is thick because it extremely holds heavy materials. Among the materials I select to use for
the cylinder cast iron. According to the maximum shear stress theory of failure and tangential
stress induced in the cylinder walls from the above listed material I will use cast iron for that of
air cylinder.
Shaft
A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft. These members along with the forces exerted upon them causes the shaft to bend.
UNIT FOUR
GEOMETRIC ANALYSIS
Geometric analysis is a mathematical discipline at the interface of differential geometry and
differential equations. It includes both the use of geometrical methods in the study of partial
differential equations and the application of the theory of partial differential equations to
geometry. It incorporates problems involving curves and surfaces, or domains with curved
boundaries, but also the study of Riemannian manifolds in arbitrary dimension. The calculus of
variations is sometimes regarded as part of geometric analysis, because differential equations
arising from variation principles have a strong geometric content. Geometric analysis also
includes global analysis, which concerns the study of differential equations on manifolds, and the
relationship between differential equations and topology. To start the design process first the
analysis of basic length and angles have to be calculated inconsideration with some assumption.
The first analysis is starts with the geometry of the lever arm.
TABLE -1
=60 M Cos
sin ( m)
=60==10 6 7.16
7 9.55
8 14.3
=60= =12
6 4.78
7 5.716
8 7.16
=60= =14 6 3.59
7 5.76
8 4.78
=60= =16 6 2.42
7 2.7
8 3.02
=60= =18 6 2.02
7 2.42
8 2.2
=60= =20 6 1.746
7 1.87
8 2.02
=70= =22 6 1.24
7 1.32
8 1.412
Assume 60 70
10222
6m8
F will be minimum for =740

Decision =22 m=80
=1.6
=500
(hmax-c1) (hmin- C) = hmax hmin
L1 sin 70+L1sin 14 = 160-140
160146
L1 =
sin74 +sin 16
L1=12.8mm
L1 L1 12. 8
But =1 .6 L2 = =
L2 1. 6 1. 6
L2 = 8mm
h1 =L2 sin 50 L2 sin 22
h1 = L2 sin - L2 sin 2
8 sin 50 8sin 22
h1 = 3.13mm
220
FIGURE-1
h1 h1 3 . 13 3. 13
sin m= L3 = =
l3 sin m sin 8 0 .139
L3 = 22.5mm
To determine stroke
Stroke = ( L2 cos+L2 cos +L3 cos m) L3
S =8cos 50+8cos22+22.5*cos8)-225
S=5.142+7.4+22.28 22.5
S= 34.6mm
P0 determine pivot distance

P= (hmin- L1)+ L1 sin m
P=(146 40) +12.8 sin 8
P= 107.78mm
To determine hydraulic base unit will be put at the distance from the pivot
b2 = P L2sin
b2 =107.78 8sin 50
107.78 6.12
b2 = 101.65mm
2
b1 = hmin 75 2 take 2 = 8mm
8
b1 = 146 75 2
72 8 1448

1 2 2
b1 = 68mm
UNIT FIVE
FORCE ANALYSIS
To analysis the force on the hydraulic service jack we should first determine the position at
which the force on the link and support will be minimum. to do that we have to find governing
relationship between the piston on the force and the force on the link.
Force Analysis
To analysis the force on the hydraulic service talk.
To determine the position at which to force on the links and support will be minimum and we
have to find governing relationship between the position (F) and the force in the links
R4
Ray RA
Rax F21
RB
Rex
R FIGURE-2
R4 and R on the links and supports respectively will not change both in longitude and direction
for any angle t or s however F21 will change with angle t , s ant therefore we should find the
angle at which F21 will be maximum to analyze the force on the link and supports.
R4
For link 1
F21 = - F12
F21 |F21| = ( - F12)
Fcos
F21 = K
For link 2
D F32
C F=0
F12 F12 = F32
F
F12=
cosK
Link 3 fx = 0 F23 cos k = F

fy = 0 F23 sin k + F3 Fo3 = 0
F3
F maximum position
t
F2 Fo3 t
Minimum position
FIGURE-3
For 50 t 120
For 50 t 120
mo=0 F21 L2 cosk sint + sink cost = L1h1 coss
L1 cos s L
F21= (
L2 sin ( t+ k ) )
h1 , but 1 =1 . 6
L2 For 120 t 140
L1 cos s
F21= ( h
L2 sin ( 18tk ) 1 )
cos s
F21=1 . 6
( )h
sin ( 180t k ) 1
The relationship d/c angle calculated as
S= 180 110
S= 170 t
L2 sin t L 2 sin50 L2 (sin t L2 sin 50) 8(sin t 0 .76)

Sin k = L3 Sin k = L3 Sin k = 22 .5
Sin k = 0.35 sin t 0.0337 K = sin-1(0.35 sin t 0.0337)

Lets literate the relation found in the previous page to find position where F21 and will be
maximum
TABLE -2
T S K cos s
F21
( sin ( 180t k ) )
50 14 19.55 1.9 L1
58 12 15.25 1.157 L1
66 4 16.62 2.83 L1
74 6 17.6 2.7 L1
82 12 18.2 1.944 L1
90 20 18.4 1.5 L1
98 28 18.2 1.09 L1
106 36 17.6 1.005 L1
124 44 16.6 0.82 L1
Decision The force analysis should be done at t = 50,S=6

K=13.58 because of the minimum lifting position
The force on the links and supports at the minimum lifting position will have to be determined
At the minimum lifting position t= =50
At the minimum lifting position
t==54
S=20
= 14
k=13.55
Link 2
F32=F23=F
F =0 F12=F32 F033
F12=F F23 F
F03
Link 1
F21=F12
F2 F21=F
Force analysis for the saddle
Rx
Ray 4 Rbx 20
FIGURE-4
RBy
FX = 0 R4x Rbx = 0
FX = 0 R4x + RBY = 539.5
MA = 0 RBY*30 RBX *20 L*1 30 RBY 20RBX 539.5*10=0
30 RBY 20RBX 5395= 30 RBY 20RBX 539.5=0
Ray (0.3*539.5)=539.5 Ray = 377.6kn
Rby =0.3L
Ry =b0.3*539.5 =Rby =161.85kn
30 RBY 20RBX 539.5 =30*161.85 20Rbx = 539.5 =4855.5 20Rbx =539.5
4316
Rbx= =Rbx=215.8kn
20
Rax=Rbx =Rax=215.8kn R= tan-1 ( Ray

Rbx ) =tan (
1 377 . 6
215 . 8 )
R= 60.3 600
b= tan-1 ( Rby
Rbx )
=tan (
1 161 .85
215 .8 )
b= 36.85390
RA= ( Rax)2 +(Rbx)2
RA= (215 . 8)2+(977 . 6)2
RA= 434.9kn
Rb2= Rbx2+Rby2
Rb= (Rax)2 +(Rby)2 Rb= 269.75kn
4
Force analysis for the arms
Rx Roy Ray
500
Rax
F211
Minimum lifting position FIGURE-5
Ray 377 . 6
Let Ray =
= = 188 .8 kn
2 2
Rax 215 . 8
=
Rax = 2 2 = 107.9kn
FX =0 F21+Rox Rax=0 F21 Roa=1
FX=0 Ray+Roy=0 Roy=Ray
Roy= 188.8kn
F21(2sin) Ray(1cos) Rax

(1sin)=0
F21(8sin50) Ray(12.8cos14) Rax(12.8 sin14)
160 . 46 5023 . 8
=
6.12 F21 140.34 20.12 ,6.12 F2 = 160.46 ,F21= 6 .12 6 . 12
F21=820.8kn
F21+Rox=1 Rox=1 F21 Rox=1 820.8kn
Rox = - 819.8kn
Force analyze for the rods for every arms we have two linking rods connecting rods
'
F21 820 .8 kn
F11
12 = = = 410kn
2 2
Fo F1211=F3211 F32= 410.4kn

Force exerted By the piston we have four rods that trausinot force of
F2311=F3211 each Fo3
F32 F
Fo3
F32=4F3211
FX =0 F= 4F32 F=4*430.4kn
The maximum force exerted by the piston force analysis for the support arms
Rey
Rex Rbx
FIGURE-6 Rby
Rbx
Rbx= 2 = 1kn
Rby 161 . 85
Rby = 2 = 2
Rby = 80.9kn
FX = 0 Rax = 0 Rex = kn
FY = 0 Rby = Rey= 262.8kn
H 100m FG50 RF
FH*1050 FG*50
90*1050 FG*50
FG = 1890kn = 1.89kn
Force analysis of hydraulic system
41 42
P1=P2
FG F AD 2
= A 1=
A1 A 2 4 FIGURE-7
AD22 F A
A 2= = 2
4 FG A 1
2
d 1
F 4 F 52. 4 d 2
= = =
FG 2 FG 1 .89 d 1
d
4
d 22 d
2
=27 . 7 2 = 5.26
d1 d1
d2=5.26d1
decision Assume d2=5d1
d2=30mm
30=5d1
d=6mm
Strength analysis
the Ft material are to be use for the components of the hydraulic service jack. They are related on
the basis that they have strength and easy machine ability
link modulus =608Gpa 650Mpa comprehensive strength = Mpa
density=62glow elongation tat break (y)=13%

elastic modules =94Gpa hardness =160
elongation at break (g)=0.6% ultimate strength =690Mpa
fracture toughness=380Mpa yield strength=415
hardness =210 elastic modulus=150Gpa
Posisons ratio =0.28 hard drawn wire ASTM A 227
shear modules =50Gpa exponent m=0.19
tensile ultimate strength =215Mpa diameter 0.6-12.6
yield strength =120mpa modulus of electricity (E)=198.6Gpa
A1S1 1045 carbon street S(Mpa. mmm)=783
density =7.8 q/cm3
TITLE DESIGN OF SERVICE JACK
Strength analysis for the saddle
38
A A 3600=2 r* x
360=2 (40)x
360=215.2x
55mm
360=2 (40)
14=x
360y=14x2 (40) FIGURE-8
3516.8
3516 . 8
x=
= 9 . 76 mm
360
16 16
A1= 360
( 55 )2 - (38)2
360
A =422.28 201.5
A1=21.76mm2=220.6mm2
AT=4A1
AT=882.6mm2
check for compressive strength material ASTM grade 30 cast iron
3
L 539 . 510
compressive strength ( )= A T = 87 .04106 M 2
539 . 5103
= 8825. 6106
=611.2Mpa
sdut 650 Mpa

=
n= 611 . 2
n=10.6
WOLLEGA UNIVERSITY Page 26

INSTITUTE OF TECHENOLOGY AND DEPARTIMENT OF MECHANICAL ENGINEERING
check for the shear strength

2m
2mm
3mm FIGURE-9
10mm
Saddle is subjected to Shear stress

To shear area
A= 2*5mm
A= 2 (0.038)*0.005)
A=1.19*10-3m2
using distortion energy tesry (DET)
SSy = 0.577*Sy
=0.577*800
max
max 577Mpa
461. 6 539 .5 kn
= = =453.36Mpa
A 1 . 19103
max 461 .6
=1. 01
n= = 453 .36 safe
n=2.74 safe
principal stress
A 2
1= 2 + B + (A-)2+ x y

but A=287.05
B=0
xy =15
287 . 05
2 +0 ( 2870 2
2 ) +122
1= 430Mpa
mc
n= 1
650 Mpc
n= 430 =1.5 safe
strength analysis for the saddle ulder the saddle holders is subjected to normal stress shear stress
and bearing stress
material ASTM grade 30 cast iron safety factor n=3
650
a all = 3 = 216Mpa
L
all = AC AC = 24976.8mm2
Check for bearing stress
539.5
dia
AP= projected area
RA
2
take thickness t=3mm At A FIGURE-10
RA 26 . 1 kn
2
Ap=td all= 2 216=
td 3103 d

13 . 05
d= 648
= 20 .13 mm 20mm
At B
RB 269 .75
2 18 mm
all= 2 =216= =d=
td 3103d
3
310 216
d= 134 . 875 = 4.8mm
Check for the shear stress
Using distortion energy theory
max y
=0.577
=0.55x800Mp
=461.6Mp
461. 6 Mpa
all
Use n=3 = 3 =153.8Mpa
( 0 . 08 ) t
l L
all
= A = ( 0. 090 . 01 ) t 153.8MPa= l

153.80.08t=539.5
12.3t=539.5
t=40mm

STRENGTH ANALYSIS FOR ARM
The arm is mainly subjected to normal stress ,shear stress and bending stresss.
Material: ASTM grade 30 cast iron
Strength analysis will be done for the minimum position
RA ' X sin 14RA X' cos 14
=107.9 sin 14107 . 9 cos 14
R XO =105.3Kn
RA 'Y cos 14 + R'AX sin 14
188.8 cos 14 +107 . 9 sin 14
Roy =216.6MPa
650 Mpa
all=
3 =216.6Mpa
RAx
all=
A
105. 3
all =
A
A=105.5 650 Mpa
2
A=6.8m m
A=st-td
6.8=S 40-4 20
80 +6 . 8=40 s

S=2.17
max
For the shear stress =461.6MPa
Ryo
max =
A
207 . 7
= A =650Mpa
2
A=449.9 mm
A=ST-SD
449.9=S 40 20
S=13mm
Check for the bearing stress take n=3
650
ball
= 3 =216Mpa
RA /2 434 . 9/2
b
= t = td
217. 45
b=
80 =2.7Mpa
ball b
So that > then the design is safe
Bearing stress at point O
RO' = ROx2 + ROy2
RO' = 105. 32 + 207 .7 2

'
RO =232kn

650
all= =260 Mpa
Take n=2.5 2.5
Take n= d 20mm
STRENGTH ANALYSIS FOR THE ARM
At minimum lifting position

'
RBX 2
= RB X cos 14 + RB Y sin 14
=107.9X cos 14+ 80 . 9 sin 14
RBX 2 =122.94KN
RB y 2=RB '
cos 14+ RB 'Y sin14
Y
RBY 2 = -107.9X sin 14+80 . 9 cos 14
=-23.53 +78 . 9 =55.42KN
RBx 2
all=
A
122 . 9
A= 2
650 =0.189 mm
Take n=3mm
t=3mm
d=4mm

so that A=th-td
0.189=th-td
3
A+ td 0 .189+3 10
h= = h=4mm
t 3 x 103
check for the shear stress
using energy distortion theory
RB y
all=
A
55 . 42
461.6= ht td
55 . 42
Ht-td= 461. 6
3 3 3
hx 3 x 10 3 10 x 4 =0 . 34
0 . 34
h= 12 . 34 X 103
3
h= 4 x 10 m
h=4mm
check for the bearing stress
2
122. 9 +( 55 . 422 )
RB=

RB=134KN
After that A=td A=4mmx3mm=12mm

650
134 Kn ull = =260 Mpa
b=
12 =11.62Mpa take n=2.5 ball=
3
2 .5
b< ball then the design is safe
b<
So that ball
then this design is safe
Check for the bending stress
RB y 2x
M=
M=122.9x0.08
M=983.2N/m
0 . 02

I= 1
( 0 .008 )
12
9
I= 5 .5 X 10 N/M after that we calculate bending stress
M
b=
I
983 . 3
= 5 . 33 X 109
b=184. 46 Mpa
650
Take n=3 all=
3

all=216 .6 Mpa
b<
So that ball
then this design is safe
STRENGTH ANALYSIS FOR THE CONNECTING LINKING RODS
Material AISI carbon steel

If will be subjected to normal stress and the bearing stress
Check for the normal stress
F 12 17 . 95
= =
bh 8 x 22 =49.36Mpa
ull 215
Then n= =
49. 36
n=4.3 then the safety factor is safe
F'12
all=
dt
17 . 95 215
8 d = n when n=3
215 17 . 95
3 = 8d
D=31mm
Strength of analysis for the pins

Pins is subjected to shear stress at point A
RT=434.9KN
Material AISI 1045 carbon steel
max =0.577 690MPa

=398.3MPa
0. 01

4 RA
= =
=55.4MPa then
D2
434 . 9 4

< max the safety factor safe
At point B
Material AISI 1045 carbon steel
4 RB 4 269 . 75
= = 2 =963.39PMa
d2 (0 . 01)
Then is not safe
Change the dimension of material selection late take D=10MM
Use AISI carbon steel MAX =0 . 55 Y
=302.5MPa
4 RB
= 2
d
4 269 . 75
2 =34MPa
(0 . 01)
Then < max is safe
At point C diameter was taken as d=8mm
Material selection AISI 1045 carbon steel
max =302.5 MPa

4 161 . 8 kn
= = 32.2MPa
d2
< max is safe
At pin D
F
21=161.6 KN
Material selection AISI 1095 carbon steel
max =0 .577 y

=0.577PMa 50MPa
=303MPa
Take d=6mm
161. 6
=
(0 . 062 )

4
=28 .8 mm
< max
so that then the design is safe
STRENGTH ANALYSIS OF THE PISTON ROD
the piston is subjected to the compressive stress and bucking
material; AISI 1045 carbon steel
F
= all =
550 MP
A but 3
all=183. 3 Mpa
F
A= all

161. 6 KN 2
mm
A= 183 . 3 Mpa =0.88
D2 3
= 0 . 88 X 10
4
2 3
d =4 x 0 . 88 x 10
d=10mm
STRENGTH ANALYSIS FOR THE CYLINDER PRESSURE IN THE CYLINDER
F
P=
A
Diameter of the cylinder was determined in the force analysis to be take d=30mm
4 215 . 8
p= 2 =305.6MPa
(0 . 03)
Curcimnfial stress on the cylinder is given by
pd
h=
2t
Material AISI 1040 carbon steel n=3
650
all=
3 =216.6MPa
all= pd
all =
2t
pd 305 .6 10 mm
t = = =7 . 05 mm
2 all 2 216 . 6
all=216 .6 MPa= b

p d 305 . 6 10 mm
t= = =3 . 5 mm 4 mm
4 b 4 216 . 6
So that takes the thickness of the cylinder to be 7mm
DESIGN OF HELICAL EXTENSION SPRING

Material hard drawn wire ASTM A227
assume =c=5mm
wire diameter =3mm
D
d=3mm= =5
d
D=15mm
number of coil NB=30.2
4 c+2 4 5+2
KB= = =1 .29
4 c3 4 53
Gd
4
(0 . 035)2 80 10
k= = =30062 N / M
8 D3 NA 8 (0 . 035)3 30. 2
PLUNGER DESIGN
MATERIAL SELLECTION AISI1045 carbon steel
The plunger is subjected to normal stress and
2
d 2 ( 0. 01)
A= = =7 .8 105 m2
4 4
FG 2 . 5 KN
= = =31. 8 KN
A 7 . 85 105
650 MPa
all= =162.5 MPa
4
< all is safe

CHECH FOR BUCKING
d
4
( 0. 01)4
I= = =4 . 9 1010
64 64
4 d4 d2 10
= = = =2. 5 mm
64 d
2
4 4
WHEEL DESIGN
To design the wheel we heed to calculate the force
For minimum doffing position
FY = RN + RM L=0

RN+ RM 539 . 5=0
RN + RM =539 .
M n=0 ant clock wise
RM 510L 140=0
539 . 5 140
RM= =391 .5 KN
510
For maximum lifting position
F Y =0 at clock wise
RN + RM =539 . 5 KN
RM +310=539 .8 150
RM=261.0KN
RN=2.66KN

The front wheels should be design minimum lifting position and the shear modulus at maximum lifting position
Design for the front wheel
At minimum lifting position
Rm 391. 5
Rm' = = =198 .15 KN
2 2
Fy=0 , RT y 1=Rm '
R y 1=198 . 15 kN
the wheel are subjected to the to the fatigue stress since the may rotate during operation.
max+
m= min
198. 5
max= =99. 25 Mpa
2
130 =65 Mpa

min=
2
m=164 Mpa
so that
max
a= min
99 .2565
a=
2
m
=17Mpa
material AISI 1095 carbon steel
'
se=Ka *Kb* Kc *Kd *Ke *Kd *Ke* kf
se
however Ka=
a ulb take a=4.51
b=-0.265

Ka=
4 .51 x 8250 . 265 k=0.761
Kb=size factor
kc=loading factor
Kc=0.85 for axial load
kd=temperature factor take =1
ke=reliable factor take Ke=0.868
Kf=misllneous factor take Kf=1
then we calculate safety factor of the fatigue failure
a m 1
+ =
se ull n
177 . 648
n= 825 25+177 . 6 288 .25
n=2.04
DESIGN FOR THE OIL RESERVIOR
the amont of oil needed to push the piston all the way out can be calculate as V=AXS where the p=piston base area
s= distance of the piston from the minimum position
take d=3omm
d 2
A= 4
( 0 . 03 )2
=7 . o 7 x 104 m 2
A= 4

V=AXS
V =7.06 X 104 X 24 X 103
3 3
V=
24.4 10 m
3 3
there fore the reservoir to have volume of VR=
24.4 X 10 m to compensate for the volume of oil that will be in the pipes connecting the reservoir and
the cylinder and to compensate for small linkage if there is any way DR=diameter of the reservoir
t=thickness of the reservoir
VL=volume of the reservoir
LR=Length of the reservoir
do=outer diameter of the reservoir
+2 t +2 6
do =d1 30mm
do = 42mm
( DR do)2
VR= 4
2
(DR0.03)
24.4 x 103 =
4
DR=16mm
STANDARD MACHINE ELEMENT
DESIGN OF BOLT
Bolt is subjected shock loading
The relicense of the bolt should be considered in order to prevent break age at the thread

material :carbon steel
k=5mm
Ds=9mm
s=15mm
l=40mm
b=25mm
bolt in the piston
k=7mm
b=10mm
DS=10mm
l=16mm
DESIGN OF PINS
pin A :Dowel pin:9x9,standard machine duty
pin B:Dowel pin 7x9 standard machine duty
pin C:dowel pin 12x16 machine duty
COTTER PIN
materiel stainless steel
standard: D4x70
WHEELS
material :carbon steel
standard
D=70mm
W=40mm
Bearing diameter=25mm

Maximum load capacity=1400kg
REAR CASTOR
Material: carbon steel
Standard
D=40mm
w=15mm
Maximum capacity load=200kg
UNIVERSAL JOINT LOAD
Standard
Do=1.5cm
E=2.23cm
L=3cm
C=1.4cm
LOCK WASHER
Material steel
Standard flat washer
M6, d2=8.5mm do=15mm,t=1.6
M8, d2=10.5, do=19mm
M11,d2=20 do=2.7mm
COMPRESSION SPRING
Standard material hard spring drawn wire
Do=25mm
Di=20mm
d=5mm
Lo=50mm

where Do: outer diameter
Di= inner diameter
Lo= length
EXTENSION SPRING
standard
material hard drawn material
Do=25.8mm
d=5mm
Lo=150mm
k=1556N/M
total coil =40mm
L1=315mm
APENDIX - A

APENDIX-B
APENDIX -C
APENDIX -D

PROJECT SCHADULE PLAN
TABLE -3
MARCH APRIL
WEE WEE WEE WEEK WEE WEE WEE
K2 K3 K3 1 K2 K3 K4
1 Data
collection
2 Data
analysis
3 Project
writing
4 consultatio
n
5 Printing the
project
6 Submission
BUDGET DES CRIPTION

For any application there is a limiting cost beyond which the design cannot go. When this
ultimate exceed I have to be consider another alternative solution or materials. In cost analysis
there are two factors namely
Cost processing the material in to goods

Cost of material it is likely that the cost of the material must be law and the processing
involves costly manufacturing process.
CONCULUSION

A service Jacks are the ideal product to push, pull, lift, lower and position loads of anything from
539.5K/N. The need has long existed for an improved portable jack for automotive vehicles. It is
highly desirable that a jack become available that can be operated at different area for lifting
application. Such a jack should desirably be light enough and be compact enough so that it can
be stored in an automobile, can be lifted driven and carried by most adults to its position of use,
and yet be capable of lifting a wheel of a three ton pound vehicle off the ground. Further, it
should be stable and easily controllable so that jacking can be done from a position of safety. It
should be easily movable either to a position underneath the axle of the vehicle or some other
reinforced support surface designed to be engaged by a jack.
RECOMANDETION
The service jack lifting power will depend on the amount of oil reservoir enters to the power
unit part, so in order to protect the service jack from failures it is recommended to check the
pumping system every time before using for application of the service jack. Since the jack has
movable links, within sometime of period maintenance will recommended. Lubricating the parts
of pins, casters and wheels will helps to improve the service jack operation
REFERENCE
1) Shigley, charlesR.mischke (2008), standard hand book of machine design Shigleys 2 th
edition
2) Richard G.Budynas,J.Keith Nisbett.(2009) mechanical engineering design,9th edition
3) mechanism and mechanics ,applied kinematics analysis, David H.Myszka
4) Hydraulic cylinder, general catalog
5) design of machinery ,an introduction to the synthesis and analysis of mechanism 2 nd

edition.
6)fastener hand book ,block fastener



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Table of Contents

DESIGN FOR THE OIL RESERVIOR ..................................................................................38

UNIVERSAL JOINT LOAD

max= maximum s h ear styress

H = Hoop stress (circumferential stress)

=angle between horizontal and length

=angle at which minimum height

= angle at which maximum height

all =allowable shear stress

t =thickness of the of material

b=base unit distance

Affecting safety of customer

METHEODOLOGY OF THIS PROJECT

CONCEPTUAL DESIGN OF THIS PROJECT

FACTORS TO BE CONSIDERED IN SELECTION OF MATERIAL

Cost of processing the material into finished goods

MATERIAL SELECTION FOR THE MAIN SERVICE JACK .

Material selection for the saddle

Material selection for the cylinder

F will be minimum for =740

h1 =L2 sin 50 L2 sin 22

Stroke = ( L2 cos+L2 cos +L3 cos m) L3

P0 determine pivot distance

P=(146 40) +12.8 sin 8

To analysis the force on the hydraulic service talk.

F21 |F21| = ( - F12)

F12 F12 = F32

Link 3 fx = 0 F23 cos k = F

mo=0 F21 L2 cosk sint + sink cost = L1h1 coss

The relationship d/c angle calculated as

L2 sin t L 2 sin50 L2 (sin t L2 sin 50) 8(sin t 0 .76)

Sin k = 0.35 sin t 0.0337 K = sin-1(0.35 sin t 0.0337)

Decision The force analysis should be done at t = 50,S=6

Force analysis for the saddle

FX = 0 R4x + RBY = 539.5

MA = 0 RBY*30 RBX *20 L*1 30 RBY 20RBX 539.5*10=0

30 RBY 20RBX 5395= 30 RBY 20RBX 539.5=0

Ray (0.3*539.5)=539.5 Ray = 377.6kn

Ry =b0.3*539.5 =Rby =161.85kn

30 RBY 20RBX 539.5 =30*161.85 20Rbx = 539.5 =4855.5 20Rbx =539.5

Rax=Rbx =Rax=215.8kn R= tan-1 ( Ray

RA= ( Rax)2 +(Rbx)2

RA= (215 . 8)2+(977 . 6)2

Minimum lifting position FIGURE-5

FX =0 F21+Rox Rax=0 F21 Roa=1

FX=0 Ray+Roy=0 Roy=Ray

F21(2sin) Ray(1cos) Rax

F21+Rox=1 Rox=1 F21 Rox=1 820.8kn

Fo F1211=F3211 F32= 410.4kn

FY = 0 Rby = Rey= 262.8kn

Force analysis of hydraulic system

link modulus =608Gpa 650Mpa comprehensive strength = Mpa

density=62glow elongation tat break (y)=13%

Strength analysis for the saddle

sdut 650 Mpa

WOLLEGA UNIVERSITY Page 26

check for the shear strength

Saddle is subjected to Shear stress

using distortion energy tesry (DET)

WOLLEGA UNIVERSITY Page 27

Check for bearing stress

take thickness t=3mm At A FIGURE-10

WOLLEGA UNIVERSITY Page 28

MA = 0 RBY30 RBX 20 L1 30 RBY 20RBX 539.510=0