WOLDIA UNIVERSITY

FACULTY OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

Design and Modeling of Manual Operated Drum Extractor Machine in

Drum Brake for Light Vehicles
A Thesis Paper Submitted for the Partial Fulfillment of Degree of Bachelor of
Science in Mechanical Engineering at Woldia University

NAME ID NO
1. BEREKET HABTAMU..................................................0670/07
2. TEMESGEN TADESSE….............................................1340/07
3. YILKAL MIKRU............................................................1418/07

Advisor: - Mr. Getachew Fentaw

Co-advisor:- Mr. Tsegaye Birhanu

JUNE 2019
WOLDIA, ETHIOPIA
 WOLDIA UNIVERSITY
FACULTY OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Design and Modeling of Manual Operated Drum Extractor Machine in Drum
Brake for Light Vehicles
A Thesis paper Submitted for the partial fulfillment of Degree of Bachelor of science in Mechanical
Engineering at Woldia University

Approved by Board of Examining:

Chairman of Department Signature Date
Tadesse Teshome (MSc)
Advisor Signature Date
Getachew Fentaw (MSc)
Co - advisor Signature Date
Tsegaye Birhanu
Examiner Signature Date
Nebyat Yazachew (MSc)
 DECLARATION
Woldia University
Faculty of Technology
This is to certify that the thesis prepared, entitled: Design and Modeling of Manual Operated Drum
Extractor Machine in Drum Brake for Light Vehicles, do here by declare this thesis is our original
work and that it has not been submitted in full for a degree in any university/institution, which
compiles with the regulations of the university and meets the accepted standards with respect to
originality and quality.

Name Signature Date

1. Bereket Habtamu

2. Temesgen Tadesse

3. Yilkal Mikru

Place: Woldia, Ethiopia

Signed by the Examining Committee:-

Advisor: - Getachew Fentaw Signature Date
Co- Advisor: - Tsegaye Birhanu Signature Date
 Acknowledgment

First and foremost, we would like to thank GOD which gives us strength in every step of our life. Next,
we need to express our deep gratitude to our academic advisor Mr. Getachew F. for his support
valuable comments, encouragement and guidance revealed and offered from the initiation to the last
time at which our thesis project has come true. And also, we wish to appreciate the encouragement and
sympathetic of our families for the duration of every part of our enjoyable and dreadful moment.
Finally, we would like to acknowledge and appreciate all our friends and teachers who have been
played a valuable role to our work by sharing supportive materials, information, and giving concrete
ideas.

i
 Abstract

This thesis project is basically focus on design and modeling of drum extractor machine in drum brake
for light vehicles with help of hydraulic operation which provides easy removal of drum from drum
brake with less human efforts by using the puller (extractor). The aim of this work is replace traditional
methods of hammering to extract drum by new extractor machine. Designing of each components of
manual operated drum extractor machine has been done using equations from machine design books.
The objectives of this work are design and modeling of drum extractor machine for light vehicles,
could develop conceptual design by taking different alternative criteria and also could select the best
alternative. For further reliable and avoid failures, materials like alloy steel, plain carbon steel and cast
iron would be selected for the components based on the geometry, type of force, stresses induced,
availability. It’s exposed to and each component is checked whether it is capable of resisting different
stresses due to the loads applied on it or not. Therefore the required length, thickness and width are
obtained. The obtained applied load on jaw is 5000N and a stress induced in this component is 38Mpa
in addition to could prepare 3D model or to prepared geometrically model for the machine assembly
byAutoCAD2015software.

Keywords: Drum extractor, Hydraulic operations, Drum brakes.

ii
 Table of Contents
Contents page
Acknowledgment.......................................................................................................................................i
Abstract.....................................................................................................................................................ii
List of Figures..........................................................................................................................................vi
List of Tables.........................................................................................................................................viii
List of Symbols and Abbreviations..........................................................................................................ix
CHAPTER ONE........................................................................................................................................1
1. INTRODUCTION.............................................................................................................................1
1.1. Background.....................................................................................................................................1
1.2. Statement of the problem................................................................................................................3
1.3. Objective.........................................................................................................................................4
1.3.1. Main Objective.........................................................................................................................4
1.3.2. Specific Objectives..................................................................................................................4
1.4. Scope of the Study..........................................................................................................................4
1.5. Significance of the Study................................................................................................................4
1.6. Limitation of the Project.................................................................................................................5
1.7. Methodology...................................................................................................................................5
1.7.1. Data Source and Collection Method........................................................................................5
1.7.2. Method of Designing for Each Component.............................................................................6
1.7.3. Methodology Flow Chart.........................................................................................................7
1.8.Thesis Organization.........................................................................................................................8
CHAPTER TWO.......................................................................................................................................9
2. LITERATURE REVIEW..................................................................................................................9
2.1. Previous Related Works.................................................................................................................9
2.2. Components of the Manual Operated Drum Extractor Machine..................................................12
2. 3 Material description......................................................................................................................14
2.3.1 Classification of material........................................................................................................14
2.3.2. Physical and Mechanical Properties of Metallic Materials....................................................14
CHAPTER THREE.................................................................................................................................16
3. CONCEPTUAL DESIGN...............................................................................................................16
3.1. Introduction of Conceptual Design...............................................................................................16
3.2. Concept Generation Methods.......................................................................................................16
iii
 3.3. Generating and Evaluating Alternative Design Concept..............................................................19
3.3.1. Design Concept – 1(Manual and Hydraulic Drum Extractor Machine)................................19
3.3.2. Design Concept – 2 (Electric Drum Extractor Machine).......................................................20
3.3.3. Design Concept – 3 (Pneumatic Drum Extractor Machine)..................................................21
3.3.4. Design Concept – 3 (Manual and Mechanical Drum Extractor Machine)............................22
3.4. Basic Selection Criteria Based Design Consideration..................................................................25
3.5. Function Tree Flow Diagram.......................................................................................................27
3.6. Embodiment Design.....................................................................................................................27
3.6.1. Basic Rules of Embodiment Design and Principles of Embodiment Design........................28
CHAPTER FOUR...................................................................................................................................29
4. MATERIALS AND METHODS........................................................................................................29
4.1. Material Selection.........................................................................................................................29
4.2. Component Design.......................................................................................................................32
4.2.1. Design of Handle...................................................................................................................34
4.2.2. Design of Handle Clevis (link)..............................................................................................39
4.2.3. Design of Plunger...................................................................................................................40
4.2.4. Design of Liner Tube.............................................................................................................41
4.2.5. Design of Solid Ram..............................................................................................................42
4.2.6. Design of Cylinder.................................................................................................................44
4.2.7. Design of Reservoir Cylinder................................................................................................46
4.2.8. Design of Screw.....................................................................................................................47
4.2.9. Design of Jaws.......................................................................................................................50
4.2.10. Design of Plates...................................................................................................................52
4.2.11. Design of Spring for Return in Jaw.....................................................................................54
4.2.12. Design of Cross Arm............................................................................................................56
4.2.13. Design of Pins......................................................................................................................58
4.2.14. Design of spring for Discharge and Intake Valve................................................................60
4.2.15. Design of Frame...................................................................................................................62
4.2.16. Design of Support Arm (Plate)............................................................................................71
4.2.17. Design of Bolt......................................................................................................................74
4.2.18. Design of Nut.......................................................................................................................76
4.2.19. Design of Washer.................................................................................................................78
4.2.20. Selection of Wheel...............................................................................................................79

iv
 4.2.21. Selection of Seals.................................................................................................................84
4.2.22. Valve Selection....................................................................................................................88
4.2.23. Hydraulic Fluid Selection....................................................................................................90
4.3. Manufacturing Method or Fabrication..........................................................................................92
4.4. Assemble Method.........................................................................................................................93
4.5. Cost Analysis or Cost Breakdown................................................................................................94
4.6. Maintenance Method....................................................................................................................99
4.7. Working Principle.......................................................................................................................101
CHAPTER FIVE...................................................................................................................................103
5. RESULT AND DISCUSSION..........................................................................................................103
5.1. Result..........................................................................................................................................103
5.2. Discussion...................................................................................................................................105
CHAPTER SIX.....................................................................................................................................106
6. CONCLUSION AND RECOMMENDATION................................................................................106
6.1. Conclusion..................................................................................................................................106
6.2. Recommendation........................................................................................................................106
REFERENCES......................................................................................................................................107
APPENDIX...........................................................................................................................................109

v
 List of Figures
Figures page

Figure 1.1: Brake drum.............................................................................................................................1

Figure 1.2: Thesis project flow chart method............................................................................................7
Figure 3.1: Concept generation method structure...................................................................................16
Figure 3.2: Input and Output Diagram of the machine...........................................................................17
Figure 3.3: Main Functional decomposition...........................................................................................18
Figure 3.4: 3D Conceptual design for manual and hydraulic drum extractor machine..........................20
Figure 3.5: 3D Conceptual design of electric drum extractor machine...................................................21
Figure 3.6 : 3D Conceptual design for pneumatic drum extractor machine...........................................22
Figure 3.7: 3D Conceptual design for manual and mechanical drum extractor machine.......................23
Figure 3.8: Function Tree diagram for drum extractor machine.............................................................27
Figure 4.1: Shear force and bending moment diagram of the handle.....................................................37
Figure 4.2: Free body diagram handle clevis..........................................................................................39
Figure 4.3: Solid ram or piston................................................................................................................42
Figure 4.4: Reservoir cylinder.................................................................................................................46
Figure 4.5: Development of Screw.........................................................................................................48
Figure 4.6: Free body diagram of jaw.....................................................................................................50
Figure 4.7: Force acting on the jaw plate................................................................................................53
Figure 4.8: End Connections for Tension Helical Spring.......................................................................54
Figure 4.9: Crossed arm..........................................................................................................................56
Figure 4.10:Wahl’s stress factor for helical springs................................................................................60
Figure 4.11: Section view of frame -1.....................................................................................................63
Figure 4.12.Neutral axis of x- axis..........................................................................................................64
Figure 4.13: Cross section of frame -1....................................................................................................65
Figure 4.14: Section view of main frame................................................................................................65
Figure 4.15: Section view of frame -3.....................................................................................................68
Figure 4.16: Free body diagram for frame - 3.........................................................................................68
Figure 4. 17: Section view frame -3........................................................................................................69
Figure 4.18: Force applied on arm..........................................................................................................71
Figure 4.19: geometry of bolt, nut and washer.......................................................................................74
Figure 4.20: Geometry of washer............................................................................................................78
Figure 4.21: Hexagonal headed bolt position..........................................................................................81
vi
Figure 4.22: Geometry of hexagonal nut.................................................................................................83
Figure 4.23: C- type of seal.....................................................................................................................84
Figure 4.24: ISO Viscosity grade for hydraulic fluids based on working temperature..........................91
Figure 4.25: 3D Geometrical model of the machine by AutoCAD2015 software................................102

vii
 List of Tables
Table’s page

Table 2.1: The Table shows weakness, strength, and gaps of the literature...........................................11
Table 2.2: Some mechanical properties of maerials................................................................................15
Table 3.1: Concept design depending on internal searches by taking different alternative....................24
Table 3.2: Selection criteria based on design matrix...............................................................................26
Table 4.1: Some mechanical property of selected material for each component of the machine...........31
Table 4.2: Hammering frequency per one drum extract.........................................................................32
Table 4.3: Values of factor of safety.......................................................................................................34
Table 4.4: O-Ring Material Guides.........................................................................................................85
Table 4.5: O- ring type property..............................................................................................................86
Table 4.6: Valve selection guide for liquid based fluid..........................................................................89
Table 4.7: Properties hydrualic oil with ISO VG 46...............................................................................92
Table 4.8: The Total material and labor cost...........................................................................................98
Table 4.9: Maintenance Schedule.........................................................................................................100
Table 5.1: Dimensions designed components.......................................................................................103

viii
 List of Symbols and Abbreviations

𝜎𝑎𝑙𝑙 =Allowable stress

𝐴𝑠𝑟 = Area of the solid ram
W = Axial force
𝐴 = Area of cross-section
𝜎𝑏 = Bending stress
𝑀 = Bending moment acting at the given section n about the centroidal axis
𝐾𝐵= Buckling factor
𝜎𝑐𝑟 = Crushing stress
A = Cross-sectional area of the column
W𝑐𝑟 = Critical axial load
𝑒 = Distance from the centroidal axis to the neutral axis
𝑌 = Distance from the neutral axis to the extreme
fiber L = Equivalent length of the column
𝐹𝑝 = Force on the pin
𝐹𝐹 =Fulcrum (plunger) force
𝐹h = Human force on pump handles
𝐿ƒ = Free length of the
spring k = Least radius of
gyration
𝑃𝑐 = Pressure in the ram
𝐼 = Moment of inertia
𝑃𝐶 = Pressure in the cylinder
𝑃𝑝 = pressure created by the pump
𝑅 =Radius of curvature of the beam
𝑅𝑛 =Radius of curvature of the neutral axis
a = Rankin’s constant
𝐾𝑟 = Spring rate or stiffness of the spring
𝑟 = Shear stress
𝐸 =Young’s modulus of the material
𝐺 = Modules of

ix
elasticity z = Section
modulus
AutoCAD = Automatic computer -aided design.

x
3D = Three dimensional
FJET = FUOYE Journal of Engineering and Technology.
IJMET = International Journal of Mechanical Engineering and Technology.
IJIRST = International Journal for Innovative Research in Science and
Technology. PPT = Microsoft power point.
PDF = Portable document format.

xi
 CHAPTER ONE

1. INTRODUCTION

1.1. Background
The modern automotive brake system has been refined for over 100 years and has become extremely
dependable and efficient. The typical brake system consists of disk brakes in front and either disk or
drum brakes in the rear connected by a system of tubes and hoses that link the brake at each wheel to
the master cylinder [5]. But this thesis project focuses on drum brake type. In this type of brake, a
drum is attached to the axle hub whereas on the axle casing is mounted a back plate. The back plate is
made of pressed steal sheet. It provides support for the expander, anchor and brake shoes. It also
protects the drum and shoe assembly from mud and dust. It also known as the torque plate because it
absorbed the complete torque reaction of the shoe. Two brake shoes are mounted on back plate with
friction linings. One or two retractor spring are used to separate brake shoe from drum when the brakes
are not applied. The brake shoe is anchored at one end, whereas on the other end force is applied by
means of some brake actuating mechanism which forces the brake shoe against the revolving drum, so
the friction force is generated between drum and the shoe and brake applied [6]. Figure 1.1 below
shows brake drum model by AutoCAD 2015software.

Figure 1.1: Brake drum

Manual operated drum extractor machine is used for removing drum from drum brake assembly and
rear wheel hub. In the drum brake the removing operations are very complicated for disassembly. For
this type of operations, we require heavy force for disassembly of the drum from the drum brake. It can
be used widely and effectively for removing the drum. A hydraulic drum extractor performs removing
operation of drum safely and without damaging the drum surface and other drum brake components.

1
A hydraulic fluid power system is defined as a means of power transmission in which relatively
incompressible fluid is used as the power transmitting media. The primary purpose of hydraulic system
is the transfer of energy from one location to another location and this energy converted into useful
work. Power clamping is used for holding the job as far as quickly and maintains the constant pressure
over the job. The hydraulic system pressure can be generated in the form of any physical action which
result a compression over the hydraulic systems that are developed in the form of air compressing
externally can be applied to activate hydraulic system. There is a constant relation between pressure
density, and volume, according to Bernoulli equation [7].

2
1.2. Statement of the problem
Now a day’s most of the automobile service centers still using the hammer to remove or extract drum
from drum brake assembly and rear wheel hubs. This method is traditional, takes more effort and also
which is not economical from surface quality, time and effort power used perspective. And also causes
several problems like unsafe and excessive hammering cause’s damage to drum surface, unwanted
parts to be pulled out and the brake shoe to be damaged and left scratched (worn out), inside wheel
cylinder seal losses and leaks and damage to the rear wheel hub edges or sometimes there is a chance
of failure and excessive human effort is required to remove drum because of hammering. During the
removal of drum it could also damage the hammer itself. In addition to this mechanics consume their
energy and inhibits them from doing any other tasks .Thus, in order to solve all of the above problems,
we design and modeling manual operated drum extractor machine which remove a drum without
damaging any parts by using hydraulic operation within simplest and cheapest way while saving time
and energy.

3
1.3. Objective

1.3.1. Main Objective

The main objective of this thesis project is to design and modeling a manual operated drum extractor
machine in drum brakes for light vehicles.

1.3.2. Specific Objectives

 To design each components of a manual operated drum extractor machine.

 To select the right hydraulic fluid, valve and seal for the machine.
 To prepare a 2D and 3D model of the machine using AutoCAD2015software.
 To compare the performance of a new design machine with the traditional removal method.

1.4. Scope of the Study

This thesis project is confined in preparing the documentation of an analytical design using equations
from different design books for each component of the machine at efficient working principles at an
optimum cost within simple and available material. And also 3D model by AutoCAD 2015software are
included whereas simulation of the designed mechanism is not part of this work.

1.5. Significance of the Study

After the manual operated drum extractor machine is designed and manufactured, car service center
can use it to reduce lots of its problems from the perspective of time, human power, economy and
quality regarding pulling and removing drum from drum brakes. Therefore, the new design machine
has main significant for worker and light car service center. Those significant are: -

 Overcoming the traditional methods of drum removal for long year lied in our country
 Decreasing or avoiding the workers fatigue or accident and improve a good working
condition for worker.
 Improve working efficiency and profitability of the workers and car service centers.
 Saving labor force and time for workers and car service centers.
 It will assist and contribute for the car service center to accomplish its mission and
vision quickly by facilitating the works and reducing material failure.

4
1.6. Limitation of the Project
Designed and Modeling of the project document has been successful completed. But manufacturing of
each component and the machine is not successful because of many reasons:-

 Shortage of material supply in the shop.

 Lack of machine required to manufacture the product in the shop.
 Shortage of Budget supply for fulfillment of the required parameters is the main obstacles.

1.7. Methodology
There are two main procedures in the methodology part. Those are

1.7.1. Data Source and Collection Method

a. Data source
The following are data sources which we get information it is used for our design machine.
 books
 Videos from YouTube
 A person who works at car service center and
 Some other documentation such as manual book car service centers.
b. Data collection method
We use the following data collection method to collect the data that used for doing this project. The
study started with literature review from previous papers on design and analysis of manual operated
drum extractor machine using different materials.
Method of data collection: we collect data’s by two ways.
a. Primary data collection: -
 By observing car service working environments.
 By Interview or questioner the professional person.
During collection of data by direct measuring and interview from car service center the drum
maximum extracting force has been analyzed, the dimension of each side of the drum was determined
and also known the mechanic maximum hammering force applied on drum.
b. Secondary data: Mainly this data’s were collected through literature review, detail study, in
addition to that secondary data were collect from the following references
 Review of different journals, books, Web pages (website) and articles.

5
1.7.2. Method of Designing for Each Component.

These procedures are the basic procedures that were followed in order to fulfill the objectives of this
project or thesis research proposal, those stated below: -
 Identifying the material types considering cost, availability, and their weight.
 Developing conceptual and embedment design
 Determine the dimension of manual operating drum extractor machine by theoretical design.
 Analyze the force applied and stress induced on each component of the machine.
 Modeling and analyzing the machine by using AutoCAD 2015softwar.
All the above procedures have been conducted with application of a specified conditions and
constraints that helps to get the suitable and reliable result.

6
1.7.3. Methodology Flow Chart

The overall methodologies that were followed in doing this work are shown on the figure 1.2 below.

Start Literature review

Problem identification

Conceptual design

Material selection

Design of No
components

Yes

No Modeling

Yes

Preparation of document/submission

End

Figure 1.2: Thesis project flow chart method

7
1.8.Thesis Organization
This work focuses on to design and modeling a manual operated drum extractor machine in drum
brakes for light vehicles. Mechanical property such as tensile, compressive and also others are
considered .This work includes six chapters:-
Chapter 1 is about introduction drum brake and drum brake extractor machine, the thesis objectives
and statement of the problem, scope, significance, limitations and methodology.
Chapter 2 reviewed relevant research papers regarding to the project.
Chapter 3 deals with development of conceptual design taking different alternative criteria (concept -
1, concept–2, concept – 3 and concept -4).
Chapter 4 describes about material selection, design and modeling of each components the machine.
Chapter 5 reports result and discussion about each dimension and other parameters.
Chapter 6 provides the conclusion and recommendations.

8
 CHAPTER TWO

2. LITERATURE REVIEW

2.1. Previous Related Works

Bethrand N. Nwankwojike et.al (2017), Design and development of a manual operated hydraulic Press
and puller machine, designed hydraulic puller machine comprising of a frame, cylinder and piston, two
threaded studs, hydraulic pump and hose, pulling clamp and a work piece support was designed,
fabricated and evaluated. The machine is manually operated. The maximum shear force, maximum
bending moment and maximum displacement of the machine work piece support were determined and
also obtained maximum axial, bending and torsional stresses were also determined and dismantled
afterwards using three different methods: traditional hammering, the developed, manual hydraulic
puller machine and already existing electrically powered hydraulic puller. as results of analyzed that
experiments showed in traditional hammering is the most time-consuming method of mounting and
dismounting force fits followed by the use of the developed press-pull machine while electrically
powered hydraulic presses are the fastest. The machine which was fabricated with local materials will
reduce the time and stress associated with installation and removal of bearings, and other forms of
force fits in machine assemblies [1].
A. Saravana Kumar (2017), Design and fabrication of hydraulic cylinder liner puller, conducted that a
triple column by which a rod is connected to it. At the center of the column a hydraulic jack is
provided to lift the column. A rod is connected to the puller to remove the cylinder liner and to remove
the head of the engine piston, crank case, and connecting rod. Then the hydraulic jack has been
operated pulling rod pull the liner very easily without damage to the other liner. The project has been
applicable for all heavy and light duty vehicles (This can be effectively used for removing cylinder
liners for such as LEYLAND 370, BENZI 1210E, Perkins and generators oil engines etc) according to
geometric, force and stress analysis [2].
C. Senthil kumar et.al (2018), Design and analysis of pneumatic bearing pusher and puller machine,
the modification their project has made which is easy remove and installation of bearing. Pneumatic
bearing puller and pusher works based on Pascal law “pressure distribution in an enclosed cylinder is
uniform in all direction “are developed to solve the conventional hammering process. Their projects
have been mainly focused to reduce the human effort and the wear and tear that occurs while
mounting and unmounting a bearing. The mounting and unmounting of a bearing from an engine or
from a shaft are a tedious job as the conventional method is hammering which involves lot of human
effort and there are many chances for bearings to get damaged. So, to reduce these ambiguities the
9
solution is brought with the help of pneumatic systems where air pressure is utilized to mount and
unmount the bearings. Those were achieved by using a pneumatic cylinder which is operated using a
compressor and the plunger of the pneumatic cylinder is fitted with the corresponding pusher or puller
depending upon the needs. The pneumatic cylinders are available in different ranges of operating
pressures, so depending upon the load requirements the pneumatic cylinder can be chosen. The project
work developed after conducted a number of experiments before finalizing the design work which
reduced the bottle necks. Using their project, the bearings can be easily mounted and unmounted with
less effort and also in safer manner. As the initial and maintenance cost are low. So, this can
implement in automobile industries, workshops, and in other factories where bearings may be a part of
the product. The studied journal deals with the positions of pneumatic actuators and its merits over
other actuators. Pneumatic actuators offer several advantages over electromechanical and hydraulic
actuators for positioning applications [3].
Rakesh Y. et.al (2015), Design and Fabrication of hydraulic bearing puller and pusher machine, the
studied work focuses on the development of concept design by hydraulic operation. Hydraulic pulling
consists of adjustable mechanical jaw puller inbuilt with the hydraulic jack. When pump operated,
plunger comes outside. Then mechanical jaws adjusted bellow the bearing and again operate the pump.
During operation, hydraulic jack applies continuous pressure on shaft and mechanical jaw remove
bearing from shaft. during pushing operation, two pushers inbuilt in a frame which pushes a bearing
clamp. Bearing clamp supports the bearing while performing pushing operation. The middle portion
clamping plate is in elliptical shape and provided with sitting arrangement and is adjustable range
based on analysis dimension. The clamping plate is adjustable by means providing stud on both sides.
The modification made was easy removing and installing bearing in conducted design. The purpose of
conducted that modification are required less human effort, simplicity of operation, removing and
installing bearing done without damaging bearing surface, compact, portable and well suited,
multifunctional, safe, versatile and also individual can lift a load weighing several ton [4].

10
Table 2.1: The table shows weakness, strength, and gaps of the literature

Scholar Name
Their works Bethrand N. A. Saravana C. Senthilkumar Rakesh Y.
Nwankwojike Kumar et.al et.al
et.al

Consideration Hydraulic
system   × 
brief explanation of each  ×  ×
component
Compatibility, portability ×   
and well suited.
Feasibility on market × × × 
Capacity 1000N 40000N 254.5 N 50000N
Type of vehicle Light Heavy and light Heavy
light
Selection Material More use mild Mild steel and More use Mild Mild steel and
steel carbon steel steel cast iron

Description for above table: -

 √: - This describe that the scholar has done and it express the strength of their work.
 X: - This describe that the scholar has not done and consider and express their weakness.
 The difference between "√ “and “X” are the gaps between their works.
But, we can design this thesis project is fully packed with advanced features that enhance their
functionality and usability by keeping their limitation or weakness and gap in minds client’s different
requirements, techniques, and their modification used as input parameter, then we can design and
manufacture a new manual operated drum extractor machine that offer the entire range in various
technical specifications. The purpose of this project is to design and manufacture the machine in terms
of its functionality and also light vehicle factors considerations. Those our considerations are the
machine should be easy handling and extract of drum from drum brake assembly and also travel it to
the required place at a comfortable situation and short period of time with minimized human force.
We can see that the difference between hydraulic system and mechanical system were used in which
moving parts like bearing, gears and pistons were used. But due to the usage of that mechanical system
considerable amount of power loss and inefficiency was reported. So in order to avoid the wear and
tear, which occurs between the moving parts, the principle of hydraulics was implemented. Hydraulics
system has the following advantages over mechanical;
11
  Higher power to weight ratio
 Safe operation.
 Better overload safe power system.
 It can generate and transmit large tones and forces.
 It has accurate feedback control of load positions etc.
The difference between hydraulic system and pneumatic system, the advantage of hydraulic system
include the ease and accuracy by which they can be controlled and large amount of power they can
generate. In general use fewer moving parts than some mechanical, electrical and pneumatic system.
They also provide constant force and torque. Hydraulic system is capable of moving heavier loads and
providing greater force than pneumatics [8].
The difference between hydraulic system and electrical system is the electrical actuator offer the
precision setting. The set up are scalable for any force and are quieter than pneumatic and hydraulic
actuator, allowing for smooth and repeatable usage, its advantages are no leakages, very precise and
low noise than other system but it cannot be used at hazards environments and can overheat(which
increases wear and tear on the reduction gear)[8].
From the above point of view, we choose hydraulic systems for our new design, because of hydraulic
actuators are robust and suited for high force application; they can also produce 25 times greater than
pneumatic cylinders of equal size, operated in pressure of up to 27.58Mpa In addition to this hydraulic
system holds forces (constant force and torque output) and maintains power (minimum power loss).

2.2. Components of the Manual Operated Drum Extractor Machine

The purpose hydraulic manual operated drum extractor machine is designed to help extend drum and
component life in applications through proper removal and service of components. They are ideal for
removing large gears, wheels, bushings, couplings, fly-wheels, pulleys, sleeves, sprockets and more
utilizing a manual operated drum extractor machine adds efficiency and eliminates unsafe practices
such as hammering, heating components to be removed and limit damage that may otherwise occur by
other methods of disassembly. The manual operated drum extractor machine assembly mainly
consisting of: -
Jaws: - part used to grip the body (drum) which is going to be removed out. Jaws can be of two or
three in number in a remover. But in this project the hydraulic extractor designed have three jaws at
angle of 120° to each other for better gripping power, a more uniform displacement of extracting
force, occupies less space and cost effectiveness.
Crossed arm: - It is a mechanical device that holds or supports the three branch jaws.
12
Rams (Actuating Pistons):- The Ram is used to convert 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 [9].
Return spring (helical compression springs) are made up of a wire coiled in the form of a helix and
primarily intended for compressive load. The cross-section of the wire from which the spring is made
may be circular, square or rectangular. Help absorb some of the vibration and shock produced coming
from hydraulic system [9].
Manually operated pump: - used in a hydraulic extractor is a plunger type reciprocating pump. The
pumping chamber of this type of pumps are surrounded by one-way valves, so that the hydraulic fluid
only moves from in to the low-pressure side i.e. suction side and out from the high-pressure side i.e.
discharge side. Therefore, this type of pump is used to converts mechanical energy to hydraulic energy
in the form of flow [9].
 Main cylinder: - It is the cylinder that the pump cylinder delivers the oil through the delivery
valve.
 Plunger: - That draws fluid from the reservoir on its up, suction or intake stroke then creates p
piston or ram pressure on its down or power stroke pushing the fluid through a check valve.
 Valves: - the simplest type of valve are used in hydraulic extractor 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. It is used to control the pressure
requirement of the system. The hydraulic extractor consists of three types of valves. These are
Intake valve, Discharge valve and Pressure release valve [9].
Reservoir (oil tank):- used to store the fluid which is required for the operation. The type of tank used
in hydraulic system is pressurized tank with filler piston; this type of tank is sealed from the
atmosphere, keeping dirt and humidity out of the tank. The internal pressure also forces oil towards the
pump, avoiding pump cavitation’s [9].

Handle: -It is a member in which the manually enacted force is going to applied on which in turn is
connected to the oil holder and when it pushes, the oil pushes the piston and the arm lifting being to
rise. This allows the fluid to return to the reservoir (after the hydraulic system has done its job and it is
time to release the pressure allowing the ram piston to return back in to the main cylinder the release
valve is opened and the fluid is ported back in to the reservoir so the hydraulic cycle can be repeated)
[9].

13
Support plate or arm: - we have four support arms or plate. Plate or arm is joined to the base frame
and the support table part of the manual operated hydraulic extractor machine the help of bolt joint.
Frame (1, 2 and 3): - which hold all hydraulic system of the machine.
Base frame: - which is used to adjust or safe the stability the support arm.

2. 3 Material description
2.3.1 Classification of materials

The knowledge of materials and their properties is of great significance for a design machines. The
machine elements should be made of such a material which has properties suitable for the conditions of
operation. In addition to this, in a designing machine must be familiar with the effects of
manufacturing process and heat treatment have on the properties of the material.
Materials are mainly classified as:-
a. Metals and their alloys, such as iron, steel, copper, aluminum, etc.
b. Non-metals, such as glass, rubber, plastic, etc.
The metals may be further classified as: - Ferrous metals, and Non-ferrous metals.
i. Ferrous metals are those which have the iron as their main constituent, such as cast
iron, wrought iron and steel.
ii. Non-ferrous metals are those which have a metal other than iron as their main
constituent, such as copper, aluminum, brass, tin, zinc, etc. [9].
The important properties, which determine the utility of the material, are physical, chemical and
mechanical properties. The physical and mechanical properties of the material in the following for this
thesis projects.

2.3.2. Physical and Mechanical Properties of Metallic Materials

 Physical Properties of Metals

The physical properties of the metals include luster, color, size and shape, density, electric and thermal
conductivity, and melting point [9].
 Mechanical Properties of Metals
The mechanical properties of the metals are those which are associated with the ability of the material
to resist mechanical forces and load. These mechanical properties of the metal include strength,
stiffness, elasticity, plasticity, ductility, brittleness, malleability, toughness, resilience, creep and
hardness.

14
  Strength: - It is the ability of a material to resist the externally applied forces without breaking
or yielding. The internal resistance offered by a part to an externally applied force is called
stress.
 Ductility: - It is the property of a material enabling it to be drawn into wire with the application
of a tensile force. A ductile material must be both strong and plastic.
 Brittleness: - It is the property of a material opposite to ductility. It is the property of breaking
of a material with little permanent distortion. Brittle materials when subjected to tensile loads
snap off without giving any sensible elongation. Cast iron is a bra title material.
 Machinability:- It is the property of a material which refers to a relative cause with which a
material can be cut. The Mach inability of a material can be measured in a number of ways
such as comparing the tool life for cutting different materials or thrust required to remove the
material at some given rate or the energy required to remove a unit volume of the material.
 Hardness: - It is a very important property of the metals and has a wide variety of meanings. It
embraces many different properties such as resistance to wear, scratching, and deformation and
Machinability [9].

Table 2.2: Some mechanical properties of materials

Materials young’s Modulus of Poisson’s Density Yield stress Tensile

modulus elasticity ratio (𝑔⁄𝑐𝑚3) strength
stress
AISI 1010 200Gpa 80Gpa 0.29 7.87 180Mpa 325Mpa
steel
Mild steel 220Gpa 140.25Gpa 0.28 7.86 207 Mpa 345 Mpa
AISI 304 204.773Gpa 79.97Gpa 0.29 7.85 215 Mpa 505 Mpa
Stainless steel
Carbon steel 200Gpa 79.7Gpa 0.29 7.878 350 Mpa 420 Mpa
Aluminum 68.9Gpa 25.86Gpa 0.33 2.71 275 Mpa 310 Mpa
Alloy steel 205Gpa 80Gpa 0.3 7.85 250 Mpa 235 Mpa
Copper 117.5Gpa 46Gpa 0.34 8.94 330 Mpa 380 Mpa
Magnesium 44Gpa 16.3Gpa 0.35 1.74 115 Mpa 180 Mpa

15
 CHAPTER THREE

3. CONCEPTUAL DESIGN

3.1. Introduction of Conceptual Design

The conceptual design stage involves clarification of the task in which specifications are
elaborated to come up with specifications of the design concept as the output. The feasibility study of
manual operated drum extractor machine is the process by which its design is initiated, carried to the
point of creating a number of possible solutions of manual drum extractor, and narrowed down to a
single best concept, we call this Conceptual design phase.
The design of drum extractor machine must have based on much aspect actually. The design
consideration must be done carefully so that the design can be fabricate easily and the system
functioning. Then the material used in each design influence the selection thing because absolutely we
need a lightweight material suitable with product size.

3.2. Concept Generation Methods

In the concept generation, phase we should ask the following questions to start with,
 What existing solution concepts, if any, could be successfully adapted for this application?
 What new concept might satisfy the establishment needs and specifications?
 What methods should be used to facilitate the concept generation process?
Basically there are five concept generation methods. Those are shown figure 3.1 below.
- Understanding
- a. Clarify problem - Problem decomposing
- focus on critical sub problems

New
b. Search external b. Search internal
Existing Design Design
- Lead users - individual
- Experts c. Explore systematically - group
- Patents solution - constructive feed back
- Literature
- Benchmarking d. Reflect on solution and processes

Figure 3.1: Concept generation method structure [20].

16
 a. Decomposition problem into main Function and Sub Function

A common strategy for solving any complex task or describing any complex system is to decompose it
into smaller units that are easier to manage. Decomposing must result in units that meaningfully
represent the original entity. The units of the decomposition must also be obvious to the decomposer.
The decomposition defined in this section is the breaking up of the product itself, not the process of
design [20].
Decompose complex problem into simpler sub-problems is essential because many design challenges
are too complex to solve as a single problem [20]. Consequently let’s decompose the drum machine in
to simpler sub problems in order to tackle the problems which traditional remove the drum. This
traditional method, takes more effort and also which is not economical from surface quality, time and
effort power used perspective. This method causes several problems like unsafe and excessive
hammering cause’s damage to drum surface, unwanted parts to be pulled out and the brake shoe to be
damaged and left scratched (worn out), inside wheel cylinder seal losses and leaks and damage to the
rear wheel hub edges. But in the new design the main function of the manually operated drum extractor
machine with the input and output diagram as shown below figure 3.2 presents by black box method.

Energy (manual or hand) Energy which is kinetic energy

Materials (drum on drum brake) Manual operated drum drum from brake assembly
Brake and axle shaft extractor machine
Signal
Signal Signal

Figure 3.2: Input and Output Diagram of the machine

17
As shown below figure 4.3were main function decomposition method for the new product.

Energy
Material Signal

Drum in drum assembly

Hydraulic operation
External

Solid ram or Jaw or extractor

Mechanical links
piston

Product

Figure 3.3: Main Functional decomposition

b. External and internal search

I. By conducting external searches from literature and observing from working environment to
find existing solutions to satisfy either the overall problem or a sub-problem identified
during the decomposition step. These results are found; hydraulic puller machine which is
 Heavy duty,
 Medium duty and
 Light duty and for small size.
II. Conducting internal searches to find the new solution to satisfy the overall or sub function.
Finally come up with the following solution.
 Human force operate extractor machine.
 Manual and hydraulic power operate extractor machine
 Electric power operate extractor machine
 Pneumatic system operate extractor machine.
 Mechanical power operate extractor machine.

18
3.3. Generating and Evaluating Alternative Design Concept
To select one of the superlative choices given for each component, few steps have been followed.
 Selecting Criteria
 Evaluating each design with respect to the selected criteria by using a decision matrix.
 Select the preeminent design based on the decision matrix.
In order to make any kind of evaluation, it is necessary to have a set of criteria and these must
be based on the design objectives i.e. what it is that design is meant to achieve. The objective will
include technical and economic factors, user requirements and so on. Hence the following objectives
are chosen to evaluate the design characteristic of each feature. Cost, performance, reliability,
availability, maintainability, power we may have the same or different evaluating criteria, which
depend on the type of features to be evaluated as well as the amount of dependency if it affects
adversely, we could use as a measuring criteria for that feature.

Based on alternating design concept, we can choose the best design concept from internal search
(concept – 1, concept – 2, concept -3 and concept -4).

3.3.1. Design Concept – 1(Manual and Hydraulic Drum Extractor Machine)

Working principle and 3D modeling for manual and hydraulic drum extractor machine
When the handle moves up ward or the plunger of the pump makes moves up, a partial vacuum is
generated in the pump cavity. The vacuum created in the cavity makes the outlet check valve to close
the outlet line and allows the atmospheric pressure to push fluid from the reservoir into the pump via
the inlet check valve.
When the handle moves down ward or the plunger of the pump makes down, the fluid movement
forces the inlet check valve to close and open the outlet check valve. The plunge compresses the fluid
and the hydraulic pressure developed by pump. The hydraulic power developed by pumps is converted
back into mechanical energy by hydraulic actuators connected to the output solid ram. Then when the
solid ram pushes the axle shaft or rear wheel hub simultaneously in reverse direction, then jaws extract
or remove the drum that fitted from drum brake assembly and rear hub wheel hub. After that jaws
return to original place by help of return spring. As shown figure 3.4 below 3D conceptual design for
manual and drum extractor machine.

19
 Figure 3.4: 3D Conceptual design for manual and hydraulic drum extractor machine

3.3.2. Design Concept – 2 (Electric Drum Extractor Machine)

Working principle and 3D modeling for electric drum extractor machine

The source of power for all components of the extractor comes from the dc motor drives it by rotating
the drive shaft and pulley, then power transfer to the second shaft by means of drive belt, the second
shaft transmit the power to third shaft by means of two intermediate belts, then after third shaft power
transfer to rack and pinion gear, this gears change the rotational motion to linear motion, A pusher rod
to push the large piston. This piston rod pushes the axle shaft or rear wheel hub simultaneously in
reverse direction; final jaws extract or remove the drum that fitted from drum brake assembly and rear
hub wheel hub. As shown figure 3.5 below 3D conceptual design for electric drum extractor machine

20
 Figure 3.5: 3D Conceptual design of electric drum extractor machine

3.3.3. Design Concept – 3 (Pneumatic Drum Extractor Machine)

Working principle and 3D modeling for pneumatic drum extractor machine

When the switch on the compressor which acts the input for the pneumatic cylinder. The compressed
air from the compressor is then sending to the leg lever valve through the filter regulator lubricator.
Filter regulator lubricator removes the dust particles from the compressed air and helps us to set the
required amount of air pressure needed for the operation. Then turn on the Filter regulator lubricator
and set the required air pressure. Now the air comes to the leg lever valve. Leg lever valve act as the
direction control of the air. When the leg lever valve is moved forward, the pressure of air goes to the
bottom port of the cylinder and this makes the solid ram of the cylinder to move in the forward
direction .when the leg lever valve is moved towards reverse, the pressure of air goes to the top port of
the cylinder and thus makes the solid ram of the cylinder to move in the reverse direction. Then when

21
the solid ram pushes the axle shaft or rear wheel hub simultaneously in reverse direction, then jaws
extract or remove the drum that fitted from drum brake assembly and rear hub wheel hub. After that
jaws return to original place by help of return spring. As shown figure 3.6 below 3D conceptual design
for pneumatic drum extractor machine

Figure 3.6 : 3D Conceptual design for pneumatic drum extractor machine

3.3.4. Design Concept – 3 (Manual and Mechanical Drum Extractor Machine)

Working principle and 3D modeling for manual and mechanical drum extractor machine drum
extractor machine
When person rotate the handle then power screw the rotate and push the axle shaft or rear wheel hub
simultaneously in reverse direction, then jaws extract or remove the drum that fitted from drum brake
assembly and rear hub wheel hub. As shown figure 3.7 below 3D conceptual design for manual and
mechanical drum extractor machine.

22
 Figure 3.7: 3D Conceptual design for manual and mechanical drum extractor machine
And also we can select ranking criteria based on internal search by using scoring method. Concept
scoring is used when increased resolution will better differentiate among competing concepts.in this
stage, the team weighs the relative importance of the selection criteria and focuses on more refined
comparisons with respect to each criterion. The concept scores are determined by weighted sum of the
thing. In describing the concept scoring process,

Relative performance rating

 Excellent 1
 High 2
 Low 3
 Very low 4

As shown table 3.1 below were selecting or ranking criteria depending on internal searches.in concept
scoring method.

23
Table 3.1: Concept design depending on internal searches by taking different alternative

Concept – 1 Concept-2 Concept – 3 Concept – 4

Selecting or ranking Using Manual Electric power Pneumatic Manual and

No. criteria and hydraulic system mechanical

operation power

Weight Rating Score Rating Score Rating Score Rating score

(%)
1 Force 20 1 0.2 2 0.4 3 0.6 2 0.4
multiplication
2 Movement 10 3 0.3 1 0.1 2 0.2 2 0.2
parts
3 Noise and 20 2 0.4 4 0.8 1 0.2 3 0.6
leakage
4 Heat 15 4 0.6 1 0.1 4 0.6 2 0.3
absorbance
(self-cooling)
5 Load 15 1 0.15 2 0.3 3 0.6 2 0.3
6 Environmental 20 4 0.8 2 0.4 1 0.1 3 0.6
hazard
Net score 15 2.45 12 2 14 2.3 14 2.35
7 Actuator Hydraulic Electric Pneumatic Mechanical
8 Working Compressible Electric motor Air Solid or gear
media Fluid
9 Application Mobile app. Mostly in Mostly for food Mostly for
area Heavy electric access application mobile parts
equipment and area such car,
tracks machine etc.
10 selection Yes No No No

Description for above table: -

1:- describes excellent, 2:-describes high, 3:- describes low, 4:- describes very low.

24
From above criteria, we can choice concept-1(manual and hydraulic operation) because of the net score
15 and 2.45 and hydraulic actuators are robust and suited for high force application; they can also
produces 25 times greater than pneumatic cylinders of equal size, operated in pressure of up to
27.58MpaIn addition to this hydraulic system holds forces (constant force and torque output) and
maintains power (minimum power loss) and also design concept -1 (manual and hydraulic drum
extractor machine ) selected based on working principle and its operation.
3.4. Basic Selection Criteria Based Design Consideration
Evaluating component wise and for the design as a whole too. But, may not use all the criteria for
every component. Criteria that considered in designing the any machine are: durability, ease of
handling, ease of maintenance, ease of manufacture, ease of mountable, ease of use, few disturbing
factors, low complexity of components, low cost, low susceptibility of vibration, low wear of moving
parts, many standards and bought out parts, portability, ease of assembly and small number of
components.
 Design matrix based on design considerations
Depending on the above criteria select the best design option as mention below table 3.2 and based on
alternative design concept. And R means rating, S means score and W means weight in percent

25
Table 3.2: Selection criteria based on design matrix.

Design W(%) Concept -1 Concept -2 Concept-3 Concept- 4

considerations R S R S R S R S
Material 5 3 0.1 3 0.1 4 0.2 1 0.0
availability 5 5 5
Material cost 8 4 0.3 2 0.1 1 0.0 3 0.2
2 6 8 4
Strength 6 3 0.1 4 0.2 4 0.2 1 0.0
8 4 4 6
Design 9 1 0.0 2 0.1 2 0.1 2 0.1
simplicity 9 8 8 8
Manufacturab 10 3 0.3 1 0.1 4 0.4 2 0.2
ility
Weight 9 4 0.2 3 0.2 2 0.1 4 0.3
7 7 8 6
Maintaina 8 3 0.2 2 0.1 1 0.0 4 0.2
bility 4 6 8 4
Effective 7 2 0.1 1 0.0 3 0.1 4 0.2
ness 4 7 4 8
Operabilit 6 3 0.1 1 0.0 2 0.1 4 0.2
y 8 6 2 4
drum 12 2 0.2 4 0.4 3 0.3 2 0.2
safety 4 8 6 4
Long life 10 4 0.4 3 0.3 2 0.2 2 0.2
Assembli 10 4 0.4 3 0.3 2 0.2 1 0.1
ng
Net score 31 2.9 30 2.3 30 2.3 29 2.1
1 8 8 7
Selection Yes No No No

After the concept design, we can select the best design from the above criteria based on net score
concept -1 is best and has net score 31 and 2.91.

26
3.5. Function Tree Flow Diagram
Using function tree means can analyze further the function of the manual operated drum machine,
divide the main function of the extractor into sub functions and also can determine the means
for these sub functions. As shown figure 4.5 below were show as the best working flow mechanism
the machine.
Manual operated drum
extractor machine

Body Puller Extractor

mechanism

Hands
Frame Puller Drum tight Hydraulic Manual
assembly assembly Operation puller

Hydrauli
Handle c
Hydraulic
Support actuator
plate Hydraulic actuator Jaw
push piston extracts the drum Piston
Force out
Solid
Main frame

Jaw
Base Spring
frame Links (jaw, crossed return jaw
ram and spring)

Figure 3.8: Function Tree diagram for drum extractor machine

3.6. Embodiment Design

Embodiment design of the manually operated drum extractor machine is concerned with two major
tasks: product architecture and configuration design.
 Product architecture: - determining the arrangement of the physical elements of the design
into groupings called modules. It is concerned with dividing the overall design system into
subsystems or modules [20]. In this step decided arrangements and combinations of the

27
 components; handle with handle clevis, hydraulic assembly, crossed arm with jaw, frame
with support plate and table, and jaw with return spring etc. of the drum extractor machine
to carry out the hydraulic operation properly.
 Configuration design of parts and components: -the design of special-purpose parts and the
selection of standard components, like pump. A part is characterized by its geometric
features such as holes, slots, walls, ribs, projections, fillets, and chamfers [20]. In
configuration design establish the shape and general dimensions of new machine
components.

3.6.1. Basic Rules of Embodiment Design and Principles of Embodiment Design

The final design phase will finish the development of the extractor. At the end it has to be
completely defined in the following three basic rules of embodiment design: simple,
unambiguous, reliable.
 Unambiguous: - fulfillment of technical use of manual operated drum extractor is
clear and uncomplicated
 Simple: - there are no unnecessary functions or shapes other than fulfilling the main
function in which any one can simply understand how it will work, can use the
machine.
 Reliable: - the machine is usable in a myriad of conditions without harming the user or
environment [20].

Principles of embodiment design: - Minimum manufacturing cost, minimum space requirement,

minimum weight, minimum losses and optimum handling [20].

28
 CHAPTER FOUR

4. MATERIALS AND METHODS

4.1. Material Selection

In this section, we consider the limitations and qualification for materials based on their inherent
properties.
Material selection is a step in the process of designing any physical object. In Material selection
engineering understanding of material science is the key to engineering any application and/or part
design. Material selection is the foundation of all engineering applications and design. This selection
process can be defined by application requirements, possible materials, physical principles, and
selection. The possible materials are simply the only materials that can be used in the application.
Possible Materials are defined by the application requirements of the material/part. Systematic
selection of the best material for a given application begins with properties and costs of candidate
material. While selecting material the following specific requirements are taken out
 Temperature and pressure or atmospheric condition effects of process reactions.
 Use of cladding, lining or other protective materials to reduce the effects corrosion and
abrasion.
The main factors that influence material selection are
 Strength requirement and Fracture Toughness
 corrosion Resistance
 cost of the material and availability
 Ease hydraulic operation and fabrication [10].
For design the manual operated drum extractor machine, we can choose the material have the
following properties or which are satisfied: - low in cost, good corrosion resistance, better strength and
ductility, long life of the machine and good machinability and other property.
Based on above requirement, we select the material for our thesis project.
 Material selection for jaw and crossed arm :- The selected material was cast iron grade SAE
1015 HR because of cast iron is a valuable material for engineering purposes which has low
cost, good casting characteristics, high compressive strength, wear resistance and excellent
machinability. The compressive strength of cast iron is much greater than the tensile strength
[10].

29
  Material selection for handle, cylinder, screw, plunger, liner tube and piston: - the
selecting material was alloys steel as result of increase wearing resistance, corrosion resistance
and to improve electrical and magnetic properties. Alloy steel which makes elements other than
carbon is added in sufficient amount to produce an improvement in properties [12].
 Material selection for spring:- we select as hard-drawn spring steel wire this due to the
material which have high fatigue strength, high ductility, high resilience and creep
resistant. It largely depends upon the service for which it is used i.e. severe service, average
service or light service [10].
 Material Selection for reservoir, plates, pin and link: - we can select as mild or low carbon
steel this because it has high strength, good Machinability, good heat treatment properties and
high wear resistant properties. Low-carbon steels contain less carbon than other steels and are
easier to cold-form, making them easier to handle. Mild steel contains approximately 0.05 –
0.25% carbon making it malleable and ductile. Mild steel has a relatively low tensile strength,
but it is cheap and easy to form; surface hardness can be increased through carburizing [14].
 Material selection for Support arm, Support table and fastener :- we select plain carbon
steel select, this because of plain carbon steel is an increase in the carbon content from 0.01 to
1.5% in the alloy, its strength and hardness increases but still such an increase beyond
1.5% causes appreciable reduction in the ductility and malleability of the steel[14].
 Material selection for main and base frame:- we can select as Cast steel, this due to Steel
castings are solid metal objects produced by filling the void within a mold with liquid steel.
They are available in many of the same carbon and alloy steels that can be produced as wrought
metals. Material Properties of Cast steels can be produced with a wide range of properties.
These properties are often inter-related for example, steel ductility and strength have an inverse
relationship. The physical properties of cast steel change significantly depending on chemical
composition and heat treatment. They are selected to match performance requirements of the
intended application [13].
Based on above material selection, we can design each component of a machine.
Some mechanical property of selected material for each component of the machine as shown table 4.1
below.

30
Table 4.1: Some mechanical property of selected material for each component of the machine [11].

No. Component Material used Code Type Ultimate Tensile yield

strength strength(𝑀𝑃
(𝑀𝑃𝑎) 𝑎)
1 Jaw Cast iron SAE 1015 HR ---- 190
2 Crossed arm Cast iron SAE1018HR ---- 280
3 Cylinder mild steel SA-210 330 270
4 Reservoir Mild Carbon steel SA-106 256 207
5 Handle Alloy steel AISI 1010 370 300
6 Small Plunger Alloy steel AISI 1010 CD 370 300
7 Handle clevis Mild Carbon steel SA 106 258 206
8 Piston ram Alloy steel AISI 1015 392 313.7
9 Valve Selection ---- ----- ----
10 Spring Mild Carbon steel helical ----- 651
compression
spring
11 Support arm Plain carbon steel ----- 550-700 380
12 Support table (frame -1) Plain carbon steel ----- 550-700 390
13 Main frame(frame -2) Cast steel grade - CS640 640 390
13 base frame (frame -3) Cast steel grade - CS640 640 390
14 Screw Alloy steel AISI HR 1006 220 170
15 Liner tube Alloy steel AISI 1010 370 300
16 Plates for jaw Mild steel SA 106 ---- 207
17 Bolt, nut and washer Plain carbon steel ------ 550-700 385
18 Pin Mild carbon steel ------ 140 112

31
4.2. Component Design
 A capacity of the machine
One normal person hammering (pulling) capacity :-
Average weight = 70kg + hammer weight + hammer stick weight = (72 + 2.5 + 0.5) 𝑘𝑔
Then, total force = 75 × 9.81 = 735.37𝑁,

735.37𝑁, from this force half of the weight, one normal person exerts on drum hammer application
because half of the weight uses to save or return to back to his position (in the application of action and
reaction force in Newton’s third of motion and inertial force that means Newton’s second law),
i.e 367.857𝑁 is exert on drum on the other hand 367.875N is resist the balance on his
735.37
= 365.875𝑁 , but average of one normal person hammering frequency is
2
workingposition.

13times from direct measures of car service center present at the moment. From this there is no equal
force is applied on each interval of time frequency (13redundant). As shown table 4.2 below were
hammering frequency per one drum extract.
Table 4.2: Hammering frequency per one drum extract

Number of frequency Applied force on drum (N)

1 367.87
2 367.87
3 365.87
4 360.87
5 345.87
6 340.87
7 338.87
8 335.87
9 333.87
10 328.87
11 320.87
12 306.87
13 300.06

 Thirteen (13) refers maximum hammering time frequency to extract the drum, but minimum is
below thirteen some of the drum extracted

32
Then, the maximum force applied on drum = summation force= 4414.5𝑁
But, some little allowance is added by expecting drum tighten difficulties and below 72kg person
hammering ability (capacity).
Then total force = 4414.5𝑁 + 585.5𝑁 = 5000𝑁
Design specifications are,
 The capacity = 5000 𝑁 , based on above calculation and justification.
 Required human effort for operation (to put on the lever considering ergonometric
conditions)As a source of force, the human being on the average, a healthy person in temperate
climates consumes energy at a sustainable rate of only about between 150 – 200N, while in
tropical climates, as a result of heat stress the rate is reduced to only about 120-145N. For our
design thesis project is we select 196.2N in order to pull the drum.

Criteria to select factor of safety for safe design

The factor of safety is the ratio of the allowable stress to the actual stress. A factor of safety of 1
represents that the stress is at the allowable limit. A factor of safety of less than 1 represents likely
failure. A factor of safety of greater than 1 represents how much the stress is within the allowable limit.
 Working stress: - when designing machine parts, it is desirable to keep the stress lower than
the maximum or ultimate tensile stress at which failure of the material takes place. This stress
is known as the working stress or design stress. It is also known as safe or allowable stress
[11].
 Factor of safety: - it is defined as the ratio of the maximum stress to the working stress, for
cast iron components ultimate tensile strength is considered to be the failure criterion. Failure
occurs when the maximum stress in the component due to external force exceeds the ultimate
tensile strength even once [11]. To account for this factor a large factor of safety, usually taken
1 to 7factor of safety are used for this project by considering which type of load is applied on
each component of the machine.
𝑦i𝑙𝑑𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
w𝑜𝑟𝑘i𝑛g
Factor of safety= for ductile material
𝑠𝑡𝑟𝑒𝑠𝑠

Factor of safety=𝑢𝑙𝑡i𝑚𝑎𝑡𝑒 for brittle material

𝑠𝑡𝑟𝑒𝑠𝑠
w𝑜𝑟𝑘i𝑛g
𝑠𝑡𝑟𝑒𝑠𝑠

In design analysis number of parameters which are difficult to evaluate accurate design such as:
 Variation in the properties of material like yield strength or ultimate strength
 Uncertainty in magnitude of external force acting on the components

33
 Variations in the dimensions of the components due to imperfect workmanship.

34
In order to ensure safety design against such circumstances, factor of safety is useful in design.
Based on design cod or standard American institute of steel manufacturing company typically, factor
of safety rang from a low of 1.3 to around 5 for carbon grade steels based on load variation and
fluctuation. Factor of safety do effect on safe life and the cost will be severe and is take generally
around 1.5 to 3 for industrial machine or equipment as required.

Table 4.3: values of factor of safety (from text book of machine design)[11].

Material Steady load Live load Shock load

Cast iron 5-6 8-12 16-20
wrought iron 4 7 10-15
Carbon steal 4 8 12-16
Soft material & alloys 6 9 15
Leather 9 12 15
Timber 7 10-15 20

Based on this above criteria factor of safety have been selected for each components of the machine
has been designed which means could consider which types of load has been exert on each and every
components of a new design machine.

4.2.1. Design of Handle

The handle used in this machine is a lever of class 2 type that’s the load is in between the fulcrum and
effort. In this case, the effort arm is more than load arm; therefore the mechanical advantage is more
than one. It is used for force multiplication purpose.
The forces acting on the lever are;
 Load (W),
 Effort (P), and
 Reaction at the fulcrum 𝐹𝐹 (RF)
The material selected for the handle is AISI 1010 CD having
Ultimate tensile stress = 370𝑀𝑝𝑎
Ultimate yield stress= 300𝑀𝑝𝑎, then
 permissible tensile stress(𝜎𝑡) by taking factor safety (fs) = 2.5, we use ultimate yield
strength because of the mild or low carbon steel is ductile material

𝜎𝑡 = Ultimate yield ƒ𝑠
stress
35
 300
= = 150𝑀𝑝𝑎 2

36
 stress(𝜎𝑡) 1
 Permissible share stress (𝑟) is one-half permissible tensile stress of

𝑟 (permissible tensile stress ) = 0.5 * 150 = 75𝑀𝑝𝑎

= 2
Considering ergonometric conditions assume and take 𝐿 = 450 mm, 𝐿1 = 70 mm and L2= 380
mm Now, using equilibrium equations, we can find the values of “F” and “W”.

 Summation of forces along x axis is zero,Z𝐹𝑥 = 0. But in this case since there is no

Summation of forces along the y axis is zero, Z𝐹𝑦 = 0. Assume forces acting in the upward
horizontal force acting on the handle.

direction are positive and those acting in the downward direction are negative
P

𝑅𝐴 𝑅𝐵
𝐹𝐹𝐿1(mm) W 𝐿2 (mm)

Z𝐹𝑦 = 0, −𝐹𝐹 + W - 𝑃 = 0,
But, since P is effort applied by the operator it is equal to 196.2 N.
W = 𝑃 + 𝐹𝐹.....................................................................................(4.1)
 Summations of moments at each point are equal to zero. Moments acting in the clockwise
direction are considered negative and those acting anticlockwise are considered as positive.
Moments at the fulcrum point is zero, ΣMA =0,
W × 𝐿1 − 𝑃 × 𝐿 = 0 , but 𝐿 = 𝐿1
+ 𝐿2 W × 𝐿1 - 𝑃 × (𝐿1 + 𝐿2)
=0
P (L1 + L2 ) 196.2N × 450
W = mm = 1261.28N
=
L1 70 mm
From the equation (4.1), 𝐹𝐹 = W- 𝑃 = 1261.28 𝑁- 196.2𝑁 = 1065.08𝑁
In order to get the diameter of the handle, let’s draw shear force and bending moment diagram
P = 196.28N

𝑅𝐴70mm 𝑅𝐵
𝐹𝐹= 1065.08N
380mm 37
W= 1261.28 N
 Then ,first can find the maximum bending moment by section
 Section 1-1 (0 < 𝑥 < 70)

𝑉1
+ 𝑀1
a
𝑅𝐴 = 𝐹 x

+𝗍 ∑ 𝐹𝑦 = 0

𝑉1 − 𝐹𝐹 + W = 0
𝑉1 = 𝐹𝐹 − W = 1065.08 − 1261.28 = −196.2𝑁
Then 𝑉 𝗍changes to 𝑉
↓=196.2N Taking moment at
point “a”
+𝗍 ∑𝑀𝑎 = 0, −𝑀𝑎 + (−𝑅𝑎 × X) = 0
−𝑀𝑎 = 𝑅𝑎 × X
𝑀 = −𝑅𝑎 × X
X𝑚i𝑛 = 0, 𝑀𝑚i𝑛
=0

Take, X max = 70mm

𝑀1 = −1065.08 * 70 = 74555.6𝑁𝑚𝑚

 Section 2-2 (70 < 𝑥 < 450)

P = 196.2N
70mm a b

+ 𝑀2
�

X
𝑅𝐴 = 𝐹
W = 1261.28 N

+𝗍 ∑ 𝐹𝑦 = 0

𝗍 +∑ƒ𝑦 = 0, −𝑉 + W − 𝑃 − 𝐹𝐹 = 0-shear force.

𝑉2 = 𝑃 + 𝐹𝐹 − W = 0
38
 𝑉2 = 0
𝗍 +∑𝑀𝑎 = 0,

39
 W + (X − 𝐴) − (𝐹𝐹 × X) − 𝑀 = 0
𝑀 = ( 𝐹 𝐹 × X ) − W + ( X − 𝐴)
𝑇𝑎𝑘𝑒, X 𝑚𝑎𝑥 = 𝐿
𝑑𝑀 −𝑃
𝑎 =𝑉
𝑑𝑥 =
𝐿
Mmax = −𝑃
𝑎 =𝑉
�

𝑀2 = (𝐹𝐹 × 450) − 1261.28 + (450 − 70)

�

= (1065.08 × 450) − 1261.28 + (450 − 70)

𝑀2 = 479286.4 − 479286.4 = 0

Therefore, the bending moment and shear force diagram of the handle
P = 196.28N

𝑅𝐴 𝑅𝐵
𝐹𝐹 = 70mm W= 1261.28 N 380mm
1065.08N

743N

74555.6N
196.2N

Figure 4.1: Shear force and bending moment diagram of the handle
From the above diagram, the maximum bending moment is M = 74555.6Nmm.
40
From the bending equation, we find the diameter of handle.
= =
E M σ.......................................................................................................................

R I y
(4.2)

41
From the above equation (4.2), the bending stress is given by,
𝜎 =
𝑀 3
𝐼 × 𝑦 =
𝑀 =� 32
, where z – section modulus = πD

𝐼/𝑦
�
Z

74555.6𝑁 = 74555.6𝑁𝑚𝑚
150𝑀𝑝𝑎 = 𝑚𝑚 0.0982𝑑3
𝜋𝐷
3

32
14.732𝑑 = 74555.6𝑁𝑚𝑚
3

74555.6𝑁𝑚𝑚
𝑑3 = =
5061.479 14.732
𝑑 = √5061.479
3
= 17.3𝑚𝑚
Therefore diameters of the handle say 19𝑚𝑚; total length of the handle is 450mm

Stress analysis of handle

 normal stress(𝜎𝑛)
Stress subjected on the handle is normal stress and shear stress.

𝜎𝑛 =
𝐹

𝐴
,

𝐴 = 𝜋(𝑑ℎ) 3.14 *
(19𝑚𝑚)2 = 283.385𝑚𝑚2
=
2

4 4
𝐹
196.2
𝜎𝑛 = = = 0.6924𝑀𝑝𝑎
𝐴 283.385
Then it is safe 𝜎𝑛 < 𝜎𝑡 that is 0.6924𝑀𝑝𝑎 < 150𝑀𝑝𝑎

3𝑇ℎ
 shear stress(𝑟ℎ)

𝑟ℎ =
𝐿 𝑑3ℎ
3 * 74555.6 ℎ

𝑟ℎ = = 0.072𝑀𝑝𝑎
450 * (19)3
Then it is safer 𝑟ℎ < 𝑟 that is 0.073𝑀𝑝𝑎 < 75𝑀𝑝𝑎

42
4.2.2. Design of Handle Clevis (link)

As shown figure 4.8 below, force acting on link or handle clevies.

1065.08 N

1261.28 N

Figure 4.2: Free body diagram handle clevis

Material selected for the handle clevis is SA 106 with

Ultimate yield stress = 206𝑀𝑝𝑎 then,

 permissible tensile stress(𝜎𝑡) by taking factor safety (ƒ𝑠) = 2, we use ultimate yield
strength because of the mild or low carbon steel is ductile material

𝜎𝑡 = Ultimate yield 206

stress = =
103𝑀𝑝𝑎 2
ƒ𝑠

stress(𝜎𝑡) 1
 Permissible share stress (𝑟) is one-half permissible tensile stress of

𝑟 = (permissible tensile stress ) = 0.5 * 103 = 51.5𝑀𝑝𝑎

2
Net force acting on the handle clevis is the resultant of the two forces. That’s
𝐹𝑛𝑒𝑡 = 1261.28 𝑁 - 1065.08 𝑁 = 196.4 𝑁

Since the handle is going to be put in to it for operation. Its internal diameter will be equal

to, Internal diameter of handle clevis = handle diameter + clearance take c =

1mm

= 19 𝑚𝑚 + 1𝑚𝑚
= 20 𝑚𝑚
𝐹 196.2 𝑁
𝜎=
=
𝜋×(𝐷2−202

𝐴 )4
43
 196.2 𝑁
= = 103 𝑀𝑃
𝜋×(𝐷2)−400)
4

44
 324.99𝐷2 − 129996 = 784.8
130780.8
𝐷2 = 324.99 = 402.4

𝐷 = 20.6 𝑚𝑚, For convenience take 21 𝑚𝑚

4.2.3. Design of Plunger

The material, we have selected for the plunger is AISI 1010 CD having
Ultimate tensile stress = 370𝑀𝑝𝑎
Ultimate yield stress = 300𝑀𝑝𝑎 𝑇ℎ𝑒𝑛,
 permissible tensile stress(𝜎𝑡) by taking factor safety (ƒ𝑠) =2.5, we use ultimate yield
strength because of the mild or low carbon steel is ductile material

𝜎𝑡 = Ultimate yield 300

stress = =
100𝑀𝑝𝑎 3
ƒ𝑠

stress(𝜎𝑡) 1
 Permissible share stress (𝑟) is one-half permissible tensile stress of

𝑟 = (permissible tensile stress ) = 0.5 * 100 = 50𝑀𝑝𝑎

2
Let, W - load acting on plunger =
1261.28𝑁. Considering compressive stress
on the plunger, Calculating the area of the
plunger, 𝐴𝑃
W 1261.28
σall = N
P =
A AP
W 1261.28 N
AP = = =
σall 12.61mm2 100 MPa
From the area equation, we can find the diameter plunger (𝐷𝑝)as follows;
π × 𝐷𝑝2 2
𝐴𝑃 = = 12.61 mm
4
𝐷𝑝 = 4.1𝑚𝑚 𝑠𝑎𝑦𝐷𝑝 = 5𝑚𝑚
Pressure developed in the plunger, P = = = 64.27Mpa
W 1261.28N
P 𝐴𝑝 π×𝐷𝑝
2
4

Assuming the slenderness ratio of 30, let’s calculate the length of the plunger
Slenderness ratio =
𝐿 = 20, 𝐿 = 20 × 𝑅 = 30 × 2.5𝑚𝑚 = 75 𝑚𝑚
𝑅

45
Therefore the length of the plunger is 75 mm

46
4.2.4. Design of Liner Tube

Material selected for the liner tube is Low alloy steel AISI 1010
having Ultimate yield stress =300Mpa Then,
 permissible tensile stress(𝜎𝑡) by taking factor safety (ƒ𝑠) =2.5, we use ultimate yield
strength because of the mild or low carbon steel is ductile material

𝜎𝑡 = Ultimate yield 300

stress = =
120𝑀𝑝𝑎 2.5
ƒ𝑠

stress(𝜎𝑡) 1
 Permissible share stress (𝑟) is one-half permissible tensile stress of

𝑟 = (permissible tensile stress ) = 0.5 * 120 = 60𝑀𝑝𝑎

2
Assuming a clearance of 1mm between the plunger and liner tube, c= 1mm
Diliner = Dplunger = (2 × clearance)
= 5𝑚𝑚 + (2 × 1𝑚𝑚) = 7𝑚𝑚
Considering the liner tube as thin walled pressure cylinder, 𝑡 < 𝐷 and using the hoop stress
1

10

Pp × Diliner
equation as the hoop stress is dominant factor than the longitudinal stress to find the thickness,

𝜎𝐻 =
2×t
Pp × D 64.27MPa × 7
𝑡 = mm = 1.87mm = say 2mm
2×σ
2 × 120 MPa
=

Then, outer Diameter of liner:-

D0liner = Diliner = (2 × t)
D0liner = 7 + (2 × 2mm) =
Stress analysis 11mm

 Checking for the hoop

stress,

𝜎𝐻 = Pp × D 64.27MPa × 7 mm
= = 74.99Mpa
2×σ 2 × 3 mm
𝜎𝐻(74.99Mpa ) < (𝜎𝑡(120𝑀𝑝𝑎), therefore it is safe.
 Checking for the longitudinal stress,
𝜎𝑡 = =
2
σH

47
74.99 = 37.49Mpa
2
Since, 𝜎𝐿(37.49Mpa) < (𝜎𝑡(120𝑀𝑝𝑎), therefore it is safe.

48
4.2.5. Design of Solid Ram

It is a linear actuator which converts fluid power into mechanical power.

As shown figure 4.9 below, 3D solid ram or piston

Figure 4.3: Solid ram or piston

The Material, we have selected for the solid Ram (Piston) is Alloy steel.
Type of Alloy steel, used in this project is AISI 1015 having
Ultimate yield stress =313.7Mpa Then,
 permissible tensile stress(𝜎𝑡) by taking factor safety (ƒ𝑠) = 3, we use ultimate yield
strength because of the mild or low carbon steel is ductile material

𝜎𝑡 = Ultimate yield 313.7

stress = =
104.55𝑀𝑝𝑎 3
ƒ𝑠
𝜎𝑦
)= = = 104.56𝑀𝑝
 Crushing stress(𝜎 313.7

𝑐𝑟 𝐹𝑆 3

stress(𝜎𝑡) 1
 Permissible share stress (𝑟) is one-half permissible tensile stress of

𝑟 = (permissible tensile stress ) = 0.5 * 104.55 = 52.28𝑀𝑝𝑎

2
The Pressure created by the pump (PP) , 𝑃𝑃 = 𝐹𝐹 /𝐴𝑝
𝜋(𝑑2
𝑝)
Where, 𝐴𝑃 =
4
W 1261.28
𝜎𝑎𝑙𝑙 = =
𝐴𝑝 𝑁
𝐴
𝑝
W 1261.28 N
𝐴𝑝 = = =
𝜎𝑎 12.61mm2 100 MPa
𝑙𝑙
49
 π(𝑑𝑝)2
 From the area equation can find the diameter as follows;
2
𝐴𝑝 = = 12.61 𝑚𝑚
4
𝑑𝑝 = 4.1 𝑚𝑚 𝑠𝑎𝑦𝑑𝑝 = 5𝑚𝑚

50
 Pressure developed in the plunger, 𝑃 = = = 64.27MPa
W 1261.28N
𝑝

𝐴𝑝 π(5)2
4

Assuming the slenderness ratio of 30, let’s calculate the length of the plunger.
Slenderness ratio =
𝐿 = 20, 𝐿 = 20 × 𝑅 = 30 × 2.5𝑚𝑚 = 75 𝑚𝑚


F
By considering Pascal’s law, we can specify the area of the cylinder of the piston.
𝑃=
A
, where F- Load applied and A- Area

Pascal’s law states that the pressure force applied to confined liquid is transmitted equally in all
directions. i.e. the pressure in the hydraulic fluid is the same every where in the system but the force at
the cylinders will be proportional to their respective crosssectional area.
According to Pascal’s principles, we know that the maximum force to be pushed by the ram is W and
Pressure in the ram (𝑃𝑐) , after that calculate diameter of solid ram (Dsr)
𝑃 = 𝐹/𝐴

W
 According to Pascal’s principles
Pp = Pc =
Ac
5000
64.27Mpa = N
A
c
𝐴𝑐 = 77.79𝑚𝑚2
W = Capacity = 5000N

𝜋 (𝐷2 )
Threfore, the diameter of solid ram (DSR)

𝐴𝑐 = 𝑠𝑟
4
4 × 𝐴𝑐
𝐷𝑠𝑟
2
=
𝜋
4 × 77.79
𝐷2𝑠𝑟= √
𝜋
Dsr = 9.95mm = 10mm
 From above diameter solid ram, design other dimension and select as material.
Dimensions
 We assume active length of solid ram= 200mm.
 From above, 𝐷𝑠𝑟 = 10𝑚𝑚
 The end fixture coefficient= 0.25
51
Checking the solid Ram whether it buckle or not, using Rankine garden formula.
According to Rankine’s formula, buckling load,

52
 𝜎𝑐𝑟 × 𝐴𝐶
W𝑐𝑟 =
1+ *
( )
1 𝐿 2

𝑎 𝐾
Where, 𝑎 = 𝑅𝑎𝑛𝑘i𝑛𝑒’𝑠 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 =
𝜎𝑐

𝜋2 ×𝐸

= 320𝑀𝑝𝑎 and 𝑎 =
1

𝜎𝑐
From the table A1 for mild stress, values for
750
0
1
The Rankin constant for solid ram(𝑎) =
= 0.00053
= 187
1
7500*0.25


5
𝜋 𝜋
𝐴 = 𝐷 2 = 102 = 78.54𝑚𝑚2
4 𝑆𝑅 4
𝐶
1 1
= = 0.00053𝑚𝑚2
𝑎 1875
4
, 𝐼 =
𝜋 𝐷
,𝐾
𝐿 𝐼

= 𝐴 64
� ,
𝐾

𝜋(10)
4
𝐼 = � 64 4 = 490.625𝑚𝑚4
𝑠𝑟
= 64
� 490.62
� 5 = 6.25𝑚𝑚
𝐾= =
� 78.54
�𝐿 200
= = 32
𝐾
6.25
Therefore, the rankine load for the solid ram (𝐹𝑅𝐿)=
𝜎𝑐𝑟 * 𝐴𝐶 320 * 78.54
W𝑐𝑟 = =
1+ * = 16291.22𝑁 = 16.291𝐾𝑁
1 + 0.00053 * (32)2
( )
1 𝐿 2

𝑎 𝐾

The permissible buckling load =16.291𝐾𝑁 = 5430.33𝑁, it is buckling load.

3


Therefore since the load (5000 𝑁) is less than the permissible buckling loads(5430.33 𝑁), it
is safe from buckling condition.

4.2.6. Design of Cylinder

 first, we select the material for cylinder

Our selection material for the cylinder is low Alloy steel and type of Alloy steel, we used is SA-210.
 Ultimate yield strength = 270𝑀𝑝𝑎

53
  And we take factory of safety (𝐹𝑆) = 2.5
Therefore,
𝜎𝑦
(𝜎 = = = 110.4𝑀𝑝𝑎
276
)=
𝜎
 Allowable tensile stress
𝑎𝑙𝑙 𝑎𝑙𝑙 𝐹 2.5
𝑆
𝜎𝑦
= = = 110.4𝑀𝑝𝑎
276
(𝜎 )=
𝜎
 Crushing stress
𝑐𝑟 𝑐𝑟 𝐹 2.5
𝑆

54
Dimensions
 Inner diameter of the cylinder = diameter of flanged parts on solid ram = 10mm
Assume the cylinder as thick walled pressure cylinder, 𝐷 ≥ 20
𝑡


By using hoop stress equation, we can get the thickness of the cylinder
By using hoop stress, we can get the thickness of the cylinder
Thickness of the cylinder (𝑡)
pc


𝜎all =
2t

𝐹 5000 5000
Where,

𝑃𝑐 = =𝜋 = 𝜋 = 63.66𝑀𝑝𝑎
𝐴 4 * (𝐷𝑆𝑅 )
2
4 * (10)
2

𝑝𝑐 * 𝐷
𝑡
= 2𝜎𝑎𝑙𝑙

𝑡 = 63.66 *
= 3.5𝑚𝑚 ≈ 4𝑚𝑚
10 2 *
110.4
𝑡 = 4𝑚𝑚,for safeness
Therefore,𝐷 = = 2.5𝑚𝑚, it is satisfies thick cylinder rule.
10

𝑡 4

 Outer diameter of the cylinder can be (𝐷𝑐𝑜 )

𝐷𝑐𝑜 = 𝐷𝑐i + 2𝑡
𝐷𝑐𝑜 = 10 + 2 * 4 = 18mm
Checking, the cylinder will buckle or not, by using Ranikne –cordan formula
 the active length of the cylinder (𝐿) = 400mm
 diameter of the cylinder (𝐷𝑐i) =10mm and (𝐷𝑐𝑜) = 18mm
 the end fixture coefficient = 0.25
1
75000
 the rankine constant = a =
1

= 187 = 0.00053
75000*0.25 1
 the rankine constant for the cylinder =

the rankine load for the cylinder(𝐹𝑅𝐿)= 5

𝜎𝑐𝑟 * 𝐴𝐶


𝐹𝑅𝐿 =
1 + ( )2
𝐿
1 𝐾
𝑎
𝜋
𝐴 = (𝐷 2 − 𝐷 2)
4 𝑐𝑜
𝐶 𝑐i

55
 𝜋
= (182 − 10
𝐴𝐶 175.93𝑚𝑚
2
) =
2
4

56
 1 1
= = 0.00053𝑚𝑚2
𝑎 1875
𝐿
𝐼 𝜋𝐷4 −𝐷4
𝐾 =
𝐾 𝐼 = 64𝑐𝑜 𝑐𝑜
,
𝐴,
𝜋𝐷4 − 𝐷4 𝜋184 − 104
𝐼 = 𝑐𝑜 𝑐𝑜
= = 4662.123𝑚𝑚4
6 64
4
� 4662.123
� = =
𝐾 = 26.499𝑚𝑚2 175.93
�
�
𝐿 400
= = 15.1
𝐾
26.499
Therefore, the rankine load for the solid ram(𝐹𝑅𝐿) =
𝜎𝑐𝑟 * 𝐴𝐶 110.4 * 175.93
𝐹𝑅𝐿 = = = 17328.59𝑁
1 + 𝐿* 1 + 0.00053 * (15.1)2
1
( )2
𝑎 𝐾

 The permissible buckling load

= 17328.59
𝐾𝑁 = 6931.437𝑁
2.
5
So that, 5000𝐾𝑁 < 6931.437𝑁, it is safe
4.2.7. Design of Reservoir Cylinder

As shown figure 4.10 below, 3D reserivoir cylinder

Figure 4.4: Reservoir cylinder

First, we select the material for reservoir

57
Our selection material for the cylinder is carbon steel and type of carbon steel, we used is SA-106.
 Ultimate yield strength = 207𝑀𝑝𝑎
 And we take factory of safety (𝐹𝑆) = 3
Therefore,
𝜎𝑦
(𝜎 = = = 69𝑀𝑝𝑎
207
)=
𝜎
 Allowable tensile stress
𝑎𝑙𝑙 𝑎𝑙𝑙 𝐹𝑆 3
𝜎𝑦
= = = 69𝑀𝑝𝑎
207
(𝜎 )=
𝜎
 Crushing stress
𝑐𝑟 𝑐𝑟 𝐹𝑆 3

58
Dimensions
v0lumes s0lid
ram(𝑉𝑝)


Diameter of solid ram(𝐷𝑆𝑅)

𝜋 ×
� 𝐷2
= �* 𝐿
� 𝑝
4
𝜋 * 𝐷2 𝜋*
𝑉𝑝 = � × 𝐿
= (10)2 × 400 = 31415.93𝑚𝑚
3

4
4
 assume the height of fluid reservoir (𝐻𝑅) =
450mm Then, volume of reservoir (𝑉𝑅) is
𝜋(𝑑2 − 𝐷2 )
𝑉𝑅 = × 𝐻𝑅
𝑅 𝐶0

4
 Inner diameter of the Reservoir (𝑑𝑅)
𝜋 (𝑑2 − 𝐷2 )
𝑉
𝐻 = × 𝜋(𝑑𝑅2 −
𝑅 182) × 450 = 31415.93
=
4 4
𝑅 𝑅
31415.93 * 4
𝑑𝑅 = (18) + = 412.888𝑚𝑚2
2 2

450 * 𝜋
𝑑𝑅 = √412.888𝑚𝑚2 = 20.32 ≈ 21𝑚𝑚, for safeness
 Then, outer diameter of reservoir(𝐷𝑅) is assuming t =4mm
𝐷𝑅 = 21 + (2 × 4) = 29
Quantity of fluid required
 the volume of fluid (𝑉𝑅)
𝑉𝑅 = 31414.93𝑚𝑚2 * 10−9 = 3.142 * 10−5𝑚3
𝑉𝑅 = 3.142 * 10−5𝑚3 = 3.142 * 10−2 liter
𝑉𝑅 = 3.142 * 10−2 liter
4.2.8. Design of Screw

The material selected for the screw is AISI HR 1006 having

Deciding factor of safety to be 2.5 as it is the major part of the machine which holds the total load of
operation that’s 5000𝑁.
Allowable compressive stress of the screw material = 𝜎𝑎𝑙𝑙 = = 68 𝑀𝑃𝑎
𝜎𝑦 =
170𝑀𝑃𝑎
2.5
𝐹.𝑆

59
 Allowable shear stress of the screw material = 𝑎𝑙𝑙 =
𝜎𝑦

2×𝐹.𝑆 =
170 = 34 𝑀𝑃𝑎
𝑀𝑃𝑎
2×2.5

Considering direct compressive stress, let’s find the code diameter of the screw. But since the screw
has an internal hole for solid ram it is considered as holed screw. That’s

60
 W W
𝜎𝑐 = 𝜎𝑎𝑙𝑙 = (𝑑2- 𝑑2)
= 𝜋 𝐴
4 𝑐 𝑟
Where,𝑑 – core diameter of screw, 𝑑 – diameter of solid ram + clearance, take 𝑐𝑎𝑠 1.5𝑚𝑚
2 2
𝑐 𝑟

= 10 𝑚𝑚 + 1.5 𝑚𝑚 = 38.5 𝑚𝑚𝑠𝑎𝑦 39𝑚𝑚

W ×4
𝑑2 = + 𝑑2
𝑐
π × σall 𝑟
5000 N × 4
𝑑2 = + (12mm)2 = 237.668mm2
𝑐
π × 68MPa
dc = 15.42mm, say 17mm f0m standard table A3
From the table A3, the normal series screw thread has a core diameter of 55 mm and other diminutions
are:-
 Nominal diameter or outer diameter, 𝑑𝑜 = 22 𝑚𝑚
 Major diameter for the nut 𝐷 = 22.5 𝑚𝑚
 Pitch of the thread (𝑝) = 5 𝑚𝑚
 Area of core (𝐴𝑐) = 227 𝑚𝑚

𝜋𝑑

 Depth of the thread of screw(h) = 2.5mm

Figure 4.5: Development of Screw

17 +
Mean diameter of the screw (𝑑),
dc +
𝑑 = 22 = 19.5𝑚𝑚
d0 =
2
2
From the tableA2selects as average quality of materials and workshop, and average running
conditions, and take coefficient of friction (𝜇) = 0.18.
 Friction angle, 𝜑 = 𝑡𝑎𝑛 − 1(𝜇)

61
 = 𝑡𝑎𝑛 − 1 (0.18) = 10.2°
5mm
Helix angle , 𝛼 = tan−1 ) = tan−1
𝑝

( (𝜋×19.5 mm) =

𝜋𝑑

62
  Effort applied at the circumference of screw thread during pulling operation,
𝑃 = W 𝑡𝑎𝑛 (𝛼 + 𝜑)
= 5000 𝑁 × 𝑡𝑎𝑛 (4.667º + 10.2º)
𝑃 = 1327.31 𝑁

tan a
 Efficiency of square threaded screw, η

η= =
tan(a + φ)
tan 4.6670
= =
tan(4.6670 + 10.20)
η = 0.3074 = 30.74 %
Maximum efficiency of screw thread, (5max)
1 − sin φ 1 − sin 10.2


5max = = = 69.9%
1 + sin φ 1 + sin 10.2
 Number of threads of the nut is calculated, (𝑛)

𝑃𝑏
, from table A5, for hand press, take 𝑃𝑏 = 22 𝑀𝑃𝑎
= πdmt
W

n 5000 N
𝑛= = 1.485, take n = 4
π × 22mm × 2.5mm × 22MPa

Stress analysis

 Checking for shear stress,

The threads of the screw at the core or root diameter and the threads of the nut at the major diameter
may shear due to the axial load. Assuming that the load is uniformly distributed over the threads of

W
cross arm, we have shear stress for screw,

𝑟𝑠𝑐𝑟𝑒w =
πdmtn
pitch 5
tn = = = 2.5𝑚
2 2
5000 N
𝑟𝑠𝑐𝑟𝑒w = = 9.36Mpa
𝜋 × 17mm × 2.5mm
×4

Since,𝑟𝑠𝑐𝑟𝑒w (9.36𝑀𝑃𝑎) < 𝑟𝑎𝑙𝑙(34 𝑀𝑃𝑎), therefore it is safe.

 Maximum compressive stress in the screw,

63
 W 5000 N
𝜎𝑐 = = 227 mm2= 22.026MPa
Ac
Since,𝜎𝑐 (22f.026𝑀𝑃𝑎) < 𝜎𝑎𝑙𝑙 (68 𝑀𝑃𝑎), therefore it is safe.

4.2.9. Design o Jaws

For this project the number of jaws is three as it is been said earlier. Thus the total load is distributed in
to three equal jaws. That’s each jaw experience one third of the total load, W and can decided the
curvature based assembling method the drum brakes and within its dimension.

As shown figure 4.12 below, force acting on the jaw.

Figure 4.6: Free body diagram of jaw

The material selected for the jaw is SAE 1015 HR which having
Ultimate yield stress = 109Mpa Then,
 permissible tensile stress(𝜎𝑡) by taking factor safety (ƒ𝑠) = 5 due to high exposure for high load,

𝜎𝑡
= = 38𝑀𝑝𝑎
190

=
Ultimate yield
stress 5
ƒ
𝑠

stress(𝜎𝑡) 1
 Permissible share stress (𝑟) is one-half permissible tensile stress of

𝑟 = (permissible tensile stress ) = 0.5 * 38 = 19𝑀𝑝𝑎

64
2
Considering equilibrium condition, ∑ 𝐹𝑦 = 0

65
 𝑅𝑦 =
W

3
=0,
W 5000 𝑁
𝑅𝑦 = = = 1666.667 𝑁
3 3
Since there is no any other force acting on the jaw, 𝑅𝑦is taken as the only load acts the jaw. Now

𝑅𝑦
using the allowable stress of the jaw material, let’s calculate the dimensions of the jaw.

𝜎𝑎𝑙𝑙 =
𝐴
Where, 𝐴j- area of the
jaw
𝐴j = 𝐿 × W

Ry 1666.667 N
Assuming the width of the jaw = 12 mm and its height = 250mm.

𝜎𝑎𝑙𝑙 = = = 38Mpa
L × L × 12 mm
W
1666.667N
L= = 36.54mm 𝑠𝑎𝑦 37𝑚𝑚
38 MPa × 12
mm
Stress analysis
A jaw bracket with a rectangular cross-section with the depth of the cross-section the force P acting on
the bracket at 60° to the vertical is1666.667𝑁. The material of the bracket is SAE 1015 and the
factor ofsafety is 5 and yield stress of the material is 190 𝑀𝑝𝑎 then dimensions of the cross-section
of the bracket by consider maximum principal stress theory of failure. The stress is maximum at point
A in section XX. The point is subjected to combined bending and direct tensile stresses.
The force P is resolved into two components: horizontal component Ph and vertical component Pv.
𝑃ℎ = 𝑃 𝑠i𝑛60° = 1666.67 𝑠i𝑛60° = 1443.38 𝑁
𝑃𝑣 = 𝑃 𝑐𝑜𝑠60° = 1666.67 𝑐𝑜𝑠6𝑜° = 833.335 𝑁
The bending moment at section XX is given by,
𝑀𝑏 = 𝑃ℎ × 37 + 𝑃𝑣 × 250

= 1443.38 × 37 + 833.335 × 250

= 53405.06 + 208333.75 𝑁𝑚𝑚

= 261738.81 𝑁𝑚𝑚 = 261.74

208333.35 × (𝑡)
𝜎𝑏 = 𝑀𝑏 ×
( (𝑡)(2𝑡)3)
1
𝑦/𝐼 = 12
312500.025/𝑡3𝑁/𝑚𝑚…………………………….……………………………………4.3
66
 Length of the jaw is 250mm.
 curviture at point to top (hieght tip) = 37mm.

67
  width of the jaw is 12mm.

direct tensile stress due to component h is given by,

𝑝h
1443.3
𝜎𝑡 = = 8
𝐴
2𝑡
2

721.69 𝑁⁄
𝑚𝑚2
…………………………………..………………………….……………..4.4
𝑡2

The vertical component P induces shear stress at section XX. It is however, small and neglected. The
resultant tensile stress is maximum at point A is given by
312500.02 721.6
𝜎𝑚𝑎𝑥 = 𝜎𝑏 + 9
𝜎𝑡 = 𝑡3
+ 𝑡2
𝑠𝑢𝑡 190
The permissible tensile stress is given by,
= 38Mpa
𝜎𝑚𝑎𝑥 = = 5
ƒ𝑠
312500.02721.69
Equating the two equation (4.1) and (4.2),

+ = 38Mpa
𝑡3 𝑡2
38𝑡3 − 721.69𝑡 - 312500.02 = 0
𝑡3 − 18.99𝑡 - 8223.68 = 0
Solving the above cubic equation by trial and error method,
𝑡 = 20.456 𝑚𝑚 = 21𝑚𝑚
The dimensions of the cross-section are 21 x 42 m because the thickness of width is twice the thickness
of the cross section.
4.2.10. Design of
Plates For the jaw

 The Ultimate yield strength = 207𝑀𝑝𝑎

 And we take factory of safety (𝐹𝑆) = 4
Therefore,
𝜎𝑦
(𝜎 = = = 51.75𝑀𝑝𝑎
207
)=
𝜎
 Allowable tensile stress
𝑎𝑙𝑙 𝑎𝑙𝑙 𝐹𝑆 4
shear stress (𝑟 ) = = 25.875𝑀𝑝𝑎
51.75

𝑠 2

68
As shown figure 4.13 below, force acting on the jaw plate

Figure 4.7: Force acting on the jaw plate

From the jaw design, tension force p on the plate is equal to half of the force acting on the jaw. Using
this force let calculate the dimensions of plates.

The services factor is the products of load factor (k1) lubrication factor (k2) and rating factor (k3)
the value of these factor are taken as follow [11].
1. Load factor (k 1 ) = 1, for constant loads
= 1.25 for variable load with mild shock
= 1.5 for heavy shock load
2. Lubricating factor (k2) = 0.8, for continuous lubrication
= 1 for drop lubrication
= 1.5 for periodic lubrication
3. Rating factor (k3) = 1, for 8 hour per day
= 1.25 for 16 hour per day
= 1.5 for continues services
Now the correction factor or over load factor, c will be;𝑐 = 1.55
having the concentration factor the design pressure, Рd should be considered to the overload for plunger
design.
P𝑑 = 1.55𝑝
𝑃 = 1.55 × 0.5 × f0rce 0n the jaws = 1.55 × 0.5 × 1666.667N =
1291.66 N and T0tal f0rce( F) = 2P = 2583.33 N
and assuming 𝑡 = 4 mm
𝑚𝑚 𝐹 F 2583.33
𝜎 =
N
= =
𝐴 L×t L ×4
69
= 51.75Mpa

70
 𝐿 = 16.2𝑚𝑚 = 17𝑚𝑚
For the fulcrum
The material selected for the fulcrum plate is same as for the jaw ones.
Here F is equal to force on the fulcrum of the handle. That’s is
F = 1065.08 N. Assume t = 2 mm
�
� = 𝐹 1065.08
𝑁
𝜎= = 69 𝑀𝑃𝑎
𝐿 × =
𝑡 𝐿 ×2
𝑚𝑚
�
�

𝐿 = 7.7 𝑚𝑚 𝑠𝑎𝑦 8𝑚𝑚

4.2.11. Design of Spring for Returning Jaw

The type of spring used in this project is tensional type spring. In this case it used to retract the
withdrawn ram or piston after the operation in conjunction with the valve.

The material selected for the spring is carbon steel having

 (allowable shear stress) = 800 𝑀𝑃𝑎

 G (modulus of rigidity) = 80 𝐾𝑁/𝑚𝑚2
 E (modulus of elasticity) = 210 𝐾𝑁/𝑚𝑚2
As shown figure 4.14 below, 3D of end Connections for Tension Helical Spring

Figure 4.8: End Connections for Tension Helical Spring

Calculating parameters of the spring,
Let diameter of the spring wire 𝑑 = 10 𝑚𝑚 and
Mean diameter of the spring (D) = 𝑑i𝑎𝑚𝑒𝑡𝑒𝑟𝑜ƒ𝑠𝑜𝑙𝑑𝑟𝑎𝑚 + 1𝑚𝑚𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 =
10 𝑚𝑚 + 1 𝑚𝑚 = 11 𝑚𝑚
index (C) = =
𝐷 11
𝑚𝑚
Spring = 1.1
𝑑 10 𝑚𝑚

From table A4 select as square and ground ends,

71
 total number of turns (𝑛') = 𝑛 + 2
 Solid length (𝐿𝑠) = (𝑛 + 2)𝑑 and free length (𝐿ƒ) = 𝑝 × 𝑛 + 2𝑑.

72
But free length of the spring is equal to the length of the ram up to the flange. Thus take Ls= 200 mm
and assume, 𝑛 = 18.
 Total number of turns ( 𝑛') = 𝑛 + 2 = 18 + 2 = 20

Lf − 2d
Pitch of coil ( p)
200 mm − 2 ×
𝑃= = = 10 𝑚𝑚
n 10mm
18
 Deflection of the spring ( δ )
8W × 3C × 8 × 5000 𝑁 × (1.1)3
n × 18 = 1.1979𝑚𝑚
δ= =
G×d 80,000 𝑁/𝑚𝑚2 ×
10
𝛿 1.1979
 Deflection per active turn

𝑚𝑚 = 0.05989 𝑚𝑚
=
n 20
 From the relation below lets calculate solid length of the spring,
𝐿𝑠 = Solid length + Maximum compressing+ Clearance between adjacent coils
(or clashallowance.
= 𝐿𝑠 + 𝛿𝑚𝑎𝑥 + 0.15 𝛿𝑚𝑎𝑥
S𝑢bstituting 𝛿 = 𝛿𝑚𝑎𝑥 = 48.28 𝑚𝑚 in the above formula to find the solid length
𝐿𝑠 = 𝐿ƒ - 𝛿𝑚𝑎𝑥 − 0.15 𝛿𝑚𝑎𝑥
= 200 𝑚𝑚 - 1.1979𝑚𝑚 - 0.15 × 1.1979 𝑚𝑚 = 198.62 𝑚𝑚
Stress analysis
 Maximum shear stress induced,

0.615
Know that Wahl’s stress factor K considering the effect of curvature,
4W −
𝐾 = 1 +
𝐶
4W −
4
4 × 5000𝑁 − 0.61
1 5 = 1.559
= +
4 × 5000 𝑁 1.1
−4

𝐾×8W×𝐶
Then maximum shear stress induced in the wire (τ)

𝜏=
π × d2

𝜏=
73
1.559 × 8 × 5000𝑁 × = 218.45 𝑀𝑃𝑎
1.1 π × (10)2

Since the maximum shear stress (218.45 𝑀𝑃𝑎) < 𝑎𝑙𝑙(800 𝑀𝑃𝑎), it is safe.

74
4.2.12. Design of Cross Arm
As shown figure 4.15 below, 3D of crossd arm.

The material selected for the cross arm is cast iron having a tensile strength of 280 𝑀𝑃𝑎. Factor
Figure 4.9: Crossed arm

of safety is taken as 2.5.

Allowable tensile strength 𝜎𝑎𝑙𝑙 = 280/2.5 = 112 𝑀𝑃𝑎
Assuming that the 3 extension of the cross arm shares the load equally,
Using direct tensile stress lets calculate dimensions of the cross arm.

𝜎𝑎 , Where,𝑙𝑜𝑎𝑑 = 5000 𝑁
𝑙𝑙
=
load
5000
are
a l0a
d Area = N = 44.64mm2
=
112
MPa
σall

π × (D2 −
30c2) = 44. .64 mm2
A=
4
4 × 44.64
D =
2
+ 302 = 956.84
cr

Dcr = 31 mm take D = 33mm

π

Stress analysis

From selecting material for crossed arm is cast iron, 𝑑𝑜 = 33𝑚𝑚 and 𝑑i =29mm
Contact stress on crossed arm

 young modulus = 210𝐺𝑝𝑎

 Poisson ratio= 0.35
 Yield strength = 280Mpa
Then, horizontal contact equations

75
Semi contact width or contact
radius
a. Line contact analysis

76
 Width (2b) and load on reservoir ( )
𝐹1

1𝑚𝑚

𝐹1
= 5000 𝑁⁄𝑚𝑚
1𝑚𝑚
Where,
𝐹1𝑟
𝑏 = 2 × √( )
𝜋𝐸
𝐹1𝑟 5000 * 16.5
𝑏=2×√(
𝜋𝐸 √( × 210 * 10)3 =
) = 23.14
𝑏 = 0.707𝑚𝑚
 Maximum contact pressure or hertz stress(𝑝𝑐)

𝑝𝑐 𝐹1 * 𝐸
= √ 𝜋𝑟

5000 * 210 * 103

𝑝𝑐 = √ = 4500.67𝑁
𝜋 * 16.5
Mean contact pressure(𝑝𝑚)
𝐹1


𝑝𝑚 =
5000 2𝑏
𝑝𝑚 = = 3536.067𝑁
2 * 0.707
 Maximum Shear stress (𝑟𝑚𝑎𝑥)
𝑟𝑚𝑎𝑥 = 0.3 × 𝑝𝑐 , where at 𝑥 = 0
𝑟𝑚𝑎𝑥 = 0.3 × 4500.67 = 1350.201𝑚𝑝𝑎
 Maximum tensile stress (𝜎𝑚𝑎𝑥)
𝜎𝑚𝑎𝑥 = 𝑧𝑒𝑟𝑜, Because not stretched.

Diameter 2b and load or actuation force ( 𝐹𝑠)

b. Circular contact stress

𝐹𝑠 = 5000N
 Semi contact width or contact radius (𝑏)
3𝐹𝑠𝑟
𝑏 = √(
3

)
4𝐸
33 × 5000 * 16.5
𝑏 = √( )=
0.668𝑚𝑚 4210 × 103
 Maximum contact pressure or hertz stress(𝑝𝑐)
1
6𝐹𝑠 × 𝐸2
3

𝑝𝑐 = √(
𝜋 )
𝑟2
1 3 6 × 5000(210 * 103)2
𝑝𝑐 = √(
3.14 ) = 4893.79𝑁
16.52

77
 pressure(𝑝𝑚) 𝐹𝑆
 Mean contact

𝑝𝑚 =
5000 𝜋𝑏
2

𝑝𝑚 = =
𝜋(0.668)2
3568.52𝑁
 Maximum Shear stress (𝑟𝑚𝑎𝑥) at r =0
𝑟𝑚𝑎𝑥 = 0.3 × (𝑝𝑐)
𝑟𝑚𝑎𝑥 = 0.3 × 4893.79 = 1468.137Mpa
 Maximum tensile stress (𝜎𝑚𝑎𝑥) , 𝑟 = 𝑏 𝑎𝑛𝑑 𝑡 = 0
1
𝜎𝑚𝑎𝑥 = (1 − 2𝑣1)𝑝𝑐
1 3
𝜎𝑚𝑎𝑥 = (1 − 2 * 0.35) * 4893.79 = 489.379𝑀𝑝𝑎
3
4.2.13. Design of
Pins
A. Design of pins at the plunger
This pin is used to retain the plunger relative to the handle socket.
First, we select the material for pin
Our selection material for the pin is alloy steel and type of alloy steel, we used is AISI - 1015
 Ultimate yield strength = 313.7𝑀𝑝𝑎
 And we take factory of safety (𝐹𝑆) = 4
Therefore,
𝜎𝑦
(𝜎 )= = = 78.425𝑀𝑝𝑎
 Allowable tensile stress 313.7

𝑎𝑙𝑙 𝐹𝑆 4
𝜎𝑦
)= = = 39.2𝑀𝑝𝑎
313.7
(𝑟
 Shear stress
𝑎𝑙𝑙 2𝐹 2*4
𝑆

We find diameter based on shear stress

 Depending on shear stress
FF 4FF
𝜎all = =
A 𝜋(d2)
4FF 4 * 2000
d=√ =√ = 5.69mm
𝜋𝜎 𝜋*
all 39.2
 depending on bending

𝑀
stress

𝑍= ,
78
� 𝑎𝑙𝑙
�
Where, 𝑍 = , 𝑀 =
3
𝜋*𝑑 𝐹𝐿
, L = 1.5d
32 4

� 𝜋* 𝐹 * 1.5𝑑
𝑍 = � 𝑑3 =
= 4𝜎𝑎𝑙𝑙
𝜎𝑎 32
𝑙𝑙

79
 𝐹𝑐 * 32 * 1.5
𝑑2 = 4 * 𝜎𝑎𝑙𝑙 * 𝜋 =
𝐹𝑐 * 32 * 2000 * 32 *
1.5 1.5 = 10𝑚𝑚
𝑑 =√ =√
4 * 𝜎𝑎𝑙𝑙 * 4 * 78.2 *
𝜋 𝜋

Therefore, the Pin diameter at the plunger is 10mm by taking larger one and it is length (L) = 1.5 * 𝑑 =
1.5 * 10 = 15𝑚𝑚
B. Design of pin at the link
 This pin is used to retain the link relative to the handle socket.
 first, we select the material for pin
Our selection material for the pin is alloy steel and type of alloy steel, we used is AISI - 1015
 Ultimate yield strength = 313.7𝑀𝑝𝑎
 And we take factory of safety (𝐹𝑆) = 4
Therefore,
𝜎𝑦
(𝜎 )= = = 78.425𝑀𝑝𝑎
 Allowable tensile stress 313.7

𝑎𝑙𝑙 𝐹𝑆 4
𝜎𝑦
)= = = 39.2𝑀𝑝𝑎
313.7
(𝑟
 Shear stress
𝑎𝑙𝑙 2𝐹 2*4
𝑆

We find diameter based on shear stress

 Depending on shear stress
The pin is subjected to double

Fp 2Fp
shear
𝜎 = = = 1800N
F
, where,
all 2A d2 p

2*
d = √ 2F 1800 = 5.4mm
=√
𝜋𝜎
p
𝜋 * 39.2
all
 Depending on bending
stress
𝑍= , Where, 𝑍 = ,𝑀 =
𝑀 𝜋*𝑑3 𝐹𝐿

𝜎𝑎𝑙𝑙
, L = 1.5d
32 4

� 𝜋 * 𝑑3 Fp * 1.5𝑑
𝑍 =
� 4𝜎𝑎𝑙𝑙
= =
𝜎𝑎 32
𝑙𝑙
80
 𝐹𝑝 * 32 * 1.5
𝑑2 = 4 * 𝜎𝑎𝑙𝑙 * 𝜋 =

𝐹𝑝 * 32 * 1800 * 32 *
𝑑 =√ 1.5 = 9.5mm
1.5 4 * =√
4 * 78.425 *
𝜎𝑎𝑙𝑙 * 𝜋 𝜋

81
 Therefore, the Pin diameter at the links is 9.5mm by taking larger one and it is length (L) = 1.5 * 𝑑
= 1.5 * 9.5 = 14.25𝑚𝑚

4.2.14. Design of spring for Discharge and Intake Valve

Taking parameter

 Spring type – helical compression spring

 Type of spring material – carbon steel with maximum spring stress,
𝑟𝑠 = 651𝑀𝑃𝑎 and young’s modules (elasticity) =210GPafrom
table A6.
 Spring index (C) = 2, from graph of stress factor (K) and spring index
(C) graph, figure 4.16.
The values of K for a given spring index (C) may be obtained from the graph as shown in Figure 4.16
below

Figure 4.10: Wahl’s stress factor for helical springs [10].

 From the earlier calculation W=5000N
W𝑠 = 5000N
 The Wahl’s stress factor (K)

𝐾 = +
4𝐶−1
= 4×2−4 +
0.615 4×2−1 0.615
4𝐶−4 𝐶 2 = 2.0575
𝐾 = 2.0575
 The diameter of spring wire (d)
82
 𝐾×8×W×𝐶
The maximum shear stress induced in the wire

𝑟𝑠 =
𝜋𝑑2
𝐾×8×W 2.0575 * 8 *
𝑑2𝐶=
× 5000 * 2 = 80.48𝑚𝑚2
𝜋 × 𝑟𝑠 =
𝜋 * 651𝑀𝑃𝑎
𝑑 = √80.48= 8.97𝑚𝑚 ≈ 9𝑚𝑚
𝑑 = 9𝑚𝑚
 Mean diameter of the coil

𝐷 =𝐶×𝑑 =2*
(D)

9𝑚𝑚
𝐷=
18𝑚𝑚

W 𝐺𝑑
 Deflection of helical spring of circular wire (𝛿)
=
𝛿 8𝐶3 × 𝑛

Then,
8 × 23 × 5 × 5000𝑁
𝛿 = =
210 × 103𝑀𝑃𝑎 × 9𝑚𝑚
1.07𝑚𝑚

𝛿 = 1.07𝑚𝑚
 Total number of turn (𝑁𝑡)
𝑁𝑡 = 𝑛 + 2 ….. For square and spring
𝑁𝑡 = 5 + 2 = 7
𝑁𝑡 = 7
 Free length of the spring
(𝐿ƒ )
𝐿ƒ = 𝑁𝑡 × 𝑑 × 𝛿 + 0.15𝛿
𝐿ƒ = 7 × 9 × 1.07 + 0.15 × 1.07 = 67.57𝑚𝑚
𝐿ƒ = 67.57𝑚𝑚
 The pitch of the coil

ƒ𝑟𝑒𝑒𝑙𝑒𝑛𝑔𝑡h𝑜ƒ𝑡h𝑒𝑠𝑝𝑟i𝑛
(P)

𝑃
𝑔
=
𝑡𝑜𝑡𝑎𝑙𝑛𝑢𝑚𝑏𝑒𝑟𝑜ƒ𝑡h𝑒𝑡𝑢𝑟

83
� −1
67.5
�
𝐿
𝑃= 7 = 11.26𝑚𝑚
ƒ =
7− 7−
1
1
𝑃 = 11.26𝑚𝑚
 Solid length
(𝐿𝑠)
𝐿𝑠 = 𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜ƒ 𝑐𝑜i𝑙 * 𝑑
𝐿𝑠 = 5 × 9 = 45mm

84
 𝐿𝑠 = 45𝑚𝑚
 Spring rate
(𝑘𝑟) W𝑠
𝑘𝑟 =
𝛿
5000
𝑁 = 4672.89 𝑁⁄𝑚𝑚
=
1.07𝑚
𝑚
𝑘𝑟 = 4672.89 𝑁⁄𝑚𝑚
Buckling of completion spring (W𝑐𝑟)
W𝑐𝑟 = 𝐾 × 𝐾𝐵 ( buckling fact0r) × 𝐿ƒ


𝐿ƒ (free length of the spring)

( ), whereas built in end spring which is squared and ground
Therefore the
ratio
𝐷

𝐿 67.57
end spring
= = 3.754 = 4
ƒ 18
�
�
From standard table A7, assume as
= 4, the hinged end spring constant ) = 0.121
𝐿
ƒ

Therefore, � (𝐾𝐵

W𝑐𝑟 = 𝐾 × 𝐾𝐵 × 𝐿ƒ = 4672.89 × 0.121 ×

�

67.57𝑚𝑚 W𝑐𝑟 = 38.21𝐾𝑁

4.2.15. Design of Frame

First, we select the material for design of frame is cast steel which is Cast steel grade - CS640
Ultimate Tensile Strength= 640Mpa
Ultimate Yield Strength=390Mpa
A. Design of Frame -1(support table)

Force analysis for frame -1

𝑅1 W= 490.5N 𝑅2
For designing of the first frame -1, first we give our assumption
 The Weight of drum and weight of extractor machine, 𝑤 = 50𝑘𝑔 = 50 * 9.81 = 490.5𝑁.
85
 The length of the frame(𝐿) = 0.6𝑚
 The width (W) = 0.06𝑚

86
  The height(𝐻) = 0.08𝑚
From above figure, we force analysis is

+𝗍 ∑ 𝐹𝑦 = 0……………………………………………………..............................4.5
Taking resultant force in the y direction:-

𝑅1 + 𝑅2 − 490.5 = 0
490.5𝑁 − 𝑅1 − 𝑅2 = 0..................................................................................(a)
Taking summation of moment at point 1
∑ M@1 unti − cl0 + ve = 0 →.....................................................................4.6
−𝑅2 * 0.6 + 490.5 * 0.3 = 0
−𝑅2 * 0.6 + 147.15 = 0
𝑅2 = 245.25𝑁
Substituting the value of 𝑅2 in equation

490.5𝑁 − 𝑅2 =
“a”

𝑅1
𝑅1 = 490.5 −
245.25
𝑅1 = 245.25𝑁
Finding thickness of frame -1, based on stress analysis
 Based on bending stress y

𝐻 = 80𝑚𝑚

x x

y
Figure 4.11: Section view of frame -1

𝑎𝑟𝑒𝑎(𝐴) = ℎ𝑡.................................................................................................4.7
Moment of inertia at XX

𝐼=
=
𝑡ℎ................................................................................................................................................
𝐼KK 12
4.8

ℎ 2
𝑌=
87
80 = =
40𝑚𝑚 2

Moment (M) =
𝐹𝐿

88
 = =
𝑀 𝜎𝑏 𝐸

𝐼 𝑦 𝑅
………………………………………………………………………4.9

H = 80mmm

300mm W = 490 300mm

Figure 4.12.Neutral axis of x- axis
By using the a above
𝐼 =
𝑡ℎ3................................................................................................................................................................................

12
4.10

𝐼 = 𝑡(80)
𝑡h 3
= 42666.667𝑡
3
=
12
1
2
ℎ
= 40𝑚𝑚
80
𝑦= =
2 2
𝐹 490.5 *
𝑀= 600 = 73575𝑁𝑚𝑚
𝐿=
4
4
M = 73575Nmm

𝑀𝑌 73575 * 40
Substituting the value of moment and equation 4.10 into equation 4.9

𝜎𝑏 = =
𝐼 42666.667𝑡
𝜎𝑏
=
68.8
……………………………............................................................4.11
𝑡

By using maximum distortion theory, we have

𝜎𝑦
𝜎 = = = 55.7𝑀𝑃𝐴 ,
390
𝑏
Where:-
𝐹𝑆 7
𝐹. 𝑆 = 𝑡ℎ𝑒 ƒ𝑎𝑐𝑡𝑜𝑟 𝑜ƒ 𝑠𝑎ƒ𝑒𝑡𝑦 = 7
68.8
𝜎𝑏 55.7
=
68.
𝑡 =9 = 𝑡 69.
= 9
𝜎𝑏
89
 𝑡 = 1.24𝑚𝑚 = 4𝑚𝑚
𝑡 = 4𝑚𝑚
 Based on shear stress
From maximum shear stress theory we
have

𝑟𝑚𝑎 = 𝜎𝑦

𝑥 2×𝐹𝑆
, Where:-
F. S = the fact0r 0f safety = 7

90
 𝜎𝑦 390
𝑟𝑚𝑎𝑥 = = = 27.86𝑀𝑃𝐴
2 × 𝐹𝑆 2×6
We also know that for a rectangular cross-section having area the

Figure 4.13: Cross section of frame -1

1.5𝐹
𝑟𝑚𝑎𝑥 =
𝑡ℎ
𝑟 = = =
1.5𝐹 1.5*490.5 9.3

𝑚𝑎𝑥
…………………………………………..………4.12
𝑡ℎ 80*𝑡 𝑡

9.
Substituting the above result in equation 4.12

3 =
𝑡
27.86𝑀𝑃𝐴
𝑡=
9.3
= 0.45𝑚𝑚
27.86
t = 2mm
In designing frame 1’s thickness, we have got two different values but choosing one of this value must
consider resistance of both bending and shear stresses. In other word, we will take the safest thickness

So, 𝑡, will be 2𝑚𝑚, so from standard table

from the two.

t = 2mm
B. Design of frame – 2 (main frame)
Cross sectional view main frame as shown below figure 4.20.

Total height (h) = 0.5m

θ
0.4m
Figure 4.14: Section view of main frame

91
 By using Pythagorean Theorem,
 Then to determine the height (ℎ)
h2 = 0.42 + 0.52

h = √0.41 = 0.64𝑚 = 640𝑚𝑚

𝑜𝑝𝑝 0.5
sin 𝜃 = = = 0.7813
0.64
𝜃 = sin−1(0.7813) = 51.4°
h𝑦𝑝

width(𝑤) =
150𝑚𝑚


Determine the thickness based on stress analysis

 Based on design of tension stress
Yield strength of the material (𝜎𝑦) = 390𝑀𝑝𝑎
Where: - F. S = the fact0r 0f safety = 7

𝜎𝑎𝑙𝑙 = 390
= 55.72𝑀𝑃𝐴
7
Note: - the maximum tensile stress will lay in the body of the frame around the pin hole so
 The tensile area (𝐴𝑇) , will be the all section area -
𝑑𝑝t We have from pin
𝑑𝑝 = 20𝑚𝑚 – Diameter of pin
All section area - 𝑑𝑝t
𝐴𝑇 = 150𝑡 − (20)𝑡
𝐴𝑇 = 130𝑚𝑚 × 𝑡
By definition of stress

𝜎𝑡
=
𝐹𝑡
…………………………………………………………………….4.13
𝐴𝑡

𝐹𝑡 = 490.5𝑁 = vertical force

�
� = 490.5
130𝑚𝑚 × 𝑡
𝜎𝑡 =
𝑡

�𝑡

490.5
From equation (4.12), determine to the thickness (t).
𝑡 =
130 × = 0.0677mm
55.72
 Based on buckling
92
The frame part between the holes may buckled by the bolt.
 Buckle area (𝐴𝑏), where, r is pin radius

𝐴𝑏
=𝜋 ×𝑟 ×𝑡 , r = 20 = 10𝑚𝑚
2

93
 So that, 𝐴𝑏 = 𝜋 * 𝑟 * 𝑡,
𝐴𝑏 = 𝜋 * 10𝑚𝑚 * 𝑡
𝐴𝑏 = 31.4𝑡
𝐹𝑏 = 𝑚𝑔 = 50 * 9.81 = 490.5𝑁
𝜎 = =
𝐹𝑏 490.5
……………………………………..…………………………4.14
𝑏 𝐴𝑏 31.4𝑡

490.5
Substituting working stress into equation (4.14), get

𝑡=
31.4 × 𝜎𝑏
490.
𝑡= 5 = 0.28𝑚𝑚
31.4 ×
55.72
𝑡 = 0.28𝑚𝑚
Based on shear stress
The frame part between the pin holes may also sheared by the pin as follows

𝜎𝑦 390
Using maximum shear stress theory, factory of safety = 7

𝑟𝑚𝑎𝑥 = = =
2 * 𝐹𝑆
27.86𝑀𝑃𝐴 2*7
𝑟𝑚𝑎𝑥 = 27.86𝑀𝑃𝐴
In the other cases

𝑟𝑚𝑎𝑥 = 𝐹𝑆
,……………………………………….…………………….... 4.15
𝐴𝑆

𝐹𝑆 = 490.5𝑁
𝐴𝑆 = 2 * 150𝑡 =
300𝑡
Then,
𝑟𝑚𝑎
=
19620𝑁
𝑥
300𝑡
………..………………………………………………….. 4.16

Substituting the above maximum shear in to equation (4.16)

490.5𝑁
𝑡 = = 0.586𝑚𝑚
300 ×
27.86
𝑡 = 0.586𝑚𝑚
Since, designing for different stresses gets as different values of frame thickness. But, in order to be
safe from any failure take the biggest one among those three.
94
So,𝑡 = 2𝑚𝑚, from standard table.

95
C. Design of frame – 3 (base frame)
Based on frame (1), can design frame -3
Assumption for frame -3, depending on objective, significance the project that is decreasing space and
taking hollow frame :-
 Front length(𝐿𝐹) = 500mm
 Back length(𝐿𝐵) = 600mm
 The length of rectangular hole of the frame is 400mm
 The height of frame(H) = 120mm
Cross sectional view of frame-3, as shown figure 4.22 below.
120mm

400mm
600mm

500mm

Figure 4.15: Section view of frame -3

We find weight (W)
W =
𝑚𝑔
𝑤1 = 𝐹1 = 50 * 9.81 =
490.5𝑁
490.5N

H H

600mm

Figure 4.16: Free body diagram for frame - 3

96
Taking resultant force in the Y- direction
+𝗍 ∑ 𝐹𝑦 = 0 ……………………………………………………………4.17
𝑅1 + 𝑅2 − 490.5𝑁 = 0
𝑅1 + 𝑅2 = 490.5𝑁............................................................................(a)
Taking resultant of moment at point -1
∑ M@1 unti − cl0 + ve = 0 → = 0 ,
𝑅2 * 500 − 490.5 * 200 = 0
𝑅2 = 196.2𝑁
Substituting the value of 𝑅2 in equation (a)

𝑅1 + 𝑅2 = 490.5
𝑅1 + 196.2 = 490.5
𝑅1 = 490.5 − 196.2 = 294.5𝑁
𝑅1 = 294.3𝑁
Us we mention before in the assumption we have the same force in the other side of the stands, since
there is the same frame at the back so frame one is with the following forces
𝑅1 = 294.3𝑁, 𝑅1 = 196.2𝑁.
𝑅, = 294.3𝑁 𝑅, = 196.2𝑁.
1 2

NB. Since we have assumed load concentrated at a point and symmetric geometry getting the different
force at different places will be expected as a result.
Determine the thickness based on stress analysis
 Based on bending stress
y

x x

y
Figure 4. 17: Section view frame -3

Area (A) = ℎ𝑡.....................................................................................4.18

97
 𝐼=𝐼= , 𝑦=
𝑡ℎ3 ℎ
𝑥𝑥 12 2

𝑀=
𝐹𝐿

4
,

= =
𝑀 𝜎𝑏 𝐸

𝐼 𝑦 𝑅
…………….……….……………………………………4.19

By using the above equations:-

By taking, F.S= the factor of safety =

ℎ3 (120) 𝑡 3

=
6
𝐼
= 𝑡 12
1
2
𝐼 = 144000𝑡 …………..……………………………………………4.20
ℎ 12
𝑦=
2 0 = 60
=
2
𝐹 490.5 * 500
𝑀 = =
𝐿 4
4
𝑀 = 245250𝑁𝑚𝑚
Substituting the value of moment and equation (4.20) into equation (4.19)
𝑀𝑦 245250 *
𝜎𝑏 = =
𝐼 60
144000𝑡
𝜎𝑏 102.1
= 8
𝑡
𝜎F 390
= 55.72𝑀𝑃𝐴 , 𝐹𝑆 = 7
𝜎𝑏 = = 7
𝐹𝑆 102.18
𝑡 = = 1.83𝑚𝑚
55.7
2
𝑡 = 2𝑚𝑚
 Based on shear stress
From maximum shear stress theory,

𝜎𝑦
𝑟𝑚𝑎𝑥 =
2 * 𝐹𝑆
𝜎𝑦 390
𝑟𝑚𝑎𝑥 = = = 27.86𝑀𝑃𝐴
2 * 𝐹𝑆 2*7

𝑟𝑚𝑎𝑥 =
For a rectangular cross – section having area

98
1.5𝐹 𝑡ℎ
1.5 * 6.13
490.5 =
= 𝑡
𝑡 * 120
6.13
𝑡= = 0.22𝑚𝑚
27.8
6
𝑡 = 1𝑚𝑚

99
Since, we have designing for different stresses we have also get different values of frame thickness.
But, in order to be safe from any failure we have to take the biggest one among those two,
So, t will be 2mm
t = 2mm

4.2.16. Design of Support Arm (Plate)

Due to nature of applied force the arm may be buckle in vertical plane and also the arm are considered
to be hinged at both end.
First, determine the applied weight ( W) on the plate or arm.
W = 40𝑘𝑔 * 9.81 𝑚⁄ 2 = 392.4N
𝑚

W = 392.4N
t

Length of arm = 0.8𝑚

Figure 4.18: Force applied on arm

The force of arm (𝐹𝐴)

𝐹𝐴 = W = 392.4N
First we take as assumption
 compressive force acting on the link
 Let "𝑥"is the width of arm

100
 “t” the thickness of the arm

101
  𝑥 = 3𝑡,
We find the crippling load on vertical plane
Assume the length of the arm is
𝐿 = 800𝑚𝑚 = 0.8𝑚
Then, we select the material for our design which is plain carbon steel
Ultimate Tensile Strength= 550-700Mpa
Ultimate Yield Strength=385Mpa
Then, permissible tensile stress𝜎𝑡 by taking factor safety (ƒ𝑠) =4, we use ultimate yield strength
because the material is Ductile.

� = = 96.25𝑀𝑝𝑎
385
=
Ultimate yield
stress 4
� ƒ
𝑡 𝑠

Permissible share stress (𝑟) is one-half of permissible tensile stress(𝜎𝑡)

1
𝑟 = (permissible tensile𝑠𝑡𝑟𝑒𝑠𝑠) = 0.5 * 96.25 = 48.25𝑀𝑝𝑎.
2
 Crushing stress (𝜎𝑐𝑟)
𝜎 = = = 175𝑀𝑝𝑎 , take maximum Ultimate Tensile Strength which
Ultimate Tensile Strength 700

𝑐𝑟
is
ƒ𝑠 4

 Crushing load ƒ𝑐𝑟

700Mpa.

𝐹𝑐𝑟 = 𝐹𝐴ƒ𝑠
𝐹𝑐𝑟 = 392.4 * 3 =
 Critical load (𝐹𝑐𝑟𝑡) 1177.2N
According to rankines

𝜎𝑐𝑟𝐴
formula

ƒ𝑐𝑟𝑡 =
1 + 𝐿 )2
𝑎(
𝑘r

𝐴 = 𝑥 * 𝑡 , 𝐴 = 3𝑡2
𝐼𝑦𝑦
𝑘𝑟 = √ , 𝐼𝑦𝑦 𝑡𝑥*3 12 = 12 * 27𝑡
1 4
1

𝐴
=
𝑡ℎ𝑒𝑛, 𝐼𝑦𝑦 = 2.25 * 𝑡4
2.25𝑡4
𝑡ℎ𝑒𝑟𝑒ƒ𝑜𝑟𝑒 𝑘𝑟 = √ = 0.866𝑡
3𝑡2
constant “ 𝑎" =
1

7500

Then, critical load is equal to crushing load
102
 𝜎𝑐𝑟𝐴 233.3 * 233.3 * 3𝑡2
3𝑡2
𝐹𝑐𝑟𝑡 = , 1177.2 = 1177.2
1+
1
1 + 𝑎( = =
𝐿 461.5
) 750 (0
160
1+
0.866)
2 2 𝑡2
𝑘r 0
𝑡

103
 233.3 * 3𝑡2 233.3 * 𝑡2 * 233.3 * 3𝑡2
1177.2 = = 2 = ,
3𝑡 𝑡2 + 461.5
1 + 𝑡2
461.5
𝑡2+461.
5
𝑡2

1177.2(𝑡2 + 461.5) = 𝑡2 * 233.3 * 3𝑡2

699.9𝑡4 = 1177.2𝑡2 + 543277.8
699.9𝑡4 − 1177.2𝑡2 − 543277.8

𝑎𝑦2 + 𝑏𝑦 + 𝑐 = 0
 Then ,find the solution by quadratic equation formula

−𝑏 ± √𝑏2 − 4𝑎𝑐
𝑦=
2𝑎
Let, 𝑡2 = 𝑦
699.9𝑡4 − 1177.2𝑡2 − 543277.8
−𝑏 ± √𝑏2 − 4𝑎𝑐
𝑦=
2𝑎
−(−1177.2) ± √(−1177.2)2 − 4 * (−543277.8) *
𝑦=
(699.9)
2*
699.9
−(−1177.2) ± 39017.26
𝑦=
2 * 699.9

Therefore,
𝑦 = 28.71 𝑚𝑚2𝑎𝑛𝑑 − 27.02𝑚𝑚2

Then,𝑡2 = 𝑦, 𝑡2 = 28.7
But, take positive one

𝑚𝑚2,
𝑡 = ± 5.35𝑚𝑚 , 𝑡hi𝑐𝑘𝑛𝑒𝑠𝑠i𝑠 𝑡h𝑒
𝑝𝑜𝑠i𝑡i𝑣𝑒
𝑡 ≈ 7𝑚𝑚 , ƒ𝑜𝑟 𝑔𝑜𝑜𝑑 𝑠𝑡𝑎𝑏i𝑙i𝑡𝑦
Then, width (w) and area
(A) 𝑤i𝑑𝑡ℎ(𝑥) = 3𝑡 = 3 * 7 = 21𝑚𝑚
𝑎𝑟𝑒𝑎(𝐴) = 𝑥 * 𝑡 = 21 * 7 = 147𝑚𝑚2

𝐼𝑦𝑦 = 2.25 * 𝑡4 = 2.25 * 74 = 5402.25𝑚𝑚4

𝐼𝑦𝑦 √5402.25
=
𝑘𝑦𝑦 = √ = 36.75𝑚𝑚 147
𝐴
Then, we to find the critical load ( 𝐹𝑐𝑟𝑡)
𝜎𝑐𝑟𝐴 175 × 175 × 175 × 3 × 25725
3𝑡2 3𝑡2 72
104
 𝐹𝑐𝑟𝑡 = =
1+ =
1
3.32
113.78 443.7
( )2
𝐿 800
=
5
=
750
0 1+ 1+
1 + 𝑎( )2
0.866𝑡 72
𝑡2
𝑘r
𝐹𝑐𝑟𝑡 = 7748.48𝑁 = 7.748𝐾𝑁
Then we concluded that, critical load is greater than crippling load,7748.48𝑁 > 1177.2𝑁
So, it is safe.

105
4.2.17. Design of Bolt

Figure 4.19: geometry of bolt, nut and washer [16].

There are 6 number of bolts, each nut carries (1/6) of the total load on the jaw. The material for this
roll is mild steel which has relatively higher yield strength the magnitude of the force on the square
threaded nut.

For design of bolt we can select the material plain carbon steel
Ultimate tensile stress = 550 − 700𝑀𝑝𝑎
Ultimate yield stress = 385𝑀𝑝𝑎
Then, permissible tensile stress(𝜎𝑡) by taking factor safety (ƒ𝑠) = 3, we use ultimate yield strength
because of the plain carbon steel is ductile material

� = = 128.33𝑀𝑝𝑎
385
Ultimate yield
� =
stress(𝜎 𝑦) 3
ƒ
𝜎𝑦
Permissible share stress (𝑟 ) = = = 64.1667𝑀𝑝𝑎
𝑡 𝑠 385
𝑠 𝐹.𝑆 2*3

𝜋
 The core diameter of the bolt
(𝑑𝑐) 𝑝= 𝑑2 ×𝑛
×𝜎
4 𝑐 𝑡𝑛

Where, P is total load

𝑃 = 5000𝑁
P
5000N
l0ad 0n each b0lt(w) = = 833.33N
= (n0 0f 6
b0lts)
 The number of bolt (n) = 6
P = total resisting force by bolt = 5000N
106
𝜋
𝑑2 × 𝜎 × 𝑛 = 5000 = 𝑃
4 𝑐 𝑡𝑛

107
 𝜋
𝑑2 × 128.33 * 6 = 5000
4 𝑐

5000 = 8.268
𝑑𝑐2 =
604.74
𝑑𝑐 = √48.47 = 2.875𝑚𝑚
2.875𝑚𝑚, take the corresponding3.141mm from table A8
From standard designation table A8, coarse series𝑀4 which have nominal diameter (𝑑𝑜) =4mm
 Nominal diameter or major diameter, 𝑑𝑜 = 4 𝑚𝑚
 Minor or core diameter (𝑑𝑐) = 3.141𝑚𝑚
 Pitch of the thread (𝑝) = 0.7 𝑚𝑚
 Stress area(𝑚𝑚2) = 8.78
 Depth of the thread of bolt(h) = 0.429

𝑝
 Thickness of pitch(t)
0.
𝑡= 7 = 0.35𝑚𝑚
=
 Bolt head diameter(𝑑ℎ𝑏) 2 2

𝑑ℎ𝑏 = 2 × 𝑑𝑜 = 2 * 4 = 8𝑚𝑚
 The bolt head length
(𝐿ℎ𝑏)
𝐿ℎ𝑏 = 0.75 × 𝑑𝑜 = 0.75 * 4 = 3𝑚𝑚
 The bolt thread length (𝐿𝑏𝑡)
𝐿𝑏𝑡 = 6𝑑𝑜 = 6 * 4 = 24𝑚𝑚

(𝑏𝑡𝑙)
 Total length of bolt
𝑏𝑡𝑙 = 𝑑ℎ𝑏 + 𝐿𝑏𝑡 × ƒ𝑟𝑒𝑒 𝑙𝑒𝑛𝑔𝑡ℎ +
𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝑏𝑡𝑙 = 8 + 24 + 16 + 2 =
50𝑚𝑚
 The number thread (𝑛𝑡) = 16
Stress analysis for bolt
Let as check the principal stress

w × 𝑑𝑐
 Maximum torque required=

T= 833.33 ×
= = 436.248Nmm
3.141m
(n0 0f
b0lts) m6

108
 Maximum torsional shear stress (𝑟) and tensile stress(σt),
16T 16 * 436.248Nmm
𝑟= 3
= 71.69MPa
π(3.141mm)3
=
π(dc)

𝑟 = 71.69MPa, safe

109
 W 833.33𝑁
σt = = = 107.54𝑀𝑃
𝜋/4 * 2
𝜋/4(3.141𝑚𝑚)2
𝑑𝑐
σt = 107.54𝑀𝑃𝑎, which is safe
Maximum principal tensile stress (𝜎tmax)
𝜎t 1

𝜎 max = + √𝜎 2 + 4𝜏2
t
2 2 t
128.33MPa 1
𝜎tmax + √(128.33MPa)2 + 4(64.1667MPa)2 =
124.165MPa 2 2
=
𝜎tmax = 124.165MPa
124.165𝑀𝑃𝑎 < 128.33𝑀𝑃𝑎, it is fully safe

4.2.18. Design of Nut

Design nuts for drum extractor machine which are fixed all parts. In designing of nut we find the
number thread (𝑛), thickness of the nut (𝑡𝑛) and width of nut (𝑤𝑛).

Let the number of thread in contact with the screw and load is uniformly distributed over cross section
area of the nut. Let 𝑝𝑏 be the allowable pressure between the thread.
We select the material which is cast steel, so it’s bearing pressure is assumed as 65𝑀𝑝𝑎.
 Ultimate Tensile Strength= 650𝑀𝑝𝑎
 Ultimate Yield Strength = 360𝑀𝑝𝑎
Then, permissible tensile stress𝜎𝑡 by taking factor safety (ƒ𝑠) = 2, we use ultimate yield
strength because of the Ductile caststeel.
� = = 180𝑀𝑝𝑎
360
=
Ultimate yield
�
stress 2
ƒ
𝑡 𝑠

Permissible share stress (𝑟) is one-half of permissible tensile stress(𝜎𝑡)

1
𝑟 = ( permissible tensile𝑠𝑡𝑟𝑒𝑠𝑠) = 0.5 * 180 = 90𝑀𝑝𝑎
2

𝑝 =
𝑇𝑡
= t0tal tensi0n = 6397.78
 the number of thread(𝑛)
T𝑏 𝜋 2 2
Where,
t
(𝑑 −𝑑 )𝑛
𝑜 𝑐

do = 0uter diameter 0f b0lt

4

dc = c0re diameter 0f screw

𝑛=𝜋 𝑇𝑡
(𝑑2 − 𝑑2)𝑝
𝑜 𝑐 𝑏
4
 thickness of the nut(𝑡𝑛)

110
 6397.78 .44 = 21
�
�
𝑡𝑛 = 1.5𝑛 = 1.5 * 21 =
31.5𝑚𝑚
=

0
.
7
8
5
(
(
4
)
2

(
3
.
1
4
1
)
2

)
6
5
�
�

2
0
111
  Width of nut (𝑤𝑛).
wn = pitch * 0uter diameter =
p * do
 𝑤𝑛 = 2 × 4 =
8𝑚𝑚
thickness nut
thread(𝑡)

𝑝
𝑡 =
2
0.7
𝑡 = = 0.35𝑚𝑚
2

R = 1.5 × 4 = 6𝑚𝑚
 the radius of champers (R)

nut(𝐿𝑛)
 Length of
𝐿𝑛 = 2𝑛 +
𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒
𝐿𝑛 = 2 * 21 + 2 =
44𝑚𝑚

 Shearing stress induced in side nut thread (𝑟𝑛𝑢𝑡)

Stress analysis on nut

𝑙𝑜𝑎𝑑 𝑜𝑛 𝑒𝑎𝑐ℎ 𝑛𝑢𝑡

𝑟𝑛𝑢𝑡 =
𝜋𝑑𝑜𝑡
833.33𝑁
𝑟𝑛𝑢𝑡 = = 75.787𝑀𝑝𝑎
𝜋 × 4 × 0.35
𝑟𝑛𝑢𝑡 = 75.787𝑀𝑝𝑎
Then, the design is safe because 𝑟 i𝑠 𝑔𝑟𝑒𝑎𝑡𝑒𝑟 𝑡ℎ𝑎𝑛 𝑟𝑛𝑢𝑡 or 75.787𝑀𝑝𝑎 < 90𝑀𝑝𝑎.

Crushing and tearing stress(𝜎𝑏

𝑤

𝜎𝑏 =
)
2𝜋 * 𝐿𝑛
𝑑
�

𝜎𝑏
= 2𝜋*𝑑𝑝 = 2*𝜋*8*4 = 2.261𝑀𝑝𝑎 ,
w 5000

𝐿𝑛 4

𝜎𝑏 = 2.261𝑀𝑝𝑎
So that,𝜎𝑏 < 𝜎𝑡 𝑜𝑟 2.261𝑀𝑝𝑎 < 180𝑀𝑝𝑎. 𝑠𝑜 𝑡ℎ𝑒 𝑑𝑒𝑠i𝑔𝑛 i𝑠 𝑠𝑎ƒ𝑒

112
4.2.19. Design of Washer

We know that washer is used to prevent misalignment of two bodies. In this project we want to design
the washer which is used to align or preventing misalignment between the different components. As
shown below geometry of washer.

Figure 4.20: Geometry of washer [15].

Selected the material for design of washer which is plain carbon steel
 Ultimate Tensile Strength= 550 − 700𝑀𝑝𝑎
 Ultimate Yield Strength= 385𝑀𝑝𝑎
Then, permissible tensile stress(𝜎𝑡) by taking factor safety (ƒ𝑠) = 1.5, we use ultimate yield strength
because the material is Ductile.

𝜎𝑡 = Ultimate yield 385

stress = =
256.667𝑀𝑝𝑎 1.5
ƒ𝑠

stress(𝜎𝑡) 1
Permissible share stress (𝑟) is one-half of permissible or allowable tensile

𝑟 = ( permissible tensile𝑠𝑡𝑟𝑒𝑠𝑠) = 0.5 × 256.66 = 128.33𝑀𝑝𝑎

2

 Internal diameter washer (𝑑w)

 the nut diameter is D = 7mm from bolt diameter

𝑑w = 𝐷 +Allowance
𝑑w = 4 + 1 = 5𝑚𝑚

(𝐷w) 𝐷w = 2𝐷 + 4
 external diameter washer

𝐷w = 2(4) + 4 =
12𝑚𝑚

 thickness of washer(𝑡w)
𝐷w −
𝑡w
= 𝑑w
2
 l ngth of washer(𝐿w)
e
113
 12 − 5 2
𝑡w = =
3.
5
𝑚 𝐿w = 0.15𝐷
𝑚
𝐿w = 0.15 × 4 = 0.6𝑚𝑚 ≈ 2𝑚𝑚

114
 Considering the failure of washer in crushing(𝜎𝑐𝑟),
Stress analysis washer

𝜎𝑐𝑟 = W


((𝐷2 − 𝑑2 )
𝜋

4 w w
From previous, W = 5000𝑁
5000
𝜎𝑐𝑟 = 3.14 = 53.524𝑀𝑝𝑎
4 (122 − 52)
53.524𝑀𝑝𝑎 < 256.66𝑀𝑝𝑎, So it is safe

l0ad 0n each washer

 Considering the failure of washer in shearing (𝑟w)
𝜏w =
𝜋 × × tw
dw
833.33
𝑟w = = 90.9𝑀𝑝𝑎
𝜋 × 5 × 3.5
So it’s safe,𝑟 > 𝑟w, 90.9𝑀𝑝𝑎 <
4.2.20. Selection of Wheel 128.33𝑀𝑝𝑎.

There is no simple formula or rule that can be followed in selecting the proper casters. Many varying
and individual factors must be balanced to make the selection best job. The following are several of the
more important consideration we have considered.
 Load Weight. The heavier the load, the larger the wheel required for the caster. The weight of
the load also influences the mobility of the wheel. Capacities are shown for each caster in the
catalog below.
 Floor Conditions. The wheel we select is large enough to pass over cracks in the floor, tracks,
moldings and other obstructions.
 Unusual Conditions. Check conditions, each wheel material has certain characteristics which
will give the best results where unusual conditions exist. For example, where acids, oils,
chemicals and other conditions harmful to rubber are present, Colson polyurethane, polyolefin,
Maxim, phenolic or steel wheels are recommended.
 Rolling Ease. The larger the wheel diameter, the easier it rolls. Roller bearings carry heavier
loads. Ball bearings roll easier but carry lesser loads. When possible, use the largest ball
bearing wheel for best results. For this design we have selected roller bearings[16].
 Extreme Climates. Room temperatures are no problem for most casters. But extreme cold or
heat can be a problem. Colson helps solve this problem with “Colson 45” the green lube which
assures caster rolling ease from 45°F below zero to 260°F above. It’s standard on all Colson
casters.

115
 Selected type wheel is Colson polyurethane.
 Light-weight and ultra-durable, this wheel has a very high strength-to-weight
 Ratio and is capable of long service under heavy loads. Maroon color
 Polyurethane is permanently bonded to the aluminum core.
 Temperature range:-45°F to +180°F.
 Hardness:95(±5) Durometer Shore A scale.
 Finish: Aluminum

From the table below for the corresponding 700 pounds’ load distribution of roller type bearing the
following parameters has selected.

From table A9 colsonmold on polyurethane aluminum core wheels, which capacity up to 1500 Ibs has
the following Recorded values:-

 Bearing bore of wheel:3/4"

 Wheel model no: 5.00004.939
 Bore less bearing of wheel:13/16"
 Hub length of wheel:23/16"
 bore of spanner bushing:1/2"
 length of spanner bushing:27/16"

Design of bolt, nut and washer for each wheel

A. Design of Bolt for each wheel

There are 24 number of bolts, each nut carries (1/24) of the total load on the lift. The material for this
roll is mild steel which has relatively higher yield strength the magnitude of the force on the square

P 5000N
threaded screw is given by.

= 208.33N
l0ad 0n each b0lt(w) = 24
= 24(n0 0f
b0lts)

Selected material; low carbon steel 𝜎y = 750MPa

𝜎y
Factor of safety=4.
750MP
𝜎c,t = = a
FS = 187.5MPa
4
𝑟_𝑚𝑎𝑥 = 0.5𝜎𝑦/𝐹𝑆 = 0.5 * 750𝑀𝑃𝑎 = 93.75𝑀𝑃𝑎
116
Load on boltW =
2
dc
𝜎t
4

117
 𝜋dc2 *
208.33N =
187.5M
Pa 4
dc = 2.108mm, take the corresponding 2.387mm

From the standard table the nearest maximum core diameter is 2.387mm.

For M3 designation other dimensions from the table are;

 Pitch = 0.5mm
 Major or nominal diameter of nut and bolt=3mm
 Pitch diameter = 2.675mm
 minor core diameter of bolt = 2.387mm
 minor core diameter of nut = 2.459mm
 Depth of thread = 0.307mm
 Stress area = 5.03mm2

Figure 4.21: Hexagonal headed bolt position [15].

 Length of bolt head

0.75𝐷 = 0.75 × 3𝑚𝑚 = 2.25𝑚𝑚

=

 Length of bolt =

2D + thickness 0f washer
= 2 × 3𝑚𝑚 + 0.45𝑚𝑚 = 6.45𝑚𝑚
 Diameter of hexagon of head of bolt =
2𝐷 = 2 × 3𝑚𝑚 = 6𝑚𝑚
 Outer diameter of bolt =
2𝐷 + 4𝑚𝑚 = 2 × 3𝑚𝑚 + 4𝑚𝑚 = 10𝑚𝑚
118
 Stress analysis
Let as check the principal stress

W×d
 Maximum torque required=

T= 490.5N ×
24(n0 0f 3mm = 61.3125Nmm
b0lts) =
24

 Maximum torsional shear

16T
𝑟 =
stress,

𝜋(dc)3
16 × 61.3125Nmm
𝜏= =
𝜋(2.387mm)3
𝜏 = 22.95MPa, safe
W 490.5
𝜎𝑡 = 4× N
=
dc
2
𝜋/4(2.387mm)2
=

𝜎𝑡 = 109.6𝑀𝑃𝑎, safe
Maximum principal tensile stress (𝜎tmax)
𝜎t 1

𝜎 max = + √𝜎 2
+ 4𝜏2
2 2
t t

109.6MPa 1
= + √(109.6MPa)2 +
4(22.95MPa)2 2 2
= 114.21MPa
=114.21MPa<250MPa, it is fully safe

1
+ 4𝜏2
 Maximum shear stress (τmax)
max= √𝜎t
2
2
τ
1
= √(109.6MPa)2 + 4(22.95MPa)2 =
59.41MPa 2

𝜏max = 59.41MPa< 93.75Mpa, It is fully safe

B. Design of Nut for each wheel

Selected material; low carbon steel 𝜎y = 750MPa
Factor of safety = 4
𝜏max = 0.5 𝜎𝑦/𝐹𝑆
𝜎y
119
𝜎c,t = = 750MP
FS a
= 187.5𝑀𝑃𝑎
4

120
 Figure 4.22: Geometry of hexagonal nut [15]

 Major core diameter of nut= 3𝑚𝑚 (from table at diameter of bolt)

 Outer diameter of nut= 2D
2D = 2 * 3mm =
6mm
 Length of nut
head=0.75D=
0.75D = 0.75 * 3mm =
 Pitch= 0.5mm 2.25mm

2.675mm
 Pitch diameter=

Stress analyses

w
Check the nut for tensile and compressive stress
490.5N
𝜎𝑡,𝑐 = = = 69.39𝑀𝑃𝑎
𝜋/4 (dc)^2 4 (3mm)2
𝜎𝑡,𝑐 = 69.39MPa , for tensile and compressive stress, it is fully safe
C. Design of Washer for wheel

From figure 4.26, can design the washer for wheel

Selected material; low carbon steel 𝜎y =
750MPa Factor of safety=4
𝜏max = 0.5 𝜎𝑦/𝐹𝑆
𝜎y 750MP
𝜎c,t = = a
FS = 187.5𝑀𝑃𝑎
4
𝜏max = 0.5 × 750MP𝐴/3 = 93.75𝑀𝑃𝐴
121
 Inner diameter washer= D + all0wance
D + all0wance = 3mm + 1mm = 4mm

122
  Outer diameter of washer= 2𝐷 + 4
2D + 4 = 2 × 3mm + 4mm = 10m
Outer diameter of washer −nner diameter
2
Outer diameter 0f washer − nner
Thickness of washer =

diameter 10 −
= 4 = 3𝑚𝑚
2
2
 Length of washer = 0.15𝐷
0.15D = 0.15 * 3 = 0.45m ≈ 1.5mm

Stress analysis
Check for tensile and compressive stresses
𝜎𝑡,𝑐 = w
((d )2 − (d )2)
4 o i
490.5N
𝜎𝑡,𝑐 = = 43𝑀𝑃𝑎
((10mm)2 − (4mm)2)
4

𝜎𝑡,𝑐 = 7.43MPa, for tensile and compressive stress, it is fully safe

4.2.21. Selection of Seals
In this hydraulic drum extractor machine two types of seals are used. These are C- rings and O- rings.
These rings are selected from the standard tables based on their groove dimensions.

a. C- type seal for the liner tube

Figure 4.23: C- type of seal [19]

Seal selection based on a table A10.

Selecting for the radial pressure seal has been external pressure.

 Seal internal diameter (𝐼𝐷) = outer diameter of the tube = 11 𝑚𝑚 ± 0.05

 From table A11 for Teflon coated ring with 𝐶𝐿 = 0.25𝑚𝑚 , 𝐶𝑠 = 1.6𝑚𝑚
123
  Groove internal diameter = seal internal diameter ( ID ) – clearance ( CL) – maximum
plating thickness × 2
= 11 𝑚𝑚 - 0.25𝑚𝑚 − 0.08𝑚𝑚 × 2 = 10.75 𝑚𝑚

 Depth of the groove = 1.24𝑚𝑚 / 1.30 𝑚𝑚

 Minimum groove width = 1.91 𝑚𝑚

b. O- Rings selection
Seals are selected based on the following steps;
Step 1:- Choose rubber properties by going to O-ring Material Guide table.
Step 2:- Make sure that the material choose will withstand the temperature of system by going to the
rubber temperature range chart.
Step 3:- Choose the correct hardness from rubber hardness data.
Step 4:- Design and dimension the groove that O-ring will go into by referring the O-ring Groove
Design guide.
Step 5:- Choose a standard size AS568 O-ring using the O-ring Size Chart [19].
 O- ring material guide properties
As shown below table 4.4 and 4.5, O – ring material guide and properties
Table 4.4: O-Ring Material Guides [19].

No. Elastomer Brief summary

1 Buna – N(nitride ) Good mechanical properties and high wear resistance relative to
other Elastomer. Unless special compounded this is not resistant of
weathering. Example sunlight and ozone
2 Butadiene, styrene Similar to natural rubber mostly used tires and seals for non-
butadiene mineral oil based on applications
3 Butyl It has very low permeability rate making it a great seal under
vacuum and has good electrical damping property.
4 Chloroprene Have good mechanical properties and chemical resistance
(neoprene)
5 Ethylene propylene Excellent resistance to weathering, ozone depletion
6 Fluorocarbon Good resistance to ozone and temperature used for universal ring
7 Fluor silicone Used to petroleum oils and fuels, abrasion resistance
8 Hydrogenated Resists ozone, sun light and atmospheric environment hazards

124
 nitride
9 Natural rubber/ It has excellent dynamic properties, résistance to ozone
isoprene
9 Polyacrylate For transmission application, high temperature resistance
10 Silicone High temperature capabilities, good resistance to ozone

Table 4.5: O- ring type property

No Elastomer Lubricatin Aliphatic Aromatic Halogenated Phosphat Polm4e

. g oil hydrocarbon hydrocarbo hydrocarbon e ester r
s n s
1 Buna – 1 2 4 3 4 4
N(nitride )
2 Butadiene, 4 4 4 4 4 2
styrene
butadiene
3 Butyl 4 4 4 4 2 4
4 Chloroprene 2 3 4 4 4 1
(neoprene)
5 Ethylene 4 4 4 4 1 4
propylene
6 Fluorocarbon 1 1 1 1 4 4
7 Fluor silicone 2 3 3 3 3 4
8 Hydrogenate 1 2 3 4 1 4
d nitride
9 Natural 4 4 4 4 4 2
rubber/
isoprene
9 Polyacrylate 1 3 4 3 4 4
10 Silicone 3 4 4 4 4 4

Description for above table, 1: excellent, 2: good, 3: fair and 4: poor

Based on depending above steps and we can select O-Ring one from table 4.4, Table 4.5, Table A12,
Table A13, Table A14 and Table A15.
 For piston
Step 1: - rubber material selected: Buna –N (nitride) from Table 4.4 and Table 4.5.
Step 2:- working temperature range for the selected material, - high temperature = 250 º𝐹 and
- Low temperature= −40 º𝐹 from Table A12.
Step 3: - choosing the correct hardness number: Shore 70A* from Table A13.

125
Step 4:-dimension the groove that the O-ring will go into: take L =0.049, G = 0.091 and Cs = 0.06,
from Table A14.
Step 5:- Choosing a standard size AS568 O-ring using this O-ring Size Chart : AS568003 having
Nominal 𝐼𝐷 = 1/16; Actual 𝐼𝐷 = 0.056; Nominal 𝐶𝑠 = 1/16 and actual 𝐶𝑠 = 0.060.from
Table A15.
 For between oil bag and oil tank
Step 1: rubber material selected: Buna –N (nitride)from Table 4.4 and Table 4.5.
Step 2: working temperature range for the selected material, - high temperature = 250 º𝐹 and
- Low temperature = 40 º𝐹from Table A12.
Step 3: choosing the correct hardness number: Shore 70A* from Table A13.
Step 4: dimension the groove that the O-ring will go into: take 𝐿 = 0.055, 𝐺 = 0.095 𝑎𝑛𝑑 𝐶𝑠 = 0.07
from Table A14.
Step 5: Choosing a standard size AS568 O-ring using this O-ring Size Chart : AS568004 having
nominal 𝐼𝐷 = 5/64;Actual𝐼𝐷 = 0.070; Nominal 𝐶𝑠 = 1/16; 𝑎𝑐𝑡𝑢𝑎𝑙 𝐶𝑠 = 0.070 is
selected from Table A14.

 For inlet and outside of plunger

Step 1: rubber material selected: chloroprene from Table4.4 and Table 4.5.
Step 2: working temperature range for the selected material, - high temperature = 260 º𝐹 and - Low
temperature = −45 º𝐹 from Table A12.
Step 3: choosing the correct hardness number: Shore 70A* from Table A13.
Step 4: dimension the groove that the O-ring will go into: take L =0.088, G = 0.146 and C s = 0.103
from Table A14.
Step 5: Choosing a standard size AS568 O-ring using this O-ring Size Chart : AS568103 having
nominal 𝐼𝐷 = 3/32; actual𝐼𝐷 = 0.081; nominal𝐶𝑠 = 3/32and actual 𝐶𝑠 = 0.103 is selected
from Table A15.
For intake and discharge value
Step 1: rubber material selected: hydrogenated nitrile, Table 4.4 and Table 4.5.
Step 2: working temperature range for the selected material, - high temperature = 330 º𝐹 and
- Low temperature = −30 º𝐹from Table A12.
Step 3: choosing the correct hardness number: Shore 70A* from Table A13.
Step 4: dimension the groove that the O-ring will go into: take L =0.032, G = 0.0.73 and Cs = 0.04
from Table A14.
126
Step 5: Choosing a standard size AS568 O-ring using this O-ring Size Chart; AS568001 is having
nominal 𝐼𝐷 = 1/32actual𝐼𝐷 = 0.029; nominal 𝐶𝑠 = 1/32 and actual 𝐶𝑠 = 0.040 is
selected.from Table A15.
4.2.22. Valve Selection
Valves are selected taking the flow rate of the piston which is 𝑉 = 2.075𝐺𝑃𝑀 and speed of flow
(𝑣) = 0.788 𝑚/𝑠

 Calculating 𝐶𝑣(valve flow coefficient),

CV combines the effects of all flow restrictions in the valve into a single number. CV represents the
quantity of water, at 68°F and in gallons per minute (GPM) that will flow through your valve with a

V
1psi pressure differential.

Cv =
√SG
∆P

But ∆P = P1 − P2
Where, P1 – inlet pressure or higher pressure in 𝑀𝑝𝑎 = 64.27𝑀𝑃𝐴
P2 – outlet pressure or lower pressure in 𝑀𝑝𝑎 = 55.33𝑀𝑝𝑎
SG- specific gravity of the fluid = 0.871
But ∆𝑃 = 𝑃1 - 𝑃2 = 64.27 − 55.33 = 8.94𝑀𝑝𝑎 Cv = =
V

∆P
√SG

2.075
Cv = 2.07
= 5 = 0.64
√
8.94
0.871
3.2
2

127
  Identifying valve function,
As shown table 4.6 below valve function and type disc for valves

Table 4.6: valve selection guide for liquid based fluid [18].

Conveyed fluid Nature of fluid Function of valve Type of disc

Gate
Rotary ball
On /off Plug
Diaphragm
Butterfly
Natural (water, oil Plug gate
etc...) Globe
Liquid Control valve , Butterfly
modulating Plug gate
Diaphragm
Needle
Gate
Corrosive (acid, Plug gate
alkaline, etc…) On /off Rotary ball
Plug
Diaphragm

From table 4.6 since the petroleum is used and the valve function is to on/ off. The type of disc used is
rotary ball and it is 2 way normally closed valves.

 Identifying the valve series

Using the charts or table, select as maximum operating pressure differential (MOPD), the CV range,
and additional specifications needed for application to select possible valve series.
The valve series selected is general purpose. Under the general purpose group, the selected valve
parameters from table A16 are
 Media – Gas and liquid
 Size - miniature
 Orifice diameter - 0.062 − 0.210

128
  Valve series - 𝐵
 maximum operating pressure differential (MOPD) = 400𝑃𝑠i
4.2.23. Hydraulic Fluid Selection
The fluid in hydraulic system is used to transmit energy as the fluid is pumped through the system
because liquids are virtually incompressible .It is important to use a fluid with the proper fluid
viscosity in order to avoid the problems that may occur if the wrong fluid is used. The other functions
of hydraulic fluids are to provide lubrication for move parts, and to protect components from rust and
corrosion.
With hydraulic, there are two primary considerations- the viscosity grade and the hydraulic oil type.
The specifications are typically determined by the type of pump employed in the system, operating
temperatures and system’s operating pressure. But it does not stop there. Other considerations are: base
oil type, overall lubricant quality and performance properties. A systems requirements for these items
can vary dramatically based on the operating environment, the type of the machine for which the unit
is employed and many other variables [17].
The most common hydraulic fluid used in general or mobile systems are petroleum based oils. These
fluids contain additives to protect the fluid from oxidation ( antioxidant ), to protect system metals
from corrosion (anticorrosion ) to reduce tendency of the fluid to foam ( foam suppressant) and to
improve viscosity. In the selection of oil type viscosity is main parameter which plays a fundamental
role in lubrication. Different oils exhibit different viscosities. In addition, oil viscosity changes with
temperature, shear rate and pressure and the thickness of the generated oil film is usually proportional
to it. For design applications the oil viscosity is usually chosen to give optimum performance at the
required temperature. Knowing the temperature at which the oil is expected to operate is critical as oil
viscosity is extremely temperature dependent. The viscosity of different oils varies at different rates
with temperature. It can also be affected by the velocities of the operating surfaces (shear rates). The
knowledge of the viscosity characteristics of a lubricant is therefore very important in the design and in
the prediction of the behavior of a lubricated mechanical system. Petroleum based oils contain most of
the desired properties of a hydraulic liquid. However, they are flammable under normal conditions can
become explosive when subjected to high pressures and source of flame or high temperatures.
Therefore the hydraulic fluid selected for the drum extractor machine is petroleum based fluid.

129
It the fluid is to thin, it can cause:-
 Increase in internal and external leakage
 Pump slippage
 Reduction in system pressure
 Excessive component wear from inadequate lubrication
If the fluid is too thick, it may result in:-
 Increase in internal friction
 More power required for operation.
Therefore, in order to avoid the above described problem the selected fluid should have the right
viscosity for the application.

Figure 4.24: ISO viscosity grade for hydraulic fluids based on working temperature [17].
From a table A17 and figure 4.30, the hydraulic drum extractor machine or puller is assumed to work
under a maximum temperature of 70⁰c. So according to table A17, for piston pump working under a
temperature of 70⁰c and a pressure of 172.5 bar, the viscosity VG is in the range 22 – 46. And also
referring to figure 4.30 for a working temperature of 70 ⁰c the recommended viscosity VG is 46.
Therefore the selected petroleum based oil should have viscosity VG of 46.
As shown below table 4.7 right hydraullic oil with ISO VG 46 has the following properties,

130
Table 4.7: properties hydrualic oil with ISO VG 46[17].

Hydraulic oil ISO 46

Mineral/ petroleum based oil
Density at 15.6 ⁰c 871 𝑘𝑔/𝑚3
Kinematic viscosity at 40 ⁰c 46.3 𝑐𝑆𝑡
Kinematic viscosity at 100 ⁰c 6.94 𝑐𝑆𝑡
Viscosity index 106
Flash point 220 º𝑐
Pour point −30 º𝑐

4.3. Manufacturing Method or Fabrication

There are many factors which affect the selection of suitable manufacturing process for a component.
Some of the factors are commercial such as the unit cost of production and whether the existing plant
is to be used, or whether it is to investment in new and more economical plant .
The fundamental consideration of manufacturing process to be used mainly depends on:-
 Shape of the component and
 Material from which the component is to be made.
The quality of the component that is
 Dimensional accuracy,
 Geometrical accuracy and
 Surface finish etc.
Manufacturing process that takes place fabricating manual operated drum extractor machine are:-

 Primary shaping processes: -The processes used for the preliminary shaping of the machine
component are known as primary shaping processes. The common operations used for this
process are casting, forging, extruding, rolling, drawing, bending, shearing, spinning, powder
metal forming, squeezing etc.
 Machining processes: -The processes used for giving final shape to the machine component,
The following are the various manufacturing processes used in Mechanical engineer.
According to planned dimensions are known as machining processes. The common operations
used for this process are turning, planning, shaping, drilling, boring, reaming, sawing,
broaching, milling, grinding, hobbling etc.

131
  Surface finishing processes: - The processes used to provide a good surface finish for the
machine component are known as surface finishing processes. The common operations used for
this process are polishing, buffing, honing, lapping, abrasive belt grinding, barrel tumbling,
electroplating, super finishing etc.
 Joining processes: -The processes used for joining machine components are known as joining
processes. The common operations used for this process are welding, riveting, soldering,
brazing, screw, fastening, pressing, sintering etc.
 Processes effecting change in properties. These processes are used to impart certain specific
Properties to the machine components so as to make them suitable for particular operations or
uses. Such processes are heat treatment, hot-working and cold-working.

4.4. Assemble method

1. Prepare all components or machine components.
2. First, join spring and ball on the inlet check value.
3. Join spring and ball on the outlet check valve.
4. Join screw plug in both outlet and inlet check valve.
5. Arranging and ordering the cylinder, solid ram, extension screw and reservoir then insert body.
6. Join plunger and pump cylinder, and also join pump cylinder and plates.
7. Join pin and links.
8. Accession of the fluid in reservoir tank.
9. And join the handle within links.
10. Tighten cylinder body on the top or frame table by means bolts, nuts and washers.
11. Join the crossed arm and cylinder body.
12. Tighten the jaw on the crossed arm by means of plate, spring, bolt, nut and washer.
1.3 Arranging and ordering the three frame in order to carry the body.
14. Tighten the base frame and main frame on the frame tables by means of bolts, nuts and washers.
15. Tighten the caster wheel on the base frame by means of bolt and nut.

132
4.5. Cost Analysis or Cost Breakdown
In order to find cost it is required to find the mass of each material, and solve the density and volume.
We find the volume each component (V)
1. volume of screw(𝑉𝑠)
𝜋
𝑉= 𝑑2𝐿
4 𝑜 𝑆
𝑠
𝜋
(22)32(120) = 45615.93𝑚𝑚3 = 4.561593 ×
𝑉𝑠 = 10−5𝑚 4
Density of screw material = 7845𝑘𝑔/𝑚3
𝑀𝑎𝑠𝑠 = 𝜌 * 𝑉 = 7845 × 4.561593 × 10−5 =
0.3578. 𝑘𝑔 1𝑘𝑔 = 18.2 𝑏i𝑟𝑟
0.3578. 𝑘𝑔 = 𝑘, 𝑘 = 18.2 × 0.3578 𝑏i𝑟𝑟 = 6.52𝑏i𝑟𝑟

𝜋
2. volume of

𝑉= * 𝑑2 * 𝐿
pin(𝑉𝑝)

4 𝑝𝑝
𝜋
𝑉𝑝 = 10−6
(8)23 * 23 = 1156.106𝑚𝑚3 = 1.156 *
𝑚 4
Density of pin material = 7850kg/𝑚3
𝑀𝑎𝑠𝑠 = 𝜌 × 𝑉 = 7850 × 1.156 * 10−6 =
0.00907𝑘𝑔 1𝑘𝑔 = 40.6
0.00907𝑘𝑔 = 𝑘, 𝑘 = 40.6 × 0.00907 𝑏i𝑟𝑟 = 0.368𝑏i𝑟𝑟 × 4 = 1.473𝑏i𝑟𝑟
3. volume of nut(𝑉𝑛) for jaw
𝑉𝑛 = 𝐿𝑛 × 𝑤𝑛 × 𝑡𝑛
𝑉𝑛 = 44 * 8 * 0.35 = 123.2𝑚𝑚3 = 1.232 * 10−7𝑚3
Density of jaw nut material = 7820kg/𝑚3
𝑀𝑎𝑠𝑠 = 𝜌 * 𝑉 = 7820 × 1.232 × 10−7 =
0.000964𝑘𝑔 1𝑘𝑔 = 28.56𝑏i𝑟𝑟
0.000964𝑘𝑔 = 𝑘 , 𝑘 = 28.56 × 0.000964 𝑏i𝑟𝑟 × 6 = 0.1656𝑏i𝑟𝑟
4. volume of nut(𝑉𝑛) for wheel
𝑉𝑛 = 𝐿𝑛 × 𝑤𝑛 × 𝑡𝑛
𝑉𝑛 = 9 × 4 × 0.25 = 9𝑚𝑚3 = 9 × 10−9𝑚3
Density of wheel nut material = 7820kg/𝑚3
𝑀𝑎𝑠𝑠 = 𝜌 × 𝑉 = 7820 × 9 × 10−9 = 0.000071𝑘g
133
 1kg =28.56birr
0. 000071𝑘𝑔 = 𝑘, 𝑘 = 28.56 × 0.00007𝑏i𝑟𝑟 × 24 = 0.04866𝑏i𝑟𝑟

5. volume of bolt(𝑉𝑏) for jaw

𝑉
𝜋
2 𝜋 3 −7 3
2
= × 𝑑𝑏 × 𝐿𝑏 = × 50 =
628.318𝑚𝑚 = 6.28310 𝑚
(4)
𝑏
4 4

Density of jaw bolt material = 7820kg/𝑚3

Mass = 𝜌 × 𝑉 = 7820 × 6.28310−7 = 0.0004913𝑘𝑔
1𝑘𝑔 = 42𝑏i𝑟𝑟
0.0004913𝑘𝑔 = 𝑘 𝑘 = 42 × 0.0004913𝑏i𝑟𝑟 × 6 = 0.123𝑏i𝑟𝑟
6. volume of handle (𝑉ℎ)
𝜋
(𝑉 = (𝑑2 )𝐿
4 ℎ
ℎ ℎ
𝜋
𝑉ℎ = * 10
(19) * 450 = 127587.93𝑚𝑚3 = 1.2758793
2
−4
𝑚3 4
Density of handle material = 7870kg/𝑚3
Mass = 𝜌 × 𝑉 = 7870× 1.2758793 × 10−4 = 1.004𝑘𝑔
1kg = 24
1.004𝑘𝑔 = 𝑘, 𝑘 = 24 × 1.004 𝑏i𝑟𝑟 = 24.096𝑏i𝑟𝑟
7. volume of plunger(𝑉𝑝 ) =
𝜋
(5)2 × 75 =1472.63𝑚𝑚3 = 1.47263 × 10−6𝑚3
4

Density of plunger material = 7870kg/𝑚3

Mass = 𝜌 × 𝑉 = 7820× 1.47263 × 10−6 = 0.01152kg
1𝑘𝑔 = 24
0.01152𝑘𝑔 = 𝑘, 𝑘 = 24 × 0.01152 𝑏i𝑟𝑟 = 0.27648𝑏i𝑟𝑟

8. volume of cylinder(𝑉𝑐)
𝜋
* 𝑑2 𝑑2 * 𝐿
=

4
𝑜− i 𝑐
𝜋 2 2 −5 3
𝑉𝑐 = ×
3
((18) −
(10)) × 75 = = 1.319468 × 10 𝑚
4 13194.689𝑚𝑚
Density of cylinder material = 7840kg/𝑚3
Mass = 𝜌 × 𝑉 = 7840× 1.319468 × 10−5 = 0.1062kg
1𝑘𝑔 = 36
134
0.1062𝑘𝑔 = 𝑘 , 𝑘 = 36 × 0.1062 𝑏i𝑟𝑟 = 3.82𝑏i𝑟𝑟

135
9. volume of solid ram(𝑉𝑠𝑟)
𝑉 =𝜋 × 𝑑2 × 𝐿 =𝜋 (10)2 × 200 = 15707.96𝑚𝑚3 = 1.57079 × 10−5𝑚3
𝑠𝑟 4 𝑠𝑟 𝑠𝑟 4
Density of solid ram material = 7875kg/𝑚3
Mass = 𝜌 * 𝑉 = 7875× 1.57079 × 10−5 = 0.14284kg
1𝑘𝑔 = 18.2𝑏i𝑟𝑟
0. 14284𝑘𝑔 = 𝑘, 𝑘 = 18.2 * 0.14284 𝑏i𝑟𝑟 = 2.599𝑏i𝑟𝑟
10. volume of reservoir(𝑉𝑟) =
𝜋
* 𝑑2 𝑑2 * 𝐿
4
𝑜− i 𝑟
𝜋 2 2 −4 3
𝑉𝑟 = *((29)
3
−
(21)) *141371.669𝑚𝑚
450 = = 1.4137166 * 10 𝑚
4

Density of reservoir material = 7860kg/𝑚3

Mass = 𝜌 * 𝑉 = 7860*1.4137166 * 10−4
=1.1118 kg 1kg = 70
1.1118 kg = k , k = 70*1.1118 birr = 77.83birr

11. volume of jaw (𝑉j)

𝑉j = 𝐿𝑛 * 𝑤𝑛 * 𝑡𝑛
𝑉j = 𝐿j * 𝑤j * ℎj = 37 * 12 *250 = 111000𝑚𝑚3 = 1.11 * 10−4𝑚3
Density of jaw material = 7850kg/𝑚3
Mass = 𝜌 * 𝑉 = 7850*1.11 * 10−4 =0.872
kg 1kg = 18.2birr
0.872 kg = k, k = 18.2*0.872 birr = 15.871birr
12. volume of crossed arm(𝑉𝑐𝑎) =
𝜋
* 𝑑2 𝑑2 * 𝐿
4
𝑜− i
𝜋 𝑐𝑎
2 −6 3
2 3
𝑉 *((33) − *2375.044𝑚𝑚
16 = = 2.375 * 10 𝑚
= 𝑐𝑎 4 (30))
Density of crossed arm material = 7450kg/𝑚3
Mass = 𝜌 * 𝑉 = 7850*2.375 * 10−6
=0.01865 kg 1kg = 23.8birr
0.01865 kg = k, k = 23.8*0.01865 birr = 0.4438birr

13. volume of liner tube(𝑉𝑙𝑡) =

136
 𝜋
* 𝑑2 𝑑2 * 𝐿
4
𝑜− i 𝑙𝑡
𝜋 2 2 −7 3
𝑉𝑙𝑡 = *((11) − *904.778𝑚𝑚
20 = = 9.0477 * 10 𝑚
3
4 (7))
Density of liner tube material = 7870kg/𝑚3
Mass = 𝜌 * 𝑉 = 7870*9.0477 * 10−7 =
0.007121kg 1kg = 24birr
0.007121kg = k, k = 24*0.007121 birr = 0.17088birr
14. volume of washer(𝑉w) =
(𝑉 ) =𝜋 * 𝑑 2 𝑑 2 * ℎ
w 4 𝑜− i
𝜋 2 w −7 3
𝑉w = *((8) − (4)) * 6 =
2 3
= 2.26195 * 10 𝑚
4 226.195𝑚𝑚
Density of washer material = 7820 kg/𝑚3
Mass = 𝜌 * 𝑉 = 7820*2.26195 * 10−7 =
0.0017688kg 1kg = 28.56birr
0.0017688kg = k, k = 28.56*0.0017688 birr*30 = 1.52birr

As shown below in table 4.8 the total material and labor costs.

137
Table 4.8: The Total material and labor cost

1.material cost
No. Material name Selected Quantity Density of Volume Total Mass unit price Total
material of material (kg/𝑚3) for each birr per cost
(kg/𝑚3)
𝜌*𝑉
material material kg in birr

4.561593
* 10
1 Screw AISI 1 7845 0.3578 6.52 95
HR −5

1.156
1006

* 10−6
2 Pin for handle Mild 3 7850 0.00907 0.368 50
steel
3 Nut for wheel Carbon 24 7820 9*10−9 0.000071 0.00203 140

1.232
steel

* 10−7
4 Nut for jaw Carbon 6 7820 0.000964 0.0276 90

6.28310
steel
5 Bolt for jaw Plain 6 7820 0.0004913 0.0205 95
−7
carbon

1.275879
steel

3
6 Handle AISI 1 7870 1.004 24.096 70

* 10−4
1010

1.47263
CD

* 10−6
7 Plunger AISI 1 7820 0.01152 0.2764 65
1010

1.319468
CD

* 10−5
8 Cylinder SAE 1 7840 0.1062 3.82 225

1.57079
2010

* 10−5
9 Solid ram AISI 1 7875 0.1428 2.599 220

1.413716
1015

6
10 Reservoir SAE 1 7860 1.1118 77.83 150

* 10−4
106

1.11
* 10−4
11 Jaw SAE 3 7850 0.872 15.87 390
1015

2.375
HR

* 10−6
12 Crossed arm Cast 2 7450 0.01865 0.443 305

9.0477
iron

* 10−7
13 Liner tube AISI 1 7870 0.00712 0.17088 30
1010

2.26195
CD

* 10−7
14 Washer Carbon 24 7820 0.001768 1.52 195
steel
15 Handle clevis SAE 7860 3.54*10−6 0.02782 3.67 200
𝑘𝑔
7820 ⁄ 8.095
106
3
𝑚 * 10−5𝑚3
16 Frame 1 Mild or 1 0.63302kg 12.67 280
low birr
carbon
𝑘𝑔
7820 ⁄ 9.2245
steel
3
𝑚 * 10−7𝑚3
17 pin Mild or 4 0.007214kg 8.67birr 60
low
carbon
steel

138
 𝑘𝑔
⁄ 3 3.456
𝑚 * 10−6𝑚3
18 nut Cast 24 7200 0.024883kg 4.137birr 288
steel
7850𝐾𝐺⁄ 2.61219
* 10−5𝑚3
19 Frame 2 Plain 1 0.2051kg 11.80birr 310
𝑚3
carbon

7850𝐾𝐺⁄ 4.35365
steel

* 10−5𝑚3
20 Frame 3 Plain 1 0.34175kg 11.80birr 235
𝑚3
carbon
𝑘𝑔
7820 ⁄ 1.36
steel
3
𝑚 * 10−5𝑚3
21 support plate Mild or 5 0.1064kg 290
low 12.67birr
carbon
𝑘𝑔
7820 ⁄ 4.99275
steel
3
𝑚 * 10−5𝑚3
22 bolt Mild or 24 0.390kg 332
low 12.67birr
carbon
steel
11 total - 4115
Total material - - - - - 25% of 1028.75
wastage before total
machining material
cost
2. Lobar cost
Lobar cost for Hr per day*no of day*money hr No of lobar Total cost
12 Machining
turning 2hr per day*1day*90birr 3 540
drilling and 3hr per day*3day*70birr 1 630
Boring
tapering 3hr per day*1days*60birr 1 160
threading 2hr per day*2days*60birr 2 480
facing 2hr per day*2days*50birr 2 400
13 forging 2hr per day*2days*40birr 1 160
14 rolling 2hr per day*1day*60birr 2 240
13 Transportation - - 280
Total 2890
Then, the total cost = material cost + machining cost + contingency cost (15 %)
Total cost = 5143.75+2890 + 1205.06 = 9238.8birr.

4.6. Maintenance Method

Maintenance means upkeep, support, or subsistence of an object. First all the machine must be:-
 To clean and lubricate all moving parts.
 Before uses by checking for broken, cracked, bent, or loose parts, or any visible damage
to welds, saddle, frame and all parts including nuts, bolt, and other fasteners. If any
suspect item is found machine and taking necessary action to remedy the problem.
 Periodically check the machine for signs of rust and corrosion.

139
The main or primary goals of maintenance are to avoid or mitigate the consequences of failure of
equipment.
From maintenance type we select preventive type maintenance (PM)
 Preventive type maintenance (PM):- It is a set of activities that are performed on plant
equipment, machines, and systems before the occurrence of failure in order to protect them and
to prevent or eliminate any degradation in their operation conditions.
The maintenance schedule depends on the inspection results that is it may be replace, repair, services,
and the conditions where the operation is takes place.
Maintenance Schedule
Due to this reason the table 4.9 showed each parts and inspection durations.
Table 4.9: Maintenance Schedule

Design part Material hourly Daily weekly monthly yearly

Jaw Cast iron 
Crossed arm Cast iron 
Cylinder mild steel 
Reservoir Mild Carbon steel 
Handle Alloy steel 
Small Plunger Alloy steel 
Handle clevis Mild Carbon steel 
Piston ram Alloy steel 
Valve Selection 
Spring Mild Carbon steel 
Support arm Plain carbon steel 
Support table(frame one) Plain carbon steel 
Main and base frame Cast steel  
Screw Alloy steel
Liner tube Alloy steel 
Plates for jaw Mild steel 
Bolt, nut and washer Plain carbon steel 
Pin Mild carbon steel 

140
4.7. Working Principle
When the handle moves up ward or the plunger of the pump makes moves up, a partial vacuum is
generated in the pump cavity. The vacuum created in the cavity makes the outlet check valve to close
the outlet line and allows the atmospheric pressure to push fluid from the reservoir into the pump via
the inlet check valve.

When the handle moves down ward or the plunger of the pump makes down, the fluid movement
forces the inlet check valve to close and open the outlet check valve. The plunge compresses the fluid
and the hydraulic pressure developed by pump. The hydraulic power developed by pumps is converted
back into mechanical energy by hydraulic actuators connected to the output solid ram. Then when the
solid ram pushes the axle shaft or rear wheel hub simultaneously in reverse direction, then jaws extract
or remove the drum that fitted from drum brake assembly and rear hub wheel hub. After that jaws
return to original place by help of return spring. As shown figure 4.25 below the 3D modeling of the
machine

141
Figure 4.25: 3D Geometrical model of the machine by AutoCAD2015 software.

142
 CHAPTER FIVE

5. RESULT AND DISCUSSION

After finishing designing components of hydraulic puller or extractor the following results are obtained
by using max hammering force which is measured on car service center by presenting us in that work
place in addition to inform professional mechanics working experience seen manual. Total hammering
force = 5000N and one normal handle press operator force = 196.2N. By using above data we have
obtained following presented values.

5.1. Result
Table 5.1: Dimensions designed components

Components Types of materials Specifications Values

Handle AISI 1010 CD Length 450 mm
Diameter 19 mm
Handle clevis SA 106 Outer diameter 20mm
Inner diameter 15 mm
Plunger AISI 1010 CD Length 75 mm
Diameter 5 mm
Liner tube AISI 1010 Inner diameter 7 mm
Outer diameter 11 mm
height 20 mm
Bolt for wheel Low carbon steel Outer diameter 3 mm
Nut for wheel Low carbon steel Inner diameter 3mm
Washer Low carbon steel Inner diameter 4mm
Solid ram AISI 1015 Length 200 mm
Diameter 10 mm
Screw AISI HR 1006 Length 120 mm
Core diameter 17 mm
Nominal diameter 22 mm
Pitch 5 mm
Height of thread 2.5 mm
Jaw SAE 1015 HR Length 37 mm.

143
 Width 12 mm
Height 250 mm.
Cross arm Cast iron Outer diameter 33 mm
Cylinder SA 210 Outer diameter 18mm
Internal diameter 10 mm
Height 15 mm
Bolt for cross arm Plain carbon steel Total length 50 mm
Thread length 24 mm
Diameter 8 mm
Oil tank SA-106 Height 450 mm
Internal diameter 21 mm
Outer diameter 29mm
Pins for handle clevis and mild steel Diameter 8 mm
for the universal ring
Length 23 mm
maximum bending 74555.55Nmm
moment
Pin connecting plunger and AISI 1015 Diameter 8 mm
handle clevis

Length 20 mm
maximum bending 74555.55Nmm
moment
Jaw return spring Carbon steel Mean diameter of the 11 mm
spring

Spring index 1.1

diameter of the spring wire 10 mm

Total number of turns 20

144
 Pitch of coil 10 mm

Deflection of the spring 1.1979 mm

Solid length 200 mm
Free length 220 mm
Plates for the handle fulcrum SA 106 Length 3 mm.

Width 1.5 mm
Height 4 mm
Plates for the jaw SA 106 Length 17 mm
Width 2 mm
Height 20 mm
Nut for the jaws Carbon steel Major diameter 8 mm

Hydraulic fluid petroleum based oil Viscosity grade ISO VG 46

Number of stroke needed to pull up to its max reach Strokes 8

5.2. Discussion

The dimensions of components are determined using equations and also taking different assumptions.
During the designing process, when the calculated parameters are in decimal figures it is rounded off
to the upper convenient numbers. When the dimensions of components and material used are
compared to the other manufactured hydraulic pullers in foreign markets, it has much similarity to the
one the project utilized.
The components designed are safe due to a proper selection of material type and making of the design
using the right equations from best design books. As a result of this, the objective of the project to
design efficient hydraulic puller or extractor is accomplished.
The hydraulic designed here needs only about 8 strokes in one stroke 5000/8 = 625𝑁 to pull the
drum part from the shaft. So the objective of the project regarding to reducing time spent for pulling
tasks is fulfilled. And also objective of the project regarding to minimizing labor force applied on
pulling operations is accomplished as the machine needs only 196.2 N (5000/196.2 = 26 times press)
force from the operator.

145
 CHAPTER SIX

6. CONCLUSION AND RECOMMENDATION

6.1. Conclusion

From the result and discussion and overall design, it could be concluded that the objectives of this
thesis project is accomplished and problems raised in car service center due to improper extracting or
pulling operation will be solved if the machine is utilized wisely and properly. All the required
parameters like component dimension and capacity are properly accomplished by using measured data
values effectively designed. we have known that how theoretical studies are related to practical
applications and initiated to perform a better effort on this project.
Finally conclude that the new extractor machine is more advanced than traditional way in the
perspectives of time wastage, drum safety and workers safety.

6.2. Recommendation

We strongly recommend car service centers to buy this machine and use this hydraulic extractor or
puller effectively, it can make a further advancements in its contribution for the society and the country
especially in its maintenance and service sectors and also be able to reduce its loss related pulling
operations.
Finally, we recommended that to done simulation of each part, different average vehicle drum
extracting data recorded for safe design, and checking the performance of the real designed machine
and traditional ways of extracting operations.

146
 REFERENCES

[1].BethrandN. Nwankwojike, Chukwunonso N. Nwogu and GodswillKalu (September 2017)

Development of aManually Operated Hydraulic Puller Machine. FUOYE Journal of
Engineering and Technology/Volume 2/ Issue 2/ ISSN: 2579-0625 (Online), 2579-0617.
[2].A. Saravana Kumar (August 2017) design and fabrication of hydraulic Cylinder liner
puller,International Journal of Mechanical Engineering and Technology (IJMET) /Volume 8/
Issue 8/ ISSN Print: 0976-6340 and ISSN Online: 0976-6359.
[3].C.Senthil kumar, S.Raja and L.Vadivelkannan (November 2018) Design and Analysis of
Pneumatic Bearing Pusher and Puller, International Journal of Mechanical Engineering and
Technology (IJMET)/ Volume 9/ Issue 11/ISSN Print: 0976-6340 and ISSN Online: 0976-
6359.
[4].Rakesh Y Suryawanshi, Pranay S. Ramteke, NirajPatil, and Deepak Kumar. (April, 2015)
Design and fabrication of hydraulic bearing puller and pusher. IJIRST –International Journal
for Innovative Research in Science & Technology / Volume 1/Issue 11 / ISSN (online): 2349-
6010.
[5].www.google.com, https://brakes/MB service center.co.uk. (Accessed date in April 7, 2019 at 6
PM).
[6].www.google.com, https://www.my – car dictionary.com /brake/brake drum.html (accessed date
in April 8, 2019 at 3AM).
[7].www.Engineering mini projects .com/design and fabrication of hydraulic puller (accessed date
in April 8, 2019 at 5PM).
[8].www.google.com.https://me-mechanical enginnering.com/comparison electrical, pneumatic
hydraulic systems. (Accessed date in April 11, 2019 at 4AM).
[9].www.automotive technology serivece.com Nike express hydraulic bearing puller machine
(2008) (accessed date in April 9, 2019 at 9AM)
[10]. R.S. Khurmi and J.K.H. Gupta (2005), Textbook of Machine Design, 14th Edition, publisher,
Eurasia publishing house (PVT.) LTD. Ram Nagar, New Delhi – 110-055.
[11]. Shigley’s (2006), Mechanical Engineering Design, 8th Edition, publisher, McGraw-Hill
Companies, Americas New York.
[12]. William D. Callister (2011), Materials Science and Engineering, 17th Edition, Publisher,
John Wiley and Sons, Inc., 605 Third Avenue, New York, NY 10158-0012.
[13]. Donald R. Askeland (2003), Science and Engineering of Materials, 6thEdition, Publisher,

147
 Global engineering, Christopher M.shortt.
[14]. www.reliance-fundlry.com/plain carbon steel and low carbon steel,( march 12, 2019 at 7AM).
[15]. K.L. Narayana and P. Kannaiah, (2003), Machine Drawing, 3thEdition, published by new
Age international (P) Ltd, 4885/24, Ansari road, daryaganj, New Delhi -110002.
[16]. https://www.caster wheel.net/technology/caster selection.html, (April 05, 2019 at 5AM).
[17]. Stephen Sumerlin, how to select the right hydraulic oil lubrication. (Accessed date in June 04,
2019 at 6AM)
[18]. Engineering Toolbox (2003), Valveselectionguidehttps://www.engineeringtoolbox.com/valve,
(Accessed date in June 01, 2019 at 3AM)
[19]. MYKIN Inc.2018.O ring design guide. http://mykin.com/seal and o-ring-design guide.html.
(Accessed date in June 04, 2019 at 5AM)
[20]. George E. Dieter (2004), Engineering design, 4th edition, published by McGraw-Hill, a
Business unit of the McGraw – hill companies, Inc., 1221 Avenue of the Americas New York,
NY 10020.

148
 APPENDIX

Appendix A
Table A1: Values of crushing stress (𝜎𝑐) and Rankine’s constant (a) for various materials[10].
𝜎𝑐 i𝑛 𝜎𝑐
𝑎= 2
𝑀𝑝𝑎 𝜋 ×𝐸
No. Material

1
9000
1 Wrought iron 250

1
1600
2 Cast iron 550

1
7500
3 Mild steel 320

1
750
4 Timber 50

Table A2: Coefficient of friction under different condition

No Condition Average coefficient of friction

Starting Running
1 High grade material and workshop and best 0.14 0.10
running condition
2 Average quality of materials and workshop 0.18 0.13
and average running conditions.
3 Poor workmanship or a very slow 0.21 0.15
and infrequency motion with in
different
lubrication or newly machined surface

149
TableA3: Basic dimensions for square threads screw in mm (Normal series) according to IS : 4694 –
1968 (Reaffirmed 1996)[10].
Nominal Major diameter Major Pitch(P) Depth of thread Area of
diameter Bolt(d) Nut(D) diameter(𝑑𝑐) Bolt(h) Nut(H) core(𝐴𝑐)
(𝑑1) in 𝑚𝑚2
22 22 22.5 17 227
24 24 24.5 19 5 284
26 26 26.5 21 2.5 2.75 346
26 28 28.5 23 415
30 30 30.5 24 452
32 32 32.5 26 6 3 3.25 531
34 34 34.5 28 616
36 36 36.5 30 707
38 38 38.5 31 755
40 40 40.5 33 7 3.5 3.75 855
42 42 42.5 35 962
44 44 44.5 37 1075
46 46 46.5 38 1134
48 48 48.5 40 8 4 4.525 1257
50 50 50.5 42 1385
52 52 52.5 44 1521
55 55 55.5 46 1662
58 58 58.5 49 9 4.5 5.25 1886
60 60 60.5 51 2043
62 62 62.5 53 2006

150
Table A4: Total number of turns, solid length and free length for different types of spring end
connection [10].
No. Type of end Total number of Solid length Free length
turns (n”)
1 Plain ends N (n+2)𝑑 p× 𝑛 + 𝑑
2 Ground ends N n× 𝑑 p× 𝑛
3 Squared ends n+2 (n+3)𝑑 p× 𝑛 + 3𝑑
4 Squared and ground ends n+2 (n−2)𝑑 p× 𝑛 + 2𝑑

Table A5: Limiting values of bearing pressure [10].

No Application of screw Material Safe bearing Rubbing speed at
1 Hand press Screw Nut pressure(𝑃𝑏) thread pitch diameter

in
𝑁⁄𝑚𝑚
2

2 Hand press Steel Bronze 17.5 – 24.5 Low speed, well

lubricated
2 Steel Cast steel 12.6 – 17.5 Low speed <
Screw jack 2.4𝑚 / 𝑚i𝑛
Steel Bronze 11.2 – 17.5 Low speed < 3m/min
3 Steel Cast iron 4.2 – 7.0 Medium speed 6 –
Hoisting screw 12m/min
Steel Bronze 5.6 - 9.8 Medium speed 6-
12m/min
4 Land screw Steel Bronze 1.05 – 1.7 High speed >
15m/min

151
Table A6: Values of allowable shear stress, Modulus of elasticity and Modulus of rigidity for various
spring materials [10].

Allowable shear stress (𝑟)𝑀𝑝𝑎 Modulus of Modulus of

No Material Server Average Light rigidity (G) elasticity(K)
Service service service (𝑘𝑁⁄𝑚2) (𝑘𝑁⁄𝑚2)
1 Carbon steel
(a) 𝑢𝑝𝑡𝑜𝑡𝑜 2.125𝑚𝑚 420 525 651 80 210
(𝑏) 2.125 𝑡𝑜 4.625𝑚𝑚 280 485 595 80 210
(𝑐) 4.625 𝑡𝑜 8.00𝑚𝑚 336 420 525 80 210
(𝑑) 13.25 𝑡𝑜 24.25𝑚𝑚 294 364 455 80 210
(𝑒) 24.25 𝑡𝑜 38.00𝑚𝑚 252 315 392 80 210
2 Music wire 292 490 612 80 210
3 Oil tempered wire 336
4 Hard – drawn spring wire 280 350 651 80 210
5 Stainless- steel wire 280 350 437.5 80 196
6 Monel metal 196 245 306 44 105
7 Phosphor bronze 196 245 306 44 105

TableA7: Buckling of Compression Springs and Values of buckling factor (KB)[10].

𝐹𝐿
𝐹𝐿 𝐷
Hinged end Built – in end Hinged end Built – in end

𝐷
spring spring spring spring

1 0.72 0.72 5 0.11 0.53

2 0.63 0.71 6 0.07 0.38
3 0.38 0.68 7 0.05 0.26
4 0.20 0.63 8 0.05 0.19

152
Table A8: The design dimensions of I.S.O. screw threads for screws, bolts and nuts of coarse and
fine series[10].
Designation Pitch in Major or Effective Minor or core Depth of Stress
mm nominal or pitch diameter (𝑑𝐶) thread area(𝑚𝑚2)
diameter diameter Bolt nut (bolt) mm
of nut of nut and
and bolt bolt(𝑑𝑝)
(d=D)
1 2 3 4 5 6 7 8
Coarse series
M 0.4 0.1 0.400 0.335 0.277 0.292 0.061 0.074
M 0.6 0.15 0.600 0.503 0.416 0.438 0.092 0.166
M 0.8 0.2 0.800 0.670 0.555 0.584 0.123 0.295
M1 0.25 1.000 0.838 0.693 0.729 0.153 0.460
M 1.2 0.25 1.200 1.038 0.893 0.929 0.158 0.732
M 1.4 0.3 1.400 1.205 1.032 1.075 0.184 0.983
M 1.6 0.35 1.600 1.373 1.171 1.221 0.215 1.27
M 1.8 0.35 1.800 1.573 1.371 1.421 0.215 1.70
M2 0.4 2.000 1.740 1.509 1.567 0.245 2.07
M 2.2 0.45 2.200 1.908 1.648 1.713 0.276 2.48
M 2.5 0.45 2.500 2.208 1.948 2.013 0.276 3.39
M3 0.5 3.000 2.675 2.387 2.459 0.307 5.03
M 3.5 0.6 3.500 3.110 2.764 2.850 0.368 6.78
M4 0.7 4.000 3.545 3.141 3.242 0.429 8.78

Table A9:colsonmoldon polyurethane aluminum core wheels, capacity up to 6672Nor each [16]

Whee Tread Capacity Bear Whee Bearin Bore

l dia width each ing l g less
(pounds) mode bore bearin

3⁄ ” 13⁄1
l no g

4
4” 2” 700 Delri 5.000

6”
n 04.93

153
 ”

3⁄ ” 13⁄1 3⁄
1⁄ ” 27⁄16 TG1:5 23⁄8
4 2
5” 2” 1000 Delri 5.000 2
n 05.93
6” 16 ” 7866.0
1 1
3⁄ ” 13⁄16 3 2 1⁄ ” 27⁄16 23⁄8
”

4 ⁄16 2
rolle 5.000
r 05.93 ” ”
9
3⁄ ” 3 1⁄ ” 27⁄16 TG1:5 23⁄8
”
1 ⁄16 3
4 ⁄16 2
6” 2” 1200 Delri 5.000 2
n 06.93 ” ” 7866.0
1 1
3⁄ ” 13⁄16 3 2 1⁄ ” 27⁄16 23⁄8
”

4 ⁄16 2
rolle 5.000
r 06.93 ” ”
9
3⁄ ” 13⁄16 3 1⁄ ” 27⁄16 TG1:5 23⁄8
”

4 ⁄16 2
8” 2” 1500 Delri 5.000 2
n 08.93 ” ” 7866.0
1 1
3⁄ ” 3 1⁄ ” 27⁄16 23⁄8
”
1 ⁄16 3
4 ⁄16 2
rolle 5.000 2
r 08.93 ” ”
9 ”

Table A10:standard seal, groove diameters and tolerances[20].

groove Tolerance
Seal
Cross Seal clearance Groove Minimum diameter Seal Groove
section diameter depth groove tolerance tolerance
range f width G t H
0.032 0.250 to 0.010 0.025/0.027 0.040 0.126 to 0.002 0.002
1.000 1.000
0.063 o.375 to 0.010 0.049/0.051 0.075 1.001 to 0.002 0.003
8.00 2.000
0.094 0.500 to 0.010 0.072/0.076 0.105 2.001 to 3.00 0.003 0.003
13.500
0.125 1.00 to 0.010 0.097/0.103 0.135 3.001to 0.004 0.004
13.5 5.000
0.157 2.000 to 0.010 0.123/0.129 0.170 5.001 to 0.006 0.006
13.500 7.000
0.188 3.000 to 0.010 0.148/0.154 0.200 7.001 to 0.010 0.006
13.500 13.50
0.230 4.00 to 0.010 0.196/0.204 0.260 - - -
13.500
0.8 3.2 to 0.25 0.64/0.69 1.02 3.20 to 25.4 0.05 0.06
25.4
1.6 9.5 to 0.25 1.24/1.30 1.91 25.42 to 0.05 0.08
203.2 50.80

154
 2.4 27.5 to 0.25 1.83/1.93 2.67 50.83 to 76.2 0.08 0.08
406.4
3.2 25.4 to 0.25 2.46/2.62 3.43 76.23/127.00 0.10 0.10
635.00
4.0 50.8 to 0.25 3.12/3.28 4.32 127.03 to 0.15 0.15
635.0 177.80
4.8 76.2 to 0.25 3.76/3.91 5.08 177.83 to 0.25 0.2sss
635.0 406.40
6.4 101.6 to 0.25 4.98/5.18 6.60 - - -
635.0

Table A11: Coating Thickness value for different coating/ plating material[20].

Plating/coating thickness Groove finish Temperature limits

Teflon 0.001/0.003(0.03/0.08mm) 16-32RMS(0.4-0.8Ra μm) Cryogenic 500 °F
0.003/0.004(0.08/0.1mm) (260°c)
Silver 0.001/0.002(0.03/0.05mm) 16-63RMS(0.4-1.6Ra μm) Cryogenic 1200 °F
0.002/0.003(0.05/0.08mm) (649°c)
Nickel 0.001/0.002(0.03/0.05mm) 16-32RMS(0.4-0.8Ra μm) Cryogenic 2200 °F
(1200°c)
None N/A <16 RMS(<0.4Ra μm) N/A

Table A12: Rings materials working temperature range [20].

Elastomer Low F High F

Buna – N(nitride ) -40 250
Butadiene, styrene butadiene -50 212
Butyl -50 250
Chloroprene (neoprene) -45 260
Ethylene propylene -60 260
Fluorocarbon -25 400
Fluor silicone -100 395
Hydrogenated nitride -30 330
Natural rubber/ isoprene -55 210
Polyacrylate -25 300
Silicone -100 450

155
Table A13: Rubber Hardness data [20].

No Rubber Rubber hardness data

1 Rubber band Shoe 20A
2 Pencil Eraser Shore 40A
3 Car Tire Tread Shore 60A
4 Running Shoe Sole Shore 70A*
5 Leather Belt Shore 80A
6 Shopping Cart Wheel Shore 100

TableA14: O-ring groove design (dimensions given are in inch)

O-ring CS L G
0.04 0.032 0.073
0.05 0.041 0.080
0.06 0.049 0.091
0.07 0.055 0.095
0.103 0.088 0.146
0.139 0.121 0.193
0.21 0.186 0.286
0.275 0.239 0.380

Table A15: Standard size AS568 O-ring using the O-ring Size Char

Nominal Actual Nominal Actual

AS568
No. ID ID CS CS
001 1/32 0.029 1/32 0.040
002 3/64 0.042 3/64 0.050
003 1/16 0.056 1/16 0.060
004 5/64 0.070 1/16 0.070
005 3/32 0.101 1/16 0.070
006 1/8 0.114 1/16 0.070
007 5/32 0.145 1/16 0.070

156
 008 3/16 0.176 1/16 0.070
009 7/32 0.208 1/16 0.070
010 1/4 0.239 1/16 0.070
012 3/18 0.364 1/16 0.070
019 13/16 0.301 1/16 0.070
020 7/8 0.801 1/16 0.070
021 15/16 0.926 1/16 0.070
023 1/16 1.051 1/16 0.070
102 1/16 0.049 3/32 0.103
103 3/32 0.081 3/32 0.103
162 5-3/4 5.737 3/32 0.103
163 6 5.987 3/32 0.103

Table.A16: Valve series and their specifications [19].

General purposes
Function 2-&-3way
Media Gas only Gas and liquid
Size Sub- miniature Miniature
𝐶𝑣 range 0.018- 0.070 0.019 – 0.430 0.045 –
0.880
Port # 10 – 32 Barb # 10 – 32 1/8 , ¼,
configuration Manifold mount (1/16, 1/8 , ¼ NPT 3/8 NPT,
5/64, 1/8) manifold mount manifold
mount
Orifice 0.32 – 0.440 0.031 - 0.032 – 0.156 0.062 – 0.210 0.047 –
𝑑i𝑎(i𝑛) 0.052 0.375
Power(w) 0.65, 2 0.5, 1, 2 6 7 10
MOPD(psi) 175 250 100 1000 400 900
Valve series E, EH G, GH M A B C D
Pages J – 7, J - J – 9, J- 6 J – 5, J - 6 J – 11, J - 12 J – 15 , J – 15 , J – 17, J –
10 J - 14 J – 16 18

157
Table A17: ISO viscosity grade for different pump types at different temperature and pressure.

/E𝑚𝑎𝑥.
Pump type temp Pressure bar/psi Viscosity ISO VG

Gear 70/158 34.5/500 32 – 38

60/140 34.5/500 15 – 32
70/158 34.5/500 15 – 32
Vane 60/140 69/1000 22 – 46
40/104 69/1000 15 – 32
70/158 69/1000 10 – 15
70/158 34.5/500 15 – 22
70/158 172.5/2500 22 – 46
60/140 172.5/2500 32 – 46
Piston 40/104 172.5/2500 15 – 22
70/158 293/4250 46 – 68
60/140 293/4250 22 – 46
40/104 293/4250 15 – 22

158
Appendix B
Part and Assembly Drawing

159