DESIGN CALCULATION & ANALYSIS

Every project has specific dimensions & every dimension value needs
calculations as we have studied the different parts of the project hydronus now its time to
calculate the excite dimensions of the project
5.1

THE PISTON ROD

The piston rod is circular in shape & has length of 150 mm. The piston rod is
made up of mild steel SA 36 Grade A. The compressive stress of SA 36 mild steel is
407.7 MPa.
Since the oil concentrates in the cylinder when pumped by plunger pump. This oil
creates pressure in the cylinder and as the piston is free to move in the cylinder, the whole
pressure acts on the cross sections of the piston.
In order to design hydraulic cylinder, we should know the load bearing capacity
of the hydraulic cylinder depends upon the two factors.
1. Load bearing capacity of piston rod.
2. Load bearing capacity of
5.2

CALCULATING LOAD BEARING CAPACITY OF PISTON ROD

In our case the pressure is applied by on one face of the piston while the other
cross section of the piston faces the fixed wall. This means that the failure or breakage of
piston rod will occur only due to excessive compressive stress developed in the piston
rod.
As we know that the maximum limit of compressive stress that a mild steel
specimen can bear is 407.7 MPa.
Since the diameter of the piston is 25 mm therefore we can lastly calculate the
amount of maximum load which can be beard by the piston.
=>

F
A

Where.,
R = radius of the piston rod,
= stress,
A = area of the piston head.
A = R2

But,
=>
=>
=>

= x (25)2
4
=>
A
= 490.87 mm2
stress () = 407.9 N/mm2
force = stress x Area
Area

= 407.7 x 490.87
= 200127.699 N
We know,
1 Kg force = 9.81 N
Force (F) = 200127.699
9.81
F = 20400.37 Kg

=>
=>
Also we know,
=>
=>

1 Tone = 1000 kg.

F = 20.4 Tones

This means that 20.4 tones is that 20.4 tones is the last limit of our piston rod. But our
aim is to design the hydraulic cylinder which can easily with stand with 3 to 5 tones.
5.3
CALCULATING THE MAXIMUM INSIDE PRESSURE OF BAREL
Lets assume a weight of 5 tones acts on the piston. Therefore the pressure created by the
piston in the cylinder or barrel can be calculated by the following formulae
Pressure = Force
Area
Where area is the cross section of the piston rod.
=>
Area = IID2
4
= II(25)2 mm2
= 490.81 mm2
Pressure = Force
Area
=>

Force = 5 tonnes

We know,
=>

1tonnes = 1000 kg
force = 5000 kg.

Again, we know
1 kg force = 9.81N
Force = 9.81 x 5000N
=>

Pressure = 9.81x5000

N/mm2

490.87
=>
Pressure = 99.924 N/mm2
This means that pressure of 100 MPa or 100N/mm2 walls of the cylinder barrel when the
hydraulic cylinder will loaded with 5 tones force.
5.4
CALCULATING THE THICKNESS OF THE BARREL
The lame's equations are:r = b - a
r2
c = b + a
r2
Where,
r = The radial stress
c = The circumferential stress
a and b = constants
r = radius
Since the internal dia meter of the barrel is 40 mm as per design. Now we have to
calculate the outer diameter of the barrel.
Inner radius = r1 = Di
= 40 = 20 mm
2
2
Let outer radius = 80 mm
Since the material used for making cylinder barrel is mild steel SA 36 there maximum
tensile stress for this material is 410 MPa
i.e.
c at inner radious (ri) equal to 410 MPa
=>
c = 410 =
b +a
(20)2
=>
b + a = 410
(20)2
Also,
=>

r = b

- a
(ri)2

Since pressure at inner surface is 100 MPa

r at inner radius is equal to 100 N/mm2
=>

b - a = 100

. (1)

(20)2
r at inner radius is equal to 100 N/mm2
=>

b - a = 100
(20)2

(2)

adding equation (1) & (2) we get,

=>
b + a + b - a = 410 + 100
(20)2
(20)2
=>

2b

=>

b =

510
(20)2
510 x 202
2

=>

b = 102, 000 N

Put the value of b in Equation 2 & we get

=>

102000

- a = 100
(20)2

=>

a =

102000

=>

a = 155 N/mm2

- 100
(20)2

Therefore, Lamen's equation for our case become

=>

c = 102000 + 115
r2

=>

r = 102000

and,
- 115
r2

Now the barrel was must be strong enough to absorve all the stress such that the stress at
the outer surface of the barrel must be zero.
i.e.
=>
r = o (at radious ro)
=>

r = 102000

115 = o

(ro)2
=>
=>

102000
ro2

- 115 = o
(ro)2
= 102000
115

=>
(ro2) = 886.956
=>
ro = 29.78 mm
=>
ro = 30 mm
=>
outer diameter (do) = 30x2 = 60 mm
Barrel wall thickness (t) = Outer radious - Inner radious
=>
t = ro ri = 30 -20 = 10 mm
5.5

Base Design

The base should be design with such specifications so that it can easily with stand with
the maximum pressure exerted by the horizontal hydraulic cylinder. The force exerted by
the horizontal cylinder should be less than tones as per our design considerations sour
aim is to find the thickness of the channel used to design the base

let the force of tones is applied across the channel.

=>
Force (f) = 5 tones = 9.81 x 8000 N
Area of the channel on which the force will act
=>
A = a2 - b2
Where,
a = side of outer square
b = side of inner square
let a = 80 mm & b = 70 mm
Therefore wall thickness of channel
=>
t = a-b
= 80-70
2
2
2
=>

10 mm
2

t = 5mm

Stress in the channel when a force of 5 tones is applied

=>

stress () = Force
Area

=>

=>

Stress =

9.81 x 5000
802 - 702
9.81 x 5000
1500
= 32.7 N/mm2
= 32.7 MPa

Since the above calculated stress is very much less than the ultimate tensile stress of mild
steel SA36 i.e. 407.7 MPa so our design is within the safe unit.
5.6
STRESS CALCULATION AT WEAKER POINT OF CHANNEL
In order to level the inner side of the hydnuos base, a cut should be given to inner face of
hydronus so that the flange of the vertical cylinder should set in the cut. This cut is
necessity because if the cut is not given the flange of the vertical hydraulic cylinder
remains outside the base & this leads to improper placement of the hydronus in the
door. The depth of the cut in the base & this leads to improper placement of the hydronus
in the door. The depth of the cut in the base from the inner side should be equal to the
overall thickness of the flange.
Due to this cut given to the base, a weaker section immerge due to reduction in
area our which load of o5 tonnes acts consider the following figure.
Since a cut of 20 mm is given therefore area on which full load will act will be as under:Therefore area of shaded portion
A = 80 x 60 - 70 x 55
=>
A = 950 mm2
Also,
Stress = Force
Area
Force = 5 tonne
we know,
1 Tonne = 1000 KG
1 Kg
= 9.81 N

Force (f) = 5000 x 9.81 N

=>
=>

Stress = 5000 x 9.81

950

Stress = 51.63 N/mm2

or
=>
Stress = 51.63 MPa

Which is less than ultimate compressive stress of mild steel SA 36 i.e. 407.7 MPa
therefore our design is completely safe.
5.7
CALCULATING THE LENGTH OF HORIZONTAL & AND VERTICAL
CYLINDERS
In order to determine the length of each we need to decided the strock length of each
cylinder both the cylinder have different stock lengths which are described as under.
5.7.1 CALCULATING THE LENGTH OF HOROZONTAL CYLINDER
Horizontal cylinder is the cylinder which runs parallel to the plane of door horizontal
cylinder is used to clamp or lock the project hydronus in the door. The stock for this
hydraulic cylinder is about 250 mm for calculating the length of cylinder, consider the
following figure.
The length of the cylinder (c) is the sum of the thickness of the end will thickness, oil,
gap thickness, piston thickness, thickness of the bush, the thickness of seal and the stroke.
Therefore length of cylinder

=>

LH = t1 + t2 + t3 + t4 + Stock
=>
LH = 10 + 25 + 30 + 10 + 250
LH = 325 mm

Where
t1 = thickness of the end cap
t2 = thickness of the bush
t3 = thickness of the cylinder head
t4 = thickness of the top tap inside the cylinder head
5.7.2 CALCULAING LENGTH OF VERTICAL CYLINDER
Similarly as in the case of horizontal cylinder the length of the vertical cylinder
will be decided from the stock required from this cylinder. It is practically seen that even
a gap of 20 or 30 mm between the door and its fixed chowkhat, at the point of lock, the
door can't be locked. So by creating a gap of 60 to 80 mm use can easily break the lock of

the door. So the stock needed for the vertical cylinder is about 100 to 120 mm is enough
for the operation of hydronus. The length of vertical cylinder equals to the sum of the end
wall thickness, oil gap, piston thickness, stock bush thickness and thickness of the seal
i.e.

=>
LV = t1 + t2 + t3 + t4 + Stock
=> LV = 10 + 25 + 30 + 10 + 120 = 195 mm
=>
LV = 195mm
=>
LH = 325 mm

Where
t1 = thickness of the end cap
t2 = thickness of the bush
t3 = thickness of the cylinder head
t4 = thickness of the top tap inside the cylinder head
5.8
CALCULATING THE CAPACITY OF OIL REQUIRED BY HYDRAULIC
CYLINDER
In order to decide the oil capacity and the reserve oil capacity we need to calculate the
minimum amount of oil used in the horizontal and vertical cylinder as well as the oil
reserves in the hydraulic pips which completes the hydraulic diagram.
5.8.1 OIL REQUIRED OF HORIZONTAL CYLINDER
Oil required to run the piston out of the cylinder describes the oil capacity of he hydraulic
cylinder. This oil capacity can be figured out by calculating the working strock valume at
the cylinder. The formula for calculating the strock volume of the hydraulic cylinder is
given as
Stock volume = x
4
=>

VN

=
4

(dia of oculinder)2 x (Stock length)

(dH)2 x SH

Where,
VN = Stock volume of horizontal cylinder.
dH = Inner diameter of Horizontal cylinder
SH = Stock length of horizontal cylinder
dH = 40 mm
Sh = 350 mm

VH

= (40)2 x 350 mm
4
= II x 5,60,000 mm3
4
= 439822.97 mm2
= 4.398 x 10-4 MS

We know1
1 L = 1 dm3
And
=> (1 dm)3 = (10 cm)3
=>
1 L = 1000 cm3
=> ( 1 cm )3 = { 1 m }3
100
1 L = 1000 x 1
M3
(100)3

=>

=>

1 L = 1000

M3
1000000

=>
1m3 = 1000 L
=> 4.398 x 10-4 M3 = 1000 x 4.398 x 10-4
=>
VH = 0.4398 2 L
We also know,
1 L = 1000 mL
=>
VH = 439.82 mL
=>
VH = 440 mL
5.8.2 OIL REQUIRED FOR VERTICAL RAM :
Let,
VV = stock volume for vertical cylinder
dv = inner diameter of vertical cylinder
SV = stock length of vertical cylinder

=>

VV =
4

(dv)2 x sv

Here,
dV = 40 mm
VV = (40)2 x 120 mm
4
VV = x 192000
4
VV = 150796.44 MM3
We know
1 mm3 = ( 1 )3 M3
1000
VV
We know,

= 1.50796 x 10-4 M3

1 m3 = 1000 L
VV = 1.50796 x 10-4 x 1000 L
VV = 0.150796 L
Or,
=>

VV = 150.796 mL
=>
VV = 151 mL

Therefore the net amount of oil required to drive both hydraulic cylinder is.
VNet = VH + VS
= (445 + 155) mL
= 595 mL
VNet = 600 mL approx.
5.8.3 CALCULATING THE AMOUNT OF OIL IN PIPS & VAIVS
Since total length of pipe is about 2 m which will be cut and use for transfering oil to the
hydraulic rams. The diameter of this pipe is about 1.5 mm or 0.015 m. Therefore volume
of oil which remains in the pipe can be calculated as under
volume of pipe = x (dia of pipe)2 x (length of pipe)
4
=> VP = II (0.015)2 x (2)
4

= 3.53 x 10-4 m3
=>
1M3 = 1000 L
=>
VV = 3.55 x 104 x 1000 L
=>
VV = 0.35342 L
Or,
=>
=>

VV = 353.42 ML
VV = 354 ML approx.

5.8.4 CALCULATING TOTAL OIL CAPACITY REQUIRED FOR HYDRAULIC

HAND PUMP
The net capacity of the hydraulic hand pump must satisfy the oil demand of horizontal
and vertical hydraulic cylinder as well as the pipes. Therefore the capacity of the pump
tank must be equal to the sum of volume of the two rams
and the pipe reserves i.e. the capacity of the tank must be greater than the oil civilized by
the project.
V = VH + VV + VP + VR
Where,
VR = Reserve oil in tank
= 1000 ml for being in safe unit.
=>
V = 440 + 155 + 354 + 1000
=>
V = 1949 ml
=>
V = 2L approx.

How Stuff Works

This commercial website provides no technical

explanations of technical topics.

www.wikipedia.com

Working of single acting and double acting cylinder.

www.wikipedia.com

Working of single acting and double acting pumps.

www.festo.com

This site is a good free source for information about the

calculations and designing of cylinder & pumps.

www.wikipedia.com

Piston seals.

www.google.com

Hydraulic Fluid.

Books Considered :

Strength of materials

By Dr. Sadhu Singh, Art. 12.9 Beam Column, pg. 566.

Machine Dersign

By R.S.Khurmi, Art.4.3,4.4,4.9 pg.88.

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3 comments:

Pratik Suthar says:

12 December 2012 12:11Reply

HOW CAN I ANALYSE THE FAILURE OF PISTON AND PISTON ROD ASSEMBLY BORE=140,ROD=63? TELL ME
THE EXACT FORMULA TO FIND FAILURE ..?
SEND ANS ON MY MAIL ID..
PRATIK SUTHAR
Id:PRATIK4918@YAHOO.COM

Anonymous says:

19 March 2013 00:39Reply20

Dear Sir,
I need help to perfect my design of Hydraulic pump,'evolved' to work in Marine environment. Please reply to
arkundapur at yahoo dot com.
Ashok Kundapur

Anonymous says:
7 February 2014 17:24Reply

Side loads in cylinder are normally borne by guide ring/wear ring at both ends. How to calculate how many guide
rings required for both piston as well as rod side.

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