Sep

29
DESIGN CALCULATION & ANALYSIS - HYDRONUS
DESIGN CALCULATION & ANALYSIS
Every project has specific dimensions & every dimension value needs calc
ulations as we have studied the different parts of the project hydronus now its t
ime 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 t
he 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 s
tress developed in the piston rod.
As we know that the maximum limit of compressive stress that a mild stee
l specimen can bear is 407.7 MPa.
Since the diameter of the piston is 25 mm therefore we can lastly calcul
ate the amount of maximum load which can be beard by the piston.
=>

F
A

Where.,
R =
=
A =
A =

But,
=>
=>
=>

Area

radiu of the pi ton rod,

tre ,
area of the pi ton head.
R2

= x (25)2

=>
stress () = 407.9 N/mm2
force
= tre x Area

4
= 490.87 mm2

= 407.7 x 490.87
= 200127.699 N
We know,
=>

1 Kg force = 9.81 N
Force (F) = 200127.699
9.81

=>
Al o we know,

= 20400.37 Kg

=>
=>

1 Tone = 1000 kg.

F = 20.4 Tone

Thi mean that 20.4 tone i that 20.4 tone i the la t limit of our pi ton ro
d. But our aim i to de ign the hydraulic cylinder which can ea ily with tand
with 3 to 5 tone .
5.3
CALCULATING THE MAXIMUM INSIDE PRESSURE OF BAREL
Let a ume a weight of 5 tone act on the pi ton. Therefore the pre ure creat
ed by the pi ton in the cylinder or barrel can be calculated by the following fo
rmulae
Pre ure = Force
Area
Where area i the cro
ection of the pi ton rod.
=>
Area = IID2
4
= II(25)2 mm2
= 490.81 mm2
Pre ure = Force
Area
=>

Force = 5 tonne

We know,
1tonne
=>

= 1000 kg
force = 5000 kg.

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

Pre ure = 9.81x5000

N/mm2

490.87
=>
Pre ure = 99.924 N/mm2
Thi mean that pre ure of 100 MPa or 100N/mm2 wall of the cylinder barrel whe
n the hydraulic cylinder will loaded with 5 tone force.
5.4
CALCULATING THE THICKNESS OF THE BARREL
The lame
equation are:r = b
- a
r2
c = b

+ a
r2

Where,
r = The radial tre
c = The circumferential
a and b = con tant
r = radiu

tre

Since the internal dia meter of the barrel i 40 mm a per de ign. Now we have t
o calculate the outer diameter of the barrel.
Inner radiu = r1 = Di
=
40 =
20 mm
2
2
Let outer radiu = 80 mm
Since the material u ed for making cylinder barrel i
imum ten ile tre for thi material i 410 MPa

mild teel SA 36 there max

i.e.
=>

c at inner radiou
(ri) equal to 410 MPa
c = 410 =
b
+ a
(20)2

=>

b +
. (1)

410
(20)2

Al o,
=>

r = b

a
(ri)2

Since pre ure at inner urface i 100 MPa

r at inner radiu i equal to 100 N/mm2
=>

b - a = 100
(20)2
r at inner radiu i equal to 100 N/mm2
=>

a =
(20)2

100

(2)

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

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

2b

510
(20)2

=>

b =

510 x 202
2

=>

b = 102, 000 N

Put the value of b in Equation 2 & we get

=>

102000

100
(20)2

=>

a =

102000

100
(20)2

=>

a = 155 N/mm2

Therefore, Lamen
equation for our ca e become

=>

c = 102000 + 115
r2

and,
=>

102000

115
r2

Now the barrel wa mu t be trong enough to ab orve all the

tre at the outer urface of the barrel mu t be zero.
i.e.
=>
r = o (at radiou ro)
=>

r = 102000

115

= o

tre

uch that the

(ro)2
=>

102000

115

= o
(ro)2

=>

ro2

102000
115

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

Ba e De ign

The ba e hould be de ign with uch pecification o that it can ea ily with t
and with the maximum pre ure exerted by the horizontal hydraulic cylinder. The
force exerted by the horizontal cylinder hould be le than tone a per our de
ign con ideration our aim i to find the thickne of the channel u ed to de
ign the ba e

let the force of tone i applied acro the channel.

=>
Force (f) = 5 tone = 9.81 x 8000 N
Area of the channel on which the force will act
=>
A = a2 - b2
Where,
a = ide of outer quare
b =

ide of inner quare

let a = 80 mm & b = 70 mm
Therefore wall thickne of channel
=>
t = a-b
=
80-70
2
2
=>
Stre

10 mm
2

5mm

in the channel when a force of 5 tone i applied

=>

tre

() = Force
Area

=>

9.81 x 5000
802 - 702

=>

Stre

9.81 x 5000

1500
= 32.7 N/mm2
= 32.7 MPa
Since the above calculated tre i very much le than the ultimate ten ile t
re of mild teel SA36 i.e. 407.7 MPa o our de ign i within the afe unit.

5.6
STRESS CALCULATION AT WEAKER POINT OF CHANNEL
In order to level the inner ide of the hydnuo ba e, a cut hould be given to i
nner face of hydronu o that the flange of the vertical cylinder hould et in
the cut. Thi cut i nece ity becau e if the cut i not given the flange of th
e vertical hydraulic cylinder remain out ide the ba e & thi lead to improper
placement of the hydronu in the door. The depth of the cut in the ba e & thi
lead to improper placement of the hydronu in the door. The depth of the cut i
n the ba e from the inner ide hould be equal to the overall thickne of the f
lange.
Due to thi cut given to the ba e, a weaker ection immerge due to reduction in
area our which load of o5 tonne act con ider the following figure.
Since a cut of 20 mm i given therefore area on which full load will act will be
a under:Therefore area of haded portion
A = 80 x 60 - 70 x 55
=>
A = 950 mm2
Al o,
Stre

= Force
Area

Force

= 5 tonne

we know,
1 Tonne = 1000 KG
1 Kg
= 9.81 N
Force (f) = 5000 x 9.81 N
=>

Stre

= 5000 x 9.81
950

=>
=>

Stre
Stre

= 51.63 N/mm2
= 51.63 MPa

or

Which i le than ultimate compre ive tre

a therefore our de ign i completely afe.

of mild teel SA 36 i.e. 407.7 MP

5.7
CALCULATING THE LENGTH OF HORIZONTAL & AND VERTICAL
CYLINDERS
In order to determine the length of each we need to decided the trock length of
each cylinder both the cylinder have different tock length which are de cribe
d a under.
5.7.1 CALCULATING THE LENGTH OF HOROZONTAL CYLINDER
Horizontal cylinder i the cylinder which run parallel to the plane of door hor
izontal cylinder i u ed to clamp or lock the project hydronu in the door. The
tock for thi hydraulic cylinder i about 250 mm for calculating the length of
cylinder, con ider the following figure.
The length of the cylinder (c) i the um of the thickne of the end will thick
ne , oil, gap thickne , pi ton thickne , thickne of the bu h, the thickne
of eal and the troke. Therefore length of cylinder
LH = t1 + t2 + t3 + t4 +
Stock
=>
LH = 10 + 25 + 30 + 10 + 250
=>
LH = 325 mm

Where
t1 = thickne
t2 = thickne
t3 = thickne
t4 = thickne

of
of
of
of

the
the
the
the

end cap
bu h
cylinder head
top tap in ide the cylinder head

5.7.2 CALCULAING LENGTH OF VERTICAL CYLINDER

Similarly a in the ca e of horizontal cylinder the length of the vertical cylin
der will be decided from the tock required from thi cylinder. It i practicall
y een that even a gap of 20 or 30 mm between the door and it fixed chowkhat, a
t the point of lock, the door can
t be locked. So by creating a gap of 60 to 80
mm u e can ea ily break the lock of the door. So the tock needed for the verti
cal cylinder i about 100 to 120 mm i enough for the operation of hydronu . The
length of vertical cylinder equal to the um of the end wall thickne , oil ga
p, pi ton thickne , tock bu h thickne and thickne of the eal i.e.
=>
LV = t1 + t2 + t3 + t4 +
Stock
=> LV = 10 + 25 + 30 + 10 + 120 = 195 mm
=>
LV = 195mm
=>
LH = 325 mm
Where
t1 = thickne
t2 = thickne
t3 = thickne
t4 = thickne

of
of
of
of

the
the
the
the

end cap
bu h
cylinder head
top tap in ide the cylinder head

5.8
CALCULATING THE CAPACITY OF OIL REQUIRED BY HYDRAULIC CYLINDER
In order to decide the oil capacity and the re erve oil capacity we need to calc
ulate the minimum amount of oil u ed in the horizontal and vertical cylinder a
well a the oil re erve in the hydraulic pip which complete the hydraulic dia
gram.
5.8.1 OIL REQUIRED OF HORIZONTAL CYLINDER
Oil required to run the pi ton out of the cylinder de cribe the oil capacity of
he hydraulic cylinder. Thi oil capacity can be figured out by calculating the
working trock valume at the cylinder. The formula for calculating the trock
volume of the hydraulic cylinder i given a
Stock volume = x
4

(dia of oculinder)2 x (Stock length)

=>

Where,
VN =
dH =
SH =
dH =
Sh =
VH
4

VN

(dH)2

x SH
4

Stock volume of horizontal cylinder.

Inner diameter of Horizontal cylinder
Stock length of horizontal cylinder
40 mm
350 mm
= (40)2 x 350 mm
= 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
(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 =

(dv)2
4

x sv

Here,
VV

dV = 40 mm
(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

M3

Therefore the net amount of oil required to drive both hydraulic cylinder is.
VNet

VH + VS
= (445 + 155) mL
=
595 mL
VNet = 600 mL arox.
5.8.3 CALCULATING THE AMOUNT OF OIL IN PIPS & VAIVS
Since total length of ie is about 2 m which will be cut and use for transferin
g oil to the hydraulic rams. The diameter of this ie is about 1.5 mm or 0.015
m. Therefore volume of oil which remains in the ie can be calculated as unde
r
volume of ie = x (dia of ie)2 x (length of ie)
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 arox.
5.8.4 CALCULATING TOTAL OIL CAPACITY REQUIRED FOR HYDRAULIC HAND PUMP
The net caacity of the hydraulic hand um must satisfy the oil demand of horiz
ontal and vertical hydraulic cylinder as well as the ies. Therefore the caac
ity of the um tank must be equal to the sum of volume of the two rams
and the ie reserves i.e. the caacity of the tank must be greater than the oil
civilized by the roject.
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 arox.