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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
F
A
Where.,
R =
=
A =
A =
But,
=>
=>
=>
Area
= 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
=>
=>
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
=>
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
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
b - a = 100
(20)2
r at inner radiu i equal to 100 N/mm2
=>
a =
(20)2
100
(2)
2b
510
(20)2
=>
b =
510 x 202
2
=>
b = 102, 000 N
102000
100
(20)2
=>
a =
102000
100
(20)2
=>
a = 155 N/mm2
c = 102000 + 115
r2
and,
=>
102000
115
r2
r = 102000
115
= o
tre
(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 a = 80 mm & b = 70 mm
Therefore wall thickne of channel
=>
t = a-b
=
80-70
2
2
=>
Stre
10 mm
2
5mm
=>
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
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
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
=>
Where,
VN =
dH =
SH =
dH =
Sh =
VH
4
VN
(dH)2
x SH
4
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
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,
=>
=>
=>