UNIVERSITY OF SOUTH AUSTRALIA Assignment Cover Sheet - Group

An Assignment cover sheet needs to be included with each assignment. Please complete all details clearly. If you are submitting the assignment on paper, please staple this sheet to the front of each assignment. If you are submitting the assignment online, please ensure this cover sheet is included at the start of your document. (This is preferable to a separate attachment.) Please check your Course Information Booklet or contact your School Office for assignment submission locations. Student Name (Print clearly) 1. Christian-Raymund Sarmiento 2.Deepak kumar 3.Rajeesh 4. Chen, Jiajie UniSA Email ID sarcr001@mymail.unisa.edu.au Yyydy003@mymail.unisa.edu.au Chiry007@mymail.unisa.edu.au chejy088@mymail.unisa.edu.au

Course code and title: (MENG 2004) Mechanical Design Practice Program Code: School: School of Advanced Manufacturing and Mechanical Engineering Day, Time & Location of Tutorial/Practical: Thursday, 4-7 pm, J2-25 Course Coordinator: John Fielke Tutor: John Fielke Extension granted (Yes/No): Due Date: Friday 16 September 2011 Assignment number & topic: Assignment 1 Design of a Mechanism We declare that the work contained in this assignment is our own, except where acknowledgement of sources is made. We authorise the University to test any work submitted by us, using text comparison software, for instances of plagiarism. We understand this will involve the University or its contractor copying our work and storing it on a database to be used in future to test work submitted by others. We understand that we can obtain further information on this matter at http://www.unisa.edu.au/learningadvice/integrity/default.asp Signed: 1. Christian-Raymund Sarmiento 2.Deepak kumar 3.Rajeesh 4. Chen, Jiajie Date received from student Assessment/grade Date:
17/09/10 17/09/10 17/09/10 17/09/10

Assessed by:

Recorded:

Dispatched:

Mechanical Design Practice

University of South Australia School of Advanced Manufacturing and Mechanical Engineering

MENG 2004 Mechanical Design Practice

Assignment 1 - Final Report Design of a Lifting Mechanism

Course Coordinator: Associate Professor John Fielke

Due date: 16th September 2011

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Executive Summary
Design This is the chosen design for the lifter which has capacity to lift 100kg at an inclination of 450 to the horizontal (Considering if the lifter being used in mountains and hilly areas). The mechanical advantage of the system incorporates with the use of hydraulics which allows us to put small input and obtain large output. In fluid power, hydraulics is used for the generation, control, and transmission of power by the use of pressurized liquids. Its a low maintenance system which is controlled by fluids and a power screw. The operating effort used in lifting the Mass is at bare maximum that is 400N such that with hydraulics (by foot) and Figure 1- Lifter Mechanism the lifter travels to and from the car boot with the help of parallel tracks installed inside. The operating effort applied with hands is 200N.

Figure 2 - Lifter Installed in Boot Space of the Safari Car

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ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 Design Project

PART NUMBER Car Boot Frame Fixture Link1 Link2 Lifting Platform Hydraulic Arm (M) Hydraulic Arm (F) Pin(Hydraulic Arm) Pins(Lifting Arms) Bolted Part Welded Part Power Screw Rings(Fixture) Hydraulic Cylinder Arm Hydraulic Cylinder

DESCRIPTION Safari car with parallel tracks installed inside Rectangular tubes built with welding operation Fastened on the frame with two screws each Freely rotating on the cylindrical surface of Fixture Freely rotating on the cylindrical surface of Fixture Accommodated with 2 no. of Link1 and Link2 each Attached to the Frame which enables linear motion Attached to two Link1's to provide circular motion Provides rigid connection on the frame Holds the Lifting platform with cylindrical fits Fastened with 4 bolts on the rear side of frame Welded on rear side of the Frame Mounted between Bolted and Welded Part Provides a back-up for fixtures and Link1 Used to advance with low input manually Cylinder used to pressurize liquids to Hydraulic Arms 4

QTY. 1 1 4 2 2 1 1 1 1 4 1 1 1 4 1 1

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Isometric View of Main Assembly

9 8 2 3 4 14 6 7

10

11 10 12 13

17 16

Figure 3 - Isometric Projection

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PARTS Frame Fixture Link1 Link2 Lifting Platform Hydraulic Arm (M) Hydraulic Arm (F) Pin(Hydraulic Arm) Pins(Lifting Arms) Bolted Part Welded Part

MATERIALS 2014 T6 Aluminium Alloy 2014 T6 Aluminium Alloy AISI 304 2014 T6 Aluminium Alloy RHS 1040 Steel alloy Cold Rolled AISI 304 AISI 304 2014 T6 Aluminium Alloy 2014 T6 Aluminium Alloy

SPECIFICATIONS/DIMENSIONS 1074 mm 1008 mm 80 mm, 74 mm 74 mm 100 mm 74 mm 444 mm 40 mm 74 mm 444 mm 40 mm 1008 mm 1172 mm 600 mm 50 mm 227 30 mm 227 mm 40 mm 70 mm 40 mm 80 mm 137.5 mm 148.5 mm 200 mm 230 mm 215 mm 137.5 mm Square thread, Double start, dm (30mm), dr (23 mm), length = 1074 mm 65 mm 20 mm

Power Screw Rings(Fixture)

Stainless Steel 2014 T6 Aluminium Alloy

Hydraulic Cylinder Arm AISI 304 Hydraulic Cylinder Design Project -

1225 mm 115 mm 80 mm Maximum Pumping Pressure Capacity = 46 MPa 6

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Figure 4 - Poster

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Table of Contents
Executive summary Description Rendered image Isometric View Bill of materials 3 3 4 5 6

Poster Table of contents The design of brief The Group Charter Concept map Task/roles Alternative ideas Design 1 Design 2 Design 3 Design 4 Design documentation Power screw design Bolted joint design Welded joint design Lifting platform design Pin design Material cost calculation Appendix

7 8 9 10 11 12 13 13 15 18 20 23 25 27 30 33 35 41 42

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Design Brief
Mobility scooters have been a beneficial aid in helping senior and disabled people travel from location to location. The design of mobility scooters have given many consumers who are who are unable to walk around an opportunity to travel with ease. Since its creation in 1968 by Allan R. Thieme () mobility scooters has been an essential part of many peoples lives. Recently with the UniSA company commencing business on July 2011, it is given at hand that the company has given responsibility to UniSA Design Group C1. Pty Ltd. The group consists of four designers to develop another approach in aiding the consumers of mobility scooters. The task is to develop a hand operated system for loading a mobility scooter into a car. The group is to also choose appropriate materials, so that money is not lost. The company would also like to sell as many of the designs as possible. The design group needs to follow a few needs in order for the design to be applicable. By approaching a method of selecting suitable types of cars and mobility scooters, the initial design concepts must be mechanically operated and proven to lift. The operating specifications must also be followed stating a maximum operating effort of 200 N by hand and 400 N by foot. This is reasonable due to the disadvantages of senior and disabled users. By developing the initial concepts and proceeding to the final appropriate design, the design group must also document the final design; its materials, total cost and recommended retail price (RRP).

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Group Charter
It is highly important that each group member attends all group meetings, to ensure that the group is up to date with work. Meetings are not to be missed. If so the group member must inform the group members via email, phone call, text with a valid reason. Each group member needs to be prepared and familiar with the given task to make certain that the time used is not wasted. Before and after group meetings the progress of the group should be observed, to determine that the group is heading towards the right path. It would be easier if each group member spoke out there differences of a topic so that a better solution can be found. Workloads are divided equally between the group members. Each group member is responsible for the task given at hand. Group members need to familiarise themselves with the theory and purpose of the project. This is to ensure that no one in the group struggles or slows down the progress. Group members are responsible for their calculations, and by approval can have it re-checked by another group member. It is essential that all group members work together to ensure the workload is completed on time. Failure to follow these rules will most probably result in a reasonable peer assessment.

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Concept Map

Below is the concept map outlining a step by step guide towards producing a lifter for mobility scooter.

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Task/Roles
Name Role/Designation Tasks Individual Force Balance Calculations Group Concept Map Executive Summary Statement of Task/ Roles Individual Concept Map Deepak Kumar Design Engineer Project Compiling A3 Poster Power Screw Design Material and Systems Cost Chosen Design Cad Model & Drawings (Solid Works) Individual Force Balance Calculations Group Concept Map Table of Contents Rajeesh Project Engineer Bolted Part Design Welded Part Design Individual Concept Map Project Compiling Individual Force Balance Calculations Group Concept Map Design Brief Christian Production Engineer The Group Charter Individual Concept Map Project Compiling Individual Force Balance Calculations Maintenance & Service Engineer Lifting Platform Design Pin Design Individual Concept Map

Peter

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Alternative Ideas
Each group member was given responsibility to develop designs that would aid consumers in placing a mobility scooter onto/into a car. The designs are presented as CAD models developed from Solid Works. The force balance diagrams and calculations of each design are to be proven, and that the design also follows the specifications to be applicable in the project. By applying research on certain vehicles and scooters, it was decided that the types of cars used would be wagons and safaris. Medium size scooters have also been chosen for this project.

Design 1

Design one consists of four bars, two on each side all attached to a central shaft. Also placed onto the shaft is the compartment or surface in which a mobility scooter is placed. The design procedure is fairly simple. There are two ends of the design. One end is fixed which is placed close to the boot of a safari or wagon. The other end is pinned with wheels that allow it to move forwards and backwards. Placed within the design is a welded body hydraulic cylinder. The cylinder is attached to shafts placed between the bars of the design. The particular hydraulic cylinder that would be used is a retracting cylinder. In other words the length of the cylinder decreases when pressure is applied by the piston. When the cylinder retracts, it causes the moving end to move towards the fixed end. Since they are both connected to a central shaft, the height of the device increases and the mobility scooter is lifted and also placed forward within the safari or wagon. From there on the scooter can be pushed in.

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Assume that the average weight of a mobility scooter is 100 kg. F1 = 100 kg * 9.81 m/s^2 = 981 N Assume that the max height allowed for the device to rise is 50 cm. The minimum height it can descend is 20 cm. When the hydraulic cylinder is placed within the design, an appropriate total length before retracting is 60 cm. When the device is high enough the new length of the cylinder is 30 cm. By applying the law of energy conservation we get equation. F (h1 h2) = f(l1 l2) F = 981 N, h1 = 0.5 m, h2 = 0.2 m, l1 = 0.6 m, l2 = 0.3 m 981 N (0.5 m 0.2m) = f(0.6 m 0.3 m) f = (981 N (0.5 m 0.2 m)) / (0.6 m 0.3 m) = 981 N Therefore the force needed from the hydraulic cylinder is 981 N to operate the device. Now assuming an input/output ratio of 1/5 for force gives us; Input / Output = Input = Output*(1/5) Output = 981 N Therefore Input = 981*(1/5) = 196.2 N 1/5

Depending on the pressure of the hydraulic cylinder the device can work. However for this case by assuming a1/5, input/output ratio of a cylinder the device can in fact lift the mobility scooter. Design Project 14

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Design 2

This design works on the principle of hydraulics and an effort is been made to reduce the complexity of mechanism. The whole system is been mounted on the rear boot of the car with pre-installed parallel tracks which guide the Frame. The motion of the Frame is controlled by the power screw which is mounted on the rare side. The power screw is mounted on two parts, out of which one is welded and other is fastened with screws. The hydraulic piston is mounted on the Frame with the conjunction of mechanical Pin. The Links (tip) is mounted on the Fixtures having ground surfaces (reamed surface). The links (root) is attached to the Lifting Platform with the help of 4 finished (reamed) holes and 4 Pins. All Pins have ground surfaces with two holes on one face to avoid rotation of the Pin itself. The hydraulic arm (male) is mounted on the support of the Rings which is welded on Links 1 & 2. The hydraulic piston is controlled by the pumping system which is rigidly attached at the bottom of the care.

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Force Balance Calculations Considering the maximum force condition such that a large distant force will make a large effort applied and less distant force makes small effort applied. Free Body Diagram Fd D W C E Fa Fc

(90- )

A Given: AB = 869.5, BC = 956, DE = 370, CE = 83

The only condition of maximum force Fd experienced by the hydraulic piston when Link CE is perpendicular to face DE. So = tan-1(DE/CE) = tan-1(370/83) = 77.35o = tan-1(BC/AB) = tan-1(956/869.5) = 47.713o Total Mass = Mass of the Scooter (Including Battery) + Mass of the Lifting Parts Total Mass = 100 kg + 100 kg Total Mass = 200 kg W = Mass * Gravitational acceleration = 200 9.81 = 1962 N Fa = 1962 / cos(90-) = 2.65 KN Fc = Fa cos = 1.8 KN Fd = Fc / cos = 8.15 KN

So the force acting on the hydraulic piston is 8.15 KN and now calculating the pressure exerted on the hydraulic piston that is P = Fd / (A - a) (Radius a = 12.5 mm, Radius a = 10 mm)

P = Fd / ((12.52 - 102)) = 46 MPa

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Force need to exert on the hand pump is 8.15 KN and it can be done by lever which is 1225 mm in length.

8.15 KN 55 1170

Taking moments at root of the lever 8.15 103 55 = F 1225 F = 383.10 N (which is less than required effort of 400 N )

So 383 N on 1225 mm lever will do the job. It is the proof that with this design effort is less than 400N with the foot effort.

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Design3

Main idea behind this design is to make a lifter which is safely attached to the car. The platform is attached to the links and operated using a hydraulic cylinder. Hydraulic cylinder is actuated using a hand pump and actuated using hand lever. The effort is calculated to be 192N. The lifter can be fitted to ford falcon wagon or any similar size wagons. Most of the scoter which are under 140kg, available in the market can be lifted with this lifter. Force Balance 200 700

150

1000

200 kg Design Project 18

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Total load to lift including mobile scooter and platform = 150 kg

Horizontal force

Vertical Force N Using a main hydraulic cylinder to lift the load, and total force on the cylinder is =13198N

This force can be exerted on the main cylinder using a hand pump. Using a 50mm cylinder and 20mm cylinder for hand pump

Force need to exert on the hand pump is 2111.68 Newton and it can be done by hand lever which is 220mm length.

2111.68N 20 200

2111.68

20 = 220

= 191.98N

So 191.8N on 220mm lever will do the job. It is the proof that with this design effort is less than 200N with the hand.

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Design 4

This is one of the possible designs. Assume that, there is a 1000N load on the top of the system. The maximum lifting capacity is 1m. firstly, we assuming that the weight of this system is ignored. With the lifting table change the height for 1m the hydra pumps arm will move 40cm. From the energy conservation, we have: Mgh= fs and h=1m s=40cm f2=mgd/s=2452.5N We found that, if the pump power f2 is bigger 2452.5N. This system can be derived by the hydraulic pump.

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Decision Analysis
Below is a table signifying a marking criteria/score of the conceptual designs. This is part of the decision analysis so that a final component design is chosen. Criteria Weight Design 1 Score Reliability Complexity Originality Innovative Weight Low Maintenance Standard Components Ease of Manufacture Totals 10 2 2 1 5 4 8 4 7 6 Total 40 16 8 7 30 Design 2 Score 8 8 10 9 10 Total 80 16 20 9 50 Design 3 Score 5 8 10 7 10 Total 50 16 20 7 50 Design 4 Score Total 4 7 4 5 7 40 14 8 5 35

49

28

49

49

36

30

36

48

14 200

10 243

14 242

16 215

Comments: While rating the designs using the scoring method above, each designs score was justified with given reasons. Design one received a reliability score of 4. This was because the base of the device seemed my smaller than the mobility scooter. There was disagreement that the device would balance out. The bending moment at the central shaft created reasons and made the platform unreliable. There is also a high probability of the scooter falling off. The device was simple, however was stated not original. It is described to be innovative utilising the hydraulic pump effectively. The device was assumed to be Design Project 21

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heavy therefore was a significant factor in the scoring. Parts are not available, and the design does not have complex shapes to be manufactured. Design two had a reliability of 8. However there was concern due to the probability of breaking the arms and lifting platform. The mechanism does not look complex, and was very original praised with an originality score of 10. The device was very innovative as it consisted of many mechanical components. The score of the weight was given as 10. The reason was because the device was not needed to be handled by a user instead its being held within the vehicle. The design however received reasonable scores for low maintenance, standard components and ease of manufacture. This was because some components such as the hydraulic cylinder would need to be frequently oiled. Parts are also unavailable in the market. If the parts break, they need to be manufactured. The components are also large which brings an issue to manufacturing the parts. Design three was similar to design two. The design received 5 for reliability because the device was placed at the edge of vehicle. There was a disagreement that the edge of the surface can hold the weight of the scooter. Also a force is applied to one end of the device which can cause the device to break. The device was praised with similar scores to design two. Again for design three some of the major components are unavailable in the market and need to be manufactured. The parts are also too big to be machined. Design four received a reliability score of 4. This was because the device seemed fragile and unable to lift the scooter. The device was not complex, and some group members said it was not original. However the device was fairly innovative using mechanical advantages. Again since the design had to be picked up weight was an issue. But the weight was given as 7 because the design was described to be light. The design seems to have a good low maintenance, and the materials look available in the market. Manufacturing the design also looks easy. Both design 2 and 3 had a close score with a difference being 1. Both designs also had similar components. However by group decision design two was chosen. This was because the components involved some very interesting mechanical advantages.

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Design Documentation
Component Design Calculations: In order to have a safe design the Component Strength must be greater than the Actual Maximum Stress. In many cases there is a great deal of uncertainty on both the values for the strength and the stress and these are accounted for using a Design Factor or Factor of Safety [1]

Design factor, N =

Accounts for uncertainties concerning stress and strength: Composition of materials Variations in properties within a bar of stock Effect of local processing on properties Effect of nearby welds, shrink fits Effect of heat treatment Intensity and distribution of loading Validity of loading model to represent reality Intensity of stress concentration Influence of time on strength and geometry Effect of corrosion Effect of wear Uncertainty of other factors

The uncertainties can be broken down into: Material reliability (Nm) Workshop Accuracy (Nw) Design load accuracy (Na) Consequence of Failure (Ncf) Design Project 23

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The design factor N = Nm x Nw x Na x Ncf

So for hydraulic lifter design, using all ductile materials then Most surfaces are machined, for higher safety we are selecting Most situation are well defined, for higher safety

Nm = 1.1 Nw = 1.0 Na = 1.2

Since the failure may cause injury to the disabled personnel operating Ncf = 3

Therefore design factor

Factor of safety of 3.96 can be used for all major parts from these calculations.

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Power Screw Design A Power (Lead) screw can be used in conjunction with split nut. They are the most efficient, having the least friction, so they are often used for screws that carry high power. Most preferred material for screw is steel and a coefficient of friction is generally 0.1 for steel. Let us consider a car is travelled to a hill station and now the car stopped at an inclination of 45o with the horizontal because maximum a car can climb is 45 degrees. Only few cars can climb upto an angle of 60 degrees and it applies to only few models of Audi. However Audi models are not economical to buy and use for the lifting purposes. The economical cars which can make out 45 degree climbing would be generally 44 drive.

F = Mg/sin m = 200 KG So W = mg = 200 9.81 = 1962 N = 45o And F = Mg/sin = 2452.5 N For Self Locking screw the equation is fdm > L 1 equation-

In the above equation f is the coefficient of friction, dm is mean diameter of the thread and L is lead of the screw. If d is the major diameter such that d = 30 mm dm = 30 L , f = 0.1 Solving the equation-1 0.1 (30-L) >L L < 7.17, so let us assume L=7

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For square threads, Lead = Pitch in single start which is 7 mm, but for double start thread has a Lead = 2 Pitch = 2 7 mm = 14 mm dm = 30 7/2 = 26.5 mm dr = 30 P = 23 mm

According to the convention the large composition of the force when be when the system would be raised at an inclination. So the equation as per Shigleys: ( ) ( ) ( 12000 N mm = 8863.2 N mm ( ) ( ) ( -12000 N mm -2178.4 N mm In both cases the resulted torque from the applied is less than the actual torque applied. Hence proved, it is a self-locking power screw. ) (For lowering the load) ) (For raising the load)

Part Name Date Calculated Calculated by Checked by

Power Screw 8-9-11 Deepak Rajeesh

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Bolted Joint Design This bracket is attached to the frame by bolts. This bracket used to hold the lead screw which functions as push pull mechanism to move lifter and scooter in and out of the car. Force acting at the centre of the lead screw is considered as 1.7kN which is half of the calculated total force of 3.4kN. Centre of the force acting is 95 mm away from the base. In general bracket act as a stopper in conjunction with the self locking lead screw.

25 F F

Pre tension per bolt = Required normal force to provide friction/number of bolts Assuming between steel to steel

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Maximum tension in a bolt due to force F (2000N). Assuming the bolts near the force acting wall will experience maximum tension.

Maximum bolt tension

Minimum tensile stress area

So grade 4.6, bolt will be ideal (table 8-1 and 8-11 from shigleys used for reference). Where AT is 36.6 mm2.

Bolt need to be checked for shear failure in the case of bolt coming loose.

Tensile stress in same bolt

Assume shear load is carried evenly

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Definitely

So it is safe to use a grade 4.6, M8 1.25 bolt for this application.

Part Name Date Calculated Calculated by Checked by

Bolted Joint 8-9-11 Rajeesh Christian

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Welded Joint Design This bracket is attached to the frame by welding. This bracket fixed opposite side of the bolted joint explained before. Function of this bracket is same as the bolted joint. It is assumed that force acting on is half of the calculated total force of 3.4 kN. Maximum stress on the weld only when one direction and in other direction leg of the bracket will support as well.

Maximum allowable shear stress using E 43 electrode

Neutral axis for the weld pattern

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Unit second moment of area

for the weld (Table 9-2)

( (

) )

Direct shear on the weld

Secondary shear from bending about neutral axis

)(

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Maximum allowable shear stress using a E 43 electrode = 129MPa

h=0.2mm. so preferred size for the fillet weld is 3mm

Design factor

Design factor of 14.79 is more than sufficient and weld will be safe.

Part Name Date Calculated Calculated by Checked by

Welded joint 10-9-11 Rajeesh Deepak

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Lifting Platform Design:

Normal stress = bending stress + axial stress For this case axial stress = 0 Bending moment: M= F L =981N x 582.5mm= 571432.5Nmm Bending stress = Mc/I and I =BH3/12=600 x 83 /12 =25600mm4 Mc/I= 571432.5mm x 4 mm /256004 = 89.286MPa

Shear stress: Shear stress= F /A = 981N / (600 x 8) = 0.204 MPa

Equivalent tensile stress = (bending stress2 +3shear stress2) 0.5 = (89.2862+3 x 0.2042)0.5 = 89.286 Mpa

To find out the Sy of the material we have:

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Equivalent tensile stress < Sy / N 89.286 N < Sy Thus Sy > 353.75Mpa The material we choose is 2014 T6 aluminium, the material has the following properties:

Sy = 415 Mpa St = 470 Mpa P = 2800kg/m3 Total weight of the section is 50.0kg.

Part Name Date Calculated Calculated by Checked by

Bolted Joint 16-9-11 Peter Christian

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Pins Design

There are 3 failures modes of the section of connection between the lifting table and the arms. F is the total load act on the connection: load act on the lifting table + the weight of the lifting table, the weight of the lifting table is calculated by Solid Works. F = load act on the lifting table + the weight of the lifting table = 981 +50 x 9.81 = 1471.5N Direct shear all 4 pins: 0.6 Sy(pin) /N > F /(2 x 4 x d2 /4) Then we have Sy(pin) >14.5 MPa

Shear, the connection of the plate: 0.6 Sy(pin) /N > F /((D-d)(t1+t2)) Then we have Sy(pin) > 4.95 MPa

Bearing stress across 4 pins: 0.6 Sy(pin) /N > F /( 4 x d x (t1 +t2)) Then we have Sy(pin) > 0.69Mpa

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So, final Sy for the pin should be bigger than 14.5 MPa, this is a very small value for a engineering material, then can easily choose material. The pins on other side of the arm will not have this much force as these 4 pins, we can use the same material for them. Then we can choose a cheap material. The material we choose is the AISI 304, the following is the properties of the material. Sy = 351 Mpa St = 420 Mpa P = 8000kg/m3 Total weight of the section is 0.68 kg

Part Name Date Calculated Calculated by Checked by

Bolted Joint 8-9-11 Peter Christian

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Link Design:

F is the total load act on the connection: load act on the lifting table + the weight of the lifting table + the weight of pins, the weight is calculated by Solid works. F = load act on the lifting table + the weight of the lifting table = 1769.2 N

When the arms are horizontal to the ground the F makes the biggest moment. In this situation the arms will receive the biggest bending and shear stress.

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R = 7971 N R = 8133.4 KN 288 mm 77.35o 83 mm 484 mm 370 mm

F = 1769.2 N Cross Section = 2 30 mm 60 mm ( ) F x 370 = R sin (78.2)82.15 F= 1769.2 Then we have: R = 3133.4 N R=R x sin(78.2)=7971N I=2BH3/12= 1080000mm4 C= 30mm

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SFD 1796.2 N

7971 N BMD

654.82 Nm The max moment is at 82.15mm M(max) =654.82Nm

Bending stress= MC/I=18.20MPa

Shear stress= F/2A= 0.49MPa

Equivalent tensile stress = (bending stress2 +3shear stress2) 0.5

= 18.22Mpa

To find out the Sy of the material we have: Equivalent tensile stress < Sy / N Then: Sy > 65.60Mpa From the calculation showing, we need a pump power bigger than 8133.4N. The material we choose is the AISI 304, the following is the properties of the material. Sy = 351 Mpa St = 420 Mpa P = 8000kg/m3

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Material Cost Calculation

PARTS Frame Fixture Link1 Link2 Lifting Platform Pin(Hydraulic Arm) Pins(Lifting Arms) Bolted Part Welded Part Volume (mm3) 9147720 243248 356700 323278 10451952 Density (Kg/m3) 2800 2800 8000 8000 8000 Mass (Kg) 25.6 0.68 2.85 2.58 Material Cost (AUD) 4 4 1 1 Qty. Net Price (AUD) 101.6 10.9 5.7 5.16 83.6

1 4 2 2 1

83.60 1

98310

8000

0.78

0.78

85893

8000

0.68

1.36

698295 769678

2800 2800 2800

1.95 2.15

4 4

1 1 4

7.8 8.6 1.328

Rings(Fixture) 29500

0.083 4

Total material cost = 226.8 = $ 227 Retail Price = 3 227 = $ 681

Cost of accessories: Cost of Hydraulic System = $ 350 Cost of Parallel Tracks (rotary cylinders inclusive) = $ 200 Cost of Split Nut = $ 48.95 Cost of Lead Screw = $ 270

Cost of Installation (System) = $ 150 Total Cost (System) = $ 1699.5 Design Project 40

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Appendix

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