Design and Fabrication of

Hydraulic Spring Stiffness Testing Apparatus

FYP Progressive Presentation

Supervised by:
Mr.Manzar Masud

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Mohsin Pervez UW-14-ME-Bsc-002
M.Fahad Hussain UW-14-ME-Bsc-030
Muhammad Arsalan UW-14-ME-Bsc-088
M.Zakriya Ameen UW-14-ME-Bsc-102

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 Assembly using PROE  Design of plunger
 Figurative Description displacement
 Design/Specifications  Design of lever
of spring  Graph
 Hydraulic Jack design  Next Steps
 Design of ram  Cost Estimation
 Design of ram cylinder  References
 Design of plunger
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 Visited HRFT(Shop no.8,9).
 Manufacturing and testing of
springs.
 Digital spring stiffness
testing machine.

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 Steel wire 50GrVA-4-YB285-64
 WZ-120(product code)
 Wire diameter=4mm
 Free length=66.5+1mm
 Number of coil=9
 Outer diameter=31mm
 Active/Effective coil=7±0.5
 Pitch error between two active coil
is not more than 1.
 Compressed length=20mm
 Force=37.2+4-1Kg

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 Steel wire 65Mn-3.5-YB550-65
 WR4-06-166(Product code)
 Wire diameter=3.5mm
 Free length=57.5±0.8
 Outer diameter=37-0.5mm
 Number of coil=8
 Compressed length=29.4mm
 Force=21.1±1Kg

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 Steel wire 2a-2.3-YB248-64
 WZ-120
 Wire diameter=2.3mm
 Free length=72±2mm
 Outer diameter=17±0.4mm
 Number of coils=15+0.5
 Active coils=13
 Compressed length=34mm
 Force=24.3±2Kg

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Load=60kN=6ton
Operating pressure=25MPa
Man effort on handle=50kg
Permissible tensile stress of M.S=120N/mm2

Permissible shear stress of M.S=20N/mm2

Permissible compressive stress of

M.S=20N/mm2

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Load=W=6ton
Pressure=25MPa
𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑟𝑎𝑚
A𝑟𝑒𝑎 𝑜𝑓 𝑟𝑎𝑚 =
𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒
60000
=
25∗10^6
Diameter of Ram=Dr
𝜋∗𝐷𝑟 2
Ar= =2400mm2
4
2 4∗Ar 4∗2400
𝐷𝑟 = =
𝜋 3.14
Dr=55.3mm

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According to the hoop stress
𝑃∗𝑑
𝜎𝑡 =
2∗𝑡𝑅𝑐
Thickness of ram cylinder=?
𝑃∗𝑑
𝑡𝑅𝑐 =
2∗𝜎𝑡
25∗55.3
= =5.75mm
2∗120
Diameter of ram cylinder=55.3+2*5.75
=66.8mm

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According to the design catalogue
Plunger diameter=Dp=8mm
𝜋∗𝐷𝑝2
Ap=
4
3.14∗82
=
4
=50.24mm2

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According to the hoop stress
𝑃∗𝑑
𝜎𝑡 =
2∗𝑡𝑅𝑐
Thickness of plunger cylinder=?
𝑃∗𝑑
𝑡𝑝𝑐 =
2∗𝜎𝑡
25∗8
= =0.9mm say 1mm
2∗120
Diameter of plunger cylinder=8+2*1
=9mm

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Plunger displacement=velocity ratio=VR
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑟𝑎𝑚
VR=
𝑎𝑟𝑒𝑎 𝑜𝑓 𝑝𝑙𝑢𝑛𝑔𝑒𝑟
2400
= =48
50.5
Load acting on the plunger
W=Pressure*Area of plunger
=25*10^6*50.5=1256N
=130kg

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Design of lever
Effort by man=20kg
Load acting on plunger=130kg
130
VR of lever= =6.5
20
Total length of lever=6.5*48=300mm

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 deflection vs force
700

600

500

400
force
300 Series1

200

100

0
0 5 10 15 20 25 30 35 40 45
deflection

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 Oct Nov Dec Jan Feb March April May
2017 2017 2017 2018 2018 2018 2018 2018

Literature Review

Design of HSSTM

Fabrication of HSSTM

Testing of springs

Software analysis

Comparison of Results

Final Year Project

Report
 Fabrication of HSST Machine.
 Making design using PROE software.
 Testing using Different springs by Fabricated Machine.
 Simulating Test using ANSYS (Simulation Software).
 Validation of results by comparing Experimental and
ANSYS results.
 Final Year Project Report.
 Metallic Hardware of Machine (Rs. 10,000)
 Fabrication Cost (Rs. 10,000)
 Required Springs (Rs. 5,000)
 Miscellaneous Expenditures (Rs. 10,000)

 Grand Estimated Total : Rs. 35,000

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1. Prathamesh D. Belapurkar1,Sushant. S.Jadhav ―A New
Methodology for Testing Spring Stiffness, International
Journal of Science and Research.
2. Waldemar Razck,Testing of a spring with Controllable
Stiffnes, MECHANICS, AGH University of Science and
Technology.
3. Avdhut R. Jadhav, Gajendra J. Pol and Amit A. Desai,
“Design and manufacturing of a Hydraulic Spring
Stiffness Testing Machine”, International Journal of
Emerging Engineering Research and Technology.

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THANK YOU

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