DESIGN OF ENGINE STAND AND CRANE

BY:
1. DAWIT TEMESGEN 387/10
2. MILIYON KESETE 955/10
3. YOHANNIS MAMUYE 1479/10

ADVISER: ROMANIO G.

IN PARTIAL FULFILMENT OF BACHELOR OF SCIENCE DEGREE

WITH MECHANICAL ENGINEERING
ARBA MINCH UNIVERSITY
ARBA MINCH INSTITUTE OF TECHNOLOGY (AMIT)
FACULTY OF MECHANICAL ENGINEERING
 CERTIFICATION
The undersigned certify that they have read and hereby recommend for acceptance by Arba Minch
University a thesis entitled: Design of engine stand and crane , in fulfilment of the requirements for the
bachelor of science degree in Mechanical Engineering of Arba Minch University.

Advisor:
Name: ………………………
Date: ………………………
Signature……………………
Dean of the Faculty:
Name: Atkilt Mulu (M.Sc.)
Date: ………………………
Signature……………………
 DECLARATION
We declare that this thesis is our own original work and that it has not been presented and will not be
presented to any other University for a similar or any other degree award.

1. Name: ………………………………………
Signature……………………………………
2. Name: ………………………………………
Signature……………………………………
3. Name: ………………………………………
Signature…………………………………..
AKNOWELEDGEMENT

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ABSTRACT

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 TABLE OF CONTENT

Table of Contents
AKNOWELEDGEMENT...................................................................................................................................i
ABSTRACT....................................................................................................................................................ii
TABLE OF CONTENT....................................................................................................................................iii
CHAPTER ONE..............................................................................................................................................1
INTRODUCTION...........................................................................................................................................1
1. 1Background of Study..........................................................................................................................1
1.2 Problem Statement..........................................................................................................................1
1.3 OBJECTIVE..........................................................................................................................................2
1.3.1 General objective........................................................................................................................2
1.3.2 Specific objective........................................................................................................................2
1.4 Scope and Limitation.........................................................................................................................2
1.4.1 Scope..........................................................................................................................................2
1.4.2 Limitations..................................................................................................................................2
CHAPTER TWO.............................................................................................................................................3
LITERATURE REVIEW....................................................................................................................................3
Types of engine stands........................................................................................................................8
CHAPTER THREE........................................................................................................................................13
MATERIAL SELECTION AND METHODOLOGY.............................................................................................13

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 CHAPTER ONE
INTRODUCTION
1. 1Background of Study
An engine stand is a tool commonly used to repair large heavy gasoline or diesel engines It uses
a heavy cantilevered support structure to hold the engine in midair so that the mechanic has
access to any exposed surface of the engine. While small single-piston engines can commonly be
laid on a table for repair, a large engine is normally meant to be supported from its engine
mounts or from the flywheel transmission case mounts and fragile components such as oil pans
and valve covers would be crushed if the large engine were placed on a flat surface. Engine
stands are typically mounted on large casters so than an engine can be moved around the shop to
different test and repair stations, and the engine can often be rotated in midair to provide easier
access to underside surfaces of the engine. The engine stand is commonly used in combination
with the engine crane to remove or install an engine in a vehicle, break in that engine, and
perform repairs. On the other hand, the design of the stand engine requires fundamental
requirements.

An engine stand is illustrated having a universal mounting apparatus for securing loads such as
different sizes of automotive engines and the like to a rotatable face plate which has a wheeled
stand therefor. The invention further contemplates an extension wheeled support on the stand
having adjustable means for balancing and stabilizing the load carried by the universal mounting.

1.2 Problem Statement

In our country different components of vehicles are imported from foreign countries and they
will assemble and disassemble also when the components are getting problem in their operation
they will be maintained by disassembling and then assembling. But in order to work this all
operations the company needs to have proper engine stand and crane. Especially engines, gear
box and the like heavy load parts are assemble and disassemble on the tire and sometimes they
serve on the floor. But using this method it will be exposed and be damaged, time consuming
and because it is not hoisted and cannot be rotated during working time fusing of mechanics will
be occur. That’s why the researchers would like to propose an Engine Stand and Crane to solve
this problem.

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1.3 OBJECTIVE
1.3.1 General objective
The general objective of this study is how to design the Engine Stand and Crane that will hold
the engine in midair for the purpose of repairing and doing maintenance on the component.

1.3.2 Specific objective

 To design components of the crane (vertical column, boom, crane hook and base plate
 To design the hydraulic system.
 To design the 3D model of all component of machine and assembly of the completed
machine.
 To design the supporter of the engine stand
 To design an engine stand with high strength of material
 To design mounting arms and mounting plate
 To design handle in order to rotate the engine easily
 To design casters

1.4 Scope and Limitation

1.4.1 Scope
This project is about designing of engine and crane.

1. The portable crane that we were used in this project is hydraulically operated.
2. The engine can be lifted with a height of 1.7m from the ground.

1.4.2 Limitations
This project has some limitations.

1. It doesn’t lift materials beyond 3ton of weight,

2. It need man power to move and adjust the desired material on the desired place.

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 CHAPTER TWO
LITERATURE REVIEW
Ancient Near East The first type of crane machine was the shadow, which had a lever
mechanism and was used to lift water for irrigation.[3][4][5] It was invented in Mesopotamia
(modern Iraq) circa 3000 BC.[3][4] The shadow subsequently appeared in ancient Egyptian
technology circa 2000 BC.[5][6]

A crane for lifting heavy loads was developed by the Ancient Greeks in the late 6th century BC.
[7] The archaeological record shows that no later than c. 515 BC distinctive cuttings for both
lifting tongs and Lewis irons begin to appear on stone blocks of Greek temples. Since these holes
point at the use of lifting device, and since they are to be found either above the center of gravity
of the block, or in pairs equidistant from a point over the center of gravity, they are regarded by
archaeologists as the positive evidence required for the existence of the crane.[7]

The introduction of the winch and pulley hoist soon led to widespread replacement of ramps as
the main means of vertical motion. For the next 200 years, Greek building sites witnessed sharp
reduction in the weights handled, as the new lifting technique made the use of several smaller
stones more practical than fewer larger ones. In contrast to the archaic period with its pattern of
ever-increasing block sizes, Greek temples of the classical age like the Parthenon invariably
featured stone blocks weighing less than 15–20 metric tons. Also, the practice of erecting large
monolithic columns was practically abandoned in favors of using several column drums. [8]

Figure2. 1 Simple crane type

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The first cranes were invented by the Ancient Greeks. These cranes were used for the
construction of tall buildings. Later, larger cranes were developed, employing the use of human
tread wheels, permitting the lifting of heavier weights. In the High Middle Ages, harbor cranes
were introduced to load and unload ships and assist with their construction.

Roman Construction Equipment

In construction, the Romans used Archimedes' compound pulley, and then winches or capstans.
This lead to the development of tread wheels crane, and a machine that utilized compound
pulleys, winches or capstans, and human labor. The first tread wheel crane was documented in
25 B.C. in use for a temple construction

Medieval Industry
With the fall of Roman civilization, Roman machines fell into disuse and were forgotten. Finally,
in 1244, in Utrecht, Netherlands, the Roman tread wheel was redesigned and put back to work. It
made it to England in 1331 where it was utilized in harbors and the construction of cathedrals,
castles, homes, and other large structures. Many of these cranes were left assembled and sitting
in the attic, for repairing the structure should it need it at a later date.

Some of the largest cranes of Medieval Europe had to be built into stone towers because they
were so large and their loads were so heavy, the cranes needed the added support.

Cranes in the Industrial Age

Tread wheel cranes dominated medieval construction until the beginning of the Industrial Age.
Between the 1200's and the 1700's, cranes went through a series of changes, evolving from
wooden structures to iron, steel, and cast iron. Finally. with the introduction of steam engines in
the early 1700's, industrialists were able to create the first steam crane. These were used in
construction and for loading and unloading trains.

The Modern Era

From there, the crane evolved to the hydraulic crane in the early 1840s, then to the combustion
engine crane of the early 1900s. Today's cranes are used in a wide variety of applications,
including construction, moving heavy loads. If you are in need of a crane, visit Ryan's Crane
Service Inc in Steamboat Springs, CO.

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The first crawler crane was designed and manufactured in 1911 by Bucyrus Company. It was
known as type 14, because it was powered by a gasoline engine. It was included with a standard
18.3 meters lattice boom and a 4.27 meters diameter swing ring.
In the late 1950s, the self-propelled rough-terrain hydraulic crane came into use in the
construction and material handling industries, and in the following years dominated the market
as it rendered small lattice-boom cranes obsolete.
An old engraving of William Armstrong’s hydraulic crane of 1845. It is from a Victorian book of
the 1890 discoveries and inventions during the 1800s.
Some portable cranes
Portable gantry crane
Light gantry crane also known as simple gantry crane. The maximum capacity can up to 10 ton,
general application of 3 tons and below. Wide range of applications, indoor and outdoor venues
can be used without occupying the space inside the workshop, matching with the existing
hoisting equipment in the workshop to meet various hoisting requirements. It can work with
existing lifting equipment in the workshop to meet various lifting requirements and increase
work efficiency. Unique modular design, it can be broken down into several easily transportable
parts, also can be assembled quickly in other places, which is very useful in many situations. The
crane can flexible match with various lifting equipment to meet the different requirements and
achieve various functional requirements for different operations

Figure2. 2 Portable Crane

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Electrically operated gantry crane

Electrically operated gantry crane is a product developed on the basis of manual portable crane.
It adopts two - wheel steering two - wheel electric operations, which can save manpower,
improve work efficiency. Easy to operate straight line and turn on hardened ground. You can
switch the operation between push and electric. Lifting equipment can be matched with hand pull
hoist, chain hoist, wire rope electric hoist, etc. It can be operated by remote control or the handle.

Figure2. 3 Electrically operated gantry crane

The GM ECOTEC 2.2L engine on a swivel stand is designed for student instruction and practice
covering engine mechanical inspection, disassembly, measurement and reassembly. The engine
is securely mounted to a heavy-duty rotating device equipped with an automatic lock to allow
full 360-degree rotation. A steel mounting plate is used for engine mounting that allows full
access for rear main seal and flywheel service. Each engine comes equipped with a manual
transmission flywheel. The engine starting station contains all components and systems
necessary for the starting and running of GM 2.2L ECOTEC engine. All necessary engine
systems connections are provided to allow live operation of each swivel engine stand.

ARI-HERTA Model AH-06187 Diesel Engine Stand features a solid base structure for working
on heavy duty diesel engines. This stand eliminates the need to struggle with rebuilding engines

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on a bench or on the ground. The sturdy AH-06187 helps reduce the possibility of damaging
expensive diesel engines.

Torin- T25671 engine stand has a square type sturdy design which is one of three most common
designs for engine stands. Construction consists of one base plate and two legs. The legs cannot
be folded. It means that the engine stand will take its space whole time and you cannot place it in
any other smaller size space. Engine stand is made out of high-quality steel and construction,
easy maneuver with two swivel and two rigid heavy-duty casters, center foot operated grips
firmly to stabilize stand maintenance operation, and handy oil recovery pan. One of the distinct
engines stand ever made is Rolls Royce engine tooling. The range of this tool has different
features from the other tooling equipment. For routine maintenance, a Rolls Royce engine
tooling has been traditionally striped and built on ground. The Rolls Royce engine has been
designed on the basis of two manipulators, which can be used in a complete range of engine. The
Rolls Royce engine tooling has been designed to exacting standards and the supporting tooling
like the carriers and interface tooling were all subject to individual strength tests. Their main
tooling and parts consist of build and strip tooling, ground support equipment, line maintenance
tooling, component repair tooling, whole engine transportation stand. The rolls Royce engine
stand has a unique feature such as 45 degrees, positioning wheel with ball lock pin secures
engine giving 8 angle maintenance access, welded steel construction, easy maneuvering with 2
swivel and 2 rigid heavy-duty casters, center tool operated grips firmly to stabilize stand during
maintenance operation, handy oil recovery plan to avoid damage to hanger floors and durable
powder coat tonier blue.

Black bull ES4W engine stand is made from heavy duty tubular steel that is painted in neutral
black color. Because of this material it is able to withstand weight that is up to 1⁄2 ton or 1000
pounds letting you hold most V8 type engine blocks on it while you are repairing the engine
itself or the car.

Engine stand is a tool that is used for holding an engine, while making repairs to engine or car.
Engine stand have few types and are suited for different load limits. Most common engine stand
will hold about 238 kg to 1000 kg heavy engines. Engine gets mounted to adjustable mounting
arms that are located on the top of the stand. Most stands allow rotating engine 360 degree
around, so mechanic can access all parts of the engine more conveniently. Some engine stands

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even allow changing mounting plate.so we have designed the engine stand that allows the engine
to rotate 360 degrees around it, and these can give comfort for the mechanics and prevent the
parts of engine from damaging. In addition to this we have selected the materials those have
good properties and can hold that heavy load.

Types of engine stands

There are different types of engine stands based on the arrangement and shape of the engine
cylinders. Some of them are:
Heavy duty engine stands
Medium duty engine stands
Flat Engine Stands

Heavy stand is a stand for inline cylinder engines or a v-type cylinder engine which is used to
hold and rotate the engine with the required degree while maintenance. It helps to avoid the
complexity of assembling and disassembling of engines since the engines are heavy. This type of
engine stand uses two columns or posts to support the engine from two ends.

Figure2. 4 Heavy Duty Engine Stands

Medium duty engine stands are also used for inline cylinder engines or v-type cylinder engines.
It is used to hold and rotate medium weight engine with the required degree while maintenance.
This type of engine stand has only one column and supports the engine from on end.

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 Figure2. 5 Medium duty engine stands
Flat engine stands are used for putting an engine after it is removed from a vehicle before going
through maintenance process. It is also used to put an engine after maintenance process is
finished. This engine stand does not allow engine to be rotated in any degree. It is only used to
place an engine outside of its vehicle.

Figure2. 6 Flat engine stands

Mulugeta Tadesse, and Tesfahun Meshesha, “Design and Development of Portable Crane in
Production Workshop”(2017) - This portable crane uses a hydraulic system to lift a heavy loads
applying only small force. The main advantage of the project is having detail design of the
mechanism in the production workshop of BISHOFTU AUTOMOTIVE INDUSTRY; Ethiopia
is that it is portable, moveable, and easy for operation. In this project we designed and produced
a portable crane which can lift a heavy load with a maximum capacity of 3 ton. The crane has
two loaded side bars to make the base and two links (i.e. Vertical column and boom) connected
each other by using pin joint. The Vertical column is secured on the cross bar that is welded to
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the side bars making the base using bolt connection. There are also other bars for supporting
purpose which are connected to the basic link (vertical column) using bolt connection. The crane
uses four wheels, of which two of them in the front are connected to the base using permanent
joint and the rear wheel is connected to the base using roller. Since the crane operates
hydraulically there is piston cylinder device which is connected to the vertical column and boom
for lifting up and down the objects. The maximum carrying capacity 3 ton, and maximum lifting
height is estimated as greater than greater than 2.96m from the ground run by using 3KW electric
motor rotating 2830/3620 rpm.

Adzimah, Stephen Kwasi, Akinwonmi,Ademola Samuel, Bentum-Mensah (improvement in the

design of engine crane for modern industries , 2013) - This paper presents an improvement in the
design of engine crane, introducing a rotating mechanism comprising a gearing system, electric
motor, solid shaft with flange, sleeve bearing, and a support bearing. The precision cut gears
used are made of steel with endurance strength of 55 MN/m2 (according to the American Gear
Manufacturers Association (AGMA). In the design, the limiting endurance load of 17.06 KN and
the limiting wear load of 22.96 KN are greater than dynamic load of 10.83 KN which implies the
design is satisfactory from the standpoint of wear, dynamic and endurance loads. Since the use of
cranes is indispensable in the industry, the design will aid productivity, safety of workers,
ergonomics, efficiency, effectiveness and versatility of the cranes, for which they are designed
and manufactured.

Matin Bagwan, Subham Sarwade, Dayanand Dhavane ( design analysis and fabrication of
universal engine stand, 2018) - In the Indian market thousands of two wheeler sell delay,
thousands of vehicle is goes for maintenance in workshop and garage. In on vehicle the main
part or heart of vehicle is an engine. Without engine vehicle have no meaning in the workshop or
garage. Engine repairing is most difficult work because of its complexity.

The repairing or maintaining for the doing repairing and handling of engine is more complicated
for preventing the problem we decide to make universal engine stand on universal engine stand
is a concept on which we held the sell companies vehicle engine in one stand. We try to solve
above problem of mechanic with making stand in sample construction low cost. From this
project we learn design concept and software skill. under the guidance of college staff. To better
handling of engine used “Universal Engine Stand” is to be designed based on the working

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principle of different bikes. An engine stand is a tool commonly used to repair large heavy
gasoline or diesel engines, but motorcycle engine works on locally arrangement to holding
engine has working to be done.

Amin Nur Akhmadi, M. Taufik Qurohman, Syaefani Arif Romadhon (overhaul engine stand,
2019) - Vocational High School is the biggest contributor to unemployment in the area, many
supporting factors such as the unstable condition of the company. Basically that is not all, the
teaching process for these Vocational Schools is at the forefront of the increase in the
unemployment rate of SMK graduates. From the results of community service activities, the
following conclusions are obtained: (1) With the community service at Adiwerna District 1
Vocational High School, giving at Adiwerna Nu 1 Vocational School in Tegal Regency,
providing knowledge, understanding and innovation on efficient engine stand overhauls
according to operational standards procedure; (2) Speeding up the work when the engine stand
overhaul practices in competency subjects overhaul the engine with the SOP tool so as to make
students competent in their performance practices.

Tria Mariz Arief (Design and build of TSCP-700 APU gas turbine stand engine for overhaul,
2016) – this research is the Garret TSCP-700 APU engine to be used as an aircraft engine
overhaul practicum tool. The focus of the discussion in this paper is the design and construction
of the engine stand for maintenance. The design is carried out with several aspects including
maintenance procedures, mobility and work safety.

Some researcher design comparison with our design

Similarity

 Uses for both lifting and lowering the engine from vehicle
 The crane uses hydraulic system to lift heavy load
 The crane is portable
 The two loaded side of the crane is joint each other by means of pin joint.
 The design is carried out with several aspects including maintainece procedurs,
mobility and work safety.

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Differentiation

 The material selection

 The maximum carrying capacity of crane is 2 ton
 The maximum lifting height is 3 m from the ground
 The crane is not only uses for lifting and lowering but also for maintenance
purpose of comprising the engine on stand by means of mounting arm and plate.
 The crane does not uses of electric motor for rotating mechanism comprising a
gearing system.
 The engine stand is only carrying 400kg

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 CHAPTER THREE
MATERIAL SELECTION AND METHODOLOGY
3.1 Material Selection
Is one of the foremost functions of effective engineering design as it determines the reliability of
the design in terms of industrial and economical aspects? A great design may fail to be a
profitable product if unable to find the most appropriate material combinations. So it is vital to
know what the best materials for a particular design are. How we are going to get an idea about
the best materials for a design? In this aspect engineers use several facts of materials to come to
the most reasonable decision. They are mainly concentrated on the properties of the materials
which are identified as the potential materials for that specific design. The selection of a proper
material, for engineering purposes, is one of the most difficult problems for the designer. The
best material is one which serves the desired objective at the minimum cost.

The following factors should be considered while selecting the material:

 Availability of the materials,
 Suitability of the materials for the working conditions in service
 The cost of the materials

The important properties, which determine the utility of the material, are physical, chemical and
mechanical properties. The right materials for the design of the portable crane with engine stand
parts should be selected. Selection requires one to consider the following factors which give the
best material fit for the design job:

1) Specific strength and mass.

It is preferable to select a material of high yield stress with ability to carry external load without
failure and low density in order to realize a supporter of high strength and low mass. Therefore,
the material selection process should aim to maximize the quantity termed as the specific
strength.
2) Resistance to abrasive wear

Most of engineering materials in contact with one another are subjected to surface wear due to
relative motion. It is therefore desirable to select a material from the candidate materials with
low wear rate or capacity to resist abrasive wear at the thread surfaces.

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 3) Resistance to buckling

Heavy loads may cause the mounting arm and supporter to buckle once the critical load is
exceeded. It is preferable to select a material with high resistance to buckling of the mounting
arm and supporter, that is, excellent elasticity and deflection behavior in response to application
of an external load.

4) Availability, Cost and Affordability

It is also preferable to choose a material with the high Stafford ability rating. Relative cost of the
materials is used in finding or calculating the affordable rates. Therefore, the availability of the
material and the cost of processing the material in to the finished product need to be taken into
account and considered as supporting information when making the final choice of the material.

5) Heat transmission properties

As we know there is a relative motion between parts of engine standing, which cause a friction
that generates heat which can cause change in the mechanical properties of the material.
Therefore, we should select the materials that reduce friction.

6) Other relevant properties include

Resistance to corrosion, electrical and mechanical, properties, heat transmission properties etc.

Components of portable engine crane with stand

 vertical column
 boom
 crane hook
 base plate
 center connecting bar
 pin
 hydraulic system
 Cylinder
 Caster
 Mounting plate and arms
 Solid shaft

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  Hollow shaft house
 Key, bolts, bearing
 Main frame
 worm and worm gear
Vertical column
Load that the vertical column subjected to is compressive, and material for the column is
selected to be cast iron, because it has low cost, good casting, and high compressive stress. It is
primarily made of carbon and iron with carbon content of 1.7% to 4.5%

Referring to text book of machine design by KHURMI and GUPTA, The maximum value of
crushing stress (σc) that will develop in cast iron is given to be 400MPa to 1000Mpa. Since the
induced compressive stress due to the applied load is not greater than the maximum crushing
stress developed in the cast iron. Therefore the vertical column is designed safe.

Boom
The boom is modeled as simply supported beam, and it is subjected to a bending stress due to
bending moment developed at the fixed end where it is pinned with the vertical column.

material selection of boom Since the load applied on these components is high the material used
to make these components should be strong and hard, thus the best material suited for is steel
which has carbon content of up to 1.5% which results in an increased strength and hardness. The
material selected for the boom is standard Steel Fe E-520-Indian standard designation, and it has
a minimum yield stress of 520Mpa and the allowable bending stress is

Crane Hook
Hook is the component which is fixed with the boom and it is used for hanging the load on the
boom which moves up and down in lifting the load.

Material selection for the crane hook crane hook is subjected to both tensile and compressive
stress, and wrought iron is selected for it, because it is malleable tough and ductile material. It
has carbon content of0.02%, 0.12% silicon, 0.018% of phosphorus, 0.07%of slag, and the
remaining is iron.

since the induced tensile and compressive Stress are less than for the crane hook, i.e. wrought
iron which have a stress of 250MPa to500MPa and 300MPa under tensile and compressive

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respectively, then hook is designed safe. The ultimate tensile and compressive stress of the
material that is selected

Base Plate
Base plate /Truck serve as a base for carrying all the weight of the proposed design project. In
addition it carries the load by all the components of the crane .It is composed of four bars and
each of them is modeled as a beam.

Center connecting bar

Due to the load P, the bar is subjected to equal bending moment at both end of the plate. At both
end there are two reaction forces to encounter the bending of beam due to the load applied. And
these are equals to half the load applied.

The material selected for the center bar of the base plate is standard steel of Indian standard
designation FeE520, having yield strength of 520N/mm2. Taking the factor of safety equals 4

Pin
Pin 1 Due to the load applied at the end of the boom and the load by the boom itself, the pin that
connect the vertical column and the boom is subjected to shearing stress. The shearing force
applied on the pin that connects the vertical column with the boom can be obtained using the
principle that summation of moment on the pin that connects the actuator and boom is zero.

Since the pin is subjected to high tensile and shearing stress, the material for the pin should be
ductile. And the material selected is mild steel. From Indian standard designation of steel
(Mechanical Engineering design by KHURMI and GUPTA, 8th edition) - Table 2.5 we have
selected Fe 690 which has minimum tensile strength of 690N/mm2 and minimum yield strength
of 410N/mm2.

Hydraulic System
Hydraulic cylinder or also known as linear hydraulic motor is a mechanical actuator that is used
to give a unidirectional force through a unidirectional stroke. Hydraulic cylinders get their power
from pressurized hydraulic fluid, which is typically hydraulic oil. Design of hydraulic cylinder
consists of design of cylinder, design of piston rod, hinged pin, design of flat end cover design
of piston,

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Cylinder
The main function of cylinder is to retain the working fluid and to guide the piston. Hydraulic
cylinder usually made of cast steel or cast iron, But for our design purpose we select cast steel
because of high heat resistance, easily machine able and low cost

Piston
Piston is moved by a fluid, or it moves the fluid which enters the cylinder. The most commonly
material used for piston is cast iron, cast aluminum, forged aluminum, cast steel, and forged
steel. But the material we selected for our design purpose is cast iron.

Piston is consists of the following parts, Head or crown, Piston ring, Skirt, Piston pin, Piston
The outer diameter of the piston is assumed to be equal to the inner diameter of the cylinder.
Therefore the outer diameter of the piston is 280mm.
Piston Rings
The piston rings are used to impart the necessary radial pressure to maintain the seal between the
piston and cylinder bore. The radial thickness (t r) of the ring may be obtained by considering the
radial pressure between the cylinder wall and the ring.

Piston Barrel
It is a cylindrical portion of the piston. The maximum thickness (t3) of the piston barrel may be
obtained from empirical relation:

Caster
Caster is wheeled device which can be mounted at the bottom of the engine stand to enable
relatively easy rolling movement of the engine stand. It is important for the engine stand to
move around the workshop easily and casters will provide that ability.

Mounting plate and arms

These are the parts of the engine stand where the engine is going to be bolted and held. The
arrangement can be rotated 360-degree with the help of a handle which makes every part of
the engine easy to reach

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Solid shaft
Shaft is a rotating member which is used to transmit rotating power or torque. It will transmit the
rotation from the hollow shaft house to the plate where the engine is held
Hollow shaft house
Hollow shaft is a member in which the solid shaft passes through. It will act as hub for the solid
shaft and guide its motion.
Key
It is a machine element which is used to connect rotating machine element to a shaft. It prevents
relative motion between two parts and enables torque transmission.
Main frame
Rectangular hollow steel is used for the horizontal and square hollow steel for vertical members.
The horizontal and vertical members are the main building blocks of the engine stand. Two
vertical members will hold the engine from the two ends axially.
The horizontal members will connect the vertical members and act as the base of the engine
stand. Also, casters will be fixed on the horizontal members.
Bolts
A bolt is s form of threaded fastener with an external male thread. Bolts are used to hold the
engine through the mounting arm. They are fitted on the engine through the fly wheel mounting
internal threads.
Worm and worm gear
Worm and worm gear drive is used to drive the shaft which is connected to the engine mounting
plate. The worm gear arrangement will provide 90-degree power transmission and helps reduce
the operator effort...
Bearing
It is a machine element which supports another moving machine element and guides its motion.
It will support the worm and worm wheel. The two main types of bearing are sliding contact
bearing and rolling contact bearing. The type of bearing used for this project is rolling contact
bearing because of availability.

Braces
Braces offer the necessary support for the engine stand so they should be sturdy and long
lasting. Support braces are necessary for heavier engines

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This applies for stand that support engines more than 2 tons heavy. For these components to
work as expected, the weld should also be of high quality

Depending up on the above criteria uses the following materials.

Steel:

 Have higher strength, hardness and toughness,

 High values of hardness and strength can be achieved for components with large
Section thickness

 Possess higher harden ability,

 Retain their strength and hardness at elevated temperature &have higher
resistance to corrosion and oxidation
Stainless steel
Stainless steel is not a single material but the name for a family of corrosion resistant
steels. In general, stainless steels have:

 Higher corrosion resistance

 Higher cryogenic toughness
 Higher work hardening rate
 Higher hot strength
 Higher ductility
 Higher strength and hardness
 A more attractive appearance
 Lower maintenance

Mild steel
Mild steel is one of many different grades of steel which are produced internationally. Mild steel
is very strong due to the low amount of carbon it contains. Mild steel has a high resistance to
breakage. Mild steel, as opposed to higher carbon steels, is quite malleable, even when cold.

19
Phosphor bronze
Phosphor bronze is a bronze alloy that contains a mixture of copper, tin and phosphorous.

Phosphor bronze alloys

 Good to excellent corrosion resistance.

 Good cold workability for blanking,
 Drawing, forming and bending, shearing and stamping
Why phosphor bronze is used for worm wheel?
The phosphor bronze is widely used for worms drive in order to reduce wear of the worms which
will be excessive with cast iron or steel. There is a high degree of sliding along the teeth of the
gear from the drive shaft.
30C8 steel
30C8 steel is characterized by:
 good weld ability,
 good machine ability, and
 High strength and impact properties in either the normalized or hot rolled condition.

45C8 steel

Carbon steels have carbon as the key alloying element in their composition. They also contain
up to 0.4% silicon and 1.2% manganese. In addition, the residual elements such as copper,
molybdenum, aluminum, chromium and nickel are present in these steels

20
3.2Methodology

Problem
identification

Conclusion and
Litrature review
recomendation

Material
Design analysis
selection

21
Chapter 4

Design analysis

1. Vertical column
A = bh-(b-2t)(h-2t)
= 120*100-(120-2*5)(100-2*5)
=2100mm2
b h3 90∗(110¿ ¿3)
I xx = = 100 ¿(120¿¿ 3)− ¿¿
12 12
=4,417,500 mm4

√ √
4
I xx 4417500 mm
K= = 2
=45.8647mm or 0.004586m
A 2100 mm
M=2000kg
P = mg = 2000kg*9.81N/kg
P = 19620N
p 19620 N
Pvc = 0 = 0 = 20,058.3N or 20.058KN
cos 12 cos 12

( ) ( )
P vc ec 20058.3 N 1.8 m∗0.06
σ= 1+ 2 = 1+
A k 0.0021 m2
0.045862
σ =500,041,938.5 pa∨500 Mpa
Mass of vertical column
V = A*h
= 2100mm2 *1800mm
= 3,780,000mm3 or 0.00378m3
The material for the support is selected to be cast iron, which have mass density of
7250kg/m3.

ρ =m/V, m= ρ V

, m = 7250kg/m3 * 00378m3

22
 = 27.405kg

Design of boom
A = bh – (b-2t)(h-2t) , but b=h
= b2 – (b-2t)2
=1102-(110-2*5)2
= 2100mm2 or 0.0021m2
4
b h3 b4 ( b−2t )
I xx = = – =¿
12 12 12
4
1104 ( 110−2∗5 )
= –
12 12
I xx = 3,867,500 mm4

σ b = M/Z

Where

 Z= Section modulus

 M= bending moment at point A

 σ b = bending stress

section modulus

Z=I/C = I xx/ C

Z =3867500mm4 /55mm

Z = 70,318.18mm3 or 7.0318 x 10-5m3

 Bending moment, M is

M=P*L, L is length of boom

M = 20,058.3N *1.8m

23
M = 36,104.9 Nm

σ C =¿M/Z

36,104.9 Nm
= −5 3 = 513,451,747.78N/m or 513.45Mpa
2
7.0318 x 10 m

Mass of the boom

V=A*L

= 0.0021m2 * 1.7m

= 3.57 x 10-3 m3

The boom is made of standard steel, and the mass density of steel is 7850kg/m3

ρ =m/V, m= ρ V

,m = 7850 kg/m3 * 3.57 x 10-3 m3

, m = 28.02kg

Design of connecting bar

R=20.058 KN

A= (200*80)-(193*73) mm2

A=1900mm2=0.0019m2

Section Modules

Z= (200*803-186*663)

Z=5.69*10-5m3

Moment at the two end of bar

MA,B =(PT*L)/4

= (20.058 KN*0.516)/4

M=2,587.482 Nm

24
σ b=¿M/Z

=2,587.482 Nm/5.69*10-5m3

=502.2 x 105N/m2

σ b =50.2MPa, Induced stress

The material selected for the center bar of the base plate is standard steel of Indian standard
designation FeE520, having yield strength of 520N/mm2. Taking the factor of safety equals 4

σ =¿Sy/n

=520/4=130MPa

Since the induced stress is less than the ultimate bending stress, then the bar is designed safely.

Design of pin

0.75(RC) =0.1(W) + 0.95(P)

W=39.7Kg*9.81m/s2

W=389.457N

P=20.058KN

RC= (38.9457+19055.38)/0.7

RC=27.28 KN shear force on pin 1

Fe 690 which has minimum tensile strength of 690N/mm2 and minimum yield strength of
410N/mm2.

τ Max =Sy/2n

τ Max =25.625MPa

Thus the pin will be subjected to double shear and then the pin is designed as follow.

τ =P/2A, P is shear force

A =Area subjected to shear stress

25
A=RC/2τ ,

π *d2/4 = RC/2τ ,

d=√ 2 R C /πτ

=
√ ( 2∗27.28 kN )
(π∗25.625 N /mm 2)

d=26.03 mm

Design of Crane Hook

Hook is the component which is fixed with the boom and it is used for hanging the load on the
boom which moves up and down in lifting the load.

oom which moves up and down in lifting the load.

Fig. 4.7 Plane view of crane hook

26
 Fig. 6.6 Cross section of crane hook

(From Shigley’s “Mechanical Engineering design”, 8th edition –Table 3.4)

rc = r1+h/2 and

rn = h/Ln

Due to the applied load the hook is subjected to tensile and compression stress with moment
M=P*rc

Normal stress

, rn-y=r

But rc=3cm+4cm/2=5cm

rn=4/Ln(7/2)=4.72cm

e=rc-rn=5-4.72=0.0028m

Cross sectional area at which the load act is

A=2cm*4cm=8*10-4m2

Moment due to the load applied is, M=p*rc

M=20,058N*0.05m

M=1002.9Nm

Substituting r from 3 to 7 we can determine the stress developed in compression and tensile side.

For r=3cm

σ =20058N/8*10-4+1002.9 (0.0472-0.03)/(8*10-4(0.0028)(0.03))

σ =281.7 MPa

For r=4cm

σ =20058N/8*10-4+1002.9 (0.0472-0.04)/(8*10-4(0.0028)(0.04))

27
σ =105.6 MPa

For r=5cm

σ =20058N/8*10-4+1002.9 (0.0472-0.05)/ (8*10-4(0.0028)(0.05))

σ =0MPa

For r=6cm

σ =20058N/8*10-4+1002.9 (0.0472-0.06)/(8*10-4(0.0028)(0.06))

σ =-70.44 MPa

For r=7cm

σ =20058N/8*10-4+1002.9 (0.0472-0.07)/(8*10-4(0.0028)(0.07))

σ =−120.7 Mpa

Design of Center Connecting Bar

Due to the load P, the bar is subjected to equal bending moment at both end of the plate. At both
end there are two reaction forces to encounter the bending of beam due to the load applied. And
these are equals to half the load applied.

R=10029N

A= (200*80)-(193*73) mm2

A=1900mm2=0.0019m2

Section Modules

Z= (200*803-186*663)

Z=5.69*10-5m3

Moment at the two end of bar

MA,B =(PT*L)/4

28
=19620N*0.516)/4

M=2530.98Nm

σ b=¿M/Z

=2530.98Nm /5.69*10-5m3

=444.81 x 10 5 N/m2

σ b =44.47MPa, Induced stress

Design of Pins

0.75(RC) =0.1(W) + 0.95(P)

W=39.7Kg*9.81m/s2

W=389.457N

P=19620Nx0.95

RC= (38.9457+18639)/0.7

RC=26,682.779N shear force on pin 1

Since the pin is subjected to high tensile and shearing stress, the material for the pin should be
ductile. And the material selected is mild steel. From Indian standard designation of steel
(Mechanical Engineering design by KHURMI and GUPTA, 8th edition) - Table 2.5 we have
selected Fe 690 which has minimum tensile strength of 690N/mm2 and minimum yield strength
of 410N/mm2.

τ Max =Sy/2n

τ Max =25.625MPa

29
Fig. 4.15 Pin supporting vertical column and boom

Thus the pin will be subjected to double shear and then the pin is designed as follow.

τ =P/2A, P is shear force

A =Area subjected to shear stress

A=RC/2τ ,

π *d2/4 = RC/2τ ,

d=√ 4 R C /π 2 τ

= (2*26682.8)0.5/ ( π *25.625N/mm2)

=25.7mm

Say d=30mm, diameter of pin at lower extreme

When the actuator is at its upper extreme, the pin that is used to connect the vertical column with
the boom is designed as follow. Reaction at point C is obtained by applying the principle that
summation of moment about point B is zero.

RC (0.7) cos71.45o=W (0.1) cos(71.45o) * P(0.8)cos71.45o

RC=33689.92N

d=√ 4 R C /π 2 τ

=
√ 2∗33689.92
π∗25.625

30
d=28.93mm, diameter of the pin when the actuator is at its upper extreme

Taking the larger of the two is safe, and the pin that connects the vertical column and the boom
should be 32mm of diameter. The length of pin is slightly made to exceed the width of vertical
column, that is

L=150+15

L=165mm

Similar way; for pin 2, d = 28mm

Pins for the Actuator, d = 74mm

Note:-In our project pins are subjected to tensile and shearing. The material selected for the pin
should be ductile and we have selected mild steel

4.8.7 Design of Hydraulic System

Hydraulic cylinder or also known as linear hydraulic motor is a mechanical actuator that is used
to give a unidirectional force through a unidirectional stroke. Hydraulic cylinders get their power
from pressurized hydraulic fluid, which is typically hydraulic oil. Design of hydraulic cylinder
consists of design of cylinder, design of piston rod, hinged pin, design of flat end cover design
of piston,

4.8.8 Design of Cylinder

The main function of cylinder is to retain the working fluid and to guide the piston. Hydraulic
cylinder usually made of cast steel or cast iron, But for our design purpose we select cast steel
because of high heat resistance, easily machine able and low cost.

The values taken for our design are;

σ t= permissible tensile stress

=80N/mm2

P=Maximum pressure inside the Cylinder

=3.5N/mm2

31
F=load that is applied on the actuator

=212615.4189N

Then, inner diameter of the cylinder is (di):-

F=p* π di2/4

di=√ 4 F / πp

di =
√ 4∗212615.4189
3.5∗3.14

di =280mm, Say Thickness of the cylinder;

Let, t= thickness of the cylinder

t=ri[(√ σ t + p )/(σ t− p )-1]

Where, ri = di/2= 280mm/2=140mm

t=140[(80+3.5)0.5/ (80-3.5)-1]

t=9.22mm

Outer diameter of the cylinder

Let, dO = Outer diameter of the cylinder

dO =di+ 2t =280mm+ 2* 9.22mm= 298.44mm

The cylinder head may be taken as flat circular plate whose thickness may be determined from
the following relation.

Let, th = is the thickness of the head

σ C = allowable circumferential stress in N/mm2

=30 to 50Mpa.

Take, σC = 40Mpa (for our design purpose)

th=di(c* p/ σC)

32
Where = is constant=0.1.

th=280mm(0.1*3.5N/mm2/40N/mm2)

=26.2mm

And the length of cylinder is:-

L=2*dO

=298.44*2=596.88mm

4.8.9 Design of Piston

Piston is moved by a fluid, or it moves the fluid which enters the cylinder. The most commonly
material used for piston is cast iron, cast aluminum, forged aluminum, cast steel, and forged
steel. But the material we selected for our design purpose is cast iron.

Piston is consists of the following parts, Head or crown, Piston ring, Skirt, Piston pin, Piston
head:-

The thickness of piston head (tH), according to Grashoff’s formula is given by:-

tH=√ ( 3 p ) (D0)/16 σ t ,where

p= maximum pressure

D0 =outer diameter of piston

σ t =tensile stress=38N/mm2

Note: The outer diameter of the piston is assumed to be equal to the inner diameter of the
cylinder. Therefore the outer diameter of the piston is 280mm.

tH=
√ 3∗3.5∗280
16∗38

=4.8mm, say tH= 5mm

4.8.10 Design of Piston Rings

33
The piston rings are used to impart the necessary radial pressure to maintain the seal between the
piston and cylinder bore. The radial thickness (tr) of the ring may be obtained by considering the
radial pressure between the cylinder wall and the ring.

tr=DO√[(3∗Pw )/ σ t ¿ ]¿

Where

 DO=outer diameter of piston

 Pw= pressure on the wall of cylinder, limited to 0.025 to 0.042N/mm2

 σ t=Allowable tensile stress in Mpa, it may be taken 85MPa to 110MPa for cast iron
rings.

tr=280mm√[(3∗0.035)/90 ¿ ]¿

tr =9.56mm

And also the axial thickness of the piston ring (ta) is:-

ta=0.7tT to tT

ta=7mm to 9.56mm, selecting

ta=8.5mm

We also know that the minimum axial thickness of the piston ring is:

t=Do/10nr

Where, nr=No of rings=4

ta=280mm/10*4

ta=7mm

Thus the axial thickness of the piston ring as calculated (i.e. ta = 7mm) is satisfactory.

The distance from the top of the piston to the first ring groove, i.e. the width of the top hand:-

34
b1= tH to1.2 tH

= 5mm to6mm, taking, b1= 5.5mm

And the width of the other hand of the ring

b2= 0.75ta to ta

= 6.63mm to8.5mm, taking, b2= 7.5mm.

We know the gap between the free ends of the rings:

G1= 3.5tT to4tT

= 33.46mm to38.24mm

And the gap when the ring is in the cylinder,

G2=0.002D0 to 0.004D0

=0.56mm to 1.12mm, lets select

G1=36mm, and G2=1mm

4.8.11 Design of Piston Barrel

It is a cylindrical portion of the piston. The maximum thickness (t3) of the piston barrel may be
obtained from empirical relation:

t3= 0.03Do+ b+ 4.5,

Where b = radial depth of piston, and it is taken to be 0.4mm greater than the radial thickness of
piston ring

I.e. b = tr + 0.4mm

Therefore, t3 = 0.03DO + tr +4.9

t3= 0.03(280) + 9.56 +4.9

=22.86mm, say

t3 =23mm

35
And the piston wall thickness (t4) towards the open end is decreased and should be taken as:-

t4= 0.25t3 to0.35t3

= 0.25 (23) to0.35 (23 mm)

= 5.75to8.05mm, Adopting

t4= 8mm

4.6.5 Design of mounting arm

 The arm must be designed for a buckling load of, considering mounting arm may buckle
in two planes at right angle to each other due to the load exerted. We know that the load
on single arm is,
m
F 400 kg × 9.81 2
Force on each arm = s = 981N
4
4

 Assume a factor of safety =6,

F
W cr = × F . S=981 N ×6=5886 N
4

 Let, t=thickness of the arm and b=width of the arm

 Assuming that the width of the arm is three times the thickness of the link
b1=3t1

 Therefore, cross-sectional area of the arm,

A=t1 3t1=3t12

 And moment of inertia of the cross-section of arm,

1 3 1 3
I= ×b 1 ×t 1= ×3 t 1 ×t 1=0.25t 41
2 2

 Radius of gyration

√ √
4
I 0.25t 1
K= = = 0.29t 1
A 3 t1

 Since for buckling of the arm in a plane perpendicular to vertical plane, the ends are
considered as fixed, therefore the equivalent length of arm,
l 80
L= = mm = 40mm
2 2

36
 1
 Rankin's constant, a=
7500
 According to Rankin’s formula the buckling load (Wcr)
σc × A 100 ×3 t 21
W cr = L 2= 1 40 2 = 5886N
1+ a( ) 1+ ( )
K 7500 0.29t 1

4 2 19.62 ± √ (−19.62)2−4 (−49.769)

t 1 – 19.62t 1 – 49.769 = 0; t 21= ……take (+ve) Signe
2
2
t 1 = 21.89mm2; t1=4.679mm ≈ 5mm; b1=3t1=3× 5mm = 15mm

 Now let us consider the buckling in vertical plane

l
 Moment of inertia I= t 1 b 31
12
 Cross-sectional area of arm, A=3t 21

 Radius of gyration, K=
√ 2.25 t 41
3 t 21
= 0.866t1

 For buckling in vertical plane, the ends are considered as hinged.

 Therefore, equivalent length of arm,
L=l=60mm

 According to Rankin’s formula, buckling load,

σc× A
W cr = L 2
1+ a( )
K

 Substituting the value of t1=5mm, we have

300 ×52
1
 W cr = 1+ 2 = 7312.78N
60
7500( )
0,866 ×5
 Since this buckling load is more than the calculated value (i.e., 3570N).
 Therefore, design is safe.

Figure 4.8: Designation of worm gear

5 Design of mounting plate

Figure 30 mounting plate

37
Material for head plate isStainless steel with [ σ t ] =650 MPa and [ σ y ]=275 MPa

Height of plate, h = 40cm

Width of plate, w = 40cm

Thickness of plate, t =20mm

4.6.2 Design of bearing house shaft

A shaft is component device that transmits rotational motion and power. It is integral to any
mechanical system in which power is transmitted from a prime mover, such as an electric motor
or an engine, tooth rotating parts of the system.
Shaft is a rotating machine element which used to transmit power for one place to another the
power is delivered to the shaft by some tangential force and a resultant torque (twisting moment)
set up within the shaft permits the power to be transferred to various machines linked up to the
shaft.
In order to transfer the power from one shaft to another the various members such as pulley
gears, bearing etc. are mounted on it. The shaft is rotating member usually circular cross section,
used to transmit power or motion. It provides the axis of rotation or oscillation of elements such s
gears, pulley, key, wheels, crank, sprockets etc.
Material used for shaft: the material used for shafts should have the following Properties:
 It should have high strength
 It should have good machinability
 It should have low notch sensitiveness factor
 It should have good heat treatment property
 It should have high wear resistance property

Material for shaft is 45C8.

σtu=700 MPa , τu=500 MPa

F . S=5

σtu 700
[ σt ] = = =140 MPa
F .S 5

τu 500
τ= = =100 MPa
F .S 5

πτ d 3
Te= √ M +T =
2 2
16

Bending moment, M =400× 9.81 ×40=156960 Nmm Assume p=3000w & N=20rpm

38
 2 πNT 60 P
p= ∧thenT =
60 2 πN

60 ×3000
T= =1432.3944 Nmm
2 π ( 20 )

Then, we find diameter by equating two equations:

3
πτ d
Te= √ M +T =
2 2
16

16 √ M 2+T 2 16 √ ( 156960 ) + ( 1432394.48 )

2 2
3 3 3
d= = mm =86233722.63 mm
πτ π ( 100 )

d=41.8 mm

According to maximum normal stress theory, equivalent bending moment:

1(
M + √ M +T )
2 2
Me=
2

1
Me= ( 156960+ √1569602 +1432394.482 )
2

Me=798964.28 Nmm

We also know that the equivalent bending moment (Me):

π 3
Me= × σt ×d
32

32 Me 32 ×798964.28
d 3= = mm3 =38,73 mm
πσt π ( 140 )

d=38.8 mm

Therefore, taking the larger of the two values, we have d=41.8 we say d=42 mm

Figure4.4: Designation of bearing house shaft

4.6.7 Design of circular handle

 A little consideration will show that a force applied at the end of handle will bend.
Consider maximum bending moment on the handle.
M= force applied × length of handle

39
 M = 50 N × 250 mm
M =12500 N-mm

 Let D= diameter of the handle

 Assuming that the material of circular handle 30C8carbon steel with σ y = 200MPa.
Taking
σ
 A factor of safety 7,σ b = y = 28.57 MPa
7
 We know that the bending moment (M)
π 3
M= ×σ b × D
32

π 3
12500N = ×28.57 × D
32

12500 ×32
D 3=
π × 28.57

D=16.45 mm ≈ 17 mm

Figure4.9: Designation of handle

4.6.1 Design of support

Material for support is mild steel: σc=200MPa, τ =400MPa
Assuming a factor of safety=5

The support must be designed for buckling load of:

Wcr=400Kg×9.81×5=19620N

Considering the cantilever support is subjected to a buckling or crippling load, then the width
and thickness of support may be obtained by Rankin’s formula for columns.
Let, t = thickness of the support and b = width of the support
Assuming the width of support is equal to the thickness of the support b=t, Cross-sectional area
of the support A=t^2, and moment of inertia of cross-section of the support:

40
 1 1
I= t ×t 3= t 4
12 12

Radius of gyration, K=
√ √ √
I
A
=
t4
12 t
2
=
t2
12
=0.288 t

For one end fixed and another end free, C=0.25

Equivalent length, L=2 l=750 ×2 mm=1500

1
Rankin’ s constant,a=
7500

According to Rankin’s formula, buckling load (Wcr)

σc × A
Wcr=
( )
2
L
1+ a
K
2 2
2OO t 200 t
19620= =
( )
2
1 1500 3616.898
1+ 1+ 2
7500 0.288 t t
4 2
t −98.1t −354817.6938=0

Width and thickness, t=38.4 ≈ t=40 mm

Figure4.3: Designation of support

4.6.4 Design of bolt for holding engine

Material for bolt is mild steel with [σt] =100 MPa
[τ]=50 MPa

A) Considering the bolt is subjected to direct shearing loads, it should be located in such a
way that the shearing load comes upon the body (i.e., Shank) of the bolt
Let d = Major diameter of the bolt, and
n = Number of bolts
Assuming shearing load carried by bolt is 35 KN
We know that permissible shear stress for mild steel is,

41
50 MPa n = 4
∴ Shearing load carried by the bolts,

π
PS= ×d ² × τ × n
4

π
35000 = ×d ² ×50 × 4
4

d=15mm

B) Considering the bolt is subjected Bending stress when the outside surfaces of the parts to
be connected are not in the same axis with bolt, then the bolt will be subjected to bending
action. The bending stress (σb) induced in the shank of the bolt is given by
32 M
σb= 3
πd

weight of engine
We know that the bending moment, M = × length of bolt
4

400 ×9.81
M= ×50 mm=49050 Nmm
4

And bending stress, σt or σb=100 MPa

32× 49050
σb= 3
πd

d=
√ 3 32 × 49050
π ×100

d=17.1 mm

Table 4. 1: Design dimensions of screw threads, bolt and nuts

42
Taking the larger value 17.1 mm, from Table 5 (coarse series), we find that the standard nominal
diameter of the bolt is 18 and the corresponding size of the bolt is M 18.

Figure 4.8: Designation of worm gear and trade

4.6.6 Design of nut and bolt for fastening mounting arm, gearbox and bearing house
 Material for bolt and nut is mild Steel with [σt] =100 MPa; [τ]=50 MPa
Design of bolt
 Assuming the size of bolt to be designed is M 16
 If the bolt is not initially stressed, then the maximum safe axial load which may be
applied to it is given by
 P= Permissible stress × Cross-sectional area at bottom of the thread (i.e., stress area)
 From Table 5, for M16 bolt the stress area is 157 mm2, dc=13.546 mm and pitch, p = 2
mm
 P = 100 157 =15700 N
 Checking for Shear stress across the threads.
 The average thread shearing stress for the bolt (τs) is obtained by using the relation:
P
τs= ≤[τ ]
π d c ×b × n

 Where b = Width of the thread section at the root; n= number of treads

 Assuming width of thread section b=3 mm and height of bolt is 10 mm, from this
h 10
n= = =5
P 2

15700
τs = ≤[50 MPa]
π ×13.546 × 3× 5

τ s = 24.6 ≤ [ 50 MPa ]

 therefore, the design is safe

Design of nut
43
  Let; h= Height of nut
n= number of treads in contact with bolt
d = nominal diameter
 When a bolt and nut is made of mild steel, then the effective height of nut is made equal
to the nominal diameter of the bolt; h = d = 16mm
 We know that; h = n × p
h 16
n= = = 8mm
p 2

4.6.9 Design of wheels for front and rear legs

From geometrical analysis Diameter of rear leg =100mm Diameter of front leg=100mm Total
stress of the wheel can be calculate as
Ϭ=F/A where Ϭ= stress at wheel F is force=19620N
A=Area of wheel=Пd²/4
Ϭ1=19620N ×4/П×0.1² (for rear)
Ϭ=2.5 MPa Since the number of wheels is two at rear leg the stress in induced on each the stress
in the front leg is the same as the stress of rear wheel because the wheels have the same diameter
(Ϭ=2.5 MPa).

Material selection for caster wheel

The material that used for caster wheel must have high compression ratio, high wear resistance,
excellent machine ability also must have low cost, good casting characteristic. Due to this cast
iron selected for caster wheel.
Tensile strength = 100 to 200MPa
Compressive strength = 400 to 1000 MPa
Shear strength = 120 MPa

Base Legs and casters: The base of engine stand consists of legs, casters and base tube. Engine
stands usually come with 3-6 casters. The most common wheel count for engine stand is four.
Four wheeled stands are stable and do not take as much space as six wheeled stands. Same stands
have three casters, these stands are good for engine with weight less than 2270N, but usually are
unstable with heavier engine. Five and six wheeled stands are used for larger and heavier engine
and will support load over 18140N. Stand with two legs are more stable and usually can be used
with large engines. Due to this we selected engine stand with four casters and two legs. There are
two casters on the front post and two on the back post of the stand. Front casters can be turned
360 a round to increase the maneuverability of the stand, while rear casters cannot be turned
around allow to move the stand only forward and back. This engine stand rolls very easily, even
when it is holding a load. Four-wheel designs not only allow moving the stand easier, but also
provide better stability than three wheeled engine stands.

44
 4.10 DESIGN OF ANALYSIS
4.10.1 Design of Column
 Material for support is mild steel: σ c=320 MPa
 Assuming a factor of safety =3
 Considering the cantilever support is subjected to a buckling or crippling load, then the
width and thickness of support may be obtained by Rankine’s formula for columns.
 The support must be designed for buckling load of:
 For designing purpose, we select the dimension of the
 Width of 120mmX120mm
 With thickness of 10mm
 Length of column is 800mm
 Length of base is 1200mm with thickness of 5mm
Now let us check whether the column is safe or not by using Rankine’s formula
σc × A
Wcr = L 2
1+ a( )
K

Where, Wcr =critical load

σ c =crushing stress
A=cross-sectional area

L=equivalent length of column

a = Rankine’s constant

K=least radius of gyration

Table. 2 Relation between equivalent length and actual length

45
 Equivalent length, L=2l=800×2mm = 1600 mm

Table. 3 values of end fixity coefficient (c)

 For one end fixed and another end free, C=0.25

Table. 4 Values of crushing stress and Rankine’s constant for various materials

1
 Rankine’s constant, a=
7500
P eng
Load coming at the column, P= = 2333.3KN
3
Area of cross section, A=(bh)-[(b-2t) ×(h-2t)] =4bt-4t 2 =4400mm2 since b=h
bh3 1204
Moment of inertia, I= -¿= -¿
12 12
=8,333,333.3mm 4

Radius of gyration =
√ √
I
A
=
8,333,333.3
4400
= 43.5mm

 According to Rankine’s formula, buckling load (Wcr)

σc × A
Wcr = L
2
1+ a( )
K

46
 320 ×4400
2
= 1 1600 = 1193N
1+ ( )
7500 43.5
Since the load coming to the column is much less than the crushing load the design is
safe.

Figure. 23 supporter

4.10.2 Design of Hollow Shaft

 Material for shaft is steel 45C8.

σ tu= 700MPa

47
 τ u =500MPa
If factor of safety F . S=5
σ tu 700
 We know that allowable tensile stress, [ σ t ] = = =140MPa
F .S 5
τ u 500
[ τ ]= = =100MPa
F .S 5
 Considering a shaft is subjected to a combined twisting and bending moment then the
shaft must be designed on basis of two moments simultaneously. The diameter of shaft
may be obtained by using maximum shear stress theory and normal stress theory.
Let, d=diameter of shaft in mm
Length of hollow shaft, Ls = 300mm
Length of hollow shaft house=250mm
 According to maximum shear stress theory, equivalent twisting moment
Te=√ M 2+T 2
m
 Bending moment, M = 400Kg×10 2
×0.3 m = 1200Nm
s
2 πNT
P=
60
60 P 60× 10000
T= = = 636.619Nm
2 πN 2 π ×150
 Then, we find diameter by equating two equations:
3
πτ d
Te=√ M 2+T 2=
16
16 √ M 2 +T 2 16 √(1200000) +(636619)
2 2
3
d= = mm3= 4324mm3
πτ π × 100

d =16.3mm
 According to maximum normal stress theory, equivalent bending moment:
1 1
Me= (M+√ M 2+T 2) = (M+Te)
2 2
1
Me= (1,200,000+1,358,424) Nmm
2
=1,279,212.3Nmm

48
 We also know that the equivalent bending moment (Me):
π 3
Me= ×σ t ×d a
32
32× M e 32× 1,279,212.3 3
3
d= = mm =93071.1mm3
πσt π ×140
d=45.3mm
 Therefore, taking the larger of the two values, we have 45.3mm say
d=50mm

4.10.3 Design of Mounting Plate

Figure .24 Mounting plate

 Material for head plate is Stainless steel with [ σ t ] =515 MPa and [ σ y ]=205 MPa
 Height of plate, h = 30cm
 Width of plate, w = 30cm
 Thickness of plate, t =20mm

49
 4.10.4 Design of Mounting Arm

Figure .25 Mounting arm

Considering mounting arm may buckle in one plane at right angle to each other due to the load
exerted.

We know that the load on single arm is,

F weight of engine
Force on each arm = =
4 4

m
400 Kg× 10 2
W= F s =1000N
=
4 4

Assume a factor of safety =3,

The arm must be designed for a buckling load of,

F
Wcr= ×F.S=1000N×3= 3000 N
4

50
Let, the material is mild steel which is a square within a cross section of 30×30mm2

Crushing stress, σ c=320Mpa

b 1=width of the arm

h1=¿ height of the arm¿

Therefore, cross-sectional area of the arm,

A=30×30 = 900mm2

And moment of inertia of the cross-section of arm,

b1 h13 30× 303

I= = = 67500mm 4
12 12

Radius of gyration

K=
√ √
I
A
=
67500
900
mm= 8.66mm

Since for buckling of the arm in a plane perpendicular to vertical plane, the ends are considered
as fixed, therefore the equivalent length of arm,

l 140
L= = mm=70 mm
2 2

1
Rankin's constant, a=
7500

According to Rankine’s formula the buckling load (Wcr)

σc × A 320 ×900
2
Wcr= L = 2
1 70 = 285,516 N
1+ a( ) 1+ ( )
K 7500 8.66

Since this buckling load is more than the calculated value of 5250 N

 Therefore, design is safe.

51
 4.10.5 selection of bolt and nut

Figure .26 Bolt

Table. 5 Design dimensions of screw threads, bolt and nuts

52
  Based on the table of design dimensions of screw threads, bolt and nuts we selected
nominal diameter of the bolts are;
 M 18 for holding engine.
 M14 for connecting base and caster.
 M12 for caster(pin).

4.10.6 Design of Handle

Assume

length of handle, Lh=400mm

the load applied by the operator is, P=250N

the permissible bending stress, σ b=100Mpa and

the permissible shear stress, τ=70Mpa

d h = diameter of handle

The force applied acts at a distance of one-third the length of handle, therefore maximum
bending moment is calculated as;

1 2
M= (1- )×P× Lh= (250×400) = 66,666.67Nmm
3 3

π 3
Section modulus, Z= d =0.0982d 3
32

Therefore,

π π
resisting moment =σ b × Z =σ b × × d 3 =100× ×d 3
32 32

= 9.82d 3

In order to get diameter of handle we can equate resisting moment with maximum bending
moment that is,

9.82d 3h = 66,666.67

53
d h=18.94 mm say 25 mm

Fig.27 Handle

54