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DESIGN AND FABRICATION OF

HYDRAULICCYLINDER LINER PULLER

A PROJECT REPORT

Submitted by

VISHNU G 621320114387
SIBIKUMAR N 621320114371
RAGUL K 621320114362

in partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY

(AUTONOMOUS)

THOTTIAM, TRICHY – 621215

ANNA UNIVERSITY: CHENNAI 600 025

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APRIL - 2023

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KONGUNADU COLLEGE OF ENGINEERING AND TECHNOLOGY

(AUTONOMOUS)
NAMAKKAL- TRICHY MAIN ROAD, THOTTIAM,

TRICHY DEPARTMENT OF MECHANICAL

ENGINEERING

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

PEO I: Graduates shall excel in the field of design, thermal, materials and manufacturing, as successful
engineers or researchers or as entrepreneurs.

PEO II: Graduates will analyses problems, design solutions and develop products as a team member
in advanced industrial projects.

PEO III: Graduates shall have professional ethics, team spirit, life-long learning, good oral and
written communication skills and adopt corporate culture, core values and leadership skills.

PROGRAM SPECIFIC OUTCOMES (PSOs)

 PSO1: Professional skills: Students shall understand, analyses, design and develop
integrated equipment, thermal devices and composite components.
 PSO2: Competency: Students shall qualify at the State, National and International level
competitive examination for employment, higher studies and research.
PROGRAM OUTCOMES (POs)

Engineering Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyse complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and

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design system components or processes that meet the specified needs with appropriate

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consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of
the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modelling to complex engineering activities
with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to
the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader
in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and
write effective reports and design documentation, make effective presentations, and give and
receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member and
leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in
independent and life-long learning in the broadest context of technological change.

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ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF HYDRAULIC

CYLINDER LINER PULLER’’ is the bona fide work of VISHNU G (621320114387) ,
SIBIKUMAR N (621320114371)and R A G U L K (621320114362) who carried out the
project work under my supervision.

SIGNATURE SIGNATURE

Dr. D.JAGADEESH, M.E., Mr.V.MUTHUKUMAR,M.E.,Ph.D.

Ph.D., HEAD OF THE SUPERVISOR

DEPARTMENT Assistant Professor

Associate Professor Dept. of Mechanical Engineering

Dept. of Mechanical Engineering Kongunadu college of Engineering &

Technology
Kongunadu college of Engineering &
Technology Thottiam, Trichy.

Thottiam, Trichy.

Submitted for the viva-voce examination held on………………………….

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INTERNAL EXAMINER EXTERNAL EXAMINER

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ACKNOWLEDGEMENT

We proudly render our sincere thanks to our Principal

Dr.R.ASOKAN., M.S., M.Tech., Ph.D., for the facilities and the encouragement
given to complete this project.

We feel peak of pleasure in expressing our heartiest thanks to

Dr.D.JAGADEESH., M.E., Ph.D., Head of the Department, Department of
Mechanical Engineering who always used to act as our pivot.

We sincerely acknowledge our Project Coordinator

Mr.S.K.KARTHIKEYAN.,M.E., Assistant Professor, Department of Mechanical
Engineering for his continuous support to complete this project.

We sincerely acknowledge our Internal Project Guide

Mr.V.MUTHUKUMAR.,M.E.,Ph.D.,Assistant Professor, Department of
Mechanical Engineering for his valuable guidance and encouragement to do the
project in a successful manner.

Further, We sincerely thank all the Faculties and Technical Staff of our
department and my friends for their kind assistance and help rendered completing
this project in abundantly satisfying manner.

Finally, We thank from the bottom of hearts to our loving parents who
understood and satisfy all my needs.

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ABSTRACT

CHAPTER .NO TITLE PAGE. NO

ABSTRACT vii

1 INTRODUCTION 1

2 LITERATURE REVIEW 2

3 DESCRIPTION OF EQUIPMENT

DESIGN OF EQUIPMENT

LIST OF MATERIAL

WORKING PRINCIPLE

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 Introduction

The hydraulic bearing puller and pusher is a device which is used for removing as well as installing bearing on the shaft.

In the machine the press fit operations are very complicated to align the assembly. For this type of operations required

heavy force for assembly & dissembling the bearing from the machines. It can widely & effectively used for removing

the bearing. Bearings are made to exacting tolerances and have very fine surface finishes. In order to maintain the

geometrical precision and the surface integrity of ball and roller bearing raceways and rolling elements, it is mandatory

that care in storage, handling and installation be observed. The hydraulic bearing puller and pusher perform both pulling

and pushing operation safely and without harming bearing surfaces.

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 LITERATURE REVIEW

Hydraulic Jack is perhaps one of the best examples of fluid power system. It plays very important role in automobile
industries to facillate servicing and repair. It may be portable device. By operating handle of small device and individual
can lift load of several tons. Hydraulic jack works on the principle of Pascal’s. Hydraulic Jack consists of Cylinder,
Plunger, and Handle, Oil reservoir, Pressure release and relief valve. When the handle is operated, the plunger
reciprocates then the oil from the reservoir is sucked into the plunger cylinder during upward stroke of the plunger
through the suction valve. The oil in the plunger cylinder is delivered into the ram cylinder during the downward stroke
of the plunger through the delivery valve. This pressurized oil lifts the load up, which is placed on top plate of the ram.
After the work is completed the pressure in the ram cylinder is released by unscrewing the lowering screw thus the
pressure releases and the ram is lowered, then the oil is rushed into the reservoir. Hydraulic cylinders get their power
from pressurized hydraulic fluid, which is typically oil. The hydraulic cylinder consists of a cylinder barrel, in which
a piston connected to a piston rod moves back and forth. The barrel is closed on one end by the cylinder bottom (also
called the cap) and the other end by the cylinder head (also called the gland) where the piston rod comes out of the
cylinder. The piston has sliding rings and seals. The piston divides the inside of the cylinder into two chambers, the
bottom chamber (cap end) and the piston rod side chamber (rod end / head end).

Flanges, trunnions, clevises, Lugs are common cylinder mounting options. The piston rod also has mounting attachments
to connect the cylinder to the object or machine component that it is pushing / pulling.

A hydraulic cylinder is the actuator or "motor" side of this system. The "generator" side of the hydraulic system is

the hydraulic pump which brings in a fixed or regulated flow of oil to the hydraulic cylinder, to move the piston.

A shaft is a rotating machine element, usually circular in cross section, which is used to transmit power from

one part to another, or from a machine which produces power to a machine which absorbs power. [1] The various members

such as pulleys and gears are mounted on it.

When a driver like an electric motor or a turbine is coupled to a pump, a generator, or any other piece of equipment, it is

essential that the shafts of the two pieces are aligned. Any misalignment between the two increases the  stress on the shafts

and will almost certainly result in excessive wear and premature breakdown of the equipment. This can be very costly.

When the equipment is down, production might be down. Also bearings or mechanical seals may be damaged and need to

be replaced. Flexible couplings are designed to allow a driver (electric motor, engine, turbine, hydraulic motor) to be

connected to the driven equipment. Flexible couplings use an elastomeric insert to allow a slight degree of misalignment
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 DESCRIPTION OF EQUIPMENT

3.1 HYDRAULIC JACK

Hydraulic Jack is perhaps one of the best examples of fluid power system. It plays very important role in automobile

industries to facillate servicing and repair. It may be portable device. By operating handle of small device and individual

can lift load of several tons. Hydraulic jack works on the principle of Pascal’s. Hydraulic Jack consists of Cylinder,

Plunger, and Handle, Oil reservoir, Pressure release and relief valve. When the handle is operated, the plunger

reciprocates then the oil from the reservoir is sucked into the plunger cylinder during upward stroke of the plunger

through the suction valve. The oil in the plunger cylinder is delivered into the ram cylinder during the downward stroke

of the plunger through the delivery valve. This pressurized oil lifts the load up, which is placed on top plate of the ram.

After the work is completed the pressure in the ram cylinder is released by unscrewing the lowering screw thus the

pressure releases and the ram is lowered, then the oil is rushed into the reservoir.

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3.2 BEARING

A bearing is a machine element that constrains relative motion to only the desired motion, and reduces friction

between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part

or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear

on the moving parts. Many bearings also facilitate the desired motion as much as possible, such as by minimizing

friction. Bearings are classified broadly according to the type of operation, the motions allowed, or to the directions of the

loads (forces) applied to the parts.

The term "bearing" is derived from the verb "to bear";[1] a bearing being a machine element that allows one part to bear

(i.e., to support) another. The simplest bearings are bearing surfaces, cut or formed into a part, with varying degrees of

control over the form, size,roughness and location of the surface. Other bearings are separate devices installed into a

machine or machine part. 

The first modern recorded patent on ball bearings was awarded to Philip Vaughan, a British inventor and ironmaster who

created the first design for a ball bearing in Carmarthen in 1794. His was the first modern ball-bearing design, with the

ball running along a groove in the axle assembly.[8]

Bearings played a pivotal role in the nascent Industrial Revolution, allowing the new industrial machinery to operate

efficiently. For example, they saw use for holding wheel and axle to greatly reduce friction over that of dragging an

object by making the friction act over a shorter distance as the wheel turned.The first plain and rolling-element bearings

were wood closely followed by bronze. Over their history bearings have been made of many materials

including ceramic, sapphire,glass, steel, bronze, other metals and plastic

(e.g., nylon, polyoxymethylene, polytetrafluoroethylene, and UHMWPE) which are all used today.

Watch makers produce "jeweled" watches using sapphire plain bearings to reduce friction thus allowing more precise

time keeping.

Even basic materials can have good durability. As examples, wooden bearings can still be seen today in old clocks or in

water mills where the water provides cooling and lubrication.

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Early Timken tapered roller bearing with notched rollers

The first patent for a radial style ball bearing was awarded to Jules Suriray, a Parisian bicycle mechanic, on 3 August

1869. The bearings were then fitted to the winning bicycle ridden by James Moore in the world's first bicycle road

race, Paris-Rouen, in November 1869.[9]

In 1883, Friedrich Fischer, founder of FAG, developed an approach for milling and grinding balls of equal size and exact

roundness by means of a suitable production machine and formed the foundation for creation of an independent bearing

industry.

Wingquist original patent of self-aligning ball bearing

The modern, self-aligning design of ball bearing is attributed to Sven Wingquist of the SKF ball-bearing manufacturer in

1907, when he was awarded Swedish patent No. 25406 on its design.

Henry Timken, a 19th-century visionary and innovator in carriage manufacturing, patented the tapered roller bearing in

1898. The following year he formed a company to produce his innovation. Over a century the company grew to make

bearings of all types, including specialty steel and an array of related products and services.

Erich Franke invented and patented the wire race bearing in 1934. His focus was on a bearing design with a cross section

as small as possible and which could be integrated into the enclosing design. After World War II he founded together

with Gerhard Heydrich the company Franke & Heydrich KG (today Franke GmbH) to push the development and
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production of wire race bearings.

Richard Stribeck’s extensive research [10][11] on ball bearing steels identified the metallurgy of the commonly used 100Cr6

(AISI 52100) [12]showing coefficient of friction as a function of pressure.

SHAFT

A shaft is a rotating machine element, usually circular in cross section, which is used to transmit power from

one part to another, or from a machine which produces power to a machine which absorbs power. [1] The various members

such as pulleys and gears are mounted on it.

When a driver like an electric motor or a turbine is coupled to a pump, a generator, or any other piece of equipment, it is

essential that the shafts of the two pieces are aligned. Any misalignment between the two increases the stress on the shafts

and will almost certainly result in excessive wear and premature breakdown of the equipment. This can be very costly.

When the equipment is down, production might be down. Also bearings or mechanical seals may be damaged and need to

be replaced. Flexible couplings are designed to allow a driver (electric motor, engine, turbine, hydraulic motor) to be

connected to the driven equipment. Flexible couplings use an elastomeric insert to allow a slight degree of misalignment.

Flexible couplings can also use shim packs. These couplings are called disc couplings. Tools used to achieve alignment

may be mechanical or optical, like the Laser shaft alignment method, or they are gyroscope based. The gyroscope based

systems can be operated very time efficient and can also be even used if the shafts have a large distance (e.g. on marine

vessels).

Before such a shaft alignment can be done, it is also essential that the foundations for the driver and the driven piece are

designed and installed correctly.machine could cost 20% to 30% of machine down time, replacement parts, inventory and

energy costs. Large returns are usually seen by regularly aligning the machine. The total operation life is extended and

process conditions are optimized for efficiency. Hence it becomes extremely important for the maintenance and

engineering professionals to understand machine malfunctions caused by misalignment.

Vibration signatures are widely promoted for studying machine malfunctions. However, most literature will not be able to

provide a clear picture of signature characteristics uniquely and directly attributable to misalignment. Every author will

report different signatures. There are still no reports of systematic, controlled experiments with varying parameters.

However we can carry out various experiments to elucidate any consistent features of vibration signatures for misaligned

machinery.
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To begin with lets consider a simulator which is fault free and is able generate controlled faults, it should possess three

machine operating parameters, coupling types, amount of misalignment and the motor speed which will be systematically

varied while all the other parameters will be held constant. The machine should be fault free with the exception of

deliberate misalignment which is varied systematically. Therefore, baseline vibration data is recorded for each of the test

conditions. Vibrations should be monitored via sensors which should be placed in strategic locations to get accurate data.

The X, Y, Z coordinate system is used to show direction. For this experiment we can use three different stiffness

couplings, four levels of offset should be used on the left bearing housing to simulate a combination of angular and

parallel misalignment. Equivalent offset on the right bearing housing to get parallel misalignment. The experiment must

contain four speeds of rotation and the goal here must be to determine the effects of coupling stiffness, level and type of

misalignment and finally the speed of rotation on vibration spectra.

Data can be acquired from the specially designed hardware and software for the simulator. The purpose of this

experiment should be to examine the spectra due to misalignment between the motor and the rotor shafts. Spectral

comparisons should be made across coupling measurement points on left bearing housing and the motor. The data should

be compared in both vertical and axial direction. If the results at 960 and 2100 RPM do not show significant vibration, the

study can be limited to a higher speeds of 2900 and 3800 RPM. A correlation between misalignment and vibration

signature could not be discerned. The data for all cases contained several harmonics. Both axial and lateral vibration was

present in all cases. The dominant harmonic varied from condition to condition. As a general rule, as expected, increased

misalignment yielded increased vibration peaks.As another general rule, peak vibrations in the misaligned machine were

in the axial direction. For predictive maintenance applications where the goal is machinery health monitoring, it is

sufficient to realize that the problem is complex. One can routinely trend the vibration spectra until it becomes severe.

But for root cause analysis, one must exercise caution and perform a detailed analysis. Obviously, the rules provided in

training courses and wall charts are doubtful at best.The observed changes that occurred with shifts of speed and

misalignment do not show a typical signature for misalignment vibration spectra. Hence, it can be concluded that

misalignment vibration is a strong function of machine speed and coupling stiffness. A single point vibration spectrum

does not provide good and reliable indication of machinery misalignment. Observations of spectra in axial and radial

directions at various speeds and several points are needed to diagnose misalignment effects. Orbital plots of vertical and

horizontal measurements in the time domain might also be needed. Non-linear dynamic modelling must be performed to

gain full understanding of misalignment effects. Finally, more work in this field is simply needed in order to develop
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simple rules for diagnosing machinery shaft misalignment.

DESIGN OF EQUIPMENT AND DRAWING

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WORKING PRINCIPLE

This device is working by the principle of hydraulic lifting system. In this project we use hydraulic bottle jack.

Jack is fixed with the table in the area allocated to it. A handle is attached with the hydraulic jack. When the handle is

pressed the oil in the hydraulic jack is allowed to flow which helps to actuate the jack. The rod in the jack comes up

during this process. A pressure relief valve is attached to side of the bottle jack which helps rod to come back to its

previous position. The bearing puller is attached to rod and the pulling end of the bearing puller is attached to the bearing.

When the jack is operated the bearing puller goes upwards and so the bearing is pulled out of the shaft.

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MERITS AND DEMERITS

MERITS

 It is Low cost

 It Saves the Man Power

 And also it Saves the time

DEMIRTS

 Manually operated

 It cannot be kept upside down since it leads to leakage of oil

APPLICATIONS

1.Hydraulic cylinder puller is used

 Industrial uses.

 Automobiles uses.

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LIST OF MATERIALSFACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed below.
1. PROPERTIES:

The material selected must posses the necessary properties for the proposed application. The various

requirements to be satisfied Can be weight, surface finish, rigidity, ability to withstand environmental attack from

chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal Conductivity, specific heat, coefficient of

thermal expansion, specific gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile, Compressive shear, bending, torsional and

buckling load, fatigue resistance, impact resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness,

wear resistance and sliding properties. The various properties concerned from the manufacturing point of view are,

 Cast ability

 Weld ability

 Bribability

 Forge ability

 Merchantability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. MANUFACTURING CASE:

Sometimes the demand for lowest possible manufacturing cost or surface qualities obtainable by the application of

suitable coating substances may demand the use of special materials.

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3. QUALITY REQUIRED:

This generally affects the manufacturing process and ultimately the material. For example, it would never be

desirable to go casting of a less number of components which can be fabricated much more economically by welding or

hand forging the steel.

4. AVILABILITY OF MATERIAL:

Some materials may be scarce or in short supply.it then becomes obligatory for the designer to use some other

material which though may not be a perfect substitute for the material designed.the delivery of materials and the delivery

date of product should also be kept in mind.

5. SPACE CONSIDERATION:

Sometimes high strength materials have to be selected because the forces involved are high and space limitations

are there.

6. COST:

As in any other problem, in selection of material the cost of material plays an important part and should not be

ignored.

Some times factors like scrap utilization, appearance, and non-maintenance of the designed part are involved in

the selection of proper materials.

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CONCLUSION

In order to remove and installed bearing safely, to make modification in traditional method. The modification made in

easy removing and installing bearing. The purposes of modification are Simplicity of operation, removing and installation

of bearing done without damaging bearing surface, compact, portable, well suited, low cost,

Multifunctional ,safe ,versatile and individual can lift a load weighing several ton.

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REFERENCES

.Mohammed Abuzaid, Mohammad Hasnain, Shabaj Alam, Sohail Khan, Prof. Surendra Agarwal "INBUILT

HYDRAULIC JACK IN AUTOMOBILE VEHICLES”, International Journal of innovation in Engineering and

Technology,Vol.2 Issue 2 April 2013 ISSN:2319-1058, Satyam education and social welfare society group of

institutions,Bhopal, MP (INDIA).

2.Guoping Yang, Jian Fang “STRUCTURE PARAMETER OPTIMIZATION ANALYSIS OF HYDRAULIC HAMMER

SYSTEM", Scientific ResearchVol.2 137-142, College of Automotive Engineering and Science, Shanghai, China.

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