UNIVERSITI KUALA LUMPUR

MALAYSIAN SPANISH INSTITUTE

(TWO LIFTING ARMS CAR

JACK)

BY:

MUHAMAD AFIZ BIN MOHAMMAD

(54136209191)

AIN NATASHA BINTI ZULKUFLI

(54136209015)

JACOB PEREIRA

(54136209195)

Report Submitted to Fulfill the Partial Requirements for the Diploma of

Engineering Technology in Mechanical Design and Development.

JULY 2011

DECLARATION

We hereby declare that this submission is our own work and that to the best

of our knowledge and belief it contains neither material nor facts previously

published or written by another person. Further it does not contain material

or facts which to a substantial extent has been accepted for the award of any

diploma of a university or any other institution of tertiary education except

where an acknowledgement.

……………………………….

(Muhamad Afiz bin Mohammad)

541362090

……………………………….

(Ain Natasha binti Zulkufli)

54136209015

……………………………….

(Jacob Pereira)

54136209195

Date: / /2011

Date: / /2011

Date: / /2011

2

APPROVAL

We have examined this report and verify that it meets the programmed and

University requirements for the Diploma of Engineering Technology in

Mechanical Design and Development.

……………………………….

(Mr. Zainal Nazri bin Mohd Yusuf)

Supervisor

……………………………….

(Mr. Abdul Rashid bin Abdul Rahman)

Date: / /2011

Date: / /2011

3

ACKNOWLEDGEMENT

Two lifitng arms car jack has been developed successfully with a great

contribution of many people within a period of six months. We would like to

appreciate their guidance, encouragement and willingness since without

their support the project would not have been a success.

Firstly we would like to thank God who has been the highest helper for our

project in many ways. Without God we cannot be completing this project

successfully with the weather, time an etc.

We would like to give our sincere gratitude to Mr. Zainal Nazri bin Mohd

Yusuf, who was supervise our project and helping us in many ways, sharing

some information and knowledge, giving us some idea and also help us in

solving problems to make sure our project succeed. We are also grateful to

Mr. Abdul Rasid bin Abdul Rahman who has been behind us guiding all the

projects from and giving us very valuable feedback Both our supervisor who

was a really helpful people who guided us in fabricating so many parts for

our project.

We are also grateful to the whole technician of the Workshop Section

including- Mr. Mohd Faizal bin Osman, Mr. Azren bin Ahmad, Mr. Asrulwadi

bin Ismail, Mr. Mohd Shukor bin Salleh and others for their inspiring

technician, give feedbacks and helping us on how to using workshop

equipments.

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We would also thank our parents and family member for giving us the

financial support and the courage to complete this final year project. We

would like to thank them because of the great advises and support that they

gave us from the starting till the end of this project.

CONTENTS

DECLARATION 2APPROVAL 3ACKNOWLEDGEMENT 4CONTENTS 5LIST OF TABLES 7LIST OF FIGURES 8CHAPTER 1 INTRODUCTION 9

1.1 Introduction 101.2 Project Motivation 161.3 Background 191.4 Problem Statement 211.5 Objectives 241.6 Scope and Limitation 25

CHAPTER 2 LITERATURE REVIEW 262.1 Introduction 272.2 Terminology 32

2.2.1 Design 322.2.2 Jack 32

CHAPTER 3 DESIGN DEVELOPMENT 363.1 Project Development Stages 373.2 Project Fabrication Stages 39

3.2.1 Project Planning and Scheduling 403.2.2 Gantt Chart 43

3.3 Concept of Car Jack 443.3.1 How does a two lifitng arms car jack work? 44

3.4 Fabrication and Development 553.4.1 Confirm Design 553.4.2 Build Mock-Up 55

CHAPTER 4 METHODOLOGY 564.1 Parts Development 57

4.1.1 Outer Body 574.1.2 Gears and Couplings Mechanism 624.1.3 Lifting Arm 674.1.4 Lifting Base 704.1.5 Rollers Part 80

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4.1.6 Finishing Process 81

CHAPTER 5 RESULT AND DISCUSSION 825.1 Testing the Product 835.2 Problems Facing and Solutions 845.3 Result 85CHAPTER 6 CONCLUSION AND DISCUSSION 876.1 Recommendation 886.2 Conclusion 89REFERENCES 90APPENCISES 91

6

LIST OF TABLES

Table 1 Pahl and Beitz Model of Design ProcessTable 2 Stages of project developmentTable 3 Stages of project fabrication 1Table 4 Structure of product developmentTable 5 Gantt chartTable 6 CNC Milling ProgrammingTable 7 EDM Programming

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LIST OF FIGURE

Figure 1 Screw lifting jack 10Figure 2 Long floor jack 12Figure 3 Pneumatic jack 12Figure 4 Pneumatic jack 13Figure 5 House jack 13Figure 6 Strand jack 14Figure 7 Current jack in market 14Figure 8 Tire change fail 15Figure 9 Mechanic servicing car 16Figure 10 Electric car jack 20Figure 11 Preparing tools 25Figure 12 Proper located of car jack 26Figure 13 Proper position point of car jack 26Figure 14 Place jack stands 27Figure 15 Lower the car jack to the stand 27Figure 16 Stop lowering the jack 28Figure 17 Spur gear and rack gear 41Figure 18 Marking plate 42Figure 19 Hand sawing machine 42Figure 20 DANOBAT band sawing machine 43Figure 21 Cutting plate process 43Figure 22 Position of hole in plate 44Figure 23 Surface grinding control 45Figure 24 Facing process 47Figure 25 Spur gear 50Figure 26 Position of spur gear and rack gear 50Figure 27 Gear fix into the lifting arm 51Figure 28 Assembling process of arm 51Figure 29 Dimension of lifting arm 52Figure 30 Drilling hole on arm plate 53Figure 31 Grinding process 53Figure 32 Cover of arm set 54Figure 33 Lifting base 1 & 2 55Figure 34 Process of shaping lifting base plate 57Figure 35 CNC Milling 57Figure 36 Lifting base 1 57Figure 37 Bending process 57Figure 38 Lifting base 2 60Figure 39 Cutting process of lifting base using EDM 62Figure 40 Bending process 63

8

Figure 41 Front roller 64Figure 42 Back roller 64Figure 43 Assembled of part project 65Figure 44 Result of project 68Figure 45 Result of project 69

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Chapter 1: INTRODUCTION

1.1 INTRODUCTION

This report describes about the types of jacks that are in the market now

days. It is a device used in workshop’s to lift heavy loads or apply great

forces to carry a vehicle. There are many types or jacks in the market.

Firstly, the mechanical jack. A mechanical jack is a device which lifts heavy

equipment. The most common form is a car jack, floor jack or garage

jack which lifts vehicles so that maintenance can be performed. Car jacks

usually use mechanical advantage to allow a human to lift a vehicle by

manual force alone. More powerful jacks use hydraulic power to provide

more lift over greater distances. Mechanical jacks are usually rated for a

maximum lifting capacity (for example, 1.5 tons, 2 tons, and 3 tons). The

jack shown below is made for a modern vehicle and the notch fits into a

point on the body. Earlier versions have a platform to lift on the vehicles'

frame or axle. This is a common car jack found in car when the car is

purchased by someone from the car dealer’s.

Figure 1 Screw Lifting Jack

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Secondly, the hydraulic jacks are typically used for shop work, rather than as

an emergency jack to be carried with the vehicle. Use of jacks not designed

for a specific vehicle requires more than the usual care in selecting ground

conditions, the jacking point on the vehicle, and to ensure stability when the

jack is extended. Hydraulic jacks are often used to lift elevators in low and

medium rise buildings.

A hydraulic jack uses a fluid, which is incompressible, that is forced into a

cylinder by a pump plunger. Oil is used since it is self lubricating and stable.

When the plunger pulls back, it draws oil out of the reservoir through a

suction check valve into the pump chamber. When the plunger moves

forward, it pushes the oil through a discharge check valve into the cylinder.

The suction valve ball is within the chamber and opens with each draw of the

plunger. The discharge valve ball is outside the chamber and opens when

the oil is pushed into the cylinder. At this point the suction ball within the

chamber is forced shut and oil pressure builds in the cylinder.

In a bottle jack the piston is vertical and directly supports a bearing pad that

contacts the object being lifted. With a single action piston the lift is

somewhat less than twice the collapsed height of the jack, making it suitable

only for vehicles with a relatively high clearance. For lifting structures such

as houses the hydraulic interconnection of multiple vertical jacks through

valves enables the even distribution of forces while enabling close control of

the lift.

In a floor jack a horizontal piston pushes on the short end of a bell crank,

with the long arm providing the vertical motion to a lifting pad, kept

horizontal with a horizontal linkage. Floor jacks usually include castors and

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wheels, allowing compensation for the arc taken by the lifting pad. This

mechanism provides a low profile when collapsed, for easy movement

underneath the vehicle, while allowing considerable extension.

Figure 2 Long Floor Jack

Figure 3 Pneumatic Jack

The third type of jack is the pneumatic jack. It is a hydraulic jack that is

actuated by compressed air - for example, air from a compressor -

instead of human work. This eliminates the need for the user to actuate

the hydraulic mechanism, saving effort and potentially increasing speed.

Sometimes, such jacks are also able to be operated by the normal

hydraulic actuation method, thereby retaining functionality, even if a

source of compressed air is not available.

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Figure 4 Pneumatic Jack

Next, a house jack, also called a screw jack is a mechanical device primarily used to lift

houses from their foundation. A series of jacks are used and then wood cribbing

temporarily supports the structure. This process is repeated until the desired height is

reached. The house jack can be used for jacking carrying beams that have settled or for

installing new structural beams. On the top of the jack is a cast iron circular pad that the

4" × 4" post is resting on. This pad moves independently of the house jack so that it

does not turn as the acme-threaded rod is turned up with a metal rod. This piece tilts

very slightly but not enough to render the post dangerously out of plumb.

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Figure 5 House Jack

Lastly, is the strand jack. It is a specialized hydraulic jack that grips steel

cables; often used in concert, strand jacks can lift hundreds of tons and are

used in engineering and construction.

Figure 6 Strand Jack

Figure 7 Current Jack in market

Well, this is the types of jacks that are in the market at this moment. In

conclusion, we can say that jack’s are meant for carrying heavy loads.

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1.2 PROJECT MOTIVATION

An automotive jack is a device used to lift of a vehicle into the air in order to

facilitate repairs. Most people are familiar with the basic car jack (manually

operated) that is still included as standard equipment with most new cars.

These days, a car jack is an important tool especially in automotive industry

and workshop to helping technician and mechanic repairing their customer’s

vehicle with more safety precaution and quickly.

Working near a vehicle that is supported by a car jack can be fatal. In

Australia, over the last four years at least 19 people have been crushed and

killed by a vehicle while they were working. All the deaths were men and

involved the vehicle being lifted or supported in the wrong way. Home

mechanics are most at risk of this type of death or injury.

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Figure 8 Tire change fail

In some cases the worker was killed when the vehicle was not secured by

chocks and the vehicle rolled on top of them, or the structures used to

support the vehicle failed. On average, 160 injuries are associated with car

jacks each year. Injuries have ranged from amputation to fractures and crush

injuries. The correct use of jacks can prevent death or injury.

Figure 9 Machanic servicing car

Furthermore, an organization called the American Lift Institute (ALI) was

established to promote improvements in automotive lift technology,

especially in the area of safety. As recently as the late 1990s, car lift or jack

manufacturers were allowed to declare that their products were safe even

though they did not meet any set standard.

Thanks to ALI's cooperative venture with the American National Standards

Institute, all jacks and lifts must meet a set number of performance

standards in order to be ALI/ANSI certified. Improvement in automotive car

jack is really needed to make the tool more efficient, user-friendly, practical

to use, changes in industry direction and most importantly high safety

features. Further research on car jack is very important.

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1.3 BACKGROUND

In the repair and maintenance of automobiles (car), it is often necessary to

raise an automobile to change a tire or access the underside of the

automobile. Accordingly, a variety of car jacks have been developed for

lifting an automobile from a ground surface. Available car jacks, however,

are typically manually operated and therefore require substantial laborious

physical effort on the part of the user.

Furthermore, available jacks are typically large, heavy and also difficult to

store, carry or move into the proper position under an automobile. In

addition, to the difficulties in assembling and setting up jacks, such jacks are

generally not adapted to be readily disassembled and stored after

automobile repairs have been completed.

In light of such inherent disadvantages, some researcher including students

tries to generate a new idea and their attitude on how to develop an Two

lifitng arms car jack for our future.

However, due to their size and high costs of purchasing and maintaining this

car jack, such Two lifitng arms car jacks are not available to the average car

owner. Engineering is about making things simpler or improving and

effective. So we try to develop a car jack in the small scope as an experiment

so that it could be a signal to the world on our effort to solving these

problems nowadays.

There also reports on car jacks which lead to a serious number of accidents.

These are due of safety features that are on conventional car jacks are not

enough. A specified jack purposed to hold up to 1000 kilograms, but tests

undertaken by Consumer Affairs has revealed that it is fails to work after

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lifting 250 kilograms and may physically break when it has a weight close to

its 1000 kilograms capacity.

Whilst no injuries have been reported to date, it was rising expressed

concerned about the dangers associated with the use of a vehicle jack that

does not carry the weight it is promoted to hold. Tests have proven that the

jack has the propensity to buckle well under the weight it is promoted to

withstand, and it doesn’t meet the labeling or performance requirements of

the Australian Standard for vehicle jacks.

The purpose of this project is to develop a car jack which is easy to be

operated, safe and able lift and lowering the car without involving much

physical effort. It is almost fulfill automotive industry requirement especially

in workshop to help mechanics and technician make their works easily

without any problems.

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1.4 PROBLEM STATEMENT

According to this necessity, we have find out the entire user’s problem

(especially drivers and mechanics) and try to solve it also developed this

product of car jack that existing on the market become more better based on

technology provided nowadays.

Present car jack do not have a lock or extra beam to withstand the massive

load of the car. This is for the safety precaution in case if the screw break.

Besides, present car jack just have only one lifting arm to support the load.

With this new design, we try to minimize the size of car jack with maximum

lifting capacity so it can folded up in the vehicle and safe some space, lighter

the weight of material used and also to ensure the stability when the jack is

extended so anyone can bring it easily.

Furthermore, available jacks are typically large, heavy and also difficult to

store, carry or move into the proper position under an automobile. Suppose

car jacks must be easy to use for whoever person and easy to control the

movements of the car jack.

Lastly, normally all car jacks cannot be change or modified if it is spoil. If it

spoils, the only way is to get a new one. So the cost of buying it is expensive.

The price depends on the load that the jack can be carried.

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From the problems and our effort to develop the car jack to be as Two lifitng

arms car jack, we’ve list the problem solution as shown below:-

i. We’ve developed this car jack with two lifting base that can stand with

any weight of vehicle and increase the stability and capability than one

lifting base as usual. This allow technician and users do their work

safely.

ii. First of all, we’ve planned to use a motor for supply power to the car

jack. But it is not stronger at all especially when there is sudden black

out and we need to make sure the motor is function every time before

it can be use.

Figure 10 Electric car jack

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We use hydraulic system to the jack which used a fluid, which is

incompressible, that is forced into a cylinder by a pump plunger. Oil is

used since it is self lubricating and stable.

iii. This Two lifitng arms car jack is jacking from the side, so the mechanic

has more space at the front side to do their works.

iv. When this product is not been used, it can folded up and the roller

made inside the base can move freely.

v. The lifting base of Two lifitng arms car jack can be extended to the size

of vehicle (width) and it was make by rubber padded lifting platform

prevents scratching and protects the vehicle.

vi. We used mild steel that is cheap, high stiffness and strong. Most of

mild steels are easy to machine and weld.

vii. We also use and fabricate parts that can be dismantled. This is for

maintenance purpose of the jack.

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1.5 OBJECTIVES

In order to fulfill the needs of present car jack, some improvement must be

made base on the problem statement:-

i. To design a car jack that is safe, reliable and able to raise and lower

the height level

ii. To design and fabricate the car jack which has develop with more

multi-functionality car jack.

iii. To design a car jack with easy maintenance and less cost

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1.6 SCOPE AND LIMITATION

i. A simple car jack that used for workshop and automotive industry.

ii. These car jacks are prohibited from using for lorry, bus and any heavy

vehicle.

iii. The developed car jack can only withstand below 2 ton of load.

iv. The developed car jack must be operated on a flat surface.

v. The developed car jack is only a prototype and not readily functioning

as commercial product.

vi. The design is based on current lifting base in the market with some

comparison and adjustment.

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Chapter 2: LITERATURE REVIEW

1.1 INTRODUCTION

The main purpose of this literature review is to get information about the

project from reference books, magazine, journals, technical papers and web

sites. In this chapter, the discussion will be made base on all the resources.

First of all, the concept of our product was found by doing some research on

how the car jack lifting cars (vehicle) by us at Kulim, Kedah and surfing some

videos car jack lifting cars (vehicles) by internet. Below is the manual way of

lifting cars (vehicle) by a car jack.

This how-to article aims to help illustrate proper vehicle jacking procedures.

As a disclaimer, we always recommend that you read your vehicle's manual

(or better yet - the factory workshop manual) before attempting any service

items.  In this how to, you will be required to know and identify the factory

approved "jack points".  Typically, these points can be found under

"Emergency" in the vehicle operator's manual.

Because of the dangers of having a 1000+ kg vehicle looming over you as

you work, we will accept absolutely no responsibility for any accidents that

may occur while you service your vehicle (*one of the reason for us

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developing the car jack with more safety precaution). Safety is everybody's

responsibility- the following article will attempt to reinforce this concept.

Before you buy jack-stands, and a floor jack be sure that each component is

strong enough to support at least half of the vehicle's "curb weight".

Figure 11 preparing tools

i. As safety is a major focal point of this write up, all steps will have some

proximity to safe practices - the first step is a subtle example. Before

you consider jacking up a vehicle, find as flat work area as possible.

ii. Move the vehicle into position.  You should place cinder blocks, 4 x 4

blocks, or similar large wedges in front and behind the wheels which

will remain on the ground during the initial jacking process.

iii. Be sure to chock the front wheels. If the vehicle is front-wheel drive,

put the vehicle into reverse gear. State the floor jack in the approved

25

factory location. Be sure to place the jack in an accessible location,

free of interference with any vehicle chassis parts. 

Figure 12 Proper located of car jack

iv. Begin jacking the vehicle up using the floor jack.  Be very cautious

whilst raising the vehicle. This is where most accidents occur.

Figure 13 proper position point of jack

26

v. Once the vehicle is raised sufficiently, place the jack-stands under the

factory approved jacking points. 

Figure 14 Place jack-stands

vi. Be sure to always use a minimum of two jack-stands when raising the

front or rear of a vehicle.

Figure 15 Lower the car to the jack stands

vii. Then, you may slowly lower the vehicle onto the jack-stands. If you run

into problems, jack the vehicle back up and re-position or re-plan your

jacking sequence.

27

Figure 16 Stop lowering the jack

viii. Stop lowering the jack and raise it back up one "notch. Give the vehicle

a slight nudge to ensure that the forces you will exert during your

mechanical procedures will not cause the vehicle to become unstable

and fall off the jack-stands thus killing someone below. Once you are

satisfied that you have done to make the worksite as safe as possible,

you have completed that jacking up of your vehicle.

1.2 TERMINOLOGY

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In this section, all the terminology on this project is presented.

1.2.1 Jack

A mechanical jack is a device which lifts heavy equipment. The most

common form is a car jack, floor jack or garage jack which lifts vehicles so

that maintenance can be performed. Car jacks usually use mechanical

advantage to allow a human to lift a vehicle. More powerful jacks use

hydraulic power to provide more lift over greater distances. Mechanical jacks

are usually rated for a maximum lifting capacity (for example, 1.5 tons or 3

tons).

1.2.2 Design

To design is either to formulate a plan for the satisfaction of a specified need

or to solve a problem. If the plan results in the creation of something having

a physical reality, then the product must be functional, safe, reliable,

competitive, usable, manufacturable, and marketable.

These terms are defined as follows:

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i. Functional: The product must perform to fill its intended need and

customer expectation.

ii. Safe: The product is not hazardous to the user, bystanders, or

surrounding property. Hazards that cannot be ‘designed out’ are

eliminated by guarding (a protective enclosure); if that is not possible,

appropriate directions or warning are provided.

iii. Reliable: Reliability is the conditional probability, at a given

confidence level, that the product will perform its intended function

satisfactorily or without failure at a given age.

iv. Competitive: The product is a contender in its market.

v. Usable: The product is ‘user friendly’ accommodating to human size,

strength. Posture, reach, force, power and control. The developed car

jack is only a prototype and not readily functioning as commercial

product.

vi. Manufacturing: The product has been reduced to a ‘minimum’

number of parts. Suited to mass production, with dimensions,

distortion, and strength under control.

vii. Marketable: The product can be bought, and service (repair) is

available.

It is important that the designer starts by identifying exactly how to

recognize or get a satisfactory alternative, and how to distinguish between

two satisfactory alternatives in

order to get a perfect solution. From this, optimization strategies can be

formed or selected.

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Then the following tasks unfold:

i. Invent alternative solution.

ii. Establish key performance metrics.

iii. Through analysis and test, simulate and predict the performance of

each alternative, retain satisfactory alternatives, and discard

unsatisfactory ones.

iv. Choose the best satisfactory alternatives discovered as an

approximation to optimality.

v. Implement the design.

The characterization of a design task as a design problem can introduce the

idea that, as a problem, it has solution.

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Chapter 3: DESIGN DEVELOPMENT

32

Table 1 Pahl and Beitz Model of Design Process

3.1 PROJECT DEVELOPMENT STAGES

Here, we have list the combination method used in order to accomplish our

project. We go through this procedure around four months to make and

gather some information, drawing process, and concepts of the project.

i. Doing some research to the already existing car jack

ii. Doing survey on some workshop’s about car jack

iii. Research done to improve the weakness of car jack

iv. Using common tool or equipments any mechanical works.

v. Getting information for supervisor’s about the project development.

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Table 2 Stages of project development

3.2 PROJECT FABRICATION STAGES

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3.2.1 Project Planning and Scheduling

35

Table 3 Stages of project fabrication 2

This project is concern to mechanical and development process, which we

create a model of a new car jack with some improvement and development.

Furthermore, the project coalesce with mechanical engineering, technical

drawing, and metrology needs. Formerly, before designing the products and

process plan take in action, some study and research is being approach to

advisors and all group members. Moreover, this is to ensure that we could

carry out the task given in the specific time and to achieve the objective of

the project.

Several actions that have been done before fabricate the product are:-

i. Brainstorming

Brainstorming is a process for developing creative solutions to

problems. It works by focusing on a problem, and then deliberately

coming up with as many solutions as possible and by pushing the

ideas as far as possible. One of the reasons it is so effective is that

the barnstormers not only come up with new ideas in a session, but

also spark off from associations with other people’s ideas by

developing and refining them.

ii. Analysis

Since our project is based on automotive industry requirements, we

gathered all the information from supervisor, lecturers, and

technicians and also access the internet. We had some survey with

some technician to know some of their problems with the current

jack that might help us in this project.

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The existing product in the international market is almost not

suitable for the automotive industry because of the lacking safety

and less functionality. Therefore our group has decided to fabricate

the same car jack with some improvement and development that

everyone can use it.

iii. Product development

Our product development is based on 3 stages. These three stages

consists on mechanical section. From the mechanical section stages

including drawing and design,, build the structure and lastly testing

the product.

Table 4 : Structure of product development

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Through this stage, there were confirm designed for the product

which has been agreed by the entire group’s members and also our

supervisor and co-supervisor.

iv. Flow chart

Flow chart is one of the 7 Basic Quality Control Tools. It is a diagram

that visually shows how resources move through various operation

of the production system. It shows the entire stage of the

production where the operation must be carried out following the

sequences. The flow chart makes it easier to visualize the

production operation. If any problems occur during stage, the

process needs to be returned back to their earlier stage.

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3.2.2 Gantt chart

Gantt chart represents graphically on a time scale as to when certain

operation would be performed. It is also useful in recording the progress of

the schedule. The activities are listed vertically and the time period is

indicating horizontally. It is also known as the bar chart.

Table 5

TASK DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Detail drawing / /

Confirm design /

Buy material / /

Check compatibility / /

Part fabrication / / / / / / / / /

Assemble / / /

Project testing / / /

Finding problems / / / / / /

Prototype / /

Final presentation /

Submission report /

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3.3 CONCEPT OF CAR JACK

3.3.1 How does a two lifitng arms car jack work?

i. The Mechanism

A car jack is a mechanical device that allows drivers and mechanics to

get underneath a car, usually to change a tire, oil or some body part

like brakes or struts. When most people hear the term floor jack, they

think of the automobile floor jack. It uses a pump arm, hydraulics to lift

vehicles to gain access to the undercarriage. The jack makes easy work

out of changing a tire or doing a brake job. This is not to be confused

with a hydraulic lift used in auto repair shops. A floor jack needs solid

ground or concrete to give it a good base that doesn't shift. There is a

lip that can be attached to the automobile itself and is gently raised by

pumping the arm and hydraulic system .The jacks are rated by the

amount of weight they can lift safely. A 2 jack is what you would

normally carry around in your car to change a tire or carry the front

part of the car to perform repair in front of the car (the place the engine

is).

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ii. Get the car jack to lift up the car.

The Two lifitng arms car jack uses the same concept as the floor jack

used in workshop. Where by there’s a holder to jack the jack up. By

pressing the holder up and down, the arm will raise up because of the

extension on the piston from the hydraulic system which pushes the

rack gear to left arm of the jack. And the right arm has a gear that goes

on the rack gear, so when the rack gear moves forward the gear on the

arm moves to lift the arm.

Figure 17 Spur gear and rack gear

iii. Bringing the Car Down

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There is a lot of weight supported by the jack. Make sure to follow all

the safety suggestions, and that the jack is placed on a flat, concrete

surface and no one is sitting in the car. The car descends by reversing

the process: turn the screw counterclockwise.

Chapter 4: METHODOLOGY

4.1 PARTS DEVELOPMENT

4.1.1 OUTER BODY

Step 1: Cut and shape the outer body

i. First, we measure and marking the steel plate using scriber based on

the dimension in drawing.

Figure 18 Marking plate

ii. Then, we cut the steel plate using hand sawing machine in the work

shop.

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Figure 19 Hand sawing machine

iii. After that, we use DANOBAT band sawing machines to cut the angle of

30’ at the end of the steel plate.

Figure 20 DANOBAT band sawing machine

iv. Because design of the steel plate is quiet difficult to fabricate using the

machines; we had to go to the old-school method that is by using a

handsaw and files. We request G-Clamp and Hand Saw at the FYP

Cabin’s technician to cut it by our effort.

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v. We use flat file and hand grinding to make

the finishing.

vi. Finally, we’ve finish to cut, measure and shape the outer body for Two

lifitng arms car jack.

Step 2: Drilling hole

i. First, we measure and marking the steel plate using scriber based on

the drawing, dimension and mock-up.

Figure 22 Position of hole on plate

ii. Using nail punch that struck by hammer, we marking the position that

we want to drill. (7 holes; two for shaft roller, two for pivot points of

arm, one for gear shaft, one for roller and the rest for hydraulic jack)

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Figure 21 Cutting plate process

Step 3: Surface Grinding

Figure 23 Surface Grinding Control

i. Using Surface Grinding Machine, we remove the rust and make the

plate thinner than the original width as 6 mm tp 4 mm.

ii. Procedure for Use :-

i. The first step in using the surface grinder is to make sure that

the material we wish to shape can be used in the grinder. Soft

materials such as aluminum or brass will clop up the abrasive

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wheel and stop it from performing effectively, and it will then

have to be cleaned. This process is explained by the technician.

The maximum size of a material that the grinder can machine is

18” long by 8” wide by 6” high.

ii. The next step is to make sure the material is secured. This is

done by use of a vice, and then by engaging the magnetic clamp.

Once the material is secure, it must be manually positioned

under the abrasive wheel. This is done by turning the longitude

and latitude wheels located on the front of the grinder. The

abrasive wheel itself can be moved slightly to get the material in

the perfect position.

iii. Then the machine may be started. It should reach maximum

speed before you try to use it for the safety reasons mentioned

before. If the wheel is working properly, then the hydraulic table

can be activated which will then begin to oscillate under the

wheel, cross-feeding towards or away from you as required. The

automated speed and direction of the table’s oscillations can be

set as required or manually used when very precise work needs

to be done.

iv. If needed, a lubricant may be used to speed up or facilitate the

grinding process. For this machine “Cut well 45” is used. It is

delivered via a tube beside the wheel, and falls onto the material

being used. The excess fluid is then drained into the reservoir.

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4.1.2 GEARS AND COUPLINGS MECHANISM

1 st and 2 nd coupling

The 1st coupling is used to join the piston of the hydraulic and the rack gear.

The part is done by lathe machining. The 2nd coupling is used to join the rack

gear with the shaft that is linked to the arm of the jack.

Figure 24 Facing process

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Procedure

1. Clamp the work piece onto the Chuck of the lathe machine.

2. Check the dimension of the work piece using a vernier caliper to avoid

mistake.

(Diameter of the work piece 34mm)

3. Set the cutting tool, and then drill a hole using the center drill.

4. Push the life center to the work piece. It to avoid the work piece from

coming out of the jaw’s of the Chuck.

5. On the machine, and face the work piece. Then perform turning

process.

6. Turn the work piece till the diameter is 30mm and the length of 50mm.

7. Drill a hole of 10mm on the work piece.

8. Then change the tool to the grooving tool.

9. Perform internal grooving for another 10mm.

10. Off the machine and remove the work piece.

11. Performed this procedure for the second coupling.

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Then Conventional milling is used to make the hole for the coupling so that

the rack gear can be fitted into the coupling. We had to use Conventional

milling because the Lathe machine cannot perform the cutting of a square

shape.

Procedure

1. Mark the center of other side of the work piece.

2. Clamp the work piece (standing position) using the clamps on the

conventional milling machine.

3. Clamp a drill bit of 10mm and drill the center. On the machine.

4. Remove the Arbor for the machine.

5. Clamp the end mill of the diameter 8mm onto the arbor, and clamp it

to the machine.

6. Start making a Square by making using the end mill. The width of

20mm and length of 20mm on the work piece with the depth of 20mm.

7. Performed this to both of the work piece.

8. Stop the machine, and change the Work piece in sleeping positon.

9. Then change the tool, from the end mill to the drill bit to drill a hole.

This hole is for the M4 screw that is used to clamp the gear with the

coupling.

10. Then stop the machine, and remove the work piece.

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11. Take the 1st coupling and lay it on the sleeping position. The part

that is lathe.

12. Take a drill bit of size diameter 20mm and drill the side. This is to

hole the hydraulic piston and the coupling.

13. Off the machine and remove the work piece.

14. Clean the machine.

Gears

The gears in this project, we had to purchase it from a gear shop in Seberang

Perai. This is because we do not have the knowledge and the tools to make a

gear in our university. Two solid spur gears and a rack gear.

Figure 25 Spur gear

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Figure 26 Position of spur ger and rack gear

Figure 27 Gear fix into the lifting arm

Using conventional milling, we make two holes diameter 8.3 mm to insert

two shafts into it so the first gear that attached to the arm will be in fix

condition.

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Figure 28 Assembling process of arm

4.1.3 LIFTING ARM

Step 1: Cut and shape the arms

i. First, we measure and marking the steel plate using scriber based on

the dimension in drawing.

Figure 29 Dimension of lifting arm

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ii. Then, we cut the steel plate using shearing machine that is in work

shop nearby the basic fitting workshop.

Step 2: Drilling hole and surface grinding

i. After that, we just follow the same step of making the outer body with

drilling hole using Conventional Milling and remove rust using Surface

Grinding Machine at the four pieces of our lifting arms.

Figure 30 Drillipng process

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Figure 31 Grinding process

Step 3: Welding the top cover of the lifting arm

i. Welding is a fabrication that joints materials by causing coalescence.

This is often done by melting the work pieces and adding a filler

material to form a pool of molten material (weld pool) that cools to

become a strong joint.

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Figure 32 Cover of arm set

4.1.4 LIFTING BASE

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Figure 33 Lifting base 1 and 2

1 st lifting base

Step 1: Measure and marking the steel plate

i. First, we measure and marking the steel plate using scriber based on

the dimension in drawing.

Step 2: Computer Numerical Control Milling (CNC Milling)

i. Using Computer Numerical Control Milling (CNC Milling), we keep in the

programming to cut the steel plate.

Table 6 : CNC Milling Programming

N010 G54

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N020 T1D1

N030 M06

N040 G00 X0 Y0 Z10

N050 M08

N060 G90 G94 G97 G17 F400 S1000 M03

N070 G41

NO80 G00 X-10 Y-10 Z10

N090 G01 X0 Y99.6

N100 G01 X0 Y114.6

N120 G02 X50 Y114.6 R25

N130 G01 X183.

6

Y114.6

N140 G02 X233.

6

Y114.6 R25

N150 G01 X233.

6

Y99.6

N160 G02 X216.

1

Y73 R45

N170 G03 X166.

1

Y13 R105

N180 G01 X67.5 Y13

N190 G03 X17.5 Y73 R105

N200 G02 X0 Y99.6 R45

N210 M09

N220 M30

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Figure 34 Process of shaping lifting base plate

Figure 35 CNC Milling machine

Step 3: Conventional Milling

i. After that, we make two slots on the work piece which this slot

functioning as a sliding slot to the lifting base 2. We use conventional

lathe to done this task.

Figure 36 Lifting base 1

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Step 4: Drilling porcess

i. Next, we drill four hole with diameter 8.3 mm.

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Figure 37 Lifting base 1

Step 5: Bending process

Figure 38 Bending process

In press brake forming, a work piece is positioned over the die block and the

die block presses the sheet to form a shape. Usually bending has to

overcome both tensile stresses as well as compressive stresses. When

bending is done, the residual stresses cause the material to spring back

towards its original position, so the sheet must be over-bent to achieve the

proper bend angle. The amount of spring back is dependent on the material,

and the type of forming. When sheet metal is bent, it stretches in length.

2 nd lifting base

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Figure 39 Lifting base 2

Step 1: Measure and marking the steel plate

i. First, we measure and marking the steel plate using scriber based on

the dimension in drawing.

Step 2: Electrical Discharge Machine

i. Using Electrical Discharge Machine, we keep in the programming to cut

the steel plate.

Table 7 : EDM Programming

N010 G54

61

N020 T1D1

N030 M06

N040 G90 G94 G97 G17 F400 S1000 M03

N050 G41

N060 G01 X-55 Y-53.8

N070 G01 X-11 Y-53.8

NO80 G01 X-11 Y-73.6

N090 G03 X-42 Y-

104.6

I-31 J0

N100 G01 X-102 Y-

104.6

N110 G03 X-133 Y-73.6 I0 J31

N120 G01 X-133 Y-34

N130 G03 X-102 Y-3 I31 J0

N140 G01 X-42 Y-3

N150 G03 X-11 Y-34 I0 J-31

N160 G01 X-11 Y-53.8

N170 G01 X-5.5 Y-53.8

N180 M30

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Figure 40 Cutting process of EDM

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Step 3: Drilling process

i. After that, we just follow the same step of making the first lifting base

with drilling hole using drill press. (our steel plate size and width are

smaller, so that we can use this machine than CNC or conventional

milling machine)

Step 4: Bending process

Figure 41 Bending process

In press brake forming, a work piece is positioned over the die block and the

die block presses the sheet to form a shape. Usually bending has to

overcome both tensile stresses as well as compressive stresses. When

bending is done, the residual stresses cause the material to spring back

towards its original position, so the sheet must be over-bent to achieve the

proper bend angle. The amount of spring back is dependent on the material,

and the type of forming. When sheet metal is bent, it stretches in length.

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4.1.5 ROLLERS PART

Step 1: Front rollers assembled

i. We attach the shaft and roller into the hole of the body.

Figure 42 Front roller

ii. We put washer and nut at the end of the shaft.

Step 2: Behind rollers assembled

i. First, welding the cover plate of the behind rollers to the body. We

need to make sure that the parts is stable and strong to lift heavy load.

ii. Drill hole on the top of the cover plate so we can put bolt, washer and

nut through it.

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Figure 43 Back roller

4.1.6 FINISHING PROCESS

After all the tasks have done the fabricating process, we assembled all the parts to the as a one product.

Figure 44 Assembled of part

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Chapter 5: RESULT AND DISCUSSION

5.1 TESTING THE PRODUCT

Finally, after the product had finished, we have try to test it whether it is

functional or not. Besides, we have also recorded it into the video to show

the movement of mechanism.

Based on the testing that we make on the product, the mechanism is

completely functioning including:-

i. Movement of rack gear and spur gear

ii. Movement of hydraulic jack and shaft to the end that attached with

coupling parts

iii. Movement of sliding lifting base one and two

iv. Movement of the lifting base when we lift the jack

v. Movement of the roller at the bottom of the car jack

5.2 PROBLEMS FACING AND SOLUTION

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i. At first, the lifting arm is not in stable condition especially when lifting

load so we welding the top cover onto it.

ii. We planned to attach the gear to the arm into the fix condition by

welding, but after a few discussions, we discuss to drill two hole on the

gear.

iii. First design, rack gear at the bottom of the jack is not support by

anything. And we found a problem that the rack gear will bending

when lifting the load. So, we put a shaft at the bottom of the body to

support the rack gear.

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5.3 RESULT

The Fabrication of Two lifitng arms car jack is successfully complete by our

group according to the planned. All of us were really excited in completing all

the tasks to complete this project as well.

All of the figure below shown about our parts and product :-

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Figure 45 Result of project

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Chapter 6: CONCLUSION AND DISCUSSION

6.1 RECOMMENDATION

There are some parts of our product that can be upgrade in the future such

as:

i. The mechanism itself

For example, the gear can be changed in size to the smaller one to

decrease the weight of the two lifting car jack.

ii. The hydraulic system also can be changed by using the power motor

with details safety and precaution to lifting the car jack.

iii. The two pairs of roller at the bottom of car jack body can be changed

to the 360’ movement so the car jack can move freely.

iv. The sliding of lifting car jack

For example, current product using a roller can be changed to the bearing components so the sliding lifting base can be more smoothly.

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6.2 CONCLUSION

Finally, we have managed to complete our final year project and successfully

achieved the objectives. Furthermore, the Two lifitng arms car jack had

accomplished the objectives such as:

i. To design a car jack that is safe, reliable and able to raise and lower

the height level

ii. To design and fabricate the car jack which has develop with more

multi-functionality car jack.

iii. To design a car jack with easy maintenance and less cost

Besides, during developing project, all of us had learned a lot of a new knowledge such as fundamentals of the operation and about the time management that is very important to make sure the project is finished within the time given. Moreover, we also study about the system, design of the parts, material, and safety precautions during the project method.

In addition, hopefully our product will help our automotive industry especially to the users, technicians and workers, in improving the current car jack so we can avoid any accidents that may be occur when using the car jack.

Lastly, suspiciously we can practice and applied all of the knowledge’s and experience that we have learned from the first semester until the last semester and also learned from our final year project.

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REFERENCES

i. R.C. Hibbeler, (2005), Mechanics of Materials, Prentice Hall Pearson Education South Asia Pte Ltd

ii. Ferdinand P. Bee, E. Russell Johnston,Jr, Elliot R. Eisenberg (2004), Vector Mechanics for Engineers,Tata McGraw-Hill

iii. Robert L. Mott (2006), Machine Elements in Mechanical Design, Prentice Hall Pearson Education South Asia Pte Ltd

iv. Alawiah Ariffin (2009), Complete Reference Matriculation Physics 1,Oriental Academic Publication

Internet Resources

http://www.efunda.com/processes/metal_processing/bending.cfm

http://www.botlanta.org/converters/dale-calc/gear.html

http://www.roymech.co.uk/Useful_Tables/Drive/Gears.html

http://en.wikipedia.org/wiki/Jack_(device)

http://en.wikipedia.org/wiki/Lathe

http://www2.northerntool.com/auto-jacks.htm

http://en.wikipedia.org/wiki/Milling_machine

http://www.fixya.com/tags/car_jack

http://www.workshopmachinery.com/

APPENDICES

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