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ABSTRACT
Hydraulics has proven to be the most efficient and economic system adaptable to engineering. First used by the ancient Greeks as a means of elevating the stages of their amphitheaters, the principles of hydraulics were explained scientifically by the seventeenth-century scholars Pascal and Boyle. The laws discovered by these two men regarding the effects of pressure and temperature on fluids and gases in confined areas form the basis of the principle of mechanical advantage; in other words, the “why and how” of hydraulics. A hydraulic press is a machine using a hydraulic cylinder to generate a compressive force. Frame and cylinder are the main components of the hydraulic press. In this project, press frame is designed by design procedure. The frame and cylinderare modeled by using modeling software FUSION 360. Using the optimum resources possible in designing and fabricating the hydraulic press components for effective reduction in the cost by optimizing the weight of material utilized for building the structure. An attempt has been made in this direction to reduce the volume of material.
TABLES OF CONTENTS
CHAPTER ONE 1
INTRODUCTION 1
CHAPTER TWO 5
LITERATURE REVIEW 5
Factors that may favor the use of a hydraulic press 9
Modern developments in hydraulic presses 10
CHAPTER THREE 12
DESIGN AND FABRICATION 12
Material Selection 19
Fabrication Process 20
CHAPTER FOUR 24
DESIGN ANALYSIS AND CALCULATIONS 24
Hydraulic Jack Analysis 24
Frame Design analysis 26
Upper cross member 29
Piston ram analysis 30
Design of arborplate and support pin analysis 31
Support pin shearing 32
Computer moduleanalysis of frame sections 35
Safety precautions 36
Maintenance procedure. 36
Principle of operation and Testing procedure 36
CHAPTER FIVE 38
Conclusion 38
Recommendations 38
REFERENCES 40
APPENDIX 42
BILL OF ENGINEERING MATERIALS (BEM) 46
CHAPTER ONE
INTRODUCTION
At a very basic level, hydraulics is the liquid counterpart of pneumatics, which concerns gases. Hydraulics is a technology used in engineering, chemistry and applied sciences which deal with the use of fluids and it’s mechanical properties. Fluid mechanics provides the theoretical foundation for hydraulics, which focuses on the applied engineering using the properties of fluids. In its fluid power applications, hydraulics is used for the generation, control, and transmission of power by the use of pressurized liquids. The principles of hydraulics are in use naturally in the human body within the vascular system and erectile tissue.
The term fluid power refers to energy that is transmitted via a fluid under pressure. With hydraulics, that fluid is a liquid such as oil or water. Fluid power’s motive force comes from the principle that pressure applied to a confined fluid is transferred uniformly and undiminished to every portion of the fluid and to the walls of the container that holds the fluid. Fluid power is used in a diverse range of applications from automobile construction, industrial robots, agricultural machinery and aerospace equipment, and offers several advantages over other types of motive force. With fluid power systems, a single source of fluid pressure can power many axes or fluid power devices. The power source can be located where space is not critical. Because much of the size and weight of the fluid power system is off-loaded onto the power unit, the individual actuators can be small compared to the power they produce.
Hydraulic presses are commonly used for forging, clinching, moulding, broaching, bonding, staking, press fitting, blanking, punching, deep drawing, and metal forming operations. With the growth and importance of light-weighting in the aerospace and automotive industry, more applications are present Composites, SMC Sheet Moulded Composites, Thermoplastics, GMT Glass Mat Transfer and Carbon Fibre Moulding.
The concept of the hydraulic press is based on Pascal’s theory, which states that when pressure is applied on fluids in an enclosed system, the pressure throughout the system always remains constant. In simple words, a hydraulic press is a machine that makes use of the pressure exerted on the fluids to crush something. One part of the system is a piston acting as a pump, with a mechanical force acting on a small cross-sectional area; the other part is a piston with a larger area which generates a corresponding larger mechanical force.
The hydraulic press works on the basis of Pascal’s Law. However, its working is similar to the hydraulic system. A hydraulic press consists of basic components used in a hydraulic system that includes the cylinder, pistons, hydraulic pipes, etc. The working of this press is very simple. The system comprises of two cylinders, the fluid (usually oil) is poured in the cylinder having a small diameter. This cylinder is known as the slave cylinder. The piston in this cylinder is pushed so that it compresses the fluid in it that flows through a pipe into the larger cylinder. The larger cylinder is known as the master cylinder. The pressure is exerted on the larger cylinder and the piston in the master cylinder pushes the fluid back to the original cylinder. The hydraulic press is mostly used for industrial purposes where a large pressure is required for compressing metals into thin sheets. An industrial hydraulic press uses the material to be worked upon along with the help of the press plates to crush or punch the material into a thin sheet.
Project objectives
Maintain safe work practices thus reducing practices known to cause damages to work piece/injury to personnel.
Ensures good press alignment when pressing a bearing into a hub
Reduces Man Hour wastage
Increased efficiency on job delivery
Aid in carrying out pressing operation/job(s)
Significance of this project
Increased efficiency on job delivery
Customized machine to suit user’s need
Smooth and even pressure throughout the ram stroke
Accurate job performance
Low cost of maintenance
Scope of the project
This project work is limited to the demonstration of the operation principles and functions of a hydraulic press. This machine also was designed that this hydraulic press does not require electricity for its operation.