A MINOR PROJECT REPORT

On

HYDRAULIC POWER PRESS

Submitted by

Under the guidance of

Submitted to

Department of Mechanical Engineering

 ABSTRACT

The hydraulic press is one of the oldest of the basic machine tools. In its modern
form, is well adapted to presswork ranging from coining jewelry to forging aircraft
parts. Modern hydraulic presses are, in some cases, better suited to applications
where the mechanical press has been traditionally more popular.

Under this project we have developed a “Hydraulic Power Press”. A hydraulic

press is a machine using a hydraulic cylinder to generate a compressive force. The
major components of the press designed include the cylinder and piston
arrangement, the frame and the hydraulic circuit.
The machine was tested for performance with a load of 5 ton provided by two
compression springs arranged in parallel between the upper and lower platens and
was found to be satisfactory.
This report deals with the design, development, fabrication and installation of
frame, hydraulic cylinder, motor, upper and lower platens.
Press frame and cylinder are analysed to improve its performance and quality for
press working operation.
 CONTENTS
Chapter Page No.
1.Introduction 1
 INTRODUCTION

The development of engineering over the years has been the study of finding ever
more efficient and convenient means of pushing and pulling, rotating, thrusting and
controlling load, ranging from a few kilograms to thousands of tons. Presses are
widely used to achieve this.

Presses are defined as pressure exerting machine tools. They can be classified into
three principal categories as: hydraulic presses which operate on the principles of
hydrostatic pressure, screw presses which use power screws to transmit power and
mechanical presses which utilize kinematic linkage of elements to transmit power.

In hydraulic press, the force generation and transmission are achieved using fluid
under pressure. The liquid system exhibits the characteristics of a solid and
provides a very positive and rigid medium of power transmission.
Hydraulic presses are preferred when very large nominal force is required. The
hydraulic press is invaluable equipment in the workshop and laboratories especially
for press fitting operations and for the deformation of materials such as in metal
forming processes and material testing for strength.

OBJECTIVES OF THE PROJECT

The purpose of this project is to practice a student that has he been gathered
before in solving problem using academic research and also to gain knowledge and
skills. This project also important to train and increase the student capability to get
information, research, data gathering and then solves a problem by doing the
calculation. The final year project also will generate students that have capability
to make a good report in thesis form or technical writing. It also can train student
to create in design, fabricate and analysis a new thing. The other thing, final year
project will teach student to doing a task with independently in searching and
expending the experience and knowledge.

The main objective of this project is to design powerful prototype hydraulic

machine. Another objective of this project is to practice and apply the engineering
concepts. But there are more objectives, which are:

1. Design and construct a portable machine which we can use everywhere.

2. Reduce the cost of machine.

4. Learn the advantages and disadvantages of hydraulic press.

5 Compare between theoretical and experimental study.

PROJECT SCOPE:
From the title that has been given, the development of this project must include
how to design and fabricate the mechanical part of hydraulic machine. It also needs
some knowledge and skill to finish the project.

METHODOLOGY:
A detailed discussion with faculty guide and seniors was done before the selection
of the project topic. After selecting the project topic, detailed research was done
on the topic. Research was mainly focused on market demand, aspects of projects
and areas related to this topic. With the help of the research and project mentor
guidelines, a sketch of process plan is generated. This sketch is then again checked
for mistakes and shortcoming.
After passing the sketch, a final process plan is generated. This process plan
includes-
-dividing project into segments.
-time management for each segment.
-resources required.
-monetary funds needed.
-setting up of deadlines.

PLANNING OF PROJECT WORK:

We visited in many industries, visited library, read various books pertaining to
technical side made tentative collection of these all the project. Among these all
the project we compared the feasibility of project and reached at the decision to
manufacture “Hydraulic Power Press”. In the planning stage we have also to
analyze and study the different components of the model.

PROJECT OVERVIEW

REQUIRED MACHINE TOOLS & EQUIPMENTS:

We must required different machines for different operations like.
• Disc cutter
• Bench drill m/c
• Welding m/c
• Angle grinder
• Hand drill

And also some equipments like

• Measuring Tools
• Marking Tools
• Hand Tools etc.
Components required for Hydraulic Power Press-

MS pipe 40 feet
MS sheet 02q. feet
Bush 01 no.
Round solid bar 8 inch
Hydraulic jack 01 no.
Spring 02 nos.
I- bolt 02 nos.
Fasteners etc. As per requirement

Specification:-
➢ Overall height - 48 inches
➢ Overall length - 20 inches
➢ Overall width- 20 inches
➢ Machine press capacity- 5 tonne
➢ Power source- hydraulic
➢ Opening height- 06 inches
COMPONENTS OF PROJECT MODEL

MS pipe:

Hydraulic jack:
Spring:

‘I’ bolt:
Design process
✓ Fabrication of structure
✓ Installation of hydraulic unit
✓ Installation of tension spring
✓ Fabrication of sliding bush
✓ Fabrication of job post
✓ Final check up and performance testing

FINAL MODEL DEVELOPMENT

PRESS MACHINE-
A press is a machine tool that changes the shape of a work piece by the application
of pressure. Presses can be classified according to

• their mechanism: hydraulic, mechanical, pneumatic;

Press Operations:
Press tools may be designed for carrying out the following or more operations:
➢ Piercing: Removal of a local piece of the material to form a hole of some
shape.
➢ Cutting and shearing.
➢ Blanking: Production of the contour in flat blank clipping, shearing, etc.
➢ Curling
➢ Drawing: Production of deep cup component from flat strip.
➢ Bending: Material is bent in one place.
➢ Deep drawing, shallow drawing, redrawing.
➢ Extrusion.
In addition, the operations of cupping (production of a cup from disc), coining and
trimming (truing up the edges of a pressing), coining, interlocking, riveting,
forging, impact extrusion may also be carried.

TYPES OF PRESS
Power press
Hydraulic press
Pneumatic press
Screw press
Rack and pinion press
Crank press
Eccentric press
Manual press
Foot press
Arbor press
Fly press
Toggle press
HYDRAULIC PRESS-

A typical hydraulic press consists of a pump which provides the motive power for
the fluid, the fluid itself which is the medium of power transmission through
hydraulic pipes and connectors, control devices and the hydraulic motor which
converts the hydraulic energy into useful work at the point of load resistance. The
main advantages of hydraulic presses over other types of presses are that they
provide a more positive response to changes in input pressure, the force and
pressure can accurately be controlled, and the entire magnitude of the force is
available during the entire working stroke of the ram travel.

HISTORY of HYDRAULIC PRESS-

Invented in 1795 by Joseph Bramah, the hydraulic press is also known as the
Bramah press. He used his knowledge of fluid mechanics and motion to develop
this device. This invention significantly increased the compression power available,
expanding the product groups and options available to other inventors. By applying
hydraulics to a press, an entire class of machines was invented. There is a wide
range of different hydraulic press machines, ranging from small table top units for
hobbyists to huge machines used to create metal parts.

Advantages of Hydraulic Presses

The mechanical press has been the first choice of many press users for years. The
training of tool and die makers and manufacturing engineers in North America has
been oriented toward applying mechanical presses to sheet-metal press working.
Modern hydraulic presses offer good performance and reliability. Widespread
application of other types of hydraulic power equipment in manufacturing requires
maintenance technicians who know how to service hydraulic components. New
fast acting valves, electrical components, and more efficient hydraulic circuits have
enhanced the performance capability of hydraulic presses.

Factors That May Favor the Use of a Hydraulic Press

Factors that may favor the use of hydraulic presses over their mechanical
counterparts may include the following:
1. Depending on the application, a hydraulic press may cost less than an
equivalent mechanical press.
2. In small lot production where hand feeding and single stroking occurs,
production rates equal to mechanical presses are achieved.
3. Single stroking does not result in additional press wear.
4. Die shut heights variations do not change the force applied.
5. There is no tonnage curve derating factor.
6. Forming and drawing speeds can be accurately controlled throughout the
stroke.
7. Hydraulic presses with double actions and or hydraulic die cushions are
capable of forming and drawing operations that would not be possible in a
mechanical press.

COMPONENT DESIGN

Frame Design

The frame provides mounting points and maintains proper relative positions of the
units and parts mounted on it over the period of service under all specified working
conditions. It also provides general rigidity of the machine. The design
consideration is that of direct tension imposed on the pillars. Other frame members
such as the platens are subjected to simple bending stresses.

Hydraulic Cylinder:
Hydraulic cylinders are tubular in structure in which a piston slides when hydraulic
fluid is admitted into it. The design requirement includes the minimum wall
thickness of the cylinder, the end cover plate, the flange thickness and the
specification and selection of number and sizes of bolts. The output force required
from a hydraulic cylinder and the hydraulic pressure available for this purpose
determine the area and bore of the cylinder and the minimum wall thickness.

Piston:

The required piston rod column size necessary to sustain applied load and which is
in alignment with the center line of the cylinder bore is influenced by the strength
of the rod material, the force applied to the rod column in compression, the
mounting situation of the cylinder itself and the stroke over which the load is to be
applied. The procedure for computing piston rod column size and cylinder lengths
under end thrust condition was accomplished using the procedure suggested by
Sullivan (1975). By this the size of the piston rod of diameter not less than 0.09 m
was considered adequate for the design.

Selection of Seals:

Seals are used to prevent internal and external leakages in the system under
varying operating conditions of pressure and speed. Static seal selected uses the
groove and ring principle to affect a seal. The groove dimension is calculated such
that the O ring selected is to be compressed 15-30% in one direction and equal to
70-80% of the free cross-sectional diameter. The problem in the selection of static
seal is to specify the groove such that an O-ring can be compressed in one direction
and expanded in another, Therefore; a grove dimension of 4 mm × 3 mm was
specified for the seal.

WORKING PRINCIPLE
The hydraulic press depends on Pascal's principle: the pressure throughout a
closed system is constant. One part of the system is a piston acting as a pump, with
modest mechanical force acting on a small cross-sectional area; the other part is a
piston with a larger area which generates a correspondingly large mechanical force.
Only small-diameter tubing (which more easily resists pressure) is needed if the
pump is separated from the press cylinder.
Pascal's law: Pressure on a confined fluid is transmitted undiminished and acts with
equal force on equal areas and at 90 degrees to the container wall.
A fluid, such as oil, is displaced when either piston is pushed inward. Since the fluid
is incompressible, the volume that the small piston displaces is equal to the volume
displaced by the large piston. This causes a difference in the length of displacement,
which is proportional to the ratio of areas of the heads of the pistons given that
volume = area X length. Therefore, the small piston must be moved a large distance
to get the large piston to move significantly. The distance the large piston will move
is the distance that the small piston is moved divided by the ratio of the areas of
the heads of the pistons. This is how energy, in the form of work in this case, is
conserved and the Law of Conservation of Energy is satisfied. Work is force applied
over a distance, and since the force is increased on the larger piston, the distance
the force is applied over must be decreased.

Power Press:
Power press are used for producing large quantities of articles quickly, accurately
and economically from the cold working of mild steel and other ductile materials.
The components produced range over an extremely wide field and are used
throughout industry. Sometimes the pressings may be complicated and more than
one pressing operation may be required. Now-a-days practice is to produce most
of the sheet parts of any shape by using specially designed press tools and other
combination of operations. For economical production of quantities of pressings,
consideration has to be given to the rate of production, the cost of the press tools
to be employed and the expenditure involved in setting them. It is also necessary
to plan the operations to reduce scrap material to a minimum and to use waste
material for other smaller pressings. For any operations to be performed on press,
the selection of the proper press and the design of the tool or die to be mounted
on it are very important.

Performance Test Result

It is a normal practice to subject engineering products to test(s) after manufacture.

This is a significant step in the manufacturing process. Under tests the product is
checked to see if functional requirements are satisfied, identify manufacturing
problems, ascertain economic viability, etc.
Testing is therefore employed to prove the effectiveness of the product. For the
hydraulic press, test for leakages is the most significant test. The test commenced
with the initial priming of the pump. After which the fluid was pumped. This was
carried out under no-load condition. The machine was left to stand in this position
for two hours.
The machine was then subjected to a load provided by two compression springs
arranged in parallel between the platens. The springs were then compressed axially
to a length of 100 mm. This arrangement was left to stand for two hrs and was
observed for leakages. Leakage in the system was not indicated as the lower platen
did not fall from its initial position.

PRESS SELECTION AND MAINTENANCE

Success in any activity requires that a number of tasks be done correctly. In metal
stamping, everything from poor quality parts to accelerated die wear and damage
often is caused by poor press selection, diesetting and machine maintenance. No
responsible machine shop manager would neglect machine tool lubrication,
alignment and repair. The same principle must be applied to press selection and
maintenance. A power press is a machine used to supply force to a die that is used
to blank, form, or shape metal or nonmetallic material. Thus, a press is a
component of a manufacturing system that combines the press, a die, material and
feeding method to produce a part. The designer of the manufacturing system must
also provide proper point of operation guards to safeguard pressroom personnel.
Each of the components of this manufacturing system is important and will be
discussed in turn later in this work. A foundation for understanding the system is
acquiring a working knowledge of the press. Examples of good practices and
warnings against bad practices are to be found throughout this training. It is very
important that the good practices that are appropriate for your shop are the ones
that you adopt as your standard diesetting, production and die maintenance
procedures.

Press Terminology and Component Identification

The following terms are used to describe some of the principle characteristics and
specifications of power presses. Many of the terms apply to both mechanical and
hydraulic gap frame and straight side presses.
Terms that describe the bolster size determine the maximum size die shoe that can
be accommodated in the machine. The minimum and maximum amount of vertical
open space between the ram and bolster must be known in order to know if a die
will fit the press.

Hydraulic Overload protection

Hydraulic presses limit overloading by restricting the maximum pressure supplied
to the actuating cylinder(s). When a preset maximum limit is exceeded, an overload
valve dumps the precharged oil from the overload cylinders, and trips a limit switch,
stopping the press. The cause of the overload condition is first corrected, and the
overload system recharged by actuating a key locked switch. Such systems can
accommodate maximum overload errors of approximately 0.75-inch (19 mm).

Mechanical Overload Limiting Devices

Other types of press overload devices include shear collars, bellville washers, shear
pins and stretch links. These devices are simple and low in cost. Shear collars and
bellville washer overload devices are placed under the connection in place of the
hydraulic overload cylinders shown in Figure 4.
However, there are several major problems with this type of overload protection.
The failure point of stretching or fracture overload devices is uncertain and subject
to change with repeated cycling. The occurrence of a failure of these devices may
not be immediately detected. This may result in a slide out of level condition that
can score the press gibbing, damage the die and result in the production of poor
quality stampings. The machine must be shut down and the failed part replaced.
This results in unscheduled maintenance and production delays that are normally
unacceptable.

Tie-Rods Limit Machine Overloading

Most, but not all straightside presses employ tie-rod construction. The rods hold
the press housing in compression. They provide a means to move large presses in
sections. Should the press become stuck on bottom they can be heated to relieve
the pre-stress. The rods also limit press overloading.
As long as the press columns are maintained in a pre-loaded condition by the tie-
rods, the deflection in the die-space occurs at a linear rate as a function of
increasing tonnage. However, once an overload condition exceeds the tie-rod pre-
load, the crown lifts off the press column. Once crown lifting occurs, press stiffness
is greatly decreased, limiting overloading.

Types of Mechanical Press Drives

Both gap frame and straightside presses are built with direct and geared drive
systems. In nongeared or direct drive presses as they are also known, the flywheel
is mounted on the end of the crankshaft. The flywheel is motor driven by means of
a belt drive. Directly driven presses are capable of much higher operating speeds
than geared types. Speeds range from under 100 strokes per minute to over 1,800
for short stroke high-speed operation.

Direct Drive Mechanical Press Applications

Nongeared presses find widespread application in blanking, high-speed production
and shallow forming operations. They have several major advantages over all other
press types. First, the design is simple. There are few bearings and no gears to wear
out. In addition, frictional losses are lower than that of mechanical geared and
hydraulic presses. The high operating speeds provide much greater productivity
than that of geared presses. The direct drive press is very popular for precision
progressive die and high speed perforating operations.

A nongeared drive (A) illustrating a double-throw crankshaft directly driven by the

flywheel through a frictional clutch. A single geared drive (B) illustrating a double-
throw crankshaft driven by a single end gear and frictional clutch.
Two main factors limit the application of the direct driven press. First, the full rated
force of the machine is only available very close to the bottom of the stroke,
typically 0.060-inch (1.524 mm) from bottom dead center. A second disadvantage
is that the ability to deliver rated forces is substantially reduced if the press is
operated at less than full speed.

Single Gear Reduction Presses

In single reduction presses, the flywheel is mounted on the backshaft and the
power is then transmitted through a pinion to a main gear mounted on the
crankshaft. Some single gear reduction presses have main gears mounted on both
ends of the crankshaft, which is mounted on a pinion double end gear presses.
Single gear reduction presses typically operate in the speed range of 16 to 200
strokes per minute (SPM).
Because these presses utilize gear reduction, with the flywheel on the high-speed
backshaft, more flywheel energy can be provided for a given flywheel weight than
in a nongeared press. This greater amount of flywheel energy provides greater
torque capacity, thus making the single geared press better suited for drawing and
heavy forming operations than a direct drive press.

Twin End Drive Presses

Figure illustrates a single gear reduction twin end drive on a press having a
crankshaft having two throws. By driving the crankshaft equally on both ends, there
is more accurate left to right ram to bed alignment under load than is the case of
the single end drive system. It is important that the machining and timing of the
gears, keyways and crankshaft be accomplished in a precise manner in order to
avoid binding and ensure smooth operation.

Double Gear Reduction Presses

Presses having two gear reductions from the flywheel to the crankshaft are termed
double gear reduction presses. These machines normally achieve a speed range
from 8 to 30 SPM. These presses are used for difficult applications such as heavy
deep drawing, cold forging and forming large parts such as truck frame rails. Large
transfer presses also frequently employ double gear reduction. Figure 8 illustrates
one type of clutch and gearing arrangement.
Single Connection Presses
Straightside presses with single connections often are built to provide very high
force capacities in a machine having a relatively small bed size. Figure 8 illustrates
a high tonnage single-action, straightside, eccentric-type mechanical press.
The gear train is of the double reduction type. A large gear on either side drives the
eccentric. This type of machine is very useful for heavy forming, as well as both
warm and cold forging work. The double-geared eccentric is capable of transmitting
a great amount of torque. Presses of this type are capable of developing full
tonnage relatively high in the press stroke. This factor makes them very useful for
closed die forging work.
The heavy construction and narrow bed and slide result in low deflection under
load. A press of this type is ideal for blanking work involving thick high-strength
materials. Very stiff machines, with bed sizes no larger than necessary, are subject
to much less snap-through energy release than presses with bed sizes that are
much wider than necessary for the application.
In order to avoid ram-tipping problems, the load must be carefully centered under
the connection. While this is always very important, it is especially necessary in
single point presses. Keeping the load centered minimizes the pressure on the
gibbing and lessens die wear.
Eccentric Drive for Two and Four Point Presses
Double or quadruple gear driven eccentrics normally rotate in opposite directions
to aid in slide guiding and avoid lateral thrust. This feature is found in most two and
four point presses, which are top-driven by eccentrics.
The timing of the gearing from the left to right side of all presses is critical.
Couplings are provided on the shaft driven by the clutch which are either adjustable
or may be fitted with offset keys.
Both crankshaft and eccentric driven straightside presses with two connection
points are in very widespread use. Ram parallelism from left to right is mainly
controlled by the connections, while front to back alignment is provided by the gibs.
The press shown in Figure 10 has two connections that are driven by gear-actuated
eccentrics.
Two point presses are guided by the correct adjustment of the pitman straps from
left to right. Some front-to-back guiding of the slide is provided by the saddle
bearing and wrist pin type connection. However, the gibbing provides the majority
of the front-to-back guiding. Again, it is important to center the load especially from
front-to-back.
Mechanical versus Hydraulic Presses
Mechanical presses are built with force capacities through 6,000 tons (53.4 mN) or
more. Force capacities of 50,000 tons (445 MN) or more are available in hydraulic
presses. The very large hydraulic machines are used in hot and cold forging
applications as well as various rubber-pad and fluid cell-forming processes.
Both single and double-action hydraulic presses are used for forming large parts for
the automotive and appliance industries. An advantage for deeply formed or drawn
parts is that full force is available anywhere in the press stroke.

The rated capacity of a mechanical press is available only at the bottom of the
stroke. The full force of a simple hydraulic press can be delivered at any point in
the stroke.
Unique Features of Hydraulic Presses
In most hydraulic presses, full force is available throughout the stroke. Figure
illustrates why the rated force capacity of a mechanical press is available only near
the bottom of the stroke. The full force of a hydraulic press can be delivered at any
point in the stroke. This feature is a very important characteristic of most hydraulic
presses.
Deep drawing and forming applications often require large forces very high in the
press stroke. Some mechanical presses do not develop enough force high enough
in the downward stroke to permit severe drawing and forming applications such as
inverted draw dies to be used without danger of press damage.
Another advantage is that the stroke may be adjusted to match the job
requirements. Only enough stroke length to provide part clearance is required.
Limiting the actual stroke will permit faster cycling rates and reduce energy
consumption. The availability of full machine force at any point in the stroke is very
useful in deep drawing applications. High force and energy requirements usually
are needed throughout the stroke. The ram speed can also be adjusted to a
constant value that is best for the material requirements.

Built-in Overload Protection

The force that a hydraulic press can exert is limited to the pressure applied to the
total piston area. One or more relief valves limit the applied pressure. A mechanical
press usually can exert several times the rated maximum force in case of an
accidental overload. This extreme overload often results in severe press and die
damage. Mechanical presses can become stuck on bottom due to large overloads,
such as part ejection failures or diesetting errors.
Hydraulic presses may incorporate tooling safety features. The full force can be set
to occur only at die closure. Should a foreign object be encountered high in the
stroke, the ram can be programmed to retract quickly to avoid tooling damage.

Guidelines for Press Selection

Figure illustrates how bed size does not directly relate to press force capacity.
Presses that use the tie rods for ram guiding are unsuited for jobs that produce
lateral loads. Like mechanical presses, hydraulic presses are available in many types
of construction. Factors to consider when deciding between a hydraulic and
mechanical press are stroke length, actual force requirements and the required
production rate.

Hydraulic Press Speeds

Most press users are accustomed to describing press speeds in terms of strokes per
minute. Speed is easily determined with a mechanical press. It is part of the
machine specifications.
The number of strokes per minute made by a hydraulic press is determined by
calculating a separate time for each phase of the ram stroke. First, the rapid
advance time is calculated. Next the pressing time or work stroke is determined. If
a dwell is used that time is also added. Finally, the return stroke time is added to
determine the total cycle time. The hydraulic valve reaction delay time is also a
factor that should be included for an accurate total time calculation. These factors
are calculated in order to determine theoretical production rates when evaluating
a new process. In the case of jobs that are in operation, measuring the cycle rate
with a stopwatch is sufficient.

Machine Speed
The forming speed and impact at bottom of stroke may produce different results
in mechanical presses than their hydraulic counterparts. Each material and
operation to form it has an optimal forming rate. For example, drop hammers and
some mechanical presses seem to do a better job on soft jewelry pieces and jobs
where coining is required.
In deep drawing, controllable hydraulic press velocity and full force throughout the
stroke may produce different results. Often parts that cannot be formed on a
mechanical press with existing tooling can be formed in a hydraulic press. Hydraulic
presses can be provided with controllable force throughout the press stroke and
variable blankholder pressure distribution.
 Conclusion
When any detailed design has been done, it is easily understood that no
product/design get at its best or 100% efficient in its operation. There should
always be opportunities for continual development and improvement. As shown,
despite the fact that the selected concept proved to obtain satisfactory results, a
08-ton hydraulic press was designed, manufactured, and calibrated. The machine
was tested to ensure conformability to design objectives and serviceability. The
machine was found to be satisfactory.
REFERENCES

While designing and fabrication of this project work, we studied lot of material
gathered from websites, consulted experts of various field. The information is
gathered from google.com search Engine. Regarding hydraulic press, plenty of
books are available, the following are the references made during design,
development and fabrication of the project work.

➢ https://en.wikipedia.org
➢ Khurmi, R.S. and J.K. Guota. Machine Design