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Hydraulic Press Machine
Hydraulic Press Machine
INTRODUCTION
The metal shit cutting by hand hacksaw is hardworking and time consuming. The
labour charges also increases. Hence the process is uneconomical. In our project we are
making the automatic metal shit foil mechanism. As a development part it will be of a small
capacity and simple but function properly. The metal of maximum 0 to 50 mm can cut
easily. Some industries needs a pieces of different ‘’ like 6, 7, 8, 10 & up to 50
etc. with a proper specified length of each for their special purposes. So every time the bar
has to feed up to stopper manually is the effort and extra work to operator. The machine is
capable of serving as a hydraulic press, sheet metal brake, shear for thin sheet metal, and
tubing bender is ideal for use in a home Workshop, where space may be limited.
Before starting the machine it has to locate properly on the table having height of 2.5
foot. The shit feed mechanism is aligned and placed as discussed in earlier chapter. It should
align such that the cutting bar should slide on the machine foundation flat surface. After
locating the machine, it is ready to start. The pneumatic cylinder is used to drive the
machine. The shit to be cut is located in the fixture and stopped at the stopper. The feed of
the cutting is given by travel of pneumatic cylinder piston in the direction of shit to be cut.
After the operation of cutting, the cut piece fall down and the place is taken the number of
metal pieces can be cut in a very less time. The length of piece to be cut is adjusted by the
movement of stopper and clamping fixture over the machine foundation table.
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2. Construction & Working :
2.1 Construction :
It consist of piston & cylinder arrangement :
1. WPS material with hardening & tempering for cutting of bar
2. Main equipment i.e. hydraulic power packs which itself consist of D. C. Valve, hose
supply, oil tank, motor, pump, gauge etc.
3. Rather than above construction also consist of metal pipes, base/frame, hoses,
manifold, gauge etc.
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Fig.2. Cylinder and piston arrangement
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2. LITERATURE REVIEW
2.1 HYDRAULIC BAR CUTTER MACHINE : mr. Salve n.v.1,mr.deorukhkarsairaj r.2, mr.
Khair s.s.3, mr.khanvilkar d.n.4 1(m.e. Student kolhapur institute of technology, india),
2(m.e.studentfinolexacadami of manegment&technalogy, india), 3(ast. Prof. Autodepartment,
sahyadri poly sawarde, india),, 4(hod of mech.sahyadri poly sawarde, india)
In the work of liberalization (more freedom in action) the civil & mechanical sector
has taken much importance in advancement & technology in various fields, and also much
than the core industrial sector. In most developed cities need a lot of man power to split bar in
to small parts. This man power requires various equipment viz. Hammer, chisel, hacksaw etc.
Thus in order to avoid these project benefits in various ways. Use this lightweight tool to cut
steel bars and other materials anywhere. Hydraulic power means minimum operator effort
and a smooth guillotine-action reduces the risk of jamming Double-acting operation Cutting
range 8 to14 mm in stroke. Hydraulic fluids also called hydraulic liquids are the medium by
which power is transferred in hydraulic ma-chinery. The hydraulic fluid also known as tractor
fluid, hydraulic fluid is the life of the hydraulic circuit. It is usually petroleum oil with
various additives. Some hydraulic machines require fire resistant fluids, depending on their
applications. In some factories where food is prepared, either an edible oil or water is used as
working fluid for health and safety reasons. In addition to transferring energy, hydraulic
fluids needs to lubricate components, suspend contaminants and metal filling for transport to
the filter and to function well to several hundred degree Fahrenheit or Celsius.
Keywords: Hydraulics, Valves, Hoses, Hydraulic power pack, Hydraulic bar cutter, Cutting
Tool, etc.
This machine is for sheet metal industry and can be made into multiple machines and
should be used as circle cutting cum straight cutting machine .The machine is simple to
maintain easy to operate. Hence we tried out hands on Hydraulic Shearing Machine in
shearing operation as the punch descends upon the metal, the pressure exerted by the punch
first cause the plastic deformation of the metal. Since the clearance between the punch and
the die is very small, the plastic deformation takes place in a localized area and the metal
adjacent to the cutting edges of the punch and die edges becomes highly stressed, which
causes the fracture to start on both sides of the sheet as the deformation progresses. The idea
of the project generated due to a manual sheet metal sheering machine in workshop of our
college. In that machine sheet metal is placed in between the two sheering blades of machine
and the lever is pulled down to move the upper movable blade and cut the work-piece.
Keywords: Hydraulic system, Solenoid Valve, Modeling in NX-CAD, Hydraulic cylinder.
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Hydraulic Cutting Machine:
This is a hydraulic cutting machine in Brazil. It had mayor problems before installing
the Filters. The four machines broke down regularly and the oil was full of metal waste. Now
they change their inlets about every two months and stopped changing their oil. Also, the
tools experience no abrasion anymore and down-times could be reduced to virtually cero. On
the left side you can observe a filter after being changed. Now you can imagine what would
have happened to the machine with all the metal parts not being filtered correctly.
Hydraulic machines are machinery and tools that use liquid fluid power to do simple
work. Heavy equipment is a common example. In this type of machine, hydraulic fluid is
transmitted throughout the machine to various hydraulic motors and hydraulic cylinders and
which becomes pressurized according to the resistance present. The fluid is controlled
directly or automatically by control valves and distributed through hoses and tubes.
The popularity of hydraulic machinery is due to the very large amount of power that
can be transferred through small tubes and flexible hoses, and the high power density and
wide array of actuators that can make use of this power. Hydraulic machinery is operated by
the use of hydraulics, where a liquid is the powering medium.
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3. METHODOLOGY
Very simple, non-coil springs have been used throughout history. Even a resilient tree
branch can be used as a spring. More sophisticated spring devices date to the Bronze Age,
when eyebrow tweezers were common in several cultures. During the third century B.C.,
Greek engineer Ctesibius of Alexandria developed a process for making "springy bronze" by
increasing the proportion of tin in the copper alloy, casting the part, and hardening it with
hammer blows. He attempted to use a combination of leaf springs to operate a military
catapult, but they were not powerful enough. During the second century B.C., Philo of
Byzantium, another catapult engineer, built a similar device, apparently with some success.
Padlocks were widely used in the ancient Roman empire, and at least one type used bowed
metal leaves to keep the devices closed until the leaves were compressed with keys.
The next significant development in the history of springs came in the Middle Ages. A
power saw devised by Villard de Honewort about 1250 used a water wheel to push the saw
blade in one direction, simultaneously bending a pole; as the pole returned to its unbent state,
it pulled the saw blade in the opposite direction.
Coiled springs were developed in the early fifteenth century. By replacing the system
of weights that commonly powered clocks with a wound spring mechanism, clockmakers
were able to fashion reliable, portable timekeeping devices. This advance made precise
celestial navigation possible for ocean-going ships.
A spring is mechanical device which is used for the efficient storage and
release of energy. Depending upon the requirements, a spring can take different
shapes, such as the helical coil of wire, a piece of stamping, or a flat, wound-up
strip.There are several types of springs. One of the most common consists of wire
wound into a cylindrical or conical shape. An extension spring is a coiled spring
whose coils normally touch each other; as a force is applied to stretch the spring, the
coils separate. In contrast, a compression spring is a coiled spring with space between
successive coils; when a force is applied to shorten the spring, the coils are pushed
closer together. A third type of coiled spring, called a torsion spring, is designed so the
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applied force twists the coil into a tighter spiral. Common examples of torsion springs
are found in clipboards and butterfly hair clips.
Still another variation of coiled springs is the watch spring, which is coiled
into a flat spiral rather than a cylinder or cone. One end of the spring is at the center of
the spiral, and the other is at its outer edge.
Some springs are fashioned without coils. The most common example is the
leaf spring, which is shaped like a shallow arch; it is commonly used for automobile
suspension systems. Another type is a disc spring, a washer-like device that is shaped
like a truncated cone. Open-core cylinders of solid, elastic material can also act as
springs. Non-coil springs generally function as compression springs.
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4. DESIGN AND MODELING
4.1 OIL TANK: The hydraulic system requires the oil to work the system. So we have
provide the oil tank.
4.3 CONTROL VALVE: Various types of control valves are used to regulate, control
and monitor the oil energy for control of direction pressure, flow, etc. Hydraulic
energy is regulated and controlled by hydraulic valves. Functionally valves are
divided into four major groups.
1. Direction Control
2. Flow Control
In our project electrically actuated solenoid operated 5/2 DC valves are used.
Solenoid is another name for an electromagnet. Direction control valves are very
often actuated by electromagnets. An electromagnet is a temporary magnet. A
magnetic force is developed in an electromagnet when electrical current passes
through it and force drops down as soon as it is de energized. This electromagnet is
commonly termed as solenoid. The proper working of a solenoid operated valve
depends on the reliability of the electromagnets.
It ensures
Quick and sure action
Long life.
Easy maintenance.
The hydraulic cutting and Filing machine consists of the following components to full
fill the requirements of complete operation of the machine.
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1. Double acting hydraulic cylinder
4. Connectors
5. Hoses
Technical Data
Quantity : 2
Piston : EN – 8
Media : Oil
Temperature : 0-80 º C
Technical data
Size : 0.635 x 10 ˉ² m
Quantity : 1
Technical Data
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Port size : 0.635 x 10 ֿ² m
Media : Oil
Quantity : 1
4. Connectors
Technical data
Temperature : 0-100 º C
Material : Brass
5. Hoses
Technical date
Outer diameter : 6 mm = 6 x 10 ˉ ³m
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5. ANALYTYCAL ASPECT
= p x (Πd² / 4)
= 6 x {( Π x 4² ) / 4 }
P = 73.36 Kgf
Design Stress(σy) = σy / F0 S
= 36 / 2 = 8 Kgf/mm²
= P / (Π d² / 4 )
∴d = √ 4 p / Π [ σy ]
= √ 4 x 75.36 / {Π x 18}
= √ 5.33 = 2.3 mm
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∴ Minimum diameter required for the load = 2.3 mm
Where,
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t = 0.036 cm = 0.36 mm
= 75 + ( 2 x 7.5 ) = 90 mm
= 6 x (Π / 4) x (7.5)²
= 265 Kgf
= 0.52
dp = 1.87 cm = 18.7 mm
By standardizing dp = 20 mm
Approach stroke = 50 mm
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Length of threads = 2 x 20 =
40mm
= 12.2 cm
5.3. CONNECTORS
Technical data
Temperature : 0-100 º C
Material : Brass
5.4 HOSES
Technical date
Outer diameter : 6 mm = 6 x 10 ˉ ³m
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FIG. 5.1 BARREL
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FIG. 5.3 FLANGE
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FIG.5.6 DIRECTIONAL CONTROL VALVE
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FIG. 5.8 CAM
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6. WORKING PRINCIPAL
PRINCIPLE
PASCAL’S LAW: “It states that the intensity of pressure at any point in a fluid at rest is the
same in all direction”
WORKING PROCEDURE: The block diagram of sheet cutting machine as shown in fig. The
lead-acid battery is used to drive the d.c motor. The d.c motor shaft is connected to the cam
wheel with the help of pump arrangement. If the power is given to the D.c motor, it will run
so that the cam wheel also runs to the same speed of the D.C motor. The cam shaft movement
is up and down motion due to cam mechanism.
The cam shaft of other end is connected to the hydraulic pump handle. The hydraulic
handle moves up and down according to the movement of the cam shaft. So the pressurized
oil goes to the hydraulic cylinder and moves the piston upward, so that the pressure is applied
to the cutting tool top to ground.
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OPERATION INSTRUCTIONS OF HYDRAULIC CYLINDER:
1. Before operating the cylinders first insert the notched end of the handle into the
release valve, turn the operating handle clock wise until release valve is closed.
Do not one tighten the valve.
2. Insert proper operating handle into the socket and the ram is steadily raised by the
load is thus raised; the ram will stop rising when the required height is reached.
3. Lower the ram by turning the release valve. Counter-clockwise with the notched
end slacken it slowly when a load is applied or accidents would occur.
4. Select point of action according to the gravitational centre place the cylinder on
the hardness ground If necessary, place a hard plank under the cylinders so as to
avoid tottering or falling during operation.
5. When more than one cylinder are used at the same time it is important to operate
the different cylinders at an equal speed with equal load. Otherwise, there is
danger of falling of the entire fixture.
6. For best results use specifically blended cylinder oil. If such oil is not readily
obtainable, the equivalent international oil specification is SAE 10.
7. Violent Shocks must be avoided during the operation.
8. Do not overload, do not adjust the release value.
9. Do not put any hand or human organs while in the operation is can cause a
permanent damage to user.
Basic drawing showing the layout of the components of the machine, and overall
dimensions. Positions of the bottle jack, springs, and guides should be followed. Two
140 lbf. springs work well for returning the mass of the moving system. Note: The
pin (shown in green) must be removable, but also must be attached to the bottom
surface of the "jack plate" in order to get a good, straight, rigid press.
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6.1 JACK CROSSBAR:
This piece provides a mounting surface for the jack, and the guides welded to
the crossbar insure that a "straight press" is achieved. The slot cut in the center is for
removal of the pin that is used in pressing. When using the machine as a break, the pin
must be removed, so that the jack crossbar can be used to clamp the sheet metal to the
main crossbar (shown below). The whole key to the versatility of the machine is the
fact that this pin is removable.
Fig. shown as below which shows the jack crossbar used in hydraulic metal foil
cutting machine.
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6.2 MAIN CROSSBAR :
Two of these comprise the main stationary support for all operations. The two
halves are joined when welded to the endplates. The two holes are necessary for
adjusting the crossbar height using the holes in the frame (or legs of the machine).
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6.3 END PLATES: Welded to the main crossbars and serve as the mounting surface for
the two pivot plates.
6.4 PIVOT PLATE: Plates are bolted to the endplates and serve as the pivot for the
sheet metal brake. Note the milled slot, which allows for adjustability for different
guages of sheet metal. The bolt hole and slot locations are critical to how well the sheet
metal break function works. The rest of the geometry can be roughly cut on a vertical
band saw.
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FIG. 6.4 PIVOT PLATE
6.5 MOUNTING BLOCKS: Attached to sheet metal brake to allow the handles to be
attached. A set screw allows the handles to be easily attached and removed when
desired.
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7 ADVANTAGES
7.1 DRAWBACKS:-
1. The clamping of shit is manually hence take some fraction of time.
2. One operator must.
1. High productivity.
2. Simple in operation.
3. No skilled manpower required.
4. Very low maintenance cost.
5. Manual operation cycle.
6. Minimum setup changes over time.
7. Robust in construction.
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8. CONCLUSION:
Till date project is not completed but up to today’s completed work it is concluded that
with analytical and design aspect the process which we are going to do is true .Further
work is require some more time to do project practically.
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