DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

CHAPTER 5

Design and Analysis

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
 DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

Selection of material of machine body/frame

After studying the applications of various types of materials, finally mild
steel with 0.3 to 0.4 % carbon& 0.3 to 0.6 % Manganese is selected for the frame or
body of the machine. Standard designation of this material is C 35.
Following are its properties.
Yield Stress = σ = 31 kg/mm2 = 304 N/mm2
Modulus of Elasticity = E = 2.1 x 105 N/mm2
Poisson’s ratio = υ = 0.3
Design:
Frame Design
The structural design of the frame depends on the pressing force. This
determines the required rigidity, the dimensions of dies influencing the size of the
tool area, work area accessibility that determines on the shape of the press frame, the
degree of guidance precision.
Design Procedure for Frame
The frame is the base machine element in hydraulic press. It is designed by
the following steps.
 Specification of function
The main function of the frame is to withstand the force developed by the
hydraulic cylinder. Frame is used mounting and housing the press accessories like
hydraulic cylinder, die block, ejection system etc.
 Determination of forces
The weight of the cylinder and the cylinder load is the major forces acting on
the frame structure.
Press capacity P = 19620 N
 Selection of materials
The mild steel (IS2062) is selected for the frame because it is soft and ductile
they can be easily welded and machined and sections available in the market.
 Determination of dimensions
The frame consists of many number of sections fabricated to support the
structure. The dimensions of the sections are given below

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
 DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

TABLE I
Details of Section used in Fabrication
Sr. No. Section Section Dimension Length Quantity
1. 505 4
2. 900 2
3. C-channel 600 4
4. 300 4
5. 480 2

Square
6. 290 4
Tube

7. 300 2
Rectangular
Flat
8. 178.5 4

Theoretical Design of Frame Assumptions

The material of the beam is perfectly homogeneous and isotropic i.e. it is
same material throughout and of equal elastic properties in all the direction.
The material of Structure obeys Hook’s law. The Young’s modulus E is same
in tension and compression.
Specification of machine frame
Press capacity = 2 tonnes
Tensile strength= 410X106 N / mm2
Density= 7850 kg/m3
Young’s Modulus= 2.1X105 N / mm2.
Poisons Ratio= 0.3.
Factor of Safety= 2.0
Max Allowable Stress σ =410/2
σ = 205 N/mm2
Formulas and calculations
The frame subjected to direct tensile stress and bending stresses

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
 DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

σ total=σ tensile + σ bending…………N/mm2

P M Y
σ= + b ……………………….… N/mm2
A I
Where
σ = Permissible stress in N/mm2
P = Applied load/ Force in N
A= Area of the plate section in mm2
Mb = Bending moment in Nmm
x= Perpendicular Distance in mm
y = Distance from the neutral surface to the extreme fibre in mm
I = Moment of inertia in mm4
P =2 tonnes
Applied load P= 2000X9.81N
P = 19620 N
Design of job mounting plate
The maximum force acting on the plate is 19620 N. Let us take 300 mm x
300 mm (width) as area of mounting plates of job. The active length of plate is 240
mm as the supports (30 mm both side) are subtracted from length. Now, load acts at
the centre of the plate. So, this is a case of a simply supported beam of length 240
mm with a central load of 19620 N. Thus, the plate will be only under bending load.
For simply supported beam,
Force × Length
Max. Bending Moment (Mb) =
4
19620× 240
=
4
= 1177200 Nmm
b d3
Moment of Inertia (I) =
12
240× t 3
=
12
= 20 t3
Using
M b× y
σ t=
I

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
 DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

t
1177200 ×
2
205=
2 0t 3
588600
4100 = 2
t
t = 11.98 mm
= 12 mm
Now the dimensions of the job mounting plate are 300 mm x 300 mm x 12
mm.
The calculations done for die mounting plate are also applicable to top plate.
This plate will have same dimensions as job mounting plate.
Selection of hydraulic cylinder
Single acting hydraulic cylinder bottle jack is used for this machine. Different
sizes of the cylinders are available in the market. The charts of manufacturers are
referred and model of cylinder is finalized. As the load is not heavy, standard
hydraulic cylinders of small bore is chosen for this machine. Cylinder bore = 64 mm
force 19620
=
Oil pressure = area π =6.09 N/mm2 = 60.9 bar
× 642
4
Piston Stroke = 150 mm.
Piston stroke is finalized considering the job/die mounting & position of
cylinder.
BOTTLE JACKS

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
 DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

PRODUCT MODEL CAPACITY MINIMUM LIFT ADJUSTMENT MAXIMUM NET

HEIGHT HEIGHT HEIGHT WEIGHT
    TONNES MM MM MM MM KGS
BOTTLE V20302 2T 181 116 48 345 2.7
JACK
BOTTLE V20103 3T 195 125 60 380 3.5
JACK
BOTTLE V20204 4T 180 110 50 340 3.4
JACK
BOTTLE V20105 5T 200 125 60 385 4.5
JACK
BOTTLE V20306 6T 216 127 70 413 4.6
JACK
BOTTLE V20208 8T 200 125 60 385 5.5
JACK
BOTTLE V20310 10T 230 150 80 460 6.6
JACK
BOTTLE V20312 12T 230 150 80 460 7.8
JACK
BOTTLE V20316 16T 230 150 80 460 8.6
JACK
BOTTLE V20320 20T 242 150 60 452 11.5
JACK
BOTTLE V20132 32T 285 180 0 465 23
JACK
BOTTLE V20150 50T 300 180 0 480 33.5
JACK
From this chart, model number V20302 is selected.

Analysis
Structural Analysis of Frame
The performance of a hydraulic press depends, largely, upon the behaviour of
its structure during operation. The analysis of hydraulic press structure is needed to
increased their performance and productivity. The deformation of press structure
during the loading condition is analysed to change the dimensions of plates.
For the hydraulic cylinder, the loading condition is defined with applying the
pressure to the inner surface of the cylinder. The amount of pressure developed

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
 DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

inside the cylinder during the loading condition is analysed and the wall thickness,
flange thickness and number and size of bolts are changed.
Analysis Procedure
STEP 1
The C type hydraulic press frame is created from the modelling software
Creo. Converted into *.iges format.
STEP 2
The *.iges is opened in simulation software ANSYS for analysing stress
strain distribution.
STEP 3
Open the model in Simulation, establish units, and set up a structural
analysis.
STEP 4
Apply fixed support by selecting the face shown and choosing Supports
Fixed Support and also Load from the toolbar.
STEP 5
Solve the analysis. Choose Solve from the toolbar.
STEP 6
Review the results of the structural analysis. Highlight the Shape Finder
object. The results show suggested areas of material removal.
STEP 7
Simulation of press structure is done in ANSYS software.
STEP 8
From the above results, the metal removal areas in the frame can be
determined and removed to reduce the weight and cost.

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

Fig. Assembly Model in ProE Wildfire 5.0

Fig. Structure Model in ProE Wildfire 5.0 used for ANSYS

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.
DESIGN, ANALYSIS AND FABRICATION OF 2 TON HYDRAULIC PRESS

Ms. Nivedita Bansode

D.Y.PATIL COLLEGE OF ENGINEERING, AMBI, PUNE
Page No.