International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2013): 6.14 | Impact Factor (2014): 5.611
Design and Fabrication of a Special Purpose
Hydraulic Press Performing Punching Operation
Shivasheesh Kaushik
Assistant Professor, in Department of MECHANICAL Engineering, AGI (Amarpali Group of Institute) Haldwani, Uttarakhand, India
Abstract: Hydraulics has proven to be the most efficient and economical system adaptable to aviation. 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.
The word "hydraulic" is derived from two Greek words: "hydro" meaning liquid or water and "aulos" meaning pipe or tubing.
"Hydraulic," therefore, is an adjective implying that the word it modifies is in some major way concerned with liquids. Examples can be
found in the everyday usage of "hydraulic" in connection with familiar items such as automobile jacks and brakes. As a further
example, the phrase "hydraulic freight elevator" refers to an elevator ascending and descending on a column of liquid instead of using
cables and a drum. On the other hand, the word "hydraulics" is the generic name of a subject. According to the dictionary "hydraulics"
is defined as a branch of science that deals with practical applications (such as the transmission of energy or the effects of flow) of a
liquid in motion.
Keywords: Special purpose machine, Punching operation, Hydraulic concept, Multipurpose punching.
1. Present Work Selection of the product which we are making through
this machine:
Here we are designing a hydraulic punching & bending It is Special purpose machinery, as the name suggests, is
machine. constructed for some very particular purpose. These
machines are not built en masse as is the case with most
We followed following some steps in this project are:- types of machinery and are custom made. Effectively, these
1) Study the concept of hydraulic machine and hydraulic machines are made from scratch without any preconceived
press. concepts or notions. It is also possible for them to be special
2) Selection of the product which we are making through purpose machines that are designed to be a part of a bigger
this machine. system or machine. In these cases, the special purpose
3) Selection of the operations which we have to perform on machine would be created to serve a very particular purpose
it. in the bigger scheme of things. The main function and
4) Selection of the dies which we use for it. objective of this machine is to manufacturing a complete
5) Selection of different number of part through which we design which is used in our houses as a inner supporting
create machine. housing for the circuit boards.
6) Selection of material for each part.
7) Calculation and the forces analysis of those parts. Selection of the operations which we have to perform on
8) Selection of the software on which these parts are it
design. Through this machine we perform basically two operations
9) Making the different views of that part in the auto-cad simultaneously. First is for punching hole or in other words
software. piercing and second is for bending the sheet.
10)Making the design of those parts in pro-e software and
solid work software. 1) For punching holes
11)Finally assembly of that part should do in the pro-e Here in this operation we are cutting 5 holes in a sheet one
software. by one but these five holes are cut in a single stroke of
piston. This can be achieve with the help of designing, how
Our hydraulic press or machine which we are making here we design the punch, here we design the punch in such a
depends on Pascal's principle: the pressure throughout a way that, we give a gap of 2cm between the length each
closed system is constant. One part of the system is a piston respected punch .the time interval for reaching the punch to
acting as a pump, with a modest mechanical force acting on sheet is vary due this method of designing, So in this way
a small cross-sectional area; the other part is a piston with a sheet will come in contact with punch only one time until
larger area which generates a correspondingly large the next hole does not cut. By this way we required less
mechanical force. Only small-diameter tubing (which more force for cutting holes.
easily resists pressure) is needed if the pump is separated
from the press cylinder. Pascal's law: It states that pressure 2) For bending the sheet
exerted anywhere in a confined incompressible fluid is Here we use wiping die for bending sheets. Wiping die is
transmitted equally in all directions throughout the fluid also known as flanging. One edge of the sheet is bent to 90
such that the pressure ratio (initial difference) remains the degree while the other end is restrained by the material itself
same. and by the force of blank holder and pad. The flange length
easily changed and the bend angle can be controlled by the
Volume 5 Issue 2, February 2016
www.ijsr.net
Paper ID: NOV161460 1589
Licensed Under Creative Commons Attribution CC BY
International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2013): 6.14 | Impact Factor (2014): 5.611
stroke position of the punch. Here the new thing which we Bending Die Material-EN30
are going to do is four corner bending with the help of the
punch which we are designing by our self. Properties Of EN30-
Ultimate Tensile Strength=850MPa, Tensile Yield
Selection of the dies which we use for our machine: Strength=650MPa, Percentage Elongation(%EL)=13, Brinell
For our hydraulic machine we use combination die which Hardness Number(BHN)=250
perform piercing as well as bending operation i. EN30 is a versalite high strength alloy.
simultaneously in a single stroke of a piston. This type of die ii. High toughness.
is similar to that of a compound die except that here non iii. A high strength alloy having a good combination of
cutting operation such as bending, piercing and forming are strength and impact properties
also done or includes as a part of operation. For our die we
use cast iron. Here we designing, the separate punch and Punch Holder Material- Mild Steel Sheet (Low Carbon
dies for bending and piercing in the pro-e and solid works Steel)
software. After completing it we attached both the punch Coposition:C=0.05-0.20%, Ultimate Tensile Strength=400-
and the die in a same plate and converted that into a 450MPa, Shear Strength=200MPa
combination die which do their respective operation
simultaneously in a single stroke of piston. Clamping Material-Nuts And Bolts:
Nut Material Specifications:ASTM A194 Grade A-Low
Selection of different number of part and the material Carbon Non-Geat Treat,Heavy Pattern, Bolt
through which we create machine: Specifications:ASTM A307 Grade B7-Chromium-
Cylinder , Piston , Piston ring , Piston pin , Plunger , Punch Molybdenum Steel.
for piercing purpose , Die for piercing purpose , Punch for
bending purpose , Die for bending purpose , Base stand Spring Material-Carbon-manganese Spring Steels
Cylinder supporting stand , Cylinder clamper , Supporting Composition:C=0.45-0.65%,Si=0.1-0.35%,Mn=0.5-1.0%,
stand clamper , Bench for holding motor and pump , Motor , Brinell Hardness Number(BHN)=350, Pressure Pipes: SAE
Pump , Fluid container , Pressure pipes , Nut and Bolts , 100R2AT,1/2",276bar,4000psi.
clutcher of pressure pipes. Iron Channel Beam: Mild Steel
2. Selection of Material Different types of Material Can Be Used For Making the
Product Are:
Punch and Die Material(1):
1-Aluminium
Punching Tool Material For Punching Operation-EN31 Properties Of Aluminum(1) :
Composition: C=0.95-1.20%,Si=0.10-0.35%,Mn=0.30- Ultimate Tensile Strength=200MPa, Tensile Yield
0.35%,Cr=1-1.6%. Strength=185MPa, Shear Strength=110MPa, Shear
Modulus=25GPa, Modulus Of Elasticity=68.9GPa,
Properties of EN31- Density=2.73g/cc, Thermal Conductivity,k=154W/mk,
Ultimate Tensile Strength=900-1100MPa, Tensile Yield Melting Point Temperature=643-654°C, Specific Heat
Strength=650-750MPa Capacity=0.843j/g°C, Poisson’s ratio,𝜇=0.33.
i. High Carbon Alloy Steel.
ii. High Toughness And Tensile Strength. 2-Copper
Properties Of Copper(1):
Punching Die Material-EN30 Ultimate Tensile Strength=220MPa, Tensile Yield
Composition: C=0.26-0.34%, Si=0.10-0.35%,Mn=0.40- Strength=140MPa, Shear Strength=172MPa, Shear
0.60%,Cr=1.10-1.40%,Ni=1.3-1.86%,Mo=0.20-0.40%. Modulus=48GPa, Modulus Of Elasticity=120GPa,
Density=8.02g/cc
Properties of EN30- Thermal Conductivity,k=410W/mk, Melting Point
Ultimate Tensile Strength=850-1000MPa, Tensile Yield Temperature=1357.77K (1084.62°C), Poisson’s
Strength=650MPa, Percentage Elongation(%EL)=13, Brinell ratio,𝜇=0.35.
Hardness Number(BHN)=250
i. EN30 is a versalite high strength alloy. 3-Brass
ii. High toughness. Properties Of Brass(1):
iii. A high strength alloy having a good combination of Ultimate Tensile Strength=345MPa, Tensile Yield
strength and impact properties Strength=135MPa, Shear Strength=235MPa, Shear
Modulus=34GPa, Modulus Of Elasticity=97GPa,
Punching Tool Material For Bending Operation-EN31 Density=8.47g/cc, Thermal Conductivity,k=115W/mk,
Melting Point Temperature=885-900°C,
Properties of EN31- Machinability=100%, Poisson’s ratio,𝜇=0.34
Ultimate Tensile Strength=900-1100MPa, Tensile Yield
Strength=650-750MPa 3. Problem Formulation/Design
i. High Carbon Alloy Steel.
ii. High Toughness And Tensile Strength. For the sheet metal work in the project, we use Aluminum
sheet of thickness 2 mm (millimeter), because of ease of
Volume 5 Issue 2, February 2016
www.ijsr.net
Paper ID: NOV161460 1590
Licensed Under Creative Commons Attribution CC BY
International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2013): 6.14 | Impact Factor (2014): 5.611
operation performing on it. And the grade 3003-H18 of 12) Calculation related to the force generation by the motor
aluminum is considered according to design aspect. Grade and pump.
3003 is commercially pure and the most widely used 13) Calculation related to cutting force which appears on
aluminum alloy. Its uses include cooking utensils, cabinets, the sheet.
mailboxes, fan blades, decorative trim, awnings and
chemical equipment. 4. Design Consideration
Calculation and the forces analysis of those parts: Sheet used-Aluminium alloy 3003-H18(2)
Shear strength(Ss)=110MPa, UTS=Ultimate Tensile
Here we calculated a number of calculation and forces Strength =200MPa, Thickness of sheet(t)=2mm
related to our design of machine which are as follows:-
1) Calculating the bore and length of the cylinder and Punch and Die Sizes:
select the material for it. Punch Diameter (Dp)=2.7cm=27mm
2) Calculating the thickness of cylinder wall. For a round hole of diameter Dh:
3) Calculating the stress in cylinder wall. Hole punch diameter (Dh) =27mm
4) Calculating the length of studs and cylinder head. Hole die diameter = Dh + 2c=27+2(0.5)=28mm
5) Select the material for the piston. Where, c = clearance
6) Calculating the thickness of piston head, piston rib and
cup. Cutting Force[3]
7) Calculating the die and thickness of piston ring and Fc=𝜋𝐷𝑝𝑡𝜏𝑛(2)
material selection for it. Fc =3.14*27*2*110*5=93305.3N and Fc =93.3KN
8) Calculation related to the piston barrel
9) Calculation related to the piston skirt. 5. Different Parts of Hydraulic Press
10) Calculation related to the piston pin.
11) Calculation related to piston and material selection for
it.
6. Result economically and exactly works. First of all we have done a
survey of literature review of the machine, and market
Punching or cutting force= 93.3 KN, Bending force= 4.3KN, survey for the working and constructional detailed. Then we
Cylinder Pressure = 276bar (4000PSI), Cylinder have calculated the formulas for the design of the different
Force=138.73KN, Capacity of press= 14.1 tons, Capacity of parts of hydraulic cylinder so that we can calculate the
pump= 1.0 gal/min= 3.72 lt/min, Magnitude of electric capacity of the hydraulic punching and bending machine and
motor = 2 hp= 1.5 kw Finally fabricate the machine to perform the operation on the
aluminium sheet to produce the final product. This machine
7. Conclusion is use for multipurpose punching at a single time of stoke of
ram/plunger.
The hydraulic punching and bending machine is successfully
enrolled and is calculated properly. In this we have introduce We have seen how the Hydraulic systems allow users to
a special purpose hydraulic model of Punching and Bending accurately wield large amounts of power with little input
machine and we have showed theoretically how the force. And with the combination die two operation are
hydraulic model of special purpose punching machine performed simultaneously. So we can say that the hydraulic
Volume 5 Issue 2, February 2016
www.ijsr.net
Paper ID: NOV161460 1591
Licensed Under Creative Commons Attribution CC BY
International Journal of Science and Research (IJSR)
ISSN (Online): 2319-7064
Index Copernicus Value (2013): 6.14 | Impact Factor (2014): 5.611
system of special purpose punching and bending machine is
quite economical as compare to the other alternative.
References
[1] Metals Handbook VOL.2 ASM International 10th
Ed.1990.
[2] Metals Handbook Howard E.Boyer & Timothy
L.Gall,Eds,American Society For
Metals,Materials,OH,1985.
[3] Jain R.K, ’Production Technology’, (Khanna
Publishers,17th Ed.2009).
[4] Miller Fluid Power H-Series Hydraulic Cylinder Catalog,
, September 2003. Livonia, MI: Miller Fluid Power.
[5] Khurmi, R.S.; and Gupta, J.K. 1997. A textbook of
machine design. Eurasia Publ., New Delhi, India.
[6] Bhandari V P –Design of Machine Elements,Tata
McGraw-Hill Education(2010)
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Paper ID: NOV161460 1592
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