Project proposal for

Hydraulic Press machine

1. Project contact information

 CHAPTER ONE
1. INTRODUCTION
The word “hydraulics” generally refers to power produced by moving liquids.
Modern hydraulics is defined as the use of confined liquid to transmit power,
multiply force, or produce motion. Though hydraulic power in the form of water
wheels and other simple devices has been in use for centuries, the principles of
hydraulics weren’t formulated into scientific law until the 17th century.
It was then that French philosopher Blasé Pascal discovered that liquids cannot
be compressed. He discovered a law which states: Pressure applied on a
confined fluid is transmitted in all directions with equal force on equal areas.
Modern industry is looking for flexible solutions that will be able to provide
some new characteristics of hydraulic systems, such as the ability of controlled
motion, the possibility for continuous control of the required values, simple data
transfer and signal processing, the possibility of monitoring and process
visualization, etc. The rapid developments in microelectronics in recent years
have reduced the cost of computer equipment to a level acceptable for industrial
applications, which has enabled the implementation of sophisticated control
strategies in practice. Therefore, modern hydraulic systems have evolved
towards electronics and microprocessor-controlled electro hydraulic components
in order to achieve new control possibilities Presses are one of the most
commonly used machine tools in industry for the forming of different materials.
In the past, for the pressing tasks in industry, mechanical presses were more
frequently used, but nowadays hydraulic presses take precedence due to their
numerous advantages, such as:
- Full force through the stroke,
- moving parts that operate with good lubrication,
- Force that can be programmed,
- Stroke that can be fully adjustable, which contributes to the flexibility of
application,
- Safety features that can be programmed and incorporated into the control
algorithms,
- can be made for very large force.

1.1 Back ground of the project

Among the various drives available, the hydraulic drive ranks at the forefront in
terms of application history. The history of hydraulic power dated to the
beginning of civilization, where arte facts show the applications of water
turbines in power generation
However, more significant progress in this field is generally achieved following
Pascal’s pioneering work which was later known as Pascal’s law of hydrostatic.
Bernoulli’s discovery of the hydrodynamic law in 1750, and the Industrial
Revolution in 1850 further catalyzed the development of servo hydraulic drives.

They led to the first applications of hydraulic equipment as a power source to

power industrial machines such as the press, the crane, and the jack, as they also
contributed to the development of hydraulic pumps, driven by steam engines,
which produce hydraulic energy to run hydraulic systems. In the early 20th
century, a revolutionary design of hydraulic drives used the oil, instead of water,
as the hydraulic liquid, which greatly expanded the applications of hydraulic
drives to more devices.
World War II also contributed to the development of hydraulic drives, especially
in the development of submarine control systems, radar/sonar drives, and
military cargo transportation.
Hydraulic drives are still being used today, and, in fact, their applications are
expanding to loads of increasing mass and power requirements, yet with higher
speed and control precision. The main attraction of a hydraulic drive is its high
power-to weight ratio, rendering it the natural servo drive to use for heavy
applications found in the aircraft and space shuttle. Moreover, it possesses
several desirable characteristics such as accuracy, flexibility in applications, and
simplicity of operations, as it also allows for fast, smooth, and precise start, stop,
and reversal actions.
Hydraulic presses, both vertical and horizontal, are used in many industrial
technologies. Vertical press applications include forging presses with flat dies,
used for hot work to break down ingots and shape them into rolls, pressure
vessels, mandrel forgings, forged bars, rods, plates, and so on. There are many
structure parameters in hydraulic press. If allparameters are optimized for
structural design variables of the complete machine, it leads the optimization
model complex and enormous
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1.2 Statement of the problem
The problems faced in this hydraulic press machine or (that is modifying the
machine presented in our shop)

Replaceable of tools, such as punches and dies

Change in production volume
 Change in product
The place for clamping accessories
The problems related to wastage material

In response the above problems; this project will solve the above mentioned
problems.

Here we are placing the hydraulic piston rod end on the top passed plate (top)
and the pressing tool (punch or punch holder) is tight in the footing of hydraulic
cylinder. The footing have four holes to hold or to tight the pressing tool.
The working table is placed on the top of the supporting frame it can be adjusted
according to the work piece height by adjusting the lock holes. This also has
slots on the top side of the plate to slide and to tight the die or dies holders.

The hydraulic cylinder is working with the help of supply of oil from the
pumping rod side. Here we have to tight the pressure relief valve then to start
pumping with help of pumping rod by pumping, the oil with supply to push the
piston up ward direction against the top fixed plate by this pressing tool will
move through it to pressing the work piece. By completing the pressing
operation or process we have to release the pressure relief valve then the piston
come its original position with the help of springs.

1.3 Objectives of the project

1.3.1 General objective
This project aims to play its role from all actors off technology transfer activities
involved in technology searching, selection, acquisition, learning, adaption and
utilization for all Ethiopians small and medium enterprises.
1.3.2 Specific objectives

 To improve the hydraulic press for proper utilization of people, equipment

and space.
 To investigate the effect of technology on the development of small and
medium enterprises.
 To facilitate productions in the workshops.
 To evaluate and suggest possible solution to improve training of manpower.

1.4 Significance of the project

 The project provides the way to strengthen small and medium enterprises
in the country by developing appropriate technology. By doing this, the
enterprises competitiveness, productivity, efficient utilization of resources
and innovation capability of enterprises is improved; the continuity of
these improvements in the future assists the strategy of the country.
 This project also introducing the easy method of to doing pressing,
punching, producing different holes, and bending by using replaceable
punches and dies for all manufacturers and workshops so, the project is
valuable for further and better projects.

1.5 Scope of the project

The scope of this project is:-

 producing/making different small punches and a square hole by the use of

replaceable punch and dies,
  for fittings in to connecting rods
 forcing gears on shafts
 removing axels from small wheels and similar work in the garage, service
station or shop

1.6. Delimitations of the project

There are some limitations which faced during manufacturing the hydraulic
press. Some of these limitations are:

 Availability of raw materials, equipments and tools.

 Crowded work shop.
 Less number of coordinators and assistance in the workshop.
 Shortage of Time,
 Unwillingness of store keepers.
 CHAPTER TWO

LITERATURE REVIEW

2.1 Definition of hydraulic press

What is Hydraulics?

The term hydraulics is applied commonly to the study of the mechanical

properties of water, other liquids, and even gases when the effects of
compressibility are small. [5]

The word “hydraulics” generally refers to power produced by moving liquids.

Modern hydraulics is defined as the use of confined liquid to transmit power
multiply force, or produce motion.[7]

A hydraulic press is a hydraulic mechanism for applying a large lifting or

compressive force.[1]
Hydraulic press to punch holes in metal stock to assemble cattle head gates. The
fabricator was replacing the punch on the press for the current job. [4]

2.2 History of hydraulic press

It is the hydraulic equivalent of a mechanical lever, and is also known as a
Bramahpress after the inventor, Joseph Bramah, of England. He invented and
was issued a patent on this press in 1795. As Bramah (who is also known for his
development of the flush toilet) installed toilets, he studied the existing literature
on the motion of fluids and put this knowledge into the development of the
press. Hydraulic presses are the most commonly-used and efficient form of
modern press. [1]
French philosopher Blasé Pascal discovered that liquids cannot be compressed.
He discovered a law which states: Pressure applied on a confined fluid is
transmitted in all directions with equal force on equal areas.
Modern industry is looking for flexible solutions that will be able to provide
some new characteristics of hydraulic systems, such as the ability of controlled
motion, the possibility for continuous control of the required values, simple data
transfer and signal processing, the possibility of monitoring and process
visualization, etc. The rapid developments in microelectronics in recent years
have reduced the cost of computer equipment to a level acceptable for industrial
applications, which has enabled the implementation of sophisticated control
strategies in practice. Therefore, modern hydraulic systems have evolved
towards electronics and microprocessor-controlled electro hydraulic components
in order to achieve new control possibilities Presses are one of the most
commonly used machine tools in industry for the forming of different materials.
In the past, for the pressing tasks in industry, mechanical presses were more
frequently used.[6]
Among the various drives available, the hydraulic drive ranks at the forefront in
terms of application history. The history of hydraulic power dated to the
beginning of civilization, where arte facts show the applications of water
turbines in power generation
However, more significant progress in this field is generally achieved following
Pascal’s pioneering work which was later known as Pascal’s law of hydrostatic.
Bernoulli’s discovery of the hydrodynamic law in 1750, and the Industrial
Revolution in 1850 further catalyzed the development of servo hydraulic drives.
They led to the first applications of hydraulic equipment as a power source to
power industrial machines such as the press, the crane, and the jack, as they also
contributed to the development of hydraulic pumps, driven by steam engines,
which produce hydraulic energy to run hydraulic systems. In the early 20th
century, a revolutionary design of hydraulic drives used the oil, instead of water,
as the hydraulic liquid, which greatly expanded the applications of hydraulic
drives to more devices.
World War II also contributed to the development of hydraulic drives, especially
in the development of submarine control systems, radar/sonar drives, and
military cargo transportation.
Hydraulic drives are still being used today, and, in fact, their applications are
expanding to loads of increasing mass and power requirements, yet with higher
speed and control precision. The main attraction of a hydraulic drive is its high
power-to weight ratio, rendering it the natural servo drive to use for heavy
applications found in the aircraft and space shuttle. Moreover, it possesses
several desirable characteristics such as accuracy, flexibility in applications, and
simplicity of operations, as it also allows for fast, smooth, and precise start, stop,
and reversal actions.
2.3 Terms related to features of hydraulic presses
The terms that are related to hydraulic press depend on there working function,
power source and there frame types are as follows.[3]

Press with Double Action Cylinder: -Double action cylinders are those
cylinders which can take power stroke in forward as well as reverse direction.
Such cylinder can apply pressing force as well as pulling force. Both forward
and reverse stroke achieved by pumping oil under controlled pres-sure and flow
condition, from both the oil port of cylinder. All the general purpose and
standard presses uses these types of cylinders.
Press with Single Action Cylinder: -Single action cylinder can take power
stroke only in forward direction. Return stroke may be achieved by additional
hydraulic cylinder or by gravity (i.e. own weight of ram and platen). High
capacity cylinder when bore of cylinder is more than 1000 mm, and honing the
bore of cylinder become difficult, in such cases cylinder are made single action.
Also in case of up-stroke press, when moving platen weight is sufficiently high
and return speed is not very critical than to reduce cost of press, cylinder are
made single action and return stroke achieved by gravity
Press with Regenerative Circuit:-Regenerative circuit is a special hydraulic
circuit in which we get high forward speed as compared to common hydraulic
circuit using same capacity of pump and electric motor. This is achieved by re-
pumping exhaust oil coming out from return port of cylinder back to forward
port of cylinder using some hydraulic values.
For some operations, presses with regenerative circuits are more productive as
com-pared to common presses. Regeneration circuits are commonly used in
coining, marking, Bakelite molding press etc.
Press with two Working Speed :-In a production cycle of press, generally
pressing time is less as compared to time taken for approach and return
stroke. Hence to save idle time, press are designed for two operating speed. Fast
approach and return speed and slow pressing speed. Such presses are much
productive as compared to single speed press.
Press with Pressure-compensation Feature:-Some time press has to hold job
under pressure for long time for curing. if material to be cured gets less pressure
than specified pressure, than it may get spoiled. Hence press is designed in
such a way that if pressure drops then automatically motor starts, develops
the right pressure and stops automatically. Such presses are called press with
pressure compensation feature.
Press with De-compression Feature:-Whenever there is a stress, strain is
bound to be there. Body of all press deflects within elastic limit. As pump
slowly develops pressure elongation of press column and deflection of press
body are smooth and without vibration. And the deflection and elongation is
maxi-mum, when press achieves maximum pressing capacity. Solenoids
operated direction control valve are so fast in operation that they take only 0.3
sec to get change over, and that means within 0.3 sec pressurized port of the
cylinder gets connected to tank line, and there is sudden fall in pressure. Such
sudden fall of pressure result in sudden fall of stress and strain, and severe jerk
and vibration in press body. This phenomenon is highly undesirable and should
be avoided. Hence presses are designed in such a way that the pressure slowly
gets reduced from maximum to tank line pressure before taking return
stroke of cylinder. Such presses are called press with de-compression feature.
Press with Pre-stressed Column: All presses deflect under load. Some of the
deflection is due to stress developed in press body and some of the deflection is
due to clearance between various parts of press.
Press with Cushion Cylinder, Ejector Cylinder, Blank-holding Cylinder,
Auxiliary Cylinder :-Such presses are not any special types of presses, but
these are the presses with addition cylinder, for easy and more accurate and
productive operations.

 Cushion Cylinder:- Some component requires support from bottom

side at the time of pressing operation. Such support only offer some
resistance, and do not block the movement of main cylinder and
component, these bottom support are called cushion, and hydraulic
cylinder provided for cushion is called cushion cylinder (e.g. deep
drawing operation) Cushion could be achieved by providing spring,
rubber etc.
 Ejector Cylinder:-Ejectors are required to eject the job jammed in die
after pressing operation. A hydraulic cylinder provided to eject the
component is called ejector cylinder.
 Blank holding:- Blank holding is required to hold the job before and at
the time of pressing operation. A hydraulic cylinder provider for blank
Holding is called blank holding cylinder. Presses with ejector and blank
holding cylinder are more productive.
 Auxiliary cylinder :- Auxiliary cylinder are those cylinder which are
provided in press not to perform the main pressing operation, but to assist
main cylinder in carrying out its function smoothly and efficiently. For
example auxiliary cylinder are provided along with single action
cylinder for retraction.
Vertical Press: -In vertical press axis of main pressing cylinder and press is
perpendicular to the ground. Majority of press are vertical.
Horizontal Press: -In this type of press axis of main pressing cylinder and
press is parallel to the ground. For example Aluminum/Brass extrusion presses.
Up-Stroke Press: -This is a type of vertical press in which main pressing
cylinder is mounted in bottom platen and it takes up-ward power stroke.
Down-Stroke Press: -This is also a type of vertical press in which main
pressing cylinder is mounted in top-plate and it take down - ward power stroke.
Single-Day Light Press: -In this type of press there is a single clear gap
between moving platen attached to Ram and press-table mounted on press body.
Multi-Day Light Press: -In this type of press numbers of addition plates are
added between moving platen and press-table to press number of jobs at a time.
Plywood, rubber, molding, core pressing etc are example of multi - daylight
hydraulic press.

2.4 Classifications of hydraulic presses

Presses are designed and manufactured in different shapes and sizes to suit the
pacific production, accuracy, strength requirement, and economic
constraints.Depending on their shapes, design and theycould be divided into six
broad categories.[3]
 1. Round column press.
2. Fabricated column press.
3. Close-frame press.
4. C-Frame press.
5. Fabricated chamber press.
6. Non-Conventional press.
1. Round Column Press
Main features of these types of presses are their round columns. In these types of
presses top and bottom platen are fabricated and machined individually and
then held together by means of round columns and nuts. As all the components
could be machined individually and accurately hence these types of presses are
most accurate types of presses, as compared to all other types of presses.
(Columns are also referred as pillars).

Round column presses could be further sub-divided into three categories.

a) Two columns press.
b) Three columns press.
c) Four columns press.

a)Two Column Press: -

In case of two columns press, top andbottom platens are tighten together
bymeans of only two round columns. Hydraulic presses, which are requiredto be
very accurate and pressing load al-ways remain at the central axis of
maincylinder, and also there is no chance oftaking any eccentric load,
then two column types of presses are used. For example, Lead and solder
wire extrusionpress. In this type of press material is al-ways fed in fix
container and load is applied by plunger attached to the Ram. Hence
load always remain at the central axis of main cylinder. Hydraulic universal
tensile testing machine is another example of this type of press.
b). Three Column Press:-
In three column presses, top and bottom platen are tighten together by means of
three round columns. Old aluminum and copper extrusion presses of higher
capacity were designed in this way. These presses were horizontal, high speed
and made for mass production. Three column designs is stronger than two-
column design. Advantage of this type of design in case of extrusion press is
that ample space is available for shearing the rejected billet and loading red hot
billets in container by means of over head crane.

c).Four Column Press:-

In four columns presses top and bottom platen are tighten together by means of
four round column. These types of presses are widely used in industry as
compared to other type where accuracy is more critical between Dies. For
example, power compacting presses, plastic injection molding machine etc.

2. Fabricated column press

In this type of presses top and bottom platens are permanently welded together
with the help of fabricated columns. A fabricated column pressure sturdier,
economical and has less deflection under load as compare to round column
presses.
Fabricated column press also could be divided into two categories.

a) Fabricated Four-column press.

b) Fabricated Two-column press or H-Frame press.
a) Fabricated Four Column Press: - High capacity hydraulic presses with
large size table are manufactured on the design of fabricated four-column press.
As it is sturdier and gives ample space to work and inspect pressing operation
from all sides, as compared to, two-column press. For example, deep drawing
press for automobile body, punching and blanking of large size of M.S.Steel etc.
b). Fabricated Two Column Press or H-Frame Press: - Medium and low
capacity and economical presses are manufactured on the design of
fabricated two-column or H-
Frame press. In low capacity presses rolled M.S. channel or I-section are used
as side column and in case of medium capacity press it is fabricated from steel
plate. Rubber molding, variable-day-light presses used in garages is example of
H- Frame press.

3 C-Frame Press: -
In these types of presses, press-bodies of C-Shaped. When free space required
from three sides of press table to work for loading and unloading of pressed
component then this type of presses are designed. These types of presses are
most fragile, susceptible to deflection and cracking from inside corners, if not
designed and used correctly as compared to other type of press.As main
cylinder placed eccentric to central axis of press-body, it applies eccentric
load on press-body hence heavier press-body is required as compared to
same capacity of other type of press.
These types of presses are also called as single press. Some example of C-Frame
presses is as follow.
4. Close-Frame Presses
In case of close-frame press, overall structure of press is in a shape to square
ring. A schematic diagram of close-frame press is shown in figure No. 3.10. In
case of small size of presses, they are made by cutting window in steel plates
and assembling together two or more such plates to make a press-body. In this
type minimum welding is required as top, bottom and side columns are all
internal. In case of large presses required for general fabrication, such as
dishing, plate-bending, straightening and pre-pinching of plates for rolling top,
bottom platens and side columns are fabricated separately then welded
together .Difference between fabricated column press and close-frame presses
are as follow.

 Generally accuracy is critical in case of fabricated column press, and

generally accuracy is not very critical in case of large size of close frame
press
 Side columns of fabricated column presses are long compared to top
& bottom platen, and sometimes column extend down thebottom frame
and form the standing-leg orfoot of press while Close-Frame presses
rest on their bottom platen only.
 Large size of fabricated column presses are made in premises of press
manufacturer then supplied. These presses are accurate and
requiremachining of fabricated platens and column sand then assembled
together. Parallelism and flatness of platens is controlled as per
standards of machine design. While in case of large size of close-frame
press as a accuracy may not be very critical, hence manufactures of press
may manufacture press body himself or he can give fabrication
drawing of press body to customer and customer himself can
fabricates it, if he has the facility and knowledge. As manytime press
 body does not require machining, hence parallelism and flatness are not as
per standards

5 Fabricated Chamber Press

In this type of hydraulic press a steel fabricated box-structure or container form
the main body of hydraulic press. Main cylinder, various doors, feeding
arrangement auxiliary cylinder are mounted on these fabricated box-structure as
per the requirement of production and operation. Fabricated chamberact as
loadbearing member of press. Some time they also act on container for material
to be compressed. Bailing presses and extrusion press are some of the example
of these types of presses.

CHAPTER THREE
Methodology
The methodology of this senior project is manufacturing of hydraulic press
machine begins from the problems and the questions that are to be solved; and
 also the solutions of their methodologies up to the final project is clearly by the
simple chart.

Select the project

Select the material used for design Select the material used for manufacturing

Prepare the Prepare the Preparation of Selection of Selection of

theoretical drawing the materials tools machine

Part products are prepared

Hydraulic jack
springs

Vertical column Top I-beam Footing angle Guiding Table Holding Working table
iron plate pin

Frame is produced

Assembling of parts

Finishing and
Fig.1 methodology flow chart. painting

CHAPTER FOUR
Analysis result and desiccation
4.1 Design analysis

Construction:- H –type, fabricated out of tasted mild steel “U”-channel.

 Mode of operating :-manual / mechanical
Capacity:- 10 ton
No of cylinders:- one
Ram diameter:-60 mm
Type of press:- up stroke
Closing time
Opening time
Length of ram stroke 150 mm
Space required
Hydraulic pump
 high pressure
 low pressure

Design analysis based on working stress

Permissible stress of mild steel is given 210 MPa. And also the factor of safety
is equals to (3).then the working stress of our material is
Working stress= permissible stress / factor of safety
= 210 MPa / 3 =70 MPa
Therefore our senior project is high stress or high force (i.e. 10 ton) so that the
working force or stress of the material is much greater than hydraulic jack force.
So that the design is safe.
Welding is the process of joining metal parts in the molten state without the
application of any mechanical pressure. The metal of the parts to be welded is
melted by any means of electric arc.
The weld is subjected to direct load (P). The load will cause direct force per unit
length
Fa =P/L ; where L, is the length of weld group. This force acts vertically.
Due to moment, the stress in the weld varies linearly being zero at the C.G. of
the weld and maximum at a point at farthest distance from C.G. Force due to
bending per unit length,
Fm=(M /I) Y
M= P X e where e, is the distance between the force and C.G.
I, is moment of inertia of weld group about C.G. of weld group
Y, distance from C.G. of weld
This force acts horizontally. The resultant force can be obtained by
parallelogram of force.
Fm
R
Fa

R=√ Fa+ Fm
30CM

N A

Fig.2. design of weld

The size of a normal fillet weld is the maximum leg length. The throat of
thickness is 0.7 times the size of weld for 60 o to 90o angle between fusion faces.
The permissible shear stress for butt and fillet weld is 110 MPa. The permissible
strength of fillet weld per cm length of weld.

Size of weld in 3 5 6 8 10
mm

Strength in N 2310N 3850N 4620N 6160N 7700N

Table1 permissible strength per length

The minimum thickness of first run or of a single run fillet weld. Thickness of
plate up to 9.5 mm.
Now we are finding the load that means the force that is applied by the hydraulic
jack and the spring. Let these force is P.
The ‘I’ section size is 50 X 80 mm =5 X 8 cm
Length of the weld (2 X 7 cm) + ( 2 X 5) + ( 2 X 5) =34 cm.
Then we find moment of inertia of the weld
I =2 X 5 (8/2)2 + (2 X73 )/12
160 + 57 = 217 cm4
Force on the weld per cm in flange.
Fa = P / L
=P /34
Fm =MY/ I
8
=P XeX ( 2 ) / 217

= (P X 30 X 4) / 217
=(P X 120) / 217
Resultant (R) =√ Fa2+ Fm 2
=√ 8 . 650519 x 10−4 + 0 .305803 p2
= p√❑ 0 .03066689
= 0.055377P
Strength of weld per cm=0.7*5*110*3
=1155N
0.055377P=1155N
1155
P= 0 .055377 =20857 . 03

P=20.85KN
So the design is safe because the force that is applied by the hydraulic jack much
smaller than that of we get from fillet wilding or the joint of vertical column and
the top beam.
Spring analysis
From hooks low
Consider a mass m which slides over a frictionless surface. Suppose that the
mass is attached to a light horizontal spring whose other is anchored to an
immovable object
Let I be the extension of the spring that is the difference between the spring
actual length and its un stretched length. According to hooks low, the force of
that spring exerts on the mass is directly proportional to its extension and always
acts to reduce this extension,
Hence F=−kx
Where k:-is called the force constant of the spring.
Note that the minus sign in the above equation ensure that the poles always acts
to reduce the spring extension

1 2
The potential energy of the mass takes place u ( I )= 2 K I

The potential energy is actually represents energy stored by the spring in the
form of mechanical stresses.
If the mass is directed vertically down ward or the gravitational potential energy
of a mass moving above the earth’s surface is
U=m*g*z
Where z-measures the height
The total energy of the mass is the sum of its kinetic and potential energies.
We can expand the spring constant k as a function of the material properties of
the spring.
Doing so and solving for the spring displacement gives, ∆=f/k=8FD3na/Gd4
Where G-is the material share modules
Na-is the number of active coils
D-is external diameter of the spring
D-diameter of the spring wire
Shear stress in the spring
The maximum share stress tmax in a helical spring occurs on inner face of the
8 CFW 8 FDw
spring coils and equal to Tmax¿ 2
= 3
πd πd
Where W is the Wahl correction factor which accounts for share stress resulting
4 C−1 0.615
from spring curvaturew= 4 C−4 + C and c is spring index, c can be used

express deflections The spring index c, can be used to express deflection,

3
D 8 FC F
c= ∆= na=
d Gd K

The useful range for c is about 4 to 12, with an optimum of approximately 9 .the
wires diameter d, should confirm to a standard size if at all possible.

4.2 Manufacturing process

Manufacturing item has under gone a number of changes in which a piece of

raw material has become useful product involving people who have skills and a
wide variety of machine tools, equipments and tooling with various levels of
automation in manufacturing activities.

 The product must fully need design requirement and specifications.

 The product must be manufactured by the most economic methods.
 Quality must be built in each stages.

Each different manufacturing processes uses its own basic principle or principles
for imparting desired shape, accuracy of dimensions, surface smoothness, or a
desired property within the material.

4.2.1 Types of manufacturing techniques implemented:

 Welding

Welding may be defined as the metallurgical joining together of two metal

pieces to produce essentially a single piece of the metal. It produces what is
known as a” permanent fastening”. Welding is a fabrication method in which
portions of metal plate, various rolled sections, castings and other metal pieces
are joined to produce desired shapes. Its products are known as “weldments”.
Welding is also useful as a method of repairing broken, worn or defective metal
parts. The types of welding used in these manufacturing processes are3 but joint,
lap-joint, T-joint, two kinds of corner joints, two kinds of edge joints.

 Sawing

Metals and many other materials, in addition to wood are often sawed with
power-operated sawing machines. Sawing machines may be grouped in to three
classifications as follows: power hack saws, circular sawing machines and band
sawing machines. Sawing is governed by the same cutting conditions which
apply to the other machining processes. The sawing processes is used because it
has advantages, including doing the job faster, saving material, and using less
power. Also, a minimum of material is lost as chips.

 Drilling

It is one of the cutting operations using drill bits to produce rough holes. The
machine tool involved in this case is a drill press. There are two cutting edges
that produce chips similar to those produced in turning on a lathe and a certain
web region that extrudes the metal at the center of the hole which is not removed
by the cutting edges. Both lips (cutting edges) of a drill operate with variable
rake angle, inclination angle, and clearance angle along thecutting edge. The
flutes of a drill play the important role of conveying the chips out of the hole and
the helix angle of the drill is important in this connection.

4.2.2 Steps for manufacturing of different parts of the hydraulic press

Limits, Fits and Tolerances

The maximum and minimum limitations for a given feature are known as the
limits. To ensure that an assembly will function correctly, its component parts
must fit together in a predictable manner. Now, in practice, no component can
be manufactured to an exact size, and one of the problems facing the designer is
to decide the upper and lower limits of a size which are acceptable for each of
the dimensions used to define shape and form and which will ensure satisfactory
operation in service. The algebraic difference between the upper and lower limit
of size is known as the tolerance. The tolerance the amount of variation
permitted.

 Vertical column
The main purpose of our senior project of frame is to support the hydraulic jack,
table and guiding plate. It binds top and bottom platen together firmly

Table- operation plan for vertical column

Operation Operation Feed Cuttin Dept Machi Tools coola

al no. mm/r g h of ne nt
ev speed cut tools
m/mi mm
n

001 Measuring & lay - - - - -Tape

out rule
scriber

002 Mounting the - - - - -vise

blank on power
 hacksaw

003 Sawing the blank - - - Power Power Solu

to required hacksa hacksaw ble
dimension w blade oil

Table 2 design step of vertical column (U-channel)

 . Guiding plate Moving platen is also a steel fabricated or cast

structure, Located between main hydraulic cylinder and pressing table.
It is attached to Ram of cylinder and guided by side columns of
press. Moving platen exert force on the job placed on press–table and also
used for attaching punch holders

Operational Operation Feed Cutting Depth Machine Tools

no. mm/re speed of cut tools
v m/min mm

001 Measuring & lay - - - - -Tape

out rule
scriber

002 Mounting the - - - - -vise

blank on power
hacksaw
 003 Sawing the blank - - - Power Power
to required hacksaw hacksaw
dimension blade

004 Layout and cut the Power Power

two sliding sheet hacksaw hacksaw
metals blade

Bending
machine
005 Bend the flat iron

006 Welding of the two Welding Electrode,

bending metals in machine
Face
to the tip of the
plate shield

apron

Table 3 manufacturing of guiding pate

 . Working table

Used for secured the die shoe as well as dies.

Press-Table is a thick steel plate and it can be adjusted by the holding pins
depend on the project size. It is perfectly machined and provided with slot or
tapped holes for mounting of dies and fixtures.
Operational Operation Feed Cuttin Depth Machin Tools Coolant
no. mm/rev g of cut e tools
speed mm
m/min

001 Measuring - - - - -Tape

& lay out rule
scriber

002 Mounting - - - - -vise

the blank
on power
hacksaw

003 Sawing the - - - Power Power Soluble

blank to hacksaw hacksaw oil
required blade
dimension

Join the welding

plates each machine
004
other to the
specific
shapes &
dimension

Table 4 manufacturing of working table

  . Top “I” beam: used for support the vertical plate and securing springs.
It is a steel fabricated or steel cast structure located upper side of a vertical
press, and withstand compressive and bending load developed by
hydraulic cylinder.

Operation Operation Feed Cuttin Depth Machin Tools Coola

al no. mm/re g of cut e tools nt
v speed mm
m/min

001 Measuring & lay - - - - -Tape

out rule
scriber

002 Mounting the - - - Power -vise

blank on power hacksa
hacksaw w

003 Sawing the blank - - - Power Power Solub

to required hacksa hacksaw le oil
dimension w blade

Table5 manufacturing of top I-beam

  . Footing angle iron

Operational Operation Feed Cuttin Depth Machin Tools Coolant

no. mm/rev g of cut e tools
speed mm
m/min

001 Measuring - - - - -Tape

& lay out rule
the required scriber
length

002 Mounting - - - Power -vise

the blank hacksaw
on power
hacksaw

003 Sawing the - - - Power Power Soluble

blank to hacksaw hacksaw oil
required blade
dimension

Drilling Drill bit

machine
004 Drilling
holes

Table 6 manufacturing of footing angle iron

 . Loading pins
Operationa Operation Feed Cuttin Dept Machin Tools Coolan
l no. mm/re g h of e tools t
v speed cut
m/min mm

001 Measuring - - - - -Tape

& lay out rule
the required scriber
length of
round bar

002 Mounting - - - Power -vise

the blank on hacksa
power w
hacksaw

003 Sawing the - - - Power Power Soluble

blank to hacksa hacksa oil
required w w blade
dimension

Turning Lathe HSS

&chamferin m/c
004
g

Table7 manufacturing of loading pins

  Spring hooks ring: these are prepared from diameter 6 mm round bar
which is welded on the guiding plate and top I beam. They are used for
locking the spring hooks.
 Springs: these are selected and bought from the market. it is used for
supporting the hydraulic jack to withdraws in the original position.
 Hydraulic jack: it is used as a force generator.
Main cylinder is the most important part of a hydraulic press. Cylinder
develops pushing or pulling force required to carry out desired
operation, using pressurized hydraulic fluid.

4.3 Post production process

Processes that come after manufacturing the designed system parts are
assembled. Here below they are discussed below as tips.

4.3.1 Assembly
In assembling the hydraulic press, the different parts are assembled on the frame
with their own steps in order to avoid mismatches of the system. The following
are steps that should be followed for safe, quick and easier assembly of the
hydraulic press:

Step-1 the hydraulic jack is placed in the guiding plate according to the right
position

Step-2 the two springs are then put in their positions

Step-3 the loading pins are inserted in the proper orientation of vertical plate
(frame).

Step-4 the working plates are then put in its proper position on the supporting
frame and loading pins.
4.3.2 Finishing

 Grinding and polishing.

 Cleaning the polished and grind surface and filling by the stock.
 Cleaning by abrasive
 Washing the polished and abrasive parts
 Paint anti rust .
 And finally paint the synthetic paint.
4.4 Hydraulic press operator safety
There are physical hazards like accidents tripping, pinching injuries, and
dropping heavy things on to your feet and so on. Press operate at 12 to
20(and even more) tons of pressure there is danger from flying parts if
something gives way in the press metal, can pop suddenly and produces
razor sharp, jagged ages which can cut you severely (voice of experience),
particularly if stuck in a die and being forced out with the hands
Lubricants and hydraulic flood in contact with skin can cause
dermatitis
Integrating simple precaution and safeguard your manufacturing and
production operations, all machine operates will be safer and more
productive.
 Basic safety measures
 Training:-safely operating a hydraulic press is not something that you
can learn on fly. Training must be provided to all hydraulic press
operators.
 Clothing: - never wear loose clothing always wear safety glass and steel
cap shoos
  Inspecting:-regularly inspect the hydraulic press to insure they are
functioning correctly
 Starting: - prior to operating the hydraulic press verify that the area is
free from tripping and slipping hazards .confirm that all pins and logs are
secured. Check the press for damaged or broken parts and oil leaks.
 Observing: - designate a safety team to observe operating habits use
unsafe practices as training opportunities.

CHAPTER 5

COST ANALYSIS
The cost estimate is one of the keys to the acquisition of new or follow-on
business. Its preparation cannot be left to amateurs or accountants. If the
potential new business acquisition involves the manufacture of a product,
whether newly designed or one that has been in production before, the
manufacturing engineer must play a key role and participate in preparing the
estimate.

Success in acquiring this and future new business may well depend up on how
well the job of estimating is done.Preparation of the manufacturing labor
estimate is one of the most important jobs or duties of the manufacturing
engineer. It requires experience, judgment, engineering know-how, and
knowledge of the product, including what it takes to produce it in a cost-
effective manner. So, the total man hour estimation required for one hydraulic
press is summarized in the following table:

The main elements of cost analysis include:

Raw material and standard items

Operational process cost
Power consumption and consumable materials
Labor cost
Machine depreciation cost
 Time required for the different processes (hrs)

Components Cuttin Bending drilling Facing and Welding and Total

g turning grinding time(hrs)

Vertical column 1/2 ¼ 1/2 _ 1 214

Top I- beam 1/4 _ - _ 1/4 1/2

Working table 1 _ 1 1/2 1/2 3

Guiding plate 1/4 ¼ 1/4 - 1/4 1

loading bar 1/4 1- - 1/4 112

Assembling _ _ _ _ 2 2

Painting _ _ _ _ _ 5

2.5 134 134 3/4 4.5 _

_ _ _ _ _ 15.27

Table 1 time required for different process

The man hour calculation for welding and grinding will be:

Welding cost=16.25hrs*(70 birr/8hrs)=133.61 birr

The remaining cost for manufacturing HCBM relies to the summation of costs
for man hour estimation for the other processes, electric power cost, tools and
materials purchased. To generalize the cost estimation, the total cost
corresponding to one summarized in the following table by including the
material cost along with cost of manufacturing processes:

Press components Materials used Cost of material along with cost

and some of manufacturing processes
accessories

Vertical plate U-channel 2600.00

Top I- beam I-beam 1000.00

Working table plate, angle iron, 600.00

Guiding plate Plate 100*10 250.00

Footing Angle iron 100.00

Lever Round pipe 170.00

Electrode …………………………….. 80.00

Anti rust and paint …………………………….. 80.00

Total cost 5080.00birr

Table 2. cost of material along with manufacturing process

 Conclusion and Recommendation

Conclusion

This final year report includes all the procedural processes followed in the
project. One can observe that every design can be manufactured from cheaper
materials available around and it is possible to modify the existing design by
certain parameters for its feasibility. The project has contributed much for our
design and manufacturing knowledge starting from material selection to the
assembly of the press. We have improved the performance and we also hope
that the press can be further improved.

Recommendations

For the efficient operation and longer life of the HCBM manufacturing, the
assembly, maintenance and operation tips are recommended to be noticed well.
In addition to this the following points should be strictly adhered to:

 All the parts should be welded precisely by experienced welders.

 The HCBM should be checked for its property before use.

 When producing in mass, proper testing of the sample (prototype) is a

must.

 Open for other researcher

 Materials to be used are not suitable for the work, so it should fulfill all
the required materials and tools.