A
MICRO PROJECT REPORT
ON
“Prepare report of construction and working of hydraulic press
used in nearby machine/ fabrication shop( field based)”
SUBMITTED BY
MR ONKAR BHUSHAN DANE
(DIPLOMA IN MECHANICAL ENGG)
DEPARTMENT OF MECHANICAL ENGINEERING
GAUTAM POLYTECHNIC INSTITUTE, GAUTAMNAGAR.
2024-25
KSKESS
GAUTAM POLYTECHNIC INSTITUTE, GAUTAMNAGAR
CERTIFICATE
This is to certify that MR. ONKAR BHUSHAN DANE (DIPLOMA IN
MECHANICAL ENGG) Has successfully completed MICRO PROJECT
REPORT On Prepare report of construction and working of
hydraulic press used in nearby machine/ fabrication shop( field
based)” During the academic year 2024-25. This is in partial fulfillment of the
requirement for IEQ at DIPLOMA IN MECHANICAL ENGG course as per
syllabus laid by M.S.B.T.E.
Prof.Raktate Mam Prof. Joshi.G.R Prof. BHARTI S.M
Gudies HOD Principal.
ACKNOWLEDGEMENT
I would like to express my special thanks of gratitude to my prof.
RAKTATE MAM , who gave me the golden opportunity to do this
wonderful project of Prepare report of construction and working of hydraulic
press used in nearby machine/ fabrication shop( field based)” Who also
helped me in completing my project. I came to know about so many new
things I am really thankful to them.
Secondly I would also like to thank .Prof. Joshi.G.R , Prof.Bharti .S.M
MR. ONKAR BHUSHAN DANE
(DIPLOMA IN MECHANICAL ENGG)
INDEX
1 Abstract 5
2 Introduction 6
3 Working principle 7
4 LITERATURE SURVEY 10
5 Problem Statement and Objective: Problem 11
Statement
6 Methodology 12
7 Applications 17
8 Advantages and Disadvantages 18
9 Conclusion 19
10 References 20
ABSTRACT
A hydraulic press is a machine using a hydraulic cylinder to generate a compressive
force. Frame and cylinder are the main components of the hydraulic press. In this
project press frame and cylinder are designed by design procedure. Using the optimum
resources possible in designing the hydraulic press components can effect reduction in
the cost by optimizing the weight of material utilized for building the structure. An
attempt has been made in this direction to reduce the volume of material. So in this
paper consideration for an industrial application consisting of mass minimization of
frame type hydraulic press.
INTRODUCTION
A hydraulic press is a device (see machine press) using a hydraulic cylinder to generate
a compressive force.It uses the hydraulic equivalent of a mechanical lever, and was also
known as a Bramah press after the inventor, Joseph Bramah, of England. He invented
and was issued a patent on this press in 1795.
A hydraulic press is a machine using a hydraulic cylinder to generate a compressive
force. Frame, hydraulic cylinder and press table are the main components of the
hydraulic press. Hence a hydraulic press is a machine that makes use of the pressure
exerted on the fluids to crush, straighten or mould. The concept of the hydraulic press
is based on Pascal's theory, which states that when pressure is applied on fluids in an
enclosed system, the pressure throughout the system always remains constant.
In hydraulic press, the force generation, transmission and amplification 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 and amplification. In
a simple application, a smaller piston transfers fluid under high pressure to a cylinder
having a larger piston area, thus amplifying the force. There is easy transmissibility of
large amount of energy with practically unlimited force amplification.
WORKING PRINCIPLE
A hydraulic press is a machine that uses pressurized liquid to create force. These
machines are composed of a simple cylinder and piston mechanism. The press consists
of a large cylinder, with a large piston, and a small cylinder and a small piston. The
large cylinder and the small cylinder are connected to one another by means of a pipe.
The two cylinders, and the pipe connecting them, are filled with a liquid. At this point,
the function of the hydraulic press depends on Pascal's Principle. Pascal's Principle
states that when pressure is added to a liquid at rest, there is an identical increase in
pressure at all points.
Applying this principle to the hydraulic press means that any force that is added to the
piston in the smaller cylinder will be transferred to the piston in the larger cylinder, in
a proportionally increased level of force. This allows a hydraulic press to produce a
great deal of force from the application of a small amount of force to the small piston.
The increase of the force produced by the larger piston is proportionally larger than the
force exerted on the small piston.
The amount of increase depends on the ratio of the sizes of the pistons. The ratio of the
areas of the two pistons is multiplied by the amount of force applied to the small piston
to determine the amount of force that the large piston can produce. For example, if the
ratio of the sizes of the two pistons is 10, and the amount of force applied to the small
piston is 50 N, the amount of force that the large piston will produce is 500 N.
The force applied on the fluids by the smaller cylinder results in a larger force when
pushed in the master cylinder. The hydraulic press is mostly used for industrial purposes
where a large pressure is required for compressing metals into thin sheets. An industrial
hydraulic press uses the material to be worked upon along with the help of the press
plates to crush or punch the material into a thin sheet.
The piston in this cylinder is pushed so that it compresses the fluid in it that flows
through a pipe into the larger cylinder. The larger cylinder is known as the master
cylinder. The pressure is exerted on the larger cylinder and the piston in the master
cylinder pushes the fluid back to the original cylinder.
The force applied on the fluids by the smaller cylinder results in a larger force when
pushed in the master cylinder. The hydraulic press is mostly used for industrial
purposes where a large pressure is required for compressing metals into thin sheets.
An industrial hydraulic press uses the material to be worked upon along with the help
of the press plates to crush or punch the material into a thin sheet.
Fig 1. Operations of Hydraulic press machine
Fig: 2. Manual Hydraulic Press Machine
LITERATURE SURVEY
Using the optimum resources possible in designing the hydraulic press
components can effect reduction in the cost by optimizing the weight of material utilized
for building the structure. An attempt has been made in this direction to reduce the
volume of material, cost of the press and to make is portable. Errol et al. presented a 2D
nonlinear magneto- mechanical analysis of an electromagnetic actuator based on finite
elements. The presented method enables the simulation of the complete switching cycle
off a switching, short stroke solenoid actuators with sufficient accuracy. This could be
achieved by considering nonlinear magnetic, eddy current induction and a
physical correct implementation of the contact mechanics, which are relevantforthe
complex dynamics of this valve types.
Today I’d like to discuss Hydraulic presses. Yes I know a broad subject so we are
going to take it down to the basics give you a layman’s description and give you a
little history. After searching the web and showing my findings to my techs the most
basic description of a Hydraulic press which is a machine tool and used in the
manufacturing industry was found on wiseGeek.com here it.
“A hydraulic press is a mechanical machine used for lifting or compressing large
items. The force is generated through the use of hydraulics to increase the power of a
standard mechanical level. This type of machine is typically found in a manufacturing
environment”.
A good description of “hydraulic systems” and Pascal’s Law which is what
hydraulics is based on can be found on NASA’s website I have copied it below.
Hydraulic systems use a incompressible fluid, such as oil or water, to transmit forces
from one location to another within the fluid.
Pascal’s law states that when there is an increase in pressure at any point in a confined
fluid, there is an equal increase at every other point in the container.
Brahma was a very resourceful individual and worked as a farmer, carpenter and
locksmith. But his love was inventing and improving on the designs of other
inventions.
Problem Statement and Objective: Problem Statement:
► Problem Statement Oil Leaks
One of the most reported problems is an oil leak; you will notice oil around the ram,
the hose end fittings and hydraulic lines. Make sure you are using the recommended
oil for your hydraulic press and that all fittings are tightened.
► Overheating
Overwhelming pressure and friction, and contaminated or degraded hydraulic fluid,
can cause your press to overheat. Hydraulic presses should never reach a higher
temperature than 150° F, as overheating can cause damage to sealing compounds.
Make sure you don’t overwork your press, and regularly replace the oil and clean the
filters.
► Slow Pressure Build-Up
Normally, hydraulic presses should reach required pressure levels in around one
second, any longer than this means that there is a problem with the pump; the fluid is
not being funneled to the ram quickly enough. This may be caused by leaks or dirt
caught in the fluid, so make sure you examine the pump, as well as surrounding
mechanisms like the relief valve and motor, to make sure everything is working
properly and clean.
► Abnormal Noise
If you hear banging or knocking coming from your hydraulic press, this may be a sign
of air in the fluid; you may also experience foaming and unusual actuator movement.
Loss of lubrication, overheating and damage to components are some of the problems
that stem from this. Check the fluid level and make sure it is correct, and check for
leaks at the pump shaft seal. Regular maintenance and inspections will prolong the
life of your hydraulic press, but will unfortunately not make it last forever. When you
notice more severe problems like cracked frames, electrical problems and insufficient
pump pressure, this is when it is time to say goodbye. Make sure you look after your
technology and get the most out of it.
Objectives:
According to the problem statement, our objectives are as follows.
► Design of special purpose hydraulic power press machine of capacity 5 Ton
according to customer requirement.
► Modeling of hydraulic press using suitable CAD software.
► Fabrication of hydraulic press.
Methodology
In achieving the aim of this work, component parts of the machine were designed
using various design equations. The design results were used to select materials for
various components. The detailed drawing of the developed hydraulic press machine
was done using SOLIDWORKS software. In fabricating the machine, mild steel was
used as the locally sourced material. The use of mild steel is due to the fact that its
strength, rigidity and mach inability falls within the design specifications. It is also
available and cost effective.
1. MATERIAL SELECTION:
Material selection plays a very important role in machine design. For example, the
cost of materials in any machine is a good determinant of the cost of the machi8ne.
More than the cost is the fact that materials are always a very decisive factor for a
good design. The choice of the particular material for the machine depends on the
particular purpose and the material for the machine depends on the particular purpose
and the mode of operation of the machinecomponents. Also, it depends on the
expected mode of failure of the components.
Engineering materials are mainly classified as: Metal and their alloys, such as iron,
steel, copper, aluminum etc. Non-metals such as glass, rubber, plastic etc. metals are
further classified as ferrous metals and non-ferrous metals.
Ferrous metals are those metals which have iron as their main constituent, such as
cast iron, wrought iron and steels. Non-ferrous metals are those which have a metal
other than iron as there main constituent, such as copper, aluminum, brass, tin, zinc
etc. Also, certain mechanical properties of metals have greatly influenced our
decisions. These properties include:
► Strength: It is the ability of a material to resist the externally applied force without
break down or yielding the internal resistance offered without break down or
yielding the internally applied force is called stress.
► Stiffness :It is the ability of a material to resist deformation under stress.
► Elasticity: It is the property of a material to regain its original shape after
deformation when the external force are removed.
► Plasticity: It is property of a material which retains the deformation produced under
load, permanently.
► Ductility: A very important property of the material enabling it to be drawn into
wire with the application of a tensile force. A ductile material is both strong and
plastic. Ductile materials
► Brittleness: It is the properties of a material opposite to ductility, it is the property
of breaking of a material with little permanent deformation when subjected to
tensile load, brittle materials snap off without giving any sensible elongation. Cast
iron is a brittle material.
Types of Steels:
Mild Steel: It contains 0.05 to 0.3 percent carbons it has for almost all purpose
replaced wrought iron, its greater strength giving it under viable advantages. Mild
steel can be rolled, wielded and down. It can even be cast, though not very
successfully. Among its application are plates for ship building, bicycle frame tubes,
mesh work, bolts, nuts, studs etc. solid and hollow constructional sections, sheet
metal parts and steel castings such as flywheels and locomotive wheel centers.
Stainless Steel: These are steel with high rust and corrosion resistance to meet
specific application requirements. They also have high strength and toughness. It is
an alloy of iron with about 11% chromium and other metals like nickel, molybdenum
etc. the properties of rust and corrosion resistance, toughness and strength, aesthetics
and how coefficient of friction were considered to meet all requirements and the
choice of stainless steel for the scissors members.
Fabrication of Hydraulic1P4ress Machine:
► L-Section and Square Pipe:
First step to make a hydraulic press is cutting of required metal cut everything to
its proper length and dimension such as L- square pipe etc. parts. So, we section
angle.
Fig: 3. L-Section and Square Pipe
► Drilling Operation:
Then next step is drilled a holes for proper assembly of all cutting to make a metal
parts frame of hydraulic press.
Fig: 4. Drilling of a Square Pipe
For cutting and drilling of parts you must ensures the safety protection. A pair of
work gloves is good insurance against a wire brush if it should slip, as well as cutting
down on the vibration being transmitted to your hands. With that in mind, eye and
hearing protection is a must. An angle grinder with a cut off blade makes a racket
which soon causes a ringing in the ear without proper protection, it also sprays a
shower of sparks which can bounce back off nearby objects, beware the hot spark
bouncing back off a wall over the top of your safety goggles, it’s not a fun experience
Fig: 5. Drilling of a L-Section
With that in mind, eye and hearing protection is a must. An angle grinder with a cut
off blade makes a racket which soon causes a ringing in the ear without proper
protection, it also sprays a shower of sparks which can bounce back off nearby
objects, beware the hot spark bouncing back off a wall over the top of your safety
goggles, it’s not a fun experience
Fig: 6. Parts of Hydraulic Press
► Assembly of all metal parts
Second step is assembly of all cutting metal parts. I assembled all the metal parts
without any kind of welding. I only used bolts and nuts for proper assembly of metal
parts to make a frame of the hydraulic press.
Fig: 7. Assemble of Metal Parts
► A 5 ton bottle jack and springs
We used 5 ton bottle jack to make this hydraulic press. Also I used 2 mechanical
springs to allow the hydraulic jack in its first position. Both the hydraulic jack and
springs are attached with the frame by using of bolts. Springs are attached by using of
J bolts.
Fig: 8. Hydraulic Bottle Jack and Springs
Assembled Parts of Hydraulic Press Machine
Fig: 9. Hydraulic Press Machine at Different Angles 3D Modeling
APPLICATIONS
Hydraulic presses are commonly used for forging, moulding, blanking, punching, deep
drawing, and metal forming operations. With the growth and importance of light-
weighting in the aerospace and automotive industry, more applications are present in
Thermoplastics, Composites, SMC Sheet Molded Composites, RTM Resin Transfer
Molding, GMT Glass Mat Transfer and Carbon Fiber Molding. All of these applications
require precise control and repeat-ability.
End users in many cases need to record data of every press stroke to assure parts meet
compliance issues. With I-PRESS Connected Enterprise, users can download and store
part to part information that includes, press position, tonnage, speeds, temperatures,
automation location, in-feed of material, part exit and more.
With the ongoing surge towards light-weight parts for aerospace, automotive
appliances and many other industries, Servo Hydraulic and Hydraulic presses have
become a key tool for the Thermoplastic Industries. Otherwise known as compression
molding presses, control of speed, pressures, position, heating and cooling mould
temperatures can be managed with the I-PRESS HYDRO controller for press and
automation functions
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 pressworking. 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.
Hydraulic Press Limitations
The fastest hydraulic press is slower than a mechanical press designed for high-speed
operation. For example, the high speeds together with short stroke and feed
progressions used for electrical terminal production favor the use of mechanical
presses.
CONCLUSION
It is a multi-purpose machine as it can be used for performing different tasks. By
changing the die different operation like bending, blanking etc. can be performed on a
hydraulic press machine. The design has main focus on reducing operator fatigue and
increase safety, improving the flexibility and makes operation more convenient, and to
achieve dimensional and positional accuracy. Components of press are designed to
avoid bending failure due to applied load. Mild steel is selected as material based on its
properties such as high bending & tensile strength, it compatibility with operation like
machining, welding, finishing, cutting etc. and cost as economic factor.
REFERENCES
1. Bhandari, V.B. (2009), “Design of Machine element”, Tata McGraw-Hill
Education.
2. Khurmi, R.S. and Gupta, J.K. (2005), “A Textbook of Machine Design”, Eurasia
Publication House (P.V.T.) Ltd. 14th Edition.
3. R.K. Bansal, Fluid Mechanics and Hydraulic Machines, Edn. 8, Laxmi Publications
P.Ltd., 22 Golden House, Daryaganj, New Delhi.
4. Bhandari, V.B. (2009), “Design of Machine element”,
5. Tata McGraw-Hill Education.
6. Khurmi, R.S. and Gupta, J.K. (2005), “A Textbook of Machine Design”, Eurasia
Publication House (P.V.T.) Ltd. 14th Edition.
7. R.K. Bansal, Fluid Mechanics and Hydraulic Machines, Edn. 8, Laxmi
Publications P.Ltd., 22 Golden House, Daryaganj, New Delhi.
8. A Text Book of Fluid Mechanics and Hydraulic Machines – By, R. K Rajput and
S. Chand & Co, Ram Nagar, New Delhi.
