.

DESIGN AND FABRICATION OF

HYDRAULIC AUTO COMPONENTS

FORGING MACHINE
CONTENTS
 CONTENTS

Chapter No. TITLE

1. INTRODUCTION

2. SYNOPSIS

3. CONSTRUCTION

4. WORKING PRINCIPLE

5. DESCRIPTION OF HYDRAULIC JACK

6. HYDRAULIC CIRCUIT DIAGRAM

7. MECHANICAL SPARE PARTS DETAILS

8. ADVANTAGES

9. SAFETY,CARE AND MAINTENANCE

10. FINISHING AND PAINTING

11. COST ESTIMATION

12. CONCLUSION

13. BIBILOGRAPHY

14. PHOTO VIEW

 INTRODUCTION

INTRODUCTION

This is a self – assessment test on the part of the students to assess his

competency in creativity.
 During the course of study, the student is put on a sound theoretical foundation

of various mechanical engineering subjects and of course, to a satisfactory extent.

Opportunities are made available to him to work on different kinds of machines, so

that he is exposed to various kinds of manufacturing process.

As a students learn more and more his hold on production technology becomes

stronger. He attains a stage of perfection, when he himself is able to design and

fabricate a device.

This is the project work. That is the testimony for the strenuous training, which

the student had in the institute. This assures that he is no more a student, he is an

engineer.

This report discuses the necessity of the project and various aspects of

planning , design, selection of materials, fabrication, erection, estimation and testing.

 SYNOPSIS

SYNOPSIS

A hydraulic fluid power system is defined as a means of power

transmission in which relatively incompressible fluid is used as the power
transmitting media. The primary purpose of hydraulic system is the transfer of energy
from one location to another location and this energy into useful work.

In this project of the fabricated model of DESIGN AND FABRICATION OF

HYDRAULIC AUTO COMPONENTS FORGING MACHINE is used to bend
the sheet to a shape of U and V and it will describe the working principles as well as
hydraulic machines application and its advantages. Efforts have been taken to show
the path of hydraulic fluid as it is applied and released. The Hydraulic system pressure
can be generated in the form of any physical action which result a compression over
the Hydraulic system or pneumatic pressure which is developed in the form of air
compressing externally can be applied to activate Hydraulic system. There is a
constant relation between pressure density, and volume, According to Bernoulli’s
equation. Liquids can be heated by applying high pressure without any external heat
energy supplied to them. So the specific heat of any liquid system which is used in the
hydraulic machinery must be more than enough to with stand the pressure applied over
them also viscosity must be high enough for smooth conversion of external pressure
applied over them to hydraulic pressure.
 CONSTRUCTION

CONSTRUCTION

This unit consists of

a) M.S. Fabricated stand

b) U and V shape DIE sets

c) Hydraulic jack

A ) M.S .FABRICATED STAND ;

This stand is used to hold the hydraulic jack with pressing tool and tool guide base.

The work to be pressed is placed between the male and female die set which are

mounted above jack ..

HYDRAULIC JACK
A Hydraulic Jack is a device using Hydraulic Power in its simplest possible shape
shown in figure and consists of five fundamental components.

1. pump
2. reservoir
3. cylinder
4. suction valve and
5. delivery valve
HYDRAULIC JACK
c) die set for u shape bending ;
 WORKING PRINCPLE

WORKING PRINCPLE
This device is worked by the principle of hydraulic lifting system.. This is

operated by hydraulic power without use of man power. This unit consists of

a)M.S. Fabricated stand

b)Hydraulic jack with pressing tool

c) Handle
The M.S. stand is used to hold the hydraulic jack with pressing tool. The work to be

pressed is placed between the die set. The male die is mounted at top of the frame and

the female die is mounted below the male die. The female die moves up and down by

the action of hydraulic jack. When the handled is operated , the piston in the jack

moved upward along with the female die and press the work. Finally the male part of

the die coincide with the female die to make the U or V shape workpiece.
To lower the piston in the jack , the drain valve is unscrewed. The pressurized oil

under the piston returns to reservoir . hence the piston along with the female die

lowered to take the workpiece..

WORKING OF HYDRAULIC JACK;

A Hydraulic Jack or for that matter any device using Hydraulic Power in its
simplest possible shape consists of five fundamental components.

A. The Hydraulic Reservoir storing the Hydraulic Oil (Oil is used as the medium

to transmit force and motion-such fluids are called Hydraulic Oils) should be

thoroughly clean, whether integrally built-in or used as a separate tank.

Pump, either of the integral or the remote control type, comprises of highly precision

engineered pump plunger, cylinder, suction and delivery valves, safety valves with

conical or steel balls matched with micron tolerances. Very often O Rings and special

seals are used, made from specially treated leather or synthetic nitrile rubber or Teflon

or other modern substitutes for greater resistance to wear and sealing ower
 It is imperative that these must function at peak efficiency by regular cleaning

and flushing of foreign particles which enter into the hydraulic system and may

clog the delicate valves, damage the seals and affect the functioning of other

elements in the hydraulic circuit.

B. A pump by itself would be useless without a system of VALVES to govern the

flow of hydraulic oil to perform the desired function.

C. The transmission of hydraulic oil from the reservoir by the pump through the

valves to Ram & Cylinder which converts the hydraulic pressure into a

mechanical force is by means of a Hydraulic Circuit which is nothing but a

network of passages in hydraulic systems. These passages are formed with the

help of Steel Tubes, Flexible Hydraulic Hoses or through internal holes or

cavities in metal blocks. It is of the utmost importance that the circuit is always

leak proof as well as free from obstacles. Each joint or coupling must be
 securely tightened or replaced forthwith. No air lock or foreign particles should

be allowed to interrupt or block the free flow of hydraulic oil.

D. All hydraulic cylinders consists of two basic elements – the outer housing is

called the Cylinder body and the inner sliding elements is called the Ram (or

piston or plunger) which actually converts the hydraulic pressure into

mechanical force and transmits to the desired point for performing the function.

The movement of Ram is always in line with cylinder under pressure.

Hydraulic Oil is pumped into the cylinder and as more and more oil is forced

into the cylinder pressure builds up and when enough oil is forced into the

cylinder the resultant pressure will cause the ram, plunger or piston to move and

consequently lift, press, push, pull or bend any object any object as the case

may be.

The Ram and Cylinder are also precision engineered and mostly fitted with high

quality seals which give it the necessary compression holding capacity and

prevent leakages.

The five fundamental components already illustrated and described combined

together perform the specified job by a synchronous follow through of their

individual functions.
1. The release valve is closed tightly to ensure flow of oil from the pump to the

cylinder only.

2. As soon as the pump is operated oil is sucked in from the reservoir. As the

Pump Plunger is raised up oil passes from the reservoir into the pump cylinder

with the Suction Valve opening up to allow oil from reservoir to enter into pump

cylinder.

3. When the Pump Plunger is pressed down the Delivery Valve opens up to allow

the passage of oil from the pump into the cylinder, at the same time the suction

valve automatically closes to prevent oil returning to the reservoir.

4. By repeating the above two operations successively more and more oil is

pumped into the cylinder resulting in the generation of pressure by the action of

the load being lifted.

5. When the load is desired to be lowered the pressure within the cylinder is

released by operating the Release Valve. The oil flows back into the reservoir

shown in the diagram in page 1.

6. Due to neglect or other causes pressure within the system may continue to

increase beyond the predetermined safe working limit. To prevent damage to

the system a safety relief valve is located between the cylinder and the reservoir

excessive pressure by the opening up of the safety valve and discharge of oil

into the reservoir (very often the safety overload preventive relief valve is

located in between the reservoir and the pump – the pump automatically cuts off

without delivery of oil to the cylinder due to generation of excessive pressure

within the pump).

The simple diagram shown in page 1 shall help to understand the working of the

hydraulic system in a more graphic manner.

HYDRAULIC CIRCUIT DIAGRAM
MECHANICAL SPARE

PARTS DIAGRAM
 ADVANTAGES

ADVANTAGES
1. It eliminates complicated parts like hydraulic cylinder pipe connections
and pressure tubes.
2. Fluid Power transmitted through port so high efficient.
 3. Control of system is easier
4. Maintenance cost is less
5. Can be achieved up to two ton force.
In this Hydraulic system lubricating system not necessary so that wear and tear very
low.

1. Single person is enough to operate this efficiently to make the pipe clamp.

2. Easy and efficient handling of this unit without wastage or damage to any other

parts.

3. Increase the jack life.

4. Least maintenance of the equipment.

5. Need not require any individual work place.

6. Can be worked in the work spot.

7. Suited for making pipe clamp as well as bending.

 SAFETY, CARE AND
MAINTENANCE

BASIC SAFETY RULES FOR HYDRAULIC JACKS;

The nature of lifting operation should determine the choice of jacking equipment-

integral or remote control pump type jacks. Capacity and the hydraulic lifting stroke

are vital aspects to be carefully determined before selection.

Lifting any load calls for precise and safe jacking points. Jack should be centrally

loaded eccentric loading causes dangerous accidents and damages beyond repair.

The world over prudent safety minded operators observe the flowing basic safety rules

A. To overpower the load, whether one or a dozen cylinders are used to lift the load,

the cylinder lifting capacity should be two times the weight of the load. This

allows for a reduction in the oil pressure, prevents strain and possible break-down

of the cylinder.

B. To balance the load, for large, heavy and uneven loads, it is recommended dividing

the load evenly between a number of cylinders. These cylinders should be placed

beneath the load at points providing the best support, balance and stability. For

example, to lift a 200-tonns load, the necessary 400-tonnes capacity could be

handled by four 100-tonnes cylinders.

C. Never raise the hydraulic ram beyond the specified stroke (lift).

D. Never drop (shock) load on the hydraulic ram.

E. Never go under a load supported by hydraulic ram only.

F. Never extend the hydraulic ram by means other than the pump.

G. Never use hydraulic equipment with observed leakages.

H. Use safety lock nut type jacks for supporting load on jack for long periods.

I. Use steel plates or heavy wooden sleepers where ground surface is soft and

yielding

J. Do not disturb the factory preset internal safety valve provided for preventing

overloading.

K. Do not load more than 50% of the rated head capacity on the toe (claw) of toe

lifting jacks.

Positioning the Jack

Jack should be centrally loaded, jack base and upper jacking point must be in level.

Raising the Jack

Turn the release valve in clockwise direction till tight, use end of slotted operating

handles. Start pumping with a regular handle movement. Make only few fast and

rapid download delivery strokes, Jack handle slightly downward, in case the delivery

does not close instantly. Check that the saddles rests firmly against the Jacking point.

Lowering the Jack

Turn the release valve SLOWLY anticlockwise.

Jack Storage

Retract ram completely, close oil filler, keep the Jack away in a safe clean place.

Caution

Do not use the Jack beyond rated capacity and lift mentioned on the name plate.

Making Jack ready for use

VANJAX Hydraulic Jacks are supplied ready for use. Unlock the release valve half a

turn and operate the pump few times to flush the hydraulic unit free from airlocking.

DO’S AND DON’TS

Do’s Don’ts

Air venting is an important precaution Under no circumstances the equipment

for the successful performance of any should be used beyond rated capacity

hydraulic jack or hydraulically or rated stroke. It is in the interest of

operated device, equipment or system. the user and for the protection of his

costly equipment to ensure correct

selection of the capacity and restricting

the stroke within the rated stroke

length.

All couplings and other fasteners Do not forcibly hammer fit accessories

should be properly tightened. if falling short by a fraction of the

required length or spread. Use the next

higher size equipment. Abuse of

accessories and attachments are

hazardous both for the equipment and

the personnel.

At all times the entire equipments Do not expose the equipment to areas

should be kept free from dust through of excessive heat or where dirt, dust

regular systematic cleaning. and heavily laden fumes / smoke are

prevalent. If the equipment is used in

such areas it is absolutely essential to

service it at once.

Check oil level each time before use. Do not refill without a reliable strainer

Every time the hydraulic hose is Do not use brake fluid as refill.

attached to the pump and the ram

cylinder assembly unit, it should be

thoroughly flushed.

Release valve to be properly tightened Do not hammer to open guide nuts.

by turning it in clock-wise direction Open by guide nut spanner.

when applying load. For releasing

pressure open release valve gradually

by turning it in anti-clockwise

direction.

The equipment must be centrally Do not apply extra force to close the
loaded. The pressure screw in a release valve. Normal hand pressure is
hydraulic puller should be absolutely enough.
perpendicular to the axis of the load.
As refill we recommend IOC Code No. Do not use fluffy cloth or cotton waste
Servo System 32 and 46, HPC Hydrol for cleaning cylinder ram, valve, pump
0232 or any other equivalent. and oil tank.

VANJAX cannot be held responsible for damage or injury caused by unsafe use,
maintenance or application of its products.
Trouble Shooting Chart for VANJAX Hydraulic Jacks and Hydraulically
Operated Equipment.
Trouble Probable cause Remedy
Jack will not close Air under Cylinder Open the oil filler plug/air breathe or
immediately or Oil Tank open the release key and operate the
pump handle few time to breath out
the air the close the release valve.

Pump handle stroke Air in pump chamber Open release valve. Operate the
partly effective pump handle rapidly several times.
Close release valve.
Pump handle raise Sticky suction and Remove pump, clean valve unit and
without efforts delivery valve reset valve unit Open release valve
and operate the pump rapidly a few
times.
Jack will not rise to Lack of oil or Refill with fresh oil. Check for
full height leakage leakage.
Jack raises and falls Leaky suction & Tighten the pump and then operate. If
during each stroke delivery valve defect still persists the remove valve
body, clean properly replace the
defective parts, make a fresh seat and
assemble accordingly.

Jack will not raise a) Pump is not a) Tighten the pump properly.
up to specified lift properly
Or tightened
Jack will not hold b) Release key is not b) Close release key completely
the rated load. completely closed
c) Suction and c) Check inbuilt valve capsule ball
delivery valve are seating accordingly.
defective.
PAINTING AND FINISHING

FINISHING AND PAINTING

JOB PREPARATION
 Before welding, remove any bend in the L angle with the sludge hammer on the
anvil block. Then it is cut to the required length with the hacksaw blade and fabricated
to required dimensional shape with arc welding.
FINISHING OPERATION BEFORE PAINTING

After welding, any slag on the welded area is removed with the chipping
hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed with
the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the metal
primer, the second coating is applied with the paint.
COST ESTIMATION

COST ESTIMATION
1. Work holding support and pressing tool 1800,00

2. Hydraulic jack with motor 2800.00

3 . M.S. Fabricated housing unit 1600.00

4. DC power supply to the motor 900.00

5. Painting cost 200.00

6. Transport cost 200.00

TOTAL COST 7500.00

CONCLUSION

CONCLUSION
 We make this project entirely different from other projects. Since concepts

involved in our project is entirely different that a single unit is used to various

purposes, which is not developed by any of other team members.

By doing this project we gained the knowledge of fabrication work and how the

welding is doing and material selection for particular components etc.,

It is concluded that any fabrication work can be done with the help of welding.

We have successfully completed the project work on using welding work at our

Institute.

Once again we express our sincere thanks to our staff members.

 BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY -HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY -R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY -S.S.MANIAN

4. JIG AND FIXTURE DESIGN - R.K.JAIN

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PHOTO VIEW

PHOTO VIEW