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Design Optimization of 1000 Ton Press

This document discusses the design and structural analysis of a 1000 ton hydraulic press frame structure. It begins by describing the basic components of hydraulic presses, including the hydraulic cylinder, press body, power pack unit, and control panel. It then classifies hydraulic presses into different categories based on their shape and design, including round column presses, fabricated column presses, close-frame presses, C-frame presses, and non-conventional presses. The rest of the document focuses on analyzing and optimizing the design of an H-frame type hydraulic press to improve its performance, quality, and withstand the significant forces generated during operation.

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1K views4 pages

Design Optimization of 1000 Ton Press

This document discusses the design and structural analysis of a 1000 ton hydraulic press frame structure. It begins by describing the basic components of hydraulic presses, including the hydraulic cylinder, press body, power pack unit, and control panel. It then classifies hydraulic presses into different categories based on their shape and design, including round column presses, fabricated column presses, close-frame presses, C-frame presses, and non-conventional presses. The rest of the document focuses on analyzing and optimizing the design of an H-frame type hydraulic press to improve its performance, quality, and withstand the significant forces generated during operation.

Uploaded by

bennyferguson
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
  • Introduction
  • Types of Press
  • Design Modeling of Hydraulic Press
  • Results of Finite Element Analysis and Optimization
  • Conclusion

International Journal of Research in Engineering, Science and Management 649

Volume-1, Issue-10, October-2018


[Link] | ISSN (Online): 2581-5792

Design and Structural Analysis of a 1000 Ton


Hydraulic Press Frame Structure
S. Raja Shekar1, A. C. Uma Maheshwar Rao2
1
Student, Department of Mechanical Engineering, SIET, Hyderabad, India
2
Assistant Professor, Department of Mechanical Engineering, SIET, Hyderabad, India

Abstract—Using the optimum resources possible in designing II. HYDRAULIC PRESS COMPONENTS
the hydraulic presses frame can effect reduction in the cost of the
hydraulic presses. By optimizing the weight of material utilized for Basically all presses are same in their basic constitution.
building the structure. An attempt has made has been made in this They have four main major components.
direction to reduce the volume of material. In this project 1. Hydraulic cylinder: Hydraulic cylinder converts the
structural analysis followed by mass minimization of H-frame type pressure energy in hydraulic fluid into useful pressing
hydraulic press based on topology optimization method. This press force.
has to compensate the force acting on the working plates and has 2. Press body: It withstands the force developed by the
to fulfil certain critical constraints. The frame structure has to
withstand the forces generated while in operation and it is essential hydraulic cylinder.
to calculate mechanical properties like total deformation and 3. Power pack unit: This unit supplies pressurized
developed on the machinery. Hence, here work has been being hydraulic fluid in the cylinders under controlled
carried out on 1000 ton press machine. pressure and flow.
With regarding to design specification, stress distribution, and 4. Control panel: Control panel governs over-all
cost, are focused are focused on optimized design. The operation and performance of a press. Presses are
methodology followed in work is comparison induced in machine
designed and manufactured in different shapes and
for different thickness used for construction of frame and column
of the H-frame type hydraulic press. sizes to suit the specific production, accuracy, strength
requirement, and economic constraints.
Index Terms—Hydraulic press, Quality, Optimization, plates,
A. Classification of Hydraulic Presses
design specification
Depending on their shapes, design and they could be divided
I. INTRODUCTION into six broad categories.
Round column press, fabricated column press, Close-frame
Metal forming is a process which is done by deforming metal
press, C-Frame press, fabricated chamber press, Non-
work pieces to the desired shape and size using pressing or
Conventional press.
hammering action. Hydraulic presses are being used for
forming and pressing operations with wide range of capacities.
1) Round Column Press
Hydraulic press machine works under continuous impact load.
Main features of these types of presses are their round
Because of this continuous load, tensile and compressive
columns. In these types of presses top and bottom platen are
stresses are experienced in various parts of machine. These
fabricated and machined individually and then held together by
stresses cause permanent deformation in some parts of machine.
means of round columns and nuts. As all the components could
This work is based on optimization of a 1000-ton four frame
be machined individually and accurately hence these types of
plate type hydraulic press considering constraints like design,
presses are most accurate types of presses, as compared to all
weight and cost. The work is focused on design and
other types of presses. (Columns are also referred as pillars).
optimization of top plate of the press machine. Top plate holds
Round column presses could be further sub-divided into
the hydraulic cylinder and is one of the most critical parts of the
three categories.
machine. The design is based on sizing optimization method
Two columns press, three columns press and four columns
and the results are validated by Finite Element method with
press
proper boundary conditions.
a) Two Column Press
A hydraulic press is a machine using a hydraulic cylinder to
In case of two columns press, top and bottom platens are
generate a compressive force. Frames and column and cylinder
tighten together by means of only two round columns.
are the main components of the hydraulic press. In this project
Hydraulic presses, which are required to be very accurate and
H type hydraulic press frame and column are designed by the
pressing load always remain at the central axis of main cylinder,
design procedure. Press frame is analysed to improve its
and also there is no chance of taking any eccentric load, then
performance and quality for press working operation.
International Journal of Research in Engineering, Science and Management 650
Volume-1, Issue-10, October-2018
[Link] | ISSN (Online): 2581-5792

two column types of presses are used. Frame press. In low capacity presses rolled M.S. channel or I-
b) Three Column Press section are used as side column and in case of medium capacity
In three column presses, top and bottom plates are tightened press it is fabricated from steel plate. Rubber mounding,
together by means of three round columns. Old aluminum and variable-day-light presses used in garages are example of H
copper extrusion presses of higher capacity were designed in Frame press.
this way. These presses were horizontal, high speed and made
for mass production. Three -column design is stronger than 3) C-Frame Press
two-column design. Advantage of this type of design in case of In these types of presses, press-body is of C-Shaped. When
extrusion press is that ample space is available for shearing the free space required from three sides of press table to work for
rejected billet and loading red hot billets in container by means loading and unloading of pressed component then this type of
of overhead crane. presses are designed.
These types of presses are most fragile, susceptible to
c) Four Column Press deflection and cracking from inside corners, if not designed and
In four columns presses top and bottom platen are tighten used correctly as compared to other type of press. As main
together by means of four round column. These types of presses cylinder placed eccentric to central axis of press-body, it applies
are widely used in industry as compared to other type where eccentric load on press-body hence heavier press body is
accuracy is more critical between Dies. For example, power required as compared to same capacity of other type of press.
compacting presses, plastic injection molding machine etc. These types of presses are also called as single press. Some
example of C-Frame presses are as follows.
B. Fabricated Column Press
In this type of presses top and bottom platens are 4) Close-Frame Press
permanently welded together with the help of fabricated In case of close-frame press, overall structure of press is in a
columns. Fabricated column presses are sturdier, economical shape to square ring. In case of small size of presses, they are
and has less deflection under load as compare to round column made by cutting window in steel plates and assembling together
presses. Fabricated column press also could be divided into two two or more such plates to make a press-body. In this type
categories, Fabricated Four-column press & Fabricated Two- minimum welding is required as top, bottom and side columns
column press or H-Frame press 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’s top, bottom platens and side
columns are fabricated separately then welded together.
Difference between fabricated column press and close-frame
presses are as follow.

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 chamber
act as load bearing member of press. Some time they also act
Fig. 1. Various types of hydraulic press frames, (a) Two Column Press, (b) on container for material to be compressed. Bailing presses and
Three Column Press (c) Four Column Press (d) Fabricated Four Column Press
extrusion press are some of the example of these types of
(e) Fabricated Two Column Press or H-Frame Press (f) C-Frame Press (g)
Close-Frame Press (h) Fabricated Chamber Press presses.
C. Finite Element Analysis of Hydraulic Press Frame
1) Fabricated Four Column Press
Structure
High capacity hydraulic presses with large size table are
manufactured on the design of fabricated four-column press. As The main objective of a finite element analysis is to calculate
it is sturdier and gives ample space to work and inspect pressing effects of loading conditions on frame structure. Usually it is
operation from all sides, as compared to, two-column press. For used to determine the displacement, stresses, strains and force
example, deep drawing press for automobile body, punching reactions in structures or components when subjected to loads
and blanking of large size of M.S. Steel etc. that do not induce damping and inertia effects. Assumptions are
considered for loading and response conditions i.e., the loads
2) Fabricated Two Column Press or H-Frame Press and structures response are assumed to static independent of
Medium and low capacity and economical presses are time.
manufactured on the design of fabricated two-column or H
International Journal of Research in Engineering, Science and Management 651
Volume-1, Issue-10, October-2018
[Link] | ISSN (Online): 2581-5792

III. COMPUTER AIDED DESIGN MODELLING OF HYDRAULIC surfaces by using mid surface option.
PRESS FRAME Mid surface parts are discretised with 2D elements (Shell
Geometry cleaning and simplification has been done on elements) of sizing 25 mm.
Hydraulic Press Assembly. Finite element models to perform Appropriate thickness is assigned to each and every
static structural analysis for frame. Appropriate element sizes, component of the assembly.
refinement and quality parameters have been maintained to Recommended mesh quality is maintained for quality
ensure accurate results. Proper mesh connections have been analysis results.
maintained. All components are connected through beam
TABLE I
elements and all electronic components are fixed through MATERIALS OF CONSTRUCTION
bonded contacts. All components in press are modelled with S. No. Mild Steel Parameters Value Units
shell elements with appropriate thicknesses and orientations. 1 Density 7801 Kg/m3
2 Young’s modulus 200 GPa
3 Poisson’s ratio 0.3 -
4 Yield stress 410 MPa
5 Ultimate Tensile Strength 650 MPa

B. Loads and Boundary Conditions


a) A load of 1000 ton applied vertically upwards on the
upper ring plate.
b) Reaction load of 1000 tons applied vertically
downwards on the lower ring plate.
c) Standard earth gravity of 9810.66 mm/sec2 applied
vertically downwards.
d) Bottom base of the frames structure is fixed in all
degrees of frame.
C. Results of Hydraulic press Assembly before Optimization

Fig. 2. Geometry model of hydraulic press

Hydraulic press structure Components


1. Frame Structure
2. Top plate
3. Bottom plate
4. Fabricated Box
5. Hydraulic cylinders
A. Finite Element Mesh Fig. 4. Equivalent (Von-Mises) stress

Fig. 3. Element model with 2D shell elements

Geometry of the hydraulic press frame is converted into step


format and imported into ansys workbench. Meshing of
hydraulic press assembly are carried out in ANSYS Workbench Fig. 5. Total deformation
software and below are the discretization parameters followed.
Geometry cleaning and simplification of assembly has been Maximum equivalent stress was found at corner of the frame
done in design modeler. structure and its magnitude is 349.06 MPa & Maximum
Frame structure, top plate and bottom plate are converted into deflection on top plate was found to be 1.78mm.
International Journal of Research in Engineering, Science and Management 652
Volume-1, Issue-10, October-2018
[Link] | ISSN (Online): 2581-5792

D. Results of Hydraulic Press assembly after Optimization obtained for various design configurations are tabulated and
reported which gives a detailed understanding of the effect of
design changes on deflection and stress concentrations of the
structure. Equivalent Von Mises-Stress and deflections
obtained for the final design are well within the material yield
limits.

REFERENCES
[1] Muni Prabaharan and Amarnath V.(2011)-“Structural Optimization of
5Ton Hydraulic Press and Scrap Baling Press for Cost Reduction by
Fig. 6. Equivalent (Von-Mises) stress Topology” International Journal of Modelling and Optimization, Vol. 1,
No. 3, August 2011.
[2] [Link], [Link], [Link], P. Kalimuthu (2014)-“Design and
Analysis of C Type Hydraulic Press Structure and Cylinder”. Vol.2
Issue.3, March 2014. pp. 47-56 International Journal of Research in
Aeronautical and Mechanical Engineering.
[3] Satish.G.S, [Link], Nitin.B, Chetan. M (2014)-“Structural
Optimization of Hooping Plate Of 400 ton Cotton Baling Press for Cost
Reduction”. International Journal of Pure and Applied Research in
Engineering and Technology, 2014; Volume 2 (9): 379-389.
[4] Rajdipsinh. G, Vaghela, Ravi.C,Patel, (2014)- “A Review on Design &
Analysis of C-Frame of Pneumatic Power Press Using FEA”. IJSRD -
International Journal for Scientific Research & Development, Vol. 1,
Issue 11, 2014.
[5] [Link], [Link] (2013) – “Design & Analysis of Frame of
Fig. 7. Total deformation 63 Ton Power Press Machine by Using Finite Element Method” Volume:
3, Issue: 7, July 2013, Indian Journal of Applied Research.
[6] Sumaila, M. 2002. Design and manufacture of a thirty-tonne hydraulic
Maximum equivalent stress was found at corner of the frame press. M. Eng. Project Report, Production Engineering Department,
structure and its magnitude is 162.08 MPa and Maximum University of Benin, Benin City, Nigeria.
deflection on top plate was found to be 1.19 mm. [7] Bapat.S.M, Desai.Y.M., “Design Optimization of A 30 Ton Hydraulic
Press Machine”, International Journal for Research in Applied Science
and Engineering Technology ( IJRASET ) , Belgaum . India 2009, p. 24-
IV. CONCLUSION 30.
[8] Malipatil.S.S, Mattlikalli.A.C. “Analysis and Structural Optimization of
Thousand ton hydraulic press frame structure has been 5 Ton H-Frame Hydraulic Press’’, International Journal of Innovative
designed, analyses and optimized. Fundamental design Science Engineering and Technology, [Link], ol 1, March 2014.
calculations for the Frame structure have been performed and [9] Saleh.M.M, “Design study of a heavy duty hydraulic machine using finite
element techniques”, Doctoral Thesis, Dublin City University, 1992.
detailed stress analysis has been performed on the structure. [10] Muni Prabaharan and [Link] “Structural Optimization of 5Ton
Topology optimization for the frame has been performed to Hydraulic Press and Scrap Baling Press for Cost Reduction by Topology”,
optimize the plate thickness used in fabrication of the frame. International Journal of Modeling and Optimization, vol. 1, pp 185-190,
2011.
Substantial weight reduction has been achieved by performing [11] H. N. Chauhan And M. P. Bambhania (2013) “Design & Analysis Of
topology optimization based on stress and deflection. Frame Of 63 Ton Power Press Machine By Using Finite Element
Maximum equivalent von-mises stresses and deflections Method”,Indian Journal Of Applied Research, vol. 3, pp. 285-288.

Common questions

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During the structural analysis of a hydraulic press frame, different loading and boundary conditions are applied to simulate operational environments. For instance, a load of 1000 tons is applied vertically upward to the upper ring plate, while a corresponding reaction load of 1000 tons is applied downward on the lower ring plate. Standard earth gravity is also considered, applied downward across the structure. Additionally, the base of the frame is fixed in all degrees of freedom. These conditions help analyze the stress distribution and deformation across the frame under realistic operational scenarios, guiding design improvements and ensuring the press can withstand expected forces without failure .

A C-Frame press is designed with a C-shaped body, providing accessibility from three sides, which is advantageous for tasks involving frequent loading/unloading of components. However, it is more susceptible to deflection and internal corner cracking due to its design, requiring robust construction to reduce weaknesses. Conversely, a Close-Frame press, often appearing as a square ring, requires minimal welding because its top, bottom, and side columns are assembled internally. It offers superior stiffness and less susceptibility to deflection, making it suitable for heavy and precise operations. While a C-Frame press is ideal for tasks requiring accessibility and rapid operations, Close-Frame presses are preferred for high precision and heavy-duty tasks with less deflection and higher stability .

Topology optimization affects von-Mises stress and total deformation by focusing on optimal material distribution within the hydraulic press design. After optimization, maximum von-Mises stress and total deformation are reduced, as seen in the optimization process where maximum stress decreased from 349.06 MPa to 162.08 MPa, and maximum deformation from 1.78 mm to 1.19 mm. This reduction implies that the press design can use thinner materials without exceeding material yield limits, guiding more efficient material selection that reduces costs while ensuring structural integrity .

The primary objectives of conducting a finite element analysis (FEA) on a hydraulic press structure are to calculate the effects of various loading conditions and understand the displacement, stresses, and strains within the structure. FEA helps identify stress concentrations and potential deformation areas, allowing for design optimizations that can improve performance and reduce material waste. The benefits include enhanced safety and reliability, cost reductions through material optimization, and improved efficiency and durability of the hydraulic press .

Topology optimization significantly impacts the mechanical properties and overall efficiency of a hydraulic press by strategically reducing weight while maintaining structural integrity. It helps identify unnecessary material areas, which can be removed without compromising strength or the device's ability to handle operational stresses. This leads to a lighter, more efficient, and cost-effective design, optimizing mechanical properties such as stress distribution and minimizing deformation. The result is an enhanced press with improved performance metrics and reduced material costs .

Optimization of a hydraulic press frame contributes to cost reduction by minimizing the weight of materials used in the design. This is achieved through structural analysis and mass minimization techniques, such as topology optimization. By ensuring that the frame structure is designed to only use the necessary amount of material to withstand operational forces, the cost associated with material usage can be significantly decreased. This approach not only reduces material costs but also the overall manufacturing cost .

Improper design of a C-Frame press can lead to significant consequences, including increased susceptibility to deflection, internal corner cracking, and structural failure under eccentric loading due to its open design. These issues can result in reduced accuracy and safety hazards during operation. To mitigate these risks, robust design practices such as using thicker materials, reinforcing high-stress areas, and ensuring symmetrical load distribution should be implemented. Additionally, using comprehensive finite element analysis during the design phase can help predict and address potential problems, enhancing the overall strength and durability of the press .

Round column presses are characterized by their round columns connecting the top and bottom platens, allowing individual machining for high accuracy. These presses are generally more accurate but exhibit greater deflection under load compared to fabricated column presses. Fabricated column presses, meanwhile, are sturdier and more economical, with their columns often being welded, resulting in less deflection. They offer broader applications and support in heavier and more extensive operations, being particularly useful where space and structural integrity are essential .

The control panel governs the overall operation of a hydraulic press. It is responsible for controlling the sequence of operations, adjusting pressure and flow, and ensuring safe and efficient machine performance. By managing these operational parameters, the control panel allows precise control over the pressing process, thus impacting the press's accuracy, efficiency, and safety. Properly regulated operations result in consistent product quality and reduced operational mishaps, contributing to optimal performance .

In the finite element analysis (FEA) of a hydraulic press frame structure, factors such as stress distribution, displacement, and force reactions are considered. The analysis typically assumes static loading conditions without damping and inertia effects. The finite element models help in calculating how the frame structure will respond under various loads, determining stress concentrations, and potential deformation areas. These results impact the design by guiding decisions to optimize material distribution, adjust thicknesses, and reinforce stressed areas to improve stability and performance while minimizing the use of resources .

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