CHAPTER-1

1
 INTRODUCTION
Hydraulic press is a tool to produce compressive force by means of fluid. It
depends upon Pascal’s principle that the pressure throughout an enclosed entity is
constant. By means of hydraulic system larger forces can be produced in contrast with
mechanical and electrical systems. Such forces can be used for the press work
application such as blanking, punching, piercing, coining, trimming etc. Press work is
a method of mass production involving the cold working of metals, usually in the
form of thin sheet or strip. Press working is one of the extensively employed methods
of fabricating parts of intricate shapes with thin walls.

Press working processes make use of large forces by press tools for a short
time interval which results in cutting or shaping the sheet metal. Since, press working
does not involve heating of the parts, close tolerances and high surface finish can be
obtained on the part. Since presses can produce components at fairly fast rates, the
unit cost of labour for operating the press is fairly low. Press working forces are set
up, guided and controlled in a machine referred to as a Press. Thus an attempt has
been made to automized the process of press work using Hydraulic mechanism in
press machine. The inputs and outputs of the control system including hydraulic
mechanism are solely mechanical such as rotating shaft or reciprocating plunger.

The prime remuneration of implementing this system is the movement of the

mechanical devices can be operated by means of hydraulic components such as
actuators to initiate the movement which could be in the form of lever to apply
manually or by means of switches to operate automatically. Furthermore, direction
control valves have been implemented to control the directions of piston movements
and regulate the same. Thus the whole mechanism have been simplified with the use
of hydraulic equipments. Moreover, the use of pressure control valve and direction
control valves, makes it easier to regulate the forces and control the speed of the
setup. Show in below Figure 1.1:

2
 Fig:1.1 Hydraulic Press

Fig: 1.2 H-frame hydraulic

3
(1) Main Cylinder

(2) Blank Holding Cylinder

(3) Ejector Cylinder

(4) Top Platen/Top Cylinder

(5) Bottom Platen/Bottom Frame

(6) Moving Platen

(7) Column Pillars

(8) Nut & Check-Nuts

(9) Side Guides (for column)

(10) Press-Table

(11) Foundation Plate

(12) Power Pack Unit

(13) Control Panel

(14) Manifold Block

(15) Hydraulic Piping

Main Cylinder: -

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.

Blank Holding Cylinder:

Blank holding cylinders are used in those hydraulic presses in which raw
material which is to be pressed must be held firmly in position, at the time of pressing
operation by main cylinder. For example, in deep drawing press , blank is held by
block holding cylinder at the time of deep Drawing operation.

4
Ejector Cylinder: -

These hydraulic cylinders are usually mounted below the bottom platen, and
used to eject component which are already pressed by main cylinder, and requires
some force to get removed from die in which they get pressed. For example pressed
component stuck in die after cold forming ejected by ejector cylinder.

Top Platen: -

Top press, and withstand compressive and bending load developed by

hydraulic cylinder. platen is a steel fabricated or steel cast structure located upper side
of a vertical.

Bottom Platen: -

Bottom platen is a steel fabricated or steel cast structure located lower side of
a vertical hydraulic press, and withstand compressive and bending load developed by
hydraulic cylinder. It is also used as a press-table in down-stroke presses.

Moving Platen :-

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.

Column, Nut & Chuck-nut: -

Columns are round Bar or fabricated structure. It binds top and bottom platen
together firmly. Round bars are threaded at ends and nuts are provided to hold platen
in position, check- nuts are provided to avoid loosening of main nuts.

Guides: -

Guides are provided to ensure perfect parallel and vibration free movement of
moving platen. Guides may be Round, V-Type, or flat, depending upon use and type
of columns.

5
Press-Table: -

Press-Table is a thick steel plate either integral part of bottom platen or

separately bolted to it is perfectly machined and provided with T-slots or tapped holes
for mounting of dies and fixtures. Moving plate attached to ram travel forward and
exert force on jobs placed on this press-table to carry out the pressing operation.

Power Pack Units: -

This is most important part of machine. It pumps oil under control pressure
and flow into the cylinder to impart it desired speed and to develop desire force.
Power pack consists of hydraulic valves, pump, oil tank, cooler, hydraulic accessories,
manifold block and piping etc. Hydraulic pump may be driven by electric motor or
I.C. engine.

Control Panel: -

It controls overall operation and performance of hydraulic press, by

controlling power pack unit. It consists of motor starter, push-button, indicator lamp,
current and voltage indicator, contactor, timer etc. Control panel gets it feedback from
hydraulic press by means of limit switch, pressure switch, proximity-switch, thermo
couple etc.

Manifold Block and Hydraulic Piping: -

Every hydraulic valves and pumps has number of oil port [holes] such as
suction port, delivery port, tank line [return line] port, drain line port, pilot line port,
oil port [A] for forward motion of cylinder, oil port [B] for return motion of cylinder
etc. All these ports [oil holes] should be inter-connected with each other, as well as
with oil tank and hydraulic cylinder in correct manner and sequence for correct
operation and motion of press.

These inter-connection of various hydraulic component by means of special

seamless steel pipe and special end-connection fittings are called hydraulic piping. To
reduce extensive piping, leakage and maintenance, hydraulic valves are mounted on a
solid metal block, and their oil ports are inter connected by drilling holes in metal
block. This solid drilled metal block is called manifold block.

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Ram, Piston-rod: -

Piston-rod is a round bar, which is attached to piston, and moves in and out
from cylinder for pushing and pulling operation. For small diameter it is called, piston
- rod. When diameter of piston-rod is same as cylinder inside diameter, then piston-
rod is called as Ram. But in general all the piston-rod of higher diameter is called
piston rod dia.

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 CHAPTER-2

LITERATURE REVIEW
2.1 OVERVIEW

2.1.1 History Of Hydraulic Press

Hydraulic press is a device using 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 transfer fluid under high pressure to a cylinder having a larger piston area, thus
amplifying the force. There is easy transmissibility of large with practically unlimited
force amplification.

Using the optimum resources possible in designing the hydraulic press

components 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. Ert 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 actuator with sufficient accuracy.
Hydraulic press is a machine using a hydraulic fluid to generate a compressing force.

8
It uses the hydraulic equivalent of a mechanical level. The hydraulic press depends on
pascal‟s principle the pressure throughout a closed system is constant.

One part of the system is piston acting up as a pump with modest mechanical
force acting on small cross-sectional area; the other parts of a piston with a larger area
which generates a correspondingly large mechanical force. Only small diameter
tubing is needed if the pump is separated from the press cylinder. Hydraulic presses
are commonly used for forging, clinching, 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 presented.

Thermoplastics, composites, SMC Sheet Moulded Composites, RTM Resin

Transfer Moulding, GMT Glass Mat Transfer and carbon Fibre Moulding. All of
these applications require precise control and repeat-ability.

In many workshops (especially small and medium scaled workshops), repair

and replacement of press fitted machine elements are done in a crude manner. This
process wastes time and consumes a lot of energy, as well as cause harm to the
environment. Also the material to be replaced or the machine/plant on which the
repairs is being carried out on may get damaged in the process. The ability of a
technician to carry out his job safely, with less time and energy application depends
on the availability of the right working tools. To perform jobs such as Pushing,
pulling, thrusting and rotation, presses are required.

The major advantages of hydraulic presses over the other types of presses
(power screw and mechanical presses) include; hydraulic press provides a more
positive response to changes in input pressure, the force and pressure can accurately
be controlled, and the en-tire magnitude of force is available during the entire working
stroke of the ram travel (Butcher, 2004; Sullivan, 2000; Cockbain, 1998; Doring,
1998). Hydraulic presses are preferred when very large a nominal force is required,
hence the best option for mounting and dismounting force fits (Lange 1975). The
hydraulic press is therefore valuable equipment in the workshop and laboratory
especially for press fitting operations and for the deformation of materials such as in
metal forming processes and material testing for strength.

Hydraulic press used in industries are generally converted or built to crush or

to press any “process" or the “product". For example, this may include steel plates,

9
aluminium rolls, metallic ores, etc. In this article, we will discuss the general principle
of hydraulic presses followed by the details of the actual industrial hydraulic press.

A piston is inserted into the slave cylinder and pressure is applied. The
pressure applied causes the fluid to move through a pipe and into a larger cylinder.
The larger cylinder is known as the master cylinder. The pressure exerted on the
master cylinder and the piston in the master cylinder pushes the fluid back to the slave
cylinder. The force applied on the fluid by the slave cylinder results in a large force,
which is experienced by the master cylinder. An industrial hydraulic press comes
along with what is known as the press plates. With the help of these press plates, the
material to be worked on is either punched or crushed into sheets. Show in below
Figure 2.1:

Fig:2.1 Pascal’s law principle

When you push on the trigger (appeared in red), you apply a generally huge
power that moves the trigger a short separation. Since the water won't press into a
littler space, it gets constrained through the body of the gun to the limited spout and
squirts out with less power yet more speed. Presently assume we could make a water
gun work backward. On the off chance that we could shoot fluid into the spout at
rapid, the water would stream the contrary way and we produce an enormous upward
power on the trigger. In the event that we scaled our water gun up commonly, we
could produce a major enough power to lift things. This is actually how a water
powered smash or jack works. On the off chance that you squirt liquid through a tight
cylinder toward one side, you can make a plunger rise gradually, however with a ton
of power, at the opposite end.

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2.2 DESIGN CONCEPTS AND CONSIDERATIONS

The hydraulic machine was designed to operate manually by push and pull
force and was based on the concept and considerations:

1. The machine was designed with provisions for adjustments, such that hydraulic
pistons can fit.

2. The hydraulic fluid is pumped manually, thus ensuring that the machine does not
require electrical energy for its operation thereby incurring no operational cost.

3. The machine was made using locally sourced and available materials for easy
operations, or repair. Also, standard components/parts were used to ensure the low
cost of production and maintenance of the machine.

2.3 OPERATIONS PERFORMED ON PRESS

Apart from punching and blanking, several other useful operations are
performed with the help of presses:

Some of these are listed below:

(i) Bending

(ii) Deep drawing

(iii) Coining, and Embossing

(iv) Notching

These operations are described briefly

2.3.1 Bending:-

Bending means deforming a flat sheet along a straight line to form the
required angle. Various sections like angles, channels etc., are formed by bending,
which may then be used for fabrication of steel structures. Three common methods of
bending are illustrated Show in below Figure 2.2:

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 Fig:2.2 Bending operation

Fig: 2.3 Bending die (Rocker type die)

2.3.2 Deep Drawing:-

In deep drawing process, we start with a flat metal plate or sheet and convert it
into cup shape by pressing the sheet in the centre with a circular punch fitting into a
cup shaped die. In household kitchen, we use many vessels like deep saucepans,
which are made by deep drawing process. If the depth of cup is more than half its
diameter, the process is termed as deep drawing and with a lesser depth to diameter
ratio, it is called shallow drawing. Parts of various geometries and shape are made by
drawing process. Show in below Figure 2.3: The deep drawing Process is illustrated.

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 Fig:2.4 Deep drawing

Fig: 2.5 Deep drawing die

2.3.3 Coining And Embossing:-

Both coining and embossing operations are done ‘cold’ and mechanical
presses with punch and die are used for these operations. In embossing, impressions
are made on sheet metal in such a manner that the thickness of the sheet remains
uniform all over even after embossing has been done. It means that if one side of the
sheet is raised to form a design, there is a corresponding depression on the other side
of the sheet. Basically it is a pressing operation where not much force is needed. The
sheet is spread on the bottom die and the stroke of the punch is so adjusted that, when
it moves down to its lowest position, it leaves a uniform clearance between the
impressions carved in the punch and the die which is equal to the thickness of the
sheet being embossed.

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 The design is transferred on to the sheet by bending the sheet up or down
without altering its thickness any where. Many decoration pieces with religious motifs
are made in this way. Many decoration pieces with religious motifs are made in this
way. In coining process, a blank of metal which is softened by annealing process is
placed between two dies containing an impression. The blank is restricted on its
circumference in such a manner, that upon the two dies closing upon the blank, the
material cannot flow laterally i.e., sideways. The material is only free to flow upwards
(as a result of which it fills up the depressions in the upper die) and downwards(when
it fills up depressions in the bottom die).

The result of the coining operation is that the design engraved on the top and
bottom dies gets imprinted on the corresponding faces of the blank in relief (i.e.,
raised material) without the size of the blank-circumference changing. Coins used as
money in usage are manufactured in this manner. Show in below Figure 2.4:Here
forces required are much higher, enough to cause plastic-flow of material for
embossing and coining process.

Fig:2.6 Coining and embossing

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 Fig: 2.7 Coining &Embossing dies

2.3.4 Notching:-

A Notching operation that removes a section from the outer edge of the metal
strip or part. Show in below Figure 2.5:

Fig:2.8 Notching

Fig:2.9 Notching die

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 CHAPTER-3

EXPERIMENTAL WORK
3.1 HYDRAULIC PRESS

3.1.1 Definition:-

A machine in which great force with slow motion is communicated to a large

plunger by means of a liquid force into the cylinder in which it moves by a piston
pump of small diameter to power is applied.

Working Principle;

In hydraulic machine, the hydraulic oil from the reservoir is cleaned by filter
and sucked by the pump when driven by motor. The pump increases the pressure of
oil high pressure oil is then passed through the pressure relief valve to drain excess
press. Now oil is circulated to the direction control valve to the actuator. The pressure
of 120 to 125 bar is passed through a pipe connected to the solenoid valve with one
input.

The oil moves to piston and rod to give output required force. The actuator
connected to blade or high strength cutter which utilizes the forces to performing the
cutting work. The oil from relief valve and output of the actuator is transferred to the
reservoir through drain line and recirculate in hydraulic system. Show in below Figure
3.1:

The hydraulic system using the on-off type or logic control device to its
control objective is to maintain the stability of value to be transferred or simple
changes of direction, also called the order of valuation and control components.

Fig:3.1 Hydraulic system working circuit

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3.2 FOUR COLUMN HYDRAULIC PRESS

Fig:3.2 Four column hydraulic press

3.3 TERMS RELATED TO PHYSICAL PARAMETERS OF

HYDRAULIC PRESS

3.3.1 I.D. of the Cylinder :-

This is the inside diameter of cylinder. This dimension helps in calculating the
pressing capacity (tonnage) of press and approach and pressing speed of Ram (Piston
Rod ).

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3.3.2 Ram ( Piston Rod ) Diameter:-

This is out side diameter of Ram. This dimension helps in calculating strength
of cylinder. This dimension depends on tonnage of cylinder, stroke of cylinder, type
of operation to be performed i.e. pulling or pushing and return speed. For higher
tonnage, long stroke and high return speed Ram diameter is more. For pulling
operation Ram diameter is comparatively less. For example steel-rope and chain
testing machines.

3.3.3 Day-Light: -

This is the maximum distance between press-table and moving platen, when
Ram is at complete retracted position.

3.3.4 Shut Height: -

This is the minimum distance between press-table and moving platen when
Ram is at most extended position.

3.3.5 Stroke of Cylinder: -

Day light – shut height = stroke. Stroke is maximum distance to which Ram
can travel.

3.3.6 Table Size:-

Table size is clear area on press table, which could be used for pressing
operation.

3.3.7 Distance between column: -

This is the distance between two columns of the press. Left to right and front
to back. Distance between columns is kept more than table size as some clearance is
always kept to avoid any damage to column during production operation.

3.3.8 Throat Distance: -

This specification is only for C-Frame press, This is distance between central
axis of cylinder and rear most inside surface of C-Frame.

3.3.9 Table Height: -

This is distance between ground level and working surface of press-table.

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3.3.10 Overall Size of Press: -

This is the complete length, width and height of press including power pack
unit piping and panel. This figure indicates floor area and roof height required for
press.

3.3.11 Weight of Press: -

This is net weight of press including all accessories. This figure is useful for
transportation and making foundation.

3.3.12 Oil Tank Size: -

This is the maximum oil storage capacity of oil tank of power pack unit. It is
generally 5-10 times discharge capacity of hydraulic pump used.

3.3.13 Pressing Capacity: -

This is the maximum force, which could be developed in the hydraulic press,
for carrying out desired pressing operation. In single cylinder hydraulic press, it is
force developed by main hydraulic cylinder, while in multi cylinder hydraulic press, it
is the sum of force developed by all the cylinders, which are used for direct pressing
operation. Those cylinders, which do not involve in desired pressing, but carry out
secondary work such as material filling and ejection etc, are not considered in
calculating pressing capacity of press.

3.3.14 Working Pressure: -

This is the pressure at which pump supply oil to the hydraulic system in
normal working operation.

3.3.15 Maximum Pressure: -

This is the pressure at which system could be operated without over-loading

the system. Above this pressure hydraulic valves could mal-function and press
structure may deform. Hence for safety, hydraulic systems are designed for maximum
pressure and operated at working pressure, which is less than maximum pressure.

19
3.3.16 Speed of Ram: -

Generally Ram has three speeds. Fast approach speed, slow pressing speed &
fast return speed. To reduce operation cycle time hydraulic power packs are designed
in such a way that it could deliver high flow of oil at low pressure and comparatively
low and controlled flow of oil at higher pressure.

This enables Ram of hydraulic cylinder to travel at higher speed at no load

condition and slow down for carrying out pressing operation. High approach speed at
which Ram travels and come close to material to be pressed is called fast approach
speed. Comparatively slow and controlled speed at which Ram presses the material is
called pressing speed. High return speed at which ram retract is called fast return
speed.

3.3.17 Cycle Time: -

This is the time, which press takes to complete one production cycle. It
includes material loading time, fast approach time of ram, slow pressing time,
processing time, fast return time and time taken to unload the finish component.
Sometimes, hydraulic press has to be kept in compressed condition to some
predetermined time for heating, cooling or curing purpose. Time for which material
kept in compressed condition is called processing time. For example Bakelite is kept
compressed in hot condition for thermo setting. In plastic injection moulding dies are
kept close after injection of molten plastic for cooling purpose. Fiberglass panels are
just kept compressed without heating and cooling for curing.

Idle cycle time is sum of fast approach time, slow pressing time and fast return
time. (or time which press take to complete one idle cycle without doing any
productive operation) Cycle time gives judgment regarding production of press per
hour or per shift. While idle cycle time give idea regarding speed and performance of
press as compared to other press.

3.3.18 Modes of Operation: -

Auto - mode, Semi–auto-mode, and Manual-mode. These terms are used when
control panel is used in hydraulic press.

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[Link] Auto Mode: -

Auto mode [Automatic mode of operation] is that state or condition of

machine in which if only once “cycle start push button” is pressed then machine will
go automatically through all the sequence of operation, and after completing one
cycle it automatically starts the next cycle and keep on repeating it. Press will keep on
running and repeating production cycles till it is stopped manually or it get stop signal
from timer, counter, material feeding or collecting arrangement or machine protective
system against over heating, filter choking etc. Hydraulic presses for lamination
stamping, honing machine etc are operated in this mode.

[Link] Semi Auto Mode: -

Semi auto mode (semi automatic mode) is similar to the auto mode but press
stopped after completing one production cycle. For next cycle again “cycle start push
bottom” has to be pressed. Plastic injection moulding machine, Bakelite moulding
press, Rubber moulding presses are operated in this mode.

[Link] Manual Mode: -

In this mode, all the operations are carried out by pressing corresponding push
- button. As soon as push button released ram halts. This mode is also called inching
mode as Ram could be operated for a inch or fraction of inch of stroke as per the will
of operates. This mode is also used for setting of press before switching

3.4 TERMS RELATED TO FEATURES OF HYDRAULIC PRESS

3.4.1 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 pressure and flow condition, from both the oil port of cylinder. All the
general purpose and standard presses uses these types of cylinders. (For further detail
refer chapter of Hydraulic Cylinder)

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3.4.2 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 (For further
detail refer chapter of Hydraulic Cylinder.)

Fig:3.3 Four column down stroke hydraulic press Fig:3.4 Four column up stroke

With double action cylinder hydraulic press with single action

cylinder

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3.4.3 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 compared
to common presses. Regeneration circuits are commonly used in coining, marking,
Bakelite moulding press etc.

3.4.4 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.

3.4.5 Press with Pressure-compensation Feature :-

Some time press has to hold job under pressure for long time for curing. In
such cases motor stops after press develops the desired load. Internal leakage is
common in hydraulic system due to wear and tear of internal component of valves,
hydraulic seals etc. Due to such leakage pressure drops. But 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.

3.4.6 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 maximum, when press achieves maximum pressing
capacity. Solenoids operated direction control value 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.

23
 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.

3.4.7 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. Such deflections are undesirable in hydraulic press used for
precision operation.

Deflection due to clearance are much more as compared to deflection due to

stress. Such deflections are avoided by pre-stressing the columns of press. For pre-
stressing columns in round column press, additional casing is provided around
Column. The rods are stretched and bolts tightened, then stretching released. As nuts
are tightened in pulling condition of cylinder the stress and strain in pressbody was in
reverse direction and casing around column was under compression. Hence on
releasing pulling load, outer casing will remain under compression load, up to certain
extent and columns will remain intension. While doing initial stressing of column and
column casing, the platen and other parts of press deflect in press body, and as
columns are permanently stress in tension, hence the press part also remain under
some stress and will not deflect back corresponding to clearance Initial columns are
loaded to rated press tonnage. In operation, compression gets released corresponding
to load. Presses with such feature are called press with pre-stressed column,
Aluminium extrusion presses are generally designed in this way.

3.4.8 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.

1] Cushion Cylinder:- Some component requires support from bottom side at the
time of pressing operation.

24
 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 also. But if cylinder is
provided then resistance of cushion could be accurately controlled. Hence when
cushion is required in pressing operation, presses with hydraulic cushion cylinder are
better and productive.

2] 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.

3] 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. Both the features could be achieved by various means.

But if hydraulic cylinders are provided them parameter could be accurately

controlled. Hence when pressing operation require ejection and blank holding and
cost is not a deciding criteria in selecting a press, then presses with ejector and blank
holding cylinder are more productive.

4] 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. Auxiliary cylinder also
provided for miscellaneous operation such as Die sliding, material filling etc.

3.4.9 Vertical Press: -

In vertical press axis of main pressing cylinder and press is perpendicular to

the ground majority of press are vertical.

3.4.10 Horizontal Press: -

In this type of press axis of main pressing cylinder and press is parallel to the
ground. For example Aluminium/Brass extrusion press.

3.4.11 Up-Stroke Press: -

This is a type of vertical press in which main pressing cylinder is mounted in

bottom platen and it take up-ward power stroke.

25
3.4.12 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.

3.4.13 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.

3.4.14 Multi-Day Light Press: -

In this type of press number of addition plates are added between moving
platen and press-table to press number of jobs at a time. Plywood, rubber, moulding,
core - pressing etc are example of multi - daylight hydraulic press.

3.5 CLASSIFICATION OF HYDRAULIC PRESS

Basically all presses are same in their basic constitution. The four main major
components.

1 Hydraulic cylinder :-Hydraulic cylinder converts the pressure energy in hydraulic

fluid into useful pressing force.

2. Press body :- It withstands the force developed by the hydraulic cylinder.

3. Power pack unit :- This unit supplies pressurized hydraulic fluid in the cylinders
under controlled pressure and flow.

4. Control panel :- Control panel governs over-all operation and performance of a

press. press are designed and manufactured in different shapes and sizes to suit the
specific production, accuracy, strength requirements, and economic constraints.

Depending on their shapes, design and they could be divided into six broad
categories.

1. Round column press.

2. Fabricated column press.

3. Close-frame press.

4. C-Frame press.

5. Fabricated chamber press.

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3.5.1 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 other types of presses.

Show in below Figure 3.5: Round column presses could be further sub-divided into
three categories.

Fig:3.5 Round column press

[Link] column press.

2. Three columns press.

3. Four columns press.

3.5.1(a) Two Column Press: -

In case of two columns press, top and bottom platen are tighten together by
means of only two columns. Hydraulic presses, which are required to be very accurate
and pressing load always remain at the central axis of main cylinder, and also there is
no chance of taking any eccentric load, then two column types of presses are used.
For example, Lead and solder wire extrusion press. In this type of press materials is
always 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. Show in below
Figure 3.6: Hydraulic universal tensile testing machine is another example of this type
of press.

27
 Fig:3.6 Two Column press

3.5.1(b) Three Column Press :-

In three column presses, top and bottom platen are tighten together by means
of three round columns. Old Aluminium 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 design 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.

Fig:3.7 Three column press

3.5.1(c) Four Column Press:-

In four columns presses top and bottom platen are tighten together by means
of four column. These types presses are widely used in industry as a compared to
other type where accuracy is more critical between Dies. Show in below Figure
3.8:For examples, power compacting presses, plastic injection moulding machine etc.

28
 Fig:3.8 Four column press

3.5.1(d) Fabricated column press : -

In this type of presses top and bottom platens are permanently welded together
with the help of fabricated columns. Fabricated column presses are more sturdier,
economical and has less deflection under load as compared to round column presses

Fabricated column press also could be divided into two categories.

(1) Fabricated Four-column press.

(2) Fabricated Two-column press or H-Frame press

3.5.1.(d).1 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 automobile body, Show in below Figure 3.9: punching and blanking of large size
of M.S. Steel etc.

29
 Fig:3.9 Fabricated four column press

3.5.1.(d).2Fabricated 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 fabricated from steel plate.
Show in below Figure 3.11: Rubber moulding, variable-day-light presses used in
garages are example of H-Frame press.

Fig:3.10 H-frame press

30
3.5.2 C-Frame Press: -

In these types of presses, press-body is 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
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 presses. Show in below Figure
3.11:These types of presses are called as single press. Some example of C-Frame
presses are as follows.

Fig:3.11 C-frame press

3.5.3 Close-Frame Press: -

In case of close-frame press, overall structure of press is in a shape to square

to square ring. A schematic diagram of close-frame press. 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. Show in below Figure 3.12:

31
1) 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

2) Side columns of fabricated column presses are long compared to top & bottom
platen, and some times column extend down the Close Frame Press for Making Dish
ends bottom frame and form the standing-leg or foot of press while Close-Frame
presses rest on their bottom platen only.

3) Large size of Fabricated column presses are made in premises of press

manufacturer then supplied. These presses are accurate and requires machining of
fabricated platens and columns and 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 him self 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 many time press body does not require machining, hence
parallelism and flatness are not as per standards.

Fig:3.12 Close frame press

3.5.4 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 on container for material to be compressed.
Bailing presses and extrusion press are some of the example of these types of presses.
A schematic diagram of fabricated chamber press is as follow. Show in below Figure
3.13:

32
 Fig:3.13 Fabricated chamber press

3.6 MATERIAL SELECTION:-

To prepare any machine part, the type of material should be properly selected,
considering design, safety. The selection of material for engineering application is
given by the following factors:-

1) Availability of materials

2) Suitability of the material for the required components.

3) Cost of the materials.

The machine is basically made up of mild steel. The reasons for the selection
are Mild steel is readily available in market .It is economical to use and is available in
standard sizes. It has good mechanical properties i.e. it is easily machined.

It has moderate factor of safety, because factor of safety results in unnecessary

wastage of material and heavy selection. Low factor of safety results in unnecessary
risk of failure. It has high tensile strength. Low Coefficient of thermal expansion. The
materials of the sheets to be cut are taken as aluminium and plastic as they are
replacing many metals in the present scenario because of their distinguished
properties and features.

33
3.7 FORCE CALCULATION

Force required to cut the Sheet = L*t*Tmax

For sheet 10 mm thickness

Force required = 25×10×30= 7500N

This is the force required to cut the sheet metal, however the initial force required to
cut the sheet is more and it is 140-

150% than we calculated, Therefore, max force required to cut the sheet = 10500 –
11250

3.8 HYDRAULIC OIL SELECTION

High performance hydraulic oil with optimal anti-wear properties (AW-

Additives) and high load capacity of the lubrication film. Its excellent oxidation
resistance delivers good performance at higher temperatures and extended operating
intervals. Antioxidants and corrosion-inhibitors, high pressure absorption, good
ageing and temperature resistance, no foam absorbance, good Demulsification.
Neutral toward ferrous metals and almost all nonferrous metals, wristbands and
gasket-materials. Hydraulic systems containing gears and bearings where good anti-
wear properties are required, where wide ambient temperatures are encountered, even
under the influence of water. So hydraulic oil HLP 68 suitable for given properties.

Typical characteristics Value

Viscosity at 40°C 68 mm²/s
Viscosity at 100°C 8 mm²/s
Specific weight at 15°C 883 kg/m³
Flash point 250°C
Pour point -24°C

Table:3.1 HLP 68 Specifications

34
3.9 SELECTION OF HYDRAULIC PUMP

A hydraulic pump is a mechanical source of power that converts mechanical

power into hydraulic energy (hydrostatic energy i.e. flow, pressure). It generates flow
with enough power to overcome pressure induced by the load at the pump outlet.

When a hydraulic pump operates, it creates a vacuum at the pump inlet, which
forces liquid from the reservoir into the inlet line to the pump and by mechanical
action delivers this liquid to the pump outlet and forces it into the hydraulic system.

Factor to be considered for selection of hydraulic pump is following:-

1. Pressure

2. Discharge

3. Speed

4. Volumetric efficiency

Pressure Discharge Speed Volumetric

Types of pumps
(bar) (lit/min) (rpm) efficiency

Gear pump 35 to 200 400 1200 to2500 85 to 95%

Vane pump 70 to 140 200 1200 to 1800 90 to 95%
Piston pump 140 to 850 1000 1200 to 3000 95 to 98%

Table:3.2 Specification of pump

3.10 DESIGNING OF CYLINDER

The hydraulic cylinder is a device that converts the energy of fluid into
mechanical energy. The fluid is pumped into the cylinder by means of a pump and it
can be used to move a load. The size of the cylinder determines the amount of load
that can be handled by it Major parts of a hydraulic cylinder

1. Piston

2. Cylinder

35
 Fig:3.14 Designing of Cylinder

Since the max force required to cut the sheet = 11250 N

And pressure applied by gear pump =125 bar

Therefore,

Force applied by the cylinder,

F = (4) × d2 ×p

11250= (4) × d2 × (125/10)

F=1206N

For safety, we have taken the cylinder of diameter 40 mm.

Bore of the cylinder 80 mm

36
3.11 DESIGN APPROACH

[Link] Name of part Material used

1 Base Mild steel

2 Movable plate Mild steel

3 Spring Mild steel
4 Upper plate Mild steel
5 Jack Mild steel
6 Body Cast iron
7 Die Mild steel (Case hardened)

Table:3.3 Details of components

3.12 ADVANTAGES OF HYDRAULIC PRESS

1) Built in overload protection

2) It is safe compared to mechanical press

3) It is compact

4) Lower tool cost due built in over load protection

5) It is quite in operation

6) Greater versatility compared to mechanical presses

7) Lower initial and operating cost

8) It offers a full power stroke

3.13 DISADVANTAGES OF HYDRAULIC PRESS

1) Handling of hydraulic oil can be messy

2) Some oils can catch fire

3) There are chances of oil leakage

4) Lines could burst due to excess pressure

3.14 APPLICATIONS OF HYDRAULIC PRESS

37
1) Making Appliances: Hydraulic presses are commonly used for assembling
the parts of refrigerators, and as shaping panels of the microwave,
dishwashers, and laundry machines.
2) Manufacturing Electric Parts: Hydraulic presses are used to assemble the
housing and switches used in switching stations. Also, thermostats (a device
used in houses and offices to maintain the temperature to the desired set point)
are manufactured using this processes.
3) Making Ceramics: Traditional method of making ceramics using heat kilns
that operate at a temperature more than 1800 degree F can be replaced using
hydraulic presses that work at room temperatures. This approach requires low
pressure and less time for manufacturing ceramics like cement, bathroom tiles,
bricks, etc. Hydraulic presses will compress ceramics into the ceramics form.
4) Manufacturing Automobile parts: Hydraulic presses are used for
automotive folding and forming applications. Sealing components, vibrations
control, brake pads, insert moulding, floor mats and carpets, trucks bed liners,
electric connectors and insulators, fuel delivery parts, etc..are the vehicle parts
manufactured using hydraulic presses.

CHAPTER-4

38
 RESULT AND DISCUSSION
Hydraulic systems that do not have the necessary hydraulic fluids will not
function, which becomes a problem when a leak occurs. You must repair the leak so
the hydraulic fluids can continue to produce flow otherwise, the hydraulic system will
begin to slow down. Fortunately, areas that have leakage will also have hotter internal
temperatures, according to insider secrets to hydraulics. This phenomenon can prove
beneficial, since these temperatures can help us to locate the leak. Prevent leaks by
using proper plumbing procedures and the correct materials. Hydraulic presses can be
perform various operations by action of fluid pressure acting upon the workpiece to
cut the material.

CHAPTER-5

39
 CONCLUSION
The hydraulic press can be used for performing different tasks, by changing
the die, different operations like bending, blanking, deep drawing, notching etc. can
be performed on a hydraulic press. The design has main focus on reducing operator
fatigue and increasing 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 operations like machining, welding, finishing, cutting, etc. and cost
as economic factor. In present scenario, pressure driven presses are accessible in both
the classifications programmed and physically worked. If you are unable to find the
exact design and capabilities of a hydraulic machine to meet your needs, remember
that many presses are custom-built to meet the desired results of most applications. In
contrast to their mechanical partners, pressure driven presses can pack any material to
a full degree.

CHAPTER-6
40
 REFERENCES
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[3] Jarmai. K and Farkas.J.“Optimal design of hoist structure frame”. Department of

mechanical Engineering, University of Miskolc, Hingary. May 2003.

[4] Brian S. Elliott (2006), “Air-Over-Hydraulic Jacks”, Compressed Air Operations

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[5] [Link]

[6] [Link]

[7] [Link]

[8] Hydraulic Power System Analysis, A. Akers, M. Gassman, & R. Smith, Taylor &
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[9] Hunter, Louis C.; Bryant, Lynwood (1991). A History of Industrial Power in the
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[10] Fluid Power Design Handbook, Third Edition, page 112, By Frank Yeaple, CRC
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41