CHAPTER - I

1.1 INTRODUCTION ABOUT SAIL:

Steel Authority of India Limited (SAIL), is one of the largest corporat
e entities in the world with a turnover of Rs. 16000 crore. Its five integrated
steel plants at Bhilai, Durgapur, Rourkela, Bokaro, and Burnpur have a total pro
duction Capacity of 12.5 million tons of crude steel. The three plants in Salem,
Durgapur and Bhadravathi are engaged in the production of special and alloy ste
el and the Plant in Chandpur, at Maharashtra in bulk producer of Ferro alloy. It
s raw Material division is located at Calcutta. Sail Consultancy division (SCD)
provides Consultancy service granted over 3 decades of steel making to the clien
ts worldwide.
ABOUT SALEM STEEL PLANT:
The cherished dream of Tamil Nadu came true on September 16, 1970 when t
he Prime Minister Mrs. Indira Gandhi inaugurated Salem steel plant.
Salem steel plant was commissioned in 1981 involves in the manufacture of cold r
olled stainless steel coils and sheets in various grades, finishes and sizes of
international standards.
In 1991, the capacity of the plant was doubled to 70,000 tons per year by the ad
dition of sendzimer cold rolling mill and related facilities. At present Salem s
teel is producing stainless steel in many as 18 grades in authentic, mattenstic,
a ferrite types.The thickness produced ranges from 0.3 mm to 6mm and in a width
from 50 mm to 1250 mm. The finished supply include no1, 2d, 2B, no 8(mirror) an
d self designed like stripe, zebra, moon rock, chequared, etc.
The plant been certified with ISO 9002: QAS April 1993 and recertification if
ISO 9001:2000 QMS took place on august 2002.
The plant has also been awarded ISO 14001: EMS on May 1999 for its environmental
standards. With a view to catalyze the stainless steel is being propagated in v
alue engineering new area like domestic appliances furniture’s sinks, bus bodies
, elevators, coinage, railway coaches etc.,
Integral to the expansion program was commissioning of the first line in the cou
ntry by the end of 1993, Which has an installed capacity of 3000 tones of coil b
lanks or 3600 tones of utility blanks per annum.
MAJOR UNITS of SSP
• Hot rolling mill
• Cold rolling mill
• Blanking line
CHAPTER – 2
LITERATURE SURVEY OF HYDRAULICS SYSTEM
In the development of the submarine from the pre-war classes, many chang
es and improvement have occurred. One of the outstanding differences is the larg
e variety of submarine devices, which are now operated by hydraulic power. In ea
rly classes, there was no hydraulic system, and power requirement were met by me
ans of air or electricity. Along with consultancy improving submarine design has
gone a constant extension and diversification of the use of hydraulic power.
2.1 COMPARATIVE ADVANTAGES OF HYDRAULIC POWER
Hydraulic system possesses numerous advantages over other system of powe
r operation. They are light in weight; they are simple and extremely reliable, r
equiring a minimum of attention and maintenance. Hydraulic controls are sensitiv
e, and afford precise controllability. Because of the low inertia of moving part
s, they start and stop in complete obedience to the desire of the operator, and
their operation is positive. Hydraulic system are self lubricated, there is very
little wear or corrosion. The operation is not apt to be interrupted by salt sp
ray of water. Finally hydraulic units are relatively quite in operation.
Therefore, in spite of the presence of two power source just described,
hydraulic power makes its appearance on submarine because of the fact that its o
perational advantages, when weight against the disadvantage enumerates for elect
ricity and air in the preceding paragraph, fully justify the additional of third
source of power to those available in the modern submarine.
Pascal s Law
Also called Pascal s Principle
Pascal s law — developed by French mathematician Blaise Pascal — states that whe
n there is an increase in pressure at any point in a confined fluid, there is an
equal increase at every other point in the container.

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

essive force. It is the hydraulic equivalent of a mechanical lever, and is also
known as a Bramah press after the inventor, Joseph Bramah, of England. He invent
ed and was issued a patent on this press in 1795. As Bramah (who is also known f
or his development of the flush toilet) installed toilets, he studied the existi
ng literature on the motion of fluids and put this knowledge into the developmen
t of the press.[1] Hydraulic presses are the most commonly-used and efficient fo
rm of modern press.
Principle
The hydraulic press depends on Pascal s principle: the pressure throughout a clo
sed system is constant. At one end of the system is a piston with a small cross-
sectional area driven by a lever to increase the force. Small-diameter tubing le
ads to the other end of the system.
Pascal s law: Pressure on a confined fluid is transmitted undiminished and acts
with equal force on equal areas and at 90 degrees to the container wall.
A fluid, such as oil, is displaced when either piston is pushed inward. The smal
l piston, for a given distance of movement, displaces a smaller amount of volume
than the large piston, which is proportional to the ratio of areas of the heads
of the pistons. Therefore, the small piston must be moved a large distance to g
et the large piston to move significantly. The distance the large piston will mo
ve is the distance that the small piston is moved divided by the ratio of the ar
eas of the heads of the pistons. This is how energy, in the form of work in this
case, is conserved and the Law of Conservation of Energy is satisfied. Work is
force times distance, and since the force is increased on the larger piston, the
distance the force is applied over must be decreased.

CHAPTER-3
DESIGN OF EQUIPMENT AND DRAWING
HYDRAULIC SYSTEM:

Fundamental features of using hydraulics compared to mechanics for force and tor
que increase/decrease in a transmission.
Hydraulic machinery is machines and tools which use fluid power to do work. Heav
y equipment is a common example.
In this type of machine, high-pressure liquid — called hydraulic fluid — is tran
smitted throughout the machine to various hydraulic motors and hydraulic cylinde
rs. The fluid is controlled directly or automatically by control valves and dist
ributed through hoses and tubes.
The popularity of hydraulic machinery is due to the very large amount of power t
hat can be transferred through small tubes and flexible hoses, and the high powe
r density and wide array of actuators that can make use of this power.
Hydraulic machinery is operated by the use of hydraulics, where a liquid is the
powering medium. Pneumatics, on the other side, is based on the use of a gas as
the medium for power transmission, generation and control.
CONTENTS
• Force and torque multiplication
• Hydraulic circuits
• Constant pressure and load-sensing systems
o 3.1 Five basic types of load-sensing systems
• Open and closed circuits
• Hydraulic pump
• Control valves
• Actuators
Force and torque multiplication
A fundamental feature of hydraulic systems is the ability to apply force or torq
ue multiplication in an easy way, independent of the distance between the input
and output, without the need for mechanical gears or levers, either by altering
the effective areas in two connected cylinders or the effective displacement (cc
/rev) between a pump and motor. In normal case hydraulic ratios is combined with
a mechanical force or torque ratio for optimum machine designs, like in boom mo
vements and track drives for an excavator.
Examples
(1) Two hydraulic cylinders interconnected:
Cylinder C1 is one inch in radius, and cylinder C2 is ten inches in radius. If t
he force exerted on C1 is 10 lbf, the force exerted by C2 is 1000 lbf because C2
is a hundred times larger in area (S = πr²) as C1. The downside to this is that
you have to move C1 a hundred inches to move C2 one inch. The most common use f
or this is the classical hydraulic jack where a
um
ing cylinder with a small di
ameter is connected to the lifting cylinder with a large diameter.
(2) Pum
and motor:
If a hydraulic rotary
um
with the dis
lacement 10 cc/rev is connected to a hyd
raulic rotary motor with 100 cc/rev, the shaft torque required to drive the
um

is 10 times less than the torque available at the motor shaft, but the shaft s

eed (rev/min) for the motor is 10 times less than the
um
shaft s
eed. This com
bination is actually the same ty
e of force multi
lication as the cylinder exam

le (1) just that the linear force in this case is a rotary force, defined as tor
que.
Both these exam
les are usually referred to as a hydraulic transmission or hydro
static transmission involving a certain hydraulic "gear ratio".
Hydraulic circuits

A sim
le o
en center hydraulic circuit.

For the hydraulic fluid to do work, it must flow to the actuator and or motors,
then return to a reservoir. The fluid is then filtered and re-
um
ed. The
ath t
aken by hydraulic fluid is called a hydraulic circuit of which there are several
ty
es. O
en center circuits use
um
s which su

ly a continuous flow. The flow
is returned to tank through the control valve's o
en center; that is, when the c
ontrol valve is centered, it
rovides an o
en return
ath to tank and the fluid
is not
um
ed to a high
ressure. Otherwise, if the control valve is actuated it
 routes fluid to and from an actuator and tank. The fluid's
ressure will rise t
o meet any resistance, since the
um
has a constant out
ut. If the
ressure ris
es too high, fluid returns to tank through a
ressure relief valve. Multi
le con
trol valves may be stacked in series. This ty
e of circuit can use inex
ensive,
constant dis
lacement
um
s.
Closed center circuits su

ly full
ressure to the control valves, whether any v
alves are actuated or not. The
um
s vary their flow rate,
um
ing very little h
ydraulic fluid until the o
erator actuates a valve. The valve's s
ool therefore
doesn't need an o
en center return
ath to tank. Multi
le valves can be connecte
d in a
arallel arrangement and system
ressure is equal for all valves.
Constant
ressure and load-sensing systems
The closed center circuits exist in two basic configurations, normally related t
o the regulator for the variable
um
that su

lies the oil:
Constant
ressure systems (CP-system), standard. Pum

ressure always equals the

ressure setting for the
um
regulator. This setting must cover the maximum re
quired load
ressure. Pum
delivers flow according to required sum of flow to th
e consumers. The CP-system generates large
ower losses if the machine works wit
h large variations in load
ressure and the average system
ressure is much lowe
r than the
ressure setting for the
um
regulator. CP is sim
le in design. Work
s like a
neumatic system. New hydraulic functions can easily be added and the s
ystem is quick in res
onse.
Constant
ressure systems (CP-system), unloaded. Same basic configuration as 'st
andard' CP-system but the
um
is unloaded to a low stand-by
ressure when all v
alves are in neutral
osition. Not so fast res
onse as standard CP but
um
life
time is
rolonged.
Load-sensing systems (LS-system) generates less
ower losses as the
um
can red
uce both flow and
ressure to match the load requirements, but requires more tun
ing than the CP-system with res
ect to system stability. The LS-system also requ
ires additional logical valves and com
ensator valves in the directional valves,
thus it is technically more com
lex and more ex
ensive than the CP-system. The
LS-system system generates a constant
ower loss related to the regulating
ress
ure dro
for the
um
regulator:
Power loss =
The average Δ
LS is around 2 MPa (290
si). If the
um
flow is high the extra l
oss can be considerable. The
ower loss also increase if the load
ressures vari
es a lot. The cylinder areas, motor dis
lacements and mechanical torque arms mus
t be designed to match in load
ressure in order to bring down the
ower losses.
Pum

ressure always equals the maximum load
ressure when several functions ar
e run simultaneously and the
ower in
ut to the
um
equals the (max. load
ress
ure + Δ
LS) x sum of flow.
Five basic ty
es of load-sensing systems
(1) Load sensing without com
ensators in the directional valves. Hydraulically c
ontrolled LS-
um
.
(2) Load sensing with u
-stream com
ensator for each connected directional valve
. Hydraulically controlled LS-
um
.
(3) Load sensing with down-stream com
ensator for each connected directional val
ve. Hydraulically controlled LS-
um
.
(4) Load sensing with a combination of u
-stream and down-stream com
ensators. H
ydraulically controlled LS-
um
.
(5) Load sensing with synchronized, both electric controlled
um
dis
lacement a
nd electric controlled valve flow area for faster res
onse, increased stability
and less system losses. This is a new ty
e of LS-system, not yet fully develo
ed
.
Technically the down-stream mounted com
ensator in a valve block can
hysically
be mounted "u
-stream", but work as a down-stream com
ensator.
System ty
e (3) gives the advantage that activated functions are synchronized in
de
endent of
um
flow ca
acity. The flow relation between 2 or more activated f
unctions remains inde
endent of load
ressures even if the
um
reach the maximu
m swivel angle. This feature is im
ortant for machines that often run with the

um
at maximum swivel angel and with several activated functions that must be sy
nchronized in s
eed, such as with excavators. With ty
e (4) system, the function
s with u
-stream com
ensators have
riority. Exam
le: Steering-function for a wh
eel loader. The system ty
e with down-stream com
ensators usually has a unique t
rademark de
ending on the manufacturer of the valves, for exam
le "LSC" (Linde H
ydraulics), "LUDV" (Bosch-Rexroth Hydraulics) and "Flow sharing" (Parker Hydraul
ics) etc. No official standardized name for this ty
e of system has been establi
shed but Flow sharing is a common name for it.
O
en and closed circuits

O
en loo
and closed loo
circuits

O
en-loo
: Pum
-inlet and motor-return (via the directional valve) are connected
to the hydraulic tank. The term loo
a

lies to feedback; the more correct term
is o
en versus closed "circuit".
Closed-loo
: Motor-return is connected directly to the
um
-inlet. To kee
u

r
essure on the low
ressure side, the circuits have a charge
um
(a small gear
u
m
) that su

lies cooled and filtered oil to the low
ressure side. Closed-loo

circuits are generally used for hydrostatic transmissions in mobile a

lications
.
Advantages: No directional valve and better res
onse, the circuit can work with
higher
ressure. The
um
swivel angle covers both
ositive and negative flow di
rection.
Disadvantages: The
um
cannot be utilized for any other hydraulic function in a
n easy way and cooling can be a
roblem due to limited exchange of oil flow.
High
ower closed loo
systems generally must have a 'flush-valve' assembled in
the circuit in order to exchange much more flow than the basic leakage flow from
the
um
and the motor, for increased cooling and filtering. The flush valve is
normally integrated in the motor housing to get a cooling effect for the oil th
at is rotating in the motor housing itself. The losses in the motor housing from
rotating effects and losses in the ball bearings can be considerable as motor s

eeds will reach 4000-5000 rev/min or even more at max vehicle s
eed. The leakag
e flow as well as the extra flush flow must be su

lied by the charge
um
. Larg
e charge
um
s are thus very im
ortant if the transmission is designed for high

ressures and high motor s
eeds. High oil tem
eratures, is usually a major
robl
em when using hydrostatic transmissions at high vehicle s
eeds for longer
eriod
s, for instance when trans
orting the machine from one work
lace to the other.
High oil tem
eratures for long
eriods will drastically reduce the life time for
the transmission. To kee
down the oil tem
erature, the system
ressure during
trans
ort must be lowered, meaning that the minimum dis
lacement for the motor m
ust be limited to a reasonable value. Circuit
ressures during trans
ort around
200-250 bar is recommended.
Closed loo
systems in mobile equi
ment are generally used for the transmission
as an alternative to mechanical and hydrodynamic (converter) transmissions. The
advantage is a ste
less gear ratio ('hydrostatic' gear ratio) and a more flexib
le control of the gear ratio de
ending on the load and o
erating conditions. The
hydrostatic transmission is generally limited to around 200 kW max. Power as th
e total cost gets too high at higher
ower com
ared to a hydrodynamic transmissi
on. Large wheel loaders for instance and heavy machines are therefore usually eq
ui

ed with converter transmissions. Recent technical achievements for the conve
rter transmissions have im
roved the efficiency and develo
ments in the software
have also im
roved the characteristics, for exam
le selectable gear shifting
r
ograms during o
eration and more gear ste
s, giving them characteristics close t
o the hydrostatic transmission.
Hydrostatic transmissions for earth moving machines, such as for tractor loaders
, are often equi

ed with a se
arate 'Inch
edal' that is used to tem
orarily in
crease the diesel engine r
m while reducing the vehicle s
eed in order to increa
se the available hydraulic
ower out
ut for the working hydraulics at low s
eeds
and increase the tractive effort. The function is similar to stalling a convert
er gearbox at high engine r
m. The Inch-function affects the
reset characterist
ics for the 'hydrostatic' gear ratio versus diesel engine r
m. when a close loo

can take res
once.
Hydraulic
um

Hydraulic
um
s su

ly fluid to the com
onents in the system. Pressure in the sy
stem develo
s in reaction to the load. Hence, a
um
rated for 5,000
si is ca
a
ble of maintaining flow against a load of 5,000
si.
Pum
s have a
ower density about ten times greater than an electric motor (by vo
lume). They are
owered by an electric motor or an engine, connected through gea
rs, belts, or a flexible elastomeric cou
ling to reduce vibration.
Rotary vane
um

Vane
um
: chea
and sim
le, reliable (es
ecially in g-rotor form). Good for hig
her-flow low-
ressure out
ut.

Rotary vane
um
. Note that modern
um
s have an area contact between rotor and
stator (and not a line contact).
1.
um
housing
2. rotor
3. vanes
4. s
ring
A rotary vane
um
is a
ositive-dis
lacement
um
that consists of vanes mounte
d to a rotor that rotates inside of a cavity. In some cases these vanes can be v
ariable length and/or tensioned to maintain contact with the walls as the
um
r
otates. It was invented by Charles C. Barnes of Sackville, New Brunswick who
at
ented it on June 16, 1874.[1]
•
TYPES
The sim
lest vane
um
is a circular rotor rotating inside of a larger circular
cavity. The centers of these two circles are offset, causing eccentricity. Vanes
are allowed to slide into and out of the rotor and seal on all edges, creating
vane chambers that do the
um
ing work. On the intake side of the
um
, the vane
chambers are increasing in volume. These increasing volume vane chambers are fi
lled with fluid forced in by the inlet
ressure. Often this inlet
ressure is no
thing more than
ressure from the atmos
here. On the discharge side of the
um
,
the vane chambers are decreasing in volume, forcing fluid out of the
um
. The
action of the vane drives out the same volume of fluid with each rotation. Multi
stage rotary vane vacuum
um
s can attain
ressures as low as 10-3 mbar (0.1 Pa)
.
USES
Common uses of vane
um
s include high
ressure hydraulic
um
s and automotive u
ses including, su
ercharging,
ower steering and automatic transmission
um
s. P
um
s for mid-range
ressures include a

lications such as carbonators for founta
in soft drink dis
ensers and es
resso coffee machines. They are also often used
as vacuum
um
s for
roviding braking assistance (through a braking booster) in
large trucks, and in most light aircraft to drive gyrosco
ic flight instruments,
the attitude indicator and heading indicator.
VARIABLE DISPLACEMENT VANE PUMPS
One major advantage of the vane
um
is that the design readily lends itself to
become a variable dis
lacement
um
, rather than a fixed dis
lacement
um
such
as a s
ur-gear (X-X) or a gerotor (I-X)
um
. The centerline distance from the r
otor to the eccentric ring is used to determine the
um
's dis
lacement. By allo
wing the eccentric ring to
ivot or translate relative to the rotor, the dis
lac
ement can be varied. It is even
ossible for a vane
um
to
um
in reverse if t
he eccentric ring moves far enough. However,
erformance cannot be o
timized to

um
in both directions. This can make for a very interesting hydraulic control
oil
um
.
Variable dis
lacement vane
um
s are used as an energy savings device, and have
been used in many a

lications, including automotive transmissions, for over 30
years.
• Axial
iston
um
: many designed with a variable dis
lacement mechanism,
to vary out
ut flow for automatic control of
ressure. There are various axial

iston
um
designs, including swash
late (sometimes referred to as a valve
la
te
um
) and check ball (sometimes referred to as a wobble
late
um
). The most
common is the swash
late
um
. A variable-angle swash
late causes the
istons
to reci
rocate.

DIRECTIONAL CONTROL VALVES

Directional control valves route the fluid to the desired actuator. They usually
consist of a s
ool inside a cast iron or steel housing. The s
ool slides to dif
ferent
ositions in the housing, intersecting grooves and channels route the flu
id based on the s
ool's
osition.
Directional control valves are usually designed to be stackable, with one valve
for each hydraulic cylinder, and one fluid in
ut su

lying all the valves in the
stack.
• Pressure relief valves are used in several
laces in hydraulic machinery
; on the return circuit to maintain a small amount of
ressure for brakes,
ilot
lines, etc... On hydraulic cylinders, to
revent overloading and hydraulic line
/seal ru
ture. On the hydraulic reservoir, to maintain a small
ositive
ressure
this excludes moisture and contamination.
• Pressure reducing valves reduce the su

ly
ressure as needed for variou
s circuits.
• Sequence valves control the sequence of hydraulic circuits; to ensure th
at one hydraulic cylinder is fully extended before another starts its stroke, fo
r exam
le.
• Shuttle valves
rovide a logical or function.
• Check valves are one-way valves, allowing an accumulator to charge and m
aintain its
ressure after the machine is turned off, for exam
le.
• Pilot controlled Check valves are one-way valve that can be o
ened (for
both directions) by a foreign
ressure signal. For instance if the load should n
ot be hold by the check valve anymore. Often the foreign
ressure comes from the
other
i
e that is connected to the motor or cylinder.
• Counterbalance valves are in fact a s
ecial ty
e of
ilot controlled che
ck valve. Whereas the check valve is o
en or closed, the counterbalance valve ac
ts a bit like a
ilot controlled flow control.
• Cartridge valves are in fact the inner
art of a check valve; they are o
ff the shelf com
onents with a standardized envelo
e, making them easy to
o
ula
te a
ro
rietary valve block. They are available in many configurations; on/off,

ro
ortional,
ressure relief, etc. They generally screw into a valve block and
are electrically controlled to
rovide logic and automated functions.
ACTUATORS
• Hydraulic cylinder
• Rotary actuator (hydraulic)
• Hydraulic motor (a
um

lumbed in reverse)
• hydrostatic transmission
• Brakes
HYDRAULIC CYLINDER
Hydraulic cylinders get their
ower from
ressurized hydraulic fluid, which is t
y
ically oil. The hydraulic cylinder consists of a cylinder barrel, in which a

iston connected to a
iston rod moves back and forth. The barrel is closed on ea
ch end by the cylinder bottom (also called the ca
end) and by the cylinder head
where the
iston rod comes out of the cylinder. The
iston has sliding rings an
d seals. The
iston divides the inside of the cylinder in two chambers, the bott
om chamber (ca
end) and the
iston rod side chamber (rod end). The hydraulic
r
essure acts on the
iston to do linear work and motion.
Flanges, trunnions, and/or clevisses are mounted to the cylinder body. The
isto
n rod also has mounting attachments to connect the cylinder to the object or mac
hine com
onent that it is
ushing.
A hydraulic cylinder is the actuator or "motor" side of this system. The "genera
tor" side of the hydraulic system is the hydraulic
um
which brings in a fixed
or regulated flow of oil to the bottom side of the hydraulic cylinder, to move t
he
iston rod u
wards. The
iston
ushes the oil in the other chamber back to th
e reservoir. If we assume that the oil
ressure in the
iston rod chamber is a


roximately zero, the force on the
iston rod equals the
ressure in the cylinder
times the
iston area (F=PA).
The
iston moves instead downwards if oil is
um
ed into the
iston rod side cha
mber and the oil from the
iston area flows back to the reservoir without
ressu
re. The
ressure in the
iston rod area chamber is (Pull Force) / (
iston area -

iston rod area).
Parts of a hydraulic cylinder
A hydraulic cylinder consists of the following
arts:
Cylinder barrel
The cylinder barrel is mostly a seamless thick walled forged
i
e that must be m
achined internally. The cylinder barrel is ground and/or honed internally.
Cylinder Bottom or Ca

In most hydraulic cylinders, the barrel and the bottom
ortion are welded togeth
er. This can damage the inside of the barrel if done
oorly. Therefore some cyli
nder designs have a screwed or flanged connection from the cylinder end ca
to t
he barrel. (See "Tie Rod Cylinders" below) In this ty
e the barrel can be disass
embled and re
aired in future.
Cylinder Head
The cylinder head is sometimes connected to the barrel with a sort of a sim
le l
ock (for sim
le cylinders). In general however the connection is screwed or flan
ged. Flange connections are the best, but also the most ex
ensive. A flange has
to be welded to the
i
e before machining. The advantage is that the connection
is bolted and always sim
le to remove. For larger cylinder sizes, the disconnect
ion of a screw with a diameter of 300 to 600 mm is a huge
roblem as well as the
alignment during mounting.
Piston
The
iston is a short, cylinder-sha
ed metal com
onent that se
arates the two si
des of the cylinder barrel internally. The
iston is usually machined with groov
es to fit elastomeric or metal seals. These seals are often O-rings, U-cu
s or c
ast iron rings. They
revent the
ressurized hydraulic oil from
assing by the

iston to the chamber on the o

osite side. This difference in
ressure between t
he two sides of the
iston causes the cylinder to extend and retract. Piston sea
ls vary in design and material according to the
ressure and tem
erature require
ments that the cylinder will see in service. Generally s
eaking, elastomeric sea
ls made from nitrile rubber or other materials are best in lower tem
erature env
ironments while seals made of Viton are better for higher tem
eratures. The best
seals for high tem
erature are cast iron
iston rings.
Piston Rod
The
iston rod is ty
ically a hard chrome-
lated
iece of cold-rolled steel whic
h attaches to the
iston and extends from the cylinder through the rod-end head.
In double rod-end cylinders, the actuator has a rod extending from both sides o
f the
iston and out both ends of the barrel. The
iston rod connects the hydrau
lic actuator to the machine com
onent doing the work. This connection can be in
the form of a machine thread or a mounting attachment such as a rod-clevis or ro
d-eye. These mounting attachments can be threaded or welded to the
iston rod or
, in some cases, they are a machined
art of the rod-end.
Rod Gland
The cylinder head is fitted with seals to
revent the
ressurized oil from leaki
ng
ast the interface between the rod and the head. This area is called the rod
gland. It often has another seal called a rod wi
er which
revents contaminants
from entering the cylinder when the extended rod retracts back into the cylinder
. The rod gland also has a rod bearing. This bearing su

orts the weight of the

iston rod and guides it as it
asses back and forth through the rod gland. In s
ome cases, es
ecially in small hydraulic cylinders, the rod gland and the rod be
aring are made from a single integral machined
art.
HYDRAULIC FLUID
Functions and
ro
erties
Function Pro
erty


Medium for ower transfer and control • Low com
ressibility (high bulk m
odulus)
• Fast air release
• Low foaming tendency
• Low volatility
Medium for heat transfer • Good thermal ca
acity and conductivity
Sealing Medium • Adequate viscosity and viscosity index
• Shear stability
Lubricant • Viscosity for film maintenance
• Low tem
erature fluidity
• Thermal and oxidative stability
• Hydrolytic stability / water tolerance
• Cleanliness and filterability
• Demulsibility
• Antiwear characteristics
• Corrosion control
Pum
efficiency • Pro
er viscosity to minimize internal leakage
• High viscosity index
S
ecial function • Fire resistance
• Friction modifications
• Radiation resistance
Environmental im
act • Low toxicity when new or decom
osed
• Biodegradability
Functioning life • Material com
atibility
Also known as tractor fluid, hydraulic fluid is the life of the hydraulic circui
t. It is usually
etroleum oil with various additives. Some hydraulic machines r
equire fire resistant fluids, de
ending on their a

lications. In some factories
where food is
re
ared, water is used as a working fluid for health and safety
reasons.
In addition to transferring energy, hydraulic fluid needs to lubricate com
onent
s, sus
end contaminants and metal filings for trans
ort to the filter, and to fu
nction well to several hundred degrees Fahrenheit or Celsius
FILTERS
Filters are an im
ortant
art of hydraulic systems. Metal
articles are continua
lly
roduced by mechanical com
onents and need to be removed along with other co
ntaminants.
Filters may be
ositioned in many locations. The filter may be located between t
he reservoir and the
um
intake. Blockage of the filter will cause cavitations
and
ossibly failure of the
um
. Sometimes the filter is located between the
u
m
and the control valves. This arrangement is more ex
ensive, since the filter
housing is
ressurized, but eliminates cavitations
roblems and
rotects the con
trol valve from
um
failures. The third common filter location is just before t
he return line enters the reservoir. This location is relatively insensitive to
blockage and does not require a
ressurized housing, but contaminants that enter
the reservoir from external sources are not filtered until
assing through the
system at least once.
CHAPTER 4
DETAILS OF THE PROJECT:
The two main com
onents in our
roject are
• Hydraulic unit
• Notching unit
Various com
onents in the hydraulic unit
1. Hydraulic
um

2. Prime mover
3. Direction control valve
4. Pressure relief valve
5. Actuator
6. Filter
7. Reservoir
8. Hydraulic fluid
9. Connecting hoses
DESCRIPTION
Hydraulic
um

The
um
used is vane
um
. It falls under fixed dis
lacement, unbalance
d um . It uses s
ring loaded dual vane for high
ressure. As the name suggests



it consist of two vanes in each slot of the rotor. The system
ressure from the

um
is directed above the smaller vane resulting in less vane loading.
The
um
ing mechanism is designed and formed as an integral assembly whi
ch normally is called as a “cartridge” assembly. This consist of Vanes, rotor an
d cam ring sandwiched between the
ort
lates.
Such an assembly is easy for maintenance and servicing when the system m
alfunctions. Another im
ortant advantage of using such an assembly lies in its e
asy re
lace ability when it is old and need re
lacement due to wear and tear. A
new cartridge assembly can o fitted in the
lace of the old one when the old on
e can be serviced if it is needed.
Another advantage of is that while fitting cartridge the
um
volume can
be increased but changing the internal dimension to suit the current and antici

ated
um
requirement.

Do
uble vane
um

SPECIFICATIONS OF THE PUMP:
Pressure out
ut = 165 kgf / cm2
Pum
ca
acity = 19.63 liter / min
No. of Vanes = 2
PRIME MOVER:
The
rime mover used to drive the
um
is and electrical A.C. induction
motor of constant s
eed. It is cou
led to the
um
by a sim
le flange cou
ling.
SPECFICATIONS OF THE MOTOR:
Power = 12 h



S eed = 1430 r
m
Motor efficiency = 84%
Voltage = 415 V
Current = 7.4 A
Frequency = 50 Hz, 3
hase constant duty
Weight = 32 kg
Power factor = 0.83
Ambient = 500 C
DIRECTION CONTROL VALVE:
The value used is s
ring centered 4/3 solenoid o
erated direction contro
l valve. The
ower is given externally to o
erate the valve
osition. It is of s
liding s
ool ty
e in constructions.
PRESSURE RELIEF VALVE:
 The valves are normally o
en
ressure control valves used to maintain re
duced ressure in the hydraulic system. They are actuated in the
ressure sensed


in the branch circuit and tend to close as it reaches the
ressure of the set v
alue to
revent the further build u
of the
ressure.
A direct acting valve generally has a s
ring loaded s
ool to control the
downstream
ressure. If the main su

ly
ressure is below the set value, the fl
uid will flow freely. An internal combustion from the outlet
assage transmits t
he outlet
ressure to the s
ool end o

osite the s
ring.

CHAPTER 5
NOTCHING UNIT
VARIOUS COMPONENTS IN THE NOTCHING UNIT
Hydraulic actuator
Base
late
Ram
To
& bottom cutter holding block
To
cutter removable holder
Cutter end sto

er
Main frame
Ram cover rear side
Ram cover front side
Bronze guide
ieces
Cylinder su

ort cover
Main frame back cover to

Base
late fixing block
Bottom cutter su

ort leg
art
Connecting nuts & bolts

Notching unit-3D view

CHAPTER 6
DESIGN CALCULATION
DESIGN OF HYDRAULIC UNIT
100mm

25mm

8mm

COMPOSITION OF STAINLESS STEEL 09 GRADE MATERAILS

C Mn Si P S Cr Ni N
0.03 0.5 0.3 0.04 0.015 10.5 0.2 0.03
- 1.5 0.8 Max Max 13.5 0.8 -
PRPOERTIES OF STAINLESS STEEL 409 GRADES
CUTTING FORCE
S
eed = 15m/min
Pressure = 100 bar
Stroke length = 1000 mm
Area of cross section = 2(25+200) 8
 = 3600 mm2
Shear strength for stainless steel = 265 N / mm2
Shear load =area of cross section x
shear strength
=3600 x 265
=9.54 x 105 N
TIME CALCULATION:
S
eed = distance/time
Time = distance/s
eed
= 1000/15
= 6 min
VOLUME OF THE CYLINDER:
Pressure = force/area
Area = force/
ressure
(π/4×D2) = 9.54 x 105/100 x 105
A = 9.54 x 104 mm2
D = 350 mm
Volume of the cylinder = (π/4×D2×1)
= 96.21 l
PUMP CAPACITY
Pum
ca
acity = volume of the cylinder/time
= (π/4×D2×l)/t
= (96.211/ 240) x 60
= 24.053 l/min
MOTOR CAPACITY
Horse
ower = (working
ressure ×
um
ca
acity)/450
= (100×25)/450
= 5.56 ≈ 6 h



Standard motor ower = 6 h

RESERVOIR CAPACITY
Assume, 6 to 8 times of the
um
ca
acity. So we can multi
ly by 7 times of
um

ca
acity.
Reservoir ca
acity = 25× 7
= 175 l/min
CHAPTER 7
WORKING PRINCIPLE:
Some of the general
ro
erties of the liquids in o
en containers have be
en described. It remains to discuss how a liquid will behave when a confined, fo
r exam
le, in an enclosed hydraulic system.
Liquids are
ractically incom
ressible. The following two basic
rinci
l
es will hel
to ex
lain the behavior of liquids when enclosed.
• Liquids are
ractically incom
ressible in the
ressure ranges being cons
idered. Staaated sim
ly, this means the liquid cannot be squeezed in a smaller s

ace then it already occu
ies.
• Therefore an increase in
ressure on any
art of confined liquids is tra
nsmitted undiminished in all direction throughout the liquid
(Pascal’s principle). For example, if pressure is applied and one end of a long
pipe, the liquid, being practically incompressible, will transmit the pressure
equally to every portion of the pipe.
DOUBLE ACTING CYLINDER OPERATION:
• When the four ways valve is in its spring centered position, the cylinde
r is hydraulically locked. Also the pump is unloaded back to the tank at essenti
ally atmospheric pressure.
• When the four way valve is actuated into the flow path configuration of
the left envelope, the cylinder is extended against its load force F load as oil
flows from port ‘P’ through port A. also oil in the rod end of the cylinder us
free to flow back to the tank via the way valve from port B through port T.
• Since that the cylinder could not extend if this oil were not allowed to
leave the rod end of the cylinder.
• When the four way valve is deactivated, the spring centered envelope pre
vails, and the cylinder is once again hydraulically locked.
• When the four way valve is activated into the right envelope configurati
on, the cylinder retracts as oils flows from port P through port B. oil in the b
lank end is returned to the tank via the flow path from port A to port T
• At the end of the stroke, there is no system demand in the coil for oil.
Thus, the pump flow goes through the relief valve is deactivated. In any event,
the system is protected from any cylinder overloads.
NEEDLE VALVE:
A needle valve is used to control the extending speed of a hydraulic spe
ed of a hydraulic cylinder. The needle valve is placed in the outlet line of the
hydraulic cylinder.
When the needle valve is fully open, all the flow from the pump goes to
the hydraulic cylinder to produce maximum hydraulic cylinder speed. As the needl
e valve is partially closed, its pressure drop increases.
This causes the back pressure P2 to increase, which results in a greater resista
nce force at the rod end of the cylinder. Since this back pressure force opposes
the extending motion of the cylinder, the result is an increase in the cylinder
blank end pressure P1. Further closing of the needle valve ultimately results i
n pressure P1 reaching and then exceeding the cracking pressure of the pressure
relief valve.
The result is a slower cylinder speed since part of the pump flow goes b
ack to the oil tank through the pressure relief valve, when the cylinder speed r
eaches the desired value P1.
Approximately equals the PRV setting and the pump flow not desired by th
e cylinder goes back through the pressure relief valve. When this occurs, the cy
linder receives the desired amount of flow rate, which equals the pump flow rate
minus the flow rate through the pressure relief valve.

CHAPTER 8
FACTOR DETREMINING THE CHOICE OF THE MATERIAL
The various factors that determine the choice of the material are discus
sed below.
PRPOERTIES
The material selection must possess the necessary properties for the pro
posed application. The various requirements that are to be satisfied are weight,
surface finish, rigidity, ability to withstand environmental attack from chemic
al, service life, reliability etc.
The following four types of principle properties are material are decisi
vely affecting their selection are.
A. Physical
B. Mechanical
C. From manufacturing point of view
D. Chemical
The various physical properties concerned are melting point, thermal con
ductivity, specifies heat, coefficient of thermal expansion, specific gravity, e
lectrical conductivity, magnetic purpose etc.
The mechanical properties concerned are strength in tensile, compressive
shear, bending, torsion and buckling load, fatigue resistance, impact resistanc
e, elastic limit endurance limit, and modulus of elasticity, hardness, wear resi
stance and sliding properties.
The various property concerned from the manufacturing point of view are
• Castability
• Weldability
• Brazability
• Forgeability
• Machineability
• Surface property
• Shrinkage
MANUFACTURING COST:
Sometimes the demand for the lowest possible manufacturing cost or surfa
ce qualities obtainable by the application of suitable coating substances may de
mand the use of special materials.
QUALITY REQUIRED:
This generally affects the manufacturing process and ultimately the mate
rial. For example, it designs to go for the casting of a less number of a compon
ent that can be fabricated much more economically by welding or hand forging ste
el
AVAILABILITY OF MATERIAL:
Some material may be scarce or in short supply. It then becomes obligato
ry for the designer to use some other material which though may not be perfect s
ubstitute for the material designed. The delivery of the material and the delive
ry date of the product should also be kept in mind.
SPACE CONSIDERATION:
Sometimes high strength materials to be selected because the force invol
ve are high and space limitation should be less.
COST:
As in any other problem, in selection of the material the cost of the ma
terial plays an important part and should not be ignored. Sometimes the factor l
ike scarp utilization, appearance, and non maintenance of the designed part are
involved in the selection of the proper materials.
COST ESTIMATION
S.NO PARTS QTY AMOUNT(Rs)
1 Hydraulic cylinder 1 2,50,000
2 Direction control valve(DG5S4102C5) 1 70,000
3 Oil tank with oil (servo system 46) 1 15,000
4 Pressure relief valve(0610C10) 1 4,000
5 Hydraulic vane pump(25V21AC22) 1 15,000
6 Filter(model 200) 1 5,000
7 Connecting hoses, collars, and reducers 1 7,000
8 Tool & punch holder 1 13,645
9 Pilot operated control valve (SL10PH-1-4) 1
2,900
10 Check valve(4SOVFR) 1 3,500
11 Induction motor (6HP) 1 70,000
TOTAL
4,55,865

CONCLUSION
Thus this project work has provided us an excellent opportunity and expe
rience, to use our limited knowledge. We gained a lot of practical knowledge reg
arding modeling, planning, assembling and analyzing while doing this project wor
k. We feel that the project is a good solution to bridge the gate between instit
ution and industries.
We are proud that we have completed the work with the limited time succe
ssfully. The fabrication and initialization of notching unit APL-II is designed
and analyzed satisfactorily.
The operating procedure of the system does not require any skilled labor
, so any person can operate. By using more techniques, they can be, modified and
developed according to the application.
REFERENCES
1. Anthony Esposito, (1980) “fluid power with application” prentice hall
publisher’s ltd..,
2. S.R.Majumdar, (1996) “oil hydraulic system”, Tata Mc Graw hill publicati
on ltd…,
3. R.S.Khurmi and J.K.Gupta (2004) “A text book of machine design”, Eurasia
publishers ltd..,
4. Andrew Parr (1993), “Hydraulics and Pneumatics”, Jaico publishers ltd..,
5. ‘Design data book’, PSG college of technology, 2003