Chapter 1 Introduction

The word "hydraulics" originates from the Greek word. Hydraulics is a topic of science and engineering dealing with the mechanical properties of liquids. Hydraulics is part of the more general discipline of fluid power. Fluid mechanics provides the theoretical foundation for hydraulics, which focuses on the engineering uses of fluid properties. Hydraulic topics range through most science and engineering disciplines, and cover concepts such as pipe flow, press. However if used incorrectly, hydraulic instruments can result in weird occurrences because of the nature of high pressure fluids. The hydraulic press is one of the oldest of the basic machine tools. In its modern form, is well adapted to presswork ranging from coining jewelry to forging aircraft parts. Modern hydraulic presses are, in some cases, better suited to applications where the mechanical press has been traditionally more popular. 1.1 Hydraulic principle The word hydraulics generally refers to power produced by moving liquids. Modern hydraulics is defined as the use of confined liquid to transmit power, Multiply force, or produce motion. Though hydraulic power in the form of water wheels and other simple devices has been in use for centuries, the principles of hydraulics werent formulated into scientific law until the 17th century. It was then that French philosopher Blaise Pascal discovered that liquids cannot be compressed. He discovered a law which states: Pressure applied on a confined fluid is transmitted in all directions with equal force on equal areas. To better understand Pascals Law, lets use a bottle full of liquid as an example. Lets say the bottle has a 1 square inch opening. If we were to apply 10 pounds of force on a cork at the opening, 10 pounds of force would be 1

applied equally to all sides of the bottle. This is expressed as 10 psi or 10 pounds of force per square inch. 10 psi represents the fluid pressure of the system. Though impressive on paper, Pascals Law wasnt put into practical application until the Industrial Revolution when Joseph Brahman, a British mechanic, built a hydraulic press using pressure, force and confined fluid in a lever-like system. A closed hydraulic system such as the one diagrammed here provides a mechanical advantage similar to that of a simple lever.

Fig. (1.1.1) Pascals law Bramah discovered that in a closed fluid system a small force exerted on a small cylinder could balance a large force on a large cylinder. For example, 1 pound of force applied to a 1 square inch cylinder can balance 100 pounds of force on a 100 square inch cylinder. This is how we can move a 100 pound weight using only 1 pound of force. The distance the 100 pounds will travel is inversely proportional to the distance the applied force travels. That means if we move a 1 square inch cylinder a distance of one inch, we only move the 100 square inch cylinder 1/100th of an inch.

1.1.1 Hydraulic system contain following key components: Fluid - can be almost any liquid. The most common hydraulic fluids contain specially compounded petroleum oils that lubricate and protect the system from corrosion. Reservoir - acts as a storehouse for the fluid and a heat dissipater. Hydraulic pump - converts the mechanical energy into hydraulic energy by forcing hydraulic fluid, under pressure, from the reservoir into the system. Fluid lines - transport the fluid to and from the pump through the hydraulic system. These lines can be rigid metal tubes, or flexible hose assemblies. Fluid lines can transport fluid under pressure or vacuum (suction). Hydraulic valves - control pressure, direction and flow rate of the hydraulic fluid. Actuator - converts hydraulic energy into mechanical energy to do work. Actuators usually take the form of hydraulic cylinders. Hydraulic cylinders are used on agricultural, construction, and industrial equipment.

Fig.(1.1.1.1) basic hydraulic system contains While there are different kinds of pumps, actuators, valves, etc., the basic design of the hydraulic system is essentially the same for all machinery. Press working is one of the basic processes of modern high-volume manufacturing with many applications in the automotive, aerospace, and consumer products industries. Although 3

processes ranging from coining to drop forging fall under the basic definition of press working, this discussion will be limited to operations in which relatively thin sheets of material are cut and/or formed between male and female dies in a hydraulically powered press. The hydraulic press is one of the oldest of the basic machine tools. In its modern form, is well adapted to presswork ranging from coining jewelry to forging aircraft parts. Modern hydraulic presses are, in some cases, better suited to applications. 1.2 Press fundamentals Common press terms include Adjustable bed/knee. A bed attached to an open-frame press that can be moved up and down with a jackscrew. The term is also used to describe a moveable bed installed on some straight side presses. Bed. The stationary base of a press to which the bolster, or sometimes the lower die, is attached. Bolster. A thick plate attached to the press bed to which the die is mounted. Bolsters typically have precisely spaced holes or T-slots to facilitate die mounting. Capacity. The force a press is rated to deliver at a specific distance above the bottom of the slide stroke. Closed/shut height. The distance from the face of the slide to the top of the bolster when the slide is fully down and the bolster, if adjustable, is fully up. The maximum amount of space available for the die set and any auxiliary components within the press. Also called daylight. Clutch. A device to couple the flywheel to the crankshaft in a mechanical press. Crown. The topmost part of a straight-side press structure. The crown usually contains the drive mechanism on a mechanical press, or the cylinder or cylinders on a hydraulic press. Die space. The space available in a press for mounting dies. Die space includes both the vertical between the ram and bolster, and the available mounting space on the bolster plate itself.

Flywheel. A massive rotating wheel used to store kinetic energy. When the clutch is engaged the kinetic energy from the flywheel is transmitted to the crankshaft. Frame. The main structure of a press. The frame may be a monolithic casting, a multipart casting, a element, or any combination of these. Guides. Guides that maintain the position of a moving machine element. Guides are normally attached to the vertical members of a straight-side press. Platen. The slide or ram of a hydraulic press; the moving member of such a press. Press. A machine with a stationary element, the bed, and a moving element, the slide or ram, reciprocating at right angles to it designed to apply force to work piece materials placed between the bed and ram. When used in conjunction with dies, a press is capable of forming metal and other materials into very complex, three-dimensional shapes. Ram/slide. The moving component of a press. Stroke. The distance a slide moves between full-up and full-down positions. Also one complete movement of the slide from full-up to full-up, used as a measure of press speed expressed as strokes per minute. Throat depth/gap. The distance between the frame and the centerline of the slide in an open frame press. Tie rod. Steel rods with threaded ends used to pressers the vertical frame members of a straight-side press, or to prevent deflection in an open-frame press. 1.3 Press Architectures Presses are generally defined by the basic architecture of the machine, the means used to generate force, and the amount of force available. The basic function of a press frame is to absorb the forces generated during the pressing operation and maintain the precise alignment of the dies. The frame also serves as a mounting for the drive system and various peripheral devices necessary to support production. While most presses are built to operate in a vertical orientation, horizontal models are also available for special purpose applications. There are two basic frame architectures, open frame and straight side. Within these basic architectures are a wide variety of subtypes and variations that have been developed to meet

specific process and production requirements. Each type has its own advantages and limitations, which will be examined briefly below.

1.4 Types of hydraulic press machine Hydraulic presses fall into two predominant types: gap frame and straight side presses. The frame types used in mechanical presses are similar to those used in many hydraulic presses. Most power presses are actuated by electrical motor driven mechanical or hydraulic energy. However, gravity drop hammer and foot powered kick presses are also used. The drive systems, clutches, brakes, counterbalance systems, die cushions, electrical, hydraulic and pneumatic features are similar in both the gap frame and straight side types.. The type and size of press selected is mainly determined by the work to be done

1.4.1 Gap frame presses Gap frame presses, also known as open frame, C-frame, or open front presses, consist of a frame shaped roughly like the letter C, with a bed at the bottom and a guide and support structure for a moving ram at the top. The frame may be a large casting, or a steel fabrication that is either welded or riveted. The bed, in turn, may be an integral part of the frame, or it may be moveable to adjust the distance between the ram and bed. One of the most common open frame press designs is the OBI press in which the frame is mounted on a pivot in the base which permits it to be tilted off vertical to facilitate stock handling or scrap removal. Other common types are the OBS, the adjustable bed stationary (ABS), and a variety of knee-type units with various systems of table adjustment and support.

Fig (1.4.1) gap frame press The major advantages of an open frame press design are economy of construction and unhindered access to the die area. Inclinable models and those with moveable beds or tables also offer a great deal of versatility, making them particularly useful for short run production or job shop applications. Open frame presses are available with force capacities ranging from a ton (8.9 kN) for small bench-type units, up to about 450 tons (4000 kN). The limiting factor on the size of open frame presses is the lack of stiffness inherent in their design. In operation the frames tend to deflect in both a linear and an angular fashion as they are loaded. The angular deflection component is particularly undesirable because it tends to cause misalignment between punches and dies which leads to rapid wear, loss of precision and even tool breakage. Various means are available to counteract deflection in open frame presses including the installation of priestesses tie rods spanning the front opening to connect the upper and lower ends of the frame, and the use of tie rods inside tubular spacers to prevent misalignment caused by the tie rod pressures. The drawback to these methods is that they largely negate the die access advantage which is one of the most important benefits of the open frame design. In general,

when an open frame press is not sufficiently stiff for a particular application the best course is to either move the work to a larger press, or move it to a straight-side press. One additional limitation of the open frame design is the fact that such presses are generally limited in practice to the use of single dies. This is a result of several factors including the lack of stiffness and the typically small force capacity and die area of open frame presses.

1.4.1.1 Features of Gap-Frame Presses Gap or C-frame presses have many useful features. These include excellent accessibility from the front and sides for die setting and operation. The machines also cost substantially less than straight-side presses. The open back is available for feeding stock as well as ejection of parts and scrap. A further advantage of a gap frame press is that the machine is easier to set-up than a straight side press. The die setter has much greater freedom of access to locate and bolt the die in place. The open back is also accessible for discharging finished parts and scrap as well as feeding stock. Gap-frame presses generally have less height than a straight side press of comparable tonnage. This is a valuable consideration when overhead clearance is limited.

1.4.1.2 Limitation of gape frame press The chief limiting factor of this type of machine is that it has more deflection than a straightside press for a given load. The deflection has both a vertical and angular component. The angular deflection or misalignment that occurs is due to the spreading of the throat opening as tonnage is developed. In many applications, this angular misalignment under load may not be objectionable. This style of press is popular for short-run work, where high accuracy of die alignment or close part tolerances are not necessarily controlling factors. For low tonnage highspeed work, precision gap presses are widely used. Here, the work is done before bottom of the stroke and the light loading avoids angular deflection problems. However, straight side presses are generally recommended for any application where angular machine deflection would cause unacceptable part quality and accelerated die wear. The lower

cost of gap frame construction machines may be poor economy if accelerated tooling wear and quality problems result. 1.4.2 Straight side Presses A straight-side press consists of a bed and a crown which are separated by upright structures at each end of the bed. The bolster is attached to the bed, and a sliding mechanism moves up and down on gibs and ways attached to the vertical members. The drive is typically mounted on the crown in a straight-side press.

Fig. (1.4.2) straight frame press

Straight-side presses may be monolithic castings, or fabrications of castings or elements held together with tie rods, welds, or mechanical keys and fasteners. Larger presses tend to be fabricated because of the difficulty of transporting large castings or elements from the press builder to the users location. Straight-side presses have two major advantages over open frame designs. First, they can be very large. Mechanical straight-side presses with capacities up to 6000 tons (53.376 Nm) have been built, although the upper limit for standard presses tends to be about 2000 tons (17.8 Nm). Straight side hydraulic presses have been built with capacities up to 50,000 tons (445 Nm), but these machines are generally used for specialized forging applications rather than traditional forming and drawing operations. The second advantage of straight-side presses is that they tend to deflect in a much more linear fashion under load than an open-frame press. They also tend to deflect much less for a given load. Taken together, these two characteristics of a straight-side press translate into greater precision and longer tool life because linear deflection does not cause punch and die misalignment in the way angular deflection does. Linear deflection is a result of the balanced geometry of the straight-side design, and the fact that the slide can be guided at all four corners during its entire stroke. As long as the press loading is applied symmetrically a straight-side press will deflect symmetrically with virtually no effect on punch and die alignment. The slide, which is normally a box-shaped element, may be connected to the press drive system at a single point, or at multiple points. Typically, in mechanical presses, this connection is via one or more connecting rods that are driven by a crankshaft in the crown. Other systems include gear drives, and a variety of linkages designed to produce controlled slide motion. Bottom-drive presses are also available. Hydraulic presses use hydraulic cylinders to supply the required force, and may also be single or multiple-point designs. Many small straight-side presses have a single point connection between the drive and the slide. Thus, any resistance not centered directly below the point of connection will tend to tilt the slide and cause misalignment.

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Presses using two or more connections are called multipoint presses, and they provide substantially more ability to compensate for uneven loading of the slide since the load is spread among the connecting points. Such presses are normally of larger size than single-point units and, therefore, more costly. Multipoint connection is recommended for progressive and single-press transfer die operations, although they can be accommodated on single-point presses if carefully designed. Some presses are designed with multipart slides which are actuated by different connections to the crankshaft. These are most commonly of the box-in-a-box type with a center slide surrounded by a hollow rectangular secondary slide. Multiple slide presses are designated at double or triple action, depending on the number of slides present. The columns or vertical members of a straight-side press may be monolithic castings, mechanically fastened multipart castings, or elements. Often tie bars attached to the base and crowns are used to compress the vertical members and provide uniform, adjustable resistance to vertical deflection. The gibs and ways are designed to prevent tipping of the slide, so the resultant misalignment largely is a function of the precision with which they are fit, and the length of contact. Any misalignment, of course, will result in wear to the components involved and a loss of precision in the operation being performed. Since the fit between gibs and ways is never perfect, special care must be taken in designing dies for a single-point press to ensure uniform loading. The gib and way configuration also contributes to slide stability, and there are many variations. Square, V, box, and gibs are all used, as well as various roller systems. Both sixand eight-point of- contact gibs are used, with the eight-point system being preferred for larger presses with high operating forces and on tie bar type presses. Six-point gibs are more commonly used on solid frame Presses. 1.4.2.1 Straight side press advantages A major advantage of the straight side press compared to the gap-frame machine is freedom from angular misalignment under load. Maintaining true vertical motion throughout the press stroke is critical to minimize tool wear and obtain accurate part tolerances.

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1.5 Advantages of Hydraulic Presses The mechanical press has been the first choice of many press users for years. The training of tool and die makers and manufacturing engineers in North America has been oriented toward applying mechanical presses to sheet-metal press working. Modern hydraulic presses offer good performance and reliability. Widespread application of other types of hydraulic power equipment in manufacturing requires maintenance technicians who know how to service hydraulic components. New fast acting valves, electrical components, and more efficient hydraulic circuits have enhanced the performance capability of hydraulic presses.

1.5.1 Advantages of hydraulic press vs mechanical press A Hydraulic press is a machine in which a large force is exerted on the larger of two pistons in a pair of hydraulically coupled cylinders by means of a relatively small force applied to the smaller piston. Whereas, a Mechanical press is a machine that exerts pressure to form or shape or cut materials or extract liquids or compress solids. There are various differences between mechanical and hydraulic presses. Following are fw of the major differences between them:

fig.(1.5.1) control of force

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Punching and forming In most of the industries sheet metal components require punching and forming. Hydraulic presses are flexible and easy for both punching and forming operations. In addition, the tooling for the hydraulic presses is also simpler. Even stamping can be done on the same press with the most inexpensive tooling. When it comes to use on such components, hydraulic presses are a better solution as against the mechanical presses and press brakes involving quiet expensive dies. Another reason for using hydraulic presses over other types of presses is that they allow fast set ups, and eliminate many forming functions and secondary forming operations. Materials handling cost is also reduced by the above. In fact, hydraulic press also replaces mechanical stamping press due to minimum set up time and low cost tooling. The hydraulic presses perform all different types of forming operations, including countersinks, lance-and-form, pierce-and-form, louvers, and single/double electrical knockouts along with marking of company logo and part numbers, etc. The hydraulic presses with their related tools, are the most versatile punching, forming and stamping presses. They can also punch and form in both up and down directions. These features provide greater flexibility as compared to mechanical presses. Much time can be saved in manufacturing of sheet metal parts by cutting and also performing many forming operations, eliminating secondary operations, which also requires moving the components to the next machine. Hydro forming Hydro forming is one of the areas in which hydraulic presses have no competition. The hydraulic press ram moves down to close the die and the hydro forming high-pressure fluid fills and acts on to the inside of the tubular parts and expands it to fill the die. This operation requires dwell time at the bottom of the stroke to perform the hydro forming operation. The mechanical presses are not capable to carrying out the hydro forming operation, as they do not have the speed control and also the provision to stay on the bottom for performing the high pressure forming operations. The slower speed of the hydraulic press offers a big advantage in hydro forming process over mechanical press, as in hydro forming, tubular and sheet metal components are formed by

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liquid pressure, which reduce the number of operations and therefore producing the finished component in much lesser time. By hydro forming the components produced are more rigid as compared to the components produced by other processes. Better controls of speed and force Hydraulic presses have major advantage of dwelling and ram speed control, which mechanical presses do not have. In mechanical presses the flywheel directly drives the stroke and there is no control over the speed and force. In a hydraulic press you gain greater control over ram action during stroke, making it more versatile for producing complex shapes. There may be different levels of sophistication in forming the desired shape and you want full control of speed force on the entire stroke. The hydraulic machines can be made with fully programmable control over ram speed and ram position, which is not possible in the mechanical press. For better material properties during forming and longer tool life, the adjustable and slower ram speed are necessary to optimize the material flow, which lead to better product quality. The full control over speed, position and dwell, produces better accuracy, crisp and clean shape and look.

Function of speed and stroke Hydraulic presses have expanded the forming capabilities for sheet metal shops for their unmatched functions of speed, stroke and force. They are becoming more popular and the old stories about them being slow and leaky have been disappearing. They can run at 200 strokes per minute or even more. The hydraulic presses deliver full force at any position in the stroke that offers a lot of flexibility in the dies. Another big advantage of these presses is that they are very easy to set for different operations. The job can be changed and reset the press easily. Hydraulic presses can have much longer strokes to accommodate the variety of dies. The ram stroke can be easily adjusted from minimum to maximum at any position without the need of additional bolster plate or gap piece.

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Fluid management Hydraulic press utilities are further increased by the new generation controls with fluid management. The shorter response time of valve delivers the oil to the actuator faster, to offer the better efficiency. For further improving the performance, accumulators are also provided in the fluid power system for better fluid management. The new generation controls along with high efficiency hydraulic circuits are the major factors in improving the hydraulic press performance. Electronically controlled proportional valves and electronic pressure switches are used to set or adjust the pressing force during the process. The stroke and distance can be controlled in microns by a laser dimension control system. The stroke, force and speed can be electronically controlled, therefore a PLC in the control panel. All these variables can be set and stored in a list of menus, which are instantly retrievable, when the job or process is to be changed. Leak control management Today, our presses are being equipped with new generation leak control management, including system save assemblies, modular concept with stack-system and Parker new generation EO-2 zero leak fittings.

Hydraulics: The smarter choice

1.5.2 The main reasons why all over the world people are changing from mechanical to hydraulic presses are: 1. Flexibility of operation 2. Multiple utilities 3. Full tonnage at any point of stroke 4. Ability to operate with a very wide range of stroke like 10 mm to 1500 mm on the same Machine. 5. The working stroke can be adjusted at any position throughout the length.

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6. Any desired speeds can be set at any position, and can be simply re-programmed. 7. Different operations can be carried at different pressures simply by adjusting the PLC command, pressure switch setting or pressure control valve. 8. Full programmable control over full ram stroke and position is possible. 9. Better tooling life and better product quality with better looking, crisp, clean forms and accuracy are achieved with a hydraulic press 10. Depending on the application, a hydraulic press may cost less than an equivalent mechanical press. Factors that may favor the use of hydraulic presses over their mechanical counterparts may include the following: 11. In small lot production where hand feeding and single stroking occurs, production rates equal to mechanical presses are achieved. 12. Single stroking does not result in additional press wear. 13. Die shut heights variations do not change the force applied. 14. There is no tonnage curve rerating factor. 15. Forming and drawing speeds can be accurately controlled throughout the stroke. 16. Hydraulic presses with double actions and or hydraulic die cushions are capable of forming and drawing operations that would not be possible in a mechanical press. 1.6 Hydraulic press limitation There are no hydraulic presses today that are as fast as the fastest mechanical presses. If speed is the sole requirement and the material feed stroke is relatively short, the mechanical press remains the best selection. 1.6.1 Stroke depth If a limit switch is used to determine the bottom, the stroke depth is not likely to be controlled much closer than .020". Many hydraulic presses can be set to reverse at a reselected pressure, which usually results in uniform parts. Generally, if absolute stroke depth accuracy is required, "kiss" blocks must be provided in the tooling.

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However, hydraulic presses are now available with an accurate built-in method of limiting the down stroke. new closed-loop servo-hydraulic system dramatically improves stroke depth control, guaranteeing consistent, repeatable results. In many applications, this system eliminates the need for "kiss" blocks. 1.6.2 Automatic feeding equipment. Hydraulic presses require some external or auxiliary power to feed stock. The feeder must have its own power, and must be integrated with the press control system. There is, however, an increasing selection of self-powered feeding systems available-roll feeds, hitch feeds, and air feeds. 1.6.3 Shock after breakthrough in blanking. Both mechanical and hydraulic presses experience this problem. But, the hydraulic system of a hydraulic press must also be isolated from the shock associated with decompression. If the hydraulic system does not contain an fittings. anti shock feature, this shock can affect the lines and

***

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Chapter 2
Design in brief
Force provided by the press 3 ton Working span 300 mm Stock length 150 mm Working height 300 mm 2.1 Frame design Using colled rolled C channel of m.s. material (c35mn75) [1]

y = 280mp
Taking f.o.s. - 3 [] =
280 3

= 93.33 Mp = 90 Mp

Fig 2.1 frame design 2.1.1 Design for link 1 Working span = length of link 1 = 300 mm For easy working = 400 mm (Handling and setting of the material)

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Bending moment BM= force x distance = 3x1000x9.81X525 = 15450750 N.mm Now for bending BM = [ ] x Z
BM Z =

15450750 90

> 171675 mm3 FOR SHEAR

force = area [ ]

[ ] =
=

[ ]
2
90 2

= 45 Mpa

area =

force

[ ]

area =

3000 9.81 45

= 654mm 2 > 2028mm 2

2.2 Cylinder design Hydraulic pressure 3000 kg. Working pressure 200 kg./cm [2]

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(according to pressure vessel)

2.2.1 Piston design 2.2.1 Diameter of plunger D=dia of plunger

p= D 2 p 4 3000= D 2 200 4 2 D =19.0969cm D=4.37cm =43.7mm;45mm

2.2.2 Diameter of cylinder D1 = dia of cylinder = clearance + (2dia.) = 1+(24.5) = 10 cm = 100 mm

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2.2.3 Thickness of cylinder D t+ p t= 1 1 2 t p 1200 = 5 1 800 = 5 [ 0.24]

= 1.2cm 1.5cm = 15mm

Stroke length = 150 mm 2.2.4 Cylinder mounting

2.2.4.1 Cylinder mounting Crussing stress

= = f area

3000 9.81

150 2 100 2 8 10 3 4 37471.43 = 11700 = 30 Mpa < 90 Mpa

d 0 2 d1 2 8 d b 2 4 3000 9.81

So,design is safe

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2.2.4.1 shearing of link 1 at cylinder joint

do t [ ] = f
t= 3000 9.81 45 150 = 1.3878mm

t = 3mm

Fig. 2.2.4.1 Standard channel

our market channel thickness = 6mm shear at welding between link 1and 2 select ark welding with m.s. welding rod (6mm) shear strength of welding material = 20 Mpa f

shear area =

[ ] 3000 9.81 = 20 = 1471.5 mm 2

2.3 Design for base Type of loading bending tension

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tensile stress =

f A 3000 9.81 2628 = 11.19 Mpa < 90 Mpa =

So, Design is safe

bending stress =

BM Z 15450750 = 196840.14 = 78.49 Mpa < 90 Mpa

design for [ ] = tensile stress + maximum bending moment stress at side A = tensile + bending = 11.19 + 78.49 = 89.68 Mpa < 90 Mpa

***

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Chapter 3 Hydraulic Power Pack

3.1 Introduction:Hydraulic power pack provides the fluid reservoir and power source to operate the machine tools, material handling devices, transport and other mobile equipment, in aviation systems.

Fig.: 3.1.1 General view of Hydraulic Power Pack 1. Electric motor 2. 3. 4. Manometer with shut-off selector Pressure relief valve Charge cover

5. Level indicator 6. Tank 7. Intake filter 8. Gear pump

9. Motor - pump connection group (bell housing) The power pack consists of a fixed displacement gear pump, directly driven by a flameproof electric motor mounted on a supply tank. The tank is fitted with a suction filter, filler/breather cap; oil level indicator; drain plug and connection manifold a flameproof, solenoid operated, directional.

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Control valve is fitted to the manifold, which is also fitted with a pressure gauge and internal pressure release valve. Switching the control valve, which directs the pump delivery alternately to the two sampler actuator connections, while, at the same time, returning the fluid, displaced from the actuator to the supply tank, operates the actuators. When the sampler probe is not being operated, the pump delivery is returned to the tank via the pressure relief valve. An additional pressure feed provides motive power for operating can changeover valves. 3.2. Component Tank Tank has the sufficient capacity to allow for drainage of the pipes and actuators in to tank. Filter breather The bypass Filter is installed on to the tank. It is self-contained and comprises an electric motor, a pump and a filter. The filter pump can also be used to filter and empty the tank by switching over a multi way valve. Due to its self-contained design, filter cartridges can be changed during operation of the hydraulic power unit.

Fig. (3.2.1) filter breather Model No. Connection BSP(F) Flow (Ipm) FSB - 05 150 FSB - 25 750 TB-05 1/4" 150 TB-25 3/4" 750

Table (3.2.1) for selection of filter breather

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stainless steel cap Vents underneath filtration 40 micron standard Metal or plastic strainer standard

Oil level indicator An oil level indicator is located immediately behind the self-contained filter system.

Fig.(3.2.2) oil level indicator -'O' Ring Type Construction - FACE TYPE: 3" & 5" between bolt centers - KNOB TYPE: 1/4" to 1 1/2" BSP (M) connection It is use for to indicate the oil level in the tank.

Suction strainer It is mounted at the end of the inlet pipe which is inner the tank.

Fig.(3.3.3) suction strainer

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Model No.

SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC 02 03 05 07 10 15 1 20 1 30 1 40 2 50 2 2 1/2 75 100 150 3 3

Connection BSP(F) Flow (Ipm)

1/4 3/8 1/2 3/4 1 8 12 20 25 4C

1/4 1/2 1/2 60 80

120 160 200 300 400 600

Table(3.3.2). Selection of suction and strainer - Reusable stainless steel 100 mesh standard - Sturdy all metal plated Steel construction - Filtration 149 microns - Paper filter also available as per custom built - Any standard Gear coupling

Fig.(3.3.4)gear coupling Model No. Pilot Bore (mm) Suitable Motor HP Table(3.3.3)- selection for gear coupling Material Steel hub & high graded plastic material sleeve Used for to connect the gear and motor shaft coupling JT-19 07 0.25 - 1 JT-28 10 1 -5 JT-38 12 5-10 JT-48 15 10-30 JT-65 20 40-60

Bell housing

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Fig. (3.3.5) bell housing - used for housing the motor on the oil tank with pump. - Material - High graded C.I. Casting - Size - 0.5 HP to 50 HP - Suitable for Gear Pumps, Vane Pumps, Piston Pumps -Also available coupling with bolt. Manifold blocks / sub plates

Fig.(3.3.6) manifold blocks Model Connection (BSP) NG-06 1/4", 3/8" & 1/2" NG-10 1/4", 3/8" & 1/2" NG-20 3/4" &1" Table(3.3.4) selection of manifold block - Manifold block for any type custom built systems are available - Any type of sub plates for DC valve-Pre. Relief valve and flow control valve 3.3 hydrostatic pumps:There is a wide range of available hydrostatic pumps and motors from the market. They are used for determining the performances of pumps are presented and some of the major

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parameters that can be used as a basis for comparison are outlined as a background for the selection process. However, because of the wide variety of the types of units that are available it is impossible to generalize on the selection process in any given application. Commonly machine builders and users have preferences for particular types of pumps that are based on experience with particular applications which are determined by factors such as the system function, its control, servicing aspects, environmental features, life expectancy, duty cycle and type of fluid to be used. The designer needs to be aware of the relative performance of the difference types and how this knowledge can be utilized in the selection process to suit a particular application. 3.3.1 Introduction Power transmission pumps in fluid power systems are usually hydrostatic or positive displacement units, which convert mechanical power into fluid power, the most common types being gear pumps, vane pumps and piston pumps. In these pumps fluid is transferred through the machine in discrete volumes e.g. a gear tooth cavity. The pump size and speed determines the fluid flow rate. Hydrostatic pumps are sources of flow so that when they are connected to a hydraulic motor, the outlet pressure will rise so that the flow can cause the motor to rotate against the load torque. Hydrostatic motors convert fluid power into mechanical power so that rotation of the output shaft can take place against an opposing torque load. Generally speaking pumps can be run as motors but a number of factors influence this possibility, some of which are: Not all pumps are reversible in direction of rotation because of their internal and external

sealing arrangements. Pumps are designed to operate at relatively high speeds and can be inefficient at low

speeds particularly during starting. Motor applications often require significant shaft side load capacity. Pump rotating

components are generally not designed to carry such shaft side loads and consequently cannot be directly coupled to the output drive where side loading exists. This chapter is concerned with describing the operating principles of hydrostatic units; some aspects involved in their selection and the determination and presentation of their performance characteristics. 3.3.2 Major aspects in the selection of pumps and motors

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The selection of pumps can be determined by a number of factors, which need to be considered by the user. These factors include: Cost Pressure ripple and noise Suction performance Contaminant sensitivity Speed Weight Fixed or variable displacement

Maximum pressure and flow, or power Fluid type. 3.3.3 Types of pumps and motors:The mechanical principle that is chosen in the design of high-pressure positive displacement pumps and motors, which includes those using pistons, vanes and various gear arrangements depends on a number of factors. These include the operating speed and pressure, the type of fluid and the requirement for providing variable displacement control. Pumps normally operate at constant speed (e.g. driven by electric motor) although in some situations (e.g. those driven by an internal combustion engine as found typically in mobile applications) the speed will vary over a small range. However, for motors it is normally required to operate at varying speeds including starting from rest (e.g. winch drives) and this aspect is reflected in the design of some available types. Positive displacement machines are quite distinct from those using rotodynamic principles, which are often used for the transfers of fluid at relatively high flow rate and low pressure. Positive displacement units operate relatively low flow rates and high-pressure and normally can only be used with fluids having good lubricating properties. However, there are machines that can be used with fire resistant fluids and pure water. 3.3.4 Fixed displacement units 3.3.4.1 External gear pumps/motors:-

30

In many applications, for operation at pressure up to 250 bar, external gear pumps/motors are used extensively because of their simplicity, low cost, good suction performance, low contamination sensitivity and relatively low weight. In applications requiring low noise, vane or internal gear pumps are often used.

Fig (3.3.4.1): External Gear Pump Essentially the unit consists of two meshing gear pinions, mounted in bearings and contained in a housing or body as shown in Figure 1. As the pinions are rotated, oil is trapped in the spaces between the gear teeth and the housing and carried round from the pump inlet to its outlet port when the trapped volume is discharged by the action of the gears meshing together. Torque is required at the input shaft at a level that is dependent on the outlet pressure acting on the gear teeth. When supplied with high-pressure flow the unit acts as a motor by providing torque to drive the load on the output shaft. Some of the outlet fluid is transferred back to the low pressure side by way of small leakage flows through the: Clearance space between the teeth and the housing Shaft bearing clearances. Clearance between the gear faces and the side plates in the housing. Most gear units have

pressure loaded side plates to minimize this leakage. The design of the unit is such as to minimize flow losses as they reduce its efficiency, particularly when using fluids of low viscosity such as with some water based fluids. The geometric capacity, or displacement, cannot be varied so their displacement is fixed. For a given gear form the manufacturer can produce pumps of different displacements by using different gear widths.

31

Standard types operate at speeds of 1000 to 3000RPM and at pressures up to 250 bar but higher speeds and pressure are available. Powers range from 1 to over 100kW. The efficiency of gear units has been raised during recent years, with peak overall efficiencies of 90% above. 3.3.4.2 Internal gear pumps:Internal gear pumps are well suited for a wide range of viscosity applications because of their relatively low speeds. This is especially true where suction conditions call for a

Fig. (3.3.4.2): Internal Gear Pump Pump with minimal inlet pressure requirements. For each revolution of an internal gear pump, the gears have a fairly long time to come out of mesh allowing the spaces between gear teeth to completely fill and not cavities. Internal gear pumps successfully pump viscosities above 1,320,000 cost / 6,000,000 SSU and very lowviscosity liquids, such as liquid propane and ammonia. In addition, lower speeds and low inlet pressures provide for constant and even discharge despite varying pressure conditions. In addition to superior high-viscosity handling capabilities, internal gear pumps offer a smooth, non-pulsating flow. Internal gear pumps are self-priming and can run dry. Because internal gear pumps have only two moving parts, they are reliable, simple to operate, and easy to maintain. They can operate in either direction, which allows for maximum utility with a variety of application requirements. How Internal Gear Pumps Works

Fig (3.3.4.3): Working Process Of Internal Gear Pump

32

1. Liquid enters the suction port between the rotor (large exterior gear) and idler (small interior gear) teeth. The arrows indicate the direction of the pump and liquid. 2. Liquid travels through the pump between the teeth of the "gear-within-a-gear" principle. The crescent shape divides the liquid and acts as a seal between the suction and discharge ports. 3. The pump head is now nearly flooded, just prior to forcing the liquid out of the discharge port. Intermeshing gears of the idler and rotor form locked pockets for the liquid, which assures volume control. 4. Rotor and idler teeth mesh completely to form a seal equidistant from the discharge and suction ports. This seal forces the liquid out of the discharge port.

> Advantages Only two moving parts. Only one stuffing box. Positive suction, non-pulsating discharge. Ideal for high-viscosity liquids. Constant and even discharge regardless of pressure conditions. Operates well in either direction.

Can be made to operate with one direction of flow with either rotation. Low NPSH required. Single adjustable end clearance. Easy to maintain.

Flexible design offers application customization. > Disadvantages Usually requires moderate speeds. Medium pressure limitations. One bearing runs in the product pumped.

33

3.3.4.3 Vane pumps/motors 3.3.5. Variable displacement units:- Vane pumps:- Piston pumps/motors:Applications: Pressurizing Fuel Oil Machine Tool Lubrication Oil Transfer Hydraulic Power Packs

3.4. Equation for pumps and motors:3.4.1Flow and speed relationship:For the ideal machine with no leakage, the displacement of the machine and its speed of rotation determine the flow rate Q Thus: Q = Dw Where D is volumetric displacement [m'rad'J W is the rotational speed [rad sec.] For pumps that are driven by electric motors the speed is often constant. However for motors, the speed depends on the level of the supplied flow: Thus: w = Q/D 3.4.2 Volumetric efficiency:The internal flow leakage in pumps and motors affects the relationship between flow and speed and is taken into account by the use of the volumetric efficiency (n). Thus for pumps equation 1 becomes Q = ncwD' And for motors equation 2 becomes w = nvQ/D The volumetric efficiency varies with the fluid viscosity, pressure and rotating speed as discussed in more detail in chapter 8. Manufacturers will usually give valves for the volumetric efficiency for operation at specified conditions.

34

3.4..3 Torque and pressure relationship:For the ideal machine, the mechanical power is entirely converted to fluid power. Power = T w = P Q Where T is torque (Nm) P is the differential pressure [Nm2]

From equation 5 we get: T = QP/W which from equation 2 gives T = PD Thus the ideal torque is proportional to the pressure for a given displacement. In a pump this is the input torque required from the prime mover and for a motor, it is the output torque available from the motor shaft. 3.4.4 Mechanical efficiency:The presence of friction between the moving parts creates mechanical losses that are represented by the mechanical efficiency (nm). Thus: For pumps the required input torque is given by T = PD /Nm And for motors the output torque is given by T-nmPD The mechanical efficiency, as for the volumetric efficiency, will vary with the fluid viscosity, pressure and rotating speed. The power input, H to a pump is: H = PQ/nmnv The power output from a motor is: H - nmnvPQ The total efficiency of both units is therefore: nT = nmnv Figure 7 and 8 show how the measured performance of pumps and motors are presented for use with a particular fluid at a particular viscosity. For the pump it can be seen that the flow output reduces with the output pressure at constant speed because of the effect of the increasing leakage flow loss.

35

For the motor, the output torque varies with increasing speed at constant pressure as a result of the variation in the mechanical efficiency. The theoretical analysis chapter 8 shows how the efficiencies are related to the system parameters, which enables the performance for operation at other conditions to be predicted. 3.5 Pump selection parameters:The process involved in the selection of a suitable pump for a given application depends on many parameters, some of which were summarized in section 2. As a consequence a generalization is not possible but some major features can be identified as shown in Table 3.6 Hydraulic Valve:Hydraulic valves control and direct the oil from the time it leaves, the pump until it starts on its return to the reservoir in a hydraulic circuit. The relief valve is almost always the first one encountered by the oil after it leaves the pump. From that point on throughout the circuit, the type of valve employed depends upon the design of the circuit. In a very simple circuit the second and only other valve used will probably be the master control valve. In a complex circuit the oil may flow through a sequence valve, master control valve, reducing valve, flow control valve, check valve and several others before it finally returns to the reservoir. Hydraulic valves as used in industrial applications are built in several pressure ranges. The majority of present applications are in the range of 0 to 1500 Ib per sq in., but the trend is toward higher pressures. Various types of valves are used in hydraulic systems to control or regulate the flow medium. Basically valves are expected to control: (a) Blocking or stopping of flow (b) Direction of flow (c) Pressure of flow media (d) Flow quantity 3.6.1 Types of hydraulic valves:3.6.1.1 Hydraulic Control Valve Hydraulic valves control and direct the oil from the time it leaves, the pump until it starts on its return to the reservoir in a hydraulic circuit. The relief valve is almost always the first one

36

encountered by the oil after it leaves the pump. From that point on throughout the circuit, the type of valve employed depends upon the design of the circuit. In a very simple circuit the second and only other valve used will probably be the master control valve. In a complex circuit the oil may flow through a sequence valve, master control valve, reducing valve, flow control valve, check valve and several others before it finally returns to the reservoir. Hydraulic valves as used in industrial applications are built in several pressure ranges. The majority of present applications are in the range of 0 to 1500 Ib per sq in., but the trend is toward higher pressures. Various types of valves are used in hydraulic systems to control or regulate the flow medium. Basically valves are expected to control: Blocking or stopping of flow

Direction of flow Pressure of flow media

Flow quantity The various parameters that need to be controlled in the case of oil energy are as follows: 1. In a hydraulic machine the actuators make to and fro motion. Hence the direction of oil feeding the cylinder or motor needs to be reversed. This means that the direction of oil flow is an essential aspect of hydraulic operation. Direction control valves achieve this. 2. Oil energy does the work due to pressure in the oil system. In a mechanical or hydraulic

system there may be a need to increase or decrease the oil pressure depending on the specific requirement. Hence a group of valves called pressure control valves have been designed. 3. The speed of the actuators needs to be altered as per operational requirement. For this

purpose hydraulic systems use flow control valves. 3.6.1.2 Hydraulic Flow Control Valve

37

Fig.(3.6.1.2.1) hydraulic flow control valve Model No. Connection BSP(F) Max. Flow (Ipm) 10 20 40 70 120 30 60 Table (3.6.1.2.1) selection of hydraulic flow control valve - Integrated check valves allows reversed free flow from outlet to inlet - Max. Working pressure 350 bar - Type: Threaded / Modular Flow-control or speed-control valves are used to control the volume of oil that passes a given point. A flow-control valve is a metering valve and a check valve built into one housing. The volume may be controlled as it approaches a component or as it leaves a component. The design of the metering valve may vary from a needle to a cam-shaped device. Cam-operated, flow-control valves are of value where flow control is only required for a portion of the cylinder stroke. They can be used as a cushioning device to provide extra long cushioning for a cylinder or for slip feeding arrangements by placing multiple cams on a trip bar. The one disadvantage of this type of valve is that the orifice must be designed for each size of pump as there is no adjustment means available. 1/4" 3/8" 1/2" 3/4" 1" DV-08 DV-10 DV-12 DV-16 DV-20 TCM 06 TCM 10

DRV - 08 DRV- 10 DRV -12 DRV -16 DRV - 20

38

Flow-control valves are normally built in sizes from 4 -inch up to 2-inch pipe size. The majority is built for 1500 Ib per sq in. maximum pressure but a number are available for much higher pressures. > Flow-control valve gives trouble due to one of the following reasons. If they are placed incorrectly or backwards in the circuit- this occurs in spite of the fact that they are usually marked with a large arrow showing the direction of the controlled flow. Dirt lodging in the orifice causes it to clog up and produce erratic feed. Dirt under the check valve seat does not allow the check to seal off thus producing leakage. A considerable change in oil viscosity has a definite effect on the flow setting, especially on a needle-type metering device. Excess internal leakage produces poor flow control. In this case, if the leakage becomes too much, it is possible that even changing the setting on the needle from one extreme to the other will not change the flow rate appreciably. > Types of Flow Control Valves > Hydraulic Solenoid Valve A solenoid consists of a coil surrounding a moveable iron core, which is pulled to the operating position with respect to the coil when the coil is energies.(Thus a solenoid is an electromagnetic mechanical transducer, which converts an electrical signal into a mechanical output force.) The hydraulic solenoid valves are used in pilot circuits for controlling spools of multiple control valves and tilting angles of variable displacement pumps. They have a compact design and ease of service providing reliable control in aerospace, defense and marine applications. The solenoid valves may have wet and dry solenoids, minimum current consumption with an exceptional force to size ratio and twin coil configuration. They offer maximum reliability in hostile environments. Solenoid controlled direction controlled valves can be either single solenoid or double solenoid operated. Most DC types are available with various powers rating from 12 V onwards and with solenoid coil indicator lights. These valves are available in sub-plate mounted type or modular/manifold type.

39

Being economical and easy to install, these valves feature integral waterproof coils, several push-on termination options and rugged metal covers and are designed for low-pressure applications such as pilot systems or power shift transmission control. 3.6.1.3 Hydraulic Check Valve The non-return valves or check valves are used to block the reverse flow of oil or gas in a fluid power circuit additionally this valve may be used for pressure control or directional control. The check valve consists of a valve body with inlet and outlet ports and an internal movable member biased by the spring. The movable member can be a flapper or a plunger but most often in valves of hydraulic systems, it is a ball or poppet. They are built to provide free flow in one direction and a check in the other direction and prevent flow-back in hydraulic systems

Fig.(3.6.1.3.1) check valve CI-10T, CMModel No. Connection BSP(F) Max. Flow (Ipm) 1/2" 80 1" 160 1 1/2" 350 30 60 OS CI-20T, CI20S CI-30T ,CI-30S CIM-06 CIM-10

Table(3.6.1.3.1)selection for hydraulic check valve - Steel poppet type construction - Prevents flow in reverse direction - Max. Working pressure 350 bar - Type : Threaded / Sub plate / Modular

40

Check valves are of several styles: swinging disc, ball, plunger, and poppet. Check valves of the pilot-operated type are also popular. The connection at the bottom is connected to a remotely operated pilot valve, as in the ordinary check valve; free flow is permitted in one direction when the line pressure lifts the plunger thus opening the valve. The flow is checked in the opposite direction until pilot pressure is applied to the blind end of the plunger through the pilot connection. This causes the plunger to unseat the valve spool and oil is allowed to flow through the valve. When system pressure at the check valve inlet port is high enough to overcome the biasing spring force on the poppet, the poppet is pushed off its seat allowing oil to flow through the valve. This is known as the check valves free flow direction. When the fluid attempts reverse direction of flow, the spring pushes the poppet back on the seat to block flow through the valve. Check valves can be direct acting or pilot operated. A pilot operated version is used where the no-flow characteristic of the valve is desired only for a portion of the system cycle. A pilot operated check valve also allows free flow from its inlet port to its outlet port just as in an in-line check valve. The design and construction of a check valve makes it one of the simplest fluid power components. Though simple, its use can make the system sophisticated. By application of check valves one can also design many sophisticated circuit diagrams where a constant flow can be maintained in both directions by using them in a bridge. 3.7 Hydraulic Fluid:Hydraulic fluids are liquids that are composed of a variety of chemicals. They are used in automobile automatic transmissions, brakes, and power steering; fork lift trucks; tractors; bulldozers; industrial machinery; and airplanes. 3.7.1 Types of hydraulic fluids:The various materials in use as hydraulic fluids range from water to inorganic salt solutions to water oil emulsions, synthetic and naturally occurring organic materials. Water was the first hydraulic fluid used during the early stages of industrial revolution. Presently, petroleum based hydrocarbon type fluids are in wide use. A good hydraulic fluid comprises of:

41

Good Lubricity

A hydraulic system has various components that contain surfaces that are in close contact and move in relation to each other. A good hydraulic fluid must protect against wear and separate & lubricate such surfaces. Stable Viscosity Viscosity is a vital fluid property that varies with temperature and pressure. Fluids having large changes of viscosity with temperature are commonly referred as low viscosity index fluids and those having small changes of viscosity with temperature are known as high viscosity index fluids. Chemical and Physical Stability The characteristics of a fluid should remain unchanged during an extended useful life. Since many aspects of stability are chemical in nature, the temperatures to which the fluid will be exposed is an important criterion in the selection of a hydraulic fluid. System Compatibility The hydraulic fluid should be inert to materials used in or near the hydraulic equipment. If the fluid in anyway attacks, destroys, dissolves or changes parts of the hydraulic system, the system may lose its functional efficiency and may start malfunctioning. Good Heat Dissipation Pressure drops, mechanical friction, fluid friction, leakages, all generates heat. The fluid must carry the generated heat away and readily dissipate it to the atmosphere or coolers. Flash Point The flash point of hydraulic oil is defined as the temperature at which flashes will be generated when the oil is brought into contact with any heated matter. Fire Resistant The hydraulic liquids are petroleum derivatives and thus for critical applications, artificial or synthetic hydraulic fluids are used which have high fire resistances. Various grades of fluids with high water content are also available nowadays for oil hydraulic systems. Prevent Rust Formation

42

Moisture and oxygen cause rusting of iron parts in the system that can lead to abrasive wear of system components and also act as catalyst to increase the rate of oxidation of the fluid. Fluids with rust inhibitors minimize rust formation in the system. Low in Volatility The fluid should posses low vapor pressure or high boiling point characteristic. The vapor pressure of a fluid varies with temperature and hence the operating temperature range of the system is important in determining the suitability of the fluid. Low Coefficient of Expansion The hydraulic fluid should have a low coefficient of expansion to minimize the total volume of the system required at the operating temperature. 3.8 Hydraulic Oil:Hydraulic oil is formulated from high quality base oils and a balanced additive system that satisfies a variety of hydraulic equipment requirements. Hydraulic oil protects using an effective balance of metallic detergents combined with inhibitors to control oxidation, wear, corrosion, and rust. The hydraulic oils have multitude of applications and usage. They increase the component life reducing downtime and are compatible with other engine oils used in hydraulic applications. They are good in hydraulic systems that encounter wide ambient temperatures, systems containing gears and bearings with anti-wear properties and industries including: agriculture, construction, trucking, mining and quarrying.

Fig. (3.8.1): Foot Mounted Motor

43

3.9 Hydraulic symbolic circuit:-

Fig. (3.9.1) Hydraulic symbolic circuit 3.10 Mounting and overall diagram:-

Fig (3.10.1): Mounting and Overall View

3.11 Calculations:Technical specifications:Oil tank: l0 ltr Q = Flow rate: 1.1 ltr/min Working pressure: 100kg/cm2 Coupling (Lt or gear) Pipe size For pressure velocity: 4m/min Suction velocity: 1m/min

44

 d.c.valve: solenoid Hand operated power supply: 10 or 30 3.12 Data to find out :Motor selection: HP: Power = Q*P/600 Where P in bar Q in lit/min Now= 100kg/cm2 => 981 * 10A4N/m2 =>98.1 bar Power (kW) =98.1 * 3.4/600 = 0.57kW = 0.74 Hp 0.75 Hp There for we so select the motor having the 0.75 Hp form motor catalog. We will select the foot mounted motor B5 Construction, frame no 63. 3.13 Pump selections; Pump Theoretical Nominal type Displacement displacement Cm3/rev atl500rev/min OP3003 1.23 Op3004 1.64 Op3006 2.18 Op3008 2.87 Op3011 3.18 1.2 1.8 2.5 3.4 4.8 Max Max speed at Min speed at max pressure max pressure continuous pressure bar rev/min 207 207 207 207 207 4000 4000 4000 4000 4000 500 500 500 500 500

Table (3.13.1): Pump Selection Catalog From above catalog we will select the pump OP3003

45

Chapter 4 Analysis

46

4.1 Summary This report documents design and analysis information created and maintained using the ANSYS engineering software program. Each scenario listed below represents one complete engineering simulation. Scenario 1 Based on the Pro/ENGINEER part. Considered the effect of structural loads. Calculated structural results. No convergence criteria defined. No alert criteria defined. See Scenario 1 below for supporting details and Appendix A1 for corresponding figures.

47

4.2 Introduction The ANSYS CAE (Computer-Aided Engineering) software program was used in conjunction with 3D CAD (Computer-Aided Design) solid geometry to simulate the behavior of mechanical bodies under thermal/structural loading conditions. ANSYS automated FEA (Finite Element Analysis) technologies from ANSYS, Inc. to generate the results listed in this report. Each scenario presented below represents one complete engineering simulation. The definition of a simulation includes known factors about a design such as material properties per body, contact behavior between bodies (in an assembly), and types and magnitudes of loading conditions. The results of a simulation provide insight into how the bodies may perform and how the design might be improved. Multiple scenarios allow comparison of results given different loading conditions, materials or geometric configurations. Convergence and alert criteria may be defined for any of the results and can serve as guides for evaluating the quality of calculated results and the acceptability of values in the context of known design requirements. Solution history provides a means of assessing the quality of results by examining how values change during successive iterations of solution refinement. Convergence criteria set a specific limit on the allowable change in a result between iterations. A result meeting this criterion is said to be "converged". Alert criteria define "allowable" ranges for result values. Alert ranges typically represent known aspects of the design specification. Unit System Angle Rotational Velocity Metric (m, kg, N, C, s, V, A) Degrees rad/s

48

Notice Do not accept or reject a design based solely on the data presented in this report. Evaluate designs by considering this information in conjunction with experimental test data and the practical experience of design engineers and analysts. A quality approach to engineering design usually mandates physical testing as the final means of validating structural integrity to a measured precision.

49

4.3. SCENARIO 1 4.3.1. "MODEL" "Model" obtains geometry from the Pro/ENGINEER part " cylinder.prt.3". The bounding box for the model measures 0.15 by 0.15 by 0.28 m along the global x, y and z axes, respectively. The model has a total mass of 8.88 kg. The model has a total volume of 1.1310-3 m. Object Name State Fully Defined Definition Source Type Length Unit Element Control Display Style C:\Documents and Settings\Administrator\Desktop\M1.PRT.4 ProEngineer Inches Program Controlled Part Color Bounding Box Length X Length Y Length Z 0.15 m 0.15 m 0.28 m Properties Volume Mass 166.31 m 1.3055e+006 kg Statistics Bodies Active Bodies Nodes 1 1 30771 Cylinder

50

Elements

14939 Preferences

Import Solid Bodies Import Surface Bodies Import Line Bodies Parameter Processing Personal Parameter Key CAD Attribute Transfer Named Selection Processing Material Properties Transfer CAD Associability Import Coordinate Systems Reader Save Part File Import Using Instances Do Smart Update Attach File Via Temp File Analysis Type Mixed Import Resolution Enclosure and Symmetry Processing

Yes Yes Yes Yes DS No No No Yes No No Yes No No 3-D None Yes Table (4.3.1)model

4.3.1.1. Mesh "Mesh", associated with "Model" has an overall relevance of 0. "Mesh" contains 26893 nodes and 15305 elements. No mesh controls specified. 4.3.2. "Environment"

51

Simulation Type is set to Static Analysis Type is set to Static Structural "Environment" contains all loading conditions defined for "Model" in this scenario. 4.3.2.1. Structural Loading Reaction Force N/A Reaction Force Vector N/A Reaction Moment N/A Reaction Moment Vector N/A

Name

Type

Magnitude

Vector

"Pressure"

Pressure

29,400.0 Pa

N/A

Table(4.3.2.1) Structural Supports 4.3.2.2. Structural Supports Reaction Force Reaction Force Vector Reaction Moment Reaction Moment Vector

Name

Type

Table(4.3.2.2) Structural Supports 4.3.3. "Solution" Solver Type is set to Program Controlled

Weak Springs is set to Program Controlled

Large Deflection is set to off "Solution" contains the calculated response for "Model" given loading conditions defined in "Environment". One or more bodies may be under constrained and experiencing rigid body motion. Weak springs have been added to attain a solution. Thermal expansion calculations use a constant reference temperature of 22.0 C for "CYLINDER". Theoretically, at a uniform temperature of 22.0 C no strain results from thermal expansion or contraction.

52

4.3.3.1. Structural Results Name "Maximum Shear Stress" Figure Scope Minimum Maximum Occurs On Max. Alert min. Criteria

A1.1, A1.2

"Model"

779.85 Pa

202,747.6 Pa

cylinder cylinder None

Convergence tracking not enabled. 4.4 Appendices 4.4.1. Scenario 1

Figure 4.1.2. "Maximum Shear Stress" Contours

53

4.4.2. Definition of "Structural Steel" 4.4.2.1. "Structural Steel" Constant Properties Name Compressive Ultimate Strength Compressive Yield Strength Density Poisson's Ratio Tensile Yield Strength Tensile Ultimate Strength Young's Modulus Thermal Expansion Specific Heat Thermal Conductivity Relative Permeability Table 4.2.2. Alternating stress Cycles 10.0 20.0 50.0 100.0 200.0 2,000.0 10,000.0 20,000.0 100,000.0 200,000.0 1,000,000.0 Alternating Stress 4.0109 Pa 2.83109 Pa 1.9109 Pa 1.41109 Pa 1.07109 Pa 4.41108 Pa 2.62108 Pa 2.14108 Pa 1.38108 Pa 1.14108 Pa 8.62107 Pa Value 0.0 Pa 2.5108 Pa 7,850.0 kg/m 0.3 2.5108 Pa 4.6108 Pa 2.01011 Pa 1.210-5 1/C 434.0 J/kgC 60.5 W/mC 10,000.0

54

n Fig.(4.2.2)alternative stress vs cycles Mean Value 0.0 4.4.2.3. Strain-Life Parameters Strength Coefficient Strength Exponent Ductility Coefficient Ductility Exponent Cyclic Strength Coefficient Cyclic Strain Hardening Exponent 9.2108 Pa -0.11 0.21 -0.47 1.0109 Pa 0.2

55

4.4.3. Distributing This Report The following table lists the files that you need to include for posting this report to an Internet or Intranet web server or for moving this report to a different location. Store all files in the same folder as the HTML page. This report was originally generated in the folder "C:\Documents and Settings\Administrator\Application Data\Ansys\v100\". 4.4.3.1. Files Included In This Report File Name "DSReport.htm" "StyleSheet.css" Description This HTML page. The Cascading Style Sheet used to format the HTML page. The ANSYS image displayed at the top of the title page. Figure A1.1. "Maximum Shear Stress" Contours Figure A1.2. "Maximum Shear Stress" Contours Table A2.2. "Alternating Stress" Alternating Stress Table A2.4. "Strain-Life Parameters" Strain-Life Parameters Fig (4.4.3.1) Files Included In This Report

"AnsCompanyLogo.gif" "DS0001.png" "DS0002.png" "Table0001.png" "Table0002.png"

56

Press frame

First Saved Last Saved Product Version

Monday, March 17, 2008 Monday, March 17, 2008 11.0 Release

Press frame body

57

4.5 SCENARIO 2

Model
o

Geometry M1

o o

Mesh Static Structural Analysis Settings Loads Solution Solution Information Results Max Equivalent Stress Results Max Shear Stress Results

Material Data
o

Structural Steel

4.5.1 Model Units Unit System Angle Rotational Velocity Metric (m, kg, N, C, s, V, A) Degrees rad/s

Table(4.5.1) Units

58

4.5.1.1 Model Geometry Object Name State Definition Source Type Length Unit Element Control Display Style Bounding Box Length X Length Y Length Z Properties Volume Mass Statistics Bodies Active Bodies Nodes Elements Preferences Import Solid Bodies Yes 1 1 30771 14939 166.31 m 1.3055e+006 kg 7.6415 m 20.472 m 19.05 m C:\Documents and Settings\Administrator\Desktop\M1.PRT.4 ProEngineer Inches Program Controlled Part Color Geometry Fully Defined

59

Import Surface Bodies Import Line Bodies Parameter Processing Personal Parameter Key CAD Attribute Transfer Named Selection Processing Material Properties Transfer CAD Associability Import Coordinate Systems Reader Save Part File Import Using Instances Do Smart Update Attach File Via Temp File Analysis Type Mixed Import Resolution Enclosure and Symmetry Processing

Yes Yes Yes DS No No Yes Yes Yes Yes Yes No No 3-D None Yes

Table(4.5.1.1) Model > Geometry 4.5.1.1Geometry

Object Name State

M1 Meshed

Graphics Properties Visible Transparency Definition Yes 1

60

Suppressed Material Stiffness Behavior Nonlinear Material Effects Bounding Box Length X Length Y Length Z Properties Volume Mass Centroid X Centroid Y Centroid Z

No Structural Steel Flexible Yes

7.6415 m 20.472 m 19.05 m

166.31 m 1.3055e+006 kg -0.4079 m 9.5673 m -5.475 m

Moment of Inertia Ip1 9.5294e+007 kgm Moment of Inertia Ip2 4.6551e+007 kgm Moment of Inertia Ip3 6.3272e+007 kgm Statistics Nodes Elements 30771 14939

Table (4.5.1.1) Model > Geometry > Parts 4.5.1.2. Mesh Object Name State Defaults Physics Preference Mechanical Mesh Solved

61

Relevance Advanced Relevance Center Element Size Shape Checking Solid Element Midside Nodes Straight Sided Elements Initial Size Seed Smoothing Transition Statistics Nodes Elements

Coarse Default Standard Mechanical Program Controlled No Active Assembly Low Fast

30771 14939

Table (4.5.4.2) Model > Mesh

Fig. (4.5.4.2) Model > Mesh > Figure

62

4.5.2 Static structural Object Name State Static Structural Fully Defined

Definition Physics Type Analysis Type Structural Static Structural Options Reference Temp 22. C

Table (4.5.2) Model > Analysis 4.5.2.1 Analysis setting Object Name State Analysis Settings Fully Defined Step Controls Number Of Steps Current Step Number Step End Time Auto Time Stepping 1. 1. 1. s Program Controlled Solver Controls Solver Type Weak Springs Large Deflection Inertia Relief Nonlinear Controls Force Convergence Moment Convergence Displacement Program Controlled Program Controlled Program Controlled Program Controlled Program Controlled Off Off

63

Convergence Rotation Convergence Line Search Program Controlled Program Controlled Output Controls Calculate Stress Calculate Strain Calculate Results At Yes Yes All Time Points

Analysis Data Management Solver Files Directory H:\M1 Simulation Files\Static Structural (2)\ Future Analysis Save ANSYS db Delete Unneeded Files Nonlinear Solution None No Yes No

Table (4.5.2.1) Model > Static Structural > Analysis Settings

Fig. (4.5.2.1) Model > Static Structural > Figure

64

4.5.2.2 Static structural load Object Name State Force Fixed Support

Fully Defined Scope

Scoping Method Geometry

Geometry Selection 1 Face Definition 2 Faces

Define By Type

Vector Force Fixed Support

Magnitude 29430 N (ramped) Direction Suppressed Defined No

Table (4.5.2.2)Model > Static Structural > Loads

Fig.(4.5.2.2) Model > Static Structural > Force

65

4.5.3 solution Object Name Solution State Solved Adaptive Mesh Refinement Max Refinement Loops Refinement Depth 1. 2.

Table(4.5.3) Model > Static Structural > Solution 4.5.3.1 solution information Object Name Solution Information State Solution Information Solution Output Newton-Raphson Residuals Update Interval Display Points Solver Output 0 2.5 s All Solved

Table(4.5.3.1) Model > Static Structural > Solution > Solution Information 4.5.3.2 solution information result Object Name State Scope Geometry All Bodies Definition Type Equivalent (von-Mises) Stress Maximum Shear Stress Total Deformation Equivalent Stress Maximum Shear Stress Solved Total Deformation

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Display Time Results Minimum Maximum 3.402e-015 Pa 4.8124e+005 Pa

End Time

1.8474e-015 Pa 2.4677e+005 Pa

0. m 7.949e-005 m

Information Time Load Step Substep Iteration Number 1. s 1 1 1

Table (4.5.3.2) Model > Static Structural > Solution > Results

Fig. (4.5.3.2)Model > Static Structural > Solution > Equivalent Stress > Figure

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Fig. (4.5.3.3) Model > Static Structural > Solution > Maximum Shear Stress > Figure

Fig. (4.5.3.4) Model > Static Structural > Solution > Total Deformation > Figure

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4.5.3.3. Maximum equivalent stress Object Name State Definition Theory Max Equivalent Stress Max Equivalent Stress Solved

Stress Limit Type Tensile Yield Per Material Table. (4.5.3.3.1) Model > Static Structural > Solution > Stress Safety Tools 4.5.3.3.1 Maximum equivalent stress result Object Name Safety Factor Safety Margin State Scope Geometry All Bodies Definition Type Safety Factor Safety Margin Display Time Results Minimum > 10 >9 End Time Solved

Information Time Load Step Substep Iteration Number 1. s 1 1 1

Table (4.5.3.3.1) Model > Static Structural > Solution > Max Equivalent Stress > Results

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4.5.3.3.2 Stress safety tools Object Name State Definition Theory Factor Max Shear Stress 0.5 Max Shear Stress Solved

Stress Limit Type Tensile Yield Per Material Table (4.5.3.3.2) Model > Static Structural > Solution > Stress Safety Tools 4.5.3.4. Maximum shear stress result Object Name Safety Factor Safety Margin State Scope Geometry All Bodies Definition Type Safety Factor Safety Margin Display Time Results Minimum > 10 >9 End Time Solved

Information Time Load Step Substep Iteration Number 1. s 1 1 1

Table (4.5.3.4) Model > Static Structural > Solution > Max Shear Stress > Results

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Material data 4.5.4.1 Structural steel Structural steel Young's Modulus Poisson's Ratio Density Thermal Expansion Tensile Yield Strength Compressive Yield Strength Tensile Ultimate Strength Compressive Ultimate Strength Thermal Thermal Conductivity Specific Heat Electromagnetics Relative Permeability 10000 60.5 W/mC 434. J/kgC 2.e+011 Pa 0.3 7850. kg/m 1.2e-005 1/C 2.5e+008 Pa 2.5e+008 Pa 4.6e+008 Pa 0. Pa

Resistivity 1.7e-007 Ohmm Table (4.5.4.1) Structural Steel > properties

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Fig.(4.5.4.1)Structural Steel > Alternating Stress 4.5.4.2 Alternating stress cycle data Cycles Alternating Stress Pa 10. 20. 50. 100. 200. 2000. 10000 20000 1.e+005 2.e+005 1.e+006 3.999e+009 2.827e+009 1.896e+009 1.413e+009 1.069e+009 4.41e+008 2.62e+008 2.14e+008 1.38e+008 1.14e+008 8.62e+007

Table (4.5.4.2)Structural Steel > Alternating Stress > Alternating Stress vs. Cycles

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Fig. (4.5.4.2) Strain amplitude>reversal to failure 4.5.4.3. strain life parameter Strength Coefficient Pa 9.2e+008 Strength Exponent Ductility Coefficient Ductility Exponent -0.106 0.213 -0.47

Cyclic Strength Coefficient Pa 1.e+009 Cyclic Strain Hardening Exponent 0.2

Table (4.5.4.3) Structural Steel > Strain-Life Parameters

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Chapter 5 Manufacturing
MANUFACTURING PROCESS OF EACH PARTS WITH SEQUENCE OF OPERATION & MACHINE USED 5.1 Operation process chart of our project An operation chart is a process chart giving an overall picture by recording in sequence only the main operation. An operation is a graphical representation of a process. It shows order of operation and inspection in O.P.C. only the principle operation to be carried out and inspection made to insure the effectiveness are recorded of worm does them and where they are performed in preparing such a chart only the symbols for operation and inspection are necessary. In marking an operation process chart usually convenient to start with a vertical line drawn on right hand side of the page to show the operation and inspection undergone by the principle unit of the component PF assembly. The symbols which are used in flow process in operation chart. The following symbols are used in flow operation process chart.

1. Operation(o) Operation indicates the main step in the process method or procedure. A circle denoted it. 2. Inspection () the inspection is denoted by a square inspection indicates a for quality or check for quality.

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2. Transport(=>) 3. It denoted by arrow it indicates the movement of work les material as equipment of workers material or equipment from place to place. 4. Delay(d) Delay indicates a delay in sequence of events of temporary. 5. Combined activities When it desired to show activities performed at the same time of by the same work station the symbols those activities are combined. 5.2 machine used 1. Center lathe machine 2. Hacksaw machine 3. Drilling machine 4. Shaper machine 5. Welding machine

Lathe machine ----------165mm 1829mm 0.008 to 734mm/min 50mm 400 k.g. 750mm 235rmm 120mm 195mm 7.5 h.p.

o Height of center o Length of bed o Range of spindle speed o Range of feeds o Hole of spindle o Net weight of machine o Distance between two center o Cross slide travel o Tail stock spindle travel o Electric motor

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Hacksaw machine --------60mm 100mm 75 to 600mm 60 350mm 1h.p. 300 k.g. 28000 RS

o Maximum dia. of rod to cut o Maximum square section to cut o Stroke adjustable o No. of stroke per minute o Blade size o Motor o Approach weight o Price in each

Drilling machine Range of spindle speeds ---35 to 700mm 400mm 350mm

o Distance from spindle to bed o Distance between center to column

shaper machine ---------500mm 4 500mm 400mm 15 0.3 to 0.4mm 10 to 33 5 2300 k.g.

o Stroke length o No. of speed o Table travel o Depth of table o Feed change o Range of feed change o Stroke per minute o Motor o Net weight

Welding machine

o 3 Phase A.C. 440 Volt TS-S-H2 o Oil cooled transformer

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o AMP from 50 to 300 AMPS o Electrode 6mm dia with coating

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5.3 Construction of main body

78

5.3 Construction of piston

79

5.4 Construction of cylinder

80

5.5 Construction of die bed

81

5.6 Construction of die bed support

82

5.7 Construction of hydraulic power pack

83

Chapter 6 Costing
PART NAME K.G. RATE LABOUR PER K.G. C CHANNEL CYLINDER RIB RIB FOR SUPPORT BED 1 ROD TOOL HOLDER ANGLE STAND L&KEY BOLTS LIMIT SWITCH PANEL BOARD POWER PACK HOSE PIPE FOOT PADLE M.S. SHEET WELDING ROD FIGHTER DISH GAS CUTTING TOTAL 2 1NO 20 300 50 1 30 8 NOS 2 NOS 50 50 25 150 10 10 7000 100 60 1800 200 300 3000 15000 500 300 1000 240 100 300 40180 60 6 20 3 50 50 10 10 50 10 3600 5000 1500 180 COST (RS)

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Conclusion From this overall project we conclude that the analytical data for the press are as bellow: Overall stress on the frame is 90 Mpa. In over calculation shear stress for the link 1 is 45 Mpa. (< 90Mpa.). The analytical calculation for the channel of link 1 at the cylinder joint thickness is required 3mm. ,so the deformation at that point is 3mm. but in our analysis report it is 2.5mm. From this result and performance of our working project and market survey we have to conclude that our design is economical, safe, and easy to operate.

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Chapter 3 Hydraulic Power Pack

3.1 Introduction:Hydraulic power pack provides the fluid reservoir and power source to operate the machine tools, material handling devices, transport and other mobile equipment, in aviation systems.

Fig.: 3.1.1 General view of Hydraulic Power Pack 1. Electric motor 2. 3. 4. Manometer with shut-off selector Pressure relief valve Charge cover

5. Level indicator 6. Tank 7. Intake filter 8. Gear pump

9. Motor - pump connection group (bell housing) The power pack consists of a fixed displacement gear pump, directly driven by a flameproof electric motor mounted on a supply tank. The tank is fitted with a suction filter, filler/breather cap; oil level indicator; drain plug and connection manifold a flameproof, solenoid operated, directional.

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Control valve is fitted to the manifold, which is also fitted with a pressure gauge and internal pressure release valve. Switching the control valve, which directs the pump delivery alternately to the two sampler actuator connections, while, at the same time, returning the fluid, displaced from the actuator to the supply tank, operates the actuators. When the sampler probe is not being operated, the pump delivery is returned to the tank via the pressure relief valve. An additional pressure feed provides motive power for operating can changeover valves. 3.2. Component Tank Tank has the sufficient capacity to allow for drainage of the pipes and actuators in to tank. Filter breather The bypass Filter is installed on to the tank. It is self-contained and comprises an electric motor, a pump and a filter. The filter pump can also be used to filter and empty the tank by switching over a multiway valve. Due to its self-contained design, filter cartridges can be changed during operation of the hydraulic power unit.

Fig. (3.2.1) filter breather Model No. Connection BSP(F) Flow (Ipm) FSB - 05 150 FSB - 25 750 TB-05 1/4" 150 TB-25 3/4" 750

Table (3.2.1) for selection of filter breather stainless steel cap Vents underneath

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filtration 40 micron standard Metal or plastic strainer standard

Oil level indicator An oil level indicator is located immediately behind the self-contained filter system.

Fig.(3.2.2) oil level indicator -'O' Ring Type Construction - FACE TYPE: 3" & 5" between bolt centers - KNOB TYPE: 1/4" to 1 1/2" BSP (M) connection It is use for to indicate the oil level in the tank. Suction strainer It is mounted at the end of the inlet pipe which is inner the tank.

Fig.(3.3.3) suction strainer Model No. SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC3 SC 02 03 05 07 10 15 1 20 1 30 1 40 50 2 1/2 75 100 3 150 Connectio 1/4 3/8 1/2 n BSP(F) " " " 3/4" 1" 2" 2" 3" 3"

1/4 1/2 1/2

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" Flow (Ipm) 8 12 20 25 4C 60

" 80

"

"

120 160 200 300 400 600

Table(3.3.2). Selection of suction and strainer - Reusable stainless steel 100 mesh standard - Sturdy all metal plated Steel construction - Filtration 149 microns - Paper filter also available as per custom built - Any standard Gear coupling

Fig.(3.3.4)gear coupling Model No. Pilot Bore (mm) Suitable Motor HP Table(3.3.3)- selection for gear coupling Material Steel hub & high graded plastic material sleeve Used for to connect the gear and motor shaft coupling JT-19 07 0.25 - 1 JT-28 10 1 -5 JT-38 12 5-10 JT-48 15 10-30 JT-65 20 40-60

Bell housing

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Fig. (3.3.5) bell housing - used for housing the motor on the oil tank with pump. - Material - High graded C.I. Casting - Size - 0.5 HP to 50 HP - Suitable for Gear Pumps, Vane Pumps, Piston Pumps -Also available coupling with bolt. Manifold blocks / sub plates

Fig.(3.3.6) manifold blocks Model Connection (BSP) NG-06 1/4", 3/8" & 1/2" NG-10 1/4", 3/8" & 1/2" NG-20 3/4" &1" Table(3.3.4) selection of manifold block - Manifold block for any type custom built systems are available - Any type of sub plates for DC valve-Pre. Relief valve and flow control valve 3.3 HYDROSTATIC PUMPS :There is a wide range of available hydrostatic pumps and motors from the market. They are used for determining the performances of pumps are presented and some of the major parameters that can be used as a basis for comparison are outlined as a background for the selection process. However, because of the wide variety of the types of units that are available it is impossible to generalize on the selection process in any given application. Commonly machine builders and users have preferences for particular types of pumps that are based on experience with particular applications which are determined by factors such as the system function, its control, servicing aspects, environmental features, life expectancy, duty

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cycle and type of fluid to be used. The designer needs to be aware of the relative performance of the difference types and how this knowledge can be utilized in the selection process to suit a particular application. 3.3.1 Introduction Power transmission pumps in fluid power systems are usually hydrostatic or positive displacement units, which convert mechanical power into fluid power, the most common types being gear pumps, vane pumps and piston pumps. In these pumps fluid is transferred through the machine in discrete volumes e.g. a gear tooth cavity. The pump size and speed determines the fluid flow rate. Hydrostatic pumps are sources of flow so that when they are connected to a hydraulic motor, the outlet pressure will rise so that the flow can cause the motor to rotate against the load torque. Hydrostatic motors convert fluid power into mechanical power so that rotation of the output shaft can take place against an opposing torque load. Generally speaking pumps can be run as motors but a number of factors influence this possibility, some of which are: Not all pumps are reversible in direction of rotation because of their internal and external

sealing arrangements. Pumps are designed to operate at relatively high speeds and can be inefficient at low

speeds particularly during starting. Motor applications often require significant shaft side load capacity. Pump rotating

components are generally not designed to carry such shaft side loads and consequently cannot be directly coupled to the output drive where side loading exists. This chapter is concerned with describing the operating principles of hydrostatic units; some aspects involved in their selection and the determination and presentation of their performance characteristics. 3.3.2 Major aspects in the selection of pumps and motors The selection of pumps can be determined by a number of factors, which need to be considered by the user. These factors include: Cost Pressure ripple and noise Suction performance

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Contaminant sensitivity Speed Weight Fixed or variable displacement

Maximum pressure and flow, or power Fluid type. 3.3.3 Types of pumps and motors:The mechanical principle that is chosen in the design of high-pressure positive displacement pumps and motors, which includes those using pistons, vanes and various gear arrangements depends on a number of factors. These include the operating speed and pressure, the type of fluid and the requirement for providing variable displacement control. Pumps normally operate at constant speed (e.g. driven by electric motor) although in some situations (e.g. those driven by an internal combustion engine as found typically in mobile applications) the speed will vary over a small range. However, for motors it is normally required to operate at varying speeds including starting from rest (e.g. winch drives) and this aspect is reflected in the design of some available types. Positive displacement machines are quite distinct from those using rotodynamic principles, which are often used for the transfers of fluid at relatively high flow rate and low pressure. Positive displacement units operate relatively low flow rates and high-pressure and normally can only be used with fluids having good lubricating properties. However, there are machines that can be used with fire resistant fluids and pure water. 3.3.4 Fixed displacement units 3.3.4.1 External gear pumps/motors:In many applications, for operation at pressure up to 250 bar, external gear pumps/motors are used extensively because of their simplicity, low cost, good suction performance, low contamination sensitivity and relatively low weight. In applications requiring low noise, vane or internal gear pumps are often used.

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Fig (3.3.4.1): External Gear Pump Essentially the unit consists of two meshing gear pinions, mounted in bearings and contained in a housing or body as shown in Figure 1. As the pinions are rotated, oil is trapped in the spaces between the gear teeth and the housing and carried round from the pump inlet to its outlet port when the trapped volume is discharged by the action of the gears meshing together. Torque is required at the input shaft at a level that is dependent on the outlet pressure acting on the gear teeth. When supplied with high-pressure flow the unit acts as a motor by providing torque to drive the load on the output shaft. Some of the outlet fluid is transferred back to the low pressure side by way of small leakage flows through the: Clearance space between the teeth and the housing Shaft bearing clearances. Clearance between the gear faces and the side plates in the housing. Most gear units have

pressure loaded side plates to minimize this leakage. The design of the unit is such as to minimize flow losses as they reduce its efficiency, particularly when using fluids of low viscosity such as with some water based fluids. The geometric capacity, or displacement, cannot be varied so their displacement is fixed. For a given gear form the manufacturer can produce pumps of different displacements by using different gear widths. Standard types operate at speeds of 1000 to 3000RPM and at pressures up to 250 bar but higher speeds and pressure are available. Powers range from 1 to over 100kW. The efficiency of gear units has been raised during recent years, with peak overall efficiencies of 90% above. 3.3.4.2 Internal gear pumps:-

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Internal gear pumps are well suited for a wide range of viscosity applications because of their relatively low speeds. This is especially true where suction conditions call for a

Fig. (3.3.4.2): Internal Gear Pump Pump with minimal inlet pressure requirements. For each revolution of an internal gear pump, the gears have a fairly long time to come out of mesh allowing the spaces between gear teeth to completely fill and not cavities. Internal gear pumps successfully pump viscosities above 1,320,000 cost / 6,000,000 SSU and very lowviscosity liquids, such as liquid propane and ammonia. In addition, lower speeds and low inlet pressures provide for constant and even discharge despite varying pressure conditions. In addition to superior high-viscosity handling capabilities, internal gear pumps offer a smooth, non-pulsating flow. Internal gear pumps are self-priming and can run dry. Because internal gear pumps have only two moving parts, they are reliable, simple to operate, and easy to maintain. They can operate in either direction, which allows for maximum utility with a variety of application requirements. How Internal Gear Pumps Works

Fig (3.3.4.3): Working Process Of Internal Gear Pump 1. Liquid enters the suction port between the rotor (large exterior gear) and idler (small interior gear) teeth. The arrows indicate the direction of the pump and liquid.

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2. Liquid travels through the pump between the teeth of the "gear-within-a-gear" principle. The crescent shape divides the liquid and acts as a seal between the suction and discharge ports. 3. The pump head is now nearly flooded, just prior to forcing the liquid out of the discharge port. Intermeshing gears of the idler and rotor form locked pockets for the liquid, which assures volume control. 4. Rotor and idler teeth mesh completely to form a seal equidistant from the discharge and suction ports. This seal forces the liquid out of the discharge port. > Advantages Only two moving parts. Only one stuffing box. Positive suction, non-pulsating discharge. Ideal for high-viscosity liquids. Constant and even discharge regardless of pressure conditions. Operates well in either direction.

Can be made to operate with one direction of flow with either rotation. Low NPSH required. Single adjustable end clearance. Easy to maintain.

Flexible design offers application customization. > Disadvantages Usually requires moderate speeds. Medium pressure limitations. One bearing runs in the product pumped.

3.3.4.3 Vane pumps/motors 3.3.5. Variable displacement units:- Vane pumps:- Piston pumps/motors:-

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Applications: Pressurizing Fuel Oil Machine Tool Lubrication Oil Transfer Hydraulic Power Packs

3.4. Equation for pumps and motors :3.4.1Flow and speed relationship :For the ideal machine with no leakage, the displacement of the machine and its speed of rotation determine the flow rate Q Thus: Q = Dw Where D is volumetric displacement [m'rad'J W is the rotational speed [rad sec.] For pumps that are driven by electric motors the speed is often constant. However for motors, the speed depends on the level of the supplied flow: Thus: w = Q/D 3.4.2 Volumetric efficiency:The internal flow leakage in pumps and motors affects the relationship between flow and speed and is taken into account by the use of the volumetric efficiency (n). Thus for pumps equation 1 becomes Q = ncwD' And for motors equation 2 becomes w = nvQ/D The volumetric efficiency varies with the fluid viscosity, pressure and rotating speed as discussed in more detail in chapter 8. Manufacturers will usually give valves for the volumetric efficiency for operation at specified conditions. 3.4..3 Torque and pressure relationship:For the ideal machine, the mechanical power is entirely converted to fluid power. Power = T w = P Q Where T is torque (Nm) P is the differential pressure [Nm2]

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From equation 5 we get: T = QP/W which from equation 2 gives T = PD Thus the ideal torque is proportional to the pressure for a given displacement. In a pump this is the input torque required from the prime mover and for a motor, it is the output torque available from the motor shaft. 3.4.4 Mechanical efficiency :The presence of friction between the moving parts creates mechanical losses that are represented by the mechanical efficiency (nm). Thus: For pumps the required input torque is given by T = PD /Nm And for motors the output torque is given by T-nmPD The mechanical efficiency, as for the volumetric efficiency, will vary with the fluid viscosity, pressure and rotating speed. The power input, H to a pump is: H = PQ/nmnv The power output from a motor is: H - nmnvPQ The total efficiency of both units is therefore: nT = nmnv Figure 7 and 8 show how the measured performance of pumps and motors are presented for use with a particular fluid at a particular viscosity. For the pump it can be seen that the flow output reduces with the output pressure at constant speed because of the effect of the increasing leakage flow loss. For the motor, the output torque varies with increasing speed at constant pressure as a result of the variation in the mechanical efficiency. The theoretical analysis chapter 8 shows how the efficiencies are related to the system parameters, which enables the performance for operation at other conditions to be predicted. 3.5 Pump selection parameters:-

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The process involved in the selection of a suitable pump for a given application depends on many parameters, some of which were summarized in section 2. As a consequence a generalization is not possible but some major features can be identified as shown in Table 3.6 Hydraulic Valve:Hydraulic valves control and direct the oil from the time it leaves, the pump until it starts on its return to the reservoir in a hydraulic circuit. The relief valve is almost always the first one encountered by the oil after it leaves the pump. From that point on throughout the circuit, the type of valve employed depends upon the design of the circuit. In a very simple circuit the second and only other valve used will probably be the master control valve. In a complex circuit the oil may flow through a sequence valve, master control valve, reducing valve, flow control valve, check valve and several others before it finally returns to the reservoir. Hydraulic valves as used in industrial applications are built in several pressure ranges. The majority of present applications are in the range of 0 to 1500 Ib per sq in., but the trend is toward higher pressures. Various types of valves are used in hydraulic systems to control or regulate the flow medium. Basically valves are expected to control: (a) Blocking or stopping of flow (b) Direction of flow (c) Pressure of flow media (d) Flow quantity 3.6.1 Types of hydraulic valves:3.6.1.1 Hydraulic Control Valve Hydraulic valves control and direct the oil from the time it leaves, the pump until it starts on its return to the reservoir in a hydraulic circuit. The relief valve is almost always the first one encountered by the oil after it leaves the pump. From that point on throughout the circuit, the type of valve employed depends upon the design of the circuit. In a very simple circuit the second and only other valve used will probably be the master control valve. In a complex circuit the oil may flow through a sequence valve, master control valve, reducing valve, flow control valve, check valve and several others before it finally returns to the reservoir.

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Hydraulic valves as used in industrial applications are built in several pressure ranges. The majority of present applications are in the range of 0 to 1500 Ib per sq in., but the trend is toward higher pressures. Various types of valves are used in hydraulic systems to control or regulate the flow medium. Basically valves are expected to control: Blocking or stopping of flow

Direction of flow Pressure of flow media

Flow quantity The various parameters that need to be controlled in the case of oil energy are as follows: 1. In a hydraulic machine the actuators make to and fro motion. Hence the direction of oil feeding the cylinder or motor needs to be reversed. This means that the direction of oil flow is an essential aspect of hydraulic operation. Direction control valves achieve this. 2. Oil energy does the work due to pressure in the oil system. In a mechanical or hydraulic

system there may be a need to increase or decrease the oil pressure depending on the specific requirement. Hence a group of valves called pressure control valves have been designed. 3. The speed of the actuators needs to be altered as per operational requirement. For this

purpose hydraulic systems use flow control valves. 3.6.1.2 Hydraulic Flow Control Valve

Fig.(3.6.1.2.1) hydraulic flow control valve Model No. DV-08 DV-10 DV-12 DV-16 DV-20 TCM 06 TCM 10

DRV - 08 DRV- 10 DRV -12 DRV -16 DRV - 20

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Connection BSP(F) Max. Flow (Ipm) 10 20 40 70 120 30 60 Table (3.6.1.2.1) selection of hydraulic flow control valve - Integrated check valves allows reversed free flow from outlet to inlet - Max. Working pressure 350 bar - Type: Threaded / Modular Flow-control or speed-control valves are used to control the volume of oil that passes a given point. A flow-control valve is a metering valve and a check valve built into one housing. The volume may be controlled as it approaches a component or as it leaves a component. The design of the metering valve may vary from a needle to a cam-shaped device. Cam-operated, flow-control valves are of value where flow control is only required for a portion of the cylinder stroke. They can be used as a cushioning device to provide extra long cushioning for a cylinder or for slip feeding arrangements by placing multiple cams on a trip bar. The one disadvantage of this type of valve is that the orifice must be designed for each size of pump as there is no adjustment means available. Flow-control valves are normally built in sizes from 4 -inch up to 2-inch pipe size. The majority is built for 1500 Ib per sq in. maximum pressure but a number are available for much higher pressures. > Flow-control valve gives trouble due to one of the following reasons. If they are placed incorrectly or backwards in the circuit- this occurs in spite of the fact that they are usually marked with a large arrow showing the direction of the controlled flow. Dirt lodging in the orifice causes it to clog up and produce erratic feed. Dirt under the check valve seat does not allow the check to seal off thus producing leakage. A considerable change in oil viscosity has a definite effect on the flow setting, especially on a needle-type metering device. 1/4" 3/8" 1/2" 3/4" 1" -

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Excess internal leakage produces poor flow control. In this case, if the leakage becomes too much, it is possible that even changing the setting on the needle from one extreme to the other will not change the flow rate appreciably. > Types of Flow Control Valves > Hydraulic Solenoid Valve A solenoid consists of a coil surrounding a moveable iron core, which is pulled to the operating position with respect to the coil when the coil is energies.(Thus a solenoid is an electromagnetic mechanical transducer, which converts an electrical signal into a mechanical output force.) The hydraulic solenoid valves are used in pilot circuits for controlling spools of multiple control valves and tilting angles of variable displacement pumps. They have a compact design and ease of service providing reliable control in aerospace, defense and marine applications. The solenoid valves may have wet and dry solenoids, minimum current consumption with an exceptional force to size ratio and twin coil configuration. They offer maximum reliability in hostile environments. Solenoid controlled direction controlled valves can be either single solenoid or double solenoid operated. Most DC types are available with various powers rating from 12 V onwards and with solenoid coil indicator lights. These valves are available in sub-plate mounted type or modular/manifold type. Being economical and easy to install, these valves feature integral waterproof coils, several push-on termination options and rugged metal covers and are designed for low-pressure applications such as pilot systems or power shift transmission control. 3.6.1.3 Hydraulic Check Valve The non-return valves or check valves are used to block the reverse flow of oil or gas in a fluid power circuit additionally this valve may be used for pressure control or directional control. The check valve consists of a valve body with inlet and outlet ports and an internal movable member biased by the spring. The movable member can be a flapper or a plunger but most often in valves of hydraulic systems, it is a ball or poppet. They are built to provide free flow in one direction and a check in the other direction and prevent flow-back in hydraulic systems

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Fig.(3.6.1.3.1) check valve CI-10T, CMModel No. Connection BSP(F) Max. Flow (Ipm) 1/2" 80 1" 160 1 1/2" 350 30 60 OS CI-20T, CI20S CI-30T ,CI-30S CIM-06 CIM-10

Table(3.6.1.3.1)selection for hydraulic check valve - Steel poppet tye construction - Prevents flow in revers direction - Max. Working pressure 350 bar - Type : Threaded / Subplate / Modular Check valves are of several styles: swinging disc, ball, plunger, and poppet. Check valves of the pilot-operated type are also popular. The connection at the bottom is connected to a remotely operated pilot valve, as in the ordinary check valve; free flow is permitted in one direction when the line pressure lifts the plunger thus opening the valve. The flow is checked in the opposite direction until pilot pressure is applied to the blind end of the plunger through the pilot connection. This causes the plunger to unseat the valve spool and oil is allowed to flow through the valve. When system pressure at the check valve inlet port is high enough to overcome the biasing spring force on the poppet, the poppet is pushed off its seat allowing oil to flow through the valve. This is known as the check valves free flow direction. When the fluid attempts reverse direction of flow, the spring pushes the poppet back on the seat to block flow through the valve. Check valves can be direct acting or pilot operated. A pilot operated version is used

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where the no-flow characteristic of the valve is desired only for a portion of the system cycle. A pilot operated check valve also allows free flow from its inlet port to its outlet port just as in an in-line check valve. The design and construction of a check valve makes it one of the simplest fluid power components. Though simple, its use can make the system sophisticated. By application of check valves one can also design many sophisticated circuit diagrams where a constant flow can be maintained in both directions by using them in a bridge. 3.7 Hydraulic Fluid:Hydraulic fluids are liquids that are composed of a variety of chemicals. They are used in automobile automatic transmissions, brakes, and power steering; fork lift trucks; tractors; bulldozers; industrial machinery; and airplanes. 3.7.1 Types of hydraulic fluids:The various materials in use as hydraulic fluids range from water to inorganic salt solutions to water oil emulsions, synthetic and naturally occurring organic materials. Water was the first hydraulic fluid used during the early stages of industrial revolution. Presently, petroleum based hydrocarbon type fluids are in wide use. A good hydraulic fluid comprises of: Good Lubricity A hydraulic system has various components that contain surfaces that are in close contact and move in relation to each other. A good hydraulic fluid must protect against wear and separate & lubricate such surfaces. Stable Viscosity Viscosity is a vital fluid property that varies with temperature and pressure. Fluids having large changes of viscosity with temperature are commonly referred as low viscosity index fluids and those having small changes of viscosity with temperature are known as high viscosity index fluids. Chemical and Physical Stability The characteristics of a fluid should remain unchanged during an extended useful life. Since many aspects of stability are chemical in nature, the temperatures to which the fluid will be exposed is an important criterion in the selection of a hydraulic fluid.

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 System Compatibility The hydraulic fluid should be inert to materials used in or near the hydraulic equipment. If the fluid in anyway attacks, destroys, dissolves or changes parts of the hydraulic system, the system may lose its functional efficiency and may start malfunctioning. Good Heat Dissipation Pressure drops, mechanical friction, fluid friction, leakages, all generates heat. The fluid must carry the generated heat away and readily dissipate it to the atmosphere or coolers. Flash Point The flash point of hydraulic oil is defined as the temperature at which flashes will be generated when the oil is brought into contact with any heated matter. Fire Resistant The hydraulic liquids are petroleum derivatives and thus for critical applications, artificial or synthetic hydraulic fluids are used which have high fire resistances. Various grades of fluids with high water content are also available nowadays for oil hydraulic systems. Prevent Rust Formation Moisture and oxygen cause rusting of iron parts in the system that can lead to abrasive wear of system components and also act as catalyst to increase the rate of oxidation of the fluid. Fluids with rust inhibitors minimize rust formation in the system. Low in Volatility The fluid should posses low vapor pressure or high boiling point characteristic. The vapor pressure of a fluid varies with temperature and hence the operating temperature range of the system is important in determining the suitability of the fluid. Low Coefficient of Expansion The hydraulic fluid should have a low coefficient of expansion to minimize the total volume of the system required at the operating temperature. 3.8 Hydraulic Oil:Hydraulic oil is formulated from high quality base oils and a balanced additive system that satisfies a variety of hydraulic equipment requirements. Hydraulic oil protects using an

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effective balance of metallic detergents combined with inhibitors to control oxidation, wear, corrosion, and rust. The hydraulic oils have multitude of applications and usage. They increase the component life reducing downtime and are compatible with other engine oils used in hydraulic applications. They are good in hydraulic systems that encounter wide ambient temperatures, systems containing gears and bearings with anti-wear properties and industries including: agriculture, construction, trucking, mining and quarrying.

Fig. (3.8.1): Foot Mounted Motor 3.9 Hydraulic symbolic circuit:-

Fig. (3.9.1) Hydraulic symbolic circuit 3.10 Mounting and overall diagram:-

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Fig (3.10.1): Mounting and Overall View

3.11 Calculations:Technical specifications:Oil tank: l0 ltr Q = Flow rate: 1.1 ltr/min Working pressure: 100kg/cm2 Coupling (Lt or gear) Pipe size For pressure velocity: 4m/min Suction velocity: 1m/min d.c.valve: solenoid Hand operated power supply: 10 or 30 3.12 Data to find out :Motor selection: HP: Power = Q*P/600 Where P in bar Q in lit/min Now= 100kg/cm2 => 981 * 10A4N/m2 =>98.1 bar Power (kW) =98.1 * 3.4/600

106

= 0.57kW = 0.74 Hp 0.75 Hp There for we so select the motor having the 0.75 Hp form motor catalog. We will select the foot mounted motor B5 Construction, frame no 63. 3.13 Pump selections; Pump Theoretical Nominal type Displacement displacement Cm3/rev atl500rev/min OP3003 1.23 Op3004 1.64 Op3006 2.18 Op3008 2.87 Op3011 3.18 1.2 1.8 2.5 3.4 4.8 Max Max speed at Min speed at max pressure max pressure continuous pressure bar rev/min 207 207 207 207 207 4000 4000 4000 4000 4000 500 500 500 500 500

Table (3.13.1): Pump Selection Catalog From above catalog we will select the pump OP3003

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Chapter 2
Design in brief
Force provided by the press 3 ton Working span 300 mm Stock length 150 mm Working height 300 mm 2.2 Frame design Using colled rolled C channel of m.s. material (c35mn75)

y = 280mp
Taking f.o.s. - 3 [] =
280 3

= 93.33 Mp = 90 Mp

Link 1

Link 2

Link 3
2.1.1 Design for link 1 Working span = length of link 1

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= 300 mm For easy working = 400 mm (Handling and setting of the material) Bending moment BM= force x distance = 3x1000x9.81X525 = 15450750 N.mm Now for bending BM = [ ] x Z
BM Z =

15450750 90

> 171675 mm3 FOR SHEAR

force = area [ ]

[ ] =
=

[ ]
2
90 2

= 45 Mpa

area =

force

[ ]

area =

3000 9.81 45

= 654mm 2 > 2028mm 2

2.2 Cylinder design

109

Hydraulic pressure 3000 kg. Working pressure 200 kg./cm (according to pressure vessel)

2.2.1 Piston design 2.2.1 Diameter of plunger D=dia of plunger

p= D 2 p 4 3000= D 2 200 4 2 D =19.0969cm D=4.37cm =43.7mm;45mm

2.2.2 Diameter of cylinder

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D1 = dia of cylinder = clearance + (2dia.) = 1+(24.5) = 10 cm = 100 mm 2.2.3 Thickness of cylinder D t+ p t= 1 1 2 t p 1200 = 5 1 800 = 5 [ 0.24]
= 1.2cm 1.5cm = 15mm

Stroke length = 150 mm 2.2.4 Cylinder mounting

2.2.4.1 Cylinder mounting Crussing stress

= = f area

3000 9.81

150 2 100 2 8 10 3 4 37471.43 = 11700 = 30 Mpa < 90 Mpa

d 0 2 d1 2 8 d b 2 4 3000 9.81

So,design is safe

111

2.2.4.1 shearing of link 1 at cylinder joint

do t [ ] = f
3000 9.81 45 150 = 1.3878mm t = 3mm t=

Fig. 2.2.4.1 Standard chennal

our market channel thickness = 6mm shear at welding between link 1and 2 select ark welding with m.s. welding rod (6mm) shear strength of welding material = 20 Mpa f

shear area =

[ ] 3000 9.81 = 20 = 1471.5 mm 2

2.3 Design for Link 2 Type of loading bending tension

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tensile stress =

f A 3000 9.81 2628 = 11.19 Mpa < 90 Mpa =

So, Design is safe

bending stress =

BM Z 15450750 = 196840.14 = 78.49 Mpa < 90 Mpa

design for [ ] = tensile stress + maximum bending moment stress at side A = tensile + bending = 11.19 + 78.49 = 89.68 Mpa < 90 Mpa

***

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CYLINDER - PRESS BODY ANALYSIS Author Chirag, brijesh, rakesh, chirag Project Created Tuesday, February 20, 2008 at 9:18:50 PM Project Last Modified Tuesday, February 20, 2008 at 9:37:48 PM Report Created Wednesday, February 20, 2008 at 10:09:15 AM Software Used ANSYS 10.0 Database D:\Ansys outputs\project\cylinder.dsdb

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1. SUMMARY This report documents design and analysis information created and maintained using the ANSYS engineering software program. Each scenario listed below represents one complete engineering simulation. SCENARIO 1 Based on the Pro/ENGINEER part. Considered the effect of structural loads. Calculated structural results. No convergence criteria defined. No alert criteria defined. See Scenario 1 below for supporting details and Appendix A1 for corresponding figures.

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2. INTRODUCTION The ANSYS CAE (Computer-Aided Engineering) software program was used in conjunction with 3D CAD (Computer-Aided Design) solid geometry to simulate the behavior of mechanical bodies under thermal/structural loading conditions. ANSYS automated FEA (Finite Element Analysis) technologies from ANSYS, Inc. to generate the results listed in this report. Each scenario presented below represents one complete engineering simulation. The definition of a simulation includes known factors about a design such as material properties per body, contact behavior between bodies (in an assembly), and types and magnitudes of loading conditions. The results of a simulation provide insight into how the bodies may perform and how the design might be improved. Multiple scenarios allow comparison of results given different loading conditions, materials or geometric configurations. Convergence and alert criteria may be defined for any of the results and can serve as guides for evaluating the quality of calculated results and the acceptability of values in the context of known design requirements. Solution history provides a means of assessing the quality of results by examining how values change during successive iterations of solution refinement. Convergence criteria set a specific limit on the allowable change in a result between iterations. A result meeting this criterion is said to be "converged". Alert criteria define "allowable" ranges for result values. Alert ranges typically represent known aspects of the design specification. Unit System Angle Rotational Velocity Metric (m, kg, N, C, s, V, A) Degrees rad/s

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Notice Do not accept or reject a design based solely on the data presented in this report. Evaluate designs by considering this information in conjunction with experimental test data and the practical experience of design engineers and analysts. A quality approach to engineering design usually mandates physical testing as the final means of validating structural integrity to a measured precision.

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3. SCENARIO 1 3.1. "MODEL" "Model" obtains geometry from the Pro/ENGINEER part " cylinder.prt.3". The bounding box for the model measures 0.15 by 0.15 by 0.28 m along the global x, y and z axes, respectively. The model has a total mass of 8.88 kg. The model has a total volume of 1.1310-3 m. Object Name State Fully Defined Definition Source Type Length Unit Element Control Display Style C:\Documents and Settings\Administrator\Desktop\M1.PRT.4 ProEngineer Inches Program Controlled Part Color Bounding Box Length X Length Y Length Z 0.15 m 0.15 m 0.28 m Properties Volume Mass 166.31 m 1.3055e+006 kg Statistics Bodies 1 Cylinder

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Active Bodies Nodes Elements

1 30771 14939 Preferences

Import Solid Bodies Import Surface Bodies Import Line Bodies Parameter Processing Personal Parameter Key CAD Attribute Transfer Named Selection Processing Material Properties Transfer CAD Associability Import Coordinate Systems Reader Save Part File Import Using Instances Do Smart Update Attach File Via Temp File Analysis Type Mixed Import Resolution Enclosure and Symmetry Processing 3.1.1. Mesh

Yes Yes Yes Yes DS No No No Yes No No Yes No No 3-D None Yes

"Mesh", associated with "Model" has an overall relevance of 0. "Mesh" contains 26893 nodes and 15305 elements.

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No mesh controls specified. 3.2. "Environment" Simulation Type is set to Static Analysis Type is set to Static Structural "Environment" contains all loading conditions defined for "Model" in this scenario.

3.2.1. Structural Loading

Name

Type

Magnitude Vector

Reaction Force N/A

Reaction Force Vector N/A

Reaction Moment N/A

Reaction Moment Vector N/A

"Pressure" Pressure 29,400.0 Pa N/A Structural Supports 3.2.2.1. Structural Supports Name Type Reaction Force

Reaction Force Vector

Reaction Moment

Reaction Moment Vector

3.2.2.2. Weak Springs Name Type Reaction Force Reaction Force Vector Reaction Moment Reaction Moment Vector

3.3. "Solution" Solver Type is set to Program Controlled

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Weak Springs is set to Program Controlled Large Deflection is set to off "Solution" contains the calculated response for "Model" given loading conditions defined in "Environment". One or more bodies may be underconstrained and experiencing rigid body motion. Weak springs have been added to attain a solution. Thermal expansion calculations use a constant reference temperature of 22.0 C for "CYLINDER". Theoretically, at a uniform temperature of 22.0 C no strain results from thermal expansion or contraction. 3.3.1. Structural Results Name "Maximum Shear Stress" Figure A1.1, A1.2 Scope Minimum Maximum 202,747.6 Pa Occurs On Max. min. Alert Criteria None

"Model"

779.85 Pa

cylinder cylinder

Convergence tracking not enabled.

121

4 APPENDICES 4.1. Scenario 1

Figure A1.2. "Maximum Shear Stress" Contours

122

4.2. Definition of "Structural Steel" 4.2.1. "Structural Steel" Constant Properties Name Compressive Ultimate Strength Compressive Yield Strength Density Poisson's Ratio Tensile Yield Strength Tensile Ultimate Strength Young's Modulus Thermal Expansion Specific Heat Thermal Conductivity Relative Permeability Table 4.2.2. Alternating stress Cycles 10.0 20.0 50.0 100.0 200.0 2,000.0 10,000.0 20,000.0 100,000.0 200,000.0 1,000,000.0 Alternating Stress 4.0109 Pa 2.83109 Pa 1.9109 Pa 1.41109 Pa 1.07109 Pa 4.41108 Pa 2.62108 Pa 2.14108 Pa 1.38108 Pa 1.14108 Pa 8.62107 Pa Value 0.0 Pa 2.5108 Pa 7,850.0 kg/m 0.3 2.5108 Pa 4.6108 Pa 2.01011 Pa 1.210-5 1/C 434.0 J/kgC 60.5 W/mC 10,000.0

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n Mean Value 0.0 4.2.3. Strain-Life Parameters Strength Coefficient Strength Exponent Ductility Coefficient Ductility Exponent Cyclic Strength Coefficient Cyclic Strain Hardening Exponent 9.2108 Pa -0.11 0.21 -0.47 1.0109 Pa 0.2

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4.3. Distributing This Report The following table lists the files that you need to include for posting this report to an Internet or Intranet web server or for moving this report to a different location. Store all files in the same folder as the HTML page. This report was originally generated in the folder "C:\Documents and Settings\Administrator\Application Data\Ansys\v100\". 4.3.1. Files Included In This Report File Name "DSReport.htm" "StyleSheet.css" "AnsCompanyLogo.gif" "DS0001.png" "DS0002.png" "Table0001.png" "Table0002.png" Description This HTML page. The Cascading Style Sheet used to format the HTML page. The ANSYS image displayed at the top of the title page. Figure A1.1. "Maximum Shear Stress" Contours Figure A1.2. "Maximum Shear Stress" Contours Table A2.2. "Alternating Stress" Alternating Stress Table A2.4. "Strain-Life Parameters" Strain-Life Parameters

125

Press frame

First Saved Last Saved Product Version

Monday, March 17, 2008 Monday, March 17, 2008 11.0 Release

126

Fig. () Press frame body

127

5 SCENARIO 2

Model
o

Geometry M1

o o

Mesh Static Structural Analysis Settings Loads Solution Solution Information Results Max Equivalent Stress Results Max Shear Stress Results

Material Data
o

Structural Steel

5.1 Model Units Unit System Angle Rotational Velocity Table() Units Metric (m, kg, N, C, s, V, A) Degrees rad/s

128

5.1.1 Model Geometry Object Name State Definition Source Type Length Unit Element Control Display Style Bounding Box Length X Length Y Length Z Properties Volume Mass Statistics Bodies Active Bodies Nodes Elements Preferences Import Solid Bodies Yes 1 1 30771 14939 166.31 m 1.3055e+006 kg 7.6415 m 20.472 m 19.05 m C:\Documents and Settings\Administrator\Desktop\M1.PRT.4 ProEngineer Inches Program Controlled Part Color Geometry Fully Defined

129

Import Surface Bodies Import Line Bodies Parameter Processing Personal Parameter Key CAD Attribute Transfer Named Selection Processing Material Properties Transfer CAD Associability Import Coordinate Systems Reader Save Part File Import Using Instances Do Smart Update Attach File Via Temp File Analysis Type Mixed Import Resolution Enclosure and Symmetry Processing Table() Model > Geometry

Yes Yes Yes DS No No Yes Yes Yes Yes Yes No No 3-D None Yes

Model > Geometry > Parts Object Name State M1 Meshed

Graphics Properties Visible Transparency Definition Yes 1

130

Suppressed Material Stiffness Behavior Nonlinear Material Effects Bounding Box Length X Length Y Length Z Properties Volume Mass Centroid X Centroid Y Centroid Z

No Structural Steel Flexible Yes

7.6415 m 20.472 m 19.05 m

166.31 m 1.3055e+006 kg -0.4079 m 9.5673 m -5.475 m

Moment of Inertia Ip1 9.5294e+007 kgm Moment of Inertia Ip2 4.6551e+007 kgm Moment of Inertia Ip3 6.3272e+007 kgm Statistics Nodes Elements 30771 14939

Table () Model > Geometry > Parts 5.1.2. Mesh Object Name State Defaults Physics Preference Mechanical Mesh Solved

131

Relevance Advanced Relevance Center Element Size Shape Checking Solid Element Midside Nodes Straight Sided Elements Initial Size Seed Smoothing Transition Statistics Nodes Elements Table () Model > Mesh

Coarse Default Standard Mechanical Program Controlled No Active Assembly Low Fast

30771 14939

Fig. () Model > Mesh > Figure

132

5.2 Static structural Object Name State Static Structural Fully Defined

Definition Physics Type Analysis Type Structural Static Structural Options Reference Temp 22. C

Table () Model > Analysis 5.2.1 Analysis setting Object Name State Analysis Settings Fully Defined Step Controls Number Of Steps Current Step Number Step End Time Auto Time Stepping 1. 1. 1. s Program Controlled Solver Controls Solver Type Weak Springs Large Deflection Inertia Relief Nonlinear Controls Force Convergence Moment Convergence Displacement Program Controlled Program Controlled Program Controlled Program Controlled Program Controlled Off Off

133

Convergence Rotation Convergence Line Search Program Controlled Program Controlled Output Controls Calculate Stress Calculate Strain Calculate Results At Yes Yes All Time Points

Analysis Data Management Solver Files Directory H:\M1 Simulation Files\Static Structural (2)\ Future Analysis Save ANSYS db Delete Unneeded Files Nonlinear Solution None No Yes No

Table () Model > Static Structural > Analysis Settings

Fig. () Model > Static Structural > Figure

134

5.2.2 Static structural load Object Name State Force Fixed Support

Fully Defined Scope

Scoping Method Geometry

Geometry Selection 1 Face Definition 2 Faces

Define By Type

Vector Force Fixed Support

Magnitude 29430 N (ramped) Direction Suppressed Defined No

Table ()Model > Static Structural > Loads

Fig.() Model > Static Structural > Force

135

5.3 solution Object Name Solution State Solved Adaptive Mesh Refinement Max Refinement Loops Refinement Depth 1. 2.

Table() Model > Static Structural > Solution 5.3.1 solution information Object Name Solution Information State Solution Information Solution Output Newton-Raphson Residuals Update Interval Display Points Solver Output 0 2.5 s All Solved

Table() Model > Static Structural > Solution > Solution Information 5.3.2 solution information result Object Name State Scope Geometry All Bodies Definition Type Equivalent (von-Mises) Stress Maximum Shear Stress Total Deformation Equivalent Stress Maximum Shear Stress Solved Total Deformation

136

Display Time Results Minimum Maximum 3.402e-015 Pa 4.8124e+005 Pa

End Time

1.8474e-015 Pa 2.4677e+005 Pa

0. m 7.949e-005 m

Information Time Load Step Substep Iteration Number 1. s 1 1 1 Table () Model > Static Structural > Solution > Results

Fig. ()Model > Static Structural > Solution > Equivalent Stress > Figure

137

Fig. () Model > Static Structural > Solution > Maximum Shear Stress > Figure

Fig. () Model > Static Structural > Solution > Total Deformation > Figure

138

5.3.3. Maximum equivalent stress Object Name State Definition Theory Max Equivalent Stress Max Equivalent Stress Solved

Stress Limit Type Tensile Yield Per Material Table. () Model > Static Structural > Solution > Stress Safety Tools 5.3.3.1 Maximum equivalent stress result Object Name Safety Factor Safety Margin State Scope Geometry All Bodies Definition Type Safety Factor Safety Margin Display Time Results Minimum > 10 >9 End Time Solved

Information Time Load Step Substep Iteration Number 1. s 1 1 1

Table () Model > Static Structural > Solution > Max Equivalent Stress > Results

139

Object Name State

Max Shear Stress Solved

Definition Theory Factor Max Shear Stress 0.5

Stress Limit Type Tensile Yield Per Material Table () Model > Static Structural > Solution > Stress Safety Tools 5.3.4. maximum shear stress result Object Name Safety Factor Safety Margin State Scope Geometry All Bodies Definition Type Safety Factor Safety Margin Display Time Results Minimum > 10 >9 End Time Solved

Information Time Load Step Substep Iteration Number 1. s 1 1 1

Table () Model > Static Structural > Solution > Max Shear Stress > Results

140

Material data 5.4.1 Structural steel Structural steel Young's Modulus Poisson's Ratio Density Thermal Expansion Tensile Yield Strength Compressive Yield Strength Tensile Ultimate Strength Compressive Ultimate Strength Thermal Thermal Conductivity Specific Heat Electromagnetics Relative Permeability 10000 60.5 W/mC 434. J/kgC 2.e+011 Pa 0.3 7850. kg/m 1.2e-005 1/C 2.5e+008 Pa 2.5e+008 Pa 4.6e+008 Pa 0. Pa

Resistivity 1.7e-007 Ohmm Table () Structural Steel > properties

141

Fig.()Structural Steel > Alternating Stress 5.4.2 Alternating stress cycle data Cycles Alternating Stress Pa 10. 20. 50. 100. 200. 2000. 10000 20000 1.e+005 2.e+005 1.e+006 3.999e+009 2.827e+009 1.896e+009 1.413e+009 1.069e+009 4.41e+008 2.62e+008 2.14e+008 1.38e+008 1.14e+008 8.62e+007

Table ()Structural Steel > Alternating Stress > Alternating Stress vs. Cycles

142

Fig. () Strain amplitude>reversal to failure 5.4.3. strain life parameter Strength Coefficient Pa 9.2e+008 Strength Exponent Ductility Coefficient Ductility Exponent -0.106 0.213 -0.47

Cyclic Strength Coefficient Pa 1.e+009 Cyclic Strain Hardening Exponent 0.2

Table () Structural Steel > Strain-Life Parameters

143

144