1.

INTRODUCTION

A hydraulic press is a device (see machine press) using a hydraulic cylinder to

generate a compressive force.It uses the hydraulic equivalent of a mechanical lever,
and was also known as a Bramah press after the inventor, Joseph Bramah, of
England. He invented and was issued a patent on this press in 1795. A hydraulic
press is a machine using a hydraulic cylinder to generate a compressive force. Frame,
hydraulic cylinder and press table are the main components of the hydraulic press.
Hence a hydraulic press is a machine that makes use of the pressure exerted on the
fluids to crush, straighten or mould. The concept of the hydraulic press is based on
Pascal's theory, which states that when pressure is applied on fluids in an enclosed
system, the pressure throughout the system always remains constant. In hydraulic
press, the force generation, transmission and amplification are achieved using fluid
under pressure. The liquid system exhibits the characteristics of a solid and provides
a very positive and rigid medium of power transmission and amplification. In a
simple application, a smaller piston transfers fluid under high pressure to a cylinder
having a larger piston area, thus amplifying the force. There is easy transmissibility
of large amount of energy with practically unlimited force amplification

A water-powered liquid power framework is characterized as a method for control

transmission in which generally incompressible liquid is utilized as the power
transmitting media. The basic role of the water-powered framework is the exchange
of vitality starting with one area then to the next area and this vitality into helpful
work.

In this venture of the created model of HYDRAULIC PIPE CLAMP, PRESSING

MACHINE is utilized to twist the pipe clasp and it will portray the working
standards and also water powered machines application and its points of interest.
Endeavors have been taken to demonstrate the way of water driven liquid as it is
connected and discharged. The Hydraulic framework weight can be created as any
physical activity which results from a pressure over the Hydraulic framework or
pneumatic weight which is produced as air compacting remotely can be connected
to initiate Hydraulic framework. There is a steady connection between weight
thickness, and volume, According to Bernoulli’s condition

This investigation is all about working and designing of bending machine. This
bending machine can bends a small plate, rods, pipes, tubes. This kind of metal has
its own particular thickness. The bending machine planner will think about various
components including kind of metal, roller bender types, the kind of power supply
and bending machine size. The bar is bending with the assistance of pressure driven
power, in light of the fact that the energy of hydraulic power is vast, so with the
assistance of hydraulic driven power we can bend the bar. Actually, bending is
procedure of plastically deforming a metal bars, tubes etc and changing its shapes.
Bending is adaptable process by which a wide range of shape can be achieved. Its
produces shapes like v shape, u shape, and circular shapes can also be achieved.
These Machines are to work easily and effectively

Functions of Bending Machine:

 This bending machine can work manually.

 The hydraulic powered jack limit from 4 ton to additional.

 This machine needs less maintenance.

 To give U-shape, circular bend of metal bar

Roller Requirement:

 Roller should be highly accurate and easy to manipulate.

 The minimum effort should be required to bend the pipe.

 It should provide the direction control.

Reason to Design a Hydraulic Bending Machine: The motivation to outline a

bending machine for pipe bending is that as there is no such a small scale bending
machine. The bending machine found in the market comes with too many varieties.
There are bending machine such as roll bending machine, press brake bending
machine and folding machine. In addition, the plan for the bending machine for pipe
bending is to bend a metal pipe. It produces sheet metal bending with want level of
bending aside from 90°. Other reason in regards to the bending machine plan, the
bending machine in the market comes with the enormous size and the bending
machine is costly. The current bending machine in the market is made for huge
capacity for bending a metal pipe. With the limit of bending machine that exists in
the market, the current bending machine isn't satisfying the necessity of the use. The
prerequisite of task of bending machine is basic. In this manner it isn't appropriate
to buy existing bending machine to be utilized for straightforward bending machine
activity. Besides, the machine is so heavy and it also requires some more space.

Background:
The use of fluids as a source of power has been
studied since the ancient Greek era. Pumps,
turbines, dams, and other devices all use
unique fluid properties to gain engineering
advantage. Our specific case, the hydraulic
press, uses a simple relationship given by
Pascal’s principle, which says that the pressure
at all points of a closed system will be constant.
Therefore, the force applied to one piston in a
hydraulic cylinder will be related to the force obtained by another piston in a
connected cylinder by the ratio of the piston areas. Joseph Bramah, our company’s
namesake, used this relationship when inventing and patenting the hydraulic press
in 1795. Today, hydraulic presses are the most commonly used and efficient form of
modern press. The Estrella Warbirds Museum has made it their legacy to restore
historic military airplanes for the public to admire. They operate out of a prime
location that sits just off a taxi way at the Paso Robles Airport in California. This
gives them a unique opportunity to accept a wide variety of airplanes that can be
flown in that would otherwise need to be dissembled and trucked in, and then
reassembled.
HYDRULIC POWER TRANSMISSION
Hydraulics now could be defined as a means of transmitting power by pushing on
confined liquid. The input component of the system is calleda pump; the output is
called an actuator.
While for the sake of simplicity we have shown a single small piston, most power
driven pumps incorporate multiple pistons, vanes or gears As their pumping
elements. Actuators are liners, such as the cylinder; orrotary, such as the hydraulic
motor.

The hydraulic system is not source of power. The power source is a prime mover
such as an electric motor or an engine which drives the pump. The reader might ask,
therefore, why not forget about hydraulic and couple the mechanical equipment
directly to the prime mover? The answer is in the versatility of the hydraulic system,
which gives it advantages over other methods of transmitting power.
COMPONNENTS OF HYDRAULIC SYSTEM
Hydraulic system content mainly following parts.
(1) Hydraulic fluids.
(2) Seals and Packing.
(3) Reservoirs
(4) Filter and strainers
(5) Cylinders
(6) Pressure control valve

2.1.1) HYDRAULIC FLUIDS: Proper selection and care of hydraulic fluids for a
machine will have an important effect on how the machine performs and on the life
of the hydraulic components.
2.1.2) PURPOSE OF THE FLUID The hydraulic fluid has four primary purposes:
(1) To transmit power,
(2) To lubricate moving parts,
(3) To seal clearance between parts, and

(4) To cool or dissipate heat.

2.1.3) LUBRICANTION:In most hydraulic component, internal lubrication by the
fluid. Pump elements and other wearing part slide against each other on a film of
fluid. For long component life the oil must contain the necessary additives to ensure
high anti-war characteristics. Not all hydraulic oils contain these additives.
2.1.4) QUALITY REQUREMENTS In addition to these primary functions,
the hydraulic fluid may have a number of other quality requirements.
Some of these are to:
Prevent rust
Prevent formation of sludge, gum, and varnish
Depress foaming

Maintain its own stability and thereby reduce fluid replacement cost
Maintain relatively stable body over a wide temperature range
Prevent corrosion and pitting
Be compatible with seals and gaskets
Separate out water These quality requirements often are the result of special
compounding
and may not be present in every mind.
2.1.5) FLUID PROPERTIES let us now consider the properties of hydraulic fluid
which enable it to carry out its primary functions and fulfill some or its entire quality
requirement:
Viscosity
Pour point
Lubricating ability
Oxidation resistance
Rust and corrosion protection

2.2) SEALS AND PACKING: Seals are device for closing gaps to prevent
leakage or make pressure tight joints and also to prevent entry of air and dirt from
outside in to the system. A wide variety of seals of different shapes and material
are used. The material of the seal must be compatible with the fluid medium.

2.2.1) SEAL MATERIALS Seals are device for closing gaps to prevent leakage
of make pressure tight joints and also the prevent entry of air and dirt from outside
into the system. A wide verity of seals of different shapes and material are used
Synthetic rubbers (elestomers), however, are the most part quite compatible with
oil. Elestomer can be made in many compositions to meet various operating
condition. Most of the hydraulic equipment seals today are made of one of these
elastomers: Nit rile (Buna-N), chloroprene (Neoprene) Teflon.ERP/EPDM (also
known as EPM),of silicon.

2.2.2) PREVENTING LEAKAGE Three general considerations in

preventing leakage are:
1. Design to minimize the possibility (back, gasket of sub-plate
mounting)
2. Proper installation.
3. Control of operating conditions.

2.2.2.1) OPRATING CONDITIONS Control over operating conditions can be

very important to seal life. A number of factor that can help prevent leakage are
discussed below.

Contamination prevention: An atmosphere contaminated with moisture, dirt or

any abrasive material shortens the life of shaft seals and a piston rod seal exposed
to the air. Protective device should be used in customized atmosphere. Equally
important clean fluid and proper filtration to avoid damage to internal seals and
surfaces.

Fluid Compatibility: Some fire-resistance fluid attack and disintegrate certain

elastomer seals. Few seals, in tact, are compatible with all fluids. The fluid supplier
should always be consulted when in doubt whether the change seals when in
change in made in the type of fluid. Fluid additives (added by the machines user)
also may attack seals and should be used only at the recommendation of the fluid
supplier.

Temperature: At extremely low temperature, a seal may become too brittle to be

effective. At too high a temperature, a seal may harden, soften, or swell. The
operating temperature should always be kept well within the temperature range of
the seals being used.
Pressure: Excess fluid pressure puts an addition strain on oil seals and may “blow”
a seal causing a leak. Lubrication: no seal should ever be installed or operated dry.
All must be lubricated prior to installation or the seal will wear quickly and leak.

2.3) RESERVOIRS The main function of the reservoir in a hydraulic system is to

store arid supply hydraulic fluid for use by the system. The section discusses this
and other reservoir function such as heat exchange and desertion.

2.3.1) FUNCTION OF A RESERVOIR Since, in addition to holding the system

fluid supply, a reservoir can also reserve several secondary functions, some system
designer feel that the reservoir is the key to effective hydraulic system. Some
examples of these functions are discussed below. By transferring waste heat through
its walls, the reservoir acts as the heat exchanger that cools the fluid within. As the
deaerator, the reservoir allows entrained air to rise and escape while solid
contaminants settle to the bottom of the tank. Making it a fluid conditioner. These
are function that can also be provided to the system by methods that do not involved
the reservoir. In some instance, the reservoir may be used as a platform to support
the pump, motor, and other system components. This saves floor space and is a
simple way to keep the is a simple way to keep the pumps and valves at the good
night the servicing.

2.3.2) RESERVOIR COMPONENTS a typical industrial reservoir is constructed

of welded steel plate with end-plate extension that support the unit. To reduce the
chance of condensed moisture within the tank causing rust, the inside of the
reservoir is painted with a sealer that is compatible to the fluid maintenance, a plug
placed at the low point on the tank to allow completed drainage. The various
components that make up a reservoir are follows.

(1) Oil level gauge

(2) Breather assembly
(3) Filler opening
(4) Clean-out plates
(5) Baffle plate
(6) Line connection and fittings

2.3.3) RESERVOIRE SIZING A large tank always desirable to promote and

separation of contaminants. At a minimum, the tank must store all the fluid the
system will required and maintain and high enough level to prevent a whirlpool
effect at the pump inlet opening. It this occurs. Air will be taken in with the fluid.
When determining reservoir size, it is important to consider the following factors:
Fluid expansion caused by high temperature. Changes in fluid level due to system
duration. Exposure of the tank interior to excess condensation. The amount of heat
generated in the system.

2.4) HOW TO SPECIFY FILTERS Specifying the correct filter of strainer for a
given application requires consideration of several important factors, including:
the minimum size of particles to be trapped, the quality or weight of the particles
to be held, the flow rate capacity, the type of filter condition indicator providing,
the pressure rating, the pressure drop through the filter element, and the filter’s
compatibility with system fluid.
2.4.1) FILTER OR STRAINER There will probably always be controversy in
the industry over the exact definition of filter and strainers. In the past, many such
devices were named filters, but technically classed as strainers. To minimize he
controversy, the national fluid power association gives these definition:

FILTER: A device whole primary function is the retention, by some porous

medium, of insoluble contaminants from a fluid. STRAINER: A course filter, to
put it simply, whether the device as a filter or strainers, its function is to trap
contaminants from fluid flowing through it. “Porous medium” simply refers to
screen or filtering material that allows fluid to flow through it. “Porous medium”
simply refers to a screen or to filtering material that allows fluid to flow through it.
But stops other materials.

2.5) HYDRAULIC CYLINDER The focus of this topic is on the output member
or actuator, a device for converting hydraulic energy in to mechanical energy. Two
types of hydraulic actuators are cylinder or motors. The type of job done and its
power requirements determine the correct type and size motor or cylinder for an
application. Cylinder and liner actuators. This means that the output of the cylinder
is a straight-line motion and/or force. The major function of the hydraulic cylinder
in to convert hydraulic power in to liner mechanical power.

2.5.1) TYPES OF CYLINDERS Following are the main types of cylinder.

(1) Single Acting Cylinder

(2) Ram
(3) Telescopic Cylinder
(4) Spring Return
 (5) Double acting cylinder
(6) Double Rod Cylinder
(7) Tandem Cylinder

2.5.1.1) DOUBLE ACTING CYLIDER

The double-acting cylinder is the most common type in industrial hydraulic.

Hydraulics pressure is applied is port, giving powered motion when extending or
retracting.Basic double-acting cylinder. The majority of cylinders is use are basic
double acting cylinders. These cylinder are classed as differential cylinder because
there are unequal area exposed to pressure during the extend and retract movements.
The different is caused by the cross-sectional area of the road which reduced area
of the road which reduced the area under pressure during retraction. Extension is
slower than retraction because more fluid is required to fill the swept volume of me
piston. However greater force is possible because the pressure operates on the full
piston area.When retracting, the same flow from a pump causes faster movement of
the

cylinder because the swept volume is less. Which the same system pressure,
the maximum force exerted by the cylinder is also less because of the smaller
area under pressure.
 2.6)

DIRECTIONAL VALVES As the same name implies, directional valves start,

stop, and control the direction of fluid flow. Although they share this common
function, directional valves very considerably in construction and operation.

They are classified according to principal characteristic such as those listed

below.
Type of internal valving element- poppet, rotary spool, or sliding spool.

Method of actuation- manual, mechanical, pneumatic, hydraulic, electrical,

or combinations of these.

Number of flow path- two-way, three-way, and four-way. Size-nominal size of

port or flange connection to the valves or its mounting pattern.

Connection- pipe thread, straight thread flange and subplate, or manifold

mounted.

2.6.1) DIRECTION CONTROL VALVES These valves are deployed to steer the
flow selected flow paths to any part of a hydraulic circuit. The spool types valves
both of the liner as well as the rotary movement are advised for the purpose. Rotary
type directions of these valves are commonly seen as applied to machine tool table
reversals. These valves are operated either on AC or DC. The AC operated valves
have a drawback in they tend to burn to due to flow through the valves and fast
response of direction control of solenoid valves are that important requirement of
direction control valves. Solenoid valves can function satisfactory at frequencies as
high as 1500-2000 operation an hour.

2.6.2) CHECK VALVES

In its simplest form, a check valves in a one-way directional valve. It allowsfree

flow in one direction, while blocking flow in the other direction. The graphic
symbol for a check valve is a ball and sheet. A light spring, usually equivalent
to 5 psi, holds the poppet in the normal closed position. Other spring pressures
are available to suit application requirement. In the free flow direction, the
poppet cracks open at the pressure equivalent to the spring rating, allowing
fluid to pass through the valves.
2.7) PRESSURE CONTROL VALVES

Pressure control valves perform function such as limiting maximum system

pressure or regulating reduced pressure in certain portion of the circuit, and
other functions where in there actuation is result of a change in operating
pressure. Their operation is based on balance between pressure and spring
force. Most are infinite positioning that is; the valves can assume various
positions fully closed and fully open, depending on flow rate and pressure
differential. Pressure control are usually named for their primary function, such
a relief valve, sequence valve, break valve, etc. they are classified by size
pressure operating range, and type of connection.

2.7.1) RELIEF VALVES The relief valve is found in virtually every hydraulic
system. It is normally closed valve connected between the pump outlet and the
reservoir. Its purpose is no limit is to limit pressure in to system to a pressure setting
is reached.
(1) Direct Acting Relief Valves
(2) Pilot Operated Relief Valves
(3) Electronically Modulated Relief Valves
(4) Pilot Operated Sequence Valve
(5) Unloading Relief Valve
LEVERS AND MECHANICAL LEVERAGE

LEVER

The principle of the lever tells us that the above is in static equilibrium, with all
forces balancing, if F1D1 = F2D2.

In physics, a lever (from Old French levier, the agent noun to lever "to raise", c. f.
Levant ) is a rigid object that is used with an appropriate fulcrum or pivot point to
multiply the mechanical force that can be applied to another object.

This is also termed mechanical advantage, and is one example of the principle
of moments. The principle of leverage can also be derived using Newton's laws
of motion and modern statics .
The three classes of levers

There are three classes of levers representing variations in the location of the
fulcrum and the input and output forces.

First-Class levers:
A First-Class Lever is a lever in which the fulcrum is located in between the Effort
Force and the Resistance Force, and works by having a force be applied by pulling
or pushing onto a section of the bar, which causes the lever to swing about the
fulcrum, overcoming the resistance force.

Examples:

Seesaw (also known as a teeter-totter)

Crowbar (removing nails)

Pliers (double lever)

Scissors (double lever)

Second-class levers
Examples:

Wheelbarrow

Nutcracker (double lever)

Third class lever

Examples:

Human arm
Let

W= Weight to be Lifted,

A=Force applied on the plunger,

A=Area of plunger,

Pressure intensity produce by the force F, p=F/Area of plunger=F/a

As per Pascal’s Law, the above intensity p will be equally transmitted in all
directions.

Therefore, The pressure intensity on Ram =p=F/a=W/A or W=F(A/a)

Above Equation indicates that by applying a small force F on the Plunger,

a large force W may be developed by ram.

Mechanical advantage of press=A/a

If the force in the plunger is applied by a lever Which has a mechanical

advantage(L/l) then total mechanical advantages of machine=(L/l)(A/a)
The ratio (L/a) is known as Leverage of Press.
Project planning

CHAPTER : 2

PROJECT PLANNING

2.1 CONCEPT OF THE PROJECT

Before starting every project its planning is to be done. Planning

a project is a very important task and should be taken up with great care
as the efficiency of the whole project largely depends upon its planning,
while planning a project each and every detail should be worked out in
anticipation should be carefully considered with all the relative
provisions aspects.

2.2PROJECT CAPACITY

The capacity of the project must be decided considering the

amount of money which can be invested. The availability of material
and machines and usefulness of the project.

2.3 DESIGN AND DRAWING

Having decided about the project to be

manufactured at must be designed. Design work should be done very
considering all the relevant factors. After design the project detailed
drawing are prepared. Detailed Specification for raw material and
finished products should be decided carefully along with the
specification of the machine required for the manufacture.

2.4 MATERIAL REQUIREMENTS

The list of material required for manufacture is prepared from the

drawing. The list is known as “Bill of materials”. Availability of these
materials is surveyed and purchased from the market.

2.5 OPERATION PLANNING

 Next work of planning is to “select the best method” manufacture
the product, so that the wastage of materials, labor, machines and time
can be eliminated by considering various methods. The best method is
to be selected for fabrication and other works. The proper method and
proper person and the purposes of operation, necessity operation, proper
machine planning. The best method is the developmed and is applied
to fabricate the project.

2.6 MACHINE LOADING

While planning proper care should be taken to find the machining

time for the operation as correct as possible. So that arrangement of
full use of machines can be made and the machine loading program can
be decided.

2.7 PURCHASE CONSIDERATION

It is difficult to manufacture all the components needed for the

project in the machine shop. In each case, we should decide whether to
make or buy about a particular item. It is decided during the planning
after making a complete study of relative merits and demertis.

2.8 EQUIPMENT PROCEDURE

Results obtained from “Operation planning: and machine loading

help in calculating the equipment require Specification of the equipment
should be laid down by considering then drawings. Drawings will also
help in deciding the necessary requirement of tools and accessories

LITERATURE REVIEW
The paper oversees collecting of channels which use control worked sheet
bending machine and physically worked sheet bending machine. It moreover
fuses confinements of physically worked bending machine. From the outcomes
of the paper the productivity of vitality worked bending machine is higher.

P. S. Thakare et al.[1].Author told in late year's pipe bending machine is used as

a piece of both industry and domestic purpose behind bending the pipe under the
required edges and angles. From time to time Heat treatment is used for pipe
bending however this strategy isn't safe and have issues are made in the pipes, for
instance, wrinkling, twist forming, decreased thickness, whole encircling,
diminished quality, basic wobbly. These bending machines have a great
advantage over the heat treatment method. V. SenthilRaja et al.

[2]. In this paper, a bicycle consolidated pipe bending instrument has been laid
out and made. The usages of bowed directs are in traces, bars, handle of bicycle.
The dominant part of endeavours uses bowed pipes as air conditioning, boiler,
control age, send building, furniture, railroad, auto, go earth street frolicking and
develop adapt, flying machine et cetera. In view of adequate human power in
countries like India, the human controlled machine will achieve change of the
economy and work of nation. In Asian countries people are defying power cut-
off in the midst of most of the days so such system expects a basic part in
commonplace areas. H. A. Hussain et al.

[3]. Weight driven equipment has wide use in various vehicle fields. These
hydraulic controlled instruments are used for cutting down and bringing seat up
in Barber shops and in dental clinics. Hydraulic bending machine is the sensible
equipment to contort channels, shafts and bars. The pipe or shaft to bend is kept
between the rollers. With usage of water driven jack we realize compel on the
pipe and bend it to the required point dependent upon the kicks the can used.
Water controlled bending machine is less expensive, flexible and flexible stood
out from those which are inspected previously. Along these lines it is quicker
witted to supplant current standard machines by weight driven pipe curving
machine

In april,2013 Prof. Nilesh Nirwan and Prof. A.K.Mahalle,Department of

Mechanical Engineering, G.H. Raisoni college of engineering Nagpur has found
a PORTABLE ROLLING PIPE BENDING MACHINE is used for reliability,
easy convey and good quality purpose. But there is some difficulties like not used
for mass production and slow process due to hand operated device. • In Nov, 2015
Prof. A. Pandiyan Of Department of Mechanical Engineering, Of Saveetha
School of engineering Chennai has found a ZIGZAG PIPE BENDING
MACHINE is used for making zigzag profile pipe. It is operated by hydraulic
bottle jack. This bending machine is only used for zigzag profile so, not used for
other bending operations.

In Sep, 2011 Prof. N.N. Jadeja Of Department of Mechanical Engineering, Of

GEC Bhvnagar has found MANUALLY OPERATED PIPE BENDING
MACHINE is used in small industries. This machine generally used for low cost
purchasing purpose. It has low accuracy of bending and force is not uniformly
distributed over a whole length of pipe so, this bending machine is not preferable.
• H.A. Husain, M. Sohil Pervez Of Department of Mechanical Engineering, Of
Anjuman college of engineering and Technology, Chennai Nagpur, has found a
BICYCLE INTEGRATED PIPE DESIGN BENDING MACHINE. It is unlike
other electric motor operating pipe bending machine. It is used for ECONOMIC
& ACCURATE DIMENSION. It will help to maintain environment green. Here
is one Disadvantage is process taking more time

In May, 2014 Basil Okafor & Danial Obiora Of Department of Mechanical

Engineering, of Fedral University Owerri Nigeria has found MOTORIZED PIPE
BENDING MACHINE WHICH IS OPERATED by 2HP MOTOR. This machine
can run in both upward and downward direction. Here worm and wheel gear
mechanism is used. Mandrel used for less thickness pipes.
OBJECTIVE:

Using the optimum resources possible in designing the hydraulic press

components can effect reduction in the cost by optimizing the weight of material
utilized for building the structure. An attempt has been made in this direction to
reduce the volume of material, cost of the press and to make is portable. Ertl et
al. presented a 2D nonlinear magneto-mechanical analysis of an electromagnetic
actuator based on finiteelements. The presented method enables the simulation of
the complete switching cycle off a switching, short stroke solenoid actuators with
sufficient accuracy. This could be achieved by considering nonlinear magnetics,
eddycurrent induction and a physical correct implementation of the contact
mechanics, which are relevant forthe complex dynamics of this valve types.
Combining the concepts of pre-magnetization as well as over excitation to
optimize the actuator dynamics, the pure valve needle flight time at valve opening
can be reduced to 200ms. Thedeveloped numerical tools enable a systematic
study of several methods to optimize the dynamics. Pohletal. presented a model
of a fast 2/2 switching valve where both the magnetic pathas well as the spool
assembly are modeled. The model also includes a description of the hysteresis
characteristics of the magnetic path. An optimization strategy has been utilized in
order to parameterize the model against measured data. However, even for major
deviations from the operational point used for the model adaptation, the model
predicts the valve response sufficiently accurately.
Chapter III

FABRICATION DETAILS

3. FABRICATION OF PARTS DETAILS

3.1 BED

It is made up of mild steel material. The base of machine is holed

centrally and its attached with compound rest of lathe. The motor is
engaged with base plate. All the parts for milling attachment are
mounted on base plate or bed.

Hydraulic jack:

Hydraulic jacks are typically used for shop work, rather than as an emergency
jack to be carried with the vehicle. Use of jacks not designed for a specific vehicle
requires more than the usual care in
selecting ground conditions, the jacking
point on a vehicle, and to ensure stability
when the jack is extended. Hydraulic jacks
are often used to lift elevators in low and
medium rise buildings.

A hydraulic jack uses a liquid, which is incompressible, that is forced into a

cylinder by a pump plunger. Oil is used since it is self lubricating and stable.
When the plunger pulls back, it draws oil out of the reservoir through a suction
check valve into the pump chamber. When the plunger moves forward, it pushes
the oil through a discharge check valve into the cylinder. The suction valve ball
is within the chamber and opens with each draw of the plunger. The discharge
valve ball is outside the chamber and opens when the oil is pushed into the
cylinder. At this point the suction ball within the chamber is forced shut and oil
pressure builds in the cylinder.

In a floor jack (aka 'trolley jack') a horizontal piston pushes on the short end of
a bellcrank, with the long arm providing the vertical motion to a lifting pad, kept
horizontal with a horizontal linkage. Floor jacks usually include castors and
wheels, allowing compensation for the arc taken by the lifting pad. This
mechanism provides a low profile when collapsed, for easy maneuvering
underneath the vehicle, while allowing considerable extension

MS ROD:

Carbon steel rodwhich contient is a steel with carbon content up to 2.1% by

weight. The definition of carbon steel from the American Iron and Steel
Institute (AISI) states:

Steel is considered to be carbon steel when:

 no minimum content is specified or required

for chromium, cobalt, molybdenum, nickel, niobium, titanium, tungste
n, vanadiumor zirconium, or any other element to be added to obtain a
desired alloying effect;
 the specified minimum for copper does not exceed 0.40 percent;
 or the maximum content specified for any of the following elements
does not exceed the percentages
noted: manganese 1.65, silicon 0.60, copper 0.60.[1]
 The term "carbon steel" may also be used in reference to steel which is
not stainless steel; in this use carbon steel may include alloy steels.

As the carbon percentage content rises, steel has the ability to

become harder and stronger through heat treating; however, it becomes
less ductile. Regardless of the heat treatment, a higher carbon content
reduces weldability. In carbon steels, the higher carbon content lowers the
melting poin

DIE: The die may be defined as the female part of complete tool for producing
work in press. It also referred to a complete tool consisting of a pan of mating
members for producing work in press.

TYPES OF DIES:

This die may be classified according to the type of press operation and
according to the method of operation.

Type of press operation: according to this to this criterion, the dies may
be classified as: cutting dies and forming dies.

Cutting dies: These dies are used to cut the metal they utilize the cutting or
shearing action. The common cutting dies are: blanking dies, piercing dies,
perforating dies, notching trimming, saving and nibbling dies etc.

Method of operation: according to this criterion, the dies may be classified as:
single operation or simple dies, compound dies, combination dies, progressive
dies, transfer dies, and multiple dies. Simple dies: simple dies or single action
dies perform single operation for each stroke of the press slide the operation may
be any of the opration listed under cutting or forming dies

Design Development:

Our research for this project encompassed not only an extensive

look into the theory and operation of hydraulic presses but also a search of
similar products on the market. Many commercial, hand-operated
hydraulic presses are currently available. However, in deciding on a design
we used a quality function deployment chart to evaluate the specific
customer needs and give these needs a numerical value with which to
compare designs and test their acceptability to the Museum. Seen in
Appendix B, our quality function deployment chart, or “House of
Quality”, takes vague customer requirements and translates them into
engineering design specifications. At the same time, it was used to
compare existing options that are already commercially available. Our
case in which we were given many specific design details to begin with
made the house of quality is somewhat unnecessary. From this chart we
concluded that the precise nature of our customer requirements would
eliminate the benchmarks as viable options.
Another aspect of our research involved the investigation of
standards and code requirements related to the construction of our
press. The U.S. Department of Labor’s Occupation Safety and
Health Administration (OSHA) website revealed a few
considerations. General machine guards (barrier guards, two-hand
tripping devices, electronic safety devices, etc.) must be provided to
protect the operator and other employees in the machine area from
hazards created by the point of operation, nip points, etc. Many other
regulations related specifically to electrically powered hydraulic
presses exist, which do not apply to our hand powered design. The
fact that our press is hand-operated and not driven by a motor makes
it inherently much safer. We have obtained the Material Safety Data
Sheet for the aircraft 5606 hydraulic fluid specified in the project
description, and have looked over potential hazards that come with
its use.

We used our research described above by applying the tried and

tested layouts of comparable hydraulic hand press designs as a platform to
design our initial concept. We also conducted brainstorming sessions to
come up with more efficient, ergonomic, useful, and time-saving ideas for
press designs to improve upon the standard commercially available
models. The best of these innovations was presented to the Warbirds
Museum for approval before proceeding with the final design. The final
design incorporated all the project objectives and was also presented for
approval. Each of these stages requiring approval was subject to
adjustment until the museum was satisfied with the plan. The building
process could not begin until this occurred. Following the construction
phase, the press was tested to see if it accomplished the project goals.
When problems with the design were encountered, it was modified or
rebuilt until the objectives were met. Also during the testing phase,
improvement of specific parameters sometimes warranted modification of
the finalized press. Once the press operation met the project objectives and
was presented at the senior design expo, the press was ready for delivery
to the Estrella Warbirds Museum to be put into service.

Progress was made in the design phase that included initial stress
calculations for the structural members of the press frame. Appendix D
shows those calculations in full, including a basic layout of the press frame.
It was concluded using the max pressing capacity of 10 tons that the
horizontal U-channel steel members must be greater than 4 inches wide.
We decided to use a 6-inch-wide dimension for the horizontal

Product Realization:

Construction of the hydraulic press began with acquiring all the

necessary steel U-channel beams for the frame structure. These beams
were transported from the museum to Cal Poly’s campus shops to be cut to
size. A horizontal metal band saw was as seen in
used for this purpose. All bolt
connection holes were then
machined, primarily using drill
presses (Figure 5). The required 32
x 1’’ diameter support pin holes
were drilled by stepping up bit sizes
in ¼’’ increments. All burred and
sharp edges were smoothed out
using pneumatirotary tools and
files. The beams were then either
sandblasted or treated with Naval
Jelly to remove all
Figure 6: Welding apparatus Figure 7:
Sandblasting set‐up

The winch, pulleys, pump handle, pressure gauge, selector valve,

and hydraulic reservoir were all bolted and/or strapped to the frame at ideal
locations for operation. Lengths of AN aircraft hydraulic hose were
acquired from the museum and attached, with the proper fittings and Teflon
wrapping, to all the mounted components. These hoses were then bundled
 and strapped to the frame for better aesthetics and to make sure nothing
would get tangled. Figure 8 shows the finalized press as presented at the
senior project expo.

CALCULATION:

Load calculations for Hydraulic jack

W = Load applied through jack

A = Area

Syt = Yield strength of material

δ = Deflection

L = Length between two bobbins

E = Modulus of elasticity

I = Moment of inertia

= Syt * Area

3. =

Table 1. Load and Deflection Calculation:

S.N Length(m Pipe Load( Deflection(m

O m) Diameter(mm) N) m)

Outer Inner
dia dia

22085.
1. 200 20 18 4 6.48

65384.
2. 200 25 20 4 4.98
 22085.
3. 300 20 18 4 21.90

65384.
4. 300 25 20 4 15.47

22085.
5. 400 20 18 4 51.92

65384.
6. 400 25 20 4 36.70

MANUFACTURING PROCESS:

Hydraulic presses are available in many types of construction which is also

true of mechanical presses. Following construction details just gives the basic
idea of dimensions of different parts used in the design module. Base is
manufactured from 75x40 mm two c-channel of length 380 mm welded together
.The height can be adjusted using rods. The die used for a particular given shape
is welded at the bottom plate. The dimensions of the frame is 725x380 mm of c-
channel of 75x40 mm with two support of c-channel Spring having free length
230 mm is fixed between middle plate and frame so as to get the flexible
movement of the Movable plate. Punch is welded at the bottom of the movable
plate. Jack is mounted in between the frame and middle plate. The basic
Manufacturing process is shown in below figure
 • A hydraulic fluid power system is defined as a means of power
transmission in which relatively incompressible fluid is used as the power
transmitting media.

• The primary purpose of hydraulic system is the transfer of energy from one
location to another location and this energy into useful work.

q In this project of the fabricated model of HYDRAULIC PIPE CLAMP

PREESING MACHINE is used to bend the pipe clamp and it will describe the
working principles as well as hydraulic machines application and its advantages.

Here, we are going to design and develop a hydraulic metal bending machine with
the help of hydraulic jack and rollers as shown in the figure. The one driving
roller is at the upper position for positioning of the metal work piece. The two
driven rollers are at the lower position. The hydraulic bottle jack is used to give
the motion by applying pressure while bending the metal. The metal piece is feed
from the roller and because of the hand wheel the metal piece is passed from the
rollers by the rolling motion. The work piece is inserted between the driven roller
and driving roller as shown in fig. The bending force is applied through hydraulic
jack when the handle is operated and the work piece can be adjusted. Thus the
work piece is bend. It works on the hydraulic principle due to pressure of
hydraulic is very high. The figure shown below is working of hydraulic bending
machine.

WORKING PRINCIPLE:

A hydraulic press is a machine that uses pressurized liquid to create force.

These machines are composed of a simple cylinder and piston mechanism. The
press consists of a large cylinder, with a large piston, and a small cylinder and a
small piston. The large cylinder and the small cylinder are connected to one
another by means of a pipe. The two cylinders, and the pipe connecting them, are
filled with a liquid. At this point, the function of the hydraulic press depends on
Pascal's Principle. Pascal's Principle states that when pressure is added to a liquid
at rest, there is an identical increase in pressure at all points. Applying this
principle to the hydraulic press means that any force that is added to the piston in
the smaller cylinder will be transferred to the piston in the larger cylinder, in a
proportionally increased level of force. This allows a hydraulic press to produce
a great deal of force from the application of a small amount of force to the small
piston.

The increase of the force produced by the larger piston is proportionally

larger than the force exerted on the small piston. The amount of increase depends
on the ratio of the sizes of the pistons. The ratio of the areas of the two pistons is
multiplied by the amount of force applied to the small piston to determine the
amount of force that the large piston can produce. For example, if the ratio of the
sizes of the two pistons is 10, and the amount of force applied to the small piston
is 50 N, the amount of force that the large piston will produce is 500 N. Hydraulic
presses can be used in any task that requires a large amount of force. These can
include any type of lifting as well, since the hydraulic press can work as a type of
lever. These presses are the most efficient contemporary press, as well as the most
common. Since the hydraulic press works on the basis of Pascal's Law, its
working is similar to the one of the hydraulic system. A hydraulic press consists
of basic components used in a hydraulic system that includes the cylinder,
pistons, the hydraulic pipes, etc.

The working of this press is very simple. The system comprises of two
cylinders, the fluid (usually oil) is poured in the cylinder having a small diameter.
This cylinder is known as the slave cylinder. The piston in this cylinder is pushed
so that it compresses the fluid in it that flows through a pipe into the larger
cylinder. The larger cylinder is known as the master cylinder. The pressure is
exerted on the larger cylinder and the piston in the master cylinder pushes the
fluid back to the original cylinder. The force applied on the fluids by the smaller
cylinder results in a larger force when pushed in the master cylinder. The
hydraulic press is mostly used for industrial purposes where a large pressure is
required for compressing metals into thin sheets. An industrial hydraulic press
uses the material to be worked upon along with the help of the press plates to
crush or punch the material into a thin sheet.

ADVANTAGES

1. It eliminates complicated parts like hydraulic cylinder pipe

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

APPLICATION
 1. Engine recondition works
2. Pump assembling works
A/C &D/C Motor repair works

Conclusion :

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

which relatively incompressible fluid is used as the power transmitting media.
The primary purpose of hydraulic system is the transfer of energy from one
location to another location and this energy into useful work.
 In this project of the fabricated model of HYDRAULIC PIPE CLAMP
PREESING MACHINE is used to bend the pipe clamp and it will describe the
working principles as well as hydraulic machines application and its advantages.

Efforts have been taken to show the path of hydraulic fluid as it is applied
and released. The Hydraulic system pressure can be generated in the form of any
physical action which result a compression over the Hydraulic system or
pneumatic pressure which is developed in the form of air compressing externally
can be applied to activate Hydraulic system. There is a constant relation between
pressure density, and volume, According to Bernoulli’s equation.

Liquids can be heated by applying high pressure without any external heat
energy supplied to them. So the specific heat of any liquid system which is used
in the hydraulic machinery must be more than enough to with stand the pressure
applied over them also viscosity must be high enough for smooth conversion of
external pressure applied over them to hydraulic pressure.

REFERENCES

(7) P. S. Thakare, P. G. Mehar, Dr. A. V. Vanalkar and Dr. C. C. Handa,

“Productivity Analysis of Manually Operated And Power Operated Sheet
Bending Machine: A Comparative Study”, International
 Journal of Engineering Research and Applications (IJERA), ISSN: 2248-
9622, Vol. 2, Issue 2, Mar-Apr 2012, PP.111-114.

V. Senthil Raja, R.Maguteeswaran, C. Karthik, S.Rajarajan and D.

Shanmuga Vadivel, “A New Model in Design and Manufacturing of Mobile
Hydraulic Pipe Bending Machine in Industry”, International

Journal of Engineering Research & Technology (IJERT), ISSN: 2278-0181,

Vol. 3 Issue 1, January – 2014 PP 2706-2713.

H. A. Hussain, M. Sohail Pervez, Md. Naushad Alam and Atul. P. Ganorkar,

“Design and Development of Bicycle Integrated Pipe Bending Machine”,
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), e-ISSN:
2278-1684, p-ISSN: 2320-334X, 2014, PP 24-28.