MAHAKAL INSTITUTE OF TECHNOLOGY AND SCIENCE,

UJJAIN (M.P)

(Rajiv Gandhi Proudyogiki Vishwavidyalaya, Bhopal M.P.)

Session 2016-17

Minor project report

On

DESIGN OF HYDRAULIC SHEET METAL PUNCHING MACHINE

USING HYDRO-MECHANICAL LEVERAGE

Submitted towards Partial Fulfillment of the degree of

Bachelor of Engineering

Under the Guidance of- Submitted By- Prof. Pankaj Gera Arun Singh RathoreAssistant Professor Harshil SehariyaMITS, Ujjain Mahendra Singh Chandrawat

Shubham BagiShubham DhaneshreeShubham Mathur

MAHAKAL INSTITUTE OF TECHNOLOGY & SCIENCE, UJJAIN

CERTIFICATE

This is to certify that Mr. Arun Singh Rathore, Mr. Harshil Sehariya, Mr. Mahendra Singh

Chandrawat, Mr. Shubham Bagi, Mr. Shubham Dhaneshree and Mr. Shubham Mathur.

Student of B.E. (Mechanical Engineering Department) of this college has carried out

Project DESIGN OF HYDRAULIC SHEET METAL PUNCHING MACHINE

USING HYDRAO-MECHANICAL LEVERAGE. It is submitted towards partial

fulfillment of the requirements for the award of Bachelor of Engineering in Mechanical

Engineering from Mahakal Institute of Technology & Science; Ujjain affiliated to Rajiv

Gandhi Proudyogiki Vishwavidyalaya, Bhopal (M.P.).

Prof. Pankaj Gera Prof. Santosh Vyas Prof.V.M Shah

Project Guide Head of Department Director

M.I.T.S., Ujjain M.I.T.S., Ujjain M.I.T.S., Ujjain

I

ACKNOWLEDGEMENTThe successful completion of the project is the result of dedicated efforts of many people

and this report would be incomplete without giving due credit to them. This

acknowledgement is taken of small gratitude in recognition of the help provided by them.

We wish to express our heartfelt appreciation to all the people who had contributed to this

project, both explicitly and implicitly. First to all we want to thank our projects guide

Prof. Pankaj Gera for giving us this opportunity to work under his guidance. His empathy

towards us made our work easy. Many thank to him for encouraging and supporting us to

complete this project work. We are thankful to Prof. Santosh Vyas Head of the

Department, Mechanical Engineering and Prof. V.M Shah Director Mahakal Institute Of

Technology & Science, Ujjain for understanding our problem and shorting them out. We

are thankful to staff of Mechanical Engineering Department for letting us know about

problem of industry and encouraging us to work on it. In the last but not least, we are also

thankful to all the persons and colleagues who have helped us directly or indirectly during

this project. .

Arun Singh RathoreHarshil SehariyaMahendra Singh ChandrawatShubham Bagi Shubham DhaneshreeShubham Mathur

II

ABSTRACT

Tools and simple machines are a natural extension of our mastery of physics. By putting

our knowledge to use, we are able to manipulate the world around us on a much larger

scale. Tools and machines have allowed us to build great monuments, to settle otherwise

inhospitable locations, and to launch ourselves into space. These simple machines which

work on mechanical advantage were evolved in complex machines. Out of these many

advantages hydraulics turned out to be a game changer. Hydraulics has proven to be one

of the most efficient and economical system for amplification of forces. First used by the

ancient Greeks as a means of elevating the stages of their amphitheatres, the principles of

hydraulics were explained scientifically by the seventeenth century scholars Pascal and

Boyle. The laws discovered by these two men regarding the effects of pressure and

temperature on fluids and gases in confined areas form the basis of the principle of

mechanical advantage; in other words, the "why and how" of hydraulics. Similarly,

another mechanical advantage ‘Lever’ was explained and proven by Archimedes in 3rd

century BC.

Both of these models of amplification of forces along with others were later used in

modern era of technology for the evolution of machines which made the modern world

possible. Making a similar contribution by using two mechanical advantages in a

machine, the aim of this project is to integrate the mechanical advantage of Leverage with

Hydraulic System to facilitate the ease of operation to manufacture smaller parts and to

reduce the dependence on heavy hydraulic machines for small punching operations. Thus

the production effort can be reduced as the dependence on complex hydraulic machines

will be alleviated. Hence an attempt has been made to provide the smooth and rapid

functioning of punching work with the help of hydraulic system.

III

CONTENTS Page No.

Certificate i

Acknowledgement ii

Abstract iii

CHAPTER 1: INTRODUCTION 2

CHAPTER 2: LITERATURE REVIEW 6

2.1 Leverages 9

2.2 Mechanical leverage 12

CHAPTER 3: COMPONENTS AND THEIR WORKING 14

3.1) Hydraulic fluids 14

3.2) Seals and packing 15

3.3) Reservoirs 17

3.4) Filter and strainer 18

3.5) Hydraulic cylinder 19

3.6) Direction valve 19

CHAPTER 4: DESIGN AND ANALYSIS 22

4.1 Design and analysis 22

4.2 Drawing of machine parts 31

CHAPTER 5: RESULTS AND DISCUSSION 36

Conclusion 38

Reference 39

List of figures-

Figure Description Page no.

Figure 1 Punch 2

Figure 2 Die Block 3

Figure 3 Pascal’s law 8

Figure 4 Lever system 10

Figure 5 First class lever 11

Figure 6 Second class lever 12

Figure 7 Third class lever 12

Figure 8 Lever arrangement 13

Figure 9 Relief valve 21

Figure 10 Frame 31

Figure 11 Punch 32

Figure 12 Die 33

Figure 13 Assembly 34

Figure 14 Final model 35

Figure 15 Existing proposed model 35

List of tables-

Table no. Name of table Page no.

1 Round Hole Diameter [inches] to be punched 37

CHAPTER 1

INTRODUCTION

Punching is a metal forming process that uses a punch press to force a tool, called a

punch, through the work piece to create a hole via shearing. The punch often passes

through the work into a die. A scrap slug from the hole is deposited into the die in the

process. Depending on the material being punched this slug may be recycled and reused

or discarded. Punching is often the cheapest method for creating holes in sheet metal in

medium to high production volumes. When a specially shaped punch is used to create

multiple usable parts from a sheet of material the process is known as blanking. Punching

machine type of cold working process in which punching done by the punch machine tool

and die designed to punch the sheet metal by applying mechanical force or pressure. The

punch governs the size of the hole and the clearance is provided on the die.

The components of punching machines are:

Punch: It is the male member of the unit and kept as small as possible consistent

with required strength and rigidity. The punch made of the hard, wear resistance

metal and is finally ground to the pre-determine size providing just opium

clearance between the punch and die.

Figure 1.Punch

Punch Retainer of punch plate: It fits closely over the body of the punch and

holds it in a proper relative position. The retainer is turn to bolt to the punch

holder.

Punch holder: It provided a wide plate surface which face against the lower end

of the press ram and is anchored to it with help of the shank which is an integral

part of the punch holder shank exactly fits in to the ram opening, to help in

properly positioning and aligning the punch holder is made of cast steel.

Backing plate: Whenever the punch is headless a hardness steel backing plate is

introduced between the back of the punch holder so that intensity of pressure does

not become excessive on the punch holder. Backing plate distributes the pressure

over wide area and intensity of the pressure on the punch holder is reduced to

avoid crushing.

Die Block: it is female working member & is kept as small as possible consistent

with required strength. It is also made of hard, wear-resistant metal and finish

ground to predetermined size and tolerance.

Figure 2.Die

Die retainer: Just like the punch retainer, the die retainer also holds the die block

at proper position with respect to punch. The retainer is mounted on the die shoe

or holder. In certain die shoe it serves as a retainer for the die block the block is

then mounted directly on to die shoe.

Die shoe: Die shoe assembly consisting of die block and die. These in turn bolted

or clamped to the bolster plate.

Guide posts and bushing: the punch and die makers once properly located

aligned are held in aligned are held in alignment by means of guide post and

bushing which resist movement or deflection of die members as operating

pressure increase guide post and bushing are part of the commercially available

punch and die holders.

Stripper and stripper plate: When the punch has completed its downward

movement and start returning, the scrape strip tries to go up along with it. The

stripper plate prevents this upper movement of scrape stripes and frees and

punches of these for next stroke.

Stock stops & Stock guide: Fixed type of stripper sometimes are used to guide

the stock are also where as stock stops locate the work material at a suitable

position in relation to previously blanked surfaced in preparation to the next

downward movement of the punch.

Bed: The bed is the lower part of a press frame that serves as a table to which a

bolster plate is mounted.

Bolster plate: This is thick plate secured to the press bed, which is used for

locating and supporting the die assembly. It is usually 5 to 12.5 cm thick.

Die set: It is unit assembly, which incorporates lower and upper shoe, two or

more guidepost and guidepost bussing.

Die: The die may be defined as a female of a complete part of a complete tool

producing work in press. It also referred to a complete tool consisting of a pair of

mating members for producing work in a press.

Lower shoe: The lower shoe of a die set is generally mounted on the bolster plate

of a press. The die block is mounted on the lower shoe. Also, the guideposts are

mounted in it.

Upper shoe: This is the upper part of the die set, which contains guidepost

bushing.

Knockout: It is mechanism, usually connected to and operated by a press ram,

for freeing a work piece from a die.

Pit man: It is connecting rod, which is used to transmit motion the main drive

shaft to the press slide.

Shut height: It is distance from top of the bed to the bottom of a slide, with its

stroke down and adjustment up.

Stroke: The stroke of a press is the distance of ram its up position to its down

position. It is equal to twice the crankshaft and eccentric drives but it is Variable

on the hydraulic press.

1.2 ADVANTAGES OF HYDRAULIC PUNCHING MACHINE

1. Full power stroke - The full power of a hydraulic press can be delivered at any point in

the stroke. Not only at the very bottom, as is the case with mechanical presses.

2. Much lower original cost and operating costs - Hydraulic presses are relatively

simple, they have a significant cost advantage over mechanical presses in comparable

sizes. The numbers of moving parts are few, and these are fully lubricated in a flow of

pressurized oil.

3. More control flexibility - Hydraulic press power is always under control. The ram

force, the direction, the speed, the release of force, the duration of pressure dwell, all can

be adjusted to fit a particular job.

4. Quiet - Fewer moving parts and the elimination of a flywheel reduce the overall noise

level of hydraulic presses compared to mechanical presses.

5. Reliability- Hydraulic punching machines are more reliable in opertaion than any

mechanical punching machines.

1.3 DISADVANTAGES OF HEAVY HYDRAULIC MACHINES

1. Hydraulic machines are complex in construction.

2. Hydraulic machines have oil leakage problems.

3. They have more maintenance issues than pneumatic machines.

4. They have slower motion than pneumatic machines.

CHAPTER 2

LITERATURE REVIEW

Hydraulics is a branch of engineering concerned mainly with moving liquids. The term is

applied commonly to the study of the mechanical properties of water, other liquids, and

even gases when the effects of compressibility are small. Hydraulics can be divided into

two areas, hydrostatics and hydrokinetics. Pascal’s law states that when a confined fluid

is placed under pressure, the pressure is transmitted equally in all directions and directed

normal on all faces of the container.

Hydraulics has proven to be the most efficient and economical system adaptable to

aviation. First used by the ancient Greeks as a means of elevating the stages of their

amphitheaters, the principles of hydraulics were explained scientifically by the

seventeenth century scholars Pascal and Boyle. The laws discovered by these two men

regarding the effects of pressure and temperature on fluids and gases in confined areas

form the basis of the principle of mechanical advantage; in other words, the "why and

how" of hydraulics.

The word "hydraulic" is derived from two Greek words: "hydro" meaning liquid or water

and "aulos" meaning pipe or tubing. "Hydraulic," therefore, is an adjective implying that

the word it modifies is in some major way concerned with liquids. Examples can be found

in the everyday usage of "hydraulic" in connection with familiar items such as automobile

jacks and brakes. As a further example, the phrase "hydraulic freight elevator" refers to an

elevator ascending and descending on a column of liquid instead of using cables and a

drum. On the other hand, the word "hydraulics" is the generic name of a subject.

According to the dictionary "hydraulics" is defined as a branch of science that deals with

practical applications (such as the transmission of energy or the effects of flow) of a

liquid in motion.

The press machine Gutenberg (Johan Gensfleisch) a German invented in 1400 was

modified one from a wooden screw type press machine for squeezing olive oil and

grapes. This was exactly the root of the screw presses and all press (punching, stamping)

machines, stamping inked print boards onto sheet with the screw. This is the type of

machine to apply static pressure.

Until 1700 AD fly press were not in engineering application. Earlier open Die or

Hammers were used to produce small components .Then gradually by 1767 AD;

Small fly presses particularly for Gold smith work in ornamental work were evolved and

used effectively.

Later, in the field of hydraulics and punching machines, various contributions have been

made, of which some are:

1. Design and Fabrication of Auto Roll Punching Machine by Kundan Kumar

ISSN(Online) : 2319-8753 In their research they revealed that design and

fabrication of auto roll punching machine will make an impressing mark in the

field of small scale industries this has also reduce the cost involved in the concern

and it required task taking minimum time.

2. Improvement in design of the manual small press machine by vivek Sharma

ISSN : 2278 – 0149 In their research they revealed that machine is capable to do

work with some shear force By putting (diametrically opposite) variable

additional weights on the flywheel we can obtained that desired energy levels to

suit the maximum load required for manufacturing different types of engineering

parts. Of course it is understood that only limited variation in capacity is possible.

If at all some bigger or odd components to be manufactured one can choose the

next higher range of the flypress.It is very clear that for given press reasonable

flexibility is possible as far as energy is total load is concerned.

3. Doc Smith & Mates in 1999 work on hydraulic press machine & give conclusion

that the press work on the Hydraulic version of the press machine

4. Oseni K Owolarafe, Michael O Faborode 25 May 2000 work on press machine

& give conclusion that The comparative evaluation of the DSP system which is

being developed and the conventional hydraulic press system undertaken in this

study revealed that the DSP system has many comparatively favorable attributes

and is to be preferred to the hydraulic system.

5. Isaac Bamgboye and Morakinyo T.A An improved oil screw press has been

designed and constructed having 98.6 % efficiency and a capacity of 0.86

tons/day. Abrasion rate of screw-shafts has been reduced from 63.3% to 12.6% by

using high carbon steel material instead of low-carbon steel. Peter Beerens in

2007 gives an idea about press machine and the result is extended due to

improvement in the plate form in the design of the machine.

The hydraulics of these machines functions on very simple principle known as Pascal's

law or the principle of transmission of fluid-pressure. Pascal’s Law is a principle in fluid

mechanics that states that a pressure change occurring anywhere in a confined

incompressible fluid is transmitted throughout the fluid such that the same change occurs

everywhere. The law was established by French mathematician Blaise Pascal.

To understand this, let us consider a system of two piston and cylinders connected

together. Now,

Figure 3 Pascal’s law

The force equation for the small cylinder:

Fs = p As

Where,

Fs = force acting on the piston in the small cylinder (N)

As = area of small cylinder

p = pressure in small and large cylinder

The force equation for the large cylinder:

Fl = p Al

Where,

Fl = force acting on the piston in the large cylinder (N)

Al = area of large cylinder

p = pressure in small and large cylinder

on combining the above equations,

Fs / As = Fl / Al  

Or,

Fs = Fl As / Al  

The equation indicates that the effort force required in the small cylinder to lift a load on

the large cylinder depends on the area ratio between the small and the large cylinder - the

effort force can be reduced by reducing the small cylinder area compared to the large

cylinder area.

2.1LEVERAGES

In its most basic form, the lever consists of a rigid bar supported at one point, known as

the fulcrum. One of the simplest examples of a lever is a crowbar, which one might use to

move a heavy object, such as a rock. In this instance, the fulcrum could be the ground,

though a more rigid "artificial" fulcrum (such as a brick) would probably be more

effective.

As the operator of the crowbar pushes down on its long shaft, this constitutes an input of

force, variously termed applied force, effort force, or merely effort. Newton's third law of

motion shows that there is no such thing as an unpaired force in the universe: every input

of force in one area will yield an output somewhere else. In this case, the output is

manifested by dislodging the stone—that is, the output force, resistance force, or load.

Use of the lever gives the operator much greater lifting force than that available to a

person who tried to lift with only the strength of his or her own body. Like all machines,

the lever links input to output, harnessing effort to yield beneficial results—in this case,

by translating the input effort into the output effort of a dislodged stone. Proper use of a

lever actually gives a person much greater force than he or she would possess unaided.

The principle of the lever tells us that the below arrangement is in static equilibrium as

shown in fig.3, with all forces balancing, if F1D1 = F2D2.

Figure 4.Lever system

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

Levers are divided into three classes, depending on the relative positions of the input

lever arm, the fulcrum, and the output arm or load. In a Class I lever, such as the crowbar

and the wrench, the fulcrum is between the input arm and the output arm. By contrast, a

Class II lever, for example, a wheelbarrow, places the output force (the load carried in the

barrow itself) between the input force (the action of the operator lifting the handles) and

the fulcrum, which in this case is the wheel.

Finally, there is the Class III lever, which is the reverse of a Class II. Here, the input force

is between the output force and the fulcrum. The human arm itself is an example of a

Class III lever: if one grasps a weight in one's hand, one's bent elbow is the fulcrum, the

arm raising the weight is the input force, and the weight held in the hand—now rising—is

the output force. The Class III lever has a mechanical advantage of less than 1, but what it

loses in force output in gains in range of motion.

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.

Figure 5.First class lever

Examples:

Seesaw (also known as a teeter-totter)

Crowbar (removing nails)

Scissors (double lever)

Second-class levers

Figure 6.Second class lever

Examples:

Wheelbarrow

Nutcracker (double lever)

Third class lever

Figure 7.Third class lever

Examples: Human arm

2.2 Mechanical leverages

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.

Figure 8.Lever arrangement

CHAPTER 3

COMPONENTS AND THEIR WORKING

Hydraulics now could be defined as a means of transmitting power by pushing on

confined liquid. The input component of the system is called a 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; or rotary, 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.

Hydraulic systems contain mainly following parts.

(1) Hydraulic fluids.

(2) Seals and Packing.

(3) Reservoirs

(4) Filter and strainers

(5) Cylinders

(6) Pressure control valve

3.1) 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.

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.

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 antiwar characteristics. Not all hydraulic oils contain these additives.

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.

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

3.2) 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.

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 (elastomers), however, are the most part quite compatible with

oil. Elastomer 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.

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.

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, intact, 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.

3.3) 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.

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.

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

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.

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.

3.4) 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 stop other materials.

3.5) 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.

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

3.6) 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.

There are basically three types of valves employed in hydraulic systems:

a. Directional control valves

b. Flow control valves

c. Pressure control valves

a. Directional control valves:- Directional control valves are used to control the

distribution of energy in a fluid power system. They provide the direction to the fluid and

allow the flow in a particular direction. These valves are used to control the start, stop and

change in direction of the fluid flow. These valves regulate the flow direction in the

hydraulic circuit.

Directional control valves can be classified in the following manner:

1. Type of construction:

• Poppet valves

• Spool valves

2. Number of ports:

• Two- way valves

• Three – way valves

• Four- way valves.

3. Number of switching position:

• Two – position

• Three - position

4. Actuating mechanism:

• Manual actuation

• Mechanical actuation

• Solenoid actuation

• Hydraulic actuation

• Pneumatic actuation

• Indirect actuation

b. Flow control valves: -The flow control valves work on applying a variable restriction

in the flow path. Based on the construction; there are mainly four types viz. plug valve,

butterfly valve, ball valve and balanced valve.

c. Pressure control/relief valves:-The pressure relief valves are used to protect the

hydraulic components from excessive pressure. This is one of the most important

components of a hydraulic system and is essentially required for safe operation of the

system. Its primary function is to limit the system pressure within a specified range. It is

normally a closed type and it opens when the pressure exceeds a specified maximum

value by diverting pump flow back to the tank. The simplest type valve contains a poppet

held in a seat against the spring force as shown in Figure 9.

Figure 9.Relief valve

CHAPTER 4

4.1 DESIGN AND ANALYSIS

In order to evaluate the force generated by the machine, force acting on the machine and

factor of safety, following assumptions and specifications were taken,

1. Tool Design:-

Specification and material-

Alloy Steel AISI 1020

Diameter of punch D=10mm

Length of punch=25mm

Yield Strength Mpa

Shear stress to punch a Plate F/A=F/ (πdt) =150/ (3.14 x 10 x .250) =19.09 N/mm2

Where F= force Assumed

T=Thickness of sheet plate

Shear yield strength of punch2=175.78 Mpa

& Here

Hence design is safe.

2. Design of die:-

Diameter of hole=10mm

Clearance C=5% of Thickness

Thickness of sheet .250

Therefore, C=0.05x.250=0.0125mm

Thus, diameter of Die= 10+2x0.0125=10.025mm

Simulation of Punch

Date: Tuesday, November 15, 2016Designer: Shubham Dhaneshree

Study name: SimulationXpress Study

Analysis type: Static

Table of Contents

Description................................1

Assumptions..............................2

Model Information....................2

Material Properties....................3

Loads and Fixtures....................3

Mesh Information......................4

Study Results.............................5

Conclusion.................................7

Description

Analysis of Punch for 150 N forces.

Model Information

Model name: Punch

Current Configuration: Default

Solid Bodies

Document Name and Reference

Treated AsVolumetric Properties

Document Path/Date Modified

Fillet1

Solid Body

Mass:0.0952514 kg

Volume:1.20571e-005 m^3

Density:7900 kg/m^3

Weight:0.933463 N

B:\PROJECT\Design\Punch.SLDPRT

Nov 15 22:41:31 2016

Material Properties

Model Reference Properties Components

Name: AISI 1020

Model type: Linear Elastic Isotropic

Default failure criterion:

Max von Mises Stress

Yield strength: 351.571

SolidBody 1(Fillet1)(Punch)

N/mm^2

Tensile strength: 420.507N/mm^2

Loads and Fixtures

Fixture name

Fixture Image Fixture Details

Fixed-1

Entities: 1 face(s)

Type: Fixed Geometry

Load name

Load Image Load Details

Force-1

Entities: 1 face(s)

Type: Apply normal force

Value: 150 N

Mesh Information

Mesh type Solid Mesh

Mesher Used: Standard mesh

Automatic Transition: Off

Include Mesh Auto Loops: Off

Jacobian points 4 Points

Element Size 2.29392 mm

Tolerance 0.114696 mm

Mesh Quality High

Mesh Information - Details

Total Nodes 11487

Total Elements 7477

Maximum Aspect Ratio 5.0427

% of elements with Aspect Ratio < 3 98.2

% of elements with Aspect Ratio > 10 0

% of distorted elements(Jacobian) 0

Time to complete mesh(hh;mm;ss): 00:00:02

Computer name: LENOVO

Study Results

Name Type Min Max

Stress VON: von Mises Stress 0.0502114 N/mm^2 2.48795 N/mm^2 (MPa)

Name Type Min Max

(MPa)

Node: 11317

Node: 8742

Punch-SimulationXpress Study-Stress-Stress

Name Type Min Max

Displacement URES: Resultant Displacement

0 mm

Node: 361

0.000324861 mm

Node: 101

Name Type Min Max

Punch SimulationXpress Study Displacement-Displacement

Name Type

Deformation Deformed Shape

Punch-SimulationXpress Study-Displacement-Deformation

Name Type Min Max

Factor of Safety Max von Mises Stress 141.31

Node: 8742

7001.82

Node: 11317

Punch-SimulationXpress Study-Factor of Safety-Factor of Safety

Conclusion:-

Design is safe, But lower shank may be fail at higher loads.

4.2 DRAWINGS OF MACHINE PARTS

Figure 11

Figure 12

Figure 10.Frame

Figure 11Punch

Figure 12.die

Final View of modelFigure 13.Assembly

Figure 14 Final Model

As shown in above solidworks generated model. Design model is more simplified that the previous model of same punching machine with mechanical leverages as given by previous researches.

Figure 15 Existing model

CHAPTER 5

RESULT AND DISCUSSION

The table no. 1 shows the tons of force required for punching a single round hole in mild

steel derived by the formula: Tons of pressure required + hole size x material thickness x

constant 80. All table figures shown are tons or percentages of tons. For sizes in-between,

you can interpolate.

To calculate the tons needed for other metals just multiply number times the tons required

for punching mild steel:

Aluminum (2024-0): multiply x .36

Brass (1/4 hard): multiply x .70

Copper (1/2 hard): multiply x .52

High Carbon Steel: multiply x 1.60

A36 Steel (recycled): multiply x 1.25

Stainless Steel: multiply x 1.50

Also remember that you should never try to punch a hole that is smaller that the thickness

of the steel. This is because the concentrated load on the punch stem will shatter it very

quickly. That is why there are blank spots on the chart. Example; if the steel is 1/4 inch

thick, you should not try to punch a hole smaller than 1/4 inch diameter. You should

consider drilling the hole instead.

A hint on how to keep your punches sharp longer; spray oil on the spot before you punch

the hole. This will prevent the punch from getting dull so quickly. This is especially true

when punching holes in stainless steel or hard aircraft aluminum. Without spraying oil,

the punches will get dull twice as fast as the die, which is a good reason to buy twice as

many punches as dies.

If you are punching metric size hole diameters and want to use this chart, divide by 25.4

to convert your mm sizes into inches so that you can find the tonnage needed to punch

your hole sizes. For your convenience we have already converted some hole sizes from

inches to mm.

To convert to metric from inches, remember 1 inch = 25.4 mm, so just multiply the inch

sizes by 25.4 to get your answer in mm.

Table no. 1 Round Hole Diameter [inches] to be punched

SteelThickness

1/8 inch diameter 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16

26 gauge (.018) .18 tons .27 .36 .45 .54 .63 .72 .81 .90 .99 1.07 1.16 1.25 1.34

24 ga. (.024) .24 .36 .48 .60 .72 .84 .96 1.08 1.20 1.31 1.43 1.5 1.67 1.8922 ga. (.030) .30 .45 .60 .75 .90 1.05 1.20 1.35 1.50 1.65 1.80 1.95 2.10 2.2420 ga. (.036) .36 .54 .72 .90 1.08 1.26 1.44 1.62 1.80 1.98 2.15 2.33 2.51 2.6918 ga. (.048) .48 .72 .96 1.20 1.20 1.43 1.67 1.91 2.39 2.63 2.87 3.11 3.34 3.5816 ga. (.060) .60 .90 1.20 1.50 1.79 2.09 2.39 2.69 2.99 3.29 3.59 3.89 4.19 4.4914 ga. (.075) .75 1.12 1.49 1.87 2.24 2.61 2.99 3.36 3.73 4.11 4.48 4.86 5.23 5.6012 ga. (.105) 1.05 1.57 2.09 2.62 3.14 3.66 4.18 4.71 5.23 5.75 6.28 6.80 7.32 7.8510 ga. (.135) - 2.02 2.69 3.36 4.04 4.71 5.38 6.05 6.73 7.40 8.08 8.75 9.42 10.093/16 (.187) - 2.81 3.74 4.68 5.61 6.50 7.48 8.42 9.35 10.29 11.22 12.16 13.09 14.031/4 (.250) - - 5.00 6.25 7.50 8.75 10.00 11.25 12.50 13.75 15.00 16.25 17.50 18.753/8 (.375) - - - - 11.25 13.13 15.00 16.88 18.75 20.63 22.50 24.38 26.25 28.131/2 (.500) - - - - - - 20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.505/8 (.625) - - - - - - - - 31.25 34.38 37.50 40.63 43.75 46.883/4 (.750) - - - - - - - - - - 45.00 48.75 52.50 56.257/8 (.875) - - - - - - - - - - - - 61.25 65.631 inch thick - - - - - - - - - - - - - -

Below is a conversion chart that converts sheet metal gauge numbers into metal thickness:

26 gauge 24 ga. 22 ga. 20 ga . 18 ga. 16 ga. 14 ga. 13 ga. 12 ga. 11 ga. 10 ga. 9 ga. 8 ga. 7 ga. 6 ga. .018" .024" .030" .036" .048" .060" .075" .090" .105" .120" .135" .150" .164" .180" .194

.46mm .61mm .76mm .91mm 1.2mm 1.5mm 1.9mm 2.3mm 2.7mm 3mm 3.4mm 3.8mm 4mm 4.6mm 4.9mm

From above data we conclude that the designing of punching machine for lower yield

stress material like aluminum, Brass etc can be punch with small thickness of sheet metal

plates. Above data is for reference purpose only for the punching machine we design

theoretically is required how much stress to punch a hole for different-different materials

and thickness.

CONCLUSION

The project carried out by us will make an impressing mark in the field of small scale

industries. It is very usefully for the workshops to carry out the punching operations

easily on our machine. This project has also reduced the cost involved in the concern. The

project has been designed to perform the required task taking minimum time.

We have estimated the capacity of the hydraulic punching machine. From the analysis we

found that the machine will be capable to perform the operation on the aluminum sheet to

produce the punched product or for mass production of washers. This machine can be

used for multipurpose punching at a single time of stoke of ram/plunger. As a

modification and extension of the project, a motor along with a flywheel can be attached

to automate the machine in order to increase the throughput time and reduce the cycle

time of the machine according to desire.

We have seen how the Hydraulic systems allow users to accurately wield large amounts

of power with little input force. So we can say that a portable hydraulic system using

leverages is quite economical as compare to the other alternative.

REFERENCE

Research papers:-

1. Design and Fabrication of Auto Roll Punching Machine by Kundan Kumar

ISSN (Online) : 2319-8753

2. Improvement in design of the manual small press machine by vivek Sharma

ISSN : 2278 – 0149

3. Hydraulically controlled punching machine by h.schmid

4. Hydraulic punching machine by f.j cloup

5. The research of new type hydraulic breaker with strike enegy and frequency

of adjusted by gouping yang & yubao chen

Books:-

1. Basic Hydraulic and Components (Pub. ES-100-2) yuken kogyo co.

Ltd.

2. Fluid Mechanics and Hydraulic Machines - Dr. R. K. Bansal, Lp

Publication

3. Machine design R.S Khurmi J.K Gupta, Eurasia publication house

Pvt. Ltd

4. Introduction to Basic Manufacturing Processes and Workshop

Technology Rajendra Singh, New age international publication.

5. Design data handbook K.Mahadevan K.balaveera Reddy, CBS

publishers & Distributors Pvt Ltd.