Presentation Report on Hydraulic intensifier (SBIT Sonepat)

PRESENTATION REPORT ON

Hydraulic Intensifier

Submitted By:

Anand Kumar (ME/13/710)

Department of Mechanical Engineering

SHRI BALWANT INSTITUTE OF TECHNOLOGYApproved by AICTE, Min of HRD, Govt of India & DTE, Govt of HaryanaAffiliated to DCR University of Science and Technology, Murthal, Sonepat

Meerut Road (Pallri), Near DPS, Sonepat-131001, Haryana

PRESENTATION REPORT ON HYDRAULIC INTENSIFIER

Abstract

My report focuses on the topic Hydraulic Intensifier and its operations. In the following

report I have studied about the basics of Hydraulic Intensifier, their operations and their uses.

As well as the report covers the inside view of the Hydraulic Intensifier and its operations. A

hydraulic intensifier is a device which is used to increase the intensity of pressure of any

hydraulic fluid or water, with the help of the hydraulic energy available from a huge quantity

of water or hydraulic fluid at a low pressure. Know about the components and construction of

intensifiers. A hydraulic intensifier is a hydraulic machine for transforming hydraulic power at

low pressure into a reduced volume at higher pressure.

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CERTIFICATE

This is certify that the seminar Topic entitled as Hydraulic Intensifier and submitted by ANAND KUMAR having Roll No ME/13/710, embodies the bonafide work done by him under my supervision.

Signature of Supervisor:

Place:

Date:

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TABLE OF CONTENTS

1. INTRODUCTION………….……………………………………...…...….……....5

2. THEORETICAL STUDY………………………………………………………....7

2.1 CLASSIFICATION…………………………………………………………...7

2.2 MAIN PARTS…………………………………………………………………8

2.3WORKING PRINCIPLE………………………………………………………8

3. THEORY OF OPERATION……………………………………………………....9

4. REFERENCES……………………………………………………….……….….12

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1. INTRODUCTION

A hydraulic intensifier is a device which is used to increase the intensity of pressure of any

hydraulic fluid or water, with the help of the hydraulic energy available from a huge quantity

of water or hydraulic fluid at a low pressure. Know about the components and construction of

intensifiers. A hydraulic intensifier is a hydraulic machine for transforming hydraulic power at

low pressure into a reduced volume at higher pressure. A hydraulic intensifier is a device

which is used to increase the intensity of pressure of any hydraulic fluid or water, with the help

of the hydraulic energy available from a huge quantity of water or hydraulic fluid at a low

pressure. These devices are very important in the case of hydraulic machines, mainly hydraulic

presses, which require water or hydraulic fluid at very high pressure which cannot be obtained

from the main supply directly. In most of the hydraulic machinery used, the usual pressure of

80 to 100-psi may not be sufficient to operate certain spool valves and other mechanisms. To

cater to the need for a high pressure requirement for a comparatively short period of time,

pumps and accessories are definitely not the solution. But the substitute can be hydraulic

intensifiers which can increase the pressure from 100 psi to 40,000 psi, using small volumes of

fluid. There are different types based on the medium of hydraulic fluids used and the number

of strokes used to intensify to the desired pressure. They are single-stroke, differential cylinder

intensifiers, oil-oil intensifiers, air-air intensifiers, and oil-air intensifiers. Recent developments

are so vast that huge pressures are achieved by using combinations of the above types. An

intensifier heightens the intensity of the meaning of an item. A hydraulic intensifier is a

hydraulic machine for transforming hydraulic power at low pressure into a reduced volume at

higher pressure. It increases the intensity of pressure of the liquid by utilizing the energy of a

larger quantity of liquid at low pressure. Such a machine is constructed mechanically by

connecting two pistons, each working in a separate cylinder of different diameter. This concept

is developed from Pascal’s law for incompressible fluid. If the diameters of the pistons are

different, the hydraulic pressure in each cylinder will vary with the area ratio of the pistons, the

smaller piston giving rise to higher pressure intensity than the larger piston pressure intensity.

The increase in the intensity of pressure is generally required when the liquid supplied by the

pump does not possess the required intensity of pressure. The hydraulic intensifier is very

important in the case of hydraulic machines, mainly hydraulic presses, which require water or

hydraulic fluid at a very high pressure which cannot be obtained from the main supply directly.

High pressure metal hydro-forming requires 20,000 psi or 1379 bar [3]. Definitely this pressure

will require a massive construction of pump. But if there is a HPI, it is possible to raise the

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pressure by using a reasonable size of pump. A machine which has come into general use very

rapidly in the last few years is the high-speed forging press for casting and forming heavy and

complicated shapes. The next broad step after the direct pump-driven press was the hydraulic

intensifier which made it possible to raise the pressure which cannot be achieved directly by

pumping action. To press two metals sheet adjacently and to lifting heavy load, as for example,

bridge slab, it requires a device which is capable of heavy load carrying capacity and smooth

operation. Again, it is hydraulic jack which possesses the capabilities of smooth operation and

heavy load carrying behavior. But for its proper functioning it is necessary to supply the

compressed fluid at high pressure and this can be done by using a HPI. Hydraulic intensifier is

used in constructing water cutting jet machine. It is also used in mining and construction firms.

The objectives of the present work is to design and construct a automatic controlled

reciprocating HPI which can maximize pressure 6.25 times the input pressure range of

maximum 5 bar. In existing rotary type HPI critical intensification ratio is 2.5 and its efficiency

is 45%.

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2. THEORETICAL STUDY

Hydraulic Pressure Intensifier is a mechanical device which is used for increasing the intensity

of pressure of the liquid by utilizing the larger quantity of liquid at low pressure. Often

hydraulic machines such as press, etc., require liquid at high pressure which may not be

directly available from a pump. It can, however, be provided by introducing an intensifier

between the pump and machine. It consists of several kinds of mechanical and electrical

equipments.

2.1 Classification

Basically there are only two types of hydraulic intensifier namely single action and double

action intensifier. These two principal types of hydraulic intensifier have been modified in so

many ways as per requirements of industry. Some of them are described as follows:

Classification based on body construction of Hydraulic intensifier:

2.1.1 Tie-Rod Construction

This type of construction is most widely used in industry. ISI standard also generally refers to

one of this type of construction. As all the components are only machined and assembled

together and not welded. Hence planning manufacturing, quality control assembly and

maintenance are more convenient than other types of construction. As long as tie-rods are used

to hold the entire components together, special care is required to tighten them and safe-guard

against loosening in operation.

2.1.2 Threaded Construction

This construction is similar to tie-rod construction, but more compact, stronger, and requires

more accuracy and care in manufacturing and quality control. In this design, both ends are

assembled with cylinder-tube by threading, as shown in following design. These are used for

medium to heavy-duty operation, and widely used in earth-moving purpose respectively.

2.1.3 Bolted Construction

This type of construction involves welding of flanges to cylinder tube, and bolting of end cover

to the welded flange. Similar to tie rod construction these are also designed and manufactured

as standard hydraulic component and widely used in industry.

2.1.4 One Piece-Welded Cylinder

Similar to shock absorber, in this design the end-covers and cylinder tube are welded together.

These are economical but cannot be repaired.

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These are used for low pressure agriculture machinery application. Figure 4 shows One Piece-

Welded HPI.

2.1.5 Custom Build HPI

In this type of cylinder, various type of construction is mixed together to suit the requirement.

One of the most widely used combinations is welded cap-end cover, bolted head-end cover

with front tube flange mounting. In case of high capacity cylinder when it is steel cast or

machined from solid steel forging, then end cover and front flange may be integral part of

cylinder tube. Cylinder with this type of construction is widely used in hydraulic press.

2.2 Main Parts

A hydraulic pressure intensifier consists of several kinds of mechanical and electrical

components. There are two main parts in the hydraulic intensifiers to be noted. These are

Piston and Cylinder.

2.3 Working Principle of HPI

The working principle of HPI is described below:

i. Oil is forced into the right half of the hydraulic cylinder.

ii. The piston-plunger assembly moves to the left. Oil is displaced out of the left half of

the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.

iii. The plunger moves to the left.

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iv. Once pressure has begun to build, the high pressure water is forced out of the intensifier

through the center of the check valve.

v. While the piston-plunger assembly is moving to the left, it is also allowing fresh water

to flow into the right high pressure cylinder through the inlet holes of the check valve.

vi. When the plunger-piston assembly has reached the end of its stroke to the left, the right

high pressure cylinder is now full of water.

vii. The directional control valve receives a signal via a proximity sensor near the piston to

reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic

cylinder and the piston moves to the right.

viii. Oil is displaced out of the right half of the hydraulic cylinder while the water in the

right high pressure cylinder is pressurized by the right plunger. Such a machine may be

constructed by mechanically connecting two pistons, each working in a separate

cylinder of a different diameter. As the pistons are mechanically linked, their force and

stroke length are the same. If the diameters are different, the hydraulic pressure in each

cylinder will vary in the same ratio as their areas: the smaller piston giving rise to a

higher pressure. As the pressure is inversely proportional to the area, it will be inversely

proportional to the square of the diameter.

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3. OPERATION

The working volume of the intensifier is limited by the stroke of the piston. This in turn limits

the amount of work that may be done by one stroke of the intensifier. These are not

reciprocating machines (i.e. continually running multi-stroke machines) and so their entire

work must be carried out by a single stroke. This limits their usefulness somewhat, to machines

that can accomplish their task within a single stroke. They are often used where a powerful

hydraulic jack is required, but there is insufficient space to fit the cylinder size that would

normally be required, for the lifting force necessary and with the available system pressure.

Using an intensifier, mounted outside the jack, allows a higher pressure to be obtained and thus

a smaller cylinder used for the same lift force. Intensifiers are also used as part of machines

such as hydraulic presses, where a higher pressure is required and a suitable supply is already

available.

Some small intensifiers have been constructed with a stepped piston. This is a double-ended

piston, of two different diameters, each end working in a different cylinder. This construction

is simple and compact, requiring an overall length little more than twice the stroke. It is also

still necessary to provide two seals, one for each piston, and to vent the area between them. A

leak of pressure into the volume between the pistons would transform the machine into an

effective single piston with equal area on each side, thus defeating the intensifier effect. A

mechanically compact and popular form of intensifier is the concentric cylinder form, as

illustrated. In this design, one piston and cylinder are reversed: instead of the large diameter

piston driving a smaller piston, it instead drives a smaller moving cylinder that fits over a fixed

piston. This design is compact, and again may be made in little over twice the stroke.

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It has the great advantage though that there is no "piston rod" and the effective distance

between the two pistons is short, thus permitting a much lighter construction without risk of

bending or jamming. In the example illustrated, the two pistons are approximately 1:2 ratio in

diameter, giving a 1:4 increase in pressure. Note that it is the diameter of the effective piston,

i.e. the seal diameter that matters. The cylinders here are relieved beyond the seal and are of

greater diameter, for easy running. Although the moving cylinder's bore is around ¾ of the

outer diameter, not ½, it is its seal diameter that matters, not its internal clearance bore.

The celebrated mechanical engineer Harry Ricardo began his career by working in his

grandfather, Alexander Rendel's, civil engineering practice. At the time they were involved in

the construction of bridges in India, which required hydraulic lifting, hoisting and riveting

equipment. As the existing transport infrastructure was poor, all plant used on site needed to be

lightweight and easily portable. Machines also needed to be connected to their hydraulic power

source by flexible tubing, which limited their working pressure to around 500 psi. At this time,

modern shipyard equipment was using pressures of up to 2000 psi. This high-pressure

equipment was smaller and lighter than the bulkier low-pressure variety, a desirable feature for

this construction work. Ricardo's innovation was to specify the use of portable hydraulic

intensifiers for these tools, permitting the use of the improved high-pressure form, even where

their supply was at low-pressure, through flexible hose. These intensifiers were so successful

that eventually several hundred were supplied and used.

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4. REFERENCES

http://en.wikipedia.org/wiki/Hydraulic_intensifier

http://experimentjournal.com

http://www.brighthubengineering.com/hydraulics-civil-engineering/43882-learn-

about-hydraulic-intensifiers/

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