Hydraulic press

CHAPTER 1
INTRODUCTION
A hydraulic press is a 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.
The hydraulic press is a kind of machine which uses the liquid as a working medium to transfer energy based
on PASCAL's principle to realize various technique. Generally, the hydraulic press machine consists of three
parts the machine (mainframe), the power system and the hydraulic control system 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. 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 .There is
easy transmissibility of large amount of energy with practically unlimited force amplification. It has also a
very low inertia effect. Hydraulic press is a tool to produce compressive force by means of fluid. It
depends upon Pascal’s principle that the pressure throughout an enclosed entity is constant. By
means of hydraulic system larger forces can be produced in contrast with mechanical and electrical
systems. Such forces can be used for the press work application such as blanking, punching, piercing,
coining, trimming etcetera. Press work is a method of mass production involving the cold working of
metals, usually in the form of thin sheet or strip. Press working is one of the extensively employed
methods of fabricating parts of intricate shapes with thin walls. Press working processes make use of large
forces by press tools for a short time interval which results in cutting or shaping the sheet metal. Since, press
working does not involve heating of the parts, close tolerances and high surface finish can be obtained on the
part. Since presses can produce components at fairly fast rates, the unit cost of labour for operating the press
is fairly low Press working forces are set up, guided and controlled in a machine referred to as a Press. Thus
an attempt has been made to atomize the process of press work using Hydraulic mechanism in press
machine. The inputs and outputs of the control system including hydraulic mechanism are solely mechanical
such as rotating shaft or reciprocating plunger. The prime remunerations of implementing this system is
the movement of the mechanical devices can be operated by means

of hydraulic components such as actuators to initiate the movement which could be in the form of lever to
apply manually or by means of switches to operate automatically. Furthermore, direction
Control valves have been implemented to control the directions of piston movements and regulate the same.
Thus the whole mechanism have been simplified with the use of hydraulic equipment’s. Moreover, the use
of pressure control valve and direction control valves, makes it easier to regulate the forces and

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control the speed of the setup Presses are one of the most commonly used machine tools in industry for the
forming of different materials.
In the past, for the pressing tasks in industry, mechanical presses were more frequently used, but nowadays
hydraulic presses take precedence due to their numerous advantages, such as: full force throughout the
stroke, moving parts that operate with good lubrication, stroke that can be fully adjustable which contributes
to the flexibility of application, built in overload protection, can be made for very large force capacities,
silent operation and more compact. 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. This
paper describes design, development and manufacturing of multi-purpose H-frame hydraulic press. For mass
minimization, we use standard steel sections instead of plates. Due to this, the fabrication of hydraulic press
frame also becomes simple. ANSYS has been used for the analysis; the main aim is to reduce the weight of
the hydraulic press without compromising on the quality of the output. This particular press is used for a
variety of tasks from doing mechanical work to straightening or intentionally bending structural components.
It is also used to take force related measurements such as spring rates of coil and leaf springs.

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CHAPTER 2
History
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 finite
elements. 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, eddy current induction and a physical correct implementation of the contact mechanics, which
are relevant for the 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. The developed 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. The switching cycle was
less than 10 ms.

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 finite
elements. 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, eddy current 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. The developed 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. The switching cycle was
less than 10 ms. At the heart of the hydraulic press is one of the most important properties of water - its low
compressibility. Due to this pressure, the water produced, enclosed in a closed vessel, is transmitted in all
directions with the same force, so that each unit area has to the same pressure as the pressure from the
outside. The force with which the impact is on the surface, determined by the formula F = P • S, where P -
pressure, S - area to which the force is applied. Imagine a closed vessel with water (or any other
incompressible fluid) in which two pistons inserted. Acting on a smaller piston with a force F, we can get to
climb the larger piston. The force with which the water will be to put pressure on the piston (as shown in the
above formula) is as many times greater in number with an area greater than the area of the smaller piston.
This is the essence of the effect of hydraulic amplification. For example, if the smaller piston to press with a

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force of 10 kg, the influence exerted on the piston in the other knee diameter twice to four times larger (as
the area of the piston in a four-fold increase), that is, it will be equal to 40 kg. Appropriate selection of the
diameters of the two piston can achieve extremely large increase in the pressure force exerted by the water
on the second piston, but to the same extent decrease the rate at which it will rise upwards. (In our example,
to a large piston rose to 1 cm, small should fall by 4 cm.)

This remarkable property of incompressible fluid that has received the widest use of modern
technology, was opened by Pascal. In his treatise on fluid balance, published posthumously in 1663, he
wrote: "If a vessel full of water, enclosed on all sides, has two openings, and one has an area of a hundred
times more than the other, with a tight-inserted piston, the a man pushing a small piston will balance the
force of a hundred people who will push a hundred times more, and 99 of them will overcome.

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CHAPTER 3
METHODOLOGY
In 1797, Brahma built the first hydraulic press in history. Here EE depict racks, D - cover, and C - the press
platform, integral with its piston, while the outer cylinder was cast together with a base for struts. In the
present section can be seen next to the cylinder collar Maudsley, also shown separately enlarged by the letter
Q. The cylinder press was connected to a flexible tube with separate pressure pump. Its solid piston
movement was set in the initial GH via a lever rod H 'and the guide rod K. The pump is normally
strengthened at the cast iron box serves as a reservoir for liquids (water, oil or glycerine) in the same
reservoir fluid flowed back when the pressure reached set value and safety valve V lifted his load P or when
the shutter opens the screw to release the liquid and allow the piston. Press Brahma became a model for
many other hydraulic devices, invented later. device for lifting - jack Soon was created. In the 20 years of
XIX century, the press has become widely used for stamping products from soft metal. But it took several
decades before were created powerful forging. The urgent need for such presses appeared in the second half
of the XIX century, when significantly increase the size of work pieces. They require the forging of ever
more powerful steam hammers. Meanwhile, to increase the impact force of a steam hammer had to either
increase the weight of falling parts, or the height of its fall. But both had their limits. Rapid Engineering
process, the need for ferrules increasingly large pieces finally brought women weight (beating of the
hammer) to colossal size - about 120 tons. In the fall of huge masses, of course, it was to achieve the
required accuracy is impossible. In addition, the impact force, causing a sharp distortion, thanks to inertia
acting only on the surface layer otkovki. From a technological point of view, slow but strong pressure was
much more appropriate, since the metal was getting time Hrazdan, and this contributed to a more regular
strain. Finally, the strong blows of the hammer so shook the ground that it had become dangerous to the
surrounding buildings and structures.

The first forging press was developed in 1860 by the director of the state railway workshops in Vienna John.
Gazvellom. Workshops were located in the city close to residential buildings, so place them in a powerful
steam hammer was not possible. Then Gazvell and decided to replace the hammer press. He created the
press served by a steam engine of double action with horizontal cylinder actuates the two pumps. Power of
the press was 700 tons, and it has been successfully used at stamping locomotive parts: pistons, clips, cranks,
and the like. Exposed in 1862 at the World Exhibition in London, he has attracted great interest. Since that
time, more and more powerful presses were established in all countries. English engineer Whitworth (one of
the disciples of Henry Maudsley and himself an outstanding inventor), delighting Gazvella example, has set
a difficult task - to create a press that we could use to get products directly from the iron and steel ingots. In
1875 he received a patent for his first forging press. Press Whitworth consisted of four towers, fortified in
the base plate. On top of the column was fixed located crossbeam (traverse) two hydraulic lifting cylinders -
with them is moved up and down movable cross member on which the die was set at the bottom. Device
media based on the combined use of force pumps and hydraulic accumulators. (Hydraulic accumulator - a
device that allows you to accumulate hydraulic energy; it consists of a cylinder and a piston, which is
attached to the goods; first water entering the cylinder lifts the load, and then, at the right time, the load is
released and the water coming out of the cylinder under its pressure, performs work necessary) in the press
Whitworth between the four columns at a certain height above the anvil K placed array P.; It was inserted
into the large cylinder C, E and the piston which was part of the forging press. This piston was connected
with two pistons and a small cylinder a1, also inserted in the array so that in all the three pistons go up and

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down simultaneously. C The space above the piston of a large cylinder was connected with the box D, which
was accelerated water pumps. In the small space above the piston cylinder was connected to the truck battery
tube AB, the load which was balanced with the weight of all three pistons E, a and a1. The real work of
forging as follows: open the valve in the discharge box d, the water pumps were sent to the space above the
piston of a large cylinder, making all three piston fell. This large piston compresses the metal, and small
pistons pressured water under them and this pressure lifted load balancing battery. When the pump discharge
valve is closed, the pressure on the large piston was stopped, and then raised load the battery begins to
descend, passing the pressure on the water, which has raised all three of the piston. Thus, the load-balanced,
and with him three pistons were like two scales. The pump is driven by a steam engine. To monitor the
compression force with forging piston was connected to the arrow F, which made it possible to keep forging
with exceptional accuracy. heating; using the hydraulic press, let's force of 4,000 tons, forging ingot
weighing 37, 5 t took only 4 days and required 15 intermediate heating. Replacement hammer forging press
reduces the cost of operation of large parts about seven times. Therefore, in a short time, press Whitworth
widespread. Soon the use of hydraulic forging presses has led to serious technical transformation of large
metallurgical and machine-building plants. Heavy steam hammers were everywhere dismantled and replaced
by presses. By the early 90-ies of the XIX century already had the press with a capacity of 1000 tonnes.
 Oil used :
Penrite Hydraulic Jack Oil is a low zinc, premium quality ISO 46 hydraulic oil made from selected base
stocks and an advanced anti-wear additive. Penrite Hydraulic Jack Oil is recommended for use in all types of
hydraulic jacks and hoists.

Oil Specifications :-
1. Capacity : 5 ton, 5000 kg Hydraulic jack
2. Oil used : penrite oil
3. Viscosity : 20W synthetic oil

Specification:

 Frame- Height: 725 mm

 Width-380 mm
 C-channel: 72x40mm
 Spring: Elastic Type- No. of Quantity: 2
 Free length: 230 mm
 Jack:-Capacity: 5 tons
 Height- 300 mm

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

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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.

Fig: Hydraulic Press

Proposed
Hydraulic presses are commonly used for forging, clinching, moulding, blanking, punching, deep
drawing, and metal forming operations. hydraulic press is advantageous in manufacturing, it gives the ability
to create more intricate shapes and can be economical with materials. A Hydraulic press will take up less
space compared to a mechanical press of the same capability. There are different kinds of the hydraulic
presses used in the automotive industry. While professional body shops employ four-column hydraulic
presses, some use 12-, 20-, and 25-ton presses with a manual pump for personal use The manual pump is
used to increase pressure.

Methodology
The design, material selection and development of the manually operated hydraulic press and pull
machine were based on the following concepts and considerations. The machine was designed with
provisions for adjustment, such that bearings of different diameters can be fit into shafts or housings of
different diameters and lengths. ii. The hydraulic fluid is pumped manually, thus ensuring that the machine
does not require electrical energy for its operation thereby incurring no operational cost. iii. The machine
was fabricated using locally sourced and available materials for easy operation, maintenance and
repair/replacement in case of breakdown. Also, standard components/parts were used where necessary to
ensure low cost of production and maintenance of the machine.
1) To analyze the problems present in existing press.

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2) To design the critical components of the hydraulic press using geometric modeling software.
3) To analyze and optimize the critical areas of 20 ton hydraulic press

Fig: Hydraulic Press

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CHAPTER 4
DESIGN AND WORKING

Now that we are aware that the hydraulic press is based on Pascal’s Principle, we can move on to the
construction and working of the hydraulic press. The components of a hydraulic press
include cylinders, pistons, and hydraulic pipes. The working of the press is quite simple and primitive. The
system comprises two cylinders that are filled with a fluid. The fluid present inside the two cylinders is
usually oil. The fluid (the oil) is filled into the smaller cylinder, which is also known as the slave cylinder.

A piston is inserted into the slave cylinder and pressure is applied. The pressure applied causes the fluid to
move through a pipe and into a larger cylinder. The larger cylinder is known as the master cylinder. The
pressure exerted on the master cylinder and the piston in the master cylinder pushes the fluid back to the
slave cylinder. The force applied on the fluid by the slave cylinder results in a large force, which is
experienced by the master cylinder. An industrial hydraulic press comes along with what is known
as the press plates. With the help of these press plates, the material to be worked
Unlike their mechanical counterparts, hydraulic presses can compress any material to a full extent. Also,
hydraulic presses take only half of the space that the mechanical ones take because they have the ability to
compress a large pressure in a cylinder having a less diameter.

Construction and working of Hydraulic Press :-

Hydraulic press is a mechanical device which is based on the ‘Pascal’s law’ which states that equal intensity
of pressure exerts on all the directions in a closed system. It applicable here in such a way that if there is any
pressure change at one point in a closed system then same intensity of pressure will change at other point in
the same system.

Hydraulic press is able to develop high forces with the application of less effort. There are two main parts in
the hydraulic press assembly, one is called as ram and second one is known as plunger. Ram works as output
medium where as plunger gives input. In between ram and plunger hydraulic fluid is filled in a closed
container which is responsible for the whole operation i.e. force and pressure transmission. In practical
situation both plunger and ram have different area. If ‘A’ is the area of ram and ‘a’ is the area of plunger
then the mechanical advantage of the system is equal to A/a; which is the ratio of ram area to plunger area

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because pressure is defined as the force per unit area, if F is the force applied to the plunger and W is the
load lift by the ram so according to the Pascal’s law pressure is
P = F/a = W/A or W = F (A/a)
Above relations shows that by adjusting the area of the ram and plunger we can able to use it in several
applications where we can easily develop high forces by applying only small amount of force. In practical
hydraulic press system, generally multiple rams are assembled together. The number of rams used depends
upon the working load. In hydraulic press multiple rams of small sizes are preferred instead of a single large
size ram to control the thrust forces because it is easy to control the thrust forces on small size as compare to
large size. In press assembly one side/table is always fixed while the other is moving by the application of
ram force and in between fixed as free side pressing operation is take place. Ram is operated by the
hydraulic pressure of fluid. The high pressure liquid is supplied by using pump and hydraulic accumulator.
Hydraulic accumulator works as the junction between the pump and the rams. Hydraulic accumulator stores
the high pressure liquid when press is at stationary position. Hydraulic press is used where high thrust is
required for operation.

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CHAPTER 5

APPLICATION

Applications of Hydraulic Press

 Aerospace industry
 Automotive parts
 Thermoplastic Industries
 Carbon Fiber Molding
 Glass Mat Transfer (GMT)
 Resin Transfer Molding (RTM)
 Sheet Molded Composites (SMC)
 Deep drawing operations
 Punching operations
 Blanking operations
 Maudling operations
 Clinching operations
 Forging operation
 The major application of the hydraulic press is in industry where big size metal objects transform into
thin sheets by the application of pressure force.
 Sheet metal operations such as drawing, deep drawing, punching and blanking etc
 In crushing of scraps and old vehicles.
 In Packaging industry.

 For crushing cars. A hydraulic press is the heart of any car crushing system. In this process, a
hydraulic motor applies a large pressure on the fluids into the cylinders. The fluid pressure makes the
plates rise and with a large force, the plate is driven on the car thereby crushing it.
 Fat-free cocoa powder. While processing the cocoa beans, a liquid known as chocolate liquor is
derived. For making fat-free cocoa powder, this liquid is squeezed out in a hydraulic press. After this
stage, this liquid is processed further to make a powder. The powder thus derived is cocoa powder,
which is fat-free.
 For sword making. In the process of making swords, a hydraulic press is used to give a flat shape to
the raw steel.

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CHAPTER 6

CONCLUSION
Hence we have studied the hydraulic press working design as well as applications and it’s methodology for
its construction and working condition also the oil used in it. And it’s various components.

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CHAPTER 7

REFERENCE
1) www.google.com
2) Reference book
3) www.wikipedia.com
4) Abstract pdf

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