International Journal for Research in Engineering Application & Management (IJREAM)

ISSN : 2454-9150 Vol-05, Issue-01, April 2019

Design and Manufacturing of Pipe Flaring and

Squeezing Horizontal Hydraulic Press Machine
1
Sumit Suresh Patil, 2Ayyankalai Muthuraja, 3Prof.Govindrao Chavan
1
MTech Design, 2Associate Professor, 3Assistant Professor, Department of Mechanical Engineering,
School of Engineering and Technology, Sandip University, Nashik, Maharashtra, India.
1
patsonu63@gmail.com, 2a.muthuraja@sandipuniversity.edu.in

Abstract - Design and manufacturing of new horizontal hydraulic press machine is implemented for the pipe squeezing
and flaring operations. Due to higher flexibility and greater accuracy, the horizontal hydraulic press machine is used
for the squeezing and flaring operations, as two vertical hydraulic presses are needed for the same operations. The
design of the considered machine is done using computer-aided software NX-CAD and a 20-ton hydraulic press is
constructed and tested using a locally sourced material, and fluid. The major components of the press design are
included the cylinder, piston arrangement, the frame, hydraulic circuit, die, and punch. In this machinery, hydraulic
actuator and clamping device are with dimensions of 200×80×200 mm and 100×60×200 mm respectively, and the stroke
length of an actuator is considered as 200 mm (working pressure 200 bar). The squeezing and flaring two different
operations are done in one machinery using the developed machine with less expensive. The flaring of the pipe is
typically performed using die and punch method. The main aim of this work is to flare and squeeze the pipe and to
analyze the performance of the horizontal hydraulic machine. The MOORA analysis is done and Programmable logic
controller (PLC) is the small computer used for the real-world process. Also, dynamic characteristics were investigated
under the various operating conditions for horizontal hydraulic press.

Key words: Horizontal hydraulic press, Squeezing, Flaring, MOORA, Programmable logic controller, dynamic
characteristics

I. INTRODUCTION of finding ever a lot of economical and convenient means

that of pushing and propulsion, rotating, jabbing and
In press, the force generation, transmission and dominant load, starting from some kilograms to thousands
amplification are achieved mistreatment fluid besieged. The of tons . Presses are wide wont to come through this.
liquid system exhibits the characteristics of a solid and Presses, as outlined by Lange, are pressure exerting
provides a really positive and rigid medium of power machine tools. they'll be classified into three principal
transmission and amplification. in an exceedingly categories as: hydraulic presses that look after the
straightforward application, a smaller piston transfers fluid principles of fluid mechanics pressure, screw presses that
underneath high to a cylinder having a bigger piston space, use power screws to transmit power and mechanical presses
therefore amplifying the force. there's straightforward which utilize kinematic linkage of components to transmit
transmissibility of huge quantity of energy with much power . In press, the force generation, transmission and
unlimited force amplification. it's conjointly a really low amplification are achieved Department of Production
inertia impact.[1] Engineering, University of Benin, Benin City, Edo State,
Main objective of project is to switch major part of ―one Nigeria. mistreatment fluid besieged. The liquid system
cylinder four post hydraulic press‖ therefore rigidity and exhibits the characteristics of a solid and provides a really
strength of the parts are increase by mistreatment optimum positive and rigid medium of power transmission and
material. The perform of the foremost part like frame, amplification. in an exceedingly straightforward
bottom plate, bed, high box are to soak up forces, to supply application, a smaller piston transfers fluid underneath high
precise slide steerage and to support the drive system and to a cylinder having a bigger piston space, therefore
alternative auxiliary units. The structural style of the part amplifying the force. there's straightforward transmissibility
depends on the pressing force this determines the specified of huge quantity of energy with much unlimited force
rigidity.[3] amplification. it's conjointly a really low inertia impact.
[7,9]
the event of engineering over the years has been the study

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

A typical press consists of a pump that provides the continuously remains constant.[18] In press, the force
mobility for the fluid, the fluid itself that is that the medium generation, transmission and amplification are achieved
of power transmission through hydraulic pipes and mistreatment fluid besieged. The liquid system exhibits the
connectors, management devices and also the hydraulic characteristics of a solid and provides a really positive and
motor that converts the hydraulic energy into helpful work rigid medium of power transmission and amplification. in
the purpose of load resistance. the most benefits of an exceedingly straightforward application, a smaller piston
hydraulic presses over alternative varieties of presses are transfers fluid underneath high to a cylinder having a bigger
that they supply a a lot of positive response to changes in piston space, therefore amplifying the force. there's
input pressure, the force and pressure will accurately be straightforward transmissibility of huge quantity of energy
controlled, and also the entire magnitude of the force is on with much unlimited force amplification. [2]
the market throughout the complete operating stroke of the
ram travel. Hydraulic presses are most popular once terribly
giant nominal force is needed. The press is a useful
instrumentation within the workshop and laboratories
particularly for press fitting operations and for the
deformation of materials like in metal forming processes
and material testing for strength. a glance at the workshop
in African nation reveals that every one such machines are
foreign into the country. Therefore, it's meant here to style
and manufacture a press, that is low value and hydraulically
operated mistreatment domestically sourced materials. this
cannot solely facilitate to recover the monies lost within the
sort of for chemist exchange however will enhance the
amount of our native technology in the exploitation of
hydraulic fluid power transmission.[16] Fig.1 Pascal’s law
The terribly basic operating principles of the press are II. TYPES OF HYDRAULIC PRESS
straightforward and straightforward and rely on variations
in fluid pressure. Fluid is pumped up into the cylinder There are many alternative kinds of hydraulic presses
below the piston; this causes the fluid pressure underneath occupation to the varied needs of industries. a number of
the piston to maximise. At the identical time, fluid is them are as follows:
pumped up out of the highest channel, ensuing the fluid 1)Arbor presses
pressure on top of the piston to decrease. the next pressure
of the fluid below the piston than the fluid over it causes the These presses are typically used once the work concerned
piston to rise. within the later step, fluid is pumped up out isn't of a heavy- duty nature. These presses are available a
from below the piston, inflicting the pressure underneath range of sizes and specifications. however, compared to
the piston to decrease. at the same time, fluid is pumped up different hydraulic presses, they are doing not compress
forcefully into the cylinder from the top; this will increase massive amounts of pressure needed to come up with
the fluid pressure on top of the piston. the next pressure of additional output. Arbor presses are utilized in processes
the fluid on top of the piston, than the fluid below it, moves like piercing holes into metals, stamping, to flatten metals,
the piston downward. Presses are one amongst the foremost tearing, marking inscriptions, etc.
usually used machine tools in trade for the forming of
various materials. within the past, for the pressing tasks in
trade, mechanical presses were a lot of oftentimes used,
however these days hydraulic presses take precedence
because of their various benefits, such as: full force
throughout the stroke, moving elements that operate with
sensible lubrication, stroke which will be absolutely
adjustable that contributes to the flexibleness of application,
in-built overload protection, are often created for terribly
giant force capacities, silent operation and a lot of compact.
therefore a press may be a machine that creates use of the Fig.2 (a)Arbor Press
pressure exerted on the fluids to crush, straighten or mould. 2) Laminating presses
The thought of the press is predicated on Pascal's theory,
that states that once pressure is applied on fluids in an Unlike different hydraulic presses that are operated
internal system, the pressure throughout the system mechanically, these presses build use of labour. Laminating
presses have 2 openings that are referred to as plates. One is

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

employed for heating whereas the opposite is used for Fig. 2(c) C Type Vertical Hydraulic Press
cooling. This makes the lamination method relatively 5)Power presses
quicker. Through these presses, materials like chemical
These presses are utilized in massive industries that demand
compound may be laminated onto paper and metal. just in
the employment of significant machinery and
case of laminating presses, the plates are typically heated
instrumentality. There are two forms of power presses on
with oil or through electricity. A laminating press is
the premise of the kind of clutch used. they're full
additionally used for common uses like laminating the
revolution and half revolution clutch. just in case of a full
identity cards, certificates and even book covers. during this
revolution clutch, the clutch can not be noncontinuous till
approach, laminating presses facilitates quick and
and unless the shaft makes a full revolution. just in case of
straightforward lamination for industrial and domestic
half revolution, the clutch may be noncontinuous at any
desires.
time, before or once the complete revolution. Power presses
involve lots of danger due to the significant operations
related to it. lots of safety measures are taken whereas
mistreatment power presses.

Fig.2(b) Laminating Press

3) C- frame presses
These presses have a 'C' like form, that is specifically
designed to maximise the ground house for the staff so as to
Fig.2(d) Power Press
maneuver around simply at the geographic point. not like
different presses that have multi-processes, the C- frame 6)Assembly presses
presses solely embody one press application. Its application These presses use the acute pressure generated by the
includes straightening, drawing and principally includes pistons and therefore the hydraulic fluids to assemble and
aggregation work. C- frame presses are available a range of maintain the components
weights. The C- frame presses are obtainable with further
options like wheel stands and pressure gauges.
4) Pneumatic presses.
These presses are the most basic hydraulic presses used in
industries because they compress the air to create a pressure
in order to gain movement. The advantage of pneumatic
presses is that the operations are performed fast whereas the
disadvantage of this press is that it cannot create extremely
high pressures, as other hydraulic presses are able to create. Fig.2(e) Assembly press
The pneumatic presses are often used in car and aircraft
7) H- frame presses
brakes system. The industrial uses of pneumatic presses
would include assembling, drawing, punching, etc. A These presses have a peculiar 'H' form and are capable of
pneumatic press usually requires a full time operator and handling over one press application.
for the sake of his safety, additional safety accessories such
as electrical safety devices are also included.

Fig. 2(f) HType Hydraulic Press

problem statement
Fluid power systems are designed by objective. the first
drawback to be resolved in planning the system is
transposing the specified performance of the system into

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

system hydraulic pressure. Stroke Length two hundred Design Calculations

millimeter (W. P. 200 bar) Hydraulic Cylinder Dia 200 X
80 X 200 mm. DESIGN, MANUFACTURING, &
SUPPLY OF 20 TON HYD POWER PRESS
MACHINE WITH PLC PROGRAMING SUITABLE
FOR PIPE FLARING UP TO DIA 100 mm X 02 mm
THK.
OBJECTIVES
Major Objectives
 Design and analysis of horizontal hydraulic press
machine.
 To reduce labour time
 To ensure safety of workers
Minor Objectives 196200X0.075-RBX0.15=0
 To reduce the cost of labour involved in
assembling and dismantling components.
 Easy to maintain
 Enhanced service life

III. DESIGN METHODOLOGY

Fig.3 Flow chart of methodology

In this horizontal hydraulic press manufacturing design
methodology, we are identifying the problem after that
survey done. While completed the survey we are studied
the existing method and processes for the hydraulic press
then proceeding to the NX-CAD model design completed. ⁄
The components fabricated and start to the manufacturing
completed after this we are inspect the components. We are
assembled all components and completed the assemblage of
the machine and test thee machine for the results after
getting results we are analysing the machine. Further we are
concluding the machine this methodology we are used
while preparing the horizontal hydraulic press.

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

Point of zero shear

Bending moment calculations

BMA=BMB=0 KN.m

Case 2
Vertical member of attached support 2 members

( )

( )

Case 3

Shear force calculation

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

Where,
P=pressure ⁄
F=Force in N
A=Area in
Vertical member attached to cylinder Therefore ,
( )
mm
We are select the standard diameter 100 m
Hydraulic Power Pack Calculations

⁄
⁄
⁄
⁄

Machine power selection is also depends on machine

operations and sequence and cylinder mounting position.oil
pressure 35 ⁄ but pessing speed slow with full
load.we used oil pressure ⁄
Shear force ( )
( )

Finally we select the standard motor of 7.5 HP. And we

select the pump model PVR-50150-FF-13-70 (Yuken
Bending moment calculation
Make).
Oil tank capacity is 300 liter given by the industry.
Frame Design
The structural style of the frame depends on the pressing
force this determines the specified rigidity, the size of dies
influencing the size of the tool space, work space
accessibility that determines on the form of the press frame,
the degree of steerage preciseness
1design Procedure For Frame
The frame is that the base machine component in
mechanical press. it's designed by the subsequent steps.
1. Specification of operate
⁄ The main operate of the frame is to resist the force
Design of cylinder body developed by the hydrauliccylinder. Frame is employed
Capacity of force =196200 N mounting and housing the press accessories like hydraulic
Hydraulic Press is 200 bar=20 ⁄ cylinder, die block, ejection system etc.

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

2. Determination Of Forces RM Size In mm. Finish Size In mm.

The weight of the cylinder and the cylinder load is the Thk. Width. Length. Thk. Width. Length.
major forces acting on the frame structure. 50 330 540 50 325 535
Press capacity P = 196200 N
50 330 540 50 325 630
3. Selection of materials
50 230 330 50 220 325
The mild steel (IS2062) is selected for the frame because it
30 225 585 30 220 580
is soft and ductile they can be easily welded and machined.
30 350 355 30 345 350
IV. DETERMINATION OF DIMENSIONS x= 1155 in mm
The frame consists of the many variety of plates fictitious
to support the structure. The dimensions of the plates are
⁄
listed below
Frame Plate Dimensions ⁄
Theroritical Design Of Frame ⁄
Assumptions Piston rod design
The material of the beam is perfectly homogeneous. And Material: Steel, EN–8
isotropic (That is, it is same material
throughout and of equal elastic properties in all the
direction).
The material of beam obeys Hook’s law.
The Young’s modulus E is same in tension and
compression.
Assumptions made
Specification of machine frame
1) Bar is straight and homogenous material.
⁄
2) Rod is continuous and no abrupt changes occur.

⁄ 3) Line of force acting coincides with the axis of ram/rod.

For pressure of 200 bar

⁄
( )

Force = Area x stress

⁄
⁄ ⁄

⁄
⁄

( )

We selected the standard

P =20 tonnes PLC Control

A programmable Logic controller may be a controller that
P = 196200 N controls the varied output devices as per the given inputs
Breadth b = 325mm supported the logic which has been programmed into PLC
Thickness d= 50 mm by the user. Thus, it's managementler which might control
variety of output devices as per any given logic. This logic
Table 1 frame design dimensions. that is employed to manage the output devices, will be
⁄ modified by the user by programming. That is, the logic is

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

programmable. Thus, the name came as ―Programmable

Logic Controllers‖. several makers refers thereto as
Programmable Controllers or computer. however the term
PLC is found to be additional acceptable, as, it avoids the
confusion with pc (PC).
This can be shown by schematic diagram as given below in
fig.

Fig.4(a) Block Diagram of PLC

PLC
Make - Siemens S7-1200.
Digital Input-16. Nos. Fig.4(c)Program Debug Interface In GX Developer
Digital Output -06. Nos. Experiment Methodology And Working
Presses are one of the most commonly used machine tools V. EXPERIMENT METHODOLOGY
in industry for the forming of different materials. In the
past, for the pressing tasks in industry, mechanical presses Experiment Methodology
were more frequently used, but nowadays hydraulic presses The methodology used for the preparation of the horizontal
take precedence due to their numerous advantages. press for compression and flaring operation is,
Study Of Previous Machining method
In this study i used to be study the various forms of the
presses like c-type hydraulic press etc. additionally studied
the operating of that machining method.
Material Used For Machining
Material used for experimentation of various press studied
additionally material used for producing elements and for
finishing the experiment material of the workpieces also
studied.

Fig. 4(b) Ladder Diagram for HHPM Study Of style method

The system computer code was completed in four For the preparation of the press, studied the assorted design
steps. Step one is to edit the ladder diagram. Step two method used from the researchers and techniques used for
is to input SFC management directions. Step three is to the preparation of the planning.
convert the program. Step four is to transfers the program to Study Of Experimentation
the mainframe. Finally, the computer code is tested for
In this study I learnt the assorted experimentation
input standing, program execution, and output standing.
techniques used from researchers for the hydraulic presses.
Figure is that the program correct interface in GX
Most of the peoples studied the vertical hydraulic presses
developer.
for the various operations. The experimentation done on
this machining.
study of research and results
For the hydraulic presses largely analysis done on the

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

Ansys however they solely analyse the bottom structure in  Maintainace is a smaller amount
most cases and in another cases, researchers are used the
 additional accuracy
shaping method on vertical press. Some Ansys but they
only analyse the base structure in most cases and in another Safety Measures And Benefits Of The Hydraulic
cases, researchers are used the forging process on vertical Press
hydraulic press. Some results are compared in the Ansys  Safety Measures As of nowadays, hydraulic
software with theoretical one.
 presses are obtainable in each the classes,
These things I studied for the experiment methodology and i.e., automatic and operated by hand.
after that I’m preparing my machine for squeezing and
flaring operations which is horizontal hydraulic press and  Benefits of the mechanical press not like their
control by PLC controller. mechanical counterparts, hydraulic presses will
compress any material to a full extent. Also,
Working of Horizontal Hydraulic Press hydraulic presses take solely half the area that the
The hydraulic press consists of the horizontal cylinder and mechanical ones take as a result of they need the
the vertical cylinder and one horizontal sliding unit in that flexibility to compress an outsized pressure in a
the pipe is putting in horizontal unit and vertical unit to very cylinder having a less diameter.
avoid the misalignment of the pipe there is bush. Bush is  The perform of The mechanism Hydraulic systems
made up of the gun metal and at the left-hand side stopper convert electricity into hydraulic energy, that
is mounted. When the pressure applied through the vertical successively is reworked into energy with the help
cylinder the cylinder pushes the die and die holder is of the individual hydraulic cylinders within the
consisting at the base plate the pipe is hold in it. When this press. The hydraulic fluid within the cylinders
pressure is applied on pipe from upper side and horizontal actuates the press slide as follows:
sliding unit they obtained the squeezing and when the
pressure is increases the pipe get flare and the whole system  Forces are generated through the action of the
is controlled by the PLC programming and HMI (Human hydraulic fluid.
Machine Interface) if any error occurs it display on this  Displacements are achieved by the provision of
screen. The folder shows the actual dimensions of the hydraulic fluid.
machine. The machine is operator use the operator unit for
the setting of the programming and controlling the machine.  Press (slide) speed is proportional to volumetrical
The power supply of this machine AC power is use. The flow rates.
power pack unit is fully air-cooled unit. The hydraulic press  Forward and reverse motions are controlled by the
ladder diagrams the programmer set the program for direction of fluid flow.cylinders among the press.
squeezing and flaring operations and we got the accurate The hydraulic fluid among the cylinders actuates
result of pipe. For the large production Zelio PLC system is the press slide as follows:
used. With the help of the Zelio soft software programmer
modify the PLC program and we got the large number of  Forces are generated through the action of the
productions of the pipe. After this we are work on the hydraulic fluid.
dynamic effect on horizontal hydraulic press for vibrational  Displacements are achieved by the availability of
test purpose. The experiment used the machine data hydraulic fluid.
acquisition and PLC interface and power pack this system
 Press (slide) speed is proportional to volumetric
LMS SCADA mobile the data acquisition used to measure
flow rates.
the acceleration. Also, the FFT Analyser and STFT is used
 Forward and reverse motions are controlled by the
for the acceleration signal and STFT test effect of
direction of fluid flow.
amplitude, frequency and time measured. This way
machine worked. VI. RESULTS AND DISCUSSION
Advantages In this research we are done the squeezing and flaring
 Two operations worn out one machine of pipe as shown in the figure. Now, we are squeeze
and flare the pipe up to Dia 100x02 mm thickness.
 Instrumentation handling is straightforward.
 The press machine less large compare to a
different machine.
 The simplicity and simple to repair style make
it very low-cost
 Time intense

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

From this above table we are concluded that the pressure

applied on the horizontal machining process for squeezing
and flaring of pipe it takes less time than the vertical
hydraulic press. The accuracy of this pipe is more than
vertical squeezing and flaring of pipe. Also if production
increases this pressure takes same time for the pipe
squeezing and flaring. This is the significance of this
machine.
Here, in this research we are considering the linguistic
criteria for the triangular fuzzy number for comparing the
which machine is more suitable for squeezing, flaring
operation and for that we considered the ten criteria’s from
Fig.5(a) Flaring pipe that criteria. MOORA method is very easy and simple for
implementation than other like MODM, GRA methods.
MOORA method is very stable method for decision making
problems. We got the result the Horizontal hydraulic
machine is most suitable machine for the squeezing and
flaring operations than vertical hydraulic press machine.
And we also got rank of this machine

Fig.5(b) flaring and squeezing pipe Table 3 Best solution with Ranking
Best Hydraulic Press Rankin Percentag
Solution g e

0.419676 Horizontal Hydraulic 1 52%

Press

0.390811 Vertical Hydraulic Press 2 48%

we got the two BNP ratio values for the vertical and
horizontal hydraulic press using the criteria for MOORA
method we ranked that values and concluded the best
solution given in the graphical (Pie Chart) as well as above
tabular form with the ranking and percentage.
Fig.5(c) flaring and squeezing of outlet pipe

Fig.5(d) squeezing and flaring pipes.

Table 2 Pressure applied and time require for
Fig.6 Best solution with Ranking
operations
Pressure Applied(bar) Squeezing Time(s) Flaring From the PLC programming is very easy programming
Time(s) using the ladder diagram that ladder diagram helps to
100 15.23 22.41 programmer for programming and programmer run the
125 12.54 20.58 program for squeezing and flaring process.in this research
140 10.45 17.36 program is done in the two steps first step pipe is squeeze
163 6.39 9.25 and further step the pipe is flare. From this programming
180 3.51 5.01
system the labour is decreases and the production rate is
200 2.0 3.11
increase. The pipe production rapidly increased.

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 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-05, Issue-01, April 2019

From the vibrational test we studied dynamic characteristics Applied Science and Engineering Technology ( IJRASET ) ,
of motion processes through experimental test.and the Belgaum . India 2009, p. 24-30.
interaction between system dynamic and tribological effects [7] Malipatil.S.S., Mattlikalli.A.C. ―Analysis and Structural
Optimization of 5 Ton H-Frame Hydraulic Press’’, International
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Journal of Innovative Science Engineering and Technology,
VII. ACKNOWLEDGEMENT Belgaum.India, vol 1, March 2014.
[8] Neville Sachas. ―Root cause failure analysis understanding
The work was supported by Samarth Engineers and design. Mechanical failure‖. Plant maintenance Recourses center home
Research department of Sandip University. Sincere Revised. Hungary .03 August 2009.
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mechanical engineering in Sandip University, Nashik for frame‖. Department of Mechanical Engineering, University of
preparation of machine and fabrication. I would also thanks Miskolc, H- 3515 Miskolc Egytemvanoc, Hungary .May 2003.
[10] Saleh.M.M, ―Design study of a heavy duty hydraulic machine
to U.B. industries, sinner. I would also thanks to all
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production. Even the hydraulic press can be completely
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automize. And using MOORA optimization technique we
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