DEPARTMENT OF MANUFACTURING AND INDUSTRIAL ENGINEERING

FACULTY OF MECHANICAL & MANUFACTURING ENGINEERING

BDA18301
MECHANICAL ENGINEERING WORKSHOP II
SEM 2 SESSION 2018/19

LAB REPORT
SKILL: Hydraulics Practice 1

SECTION: ...................................................................................
LECTURE’S NAME:...................................................................
GROUP DAY:..............................................................................
GROUP MEMBER:
No. Name Matric No.
Abdul Azim Bin Mohammad AD180179
2 Ahmad Hakimi Bin Mohd Abdul Ghafar AD180111
3 Mohd Fekri Bin Madrasah CD180187
4 Arielson Wan CD170081
 ASSESMENT FORM BDA18301

NO. PLO ELEMENT REMARKS FULL ACTUAL

MARKS MARKS
TW1 (a) On time 2 marks deduction for 5
1 every one day late.
TW2 (a) submission 5
TW1 (b) Contents is formatted/ 5
arranged properly,
TW2(b) Fulfill report
2 Font size (12), Times
requirement 5
new roman, single
spacing
TW3 Safety, punctuality, full
3 Attitude attendance, follow 5
instruction, proper attire.
LLL1 (a) 5 references and above
4 References 5
= 5 marks.
LLL1(b) Report consist of:
1) Introduction
2) Objective/scope
Completed
5 3) Methods/apparatus 5
report contents
4) Discussion
5) Conclusion &
recommendation
LLL2 (a) Explain the experiment
procedure via figures/ 5
Methods/discu diagram
6 LLL2 (b) ssion/ideas/rec Discuss the experiment
5
ommendation findings
LLL2 (c) Ideas/improvement of
5
better processes.
TOTAL 50

2
TABLE OF CONTENT

NO CONTENT PAGE
1 Introduction 4
2 Objective 4
3 Scope 4
4 Safety Precaution 5
Method and Standard Operation Procedure (SOP)
5 6
i. Task 1
6 Results and Analysis 7
7 Conclusion 8

3
INTRODUCTION

The basic idea behind any hydraulic system is very simple. Force that is applied at one
point is transmitted to another point using an incompressible fluid. The fluid is almost
always an oil of some sort. The force is almost always multiplied in the process. These
operations are performed mainly by using electrical machines or diesel, petrol and steam
engines as a prime mover. These prime movers can provide various movements to the
objects by using some mechanical attachments like screw jack, lever, rack and pinions
etc. However, these are not the only prime movers. The hydraulic system works on the
principle of Pascal’s law which says that the pressure in an enclosed fluid is uniform in
all the directions. The Pascal’s law is the force given by fluid is given by the
multiplication of pressure and area of cross section. As the pressure is same in all the
direction, the smaller piston feels a smaller force and a large piston feels a large force.
Therefore, a large force can be generated with smaller force input by using hydraulic
systems. The advantage is the system uses incompressible fluid which results in higher
efficiency. It delivers consistent power output which is difficult in pneumatic or
mechanical drive systems. Otherwise the material of storage tank, piping, cylinder and
piston can be corroded with the hydraulic fluid. Therefore one must be careful while
selecting materials and hydraulic fluid. The structural weight and size of the system is
more which makes it unsuitable for the smaller instruments.

OBJECTIVE

 Understand a hydraulic control system

 Draw and install pure hydraulic circuit to control the movement a double acting
cylinder using 4/2 way directional control valve.

SCOPE

 This experiment will emphasizing that how to assembly the component of

hydraulic and to operate the system in hydraulic trainer
 This experiment will ensure the student how to understand the hydraulic system
work in trainer.

4
SAFETY PRECAUTIONS PRACTICE 1

a) Dress appropriately.
b) Roll up sleeve if necessary.
c) Remove jewellery.
d) Connect all hoses properly before turning on the pump.
e) Beware of squirting fluid when releasing pressure in the hoses.
f) Get a TA or person in charge to scrutinize your circuit before start the pump.
g) While using actuator, motors or other component with moving part, stand clear
before start the pump.
h) Keep fingers away from places where they might be pinched.
i) Make sure the is no fluid leakage
j) No eating or drinking in lab.
k) Keep the workbench tidy to avoid any accident

METHOD AND STANDARD OPERATION PROCEDURES (S.O.P)

Task 1.

METHOD AND STANDARD OPERATION PROCEDURES (S.O.P)

1. 1 unit of 4/2 Way Directional Control Single Lever, one check valve and is obtained
and clamped to the wire grid.
2. The oil that remains inside all ports is released so that hydraulic hoses can fully plug-
in to the parts.
3. By using suitable length of hydraulic hoses, connect to the respective coupling and
between the hydraulic components refer to figure for hydraulic control circuit drawn.
4. 3 units of pressure gauges are connected to the inlet port and outlet ports of the
directional control valve respectively.
5. Ensure the hose connected correctly, where port P to port A and port T to port B.

5
6. After all the hose are connected correctly to the end fitting, the power source is
switched on.
7. By operating the hand lever of DCV, the double acting cylinder will extend the retract.
8. By operating the control valve, where the pressure are 20 bar, 25 bar, 30 bar and 35
bar, the gauge pressures at the inlet ports and outlet ports of DCV during the cylinder
extending and retracting are recorded respectively.
ANALYSIS / FINAL PRODUCT / OUTPUT

Based on the both graph above, we can see that the pressure supplied does not equal to
the
pressure that being sent to the cylinder. The result clearly shows that the pressure
somehow
dissipated. The first cause of error is leakage of pressure that makes our readings lost
pressure. The second cause is the pressure gauge. The pressure gauge may be broken and
causes the reading to give inaccurate readings. Pulsation also one of the cause of
inaccurate reading. Process pulsation can occur around the discharge of pumps as well as
quick operating valves. Many users assume that liquid filling a pressure gauge will fully
address pulsation. Although a liquid filled gauge helps to dampen the effects of pulsation,
it often does not fully address this process condition. Next is torque force. Especially for
torque sensitive gauges, excessive force when connecting pressure gauge also can be one
of the factor. It can damage the gauge and will affect inaccurate reading of the gauge.

6
Here the results are shown:

PRESSURE EXTEND RETRACT

(BAR)

PORT 2 PORT 3 PORT 2 PORT 3

20 30 14 11 32

25 36 12 11 38

30 41 13 11 42

35 46 13 11 47

Table 1 : Result
From table 1, we can conclude that, the pressure that insert to the system which caused
the cylinder to extend is the same with the pressured that leave in the system.

Cylinder extend pressure

50 46
45 41
40 36
Pressure gauge reading

35 30
30
25
20
14 13 13
15 12
10
5
0
20 25 30 35
Pressure (bar)

72
Port Port 3
 Graph 1 : Cylinder extend pressure.

Cylinder retract pressure

50 47
45 42
38
40
Pressure gauge reading

35 32
30
25
20
15 11 11 11 11
10
5
0
20 25 30 35
Pressure (bar)

Port 2 Port 3

Graph 2 : Cylinder retract pressure

8
CONCLUSION

From Task 1 we can conclude that the Hydraulic fluid is use to transmit power
mechanically throughout a hydraulic power system. It is acting as one of the main
sources for mechanical machining and also basic fundamental concepts of many other
automation systems. Besides that, we must make sure we have inserted the correct
components based on the circuit given. Furthermore, the oil in all the plugs better to be
removed so that it can be fully connected to another plug. We also gain a lot of
experiences in hydraulic power automation system and getting knows how it is
functioning and processing, so that it will benefit us for the industry manufacturing in the
future.