A PROJECT REPORT ON

“HYDRULIC PRESSING
MACHINE”

For the credit award of

“Skill Project and Hands on”
Bachelor of Technology, 4th Semester, Mechanical Engineering

Under the guidance of:

Dr. Ritanjali Sethi
Assistant Professor
Dept. Of Mechanical Engr

Submitted by:
SONU SAMANTARAY (1701106186)
ABHISHEK KUMAR (1701106170)
PRACHURYA (1701106087)
ADITI SONWANEY (1701106007)
VISWAJEET BARAL (1701106237)
AVINASH KHUNTIA (1701106)
SUBHAM SAHOO (1701106195)
BASINI BIBEK RAO (1701106128)
MAHESH KUMAR SAHOO (1821106072)
RAMAKRUSHNA SATAPATHY (1701106224)
CHANDAN SAHOO (1701106142)
ANSHUMAN UPADHYAY (1701106106)
SANGRAM BISWAL (1701106148)
OM SWARUP PANI (1701106204)

1
DEPARTMENT OF MECHANICAL ENGINEERING
COLLEGE OF ENGINEERING AND TECHNOLOGY
AN AUTONOMOUS AND CONSTITUENT COLLEGE OF BPUT
BHUBANESWAR, ODISHA

CERTIFICATE
T h is is t o cer t if y t hat SONU SAM ANT AR AY, ABHI SHE K KUM AR,
P R AC HUR YA, ADI T I SONWANE Y, VI SW AJ E ET BARAL, AVI N ASH
KHUNT I A, SUB H AM S AHOO, OM SW ARUP P ANI, BASI NI BI BE K
RAO, C H AND AN S AHOO, AN SHUM AN UP ADHY AY,
RAM AKR U SHN A S AT AP AT HY, M AHE SH KUM AR S AHOO,
S ANGR AM B I SWAL a r e stu de nts of 4t h Se mes ter B.T ec h in
M ec ha n ica l E n gin eer in g in th e Co llege of E n gine er in g a nd T ec hn o lo gy,
Bh u ba ne s war wit h Re gist rat io n Numb er s 1 70 11 0 61 86 , 1 7 01 10 6 17 0,
1 7 01 1 06 08 7 , 1 70 1 10 60 0 7 , 17 0 11 0 6 2 2 7, 17 0 11 06 , 17 01 1 06 19 5 ,
1 7 01 1 06 20 4 , 1 70 11 0 6 1 28 , 1 7 01 106 1 42 , 1 7 01 10 6 10 6, 17 0 11 06 2 24 ,
1 8 21 1 06 07 2 , 17 0 11 06 1 48 re sp ect ive ly in t he b at ch 2 01 7 -2 02 1, h a ve
t a ken a ct ive inte res t in p re par in g p roj ect r ep ort on “ HYDRULLI C
P R E SS M AC HI NE ” T h is is in f u lf ilme nt of r eq u ir e me nt for t he
Ba ch e lor of T ec h no lo gy De gr ee in Me ch a n ic a l En gin ee r in g u n de r
BP UT , Od is ha a nd gu ide d b y Dr. RIT ANJ ALI SE T HI

Dr. Ritanjali Sethi Prof. J Naik Prof. (Dr.) A. Mohanty

(PROJECT GUIDE) (PROJECT COORDINATOR) HOD
Mechanical Engineering
Department
2
 ACKNOWLEDGEMENT

I wo u ld like to ex pre ss my s inc ere re gar ds an d pro fo un d s en se of

gr at itu de t o t h ose wh o h a ve he lpe d u s in co mp let in g t he pr oj ect
s uc ce ssf u lly. At t he ver y ou tse t, o ur s pe c ia l a n d he artf e lt th a n ks t o o ur
P r oje ct gu id e Dr . RI T ANJ ALI S ETH I , As s ista nt P r of es sor ( De pt . Of
M E) an d P r of . J ite n dr a Na ik , As s is ta nt P ro fes so r ( De pt . Of M E) f or
h is pr ec io us gu id a nce , as s ist a nce a nd c o nst ant s up er vis io n t o br in g t h is
p ie ce o f wo r k int o th e pre se nt f or m.
I a lso ex te nd my h u mb le gr at it ud e t o Dr. As ho k M oh a nt y , HOD,
M E f or p ro vid in g th e o pp ort un it y t o p re se nt th is pr oj ect in th e co lle ge .
La s t but n ot t he lea st we wo u ld a lso like to ex pr es s o ur gr at it ud e t o a ll
t he per so n ne l wh o we r e d irec t ly or in d ire ct l y a sso ci ate d wi t h us for
s ucc es sf ul co m pl eti o n o f t he Pro je ct .

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 DECLARATION
We h ere b y de c lar e th at th e matt er emb o d ied in t h is r ep ort is or igin a l
a n d has n ot be en s ub mitte d for th e a wa r d of an y ot her d e gr ee . All t he
t he s is a nd wor k h as be en d o ne u nde r t he gen er a l s u per vis io n of o ur
p ro je ct gu ide a nd p roj ect c oo rd ina to r as pe r t he gu id e line s ment io ne d
b y t he c o lle ge . We c o nf ir m t he et h ica l no r ms a nd gu ide lin es la id b y th e
e th ica l c od e of co nd uc t o f t he in st it ute a nd h a ve c ite d r efe re nc es f or
d iff ere nt d ata c o llect e d an d me nt ione d th at in t he t hes is .

SONU SAMANTARAY (1701106186)

ABHISHEK KUMAR (1701106170)
PRACHURYA (1701106087)
ADITI SONWANEY (1701106007)
VISWAJEET BARAL (1701106)
AVINASH KHUNTIA (1701106)
SUBHAM SAHOO (1701106195)
BASINI BIBEK RAO (1701106128)
MAHESH KUMAR SAHOO (1821106072)
RAMAKRUSHNA SATAPATHY (1701106224)
CHANDAN SAHOO (1701106142)
ANSHUMAN UPADHYAY (1701106106)
SANGRAM BISWAL (1701106148)
OM SWARUP PANI (1701106204)

4
 ABSTRACT
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. In
an attempt to alleviate the problem of the dearth of equipment in our laboratories in most of
our higher institutions, a 5-ton hydraulic press was designed, constructed and tested using
locally sourced materials. The principal parameters of the design included the maximum load
(50 kN), the distance the load resistance has to move (piston stroke, 150 mm), the system
pressure, the cylinder area (piston diameter = 150 mm) and the volume flow rate of the
working fluid. The major components of the press designed includes the cylinder and piston
arrangement, the frame and the hydraulic circuit. The machine was tested for performance
with a load of 5 kN provided by two compression springs each arranged in parallel between
the upper and lower platens and was found to be satisfactory.
In this project press frame, cylinder and press table are designed by the design procedure.
They are analyzed to improve their performance and quality for press working operation.
Using the optimum resources possible in designing the hydraulic press components can affect
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. So, in this paper
we consider an industrial application project consisting of mass minimization of H frame
type hydraulic press. This press has to compensate the forces acting on the working plates
and has to fulfill certain critical constraints.

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 PREFACE
The project “Hydraulic press machine” is introduced by us with the help of faculties of CET.
The project enables any worker to easily do the pressing work as it is a heavy-duty hydraulic
press which uses very less human effort and it delivers up to 5 ton of pressing force. When
any component needs to be removed this machine provide controlled power to get the work
done. As the whole system is attached with a proper stand and due to the compact size and
light weight structure it is portable for the ease of work. The pressing force can be applied on
the system by work through the lever manually with very ease and a screw mechanism is
there to release the pressure of the jack which is effortless.

We give our sincere thanks to all teachers and faculty members of CTTC for their support
and believing on us. The project could not be completed without their guidance.

We are extremely thankful to each and every member associated with our project.

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 CONTENT
1. INTRODUCTION…………………………….. 8
1.1 PRINCIPLE…………………………………. 9
1.2 TYPES OF POWER PRESSES……….. 10

2. DESIGN AND ANALYSIS………………….. 11

2.1 PARTS USED……………………………… 11
2.2 MODEL DESIGN………………………… 11
2.3 MANAGEMENT PLAN……………….. 12
2.4 DESIGN DEVELOPMENT……………. 13
2.5 MATERIAL SELECTION………………. 16
2.6 DESIGN VERIFICATION……………… 17

3. PROCESSES INVOLVED………………….. 17
3.1 HAND CUTTING……………………….. 18
3.2 HAND GRINDING & POLISHING… 18
3.3 HAND DRILLING……………………….. 18
3.4 ARC WELDING…………………………… 18
4. CONCLUSION……………………………. 19

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 1. INTRODUCTION

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.

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
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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 labor 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 automize 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 renumeration
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 has been simplified
with the use of hydraulic equipment.

1.1 PRINCIPLE

The hydraulic press depends on Pascal's principle-the pressure throughout a closed system is

constant. One part of the system is a piston acting as a pump, with a modest mechanical force

acting on a small cross-sectional area; the other part is a piston with a larger area which

generates a correspondingly large mechanical force. Only small-diameter tubing (which

more easily resists pressure) is needed if the pump is separated from the press cylinder.

Pascal's law: Pressure on a confined fluid is transmitted undiminished and acts with equal

force on equal areas and at 90 degrees to the container wall.

A small effort force acts on a small piston. This creates a pressure which is transferred

through the hydraulic fluid to a large piston.

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 FIG 1

1.2 TYPES OF POWER PRESSES

Hydraulic presses are categorized as power presses, an area that also includes mechanical,
eccentric and pneumatic presses. Here is a look at the differences in the three:
• Mechanical presses generate power mechanically, using a motor that is connected to a
crankshaft, which cycles the ram for each operation using flywheels and belts. The
flywheel builds up pressure and then releases, transferring energy to the primary side in
the process. The strokes of a mechanical press are called single-, double- or
triple-action, based on the number of ram or slides it has. It can be adjusted within
limitations.
• Eccentric presses are fairly new and have a more efficient drive mechanism. They have
a linkage of the drive motor and the ram, which ensures that the operator is able to send
signals to the motor to operate at a specific speed.
• Pneumatic presses use compressed air to produce dynamic movement. They can do
most of the same functions as hydraulic presses. The big advantage of this type of press
is its ability to reach up to 400 strokes a minute. They have a controlled flow rate,
making it useful when ram velocity or flow rate is crucial. It also has fewer moving parts
compared to mechanical and hydraulic presses.

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 • Hydraulic presses use some type of fluid to generate the pressure needed for dynamic
movements.

2. DESIGN AND ANALYSIS

2.1 Parts Used:
• L-Section angle heavy
(2”*2”)
• Square pipe heavy
(1½”*1½”)
• Nos. spring
• 5 Ton hydraulic jack
• Tractor trolly pin heavy
• 12 Nos. M10 bolts ( 2½” length) with nuts
• Nos. M10 bolts (3” length) with nuts
• 2 Nos. M10 allenky bolts (1” length)
• Nos. M8 allenky bolts (½” length)
• 2 Nos. 3/8 allenky bolts (½” length)
• Nos. ¼ allenky bolts (½” length)
• 3/8 Bolt (1¼” length)
• 2 Nos. 5/16 J bolt (2½” length) with nuts

2.2 MODEL DESIGN:

(FIG 2)
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 Our design began with the project description including all size, material, and

usability requirements and are summarized as follows: Human power is to be used to

operate a hydraulic press. The hand pump should be located at a height of around 70

centimeter and positioned on the middle of the press to allow for an average-sized person

to easily operate and portable the press. The four-way, three- position hydraulic jack will

be mounted to the frame in the middle movable plate. The frame will be constructed of

U-channel steel of appropriate size to withstand five tons compression and tension. The

overall dimensions will be seven 70 cm tall and 50 cm wide with an appropriate depth to

maintain stable operation. The frame cross pieces will be doubled up to provide a wide,

stable platform as well as to hold the hydraulic cylinder in place. The entire press frame

and hydraulic components will be connected with bolts to allow for disassembly. The

final design was presented July 6th, 2019.

Fabrication and assembly of the hydraulic press was done by all the team members

with equal effort as a team with the help from our guide and teachers in college campus.

Fabrication of the press began, 2019 and was completed for testing 1st July, 2019.

2.3 Management Plan:

Our team consists of fourteen members. They were responsible for all aspects of

this hydraulic press project. Work was evenly split between the members catering

specific tasks to individual talents.

Tasks, goals, and deliverable due dates are listed on the chart presenting their

start/end dates and necessary completion time. The chart encompasses a combined total of
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3 weeks. This includes everything from project selection and writing various reports,

weekly meetings with our project advisor, construction/fabrication, assembly, and testing.

Meetings with our faculty advisor, Guide occurred every 2-3 days. We begin with

an agenda created in advance and go over what we have accomplished during the

previous week and our plans for the upcoming week. Teachers guided our efforts with

suggestions of design ideas and comments on general progress. After each meeting one

member writes up minutes documenting what was discussed. Meeting agendas. During

the second week, we were advised by Dr RITANJALI SETHI. She provided crucial

knowledge on fabrication techniques and gave us advice when it came to modification

and necessary redesigns.

2.4 Design Development:

(FIG 3)

Our research for this project encompassed not only an extensive look into the

theory and operation of hydraulic presses but also a search of similar products on the

market. Many commercial, hand-operated hydraulic presses are currently available.

However, in deciding on a design we used a quality function deployment chart to

13
 evaluate the specific customer needs and give these needs a numerical value with which

to compare designs and test their acceptability. We first analyzed the whole design and

its components in SOLIDWORKS and CATIA software to get the proper demo view and

assembly structure.

We used our research described above by applying the tried and tested layouts of comparable

hydraulic hand press designs as a platform to design our initial concept. We also conducted

brainstorming sessions to come up with more efficient, ergonomic, useful, and time-saving

ideas for press designs to improve upon the standard commercially available models. The

best of these innovations was presented to the Warbirds Museum for approval before

proceeding with the final design. The final design incorporated all the project objectives

and was also presented for approval. Each of these stages requiring approval was subject to

adjustment until the museum was satisfied with the plan. The building process could not

begin until this occurred. Following the construction phase, the press was tested to see if it

accomplished the project goals. When problems with the design were encountered, it was

modified or rebuilt until the objectives were met. Also, during the testing phase,

improvement of specific parameters sometimes warranted modification of the finalized

press.

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 (FIG 4)

Progress was made in the design phase that included initial stress calculations for the

structural members of the press frame. It was concluded using the max pressing capacity of

5 tons that the horizontal U-channel steel members must be greater than 50 cm wide use 70

cm length vertical members to allow for more room for attaching components and allow for

a significant safety factor.

The hydraulic aspect of this project has been started as well. We have looked into

the specifics of hydraulic schematics and the associated symbols, matrix to compare

potential designs to one another in order to choose the best one. In the matrix, a series of

design categories, such as the design cost, ease of use, and safety, are written next to a list

of competing designs. In these tables, each design is compared to an idea that is set as the

standard for all the other designs, therefore called the datum.
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 With the “By Hand” idea, the platform changes position by lifting it to a new

position, removing the pins that it was previously sitting on, placing them at their new

location, then setting the platform back on the pins. It is heavy, hard to operate with one

person, and unsafe when loaded. However, it is cheap (set as cost reference cost all

ideas) and easy to manufacture use. This lift should be a very safe design due to the

rigidity of the triangular frame, but also depends on where the pump handle is placed

Construction of the hydraulic press began with acquiring all the necessary steel U- channel

beams for the frame structure. A hand cutting machine was used for this purpose. All bolt

connection holes were then machined, primarily using hand drill machine. All burred and

sharp edges were smoothed out using hand polishing tools and files. Coats of rust

preventative primer were sprayed on to all frame beams, followed by finish coats.

The trolley assembly required to support the cylinder was fabricated from 5mm

thick steel flanges welded onto a steel plate. The cylinder is supported on the plate to

prevent the cylinder from swinging out of plane. Our original design called for cylinder

support beams to prevent this. The original cylinder support beams.

2.5 Material Selection:

By all the recommendation and analysis in ANSYS software by doing stress

calculation and depending on market availability we selected these materials for our

project model.

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 SL NO NAME OF PARTS MATERIAL USED

1 BASE MILD STEEL

2 MOVABLE PART MILD STEEL

3 SPRING MILD STEEL

4 UPPER PLATE MILD STEEL

5 JACK MILD STEEL

6 BODY CAST IRON

7 DIE MILD STEEL(CASE HARDENED)

We selected these materials as these are the easily available in area and this grade B

materials have best machineability which is very good for the project with high yield stress

2.6 Design Verification:

Testing of this hydraulic press included the analysis of the center of gravity of the press and

its susceptibility to tipping, as well as the determining the moving platform’s susceptibility

to jamming and pinch points. The safety of all personnel either running the press or those

working in the vicinity was the top concern when testing.

3. PROCESSES INVOLVED
• HAND CUTTING

• HAND GRINDING & POLISHING

• HAND DRILLING

• ARC WELDING

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 3.1 HAND CUTTING:

It is the process used for cutting metal parts. Hand cutting is done by the lightweight heavy

duty machine with the cutting blade attachment. We used hand cutting instead of any other

cutting device as it is very easy to use, and we can do the cutting process in any angle we

desire with the same accuracy. By hand cutting we cut all the metal rods and parts to desired

length and size for our project.

3.2 HAND GRINDING & POLISHING:

It is the process we used the maintain the accuracy if the cutting parts. Grinding and

polishing is very useful to maintain the dimensional accuracy as the material removal occurs

at very low thickness (0.01-0.1mm). Polishing is used to removing the rust from the surface

and it also help to smoothen the sharp edges of the metals. The main reason to do the hand

grinding is to do the job very easily at different angles according to our requirments.

3.3HAND DRILLING:

It is the process we used to do the holes in the model. It is done by light weight heavy duty

drilling machine. The main reason that we preferred for the hand drilling is drilling can be

done in axis of the project. It also helps a lot to maintain the alignment of the holes so that

bolts can easily enter the holes. We can do drilling without disturbing the assembled model

by this. We did M10 and M12 drill for the holes to support the whole frame.

3.4 ARC WELDING:

It is the process of joining the two metals with the help of producing heat by the electricity

which melts the metal, and this molten metal get attached and solidifies as a single metal.

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In arc welding the arc is generated between the +ve pole of DC called anode and -ve pole

of DC called cathode , when these two poles are brought together and separated for small

distance such that the current continues to flow through a path of ionized particle called

plasma an electric arc is formed . Since the resistance of this ionized gas column is high, so

more ions will flow from anode to cathode. Heat is generated as the ions strike the cathode.

There are 2 types of arc welding

• TIG (Tungsten inert gas arc welding)

• MIG (Metal inert gas arc welding)

We used normal arc welding for the fabrication process where we used FEROSEAL 12

electrode for the joining of metal. We used constant voltage current varying amplifier for

the welding purpose. Our arc welding is DCEP process where more voltage develop at

the electrode part as a result more electron discharge at the positive end so more heat is

generate at the electrode end which helps the melting of electrode. Material deposition

occurs in the globular form of metal transfer. We used forward hand welding which help

to pre-heat the base metal that helps in deep penetration.

4. CONCLUSION:
Careful study of existing products has led us to conclude that specifications like the

use of U-channel steel beams and an all bolted construction, although not ideal, are more

than satisfactory for the required purpose. Our estimations show that the hydraulic

cylinder could be used for a much higher capacity press, but the constraints mentioned

limit the strength of the frame.

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 The design has focus on reducing operator fatigue and increase safety, improving the

flexibility and makes operation more convenient, and to achieve dimensional and

positional accuracy. Components of press are designed to avoid bending failure due to

applied load. Mild steel is selected as material based on its properties such as high

bending & tensile strength, its compatibility with operation like machining, welding,

finishing, cutting etc. and cost as economic factor.

It is a multi-purpose machine as it can be used for performing different tasks, by

changing the die different operation like bending, blanking etc. can be performed on a

hydraulic press machine.

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