Full Text 01

School of Technology and Design, TD
Hydraulic press construction for fitting the

bearings to the housing
Vxj, May 2008

Thesis no: TD 048/2008
Izzettin Osman Egz
Department of Mechanical Engineering
Organisation/ Organization
VXJ UNIVERSITET
Institutionen fr teknik och design
Vxj University
School of Technology and Design
Frfattare/Author(s)
Dokumenttyp/Type of document
Examensarbete/ Diploma work
Handledare/tutor
Izudin Dugic
Izzettin Osman Egz
Examinator/examiner
Samir Khoshaba
Titel och undertitel/Title and subtitle

Hydraulic press construction for fitting the bearings to the housing.
Abstract (in English)
This report was written as a result of a Bachelor Degree Project, together with Swepart Transmission
AB. The report contains the construction of a hydraulic press for the assembly operation.
The project started with a new construction of a hydraulic press for the bearings assembly. The goal
within the thesis work was to fit the three bearings to the housing by only one press motion. This
operation should be very safety because of the sensitive tolerance at the bearings and housing.
Construction of the cylinders, rams and bolster were the most important parts at this project because
this parts functions are very important for this assembly.
The next step of this thesis was to calculate the hydraulic press components parameters and then
choose the suitable components. The focus was to choose more useful and reliable components.
The hydraulic press was modeled in the CAD program Solid Works and 2D technical drawing was
drawn in the Autocad. The frame material was chosen and the frame was analysised in the Solid Works.
Key Words
Fitting, Volvo Trucks housing, bearing, hydraulic, press, cylinder, ram, bolster, modelling, analysis
Utgivningsr/Year of issue
2008
Internet/WWW
Sprk/Language
English
Antal sidor/Number of pages

69
http://www.vxu.se/td
Abstract
This report was written as a result of a Bachelor Degree Project, together with Swepart
TransmissionAB.Thereportcontainstheconstructionofahydraulicpressfortheassembly
operation.
Theprojectstartedwithanewconstructionofahydraulicpressforthebearingsassembly.
Thegoalwithinthethesisworkwastofitthethreebearingstothehousingbyonlyonepress
motion. This operation should be very safety because of the sensitive tolerance at the
bearings and housing. Construction of the cylinders, rams and bolster were the most
important parts at this project because this parts functions are very important for this
assembly.
Thenextstepofthisthesiswastocalculatethehydraulicpresscomponentsparametersand
then choose the suitable components. The focus was to choose more useful and reliable
components.
ThehydraulicpresswasmodeledintheCADprogramSolidWorksand2Dtechnicaldrawing
wasdrawnintheAutocad.Theframematerialwaschosenandtheframewasanalysisedin
theSolidWorks.
Acknowledgements
FirstIhavetothankDanielEkman,themanwhoisengineeratSwepartTransmissionAB.He
gavemealotofadvicesandhelpedmealotduringthisproject.
IwanttothankIlhanAkceylan.HeisanengineerandworkingatHrsanPressinTurkey.
Hehelpedthehydrauliccomponentsselection.
I want thank to SamirKhoshaba. During myeducation in Vaxj University, he taught me a
lot.
Then I would like to thank Tamer Ozbey, my classmate. He helped me a lot with the CAD
programmeSolidWorks.Moreover,IwanttothankmycousinsSinanandNecdetEgzfor
theirhelpingandsupport.
Agreatthanktomyparents,especiallymyfatherforhisgreatsupportandencouragement.
Finally,IamgratefulnesstomyGodforhishelpingandfavorallthroughthisstudyingandall
mylife.
29May,2008
IzzettinOsmanEgz
TableofContents
1.Introduction
1.1SwepartTransmissionAB
1.2Background
1.3Problemdescription
1.4Goal
1.5Dispositionofthestudy
2.BasicsofIndustrialHydraulicSystems
2.1Historyoffluidpower
2.2Comparisonofhydraulicandpneumaticsystem
2.3Advantagesofahydraulicsystem
2.4Structureofahydraulicsystem
3.HydraulicPressComponents
3.1HydraulicCylinders
3.2HydraulicPumps
11
3.3ElectricMotors
12
3.4ControlValves
12
3.5HydraulicAccessories
14
3.5.1HydraulicReservoirs
14
3.5.2Filters
15
3.5.3HydraulicPipes,HosesandFittings
717
3.5.3.1HydraulicPipesandTubes
17
3.5.3.2HydraulicHoses
18
3.5.3.3HydraulicFittings
20
4.Conceptsforthehydraulicsystem
21
4.1Twodifferentcylinders
21
4.2Rams
21
4.3Bolsterplate
22
5.Conclusion
23

Appendices
Calculations
24
Datasheets
41
Modellingofthehydraulicpress
51
AnalysisoftheFrame
54
ListofReferences
59
ListofFigures
Figure1.2,Thepresenthydraulicsystem
Figure1.3,VolvoTruckshousing
Figure2.1,WorkingprincipleofBramahspress
Figure2.4,Abasichydraulicsystemandcomponents
Figure3.1a,Acylinderconstruction
Figure3.1b,Cylindermountingmethod
10
Figure3.2,Externalgearpumpoperation
11
Figure3.3,Y2seriesAluminium3phaseinductionmotor
12
Figure3.5.1,Nonpressurizedreservoirconstruction
14
Figure3.5.2,Filterslocations
16
Figure3.5.3.2a,Typicalhosemountings
18
Figure3.5.3.2b,Assemblyofflexiblehoses
19
Figure3.5.3.2c,Typesofflexiblehoses
19
Figure3.5.3c,Typicalhydraulicfittings
20
ListofTables
Table2.2,Basicpropertiesofhydraulicandpneumaticsystems
Table3.2,Criteriaestimationforsometypesofpump
11
Table3.5.2,Typicalcriticalclearanceoffluidsystemcomponents
16
Table3.5.3,Flowvelocityofpressurizedline
17
1. Introduction
Thischapterdiscribesthecompanyinformation,background,problemdescriptionandgoal
forthethesis.Italsodescribesthedispositionofthereport.
1.1SwepartTransmissionAB
The two brothers Axel and Bertil Bengtsson started their engineering shop in Hultaberg in
the South of Sweden at 1945. Their business idea was to manufacture screwvices, brass
spindlesandhydraulicequipment.In1956thecompanywasmovedtoLiatrop.
In1955,BertilpassedawayandthecompanyssecondfounderAxeldiedinatragicaircraft
accident at 1963. After these happens, Torsten who was the third brother engineer and
Torstenssontakechargeofthewholebusiness.
In 1963, the demand for gearwheels increased constantly and new modern machines for
turningandgearmillingwereacquired.Thecompanywasastablesupplieroftransmission
partsatthisyear.
AtthebeginningofseventiesSaab,ScainaandHusqvarnawereincludedamongthenewer
costumers.Nowadays,Volvoandlotsofbigcompanyaretheircostumers.Thedominating
business is the heavy vehicle industry but also automation, forestry and construction
equipmentindustriescanbecountedintheircostumerbase.
Swepart Transmission AB that manufactures transmission products including gear wheels,
spline axles and gearboxes shall, through continous improvements, achieve a quality level
whichsurpassestherequirementsoftheircustomers[11].
1.2Background
SwepartTransmissionABstartedupprojectthattheywanttodoassemblyoperationsmore
efficient.Theywanttomakemoreeffectiveandrationalizedflow,alsotheywanttocreate
betterworkenvironment.
The present hydraulic system is wasting time, human power and energy. Following Figure
1.2showsthepresentsystem.Thissystemshouldbeimproved.
Figure1.2Thepresenthydraulicsystemtoassembledthebearingstothehousing
The main idea of this project is assembled the bearings to the Volvo Trucks housing. This
operationcanbedonebytwodifferentmethods.Thismethodsarepressandshrinkfitting.
Shrinkfittingisaprocedureinwhichheatisusedtoproduceajointbetweentwopiecesof
metal, one of which is inserted into the other. We have to heat the housing and cool the
bearing at this operation. The process of shrink fitting takes a long time. This thermal
conditions of operation affect the diametral clearance. Bearing and housing has a very
sensitivetolerance.Shrinkfittingaffectsthetoleranceinanegativeway.
Allthisreasons,pressingoperationispreferredforfittingthebearingstothehousing.
1.3Problemdescription
Whilefitting,therearesomeimportantrules.Theseare:
Housingshouldbefixedonthebolsterverysafetly.
The maximum permitted pressfit force should not be exceeded. The maximum
permittedpressfitforceonthecupsshallbe25kN.Alsothisvalueisveryimportant
forbeginningofthecalculations.
Nowadays, the assembly operationis done by low efficient system. This operation is done
three different steps because the present hydraulic press has only one conic ram but the
housing have three bearings. Only one bearing is fitted to the housing at every step. So
during this assembly; hydraulic press should be stopped after every step and housings
positionshouldbechangedtothesuitableposition.Thisoperationisreallyhardforhuman
andittakeslongtime.
Thestudyfocusesconstructionofthenewhydraulicpress.
1.4Goal
ThegoalwiththisthesisistofitthethreebearingstotheVolvoTruckshousing.Following
Figure1.3showsVolvoTruckshousing.ThisFigurehelpsustounderstandthemainproblem
andthegoal.
Figure1.3VolvoTruckshousing
3
Inmygoal,ihavetofindmanyproblemssolution.Somebasicgoalintheproject:
HowshallidesignanewhydraulicpresstofitthethreebearingstotheVolvoTrucks
Housing?
Howcanthethreebearingsbefittedbyonlyonepressmotion?
Howcanthehousingbefixedonabolster?
Calculations of the cylinders, electric motors, pumps, the capacity of the oil
reservoirsetc..
What kind of motor, pump and hydraulic accessories are more useful for the
hydraulicpress?
Thehydraulicsystemscomponentsselection.
Theaimistofindabestsolutionforthisproblems.Inthemodernworldoftoday,hydraulic
playsaveryimportantroleinthedaytodaylivesofpeople.
The purpose is to familiarize one with the underlying principles of hydraulic presses and
constructthenewhydraulicpress.
1.5Dispositionofthestudy
This report is divided into five chapters. The first chapter contains history of Swepart
TransmissionAB,background,problemdescriptionandgoalofthisreport.Inchaptertwo,
thereisaninformationaboutindustrialhydraulicsandexplaintowhythehydraulicsystem
was chosen for the assembly operation. Chapter three contains description of hydraulic
press components. Chapter four describe the differences from another hydraulic press.
Chapter five contains conclusion of this report. In addition all the calculations, the chosen
componentsdatasheets,thehydraulicsystemsmodelling&technicaldrawingandanalysis
oftheframecanbefoundintheappendix.
Generally the thesis is divided into two parts, one the press construction part and one
theoreticalpart.Theconstructionpartistodesignthenewhydraulicpressthatwillfitthree
bearingstothehousing.Thetheoreticalstudyfocusesonbasicinformationabouthydraulic
pressesandhydraulicpresscomponents.
2.BasicsofIndustrialHydraulicSystems
Theaimofthischapteristoexplainwhythehydraulicsystemisthebestsolutionforthe
assembly. This chapter contains history of fluid power, comparison of hydraulic and
pneumaticsystem,generalstructureofhydraulicsystemsandadvantagesofthehydraulic
systems.
2.1Historyoffluidpower
Fluidpoweristhetechnologythatdealswiththegeneration,controlandtransmissionof
power,usingpressurizedfluids 1 .
Fluids as a source of power. In 1648, a French Physicist, Blaise Pascal, proved the
phenomenon that water transmits pressure equally throughout a container. Later on this
principle was used in industry to generate fluid force as in the Bramahs press. Following
Figure2.1showstheBramahsprinciple[3].
Figure2.1WorkingprincipleofBramahspress[3].
However due to the advent of electricity around 1850, the use of water power (water
hydraulics)inindustrydeclineduntiltheoutbreakofWorldWarII.From1920onwards,oil
hydraulicsstartedappearinginvariousmachinetoolcontrolsinEurope,USA,etc.Engineers
started using fluids for power transmission and basic elements like pumps, controlvalves,
cylinders,etc. 2
Todayfluidpowerisusedwidelyineverybranchofindustry.Sometypicalapplicationsare
hydraulicpresses,automobiles,agriculturalmachinery,robotsetc.
1
2
Esposito,2003,page1
Majumdar,2003,page2
2.2Comparisonofhydraulicandpneumaticsystem
At the beginning of this project, i asked to Mr Ekman Why dont you use air for the
pressing working . Reply was clear. Because oil is more useful for pressing working.
Hydraulic systems operate with oil but pneumatic systems operate with air. It is the basic
differencesofthissystems.
Whenchoosingthemostsuitablesystemforaparticulardesignsolution,thespecifications
on the overall operating conditions are to be strongly considered. Correct solution can be
reached,basedontheexamplesofapplicationsforthedifferentsystemtypes.
The right choice of system(or a combination of systems) requires precise information
regardingthetechnicaldataofthecomponents,theiradvantagesanddisadvantages.Table
2.2showsthebasicpropertiesofhydraulicandpneumaticsystems 3 .
Criteria
EnergyCarrier
Energytransmission
Conversion
from/into
Mechanicalenergy
Mostimportant
Characteristics
Powerefficiency
Precisionofmotion.
Allsystemsare
mproved
bypositioningaction
TypicalApplication
Hydraulics
Oil/operational
Pipes,hoses,tubes,bores
Pumps,
cylinders,
air,
hydraulic
Motors
Pressurep(30400bar)
Flowrateq
Verygoodthroughhigh
operational
Pressure(upto400bar)
Verygoodbecauseoilcan
Hardlybecompressed
Pneumatics
Air
Pipes,hoses,tubes,bores
Compressors,Cylinders
Proccessingparts,
linearactuation,
presses, rotation
forces)
Artisanry,mountingdevices,
Fittingout
Pressurep(approx.6bar)
Flowrateq
Goodbutrestrictedbecause
Oftheoperationalpressureofupto6
bar
Notgoodbecauseairiscompressible
(great
Table2.2Basicpropertiesofhydarulicandpneumaticsystems.
Most important characteristics pressure and the other criterias, designate that the best
solutionishydraulicsystemforthepressconstruction.
Gtz&Bosch,2002,page9
2.3AdvantagesofahydraulicSystem
Hydraulic Presses continue to be the press of choice for today's modern manufacturers.
Thereareveryimportantreasonsofthis.Thisreasonsarereliatedbetweenadvantageofa
hydraulicsystems.Thebasicadvantagesofthehydraulicsystemsare 4 5 :
1. Hydraulicpoweriseasytoproduce,transmit,store,regulate,controlandtransform.
2. Hydraulicsystemscantransmitpowermoreeconomically.
3. Divisionanddistributionofhydraulicpowerissimplerandeasierthanotherformsof
energy. This advantage is very important for the design because two different
cylinderswereusedatthepressconstruction.
4. Hydraulicforcesareeasilylimitedandbalanced.Easyandaccuracyofcontrolbythe
useofsimpleleversandbuttons.
5. Hydraulics is a beter overload safe power system. This can be easily achieved by
usingapressurereliefvalve.Themaximumpermittedpressfitforceonthecupsshall
be25kNforfittingbearings.Soiftheforceexceed25kN,thepressurecanbeeasily
decreased.
6. Frictionalresistanceofhydraulicpowerismuchlessthantheothermethods.
7. Hydraulicpumpsnoiseandvibrationisminimal.
8. Hydraulic systems are cheaper if one considers the high efficiency of power
transmission.
9. Maintenanceofhydraulicsystemiseasy.
10. Hydraulicsismechanicallysafe,compactandisadaptabletootherformsofpower.
Of course there are some advantages and disadvantages for every machine. But hydraulic
systemhasafewdisadvantages.Themostimportantdisadvantageisleakageofhydraulicoil
posesbutthisproblemcanbecompensabled.
Nowitsveryclearthatwhyhydraulicpressismoreusefulforthepressconstruction.
2.4Structureofahydraulicsystem
The operation of a hydraulic system includes energy conversion, energy transmission and
energycontrol.Firstlymechanicalenergyistransformedtohydraulicenergy,thenhydraulic
energyisconvertedbacktomechanicalenergy.Thisenergyconversionisdonebyhydraulic
components.ThefollowingFigure2.2showsabasichydraulicsystemandthecomponents
fromwhichitisbuiltup 6 .
Majumdar,2003,page24
Esposito,2003,page69
6
5
Functionalityofthecomponentsisshownontheleftpartofthefigure.Thecorresponding
standardsymbolofeachcomponentisshownontherightpart.
Figure2.4Abasichydraulicsystemandthecomponents
3.HydraulicPressComponents
Thispartisintendedtodemonstratecomponentsofhydraulicpresses.Thischaptercontains
a basic information of hydraulic cylinder, pump, electric motor and valve. Hydraulic is not
complete with only pump, motor, cylinder and valve. There are other components in a
hydraulic system listed under the hydraulic accessories category. This components are
reservoirsystem,filter,accumulator,hydraulicpipes,hosesandfittings.
3.1HydraulicCylinders
Thecylinderisabasiccomponentandtheengineersaregenerallystarthydrauliccylinders
designinthedesignofhydraulicsystems 7 .
Hydraulic cylinder converts hydraulic energy to mechanical energy. Hydraulic cylinder
contact with a piston rod to push or pull force to drive external load along a straight line
path.Hydrauliccylindersarewidelyusedindifferenttypesofhighpressureapplicationsin
anindustry 8 .
Theoilisdeliveredunderpressurethroughthecylinderportsinthepistonandthisincrease
of pressure starts the piston motion. This is a very simple working principle for hydraulic
cylinders.TheFigure3.1ashowsconstructionofahydrauliccylinder.
Figure3.1aCylinderconstruction:1Cylindertube2Piston3Pistonrod4Cylinderbase
5Cylindercap6Pistonseal7Pistonbearing8Pistonrodseal9Pistonrodguide
10Pistonrodwiper
7
8
Different methods can be used for cylinder mounting. Cylinders mounting depends on the
specific conditions of the system. Cylinders mounting can be done in three different way.
These are: fixed mounting, dynamic mounting, mounting to the piston rod. Cylinders are
widelyfixedatthehead.Thistypeofmountingwasusedinthehydraulicpress.Following
Figure3.1bisshownthecylindersmountingmethods 9 .
Figure3.1bCylindermountingmethods
Propeties of the hydraulic press are quite different from an other hydraulic system. This
differences are relatively low working force, low flow rate, two different cylinders etc.
Cylinderscanbemanufacturedwithspecialordersothehydraulicpressescylinderswillbe
specialordered.Thecylindersparameterscalculationcanbefoundintheappendix.
10
3.2HydraulicPumps
Engineers have to choose the most useful components for their construction. Hydraulic
pumps have a large variety of construction types. When the pump selection, we should
estimate some criteria. These are price, pressure, noise, durability, efficiency etc. The
followingTable3.2showscriteriaestimationforsometypesofpump 10 .
Typeofpump
Price Pressure Noise
Externalgearpump
Internalgearpump
Vanepump
Radialpistonpump
Table3.2Criteriaestimationforsometypesofpump:1Low2Average3High
External gear pump is the best solution for the hydraulic system. Because external gear
pumphasalowcostandmediumpressurewhichisneedforthehydraulicpress.Inaddition
external gear pump has a high volumetric efficiency and this is most widely used in a
hydraulicsystem.
A pump which is the heart of a hydraulic system, converts mechanical energy, which is
primarlyrotationalpowerfromanelectricmotor,intohydraulicenergy.Theexternalgear
pumpisthesimplestconstruction,consistsofjusttwoclosemeshinggearwheels.Figure3.2
showstheoperationofanexternalgearpump 11 .
Figure3.2Externalgearpumpoperation
10
11
Doddannavar&Barnard,2005,page3743
11
PumpwaschosenfromBoschRexroth[6]iscalledAZPB22V=2
Thepumpsparameterscalculationandtechnicaldatasheetsofthechosengearpumpcan
befoundintheappendix.
3.3ElectricMotors
Electric motors are rotary actuators. It means that electric motor provides rotational
movement.Electricmotorstransformelectricityenergytorotarymechanicalenergy.
Electricmotorshavealargevariety.But3phasemotorsarethemostusedinanindustry.3
phaseinductionhasalotofadvantages.Ithasasimplestructure,easymaintance,lowcost,
reliable operation, low noise, low vibration, energysaving and high efficiency. The chosen
electricmotorshowninFigure3.3[4].
Figure3.3Y2seriesAluminium3phaseinductionmotor
ElectricmotorwaschosenfromDasuCompany[4]iscalledY290S4P=1.1kW.
Calculationoftheelectricmotorpoweranddatasheetsoftheusedelectricmotorcanbe
foundintheappendix.
3.4ControlValves
Controlisveryimportantforallfluidpowersystems.Thehydraulicsystemsrequirecontrol
valvestodirectandregulatethefluidflowfrompumptothevariousloaddevices.Thevalves
consistofaflowpassage.Theflowpassagesareacanbechanged.Sowecancontrolledthe
fluid direction, pressure and flow easily. We have to think size, actuating technique and
remotecontrolcapabilityforvalveselection.Therearethreebasictypesofvalves:
12
Directional control valves: Direction control valves are determine the direction of
thefluidinthehydrauliccircuit.Thisvalvestarts,stopsandchangesthedirectionof
the oil flow in a hydraulic system. For instance, valves establish the direction of
motionofahydrauliccylinderormotor.
Pressurecontrolvalves:Pressurecontrolvalvesprotectthehydraulicsystemagainst
overpressure,whichmayoccurduetoexcessiveactuatorloadsorduetotheclosing
ofvalve.Pressurerelief,pressurereducing,sequence,unloading,brakeandcounter
balancearecontrolledbypressurevalvesinahydraulicsystem.
Flowcontrolvalves:Flowcontrolvalvesarecontrolledtheflowrateinahydraulic
system. The volume of oil is regulated different parts of hydraulic system by flow
controlvalves.Thisvalvesautomaticallyadjusttochangeinpressure 12 .
Controlvalvesareswitchedintovariousoperatingpositions.Ingenerallycontrolvalvesare
controlled by manually operated and manual controlling has a low price. So manual
controllingwaschosenfortheconstruction.Theconstructionhasatwocontrolbuttonsfor
controllingtotheeachcylinder.
Flow control valve with check valve was chosen from Bosch Rexroth [6] is called 2FRM 6
B363X/3QRV.Mostimportantparameterisflowratewhileflowcontrolvalvesselection.
While pressure and direction valve selection, there are two types of valves at the Bosch
Rexroth catologue. These are Direct and Pilot Operated valves. Manuel controlling was
chosensoDirectOperatedvalveshouldbeselected 13 .
The hydraulic systems working pressure was chosen 150 bar (It can be found in the
appendix).Whilepressurecontrolvalvesselection,workingpressureisthemostimportant
parameter.
Pressure control valve was chosen from Bosch Rexroth [6] is called Pressure StageH
KBD2H0AA/SV.
Direction control valves selection is very complex. Direction control valve can be chosen
TypesSMM(leveroperation)fromBoschRexroth[6].
RelatedDatasheetsofthechosenvalvescanbefoundintheappendix.
12
13
13
3.5HydraulicAccessories
3.5.1HydraulicReservoirs
Everyhydraulicsystemshouldhaveitsownoilreservoir.Theoilusedstoredinareservoirto
which it is turned after use. There are basicly two types of hydraulic reservoirs. These are
nonpressurized reservoirs and pressurized reservoirs. Nonpressurized reservoirs are the
most suitable in a hydraulic system. The Figure 3.5.1 shows nonpressurized reservoir
construction 14 .
Figure3.5.1Nonpressurizedreservoirconstruction
The basic functions of hydraulic reservoir as follows: 1. Storage of oil 2. Cooling of oil
3.Expansionoffluid4.Seperationofcontaminants.
The design of the reservoir is very important for reliable operation. Many factors have to
considered when selecting and configuration of a hydraulic reservoir. But generally a
reservoir is designed 35 times bigger than the flow rate [2]. Reservoirs are generally
constructed from welded steel plate with thin side walls to heat transferred. The inside
surfacesofthereservoirarepaintedtopreventtheformationofrust 15 .
Calculationoftheoiltankcapacitycanbefoundintheappendix.
14
15
Parr,2007,page167169
14
3.5.2Filters
Contamination is the cause of most hydraulic failures. It is estimated that 75 to 85 % of
hydraulicfailuresaredirectlyrelatedwithcontamination.Contaminationsaremeasuredby
Micron size. Contaminants are added to hydraulic systems through external and internal
sources. Generally contaminants commonly come from pumps, valves, bearings and
cylinders[5].
The oils used in hydraulic systems contain lots of foreign matters. These can be solid and
liquid. Which are mostly in solid form like dirt, dust, worn out metallic parts etc. and
sometimes in liquid form like water, acids, paints etc. Filters are used to prevent foreign
mattersenteringthesensitivepartsofthesystem 16 .
Filtersmustbeusedinahydraulicsystembecausefilters:
Improvesystemperformance.
Reducecomponentsmaintancecost.
Reducesystemdowntime.
Reduceoilpurchaseanddisposalcosts.
Typical hydraulic systems should have more than one filter. Filters can be located various
types.
Return line filters: Return filters are the most widely used in a hydraulic system.
Returnfiltersprotectpumpsbylimitingsizeofparticlesreturnedtothetank.These
filtersoperateonlylowpressure.Thisfiltersarecheap,easytomaintainandcovers
theoverallflowrateinasystem.
Suction line filters: Sunction lines are usually fitted with strainers inside the tank,
butstrainersareremovedrelativelylargemetalparticlesandsimilarcontaminants.
For this reason suction filters are needed at this line to remove finer particles.
Suctionfiltersprotectthepumpontheinlet.
Pressurized line filters: Pressure line filters mounted after the pump to protect
valves and actuators. This filters operate at high pressure so its housing should be
abletotakehighpressures.Thismakesthemexpensive 17 .
FollowingFigure3.5.2showsthesefilterslocations 18 .
16
Parr,2007,page5255
18
17
15
ReturnlinefilterSuctionlinefilterPressurizedlinefilter
Figure3.5.2Filterslocations
Ingenerallybothreturnandsuctionlinefiltersareusedinahydraulicsystem.Thehydraulic
systemsworkingpressureismediumandtheflowrateissmallsoitdoesnotneedtouse
pressurized line filter. Return and suction line filters were used in the hydraulic system.
Returnandsuctionlinefilterscanbechosensame 19 .
Filtrationratingisveryimportanttochooserightfilter.Filtrationratingcanbechosen3m
and10m[6].Gearpumpwasusedinthehydraulicsystemandgearpumps'clearancesare
showninTable3.5.2 20 .
Table3.5.2Typicalcriticalclearanceoffluidsystemcomponents
19
20
ThanktoIlhanAkceylan,engineerattheHrsanPressinTurkey.Heinformedmeaboutthissubject.
16
Tableshowsclearanceofthegearpumpis1/25msofiltrationratingshouldbechosen3
m.
FilterswerechosenfromBoschRexroth[6]iscalledABZFRS0040031X/MDIN[...SAE].
The filtersselectionanddatasheetsofthechosenfilterscanbefoundintheappendix.
3.5.3HydraulicPipes,HosesandFittings
Pipes, hoses and fittings are very important parts in a hydraulic system. The fluid flows
through the pipes, hose and fittings. It carries the fluid from the reservoir through the
operatingcomponentsandbacktothereservoir.
Returnlineflowvelocityisdifferentfrompressurizedlineflowvelocityinahydralicsystem.
The lower velocity is specified for the return line to reduce the back pressure. Generally
suction flow velocity is chosen 1.5 (m/s) and return line velocity is chosen 2 (m/s). Flow
velocityofthepressurizedlinecanbeseeninTable3.5.3[2].
WorkingPressure(Bar) Velocity(m/s)
50
4.0
51100
4.5
101150
5.0
151200
5.5
201250
6.0
Table3.5.3Flowvelocityofthepressurizedline
3.5.3.1HydraulicPipesandTubes
Apipeandtubeisafunctionalconnectionforfluidflowinthehydraulicsystem.Thefluid
flowefficiencyisinfluencedbythepipingline.
Ironpipesandsteeltubescanbeusedinahydralicsystem.ronpipesareusedforlowto
medium pressure. Heavy wall thickness and lack of annealing characteristics are basic
problemsforironpiping.Steeltubesaremorewidelyusedinanindustrybecauseoftheir
advantages. Leaking is a big problem for the hydraulic system but steel tubes ensure
maximumleakprotection 21 .
21
17
Generally hydraulic tubes are used at the pressurized line. Hydraulic tubes are chosen
accordingtotheDIN2391[9].
Allthesereasons,steeltubeswaspreferedatthepressurizedline.Thehydraulictubeswere
chosenfromHidroKontrolBenteler[7].
Calculationofthepressurizedlinepipesinnerdiametercanbefoundintheappendix.Also
thehydralictubesselectionanddatasheetsofthechosentubescanbefoundinthe
appendix.
3.5.3.2HydraulicHoses
In a hydraulic system, flexible conductors are called hose assemblies. The hoses help
overcome severe vibration and absorb hydraulic impulse shocks. Hoses are generally
manufacturedcompletewithfittings.Hydraulichosesmustbeinstalledwithouttwists.
Hosesaremountedwithsomesuitableequipmentbytheuser.Theseare:1Thread2Nut
3Hoseend4Flangenipple.ThehosemountingscanbeseeninFigure3.5.3.2a 22 .
Figure3.5.3.2.aTypicalhosemountings
Flexiblehoseshaveaspecialrulesfortheassembled.Thefollowingfigure3.5.3.2bshowsthe
assemblyofflexiblehoses 23 .
1Wrong2Correct
22
23
18
Figure3.5.3.2.bAssemblyofflexiblehoses
Thehosesaremadebysyntheticrubber.Varioustypesofsyntheticmaterialscouldbeused
forhoses.TypesofflexiblehosescanbeseeninFigure3.5.3.2c 24 .
Figure3.5.3.2cTypesofflexiblehosesa,b,cMediumpressured,e,fMediumhighpressure
24
19
Hoses were used at the return and sunction line in the hydraulic system. The hydraulic
systemoperatesatmediumpressureatthereturnandsuctionlinessoSAE100R3issuitable
forthehydraulicsystem.
Calculationofthereturnandsuctionlinepipesinnerdiametercanbefoundintheappendix.
3.5.3.3HydraulicFittings
Thisisthelaststepofabasichydraulicpressconstruction.Metaltubeorsynthetichoseis
attached to the port of the hydraulic elements by fittings. There are some important
functionsoffitting.Theseare:
Changingthedirectionoftheflow
Providingbranchconnections
Changingthesizeofline
Clossinglines
Connectinglines 25 .
Fittingsaremadeofsteel,bronze,castiron,plasticorglass.Steeltubeorsynthetichoseis
attachedtotheportofthehydraulicelementsattheendofconstruction.Typicalhydraulic
fittingscanbeseeninFigure3.5.3.c 26 .
Figure3.5.3.cTypicalhydraulicfittings(1hosetotube,2tubetotube)
25
26
20
4.Conceptsforthehydraulicsystem
ThepurposeistoconstructahydraulicpressforthreebearingsfittingtotheVolvoTrucks
housing. The housing holes and bearings tolerances are very sensitive. This system should
operateverysafety.
The main structure of the press containing frame, cylinders and working surface. Frame is
veryimportanttobalanceandcarryingtheload.Strengthoftheframewasanalysedatthe
SolidWorksProgramme.Thisanalysiscanbefoundintheappendix.
In the hydraulic press, constructions of some parts are different from another hydraulic
press.
Thesepartsare:Twodifferentcylinders,RamsandBolsterplate.Thispartsweredesigned.
Constructions of two different cylinders, rams and bolster plate are described in the
followingchapters4.1,4.2and4.3.
4.1Twodifferentcylinders
Therearetwoholesatthehousingwhicharethesamesizeandsoclosetoeachother.Two
bearings can be fitted to this two holes by one cylinder. The other bearing is fitted by
anothercylinder.Sotwoseparatecylinderswereusedforthehydraulicpress.
Maybesomepeoplethinksthatitisposibbletodonethisworkbyonlyonecylinder.Butthis
situationmakesalotofproblem.Thisproblemsoccurbecause:
Housinghastwodifferentholediameter.Oneis72mmandtheotheroneis82mm.
Onebearingwhichhas82mmdiameter,itisplaced16.3mmhigherthantheother
twobearings.
Slippingisoccurredontherambecausetheramshouldbeconstructedmuchmore
biggersizeatthissituation.
Cylindersdesigncanbefoundintheappendix.
4.2Rams
Ramisatoolfordrivingorforcingsomethingbyimpact.Itisaplungerofahydraulicpress.
Firstlybearingsareheldtotheconicram.Afterthatbearingsarefittedtothehousingbythe
hydraulicpress.
Threeconicramswereusedinthehydraulicsystem:
21
Twoofthemarethesame.Theseareattachedtothecircularramandcircularramis
attachedtothepressingcylinderandtwosupporterrods.Supporterrodswereused
topreventslipping.
Theotherconicramisdirectlyattachedtothepressingcylinder.Onlythisconicram
hasonespringbecauselowerpartofthecorrespondingbearingsholeisclosedat
thehousing.Theothertwoholeswhichareopensoitdoesnotneedtousespring
for the other two conic rams. When the operation of the bearing tightening is
finished,thespringhelpsreturningmotionofthepressingcylinder.
Designofthecircularramandconicramscanbefoundintheappendix.
4.3BolsterPlate
Bolsterplateisdesignedtoholdinplacethelowerdieshoe.Thebolsterplateisattachedto
thetopsurfaceofthepressbed.
Housingshouldbefixedonthebolsterplate.Whilefixing,centerofthehousingholesand
centeroftherelatedconicramsmustbethesameaxis.
Six rods were attached on the bolster conveniently. This rods are passed through the
convenienthousingholes.Inthisway,thehousingisfixedonthebolster.
Volvo Trucks housings are made of aluminium. Unfortunately, Aluminiums have low
strength. While tightening, housing can be distorted. So two big cylindrical supporters
attached on the bolster. This two big cylindrical supporters contact around the housings
holes.Inthisway,housingssafetyisensured.
Designofthebolstercanbefoundintheappendix.
22
5.Conclusion
SwepartTransmissionABstartedupprojectthattheywanttodoassemblyoperationsmore
efficient. For this purpose, new hydraulic press was constructed including modelling,
technicaldrawings,allparameterscalculations,selectionofthehydrauliccomponentsand
strengthanalysisoftheframe.
Thegoalofthisthesisworkwastoconstractahydraulicpresstofittingthreebearingsatthe
sametime.Ofcoursethishydraulicpressesshouldbemoreefficientandmorereliable.
Duringtheconstructing,followingarticleswereveryimportant:
At the beginning, working pressure assumed 150 bar because this is a typical
pressureofanhydraulicsystem 27 .Afterthathydraulicspressingforceandcylinders
parameters were calculated. Because these are basics in the design of hydraulic
systems.
Whilethepistonrodsdiameterscalculation,therodsdiameterswerefoundsmall
with theoretical approach. But in real life, enginneers choose the piston rods
diameter bigger than the theoretical result. If this theoretical result is chosed,
pistonsturningmotionwillbeveryfastsocylinderwillbedamaged.Allthisreasons,
pistonrodsdiameterswerechosenbiggerthanthetheoreticalresult.
Bearings should be tightened very slowly to their holes so I assumed that pressing
velocity is 5 mm/s. After this assumption, pumps and electric motors parameters
werecalculated.Thenhydraulicaccessoriesparameterswerecalculated.
Humanssecurityisanotherimportantthing.Suddenly,somebodymayputtheirhandunder
theramsduringthisoperation.Inthisinstancethemachineshouldbestoppedveryquickly.
SoBigEmergencyButtonwasconstructedforthehydraulicpress.
While operation, pressure should be controlled to protect the hydraulic system against
overpressure.Twoseparatepressureindicatorswereconstructedforthispurpose.
Electric motor and reservoir was constructed near the cylinder. The main idea of this to
minimized the hoses length and gravitational potential differences between cylinder and
reservoir.Shorthosesmeansthatlessfrictionlosseswhilefluidflowingandlesshoseusage.
Smallgravitationalpotentialdifferencesmeansthatlessenergyloses.
Now at the end of this bachelor thesis, I am very happy for my hydraulic construction.
BecauseMrEkmansaidthatitsagoodconstructionandthisisthesolutionforus.
27
Parr,2007,page4
23
CALCULATIONS
1. Calculation of Pressing Forces
The maximum permitted press fit force on the cups should be 25 kN.
In housing there are 3 bearings so
25 * 3 = 75kN
Now the press force has to be calculated

F=
75000N
9,81
F = 7645kg
The hydraulic press is selected F = 12000 kg = 12ton . Two cylinders will be used in
the hydraulic system.
One cylinder fits two bearings and this system is called Group 1.
The other cylinder fits one bearing and this system is called Group 2. This group
names will be used during the calculations.
2. Assumption for the Group 1
The hydraulic systems pressure is controlled easily by buttons. In addition all systems
lose energy while operating. So pressing force should be chosen bigger than the fitting force
50kN=5000kg for two bearings.
Maximum Press Force= 8 ton= 8000kg.
Working Pressure=150 Bar = 150 kg cm 2 [This is a typical hydraulic pressure (Parr,
2007)]
3. Assumption for the Group 2
Because of the same reason pressing force is selected bigger than the 25kN 2500 kg
for one bearing fitting.
Maximum Press Force = 4 ton = 4000 kg
Working Pressure = 150 Bar = 150 kg cm 2
24
4. Calculation of Piston Parameters

4.1. Calculation of Piston Pressing Diameter
Designations:
F pr = Pressing Force ( kg )
Ppr = Working Pressure ( bar or kg cm 2 )

A pr = Cylinders Pressing Total Area ( cm 2 )
D pr = Pistons Pressing Diameter ( mm )
Formulas:
A pr =
D pr
F pr
Ppr
4 A pr
=

0,5
4.1.1. Calculation for the Group 1
A pr =
F pr
Apr =
8000
150
Apr = 53,33cm 2
D pr2
4 A pr
=

Apr =
D pr
Ppr
D pr
4 * 53,33
=
0,5
0,5
D pr = 8,162cm = 81,62mm
The first pistons pressing diameter is chosen D pr = 82mm .
25
A pr =
F pr
Apr =
4000
150
Apr =
D pr
Ppr
Apr = 26,66cm 2
D pr2
D pr
4 * 26,66
=
4 * Apr
=

0,5
0,5
D pr = 5,81cm = 58,1mm
The first pistons pressing diameter is chosen 58mm.

4.2. Calculation of Piston Rod Diameter
Using the EULER METHOD to calculate the piston rods diameter.

Designations:
K= Buckling load
S K = Free buckling length (cm)
E= Elasticity Module ( kg cm 2 )
J= Moment of Inertia ( cm 4 )
S= Safety Factor
Safety factor is chosen 3 for piston rod. S=3
S K = 21cm
[8]
E = 2,1.10 6 kg cm 2 (For steel)

Formulas:
K = ( 2 EJ ) S K
J = d 4 64
F=K S
K = F *S
26
F= 8000 kg
K = F *S
K= 8000*3
J=
K= 24000 kg
d 4
64
d4 =
K = EJ S K
J=
64 * J
K * SK
J=
2E
24000 * 212
2 * 2,1 *10 6
J= 0,51
d4 =
64 * 0,51
d= 1,79 cm = 17,9 mm
This result is exactly correct at theoretical approach. But in the real life, the rods
diameter should be selected bigger than this result. If this theoretical result is selected, the
piston turning motion will be very fast and it damages to the cylinder.
The piston diameter of the first cylinder is D= 82 mm. Related with the piston
diameter:
The piston rod diameter is chosen 50 mm for Group 1.
D pistonrod = 50mm
27

F = 4000 kg
K = F *S
K = 12000kg
K = 4000 * 3
d 4
J=
64
d4 =
K = EJ S K
J=
64 * J
K * SK
J=
2E
12000 * 212
2 * 2,1 *10 6
J = 0,255
d4 =
64 * 0,255
d = 1,51cm = 15,1mm
Again the same reasons, the piston rods diameter is selected bigger than this result.
The piston diameter of the second cylinder is D= 58 mm. Related with the piston
diameter:
The piston rod diameter is chosen 30 mm for Group 2.
D pistonrod = 30mm
28
5. Calculation of Pump Parameters

Designation:
q = Output flow rate

D p = Pumps displacement
n p = Pumps rotation speed
nvol = Volumetric efficiency

V = Velocity
Formulas:
q = A *V
(1)
q = D p * n p * nvol
(2)
Formula (1) and (2) gives:
Dp =
A *V
n p * nvol
Assume that nvol = 0,85 .

Gear pumps revolution are generally limited at 1400 rpm.
Assume maximum rotation speed is n p =
1400
= 23,33rps .
60
Assume maximum velocity on the cylinder is V = 5 mm s = 0,005 m s . The velocity is

chosen smaller from another hydraulic press because housing and bearing has a very sensitive
tolerance. So bearings should be fitted to the housing very slowly.
5.1. Calculation for the Group 1
A = 53,33cm 2 = 0,005333m 2 (Calculated at 4.1.1.)
29
5.1.1. Calculation of Pumps Displacement for Group 1 Needed
Dp =
A *V
n p * nvol
Dp =
0,005333 * 0,005
23,33 * 0,85
D p = 1,3446 *10 6 m3 rev
5.1.2. Calculation of Pumps Output Flow Rate

q = A *V
q = 0,005333 * 0,005
q = 26,665 *10 6 m 3 s
5.2. Calculation for the Group 2:

A = 26,66cm 2 = 0,002666m 2 (Calculated at 4.1.2.)
5.2.1. Calculation of Pumps Displacement for Group 2 Needed
Dp =
A *V
n p * nvol
Dp =
0,002666 * 0,005
23,33 * 0,85
D p = 6,722 *10 7 m 3 rev
5.2.2. Calculation of Pumps Output Flow Rate

q = A *V
30
q = 0,002666 * 0,005
q = 13,33 *10 6 m 3 s
Pumps total displacement

D ptotal = D p1 + D p 2
D ptotal = (1,3446 + 0,6722) *106

D ptotal = 2,0 *10 6 m 3 rev
Pump was chosen from Bosch Rexroth [6] is called AZPB22 V=2
6. Calculation of Electric Motor Power

Designation:
P = Power
Ppr = Working Pressure
nhm = Hydraulic Mechanical Efficiency
q = Flow Rate
Formulas:
P=
q * Ppr
nvol * nhm
Assume that n hm = 0,95 .

Assume that nvol = 0,85 .
Ppr = Working pressure = 150
kg
9,81
N
= 150 * 4 = 14715000 2
2
cm
10
m
31
6.1. Calculation of electric motor power for Group 1 Needed

q = 26,665 *10 6 m 3 s (Calculated at 5.1.2.)
P=
P1 =
q * Ppr
nvol * nhm
26,655 *10 6 * 14715000

0,95 * 0,85
P1 = 486 W
6.2. Electric Motors Power Calculation for Group 2 Needed

q = 13,33 *10 6 m 3 s (calculated part 5.2.2)
P=
q * Ppr
nvol * nhm
13,33 *10 6 *14715000

P2 =
0,95 * 0,85
P2 = 243 W
6.3. Electric Motor Selection
Total power needed for both cylinders

PTotal = P1 + P2
PTotal = 486W + 243W
PTotal = 729W
Electric motor was chosen from Dasu Company [4] is called Y2-90S-4 P=1,1 kW.
32
7. Calculation of Cylinder Parameters

7.1. Calculation of Cylinder Tubes Thickness and Cylinder Diameters
Designations:
G yield = Yield Strength daN mm 2
S = Safety Factor
P = Pressure
S o = Thickness
d a = Cylinders Diameter
d i = Pistons Diameter
G yield = 23 daN mm 2
(for Steel 35 )
[1]
Assume that S= 2
P = 150 Bar 150 MPa
da
= 1,7
di
( for DIN 2413 )
[1]
d a = 1,7d i
Formulas:
We can calculate thickness from the thin wall container formulation [1]:
So =
da * P * S
200 * G yield
33

7.1.1.1. Calculation of Cylinder Tubes Thickness
d i = 82mm (Calculated at 4.1.1.)
So =
1,7d i * P * S
200 * G yield
So =
1,7 * 82 *150 * 2
200 * 23
S o = 9mm
7.1.1.2. Calculation of Cylinder Diameter
d a = d i + 2S o
d a = 82 + 2 * 9
d a = 100mm

7.1.2.1. Calculation of Cylinder Tubes Thickness
d i = 58mm ( Calculated at 4.1.2.)
So =
1,7d i * P * S
200 * G yield
So =
1,7 * 58 *150 * 2
200 * 23
S o = 6,0mm
7.1.2.2. Calculation of Cylinder Diameter
d a = d i + 2S o
34
d a = 58 + 2 * 6,5
d a = 70mm
7.2. Calculation of Cylinders Base Thickness
Designations:
G yield = Yield Strength daN mm 2
S = Safety Factor
P = Pressure
d a = Cylinders Diameter
Assume that S= 2
P = 150 Bar 150 MPa
Formulas:
So =
da * P * S
100 * G yield

d a = 100mm (Calculated at 7.1.1.2.)
So =
100 *150 * 2
100 * 23
S o = 13mm
d a = 71mm (Calculated at 7.1.2.2.)
So =
71 *150 * 2
100 * 23
S o = 9,26mm
It can be assumed S o = 10mm .
35
7.3. Calculation of all Output and Input Flow Rate at the Cylinders
Designations:
X = Coefficient
D pr = Piston Pressing Diameter
d = Piston Rods Diameter
qin = Input Flow Rate

q out = Output Flow Rate
Formulas:
X = D2 D2 d 2
qout = qin X
D pr = 82mm
(Calculated at 4.1.1.)
d = 50 mm
(Calculated at 4.2.1.)
D2
X = 2
D d2
X =
82 2
82 2 50 2
X = 1,592
qin = 26,665 * 10 6 m 3 s
(q pump output= q cylinder input Calculated Part 5.1.2.)
qin = 26,665 * 10 6 * 10 3 * 60
qin = 1,6 lt min
q out =
qin
X
q out =
1,6
1,592
qout = 1lt min
36
D pr =58 mm (calculated Part 4.1.2.)

d =30 mm
D2
D2 d 2
(calculated Part 4.2.2.)
X =
X =
58 2
58 2 30 2
X = 1,365
q in = 13,33 * 10 6 m 3 s
(q pump output= q cylinder input calculated Part 5.2.2.)
qin = 13,33 * 10 6 * 10 3 * 60
qin = 0,8 lt min
q out =
qin
X
q out =
0,8
1,365
q out = 0,59 lt min

7.3.3. Total Oil Input and Output Flow Rate
qint otal = qin1 + qin 2
qint otal = 1,6 + 0,8
q int otal = 2,4 lt min
q outtotal = q out1 + q out 2
q outtotal = 1 + 0,59
q outtotal = 1,59 lt min
NOTE: Cylinder Stroke is chosen maximum 400mm for Group 1 and Group 2.
37
8. Calculation of Hoses and Tubes Inner Diameter
Designations:
q = Pumps Flow Rate ( lt min )

V = Flow Velocity
d = Inner Diameter (mm)
d suc = Suction Hose Inner Diameter (mm)

d pr = Pressurized Tube Inner Diameter (mm)
d rt = Return Line Hose Inner Diameter (mm)
Separate hoses and tubes are used for both cylinder.

Flow velocity should be chosen.
If working pressure equals to 150 bar, the pressing flow velocity equals to V pr = 5 m s
Generally suction flow velocity equal to Vsuc = 1,5 m s . And return line flow velocity is equal
to Vrt = 2 m s .
Formula:
d 2 = (21 * q ) V
[9]
8.1. Calculation for Group 1

q = 1,6 lt min (Calculated at 7.3.1.)
d suc = (21* q ) Vsuc

2
d suc = 21 *1,6 1,5

2
d suc = 4,8mm
d pr = (21 * q ) V pr
2
d pr = (21 *1,6) 5
2
d pr = 2,6mm
38
d rt = (21 * q ) V pr
2
d rt = (21*1,6) 2
2
d rt = 4mm
8.2. Calculation for Group 2
q = 0,8 lt min (Calculated at 7.3.2.)
d suc = (21* q ) Vab

2
d suc = 21* 0,8 1,5

2
d suc = 3,35mm
d pr = (21 * q ) V pr
2
d pr = (21 * 0,8) 5
2
d pr = 1,9mm
d rt = (21 * q ) V pr
2
d rt = (21* 0,8) 2
2
d rt = 2,9mm
The pipes inner diameter can be chosen a little bigger than this result because of the
standard dimensions.
The chosen tubes properties are: Outer diameter=6mm, Wall thickness=1,5mm.
Tubes were chosen from Hidro Kontrol Benteler [7].
SAE-100R3 types of hoses were chosen. There is a large variety for the hoses
dimensions. It can be selected any company.
39
9. Calculation of Oil Tank Capacity
In real life, tank capacity is chosen 35 times bigger than the flow rate [2].
qtotal = 2,4 lt min (Calculated at 7.3.3.)
Oils cooling is very important for an hydraulic system so more oil using is better for
the cooling.
Oil tank capacity = 2,4 * 5

Oil tank capacity = 12lt
40
DATASHEETS
1.DatasheetoftheGearpump
DataFigure1.aDatasheetofgearpumpAZPB22V=2
41
DataFigure1.bDatasheetofgearpumpAZPB22V=2
42
2.DatasheetoftheElectricmotor
IN
TYPE
Output
Kw
Efficiency(%)
Moment
Power Factor cos)
Speed
380V 400V 415V (r/min) 100% 75% 50% 100% 75% 50% Tn Nm
HP
(A)
(Cos)
Tst/TN
Y2-631-2
0.18 0.25 0.53
0.50
0.49
2720
65
64 60.0
0.80
0.73 0.66
0.61
Y2-632-2
0.25 0.37 0.69
0.66
1.63
2720
68
68.5 66.0
0.81
0.74 0.67
0.96
Y2-711-2
0.37 0.5
0.99
0.94
0.91
2740
70
71.0 68.5
0.81
0.75 0.66
Y2-712-2
0.55 0.75 1.40
1.33
1.28
2740
73
73.0 69.5
0.82
Y2-801-2
0.75
1.83
1.73
1.68
2840
75
75.7 72.3
Y2-802-2
1.1
1.5
2.58
2.30
2.36
2840
78
Y2-90S-2
1.5
3.43
2.90
3.14
2840
(J)
kgm2
Noise
LWdB(A)
Weight
KG
Tmax/TN
Ist/TN
2.2
2.2
5.5
0.00031
58
4.8
2.2
2.2
5.5
0.00060
58
5.1
1.26
2.22
2.2
6.1
0.00075
61
6.0
0.76 0.69
1.88
2.2
2.3
6.1
0.00090
61
6.5
0.83
0.78 0.67
2.54
2.2
2.3
6.1
0.00120
64
8.7
80.0 78.2
0.84
0.82 0.72
3.72
2.2
2.3
7.0
0.00140
64
9.5
80.4 80.2 77.3
0.84
0.80 0.70
5.04
2.2
2.3
7.0
0.00290
69
11.8
380V50Hz Synchronous Speed 3000 r/min (2poles)
Y2-90L-2
2.2
4.85
4.10
4.44
2840
82.7 81.6
0.85
0.84 0.74
7.40
2.2
2.3
7.0
0.00550
69
13.5
Y2-100L-2
3.0
6.31
5.50
5.78
2860
83.5 83.4 81.3
0.88
0.85 0.76
9.95
2.2
2.3
7.5
0.01090
73
21.0
Y2-112M-2
4.0
5.5
8.10
7.10
7.42
2880
85.7 85.5 83.5
0.88
0.85 0.76
13.22
2.2
2.3
7.5
0.01260
74
28.0
Y2-132S1-2
5.5
7.5
11.0
9.70
10.0
2900
86.9 84.5 81.5
0.88
0.88 0.82
18.11
2.2
2.3
7.5
0.03770
77
39.0
Y2-132S2-2
7.5
10
14.9 12.90 13.6
2900
86.9 85.3
0.88
0.89 0.84
24.70
2.2
2.3
7.5
0.04990
77
44.5
Y2-160M1-2
11
15
20.8 18.70 19.0
2930
89.3 88.2 87.4
0.90
0.86 0.79
35.85
2.2
2.3
7.5
0.05500
83
69.2
Y2-160M2-2
15
20
28.1 25.10 25.7
2930
90.2 89.8 89.3
0.90
0.87 0.80
48.89
2.2
2.3
7.5
0.07500
83
78.0
18.5 25
34.0 30.80 31.1
2930
0.91
0.87 0.80
60.30
2.2
2.3
7.5
0.12400
83
88.5
Y2-160L-2
82
88
91
90.6 89.6
380V50Hz Synchronous Speed 1500 r/min (4poles)
Y2-631-4
0.12 0.18 0.44
0.40
0.40
1310
57.0 58.2 54.0
0.72
0.63 0.57
0.84
2.1
2.2
4.4
0.00050
48
4.8
Y2-632-4
0.18 0.25 0.62
0.60
0.57
1310
60.0 60.9 55.5
0.73
0.65 0.57
1.26
2.1
2.2
4.4
0.00060
48
5.1
Y2-711-4
0.25 0.37 0.79
0.70
0.72
1330
65.0 65.4 60.0
0.74
0.65 0.58
1.73
2.1
2.2
5.2
0.00080
53
6.0
Y2-712-4
0.37 0.5
1.12
1.06
1.03
1330
67.0 71.0 68.4
0.75
0.65 0.52
2.56
2.1
2.2
5.2
0.00130
53
6.3
Y2-801-4
0.55 0.75 1.57
1.49
1.44
1390
71.0 72.6 69.0
0.75
0.66 0.55
3.75
2.4
2.3
5.2
0.00180
58
9.4
Y2-802-4
0.75
2.03
1.93
1.86
1390
73.0 74.2 70.0
0.76
0.65 0.54
5.11
2.3
2.3
6.0
0.00210
58
10.8
Y2-90S-4
1.1
1.5
2.89
2.30
2.65
1390
75.0 75.8 75.0
0.77
0.70 0.57
7.50
2.3
2.3
6.0
0.00230
59
12.0
Y2-90L-4
1.5
3.70
3.10
3.39
1390
78.0 78.1 76.7
0.79
0.75 0.64
10.23
2.3
2.3
6.0
0.00270
59
13.8
Y2-100L1-4
2.2
5.16
4.40
4.72
1410
80.0 81.0 81.1
0.81
0.76 0.65
14.80
2.3
2.3
7.0
0.00540
61
20.8
Y2-100L2-4
6.78
5.80
6.21
1410
82.0 83.2 81.6
0.82
0.78 0.66
20.18
2.3
2.3
7.0
0.00670
61
23.5
Y2-112M-4
5.5
8.80
7.80
8.10
1435
84.0 84.8 82.7
0.82
0.76 0.64
26.53
2.3
2.3
7.0
0.00950
62
29.5
Y2-132S-4
5.5
7.5
11
10.7
10.8
1440
85.0 86.8 85.6
0.83
0.81 0.71
36.48
2.3
2.3
7.0
0.02140
69
41.0
Y2-132M-4
7.5
10
15.6
14.4
14.3
1440
87.0 88.2 87.2
0.84
0.83 0.74
0.74
2.3
2.3
7.0
0.02960
69
47.5
Y2-160M-4
11
15
22.0
19.5
20.1
1460
88.0 87.5 84.2
0.84
0.81 0.74
0.74
2.2
2.3
7.0
0.07470
72
72.5
Y2-160L-4
15
20
29.6
26.2
27.1
1460
89.0 89.2 88.7
0.85
0.82 0.75
0.75
2.2
2.3
7.5
0.09180
72
85.6
DataFigure2.DatasheetofelectricmotorY290S4P=1.1kW
43
3.Datasheetofthevalves
3.1Datasheetoftheflowcontrolvalve
DataFigure3.1aDatasheetofflowcontrolvalvewithcheckvalve2FRM6B363X/3QRV
44
DataFigure3.1bDatasheetofflowcontrolvalvewithcheckvalve2FRM6B363X/3QRV
45
3.2Datasheetofthepressurecontrolvalve
DataFigure3.2aDatasheetofpressurecontrolvalveHKBD2H0AA/SV.
46
DataFigure3.2bDatasheetofpressurecontrolvalveHKBD2H0AA/SV.
47
4.DatasheetoftheFilters
DataFigure4.aDatasheetoffilterABZFRS0040031X/MDIN[...SAE].
48
DataFigure4.bDatasheetoffilterABZFRS0040031X/MDIN[...SAE].
49
5.DatasheetoftheHose
HYDRAULICTUBES
Wallthickness
Weight
MaximumPressure
(mm)
(kg/m)
(Bar)
6
1
0,12
320
6
1,5
0,14
350
8
1
0,17
290
8
1,5
0,24
441
10
1,5
0,31
350
10
2
0,39
499
12
1,5
0,39
305
12
2
0,49
320
12
2,5
0,55
350
15
1,5
0,50
290
16
2
0,69
305
16.
2,5
0,83
389
16
3
0,89
420
18
1,5
0,61
210
20
2
0,89
250
20
2,5
1,08
320
20
3
1,25
332
22
2
0,99
225
25
2,5
1,39
250
25
3
1,63
250
28
2
1,28
180
30
3
2,00
250
30
4
2,56
332
35
3
2,37
215
38
4
3,35
260
38
5
4,06
290
42
4
3,75
238
Standartlengthis6mwithplaticstopperandHosearecoveredbyphosphate.
OuterDiameter
(mm)
WithDIN2391/CnormsandST37.4NBKquality.
DataFigure5.Datasheetofthetube
50
ModellingoftheHydraulicPress
ThehydraulicpresswasmodeledintheCADprogramSolidWorks.
ModelFigure1.Generalview
51
ModelFigure2.PressureindicatorsView
ModelFigure3.Sideview
52
ModelFigure4.BolstersView
ModelFigure5.Rams,EmergencyandPressureButtonsView
53
AnalysisoftheFrame
The frames material was chosen cast carbon steel. Cast carbon steel frame is prefered to
havealowworkingstressandminimumdeformationunderload.Theframeisamonoblock
construction so it has a high structural rigidity and this gives an ideal frame profile with
minimumstressconcentrations[10].
Cast carbon steels important properties are: Yield Strength
modulus
and Elastic
FramewasanalysisedintheCADprogramSolidWorks.Theanalysiswasdonetwodifferent
way.Theloadwasappliedundertheconicramsandsupporterswhichwereplacedonthe
bolster.Theloadwasappliedontheverticalaxis.Whileanalysing,theloadisselectedalittle
biggerthantheworkingloadforreliableanalysis.
54
1.Iftheloadisappliedtothesupporters
Applynormalforce18000Nusinguniformdistributiononeightsupportersfaces.
SafetyFactorwasfoundSF=2,16524withthisanalysis.Soframeisreliableatthisanalysis.
StressResultant
Name
Plot1
Type
VON:von
Misesstress
Min.
21,168
Location
Max.
(507,003mm, 1,14615
315mm,
176,528mm)
Location
(727,836mm,
720mm,
29,107mm)
AnalysisFigure1.Stressresultantonthebolster
55
Displacementresultant
Name
Plot2
Type
URES:
Resultant
displacement
Min.
0m
Location
Max.
Location
(7,64491mm, 0.000497556m (409,499mm,
1420mm,
676,8mm,
19,1071mm)
112,415mm)
AnalysisFigure2.Displacementresultantonthebolster
56
2.Iftheloadisappliedundertheconicramsfaces
Applynormalforce48000Nusinguniformdistributiononthreeconicramsfaces.
SafetyFactorwasfoundSF=3,27924withthisanalysis.Soframeisreliableatthisanalysis.
StressResultant
Name
Plot1
Type
VON:von
Misesstress
Min.
122,243
Location
Max.
(659,37mm, 7,56785
637,5mm,
223,67mm)
Location
(612,011mm,
364,528mm,
169,035mm)
AnalysisFigure3.Stressresultantontheram
57
Displacementresultant
Name
Plot2
Type
URES:
Resultant
displacement
Min.
0m
Location
Max.
Location
(7,64491mm, 0.00037465m (489,956mm,
1420mm,
430mm,
19,1071mm)
186,535mm)
AnalysisFigure4.Displacementresultantontheram
58
ListofReferences
GtzWerner(2002),HydraulicsTheoryandApplications,RexrothBoschGroup.
MajumdarS.R.(2003),OilHydraulicSystemsPrinciplesandMaintenance.
EspositoAnthony(2003),FluidPowerWithApplications.
Doddannavar Ravi and Barnard Andries (2005), Practical Hydraulic Systems Operation and
TroubleshootingforEngineers&Technicians
ParrAndrew(2007),HydraulicsandPneumatics
[1](Internet)Availablefrom
http://www.muhendisiz.net/viewtopic.php?t=3464(08.05.08)
http://makinecim.com/index.php?page=az_icerik&bilgi_id=5677#(08.05.08)
http://en.wikipedia.org/wiki/Hydraulic_press(08.05.08)
http://www.chinadasu.com/ey2cs2.htm(12.05.08)
http://www.normanfilters.com/training/training2.html(12.05.08)
http://www.boschrexroth.com/(15.05.08)
http://www.hidrokontrol.com.tr/urunlerimiz.php(15.05.08)
http://hpkon.mmo.org.tr/bildiri/200309.pdf(15.05.08)
59
http://www.asansorhaber.com/makale_oku.asp?id=11(15.05.08)
http://www.wepuko.com/wpeforgingtech1.html(23.05.08)
http://www.swepart.se/(23.05.08)
60
UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES: SS-ISO 2768-1m.
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
DO NOT SCALE DRAWING
REVISION
TITLE:
DRAWN IZZETTIN OSMAN EGUZ

CHK'D
HYDRAULIC PRESS
DANIEL EKMAN
APPV'D
COMP. SWEPART TRANSMISSION AB
Q.A
MATERIAL:
DWG NO.
1030115695
Cast Carbon Steel

1
WEIGHT:
SCALE:1:15
SHEET 1 OF 1
A3
UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES: SS-ISO 2768-1m.
LINEAR:
ANGULAR:
NAME
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
DO NOT SCALE DRAWING
REVISION
TITLE:
DRAWN IZZETTIN OSMAN EGUZ

CHK'D
HYDRAULIC PRESS
DANIEL EKMAN
APPV'D
COMP. SWEPART TRANSMISSION AB
Q.A
MATERIAL:
DWG NO.
1030115697
Cast Carbon Steel

1
WEIGHT:
SCALE:1:15
SHEET 1 OF 1
A3
School of Technology and Design

SE- 351 95 Vxj
Sweden
tel +46 470-70 80 00, fax +46 470-76 85 40
www.vxu.se

Full Text 01

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Full Text 01

Diunggah oleh

Hak Cipta:

Format Tersedia

School of Technology and Design, TD

Hydraulic press construction for fitting the

Vxj, May 2008

Izzettin Osman Egz

Titel och undertitel/Title and subtitle

Abstract (in English)

Antal sidor/Number of pages

Price Pressure Noise

Now the press force has to be calculated

4. Calculation of Piston Parameters

Ppr = Working Pressure ( bar or kg cm 2 )

4.1.1. Calculation for the Group 1

The first pistons pressing diameter is chosen D pr = 82mm .

4.1.2. Calculation for the Group 2

The first pistons pressing diameter is chosen 58mm.

Using the EULER METHOD to calculate the piston rods diameter.

E = 2,1.10 6 kg cm 2 (For steel)

4.2.1. Calculation for the Group 1

4.2.2. Calculation for the Group 2

5. Calculation of Pump Parameters

q = Output flow rate

nvol = Volumetric efficiency

Formula (1) and (2) gives:

Assume that nvol = 0,85 .

Assume maximum velocity on the cylinder is V = 5 mm s = 0,005 m s . The velocity is

5.1.1. Calculation of Pumps Displacement for Group 1 Needed

D p = 1,3446 *10 6 m3 rev

5.1.2. Calculation of Pumps Output Flow Rate

5.2. Calculation for the Group 2:

5.2.1. Calculation of Pumps Displacement for Group 2 Needed

D p = 6,722 *10 7 m 3 rev

5.2.2. Calculation of Pumps Output Flow Rate

Pumps total displacement

D ptotal = (1,3446 + 0,6722) *106

6. Calculation of Electric Motor Power

nhm = Hydraulic Mechanical Efficiency

Assume that n hm = 0,95 .

6.1. Calculation of electric motor power for Group 1 Needed

26,655 *10 6 * 14715000

6.2. Electric Motors Power Calculation for Group 2 Needed

13,33 *10 6 *14715000

6.3. Electric Motor Selection

Total power needed for both cylinders

7. Calculation of Cylinder Parameters

( for DIN 2413 )

7.1.1. Calculation for the Group 1

7.1.2. Calculation for the Group 2

7.2. Calculation of Cylinders Base Thickness

7.2.1. Calculation for the Group 1

It can be assumed S o = 10mm .

qin = Input Flow Rate

(q pump output= q cylinder input Calculated Part 5.1.2.)

qin = 1,6 lt min

qout = 1lt min

7.3.2. Calculation for the Group 2

D pr =58 mm (calculated Part 4.1.2.)

(calculated Part 4.2.2.)

(q pump output= q cylinder input calculated Part 5.2.2.)

qin = 0,8 lt min

q out = 0,59 lt min

8. Calculation of Hoses and Tubes Inner Diameter

q = Pumps Flow Rate ( lt min )

d suc = Suction Hose Inner Diameter (mm)

d rt = Return Line Hose Inner Diameter (mm)

26,655 10 6 14715000

13,33 10 6 14715000