FABRICATION OF HYDRALIC BRAKE SHOE RIVETING MACHINE

SYNOPSIS

We decided to make a project on “DESIGN & FABRICATION OF

HYDRALIC BRAKE SHOE RIVETING MACHINE”. It is used for all types
of press working operations, specifically designed for Riveting operation. Other
types of operation like cover mfg. Sheet metal work shops, stamping, riveting,
blanking; washer mfg etc can also be performed just by replacing punch and die.

It consists of two units of hydraulic power pack and Rivet press. Power
pack unit provides high pressurized fluid which is used in cylinder assemblies of
press for effective work. It is a heavy construction; it provides more power
compared to other methods; compact in size. It replaces a large amount of human
effort. The only disadvantage is its less rate of production. But it can be designed
or modified for high precise components as well as for very high capacity jobs.
 INTRODUCTION

Riveting is one the type of permanent fastening. They are generally used to
fasten mental plates and rolled steel section in structural works, such as bridges
and roof trusses and in the construction of pressure vessels such as storage tanks,
boilers, etc., Riveted joints are effective in designs subjected to pronounced
vibration loads.Where welded joints are less reliable. Riveted joints may also be
employed to connect metals which are difficult to weld together and in the joints
which permit no heating in welding due to possible tempering or warming of the
finished machine parts.
The use of rivets and machine riveting has been constantly expanding for
both job-shop and production-line operations.The automotive, electronic
appliances, electronic furniture, hardware, military, sheet metal are among the
many in which riveting is a popular fastening method. This growth in riveting has
occurred because of further refinement of high sped riveting techniques and
because over the years, it is inherent advantages have become more and more
valuable with changes in manufacturing.
OBEJECTIVE OF THE PROJECT
Once the numbers of location of rivets in an assembly are known, the goal is
to set these rivets properly at the lowest in-place-cost and with a satisfactory rate of
return on machine investment. Riveting procedures, types of rivet setting
machines, riveting fixtures, machine layouts and maintenance procedures must all
be established. These factors must consider with respect not only to the particular
riveting job but also over all riveting capabilities and volume requirements of the
assembly plant.
Before any decision can be made on rivet setting procedures certain facts about the
assembly are needed specially. These questions should be answered.
 LITERATURE REVIEW

Manish Kale, 2015 - Most of the manufacturing industries are going for
automation to increase the productivity and to overcome shortage of skill labor.
The purpose of this paper is to reduce the cycle time by replacing drilling machine
and riveting machine by special purpose machine(SPM) for drilling and riveting
operation. The concept is that the plate having different size and thickness are drill
on drilling spindle first and then riveted on orbital riveting spindle. Both the
operation performs on same machine having two separate spindles. In this paper
gives the detail information of design, fabrication and analysis of special purpose
machine and compare the cycle time with conventional method. This machine is
containing automation by using pneumatic system. Modeling is done using CAD
software and analysis by FEA tool. The design is analysed for induced stress on
work piece due to various load condition.
GirishGharat, 2015 - The pneumatic system has gained a large amount of
importance in last few decades. This importance is due to its accuracy and cost.
This convenience in operating the pneumatic system has made us to design and
fabricate this unit as our project. This unit, as we hope that it can be operated easily
with semi-skilled operators. The pneumatic press tool has an advantage of working
in low pressure, that is even a pressure of 6 bar is enough for operating the unit.
The pressurized air passing through the tubes to the cylinder, forces the piston out
whose power through the linkage is transmitted to the punch. The work piece thus
got is for required dimensions and the piece can be collected through the land
clearance provided in the die. The die used in this is fixed such that the die of
required shape can be used according to the requirement. This enables us to use
different type punch dies resulting in a wide range of products. Different types of
punch as requirement can be thus got. According to the work material the operating
pressure can be varied.
P.Goyal, 2015 - This project work deals with the design of pneumatically
controlled small scale punching machine to carry out piercing operation on thin
sheets (1-2 mm) of different material (aluminum and plastic). Reduction in
punching force requirement being the main aim of this project work is obtained by
modification in punch tool design i.e. by provision of shear on punch face.
Subsequently it results in reduction in amount of punching force requirement. And
further a CATIA model of the machine is developed on the basis of calculations
with respect to punching force requirement.
AMIT M. GEDAM, 2014 - In today world, due to advance manufacturing
process and advance machining process the time of production is reduces. Thus the
productivity increases which effect on mass production and batch production. So it
is essentially to products name plate parts to be the manufacture. There are a
variety of crafts for an embossing machine that allow you to create unusual,
signature pieces of artwork. Embossing machines come in several varieties. There
are multi-tasking embossers available at craft and scrapbooking stores that allow
you to embellish and cut card stock and paper pieces into a variety of different
designs in a single motion. You can also use embossing machines that feature
Custom-made thick rubber dyes secured with hand-held or desk-mounted metal
handles. These machines allow you to create personal monogrammed or logoed
designs with a raised surface, and they can be ordered through office and business
supply stores.
INTRODUCTION TO HYDRAULICS

The study of hydraulics deals with the use and characteristics of liquids.
Since the beginning of time, man has used fluids to ease his burden.

1.1) HYDRULIC POWER TRANSMISSION

Hydraulics now could be defined as a means of transmitting power by

pushing on confined liquid. The input component of the system is called a pump;
the output is called an actuator. While for the sake of simplicity we have shown a
single small piston, most power driven pumps incorporate multiple pistons, vanes
or gears as their pumping elements. Actuators are liners, such as the cylinder; or
rotary, such as the hydraulic motor. The hydraulic system is not source of power.
The power source is a prime mover such as an electric motor or an engine which
drives the pump. The reader might ask, therefore, why not forget about hydraulic
and couple the mechanical equipment directly to the prime mover? The answer is
in the versatility of the hydraulic system, which gives it advantages over other
methods of transmitting power.
HYDRAULICS AND FLUID POWER:

Fluid power is the muscle that moves industry. This is because fluid is used
to push, pull, regulate or drive virtually all the machines of modem industries.
Fluid power has the advantages in the following four major categories.
 Easy and accuracy of control.
 Multiplication of forces.
 Constant force or torque.
 Simplicity, safety and economy.

Description of the Work

The horizontal press brake was first introduced by SIMASV in 1957, are
particularly distinguished by their flexibility and versatility. User-friendly and easy
to maintain, the horizontal press brakes can be fitted with countless tools. The
horizontal bending press fits any small to medium-sized industry when machinery
for large-scale production must necessarily make way for machinery with distinctly
lower production costs. The hydraulic pipe bending consists of two series of
horizontal press brakes, the standard series and the super series. Both series have
gone through decades of improvements which is why no other bending press offers
as much value for the investment. One of our biggest improvements was placing
the Hydraulic Jack below the table. After years of producing machines with the
cylinder above the table (which we still produce today upon request) we
standardized on machines with the cylinder below, offering the greatest working
environment, and the most bend accuracy due to less deflection in the table. The
horizontal machine has the following features:
 Cylinder under work table allowing for better accuracy and more work surface;
 User performs operation in front of the machine instead of the side of the
machine making it easier to produce quality products, and frontal position on
our press brakes is protected and practical position for the operator;

 Our patented conical pins with lock-on bayonet fittings eliminate all
mechanical slack as far as tolerance is concerned, providing maximum rigidity
with minimal flexing of work table. This patented feature is why no other
horizontal bending press is as accurate;
 Our super series stroke control is by means of hydraulically controlled stroke
end devices that allows for greater accuracy (compared to limit switch stroke
end control) allowing for continuous movement under pressure, achieving
maximum accuracy and repeatability in position; and much more.
Twenty-five tons is the proper tonnage for approximately 50 % of all
applications out there. The horizontal press brake the operator should start with a
machine no lower than 25 tons if they want to capitalize on a greater amount of
profitable work that can be shifted to the machine. The unique cylinder is under the
table allowing for the perfect flat open work table
Environment that will bring more profit to the end user. This series is a simple
series where the operator controls the stroke in and the stroke back by two hand
wheels. Simplicity means profit. The 45 ton machine is the proper tonnage for 90%
of all applications for a horizontal press brake. For many people who buy or 25 ton
machine soon wish they would have made the small extra investment, because the
45 ton machine covers the biggest spectrum of profitable jobs. The most profitable
machine in line up for the investment made
MATERIALS AND METHODS:

Hydraulic jack consists of piston, piston rod, screw rod and hydraulic oil.
The hydraulic jack reciprocating handle is move upward and downward
continuously, so that the compressed oil goes to the hydraulic jack piston. The end
of the piston rod the moving die is fixed. The compressed oil pushes the hydraulic
jack piston forward. Already the pipe to be bended is fixed in between revolving
die and moving die. The die is supported by the die holders. By changing the die in
the hydraulic pipe bending machine, we have to produce different shape of bended
pipe such as “V” type, “L” type etc. The ram (moving die) is strike the pipe
forcibly, so that the pipe is bended according to the shape of the die in the die
holder. This is a simple pressing mechanism (Degarmo et al., 1997 and Khurmi
and Gupta, 1997). The main components in a portable hydraulic pipe bending
machine are hydraulic cylinder, ram, oil tank, plunger pump, release valve lever,
handle, die, die holder, helical spring and hydraulic drive. Hydraulic systems
possess numerous advantages over other systems of power operation. They are
light in weight; they are simple and extremely reliable, requiring a minimum of
attention and maintenance. Hydraulic controls are sensitive, and afford precise
controllability
Design Details
Design consists of application of scientific principles, technical information
and imagination for development of new or improvised machine or mechanism to
perform a specific function with maximum economy & efficiency .Hence a careful
design approach has to be adopted. The total design work, has been split up into
two parts
 System design
 Mechanical Design.
 System design mainly concerns the various physical constraints and
ergonomics, space requirements, arrangement of various components on main
frame at system, man, machine interactions, No. of controls, position of controls,
working environment of machine, chances of failure, safety measures to be
provided, servicing aids, ease of maintenance, scope of improvement, weight of
machine from ground level, total weight of machine and a lot more. In mechanical
design the components are listed down and stored on the basis of their
procurement, design in two categories namely,
 Designed Parts
 Parts to be purchased
For designed parts detached design is done & distinctions thus obtained are
compared to next highest dimensions which are readily available in market. This
amplifies the assembly as well as postproduction servicing work. The various
tolerances on the works are specified. The process charts are prepared and passed
on to the manufacturing stage. The parts which are to be purchased directly are
selected from various catalogues & specified so that anybody can purchase the
same from the retail shop with given specifications. Materials commonly used for
orbital riveting: The material commonly used for orbital riveting rivet material
includes: Low and medium carbon steel.(C07 or C10), Low alloy steels, Copper,
Aluminum, Light alloys such as Magnesium, Titanium and Beryllium. Material
Selection and their properties: Steel Designation C07, C10 Used for cold forming
and deep drawing. Rimming quality used for automobile bodies, cold heading
wires and rivets. Wrought aluminum alloy 5300, Characteristics: Tensile Strength
215 (N/mm2 ) Ductile in soft condition, but work hardens rapidly, becoming
extremely tough, having high resistance to corrosion attack, especially in marine of
rivets in the product. The setting time for the tool set should be minimum.
2) COMPONNENTS OF HYDRAULIC SYSTEM
Hydraulic system content mainly following parts.
(1) Hydraulic fluids.
(2) Seals and Packing.
(3) Reservoirs
(4) Filter and strainers
(5) Cylinders
(6) Pressure control valve
2.1.1) HYDRAULIC FLUIDS:
Proper selection and care of hydraulic fluids for a machine will have an
important effect on how the machine performs and on the life of the hydraulic
components.
2.1.2) PURPOSE OF THE FLUID
The hydraulic fluid has four primary purposes:
(1) To transmit power,
(2) To lubricate moving parts,
(3) To seal clearance between parts, and
(4) To cool or dissipate heat.

2.1.3) LUBRICANTION:

In most hydraulic component, internal lubrication by the fluid. Pump

elements and other wearing part slide against each other on a film of fluid. For
long component life the oil must contain the necessary additives to ensure high
antiwar characteristics. Not all hydraulic oils contain these additives.
2.1.4) QUALITY REQUREMENTS

In addition to these primary functions, the hydraulic fluid may have a

number of other quality requirements.
Some of these are to:
Prevent rust
Prevent formation of sludge, gum, and varnish
Depress foaming
Maintain its own stability and thereby reduce fluid replacement cost
Maintain relatively stable body over a wide temperature range
Prevent corrosion and pitting
Be compatible with seals and gaskets
Separate out water
These quality requirements often are the result of special compounding
and may not be present in every mind.

2.1.5) FLUID PROPERTIES

let us now consider the properties of hydraulic fluid which enable it to carry
out its primary functions and fulfil some or its entire quality requirement:
Viscosity
Pour point
Lubricating ability
Oxidation resistance
Rust and corrosion protection
2.2) SEALS AND PACKING:

Seals are device for closing gaps to prevent leakage or make pressure tight
joints and also to prevent entry of air and dirt from outside in to the system. A wide
variety of seals of different shapes and material are used. The material of the seal
must be compatible with the fluid medium.

2.2.1) SEAL MATERIALS

Seals are device for closing gaps to prevent leakage of make pressure tight
joints and also the prevent entry of air and dirt from outside into the system. A
wide verity of seals of different shapes and material are used Synthetic rubbers
(elestomers), however,
are the most part quite compatible with oil. Elestomer can be made in many
compositions to meet various operating condition. Most of the hydraulic equipment
seals today are made of one of these elastomers: Nit rile (Buna-N), chloroprene
(Neoprene) Teflon.ERP/EPDM (also known as EPM),of silicon.

2.2.2) PREVENTING LEAKAGE

Three general considerations in preventing leakage are:
1. Design to minimize the possibility (back, gasket of sub-plate mounting)
2. Proper installation.
3. Control of operating conditions.

2.2.2.1) OPRATING CONDITIONS

Control over operating conditions can be very important to seal life. A
number of factor that can help prevent leakage are discussed below.
Contamination prevention: An atmosphere contaminated with moisture, dirt or
any abrasive material shortens the life of shaft seals and a piston rod seal exposed
to the air. Protective device should be used in customized atmosphere. Equally
important clean fluid and proper filtration to avoid damage to internal seals and
surfaces.

Fluid Compatibility: Some fire-resistance fluid attack and disintegrate certain

elastomer seals. Few seals, in tact, are compatible with all fluids. The fluid supplier
should always be consulted when in doubt whether the change seals when in
change in made in the type of fluid. Fluid additives (added by the machines user)
also may attack seals and should be used only at the recommendation of the fluid
supplier.

Temperature: At extremely low temperature, a seal may become too brittle to be

effective. At too high a temperature, a seal may harden, soften, or swell. The
operating temperature should always be kept well within the temperature range of
the seals being used.

Pressure: Excess fluid pressure puts an addition strain on oil seals and may “blow”
a seal causing a leak. Lubrication: no seal should ever be installed or operated dry.
All must be lubricated prior to installation or the seal will wear quickly and leak.

2.3) RESERVOIRS
The main function of the reservoir in a hydraulic system is to store arid
supply hydraulic fluid for use by the system. The section discusses this and other
reservoir function such as heat exchange and desertion.
2.3.1) FUNCTION OF A RESERVOIR

Since, in addition to holding the system fluid supply, a reservoir can also
reserve several secondary functions, some system designer feel that the reservoir is
the key to effective hydraulic system. Some examples of these functions are
discussed below. By transferring waste heat through its walls, the reservoir acts as
the heat exchanger that cools the fluid within. As the deaerator, the reservoir allows
entrained air to rise and escape while solid contaminants settle to the bottom of the
tank. Making it a fluid conditioner. These are function that can also be provided to
the system by methods that do not involved the reservoir. In some instance, the
reservoir may be used as a platform to support the pump, motor, and other system
components. This saves floor space and is a simple way to keep the is a simple way
to keep the pumps and valves at the good night the servicing.
2.3.2) RESERVOIR COMPONENTS

A typical industrial reservoir is constructed of welded steel plate with end-

plate extension that support the unit. To reduce the chance of condensed moisture
within the tank causing rust, the inside of the reservoir is painted with a sealer that
is compatible to the fluid maintenance, a plug placed at the low point on the tank to
allow completed drainage. The various components that make up a reservoir are
follows.
(1) Oil level gauge
(2) Breather assembly
(3) Filler opening
(4) Clean-out plates
(5) Baffle plate
(6) Line connection and fittings
2.3.3) RESERVOIRE SIZING

A large tank always desirable to promote and separation of contaminants. At

a minimum, the tank must store all the fluid the system will required and maintain
and high enough level to prevent a whirlpool effect at the pump inlet opening. It
this occurs. Air will be taken in with the fluid. When determining reservoir size, it
is important to consider the following factors: Fluid expansion caused by high
temperature. Changes in fluid level due to system duration. Exposure of the tank
interior to excess condensation. The amount of heat generated in the system.

2.4) HOW TO SPECIFY FILTERS

Specifying the correct filter of strainer for a given application requires

consideration of several important factors, including: the minimum size of particles
to be trapped, the quality or weight of the particles to be held, the flow rate
capacity, the type of filter condition indicator providing, the pressure rating, the
pressure drop through the filter element, and the filter’s compatibility with system
fluid.
2.4.1) FILTER OR STRAINER

There will probably always be controversy in the industry over the exact
definition of filter and strainers. In the past, many such devices were named filters,
but technically classed as strainers. To minimize he controversy, the national fluid
power association gives these definition:
FILTER:
A device whole primary function is the retention, by some porous medium,
of insoluble contaminants from a fluid. STRAINER: A course filter, to put it
simply, whether the device as a filter or strainers, its function is to trap
contaminants from fluid flowing through it. “Porous medium” simply refers to
screen or filtering material that allows fluid to flow through it. “Porous medium”
simply refers to a screen or to filtering material that allows fluid to flow through it.
But stops other materials.

2.5) HYDRAULIC CYLINDER

The focus of this topic is on the output member or actuator, a device for
converting hydraulic energy in to mechanical energy. Two types of hydraulic
actuators are cylinder or motors. The type of job done and its power requirements
determine the correct type and size motor or cylinder for an application. Cylinder
and liner actuators. This means that the output of the cylinder is a straight-line
motion and/or force. The major function of the hydraulic cylinder in to convert
hydraulic power in to liner mechanical power.
2.5.1) TYPES OF CYLINDERS

Following are the main types of cylinder.

(1) Single Acting Cylinder
(2) Ram
(3) Telescopic Cylinder
(4) Spring Return
(5) Double acting cylinder
(6) Double Rod Cylinder
(7) Tandem Cylinder
2.5.1.1) DOUBLE ACTING CYLIDER

The double-acting cylinder is the most common type in industrial hydraulic.

Hydraulics pressure is applied is port, giving powered motion when extending or
retracting. Basic double-acting cylinder. The majority of cylinders is use are basic
double acting cylinders. These cylinder are classed as differential cylinder because
there are unequal area exposed to pressure during the extend and retract
movements. The different is caused by the cross-sectional area of the road which
reduced area of the road which reduced the area under pressure during retraction.
Extension is slower than retraction because more fluid is required to fill the swept
volume of me piston. However greater force is possible because the pressure
operates on the full piston area. When retracting, the same flow from a pump
causes faster movement of the cylinder because the swept volume is less. Which
the same system pressure, the maximum force exerted by the cylinder is also less
because of the smaller area under pressure.

2.6) DIRECTIONAL VALVES

As the same name implies, directional valves start, stop, and control the
direction of fluid flow. Although they share this common function, directional
valves very considerably in construction and operation. They are classified
according to principal characteristic such as those listed below.

Type of internal valuing element- poppet, rotary spool, or sliding spool.

Method of actuation- manual, mechanical, pneumatic, hydraulic, electrical, or
combinations of these.
Number of flow path- two-way, three-way, and four-way. Sizenominal size of port
or flange connection to the valves or its mounting pattern.
Connection- pipe thread, straight thread flange and subplate, or manifold mounted.

2.6.1) DIRECTION CONTROL VALVES

These valves are deployed to steer the flow selected flow paths to any part of
a hydraulic circuit. The spool types valves both of the liner as well as the rotary
movement are advised for the purpose. Rotary type directions of these valves are
commonly seen as applied to machine tool table reversals. These valves are
operated either on AC or DC. The AC operated valves have a drawback in they
tend to burn to due to flow through the valves and fast response of direction control
of solenoid valves are that important requirement of direction control valves.
Solenoid valves can function satisfactory at frequencies as high as 1500-2000
operation an hour.

2.6.2) CHECK VALVES

In its simplest form, a check valves in a one-way directional valve. It allows

free flow in one direction, while blocking flow in the other direction. The graphic
symbol for a check valve is a ball and sheet. A light spring, usually equivalent to 5
psi, holds the poppet in the normal closed position. Other spring pressures are
available to suit application requirement. In the free flow direction, the poppet
cracks open at the pressure equivalent to the spring rating, allowing fluid to pass
through the valves.
2.7) PRESSURE CONTROL VALVES

Pressure control valves perform function such as limiting maximum System

pressure or regulating reduced pressure in certain portion of the circuit, and other
functions where in there actuation is result of a change in operating pressure. Their
operation is based on balance between pressure and spring force. Most are infinite
positioning that is; the valves can assume various positions fully closed and fully
open, depending on flow rate and pressure differential. Pressure control are usually
named for their primary function, such a relief valve, sequence valve, break valve,
etc. they are classified by size pressure operating range, and type of connection.

2.7.1) RELIEF VALVES

The relief valve is found in virtually every hydraulic system. It is normally

closed valve connected between the pump outlet and the reservoir. Its purpose is no
limit is to limit pressure in to system to a pressure setting is reached.
(1) Direct Acting Relief Valves
(2) Pilot Operated Relief Valves
(3) Electronically Modulated Relief Valves
(4) Pilot Operated Sequence Valve
(5) Unloading Relief Valve
 TERMINOLOGY OF PUNCHING MACHINE

Introduction:
Punching machine type of cold working process in which punching done by
the punch machine tool and die designed to hole the sheet metal by applying
mechanical force or pressure. The punch governs the size of the hole and the
clearance is provided on the die.
(1) Punch: It is the male member of the unit and kept as small as possible
consistent with required strength and rigidity. The punch made of the hard, wear
resistance metal and is finally ground to the predetermine size providing just
opium clearance between the punch and die.
(2) Punch retainer of punch plate: It fits closely over the body of the punch and
holds it in a proper relative position. The retainer is turn to bolt to the punch holder.
(3) Punch holder: It provided a wide plate surface which face against the lower
end of the press ram and is anchored to it with help of the shank which is an
integral part of the punch holder shank exactly fits in to the ram opening, to help in
properly positioning and aligning the punch holder is made of cast steel.
(4)Backing plate: Whenever the punch is headless a hardness steel backing plate is
introduced between the back of the punch holder so that intensity of pressure does
not become excessive on the punch holder. Backing plate distribute the pressure
over wide area and intensity of the pressure on the punch holder is reduced to
avoid crushing.
5) Die Block: it is female working member & is kept as small as possible
consistent with required strength. It is also made of hard, wear resistant metal and
finish ground to predetermined size and tolerance.
6) Die retainer: Just like the punch retainer, the die retainer also holds the die
block at proper position with respect to punch. The retainer is mounted on the die
shoe or holder. In certain die shoe it self serves as a retainer for the die block the
block is then mounted directly on to die shoe.
7) Die shoe: Die shoe assembly consisting of die block and die. These in turn
bolted or clamped to the bolster plate.
8) Guide posts and bushing: the punch and die makers once properly located
aligned are held in aligned are held in alignment by means of guide post and
bushing which resist movement or deflection of die members as operating pressure
increase guide post and bushing are part of the commercially available punch and
die holders.
9) Stripper and stripper plate: When the punch has completed its downward
movement and start returning, the scrape strip tries to go up along with it. The
stripper plate prevents this upper movement of scrape stripes and frees and
punches of these for next stroke.
10) Stock stops & Stock guide: Fixed type of stripper sometimes are used to
guide the stock are also where as stock stops locate the work material at a suitable
position in relation to previously blanked surfaced in preparation to the next
downward movement of the punch.
11) Bed: The bed is the lower part of a press frame that serves as a table to which a
bolster plate is mounted.
12) Bolster plate: This is thick plate secured to the press bed, which is used for
locating and supporting the die assembly. It is usually 5 to 12.5 cm thick.
13) Die set: It is unit assembly, which incorporates lower and upper shoe, two or
more guidepost and guidepost bussing.
14) Die: The die may be defined as a female of a complete part of a complete tool
producing work in press. It also referred to a complete tool consisting of a pair of
mating members for producing work in a press.
15) Lower shoe: The lower shoe of a die set is generally mounted on the bolster
plate of a press. The die block is mounted on the lower shoe. Also, the guideposts
are mounted in it.
16) Upper shoe: This is the upper part of the die set, which contains guidepost
bushing.
17) Knockout: It is mechanism, usually connected to and operated by a press ram,
for freeing a work piece from a die.
18) Pit man: It is connecting rod, which is used to transmit motion the main drive
shaft to the press slide.
19) Shut height: It is distance from top of the bed to the bottom of a slide, with its
stroke down and adjustment up.
20) Stroke: The stroke of a press is the distance of ram its up position to its down
position. It is equal to twice the crankshaft and eccentric drives but it is Variable on
the hydraulic press.

WORKING PRINCIPLE
 Here we are placing the hydraulic bottle cylinder on the based plate, and the
pressing tool is fixed in the hydraulic piston rod end. The working table is placed
on the top of the supporting frame. It can be adjusted according to the work piece
height by adjusting the lock nuts which is placed at the either side of the work
table. The hydraulic bottle cylinder is working with the help of supply of oil from
the pumping rod side. Here we have to tight the pressure relief valve then to start
pumping with help of pumping rod by pumping, the oil will supply to push the
piston upward direction by this pressing tool will move through it to pressing the
workpiece. By the completing the bending process we have to release the pressure
relief valve then the piston comes it original position.
POWER PACK:

The main objective of power pack is to produce high pressurized fluid which
is used to activate the cylinder. The oil form reservoir is pumped with high
pressure with the help of motor. Oil from the pump enters the DCV through PRV
(Pressure Relief Valve).When the lever was towards the operator if the circuit
pressure exceeds the specified limit it flows in to the tank or else it flows to the
cylinder for downward stroke. Oil below the piston enters the reservoir through
DCV for upward stroke vice versa in neutral position oil from the pump is diverted
into the through DCV.

Riveting machines

Riveting machines are used to automatically set (squeeze) rivets in order to

join materials together. The riveting machine offers greater consistency,
productivity, and lower cost when compared to manual riveting.

Automatic feed riveting machines include a hopper and feed track which
automatically delivers and presents the rivet to the setting tools which overcomes
the need for the operator to position the rivet. [1] The downward force required to
deform the rivet with an automatic riveting machine is created by a motor and
flywheel combination, pneumatic cylinder, or hydraulic cylinder. Manual feed
riveting machines usually have a mechanical lever to deliver the setting force from
a foot pedal or hand lever.
 Riveting machines can be sub-divided into two broad groups — impact
riveting machines and orbital (or radial) riveting machines.

APPLICATIONS

HYDRAULICS APPLICATION
Oil hydraulics are power transmitted system employing pressurized liquid
(oil) to transmit energy form an energy generating source to on energy use area.
Hydraulic fluid power system is excellent for infinitely variable speed precise
control of an applied force and instant reversibility in linear and rotary application.
Application of hydraulic bending is for bending pipes for various size,
lifting, hydraulic rams for moving or compressing material hydraulic press for
drawing or forming material hydraulic elevator for transporting people or fright
vertically and hydraulic operation and control for machine tool. Other areas of
application are:

1. In machine tools like planners etc.

2. Hydraulic transmission (Presses)
3. Earth moving equipment planners etc.
4. Material handling equipment
5. Hydraulic pumps for power transmission in injection
molding M/C etc.
ADVANTAGES

Its advantage over conventional systems are listed below

1. Variable speed:
-Possible by controlling the flow of fluid using flow control valves.
2. Reversible:
 -This is done by direction control valves.
3. Overloading protection:
-A pressure relief valve / unloading valve / reducing valve protect whole
system components from overloading.
4. Compact:
-Because of high speed and pressure capabilities they have a very small
weight to power output ratio.
5. Predictable performance:
-Losses are minimum due to less number of moving parts and so gives
expected performance.
6. Self automated lubrication:
-The oil, which is used in the system also, acts as a lubricator.

7. Noise vibration control:

-Due to elegant and simple control systems, it does silent operation and no
vibration is produced.

8. Longer life
9. Flexibility
10. Efficient and dependable.
11. Simple installation.
12. Easy maintenance.

LIMITATIONS
1. Since the hydraulic fluid is transmitted through pipelines under pressure, there
is a greater possibility of leakage.
2. Leakage is always there, which makes the machines ugly and dust and dirt are
adhering to them.
3. Leakage is always there, which makes the machines ugly and dust and dirt are
adhering to them.
4. The life of the parts, like seals, packing and gaskets etc., are very short. But
they are essential to prevent leakage.
5. The oil cost is fluctuating and hence the system becomes costlier.

REFERENCES

Colliers Encyclopaedia, Manuf acturing Processe, 1997. Kalpakjian, 1997. Serope,

Manufacturing Processes for
Engineering Materials, Add ision Wesley, USA, Edition 3.

Acherkan, N., 1973. Machine tool design, Vol. 3, Mir Publications, Moscow,
Russia

Beer, F.P. and Johnston, E.R., Jr. 1992. Mechanics of Materials. 2nd edition,
McGraw-Hill, London, England, UK
Dagwa, I.M. and Ibhadode, A.O.A. 2005. Design and manufacture of automobile
disk brake pad test rig,

Nigerian Journal of Engineering Research and Development, 4(3): pp 15-24

Degarmo, E.P., Black, J.T. and Kohser, R.A. 1997. Materials and processes in
manufacturing. 8th edition, Prentice-Hall of India, New Delhi, India, pp 546-52

Khurmi, R.S. and Gupta, J.K. 1997. A textbook of machine design, Eurasia
Publications, New Delhi, India.

Lange, K. 1975. Handbook of metal forming, McGraw-Hill, New York, NY, USA.