MHYDRAULICALLY OPERATED BUSH BEARING

PULLER

Submitted in the partial fulfillment of the requirement for the award of

DIPLOMA

IN MECHANICAL ENGINEERING (FOUNDRY)

SUBMITTED BY:

1. G.K. MANIGANDAN
2. B. KARTHIKEYAN
3. P. BALASUBRAMANI

4. J. DHANAJEYAN
5. D. DURAIVEL
6. L. PRABHU

Under guidance of
Mr. V.K. RAJENDRAN,M.E.
OCTOBER 2007.
DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY)

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 602 103

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 602 103

BONAFIDE CERTIFICATE
This is to certify that this Project work on

HYDRAULICALLY OPERATED BUSH BEARING PULLER

submitted by . Reg. No.
in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING(FOUNDRY)
This is the bonafide record of work carried out by him under our supervision
during the year 2007
Submitted for the Viva-voce exam held on ..

HEAD OF THE DEPARTMENT

INTERNAL EXAMINER

PROJECT GUIDE

EXTERNAL EXAMINER

ACKNOWLEDGEMEN
T

ACKNOWLEDGEMENT
At the outset, we would like to emphasize our sincere thanks to the
Principal Mr. R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement
and valuable advice.

we thank our Esquired Head of Department Mr R. RAJKUMAR,

A.M.I.E, M.E., for presenting his felicitations on us.
We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E.,
for guiding in various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the
Mechanical Engineering (MTMR) Department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CONTENTS
Chapter No.

TITLE

1.

INTRODUCTION

2.

SYNOPSIS

3.

CONSTRUCTION

4.

WORKING PRINCIPLE

5.

DESCRIPTION OF PNEUMATIC
COMPONENTS

6.

PNEUMATIC CIRCUIT DIAGRAM

7.

MECHANICAL SPARE PARTS DETAILS

8.

ELECTRICAL PARTS DETAILS

9.

ELECTRICAL CIRCUIT DETAILS

10.

FINISHING AND PAINTING

11.

COST ESTIMATION

12.

CONCLUSION

13.

BIBILOGRAPHY

INTRODUCTION

INTRODUCTION
This is a self assessment test on the part of the students to assess his
competency in creativity.
During the course of study, the student is put on a sound theoretical
foundation of various mechanical engineering subjects and of course, to a
satisfactory extent. Opportunities are made available to him to work on
different kinds of machines, so that he is exposed to various kinds of
manufacturing process.
As a students learn more and more his hold on production technology
becomes stronger. He attains a stage of perfection, when he himself is able
to design and fabricate a device.
This is the project work. That is the testimony for the strenuous
training, which the student had in the institute. This assures that he is no
more a student, he is an engineer.
This report discuses the necessity of the project and various aspects of
planning , design, selection of materials, fabrication, erection, estimation and
testing.

SYNOPSIS

SYNOPSIS
A Hydraulically operated bush bearing puller is a device
which enables the single persons to operate it alone and removes
the bearing the from machine parts . No special skill is needed to
operate or remove the bush bearing form the machine parts. It can
widely used. It is easy to fit on the operate or remove the bearing
from the machine parts..
This device is worked by the principle of hydraulic lifting system to exert
the pulling power to remove the bearing from the machine blocks. This is
operated by hydraulic power without use of man power.
. As the bottom flange has a hole which is set below the bottom portion of
the bush bearing in the machine block, makes to provide grip for pulling
the bush bearing. Through this bottom flange hole a screw rod inserted . he
other end of the screw rod is connected to the top flange which is moving
towards upward direction by the action of hydraulic jack.

If we lift the jack, the top flange pulled the centre rod. So the centre rod
rises with bottom flange gradually with the liner. Thus the liner is removed.

CONSTRUCTION

CONSTRUCTION

This unit consists of

a) M.S. Fabricated stand
b) Hydraulic jack and
c) Handle
A ) M.S .FABRICATED STAND ;
This stand is used to hold the hydraulic jack and support guide plate. The
liner to be remove is placed at the bottom of the support .

HYDRAULIC JACK
A Hydraulic Jack is a device using Hydraulic Power in its simplest possible
shape shown in figure and consists of five fundamental components.
1. pump

2. reservoir
3. cylinder
4. suction valve and
5. delivery valve

WORKING PRINCPLE

WORKING
PRINCPLE

WORKING PRINCPLE

This device is worked by the principle of hydraulic lifting system to

excert the pulling power to remove the bush bearing from the machine
blocks. This is operated by hydraulic power without use of man power. As
the bottom flange has a hole which is set below the bottom portion of the
bush bearing in the machine block, makes to provide grip for pulling the
bush bearing. Through this bottom flange hole a screw rod inserted . he other
end of the screw rod is connected to the top flange which is moving towards
upward direction by the action of hydraulic jack.
If we lift the jack, the top flange pulled the centre rod. So the centre rod
rises with bottom flange gradually with the bush bearing. Thus the bush
bearing is removed.

HYDRAULIC JACK
A Hydraulic Jack or for that matter any device using Hydraulic Power
in its simplest possible shape consists of five fundamental components.

A. The Hydraulic Reservoir storing the Hydraulic Oil (Oil is used as the
medium to transmit force and motion-such fluids are called Hydraulic
Oils) should be thoroughly clean, whether integrally built-in or used
as a separate tank.

B. Pump, either of the integral or the remote control type, comprises of

highly precision engineered pump plunger, cylinder, suction and
delivery valves, safety valves with conical or steel balls matched with
micron tolerances. Very often O Rings and special seals are used,
made from specially treated leather or synthetic nitrile rubber or
Teflon or other modern substitutes for greater resistance to wear and
sealing ower.

It is imperative that these must function at peak efficiency by regular

cleaning and flushing of foreign particles which enter into the
hydraulic system and may clog the delicate valves, damage the seals
and affect the functioning of other elements in the hydraulic circuit.

C. A pump by itself would be useless without a system of VALVES to

govern the flow of hydraulic oil to perform the desired function.

D. The transmission of hydraulic oil from the reservoir by the pump

through the valves to Ram & Cylinder which converts the hydraulic
pressure into a mechanical force is by means of a Hydraulic Circuit
which is nothing but a network of passages in hydraulic systems.
These passages are formed with the help of Steel Tubes, Flexible
Hydraulic Hoses or through internal holes or cavities in metal blocks.
It is of the utmost importance that the circuit is always leak proof as
well as free from obstacles. Each joint or coupling must be securely
tightened or replaced forthwith.

No air lock or foreign particles

should be allowed to interrupt or block the free flow of hydraulic oil.

E. All hydraulic cylinders consists of two basic elements the outer

housing is called the Cylinder body and the inner sliding elements is
called the Ram (or piston or plunger) which actually converts the
hydraulic pressure into mechanical force and transmits to the desired
point for performing the function. The movement of Ram is always in
line with cylinder under pressure.

Hydraulic Oil is pumped into the cylinder and as more and more oil is
forced into the cylinder pressure builds up and when enough oil is
forced into the cylinder the resultant pressure will cause the ram,
plunger or piston to move and consequently lift, press, push, pull or
bend any object any object as the case may be.

The Ram and Cylinder are also precision engineered and mostly fitted
with high quality seals which give it the necessary compression
holding capacity and prevent leakages.

The five fundamental components already illustrated and described

combined together perform the specified job by a synchronous follow
through of their individual functions.

1. The release valve is closed tightly to ensure flow of oil from the pump
to the cylinder only.

2. As soon as the pump is operated oil is sucked in from the reservoir.

As the Pump Plunger is raised up oil passes from the reservoir into
the pump cylinder with the Suction Valve opening up to allow oil from
reservoir to enter into pump cylinder.

3. When the Pump Plunger is pressed down the Delivery Valve opens up
to allow the passage of oil from the pump into the cylinder, at the
same time the suction valve automatically closes to prevent oil
returning to the reservoir.

4. By repeating the above two operations successively more and more oil
is pumped into the cylinder resulting in the generation of pressure by
the action of the load being lifted.

5. When the load is desired to be lowered the pressure within the

cylinder is released by operating the Release Valve. The oil flows
back into the reservoir shown in the diagram in page 1.

6. Due to neglect or other causes pressure within the system may

continue to increase beyond the predetermined safe working limit. To
prevent damage to the system a safety relief valve is located between
the cylinder and the reservoir excessive pressure by the opening up of
the safety valve and discharge of oil into the reservoir (very often the
safety overload preventive relief valve is located in between the
reservoir and the pump the pump automatically cuts off without
delivery of oil to the cylinder due to generation of excessive pressure
within the pump).

The simple diagram shown in page 1 shall help to understand the

working of the hydraulic system in a more graphic manner.

APPLICATIONS

APPLICATIONS

By using this device many numbers of cylinders bearings are

removed.removing.

It is very much useful in repairing automobile

workshops and electrical motor and pump repair shop.

Any other type or size of cylinder bush bearings can be removed by

varying the dimensions of bottom flange relative to the dimension of the
bearings to be removed. Thus it can be useful for the following types of
bush bearings in
i)

Generators coupled centrifugal pump

ii)

Oil Engines and to other engines.

ADVANTAGES

ADVANTAGES

1. Single person is enough to operate this efficiently to remove bearings.

2. Easy and efficient handling of liner puller without wastage or damage
to the puller, machine block and to any other parts.
3. Increase the bearing life.
4. Least maintenance of the equipment.
5. Need not require any individual work place.
6. Can be worked in the work spot.
7. Suited for removing bearing in oil engine generators.

MECHANICAL
SPARE PARTS
DIAGRAM

SAFTY,CARE AND
MAINTENANCE

BASIC SAFETY RULES FOR HYDRAULIC JACKS;

The nature of lifting operation should determine the choice of jacking
equipment-integral or remote control pump type jacks. Capacity and the
hydraulic lifting stroke are vital aspects to be carefully determined before
selection.

Lifting any load calls for precise and safe jacking points. Jack should be
centrally loaded eccentric loading causes dangerous accidents and damages
beyond repair.

The world over prudent safety minded operators observe the flowing basic
safety rules :

A. To overpower the load, whether one or a dozen cylinders are used to lift
the load, the cylinder lifting capacity should be two times the weight of

the load. This allows for a reduction in the oil pressure, prevents strain
and possible break-down of the cylinder.

B. To balance the load, for large, heavy and uneven loads, it is

recommended dividing the load evenly between a number of cylinders.
These cylinders should be placed beneath the load at points providing the
best support, balance and stability. For example, to lift a 200-tonns load,
the necessary 400-tonnes capacity could be handled by four 100-tonnes
cylinders.

C. Never raise the hydraulic ram beyond the specified stroke (lift).

D. Never drop (shock) load on the hydraulic ram.

E. Never go under a load supported by hydraulic ram only.

F. Never extend the hydraulic ram by means other than the pump.

G. Never use hydraulic equipment with observed leakages.

H. Use safety lock nut type jacks for supporting load on jack for long
periods.

I. Use steel plates or heavy wooden sleepers where ground surface is soft
and yielding

J. Do not disturb the factory preset internal safety valve provided for
preventing overloading.

K. Do not load more than 50% of the rated head capacity on the toe (claw)
of toe lifting jacks.
Positioning the Jack
Jack should be centrally loaded, jack base and upper jacking point must be
in level.

Raising the Jack

Turn the release valve in clockwise direction till tight, use end of slotted
operating handles. Start pumping with a regular handle movement. Make
only few fast and rapid download delivery strokes, Jack handle slightly
downward, in case the delivery does not close instantly. Check that the
saddles rests firmly against the Jacking point.

Lowering the Jack

Turn the release valve SLOWLY anticlockwise.

Jack Storage
Retract ram completely, close oil filler, keep the Jack away in a safe clean
place.

Caution
Do not use the Jack beyond rated capacity and lift mentioned on the name
plate.

Making Jack ready for use

VANJAX Hydraulic Jacks are supplied ready for use. Unlock the release
valve half a turn and operate the pump few times to flush the hydraulic unit
free from airlocking.

DOS AND DONTS

Air

Dos
venting is an

precaution

for

the

important Under

no

Donts
circumstances

the

successful equipment should be used beyond

performance of any hydraulic jack rated capacity or rated stroke. It is

or hydraulically operated device, in the interest of the user and for the
equipment or system.

protection of his costly equipment to

ensure correct selection of the
capacity and restricting the stroke

within the rated stroke length.

All couplings and other fasteners Do not forcibly hammer
should be properly tightened.

fit

accessories if falling short by a

fraction of the required length or
spread.

Use the next higher size

equipment.

Abuse of accessories

and attachments are hazardous both

for the equipment and the personnel.

At all times the entire equipments Do not expose the equipment to

should be kept free from dust areas of excessive heat or where dirt,
through regular systematic cleaning.

dust and heavily laden fumes /

smoke

are

prevalent.

If

the

equipment is used in such areas it is

absolutely essential to service it at
once.
Check oil level each time before Do not refill without a reliable
use.

strainer

Every time the hydraulic hose is Do not use brake fluid as refill.
attached to the pump and the ram
cylinder assembly unit, it should be
thoroughly flushed.
Release

valve

to

be

properly Do not hammer to open guide nuts.

tightened by turning it in clock-wise Open by guide nut spanner.

direction when applying load. For
releasing

pressure

open

release

valve gradually by turning it in anticlockwise direction.

The equipment must be centrally

loaded. The pressure screw in a
hydraulic
puller
should
be
absolutely perpendicular to the axis
of the load.
As refill we recommend IOC Code
No. Servo System 32 and 46, HPC
Hydrol 0232 or any other
equivalent.

Do not apply extra force to close the

release valve.
Normal hand
pressure is enough.

Do not use fluffy cloth or cotton

waste for cleaning cylinder ram,
valve, pump and oil tank.

VANJAX cannot be held responsible for damage or injury caused by unsafe

use, maintenance or application of its products.

PAINTING AND
FINISHING

FINISHING AND PAINTING

JOB PREPARATION
Before welding, remove any bend in the L angle with the sludge
hammer on the anvil block. Then it is cut to the required length with the
hacksaw blade and fabricated to required dimensional shape with arc
welding.

FINISHING OPERATION BEFORE PAINTING

After welding, any slag on the welded area is removed with the
chipping hammer and cleaned with the metal wire brush. Then all the
surfaces are rubbed with the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the
metal primer, the second coating is applied with the paint.

COST ESTIMATION

COST ESTIMATION

1.Work holding support and pulling rod

800,00

2. hydraulic jack

3800.00

3 . M.S. Fabricted housing unit

600.00

5. Painting cost

200.00

6. transport cost

200.00
TOTAL COST

5600.00

CONCLUSION

CONCLUSION
We make this project entirely different from other projects. Since
concepts involved in our project is entirely different that a single unit is used
to various purposes, which is not developed by any of other team members.
By doing this project we gained the knowledge of fabrication work
and how the welding is doing and material selection for particular
components etc.,
It is concluded that any fabrication work can be done with the help of
welding.
We have successfully completed the project work on using welding
work at our Institute.

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY

-HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY

-R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY

-S.S.MANIAN

4. JIG AND FIXTURE DESIGN

- R.K.JAIN

PHOTO VIEW

PHOTO VIEW