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 Frfattare/Author(s)
VXJ UNIVERSITET
Institutionen fr teknik och design Izzettin Osman Egz
Vxj University
School of Technology and Design

Dokumenttyp/Type of document Handledare/tutor Examinator/examiner

Examensarbete/ Diploma work Izudin Dugic 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 Sprk/Language Antal sidor/Number of pages

2008 English 69

Internet/WWW 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

1.1SwepartTransmissionAB 1
1.2Background 1
1.3Problemdescription 3
1.4Goal 3
1.5Dispositionofthestudy 4
2.BasicsofIndustrialHydraulicSystems 5

2.1Historyoffluidpower 5
2.2Comparisonofhydraulicandpneumaticsystem 6
2.3Advantagesofahydraulicsystem 7
2.4Structureofahydraulicsystem 7
3.HydraulicPressComponents 9
3.1HydraulicCylinders 9
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 2
Figure1.3,VolvoTruckshousing 3
Figure2.1,WorkingprincipleofBramahspress 5
Figure2.4,Abasichydraulicsystemandcomponents 8
Figure3.1a,Acylinderconstruction 9
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 6
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

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
Esposito,2003,page1
2
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 Hydraulics Pneumatics

EnergyCarrier Oil/operational Air
Energytransmission Pipes,hoses,tubes,bores Pipes,hoses,tubes,bores
Conversion Pumps, cylinders, air, Compressors,Cylinders
from/into hydraulic
Mechanicalenergy Motors
Mostimportant Pressurep(30400bar) Pressurep(approx.6bar)
Characteristics Flowrateq Flowrateq
Powerefficiency Verygoodthroughhigh Goodbutrestrictedbecause
operational Oftheoperationalpressureofupto6
Pressure(upto400bar) bar
Precisionofmotion. Verygoodbecauseoilcan Notgoodbecauseairiscompressible
Allsystemsare Hardlybecompressed
mproved
bypositioningaction
TypicalApplication Proccessingparts, Artisanry,mountingdevices,
linearactuation, Fittingout
presses, rotation (great
forces)

Table2.2Basicpropertiesofhydarulicandpneumaticsystems.

Most important characteristics pressure and the other criterias, designate that the best
solutionishydraulicsystemforthepressconstruction.

3
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 .

4
Majumdar,2003,page24
5
Esposito,2003,page69
6
Gtz&Bosch,2002,page8

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
Gtz&Bosch,2002,page10
8
Esposito,2003,page195197

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.

9
Gtz&Bosch,2002,page16

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 1 2 3
Internalgearpump 2 2 1
Vanepump 2 1 1
Radialpistonpump 2 3 2
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
Gtz&Bosch,2002,page32
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
Doddannavar&Barnard,2005,page94
13
Gtz&Bosch,2002,page168

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
Esposito,2003,page378379
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
Majumdar,2003,page5458
17
Parr,2007,page5255
18
Gtz&Bosch,2002,page150

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
ThanktoIlhanAkceylan,engineerattheHrsanPressinTurkey.Heinformedmeaboutthissubject.
20
Majumdar,2003,page87

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
Majumdar,2003,page438439

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
Gtz&Bosch,2002,page161
23
Gtz&Bosch,2002,page161

18

Figure3.5.3.2.bAssemblyofflexiblehoses

Thehosesaremadebysyntheticrubber.Varioustypesofsyntheticmaterialscouldbeused
forhoses.TypesofflexiblehosescanbeseeninFigure3.5.3.2c 24 .

Figure3.5.3.2cTypesofflexiblehosesa,b,cMediumpressured,e,fMediumhighpressure

24
Majumdar,2003,page458459

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
Doddannavar&Barnard,2005,page160
26
Majumdar,2003,page442443

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
75000N
F= F = 7645kg
9,81
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:
F pr
A pr =
Ppr
0,5
4 A pr
D pr =

4.1.1. Calculation for the Group 1

F pr
A pr =
Ppr

8000
Apr = Apr = 53,33cm 2
150
D pr2
0,5
4 A pr
Apr = D pr =
4
0,5
4 * 53,33
D pr =

D pr = 8,162cm = 81,62mm

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

25
4.1.2. Calculation for the Group 2

F pr
A pr =
Ppr

4000
Apr = Apr = 26,66cm 2
150
D pr2
0,5
4 * Apr
Apr = D pr =
4
0,5
4 * 26,66
D pr =

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
2

(
J = d 4 64 )
F=K S K = F *S

26
 4.2.1. Calculation for the Group 1

F= 8000 kg
K = F *S
K= 8000*3 K= 24000 kg

d 4 64 * J
J= d4 =
64

( )
2
K * SK
K = EJ S K
2
2
J=
2E
24000 * 212
J=
2 * 2,1 *10 6

J= 0,51

64 * 0,51
d4 = 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
 4.2.2. Calculation for the Group 2

F = 4000 kg
K = F *S
K = 4000 * 3 K = 12000kg

d 4 64 * J
J= d4 =
64

( )
2
K * SK
K = EJ S K
2
2
J=
2E

12000 * 212
J=
2 * 2,1 *10 6

J = 0,255

64 * 0,255
d4 = 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:

A *V
Dp =
n p * nvol

Assume that nvol = 0,85 .

Gear pumps revolution are generally limited at 1400 rpm.

1400
Assume maximum rotation speed is n p = = 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

A *V
Dp =
n p * nvol

0,005333 * 0,005
Dp =
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

A *V
Dp =
n p * nvol

0,002666 * 0,005
Dp =
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:

q * Ppr
P=
nvol * nhm

Assume that n hm = 0,95 .

Assume that nvol = 0,85 .

kg 9,81 N
Ppr = Working pressure = 150 2
= 150 * 4 = 14715000 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.)

q * Ppr
P=
nvol * nhm

26,655 *10 6 * 14715000

P1 =
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)

q * Ppr
P=
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 ( for DIN 2413 ) [1]
di

d a = 1,7d i

Formulas:
We can calculate thickness from the thin wall container formulation [1]:

da * P * S
So =
200 * G yield

33
7.1.1. Calculation for the Group 1

7.1.1.1. Calculation of Cylinder Tubes Thickness

d i = 82mm (Calculated at 4.1.1.)

1,7d i * P * S
So =
200 * G yield

1,7 * 82 *150 * 2
So =
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. Calculation for the Group 2

7.1.2.1. Calculation of Cylinder Tubes Thickness

d i = 58mm ( Calculated at 4.1.2.)

1,7d i * P * S
So =
200 * G yield

1,7 * 58 *150 * 2
So =
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:
da * P * S
So =
100 * G yield

7.2.1. Calculation for the Group 1

d a = 100mm (Calculated at 7.1.1.2.)

100 *150 * 2
So =
100 * 23
S o = 13mm

7.2.2. Calculation for the Group 2

d a = 71mm (Calculated at 7.1.2.2.)

71 *150 * 2
So =
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

7.3.1. Calculation for the Group 1

D pr = 82mm (Calculated at 4.1.1.)

d = 50 mm (Calculated at 4.2.1.)

D2
X = 2
(
D d2 )
82 2
X =
(
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

qin
q out =
X
1,6
q out =
1,592
qout = 1lt min

36
 7.3.2. Calculation for the Group 2

D pr =58 mm (calculated Part 4.1.2.)

d =30 mm (calculated Part 4.2.2.)

D2
X =
( D2 d 2 )

58 2
X =
(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

qin
q out =
X
0,8
q out =
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 Efficiency(%) Power Factor cos) Moment

Output Speed Weight
TYPE 380V 400V 415V (r/min) 100% 75% 50% 100% 75% 50% Tn Nm Noise
(J) KG
LWdB(A)
kgm2
Kw HP (A) A (Cos) Tst/TN Tmax/TN Ist/TN

380V50Hz Synchronous Speed 3000 r/min (2poles)

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 2.2 2.2 5.5 0.00031 58 4.8
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 2.2 2.2 5.5 0.00060 58 5.1
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 1.26 2.22 2.2 6.1 0.00075 61 6.0
Y2-712-2 0.55 0.75 1.40 1.33 1.28 2740 73 73.0 69.5 0.82 0.76 0.69 1.88 2.2 2.3 6.1 0.00090 61 6.5
Y2-801-2 0.75 1 1.83 1.73 1.68 2840 75 75.7 72.3 0.83 0.78 0.67 2.54 2.2 2.3 6.1 0.00120 64 8.7
Y2-802-2 1.1 1.5 2.58 2.30 2.36 2840 78 80.0 78.2 0.84 0.82 0.72 3.72 2.2 2.3 7.0 0.00140 64 9.5
Y2-90S-2 1.5 2 3.43 2.90 3.14 2840 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
Y2-90L-2 2.2 3 4.85 4.10 4.44 2840 82 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 4 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 88 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
Y2-160L-2 18.5 25 34.0 30.80 31.1 2930 91 90.6 89.6 0.91 0.87 0.80 60.30 2.2 2.3 7.5 0.12400 83 88.5

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 1 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 2 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 3 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 3 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 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

OuterDiameter Wallthickness Weight MaximumPressure

(mm) (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.

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 and Elastic

modulus .

FramewasanalysisedintheCADprogramSolidWorks.Theanalysiswasdonetwodifferent
way.Theloadwasappliedundertheconicramsandsupporterswhichwereplacedonthe
bolster.Theloadwasappliedontheverticalaxis.Whileanalysing,theloadisselectedalittle
biggerthantheworkingloadforreliableanalysis.

54

1.Iftheloadisappliedtothesupporters

Applynormalforce18000Nusinguniformdistributiononeightsupportersfaces.

SafetyFactorwasfoundSF=2,16524withthisanalysis.Soframeisreliableatthisanalysis.

StressResultant

Name Type Min. Location Max. Location

Plot1 VON:von (507,003mm, 1,14615 (727,836mm,
Misesstress 21,168 315mm, 720mm,
176,528mm) 29,107mm)

AnalysisFigure1.Stressresultantonthebolster

55

Displacementresultant

Name Type Min. Location Max. Location

Plot2 URES: 0m (7,64491mm, 0.000497556m (409,499mm,
Resultant 1420mm, 676,8mm,
displacement 19,1071mm) 112,415mm)

AnalysisFigure2.Displacementresultantonthebolster

56

2.Iftheloadisappliedundertheconicramsfaces

Applynormalforce48000Nusinguniformdistributiononthreeconicramsfaces.

SafetyFactorwasfoundSF=3,27924withthisanalysis.Soframeisreliableatthisanalysis.

StressResultant

Name Type Min. Location Max. Location

Plot1 VON:von (659,37mm, 7,56785 (612,011mm,
Misesstress 122,243 637,5mm, 364,528mm,
223,67mm) 169,035mm)

AnalysisFigure3.Stressresultantontheram

57

Displacementresultant

Name Type Min. Location Max. Location

Plot2 URES: 0m (7,64491mm, 0.00037465m (489,956mm,
Resultant 1420mm, 430mm,
displacement 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)

[2](Internet)Availablefrom

http://makinecim.com/index.php?page=az_icerik&bilgi_id=5677#(08.05.08)

[3](Internet)Availablefrom

http://en.wikipedia.org/wiki/Hydraulic_press(08.05.08)

[4](Internet)Availablefrom

http://www.chinadasu.com/ey2cs2.htm(12.05.08)

[5](Internet)Availablefrom

http://www.normanfilters.com/training/training2.html(12.05.08)

[6](Internet)Availablefrom

http://www.boschrexroth.com/(15.05.08)

[7](Internet)Availablefrom

http://www.hidrokontrol.com.tr/urunlerimiz.php(15.05.08)

[8](Internet)Availablefrom

http://hpkon.mmo.org.tr/bildiri/200309.pdf(15.05.08)

59

[9](Internet)Availablefrom

http://www.asansorhaber.com/makale_oku.asp?id=11(15.05.08)

[10](Internet)Availablefrom

http://www.wepuko.com/wpeforgingtech1.html(23.05.08)

[11](Internet)Availablefrom

http://www.swepart.se/(23.05.08)

60

 1 2 3 4 5 6 7 8

A A

B B

C C

D D

UNLESS OTHERWISE SPECIFIED: FINISH: DEBUR AND

DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: SS-ISO 2768-1m.
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN IZZETTIN OSMAN EGUZ

CHK'D DANIEL EKMAN HYDRAULIC PRESS

APPV'D

F COMP. SWEPART TRANSMISSION AB

Q.A MATERIAL:
DWG NO.
1030115695 A3
Cast Carbon Steel
1 2 3 4 WEIGHT: SCALE:1:15 SHEET 1 OF 1
 1 2 3 4 5 6 7 8

A A

B B

C C

D D

UNLESS OTHERWISE SPECIFIED: FINISH: DEBUR AND

DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: SS-ISO 2768-1m.
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN IZZETTIN OSMAN EGUZ

CHK'D DANIEL EKMAN HYDRAULIC PRESS

APPV'D

F COMP. SWEPART TRANSMISSION AB

Q.A MATERIAL:
DWG NO.
1030115697 A3
Cast Carbon Steel
1 2 3 4 WEIGHT: SCALE:1:15 SHEET 1 OF 1
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