HYDRAULIC BENCH PRESS

FINAL DESIGN REPORT

FOR P2

VAAL UNIVERSITY OF TECHNOLOGY

Faculty of Engineering

Department

Of

Mechanical Engineering

MAKHURUPETSI TD 215196279

KHANDA AUTOMOTIVE ENGINEERING

30 NOVEMBER 2018

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 CONTENTS
List of tables....................................................................................................................................3
List of Charts...................................................................................................................................3
INTRODUCTION...........................................................................................................................4
IDENTIFICATION OF PROBLEM...........................................................................................4
STATEMENT OF THE PROBLEM...........................................................................................4
SUBPROBLEM 1 (MATERIAL SELECTION).........................................................................5
SUBPROBLEM 2 (MACHINE DIMENSIONS)........................................................................5
AIM OF THE PROJECT.................................................................................................................5
DESIGN LIMITATIONS................................................................................................................6
ASSUMPTIONS MADE.................................................................................................................6
BACKGROUND.............................................................................................................................7
MATERIAL SELECTION..............................................................................................................7
FLUID SELECTION.......................................................................................................................9
DESIGN SKETCHES...................................................................................................................10
CALCULATIONS.........................................................................................................................12
IMPLEMENTATION OF IDEA...................................................................................................15
RECOMMENDATIONS...............................................................................................................15
CONCLUSION..............................................................................................................................16
REFERENCES..............................................................................................................................17

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List of tables

Table 1: Material Properties ……………………..……………………………………………7

Table 2: Stainless Steel Properties ……………………………………………………………8
Table 3: The oil viscosity chart ……………………….………………………………………9

List of Charts

Figure 1: Preliminary Frame for the hydraulic Bench…………..…………………………….10

Figure 2: The final drawing of the hydraulic bench press.…….......………………………….11
Figure 3: Bending Moment and Shear Force graph……………………………….…….....….13
Figure 4: Slope and Deflection graph……………………………………………………........14

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INTRODUCTION
Diesel engines are the core of the locomotive industry. A lot of vehicles trucks, trains and ships
use this engine to propel motion. It was first discovered by Rudolf Diesel in the mid-18th
centuries. It has become so popular because of its reliability and low fuel consumptions and gas
emissions.

Over time engine sleeves wears off due to friction between them and the engine pistons and need
to be replaced. The sleeves are so tightly fitted that they cannot slip when the engine is running
and wear off quickly. At the production plant, the workshops have facilities which install these
sleeves accurately.

The main purpose of this project is to design under supervision, a Hydraulic Bench Press
machine which will aid in the removal and inserting of engine sleeves in the open cylinders and
to put the heavy-duty valve guide into the cylinder head. More details will be discussed in the
report.

IDENTIFICATION OF PROBLEM
Most engines which are to be repaired require the installation of new parts, such as valves and
sleeves. The duty of inserting these new parts is done at each respective department around the
workshop. Inserting the valves is an easy task to do, whereas in the case of engine sleeves it’s a
really challenging task.

The company had suffered from buying excessive sleeves because the artisans could not fit the
sleeves one time perfectly. Some of the failed sleeves were cracking which meant they were
scrap, while other sleeves were bent resulting from applying force on one side.

Currently the method of inserting engine sleeves is through hammer and a round faced chisel. It
was a given task to me to design a new and convenient method of safely removing sleeves. In
this way, the company will save money from buying extra stock.

STATEMENT OF THE PROBLEM

I have to design a hydraulic bench press which will securely hold the engine block in a fixed
place. This will comprise of an oil reservoir and lever to pump the fluid into the piston to
compress the sleeve gently into the block. The engine blocks are made out of different materials
such as aluminium, cast iron and steel. It would be a problem if the insertion of sleeves is applied
at high pressure and break the sleeves.

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SUBPROBLEM 1 (MATERIAL SELECTION)
It is important to know the right material for designing the bench. Engine blocks are heavy and
can cause fatigue and failure if they are put on a weak material. Thus, it is important to select the
appropriate material for building the model so it can resist all the weight of different engine
block sizes.

During material selection, there are multiple factors which need to be considered to avoid failure
of the design as much as possible. The factors are listed as follows:

 Thermal stress
 Applied pressure to workpiece ratio
 Mechanical stress
 Weight of work specimen
 Type of Lubricant

Once we figured the right methods to overcome these factors, the design can be easily
accomplished and we can select the best material for the manufacturing of the equipment.

SUBPROBLEM 2 (MACHINE DIMENSIONS)

One of the ways a mechanical structure can withstand extreme forces is by designing it in such a
way that the dimensions are not extensive for the equipment to fail. If the dimensions are made
to be long, it could result in the bending and breaking. However, it is important to know the
correct support system and locations so that the structure becomes strong and rigid.

AIM OF THE PROJECT

The main objective is to design a fully functioning hydraulic bench press which will aid in
installing new cylinder sleeves without compromising their lifespan or breaking. It will also
allow adjustments for inserting roller and ball bearings on shafts. Other technical objectives
include:

 Get exposure to a real-life project

 Take responsibility of the whole project life cycle

 Improve technical skills and knowledge

 Gain skills of project management and leadership

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DESIGN LIMITATIONS

To successfully accomplish the design project, there are some topics which are not going to be
discussed and therefore irrelevant to the main aim of this project.

The following ideas are to be excluded:

 Design of the hydraulic reservoir

 The type of hydraulic pump to be used
 The use of metal alloys to design the body of the machine
 Total surface area of the machine
 The net weight of the machine

ASSUMPTIONS MADE

 The bench press will be bolted to the ground to absorb the immense force applied.
 Working temperatures are between 30℃ and 40℃ in summer, and range between 18℃
to -2℃ in winter
 The pipes in which the fluid will run through are to be manufactured from copper, since it
is reliable and will last longer
 The equipment will adhere to all the safety regulations and standards
 All the materials will be available for utility and all the work is done at the general
engineering site.
 The Hydraulic bench press will withstand the load of all types of engine blocks
(including UD truck 460 engine)

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BACKGROUND

A hydraulic bench press (HBP) is a mechanical equipment which uses hydraulic fluid (SAE Oil)
that lifts a piston to apply force at a slow rate. In Mechanical engineering components should be
tight to avoid any means of vibration. For example, a motor shaft has bearings fitted on both end.
The bearings are fitted tightly using high pressure machines.

The HBP has an oil reservoir on the side and a lever to pump the oil to the piston. This machine
is much safer than using a hammer to apply force on a workpiece. After completion of work the
release valve is opened and the piston retracts back inside, just like a typical hydraulic jack.

In most industrial firms, the machine can be used for a wide range of activities, and will save up
time for the operator. Furthermore, more reducing the chances of damaging the workpiece.

MATERIAL SELECTION
Cast iron was selected to build up the main frame as the machine will be bolted onto the ground.
And mild steel 310S will be recommended for the piston ram module. The cast iron will have to
be initially treated with vanish. Such material tends to corrode after some time. Therefore,
treating them before assembly is the right step towards increasing lifespan.

Most engine blocks are made from cast iron and steel, which makes them to be heavier. This
means that the body taking the load should be rigid and durable, hence I selected cast iron. The
table below is the one I used to select the preferred material.

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 Table 1: Material Properties

Table 2: Stainless Steel Properties

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FLUID SELECTION

Oil is the best fluid to use in different mechanical operation. Due to its smooth viscosity, and its
other properties, it was best that I choose it for the design project. It has the ability to slip
through thin surfaces and prevent corrosion.
The HBP will have to work all round year, thus it is important to realise the fact that, due to
different seasons, oil will have to be changed to allow simple work application. Or alternatively
the best option is to use the type of oil which runs on cold and hot temperatures.
Based on the average temperature of the environment, I discovered that the temperature is mild
up to 30℃ in summer and drops down to -10℃ in winter. I made use of the oil viscosity chart
below to select the recommended oil type for the operation.
I selected the SAE-5W-30 because the maximum and minimum temperature falls within the
range of this specific oil type.

Table 3: The oil viscosity chart

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DESIGN SKETCHES
Fig 1: The Preliminary frame for the hydraulic press

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Fig 2: The final drawing of the hydraulic bench press.

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CALCULATIONS
The following calculations were simulated using the Mathcad computer programming software

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Figure 3: The Bending Moment and Shear Force graph
Based on the bending moment, the bed of the bench press can sustain high energy of up to
7kN*m

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Figure 4: The slope and deflection graph

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IMPLEMENTATION OF IDEA

After the new ideas were put into play, it is rather imperative for users to know how the bench
press will operate to its upmost potential. In such a manner, the correct procedure being
followed, the machine will last longer and meet the operator’s requirements.

The following procedural steps should be under taken to ensure a safe operation of the bench
press:

 The engine block should sit perfectly horizontal to the support bars on the bench seat,
therefore the block should be filed and made smooth with a sand paper.
 Use the locking nuts to stabilize the workpiece from moving and veering off
 In case of inserting new sleeves, the block is put upright and the steel plates of the right
bore are used as a mediator between the hydraulic piston and the sleeve.
 Use the primary lever to pump the fluid from the reservoir to the overhead piston.
 When the length of the piston maxes out, the cylinder rods will play a major role in
extending the length when operating in longer depths.
 Turn the release valve knob on top of the oil reservoir to allow the fluid back when done
working. The piston retracts back to its initial position.

RECOMMENDATIONS

After taking the model to the supervisor, he analysed it and made recommendations to the model.
First point was that due to moist atmosphere, the bench press would require frequent vanish
(once annually preferably) to kill any chances of rust and corrosion occurring.

A chain pulley was to be fitted next to the bench press to allow operator to rig heavy engine
blocks mainly cast-iron engines, whilst the blocks which exceed 100kg in weight would be
rigged using a forklift.

Adjusting the position of the bench bed could be a difficult task to perform. Hence the bed
should be rigged with a thick wire composite which will be tied to a worm gear that gets turned
by a bevel gear fitted with a lever. This idea was added by the supervisor and could be
implemented to facilitate easier operation.

And the last recommendation made was that the piston ram should be controlled by two separate
levers which pumps the fluid faster or slower to accommodate a variety of pressing applications.
Also fit in a pressure monitor gauge of the fluid.
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CONCLUSION

At the end, the project was a success. The hydraulic bench press was successfully designed and
simulated. All the theoretical ideas meet the practical standards. Using the recommended oil with
relative viscosity is going to improve the overall performance of the machine.

Now with the effective bench press at play, I can conclude that the installation and removal of
sleeves will be simple and safer. With adjustable bars at the bottom, the equipment will allow all
engines of different lengths and weight, thanks to its cast iron frame.

All the recommendations made will significantly help alleviate extensive manpower, improve the
overall safety and extend the lifespan.

I have gained great exposure to material selection and its properties. Also, how to manage
projects which will help me in my near career as a mechanical technician. With this knowledge
and skills, I can now be able to apply it and solve wide range of engineering problems.

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REFERENCES

1. ECCS (European Committee for Constructional Steelwork), Technical Committee

6, Fatigue, Recommendations for the Fatigue Design of Steel Structures, First Edition,
1985
2. Fundamentals of Machine Component Design, Updated Third Edition, Juvinall and
Marshek, Wiley, 2000
3. Operations Management, Integration Manufacturing and Services, Fifth Edition,
Davis/Heineke, McGraw-Hill, 1991
4. The Blue Book Structural Steel Tables. Johannesburg SAIS. (2007)
5. Mechanical Engineering Design. International student edition. Tokyo; McGraw-Hill,
Shigley, E.J. (1977)

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