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5 authors, including:
Osama Mohamed
University of Tripoli
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All content following this page was uploaded by Mahmoud Basyony Elmokadem on 25 July 2020.
Submitted by:
Spring 2020
i
Table of Contents
S. No. Section Page No.
1 Table of Contents 1
2 List of Figures 2
3 List of Attachments 3
4 Abstract 3
5 Keywords 3
6 Introduction 4
7 Review of Literature 4
8 Automatic Forging Hammer 5
8.1 What is it? 5
8.2 How it works 5
9 Advantages & Disadvantages of Automatic Forging Hammer 6
10 Applications of Automatic Forging Hammer 6
11 Automatic Hydraulic Forging Hammer Design 7
12 Project Components 7
12.1 Directional Control Valves 7
12.2 Check Valves 8
12.3 Two-Way Valve with Lever 8
12.4 Fixed-Displacement Hydraulic Pump 8
12.5 Hydraulic Oil Filter 9
12.6 Double-acting cylinder 10
12.7 Pressure Relief Valve 10
12.8 Sequence Valve 10
13 Working Principle & The Hydraulic Circuit 11
41 Design Calculations & Component Specifications 13
14.1 Hydraulic Cylinder 14
14.2 Hydraulic Pump 14
14.3 Electric Motor 15
14.4 Hydraulic Oil 15
14.5 Sequence valves 16
15 Conclusion 17
16 References 18
1
List of Figures
Figure No. Figure Page No.
1 Old Mechanical Hammer 4
2 Automatic Forging Hammer Hydraulic Model 5
3 Automatic Hydraulic Forging Hammer Model’s Front 5
4 Automatic Hydraulic Forging Hammer 6
5 Automatic Hydraulic Forging Hammer Model Section View 6
6 ISO, ASME Standard Communities Logos 7
7 (4/2 DCV) with Double External Hydraulic Pilots 7
8 Check Valve 8
9 Two-Way Valve with Lever 8
10 Fixed-displacement pump 8
11 Oil Filter 9
12 Double-acting cylinder 10
13 Pressure Relief Valve 10
14 Sequence & Pressure Relief Valves 10
15 Hydraulic Circuit Diagram 11
16 Hydraulic Circuit Diagram with Work Steps 12
2
List of Attachments
For All Attached Project Data Please Refer to the following Link:
mega.nz/folder/0R8jnBIS#u5Amdr8yQBLJ699jvRkd7Q
No. Attachment
1 SolidWorks Parts & Assembly Files
2 SolidWorks Graphics (Rendered Video & Pics)
Abstract
In the Field of Metallurgy and Manufacturing, Utilizing Hydraulic and
Pneumatic Mechanisms makes Capital Cost more, which makes it easier only for large
scale Industries. In order to reduce the Initial Cost, an “Automatic Hammer” has been
made using simple Hydraulic or Pneumatic Control and Drive System that can aid the
small-scale Industries and as well as making it possible to employ a semi-skilled labor.
This can be a boon for Blacksmiths who undergoes Immense manual labor and cannot
afford Automations either. So, with a view of reducing the Burdens of the Blacksmiths
an Automatic hammer has been fabricated which functions simply by a Hydraulic
Control and Power Piston Circuit Designed on Various Standards Communities Rules
like ISO, ASME…etc. to meets the Perfect Specification and Efficiency Rates with
the Massive Design Weight of 10 Tons and to be a suitable product for local Society.
Keywords
Hydraulic Hammer – Reciprocating Cylinder – Directional Control Valve
- Sequence Valve – Hydraulic Pump.
3
Introduction
We have realized the Importance of Modern Machinery in our Lives, with the
development of Science and Industry. It has become one of the basic Equipment in
any Factory that relies on Blacksmithing or Casting is the Automatic hammer, as it
works in the Drop Shape, Forging Hammers are used to mold the Metal between two
Dies. The Second Part of the Die is set on the Hammer and an Anvil. The Product is
placed in the lower Die which is in common a Lifting Table that is Shock resistant and
has different heights to reach with the work piece to the appropriate Distance to the
Hammer Ram and then hammered with the upper. Fundamentally it constitutes a
complete Hydraulic or pneumatic system with Directional Control Valve, Piston
Accumulator (in case of Pneumatic) and Sequence Valve which can realize mutual
Feedback Control between Control Valve and Impact Piston, automatically Switching
the straight Line of reciprocating movement of the piston in the cylinder by Sending
a Hydraulic Pilot Signal to the Directional Control Valve. Which is what we will
address in this Research in detail from a Drawing of the Hydraulic Circuit for this
Machine and the 3D CAD Drawings and the Way it works by Automation Studio
Simulation and Animation.
Review of Literature
At First the Huge Blacksmith Hammers
were driven by Aid of Animal Movements and
some simple mechanical Mechanisms the by
the Industrial Revolution the Steam and
mechanical Power Hammers were made in the
United States. At the end of the 19th Century
the mechanical Power Hammer became
popular in smaller Blacksmith and Repair
Shops. These Machines may still be seen in
use in small Manufacturing and Artist-
Blacksmith Shops today. In the middle of the
20th century Power Hammers driven by
compressed Air also known as Pneumatic
began to gain popularity and several
Manufacturers are currently producing these
Hammers today. Until we reached the now a
Figure 1 – Old Mechanical Hammer
days Hydraulic & Pneumatic Hammer
4
Automatic Forging Hammer
What is it?
Automatic Forging Hammer is a Machine
that uses the Hydraulic or Pneumatic Power
Source to raise the Hammer preparatory to
striking, and accelerate it onto the workpiece
being hammered. It’s also called "Power
Forging Hammers.", and it’s generally used in
Industrial Forging Processes and Massive
Production Metal Shaping starting from small
Machines with 10 Kg-Force to 15 Ton-Force
and varies in its Types to Different types such
as Hydraulic or Pneumatic which differ from
each other depending on the Power required to
lift the Ram Weight in the required Time.
Figure 2 – Automatic Forging Hammer
Hydraulic Model
How it works
Basic working Principle of Hydraulic
or Pneumatic Hammer is energy conversion
from pressurized (compressed) liquid or Gas
into a lifting Force for the Ram and from
Kinetic Energy of falling Ram into a Blow
Energy. Pressurized Oil from the Pump or
Compressed Gas from the Compressor
pushes the Piston upward to lift the Ram,
when the quick release Sequence Valve
fully opens, high pressure Oil or Gas pushes
the Piston down-ward rapidly and
accelerates the falling Ram during working
stroke as well as the Gravity Force pulling
the Ram Down , and a Hammer blow with
stipulated ,kinetic energy is formed.
Figure 3 – Automatic Hydraulic Forging Hammer
Model’s Front
5
Advantages & Disadvantages of
Automatic Forging Hammer
-
Applications of Automatic
Forging Hammer:
In Manufacturing Industries it performs
different Operations with different Ram
Designs as follows:
To perform Smithy Operation ex.
Upset Forging.
To perform the Punching Operation.
To perform Filleting Operation as
Torque Force produces sufficient for
the Operation.
To perform Riveting Operation etc...
Figure 5 - Automatic Hydraulic Forging Hammer
Model Section View
6
Automatic Hydraulic Forging Hammer Design
As our Project’s Aim is to make a Full
Design of a 10-Ton Hydraulic Hammer Circuit
so the coming up we will present our Design and
the Standards we took in our mind while putting
the Main Design of Components and
Calculations based on various Standards Figure 6 – ISO, ASME Standard
Communities like ISO, ASME and TÜV. Communities Logos
To Design the Circuit of the Project we should first determine the Components which
we are going to use and the basic Idea of the Control and Power Hydraulic Circuits
within the Project and we are going to present our Project’s Components and its
working Concept in the coming up.
7
Check Valves
Is a type of DCV allows flow only in one . Fluid
flows through the , a little is needed to the valve seat
in this direction. The valve opens when there is a flow
through the . Here in number (8) shown a ball check
valve.
Whenever there is an opposite fllow to the
direction of the valve shuts. The pressure presses the
Figure 8 – Check Valve
ball against the valve seat, thus closes the path
The obvious reason to prevent these is to prevent contaminant from cycling and
going through the system. Therefore, a clean and efficient filter is utterly critical to
the hydraulic system
9
Double-acting cylinder
Double-acting cylinder transmit
hydraulic in two different directions, with
both pulling and pushing force. They are as a
piston sealed two chambers in the . The
power transfer of the cylinders compressive
chamber is in the cylinder tube area. The
force of area of the cylinders is inside the
cylinder pipe diameter area minus the rods -
area (out of the diameter). types of cylinders
are one oil connection to the ten sion side and
other to the pressure side. Figure 12 – Double-acting cylinder
Pressure Valves
Pressure Relief Valve
Another essential component is
the Pressure Relief Valve where the is
relieved by letting the pressurized fluid to
flow an auxiliary out of the system.
The relief valve is or set to open at a
ermined set to protect pressure vessels
and other equipment fro m being subj
ected to pressu res that surpass their
Figure 13 – Pressure Relief Valve
design limits.
Sequence Valve
A sequence valve is a Pressure valve
designed to open when its set sd pressure is
reached, a of flow and
to ths e primary circuit. In some w ays,
sequence valve is a direct valve, ad flow to occur.
, it's just a Figure 14 – Sequence & Pressure
Relief Valves
relief valve with some added features.
10
Working Principle & The Hydraulic Circuit
The Hydraulic that produces continuous reciprocation of a Hydraulic
Cylinder works by using two valves, each one them senses a s completion by the
corresponding buildup s pressure. And each valve and corresponding pilot line
prevents of the four-way valve the particular stroke of a cylinder has been
completed. The valves are needed to permit pilot oil to leave either end of the DCV
while pilot pressure is to the opposite end. This the spool of the DCV to shift as
required.
The Circuit describes the mentioned in Steps, the Circuit Components is designed
by the calculations and The Circuit was created by Automation Studio V5.2 Program:
-
3 4
2
5 6
And as shown the Cycle continues to Work as long as the Lever is Pushed…...
12
Design Calculations & Component Specifications
-To calculate ram caring rod’s required diameter, we apply the following :
To guarantee safety we take (3) as Safety Factor and we choose [Mild steel 1090]
which is most suitable as Rod material and has yield tensile stress =247 MPa
Calculations :
𝜎𝑓𝑎𝑖𝑙
Fs = 3 , Fs = , 𝜎𝑓𝑎𝑖𝑙 = 247 𝑀𝑃𝑎
𝜎𝑎𝑙𝑙𝑎𝑤
247
𝜎𝑎𝑙𝑙𝑎𝑤 = = 82.33 𝑀𝑃𝑎
3
𝐹 10,000
𝜎𝑎𝑙𝑙𝑎𝑤 = = = 82.33 × 106
𝐴 𝐴
98,100
A= 6
= 1.19 × 10−3 𝑚2
82.33 × 10
4𝐴 4 × 1.19 × 10−3
𝑹𝒐𝒅 𝑪𝒂𝒍𝒄𝒖𝒍𝒂𝒕𝒆𝒅 𝑫𝒊𝒂𝒎𝒆𝒕𝒆𝒓 𝒅 = √ =√ = 0.039 𝑚 = 𝟑𝟗 𝒎𝒎
𝜋 𝜋
13
**Hydraulic Cylinder
Thus, Hydraulic Manufacturers have standards tables for cylinder selection we choose
the nearest higher value for the calculations from Eaton Inc.[ Metric Mill Type
Hydraulic Cylinders ] Table with *ISO 6022 standard :
𝐹 98,100 98,100
𝒑= = 𝜋 = 𝜋 = 𝟐𝟔. 𝟎𝟐 𝑴𝑷𝒂 = 𝟐𝟔𝟎. 𝟐 𝑩𝒂𝒓
𝐴 ( ) (𝐷 2 − 𝑑 2 ) ( ) (0.082 − 0.042 )
4 4
To estimate The Flow rate at retraction:
= 𝟑𝟏𝟔. 𝟔𝟐 𝑳 / 𝒎𝒊𝒏
**Hydraulic Pump
Based on the Pressure Valve Result we select the pump with a safety Factor (1.75)
According to The
*ISO 5198 * ISO/ASME 14414
*ISO 3555 *ASME (EA- 2/2G)
Standards to Overcame the pressure Drop in The Hydraulic circuit and the losses
so the required pump must satisfy Max Pressure more than (455 bar), with a
specification of the following: -
14
Based on Parker Inc. Pumps catalogue and the pervious standards we choose:
-An Axial Pump of type (𝐹12 − 125) with (45 𝑚𝑚 𝑘𝑒𝑦)
- Displacement: 125 𝑐𝑐/𝑟𝑒𝑣 = (1.25𝑥10−4 𝑚3 /𝑟𝑒𝑣)
-Max Pressure: 480 𝐵𝑎𝑟
-Max Operation speed: 4200 𝑟𝑝𝑚
And From the specification above we determine the pump power to select a suitable
motor
[𝑷𝒖𝒎𝒑 𝒑𝒐𝒘𝒆𝒓] 𝑷𝑾 = 1.75 × 𝑃 × Q = 1.75 × 26.02 × 106 × 5.27 × 10−3
= 𝟐𝟑𝟗. 𝟗𝟔𝟗 𝑲𝑾
**Electric Motor
And to select the Motor With ~ 240 KW we should calculate the Operating speed
(rpm) to choose wisely the lowest price motor. So, to Determine The operation
speed required we calculate the following :
Q (Volume Flow Rate) = Pump Displacement (𝑚3 /𝑟𝑒𝑣) × 𝑟𝑝𝑠 (𝑟𝑒𝑣/𝑠)
5.27 × 10−3 = 1.25 × 10−4 × 𝑟𝑝𝑠
(5.27∗10−3 )
𝒓𝒑𝒔 = (1.25∗10−4 )
= 𝟒𝟑 𝒓𝒑𝒔 ≈ 𝟐𝟓𝟖𝟎 𝒓𝒑𝒎
So, chosen Motor should be approximately 𝟐𝟔𝟎𝟎 𝒓𝒑𝒎 and can carry 𝟐𝟒𝟎 𝒌𝑾 load.
**Hydraulic Oil
For the pervious pump a suitable Hydraulic Oil should be used and satisfy the
*ISO VG-32 * ISO 2186 *ISO 5167
Standards and according to the pervious standards, we have chosen and Oil from
EXXON MOBILE EGYPT Product Data sheet with the following
characteristic:
15
**Pressure Relief Valve
To guarantee safety of the machine against any problems or failures we use a
Pressure Relief Valve within the circuit to protect it from over pressure and to
protect the pump from Overloading as we can calculate its cracking pressure by
taking a (1.5) Factor of the Pressure required to lift the Ram according to the
*ISO 5208 & *ISO 5209 Standards so:
-
**Sequence valves
According to *ISO/DIS 23632 standards, we can calculate the sequence valves
cracking pressure by adding 30% Over the Pressure required to lift the Ram so:
16
Conclusion
The Hydraulic System transfers power through incompressible Oil where the
pump pushes the Oil through Directional Control Valve to a Hammer piston . when
the Oil Pressure increases in the pipe and Vessels the Relief valve opens to release the
Pressure. The Directional Control Valve has 2 lines directions at where the Oil Flows,
the Hammer Piston or the Tank. When the Pressure increases in Hammer piston
Cylinder there is a Sequence Valves on the System Sides which Pilot the Directional
Control Calve to change the Oil Flow to the Reverse Way to the Tank and the Pump
to the Cylinder’s other Side Pipe to Reverse the Cylinder Movement and to create a
Reciprocating Movement Keeps on while the Lever Arm of the Two-Way Valve is
Pushed so at the End of Our Report we have Created a Simple Model Design for an
Automatic Hydraulic Forging Hammer which can be used in various Industrial
Sectors whether Large or Small and it has many benefits for saving Time, Money and
Efforts done in the Industrial Process in General or in Forging Process Specially.
17
References
1. Prof. Dr. Saber Abdrabbo, “Control of Hydraulic Systems Lectures”
Mechatronics Department, Faculty of Engineering, Sinai University, Egypt,
Spring 2020.
2. R.S. Khurmi, J.K. Gupta, “Machine Design”, 2nd edition, S.Chand, 2005.
6. www.iso.org/en/ics/23.html
7. www.crownoil.co.uk/guides/hydraulic-oil-guide
8. www.machinerylubrication.com/Read/25967/hydraulic-oil-lubrication-
viscosity
9. https://www.asme.org/publications-submissions/books/find-book/hydraulic-
fluids-guide-selection-test-methods-use
10. cstools.asme.org/csconnect/CommitteePages.cfm?Committee=N10062200
11. www.sciencedirect.com/topics/engineering/piston-area
12. www.anyanghammer.com/products/Close-Die-Forging-Machine/C86YT-
Fully-Hydraulic-Forging-Hammer-Power-Head.html
13. www.anyangforginghammer.com/10-ton-closed-die-forging-hammer-
supplier-5933737.html
14. womackmachine.com/engineering-toolbox/data-sheets/automatic-reversing-
circuits-for-presses
15. mobil.com/en/lubricants/for-
businesses/industrial/lubricants/products/products/mobil-dte-26 .
16. slideserve.com/felix/hydra-pneumatic-hammers .
17. https://www.asme.org/publications-submissions/books/find-book/hydraulic-
fluids-guide-selection-test-methods-use
18