Design and Development of Portable Multipurpose

Hydraulic Machine(PMHM)

Course No. : DMZG628T

Course Title: Project

Student Name: SYED FARHAAN AHMED

BITS ID: 2021HT56015

Degree Program: DIGITAL MANUFACTURING

Research Area: (Manufacturing Project)

Dissertation / Project Work carried out at:

BAUMIX SOLUTIONS

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE,

PILANI
VIDYA VIHAR, PILANI,
RAJASTHAN - 333031.

(JANUARY 2023)
Abstract

Assembly operations occurring in any workshops are pressing, where a bearing is inserted into a hole.
Pulling, where a pulley or a gear is removed from shaft. Some other basic operations involved in
workshops are punching, where a hole is made into sheet metal of minimum thickness by piercing a
die and sheet metal bending, where a sheet metal is bent to form into required shapes. These
operations are usually performed by using Hydraulic machines that provide continuous linear force
throughout the stroke.
Conventional Hydraulic Machines used for assembly operations are huge with capacity ranging from 5
ton to 500 ton, these machines are stationary and the job needs to be brought to the machine and not
vice versa. These machines offer precision assembly but operation cost is too high to bear for small
workshops.
Portable Multipurpose Hydraulic Machine is a novel concept which can be used anywhere and
everywhere for pressing and pulling assembly applications without the use of electricity or other huge
hydraulic pump setup. The machine specifications are maximum 3 ton capacity. The dimensions of
workpiece are restricted to 380mm vertical length and 200 mm width. Design of PMHM involves
selection of hydraulic cylinder and pump, design of structural components like discs, legs using
concepts of design of plates and design of bars.

Signature of the Student Signature of the Supervisor

Name: Syed Farhaan Ahmed Name: Aneesh Gopinath
Date: 18-03-2023 Date: 18-03-2023
Place: Bangalore Place: Bangalore
Contents

1. Specifications of Hydraulic Machine 3

2. Conceptual Design 6
3. Hydraulic Cylinder Capacity Estimation 8
4. Modelling 8
5. Finite Element Analysis 9
6. Future Plan 14
7. Literature Reference 15
 1. Specifications of Hydraulic Machine:
Design considerations:

Design Consideration:

Load capacity of Hydraulic cylinder 3 ton

Operating Pressure 200 bar

Stroke Length 100 mm

Permissible tensile stress of mild steel 420.5 N/mm^2

Factor of safety 2

Height and width restriction for 380 mm and 200 mm

machine

Working materials Mild Steel, Aluminium, Sheet metal and

SS

Working Dimensions (press) Outer Diameter - 100 mm,

Inner Diameter - 40 mm

Working Dimensions (punching) 1 mm thick

Working Dimensions (bending) 5 mm thick

Pump Mechanism Mechanical Operated

Design of PMHM involves selection of hydraulic cylinder and pump, design of structural components
like discs, legs using concepts of design of plates and design of bars.
Hydraulic Cylinder specifications: The cylinder select is a type of telescopic cylinder which is single
acting, spring loaded.

Figure :Hydraulic Cylinder

 Specification of Hydraulic cylinder
Specifications Values/Data

Capacity 200 bar

Stroke 100 mm

Outer diameter 42 mm

Inner diameter/piston diameter 38 mm

Oil grade G83

Hydraulic Pump Specifications:

Pump selected is VANDEC Hand Pump-Hydraulic-Single Piston Acting

Specification of pump
Specifications Values/Data

Working Pressure 800 bar

Plunger Diameter 12.07 mm

Discharge 3.2 cc

Tank Capacity 2.5 ltrs

Oil grade G83

Mild steel Properties:

The properties AISI 1018 Mild Carbon Steel required for design calculation for the component design
of PMHM
 Table : AISI 1018 Mild Carbon Steel Properties
Yield Strength Ultimate Tensile Strength Young’s Modulus
370 MPa 440 MPa 205 a

2. Conceptual Design:
According to the data reviewed from the literature study and the specifications of hydraulic machine,
conceptual designs are prepared in CATIA software with assumed dimensions.
Hydraulic Puller:

Figure: Design concept of Hydraulic puller

The setup consists of top supporting disc to which four bent arms are connected, to achieve correct
level of degree of freedom so that pulley or a disc of variable diameter can be removed easily.
Free body diagram to depict operation and forces involved:

Free body diagram of Puller

Hydraulic Press:

Figure: Design concept of Hydraulic press

The setup is obtained by rearranging the components of press machine to same puller by dismantling
the bent arms and connecting legs and bottom disc which convert the puller into press machine.
Free body diagram to depict operation and forces involved:

Figure :Free body diagram of Press

 3. Hydraulic Cylinder Capacity Estimation:
force exerted by the hydraulic Cylinder can be calculated as.
𝐹
𝑃=
𝐴
Where,
Pressure Area
𝜋
𝑃 = 200 𝑏𝑎𝑟 = 200 × 105 𝑁⁄𝑚2 𝐴 = 4 × (38)2 = 1134.114 𝑚𝑚2
𝑃 = 20 𝑁⁄𝑚𝑚2
Force
𝐹 = 𝑃 × 𝐴 = 20 × 1134.114 = 22,682.29 𝑁
𝑭 = 𝟐𝟑𝟏𝟐. 𝟗𝟒𝟗 𝒌𝒈 = 𝟐. 𝟓𝟒 𝒕𝒐𝒏

4. Modelling:
CATIA model of individual parts that are designed are developed and assembly of model which depicts
how the model actually look when fabricated is presented below.

CATIA Model of Multipurpose hydraulic machine

 5. FE Analysis:
The Finite Element Method (FEM) is a numerical technique to find approximate solutions of partial
differential equations. In a Mechanical simulation, FEM helps in producing stiffness and strength
visualizations. FEM allows for detailed visualization and indicates the distribution of stresses and
strains inside the body of a structure. FEM allows entire designs to be constructed, refined and
optimized before the design is manufactured.
Steps of FE analysis:
1. Generating FE model, by loading CAD model into software and meshing
2. Load Application
3. Finite element analysis (structural analysis) and results
Analysis of Top disc:
Puller application:
 Loading and Meshing: The CAD model of top disc is loaded into ANSYS WORKSPACE, by converting
units to mm the model is prepared for meshing. Meshing is done by specifying the medium extent
of mesh and the software meshes the model automatically.
 Load Application: The centre hole is fixed and the load of 7560.76 N is applied to holes individually.
 Simulation and results: the setup is simulated and the results are described below.

Deformation of Top disc due to pulling

 Stress distribution of Top disc due to pulling
Press application:
 Loading and Meshing: The CAD model of top disc is loaded into ANSYS WORKSPACE, by converting
units to mm the model is prepared for meshing. Meshing is done by specifying the medium extent
of mesh and the software meshes the model automatically.
 Load Application: The centre hole is fixed and the load of 7560.76 N is applied to slots individually.
 Simulation and results: the setup is simulated and the results are described below.

Deformation of Top disc due to press operation

Stress distribution of Top disc due to press operation

Deformation of Leg slider

Stress distribution of Leg slider

 Deformation of Bent Arm

Stress distribution of Bent Arm

Figure 4.1: Deformation of Bracket

Stress distribution of Bracket

Deformation of Grippers

Stress distribution of Grippers

 6. Future Plan

Phases Start Date-End Date Work to be done Status

Dissertation 05 Jan 2023 – 04.02.2023 Literature Review and prepare Completed

Outline Dissertation Outline

Design & 05.02.2023 – 20.03.2023 Design & Development Activity Completed

Development
Testing 22.03.2023 – 16.04.2023 Operate a fully working model. On-going

Dissertation 07.04.2023 – 12.04.2023 Submit Dissertation to Pending

Review Supervisor & Additional
Examiner for review and
feedback
Submission 3.04.2023 – 19.04.2023 Final Review and submission of Pending
Dissertation
7. Literature References

1. AZoM.com. (2019). AISI 1018 Mild/Low Carbon Steel. [online] Available at:
https://www.azom.com/article.aspx?ArticleID=6115 [Accessed 12 Mar. 2019].

2. Basics, G. (2019). GD&T Basics. [online] GD&T Basics. Available at:

https://www.gdandtbasics.com [Accessed 16 May 2019].

3. CIVILDATAS. (2019). [PDF] Engineering Mechanics (In SI Units) By S.

Timoshenko , D.H. Young , Pati Sukumar , J V Rao Free Download. [online]
Available at: https://civildatas.com/download/engineering-mechanics-by-s-
timoshenko [Accessed 12 Feb. 2019].

4. Grithappens.com. (2019). [online] Available at:

https://www.grithappens.com/mediadata/manufpdfs/enerpac
3_1236630902.pdf [Accessed 6 Feb. 2019].