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FABRICATION OF HYDRAULIC PRESS MACHINE FOR

FOUNDRY RAMMING
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 CHAPTER 1
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ABSTRACT
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CHAPTER-1
 ABSTRACT

Foundry or casting is one of the metal forming processes in which the

molten metal is poured into a pre shaped mould cavity and allowed to cool. On

cooing, the metal solidifies and acquires the configuration of the mould. Generally

the solidified object is called the casting. Ramming is one of the minor operations

in the foundry. Although their part is very little, they are the most important

process of the metal forming process. The ramming machine which is available in

the market nowadays is for a large scale purposes and is of high cost. Hence we

decided to fabricate a simple ramming machine that works on the principle of the

hydraulic press.

A box in which the sand is placed is operated by a hydraulic jack. The

hydraulic jack is operated manually. A fixed plate is mounted on the top of the box

such that the box hits the flat plate and the sand inside the box gets rammed.

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 CHAPTER 2
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INTRODUCTION
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 CHAPTER-2

INTRODUCTION

The ramming operations have been characterized for a long time by large,

heavy and expensive machines. This has made foundry industry to become capital

intensive and highly centralized. Although there are already many designs of

ramming machines in the market, their high prices, lack of portability and

electricity dependence, has rendered them not suitable for use.

To solve these problems associated with existing ramming machine, we

embarked on fabricating a small hydraulic press machine for foundry ramming

operation. To ensure that the designed machine was affordable, we ensured that

our machine will use locally available materials. Hydraulic jack was used for

power transmission for making the raw materials fix into the die. This is because it

is highly economical and less man power is sufficient for operating.

To prove that the hydraulic press for foundry ramming was viable, we made

a working model of the machine. We were able to ram the sands efficiently in a

shorter time using the model.

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CHAPTER 3
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COMPONENTS AND DESCRIPTION
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 CHAPTER-3

COMPONENTS AND DESCRIPTION

The major components that are involved in the fabrication of a hydraulic

brick making machine are,

 Hydraulic jack,

 Frame,

 Sandbox,

 Latch,

 Spring.

HYDRAULIC JACK

A jack is a mechanical device used a as a lifting device to lift heavy loads or

to apply great forces. A mechanical jack employs a screw thread for lifting heavy

equipment. A hydraulic jack uses hydraulic power. The most common form is a car

jack, floor jack or garage jack, which lifts vehicles so that maintenance can be

performed. Jacks are usually rated for a maximum lifting capacity (for example,

1.5 tons or 3 tons). Industrial jacks can be rated for many tons of loads.
 Hydraulic jacks are typically used for shop work, rather than as an

emergency jack to be carried with the vehicle. Use of jacks not designed for a

specific vehicle requires more than the usual care in selecting ground conditions,

the jacking point on a vehicle, and to ensure stability when the jack is extended.

Hydraulic jacks are often used to lift elevators in low and medium rise buildings.

A hydraulic jack uses a fluid, which is incompressible, that is forced into a

cylinder by a pump plunger. Oil is used since it is self lubricating and stable. When

the plunger pulls back, it draws oil out of the reservoir through a suction check

valve into the pump chamber. When the plunger moves forward, it pushes the oil

through a discharge check valve into the cylinder. The suction valve ball is within

the chamber and opens with each draw of the plunger. The discharge valve ball is
outside the chamber and opens when the oil is pushed into the cylinder. At this

point the suction ball within the chamber is forced shut and oil pressure builds in

the cylinder.

In a floor jack (aka 'trolley jack') a horizontal piston pushes on the short end

of a bell crank, with the long arm providing the vertical motion to a lifting pad,

kept horizontal with a horizontal linkage. Floor jacks usually include castors and

wheels, allowing compensation for the arc taken by the lifting pad. This

mechanism provides a low profile when collapsed, for easy maneuvering

underneath the vehicle, while allowing considerable extension. Richard Dudgeon,

Inc. was founded in New York City as a machine shop. In 1851, founder and

inventor Richard Dudgeon was granted a patent for a "portable hydraulic press" -

the hydraulic jack, a jack which proved to be vastly superior to the screw jacks in

use at the time.

Bottle jack

A bottle jack or whiskey jack is a hydraulic jack which resembles a bottle in

shape, having a cylindrical body and a neck, from which the hydraulic

ram emerges. In a bottle jack the piston is vertical and directly supports a bearing

pad that contacts the object being lifted. With a single action piston the lift is

somewhat less than twice the collapsed height of the jack, making it suitable only
for vehicles with a relatively high clearance. For lifting structures such as houses

the hydraulic interconnection of multiple vertical jacks through valves enables the

even distribution of forces while enabling close control of the lift.

They have a capacity of up to 50 tons and may be used to lift a variety of

objects. Typical uses include the repair of automobiles and house foundations.

Larger, heavy-duty models may be known as a barrel jack.

This type of jack is best used for short vertical lifts. Blocks may be used to

repeat the operation when a greater amount of elevation is required.

FRAME

This is made of mild steel material. The whole parts are mounted on this

frame structure with the suitable arrangement. Boring of bearing sizes and open

bores done in one setting so as to align the bearings properly while assembling.

Provisions are made to cover the bearings with grease.

SAND BOX

This is simply a box in which the raw material (sand) is filled and the final

rammed sand is taken out. This box is coupled with the hydraulic jack so that this

box moves along with the hydraulic jack. This box is provided with a latching
mechanism so that when the sand is ready, it can be simply latched out and taken

and can be used up in the next metal forming process.

LATCH

A latch is a type of mechanical fastener that is used to join two (or more)

objects or surfaces together while allowing for the regular or eventual separation of

the objects or surfaces. A latch typically engages another piece of hardware on the

other mounting surface. Depending upon the type and design of the latch, this

engaged bit of hardware may be known as a keeper or strike. Note that a latch is

not the same as the locking mechanism of a door or window, although often they

are found together in the same product.

Latches range in complexity from flexible one-piece flat springs of metal or

plastic, such as are used to keep blow molded plastic power tool cases closed, to
multi-point cammed latches used to keep large doors closed. The different types of

latches are readily available in the market namely,

 Bolt lock latch, including barrel bolt latches,

 Compression latch,

 Draw latch (both over- and under-center),

 Rotary latch, etc.

SPRINGS

A spring is an elastic object used to store mechanical energy. Springs are

usually made out of spring steel. There are a large number of spring designs; in

everyday usage the term often refers to coil springs. Small springs can be wound

from pre-hardened stock, while larger ones are made from annealed steel and

hardened after fabrication. Some non-ferrous metals are also used

including phosphor bronze and titanium for parts requiring corrosion resistance

and beryllium copper for springs carrying electrical current (because of its low

electrical resistance). When a coil spring is compressed or stretched slightly from

rest, the force it exerts is approximately proportional to its change in length (this

approximation breaks down for larger deflections). The rate or spring constant of a

spring is the change in the forceit exerts, divided by the change in deflection of the

spring. That is, it is the gradient of the force versus deflection curve. An

extension or compression spring has units of force divided by distance, for

example lbf/in or N/m. Torsion springs have units of torque divided by angle, such

as N·m/rad or ft·lbf/degree. The inverse of spring rate is compliance, that is: if a

spring has a rate of 10 N/mm, it has a compliance of 0.1 mm/N. The stiffness (or

rate) of springs in parallel is additive, as is the compliance of springs in series.

Depending on the design and required operating environment, any material can be

used to construct a spring, so long as the material has the required combination of

rigidity and elasticity: technically, a wooden bow is a form of spring.

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CHAPTER 3
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FABRICATION PROCESS
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 CHAPTER-3

FABRICATION PROCESS

Manufacturing processes are the steps through which raw materials are

transformed into a final product. The manufacturing process begins with the

creation of the materials from which the design is made. These materials are then

modified through manufacturing processes to become the required part.

Manufacturing processes can include treating (such as heat treating or coating),

machining, or reshaping the material. The manufacturing process also includes

tests and checks for quality assurance during or after the manufacturing, and

planning the production process prior to manufacturing.

METAL CUTTING

Metal cutting or machining is the process of by removing unwanted material

from a block of metal in the form of chips.

Cutting processes work by causing fracture of the material that is processed.

Usually, the portion that is fractured away is in small sized pieces, called chips.

Common cutting processes include sawing, shaping (or planning), broaching,

drilling, grinding, turning and milling. Although the actual machines, tools and

processes for cutting look very different from each other, the basic mechanism for
causing the fracture can be understood by just a simple model called for orthogonal

cutting.

In all machining processes, the work piece is a shape that can entirely cover

the final part shape. The objective is to cut away the excess material and obtain the

final part. This cutting usually requires to be completed in several steps – in each

step, the part is held in a fixture, and the exposed portion can be accessed by the

tool to machine in that portion. Common fixtures include vise, clamps, 3-jaw or 4-
jaw chucks, etc. Each position of holding the part is called a setup. One or more

cutting operation may be performed, using one or more cutting tools, in each setup.

To switch from one setup to the next, we must release the part from the previous

fixture, change the fixture on the machine, clamp the part in the new position on

the new fixture, set the coordinates of the machine tool with respect to the new

location of the part, and finally start the machining operations for this setup.

Therefore, setup changes are time-consuming and expensive, and so we

should try to do the entire cutting process in a minimum number of setups; the task

of determining the sequence of the individual operations, grouping them into (a

minimum number of) setups, and determination of the fixture used for each setup,

is called process planning.

These notes will be organized in three sections:

(i) Introduction to the processes,

(ii) The orthogonal cutting model and tool life optimization and

(iii) Process planning and machining planning for milling.

SAWING

Cold saws are saws that make use of a circular saw blade to cut through

various types of metal, including sheet metal. The name of the saw has to do with

the action that takes place during the cutting process, which manages to keep both
the metal and the blade from becoming too hot. A cold saw is powered with

electricity and is usually a stationary type of saw machine rather than a portable

type of saw.

The circular saw blades used with a cold saw are often constructed of high

speed steel. Steel blades of this type are resistant to wear even under daily usage.

The end result is that it is possible to complete a number of cutting projects before

there is a need to replace the blade. High speed steel blades are especially useful

when the saws are used for cutting through thicker sections of metal.
 Along with the high speed steel blades, a cold saw may also be equipped

with a blade that is tipped with tungsten carbide. This type of blade construction

also helps to resist wear and tear. One major difference is that tungsten tipped

blades can be re-sharpened from time to time, extending the life of the blade. This

type of blade is a good fit for use with sheet metal and other metallic components

that are relatively thin in design.

WELDING

Welding is a process for joining similar metals. Welding joins metals by

melting and fusing 1, the base metals being joined and 2, the filler metal applied.

Welding employs pinpointed, localized heat input. Most welding involves ferrous-

based metals such as steel and stainless steel. Weld joints are usually stronger than

or as strong as the base metals being joined.

 Welding is used for making permanent joints. It is used in the manufacture

of automobile bodies, aircraft frames, railway wagons, machine frames, structural

works, tanks, furniture, boilers, general repair work and ship building.

In the shielded metal arc welding process (SMAW) the 'stick' electrode is

covered with an extruded coating of flux. The heat of the arc melts the flux which

generates a gaseous shield to keep air away from the molten pool and also flux

ingredients react with unwanted impurities such as surface oxides, creating a slag

which floats to the surface of the weld pool. This forms a crust which protects the

weld while it is cooling. When the weld is cold the slag is chipped off.
 The SMAW process cannot be used on steel thinner than about 3mm and

being a discontinuous process it is only suitable for manual operation. It is very

widely used in jobbing shops and for onsite steel construction work. A wide range

of electrode materials and coatings are available enabling the process to be applied

to most steels, heat resisting alloys and many types of cast iron.

DRILLNG

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of

circular cross-section in solid materials. The drill bit is a rotary cutting tool, often

multipoint. The bit is pressed against the workpiece and rotated at rates from

hundreds to thousands of revolutions per minute. This forces the cutting edge

against the workpiece, cutting off chips (swarf) from the hole as it is drilled.

INSPECTION

Critical appraisal involving examination, measurement, testing, gauging, and

comparison of materials or items. An inspection determines if the material or item

is in proper quantity and condition, and if it conforms to the applicable or specified

requirements. Inspection is generally divided into three categories: (1) Receiving

inspection, (2) In-process inspection, and (3) Final inspection. In quality control

(which is guided by the principle that "Quality cannot be inspected into a product")

the role of inspection is to verify and validate the variance data; it does not involve

separating the good from the bad.

ASSEMBLY

An assembly line is a manufacturing process (most of the time called

a progressive assembly) in which parts (usually interchangeable parts) are added as

the semi-finished assembly moves from work station to work station where the

parts are added in sequence until the final assembly is produced. By mechanically

moving the parts to the assembly work and moving the semi-finished assembly

from work station to work station, a finished product can be assembled much faster

and with much less labor than by having workers carry parts to a stationary piece

for assembly.
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CHAPTER 4
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WORKING PRINCIPLE
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 CHAPTER-4

WORKING PRINCIPLE

The raw materials after the previous operations that are usually done before

ramming are completed and the raw materials are brought to this machine. Then

the raw materials are loaded into the sand box and shaped with a chisel or other

tools by hand. This shape may not be perfect since they are shaped perfectly with a

hydraulic jack. Once when the raw materials are loaded and shaped into the box,

the box is locked with a hasp for avoiding the leakage of raw materials from the

box when applying a force. A fixed plate is welded just above the box so that it

rams the raw materials inside the box.

Then the hydraulic jack is activated and the box is moved upward along with

the hydraulic jack. The hydraulic jack is activated until it touches the fixed plate

and some amount of force is given for the ramming operation. This process is

repeated twice or thrice for getting better results. Then this is left for some time for

drying and the post treatment are carried out for making the mould strong enough.

Once when they are dry, they are taken out by simply removing the hasp and

opening one side of the box. Then the next set of raw materials is loaded and the

operation is repeated for continuous ramming operations.

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CHAPTER 5
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2D DRAWING
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CHAPTER-5

2D DRAWING
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CHAPTER 6
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ADVANTAGES AND DISADVANTAGES
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 CHAPTER-6

ADVANTAGES AND DISADVANTAGES

ADVANTAGES

 Simple in operation.

 No need of skilled operator for operating the machine.

 The time consumption is less.

 Highly economical.

 Compact in size and hence portable.

DISADVANTAGES

 Large amount of sand cannot be rammed using this machine.

 This is a semi automation process.

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CHAPTER 7
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APPLICATIONS
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 CHAPTER-7

APPLICATIONS
These types of hydraulic brick making machines have a wide range of

applications in the fields like,

 Rural areas where the availability of fuel or gasoline is less.

 In small scale industries.

 In foundries.
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CHAPTER 8
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CONCLUSION
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 CHAPTER-8

CONCLUSION

This project work has provided us an excellent opportunity and experience,

to use our limited knowledge. We gained a lot of practical knowledge regarding,

planning, purchasing, assembling and machining while doing this project work.

We feel that the project work is a good solution to bridge the gates between the

institution and the industries.

We are proud that we have completed the work with the limited time

successfully. The “FABRICATION OF HYDRAULIC PRESS MACHINE

FOR FOUNDRY RAMMING” system is working with satisfactory conditions.

We can able to understand the difficulties in maintaining the tolerances and also

the quality. We have done to our ability and skill making maximum use of

available facilities.

Thus we have developed a “HYDRAULIC PRESS MACHINE FOR

FOUNDRY RAMMING” which helps to achieve the sand ramming operation at

a low time and with a low cost. This project helped us to gather knowledge about

the difficulties involved in the metal forming process, also we came to know about

the difficulties involved in fabricating a new innovation. By using more

techniques, they can be modified and developed according to the applications.