See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/344546800

Design of Hydraulically controlled Machine Tool to Perform Multiple

Machining Operations

Article · December 2019

CITATIONS READS

0 82

2 authors:

Yogendra Rajpoot Avadesh Kumar Sharma

Rajkiya Engineering Colllege ,Mainpuri Maulana Azad National Institute of Technology, Bhopal
8 PUBLICATIONS 8 CITATIONS 83 PUBLICATIONS 342 CITATIONS

SEE PROFILE SEE PROFILE

All content following this page was uploaded by Avadesh Kumar Sharma on 29 September 2021.

The user has requested enhancement of the downloaded file.

 Manufacturing Technology and Research (An International Journal)| Volume 12 | Issue 1-2 | Month Jan-Dec(2019) ISSN: 0973-0281

Design of Hydraulically controlled Machine Tool to Perform Multiple Machining

Operations
1
Mohd Almasood , Yogendra Singh Rajpoot2, Dr. A K Sharma3
1, 2, 3
Department of Mechanical Engineering, Rajkiya Engineering College Mainpuri, Mainpuri, 205119, INDIA
Affiliated to AKTU Lucknow Uttar Pradesh India

Abstract- Since the ancient period, machining is one of the most important processes to produce good overall finished product.
There are many machining operations which are required for manufacturing finish product. In earlier days almost all industries
were using conventional hand powered machines .Manual manufacturing with the help of these conventional machines leads to
high time consumption, high labour cost, less accuracy, poor quality of overall finished product. Now days, with rise in science
and technology, the industries are developing rapidly which leads to decrement in man power gradually. Therefore, there is
reduction in labour costs.

By the use of automation technology, we try to develop the hydraulic based machine tool for producing better quality products
with high productivity, accuracy and low cost. Whole machine tool is made up of hydraulic devices, sensors and mechatronics.
Primary reciprocating motion is done by movement of piston of hydraulic cylinder. Above movement is made automated using
electro hydraulic components such as hydraulic cylinder, direction control valve, throttle valve (flow control cum check valve),
hydraulic power pack, proximity sensors and other electrical and electronic devices.

For the automation of machine tool, hydraulic circuit is developed with the help of hydraulic cylinder, hydraulic power pack,
direction control valve and throttle valve while the electric circuit is developed by connecting different electrical and electronic
devices such as relays, proximity sensors switches, on/off push button switches etc.

Keywords: Automation; electrohydraulic components; hydraulic power pack; electrical and electronic devices.

1. Introduction

Hydraulic controlled machine tool is a reciprocating type of machine tool. Multiple operations
refers to combination of different machine tool i.e. drill machine tool and grinder while hydraulic
based machine tool refers to its primary mechanism which is based on electro-hydraulic
automation i.e. combination of hydraulic circuit and electric circuit. This machine tool is
expected to perform the individual operation of above two different machine tools. This machine
tool is intended to produce drill the holes, grind the job to produce good surface finish and to
improve its dimensional accuracy.
Since Drill and grinder are the parts of this machine tool, therefore the description of each
machine tool is described below:-
A drill is a machine tool primarily used for making round holes. It is fitted with a bit, either a
drill or driver, depending on application, mounted by a chuck. Around 10,000 years ago, first
machine drill i.e. bow drill was discovered by Homo sapiens [9]. In this machine tool, electrically
powered corded drill is used.
Grinder, is one of machine tools which are used for grinding, it is a type of machining using an
abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip
from the work piece via shear deformation [8]. In this machine tool, bench grinder is used.

Perpendicular axes movement of this hydraulic based machine tool:-

1
* Mohd Almasood. Tel.: +91 6394742753; fax: .
E-mail address: almamohd786@gmail.com

Page | 38
 1. Reciprocating motion in X-axis is done by movement of piston hydraulic cylinder which
is further controlled by electric circuit.
2. We can also vary the stroke length and its speed in forward direction through proximity
sensors and throttle valve respectively.
3. Motion in Y-direction is governed by screw nut mechanism which is controlled by pulley
wheel arrangement to separate motor.
4. Motion in Z-direction governed by motorized screw jack.

2. General idea of design and production of hydraulic machine tool

Development of hydraulic system: - The solution to a control problem is worked out

according to a system with documentation playing an important role in communicating the final
result. The hydraulic and electric circuit diagrams of hydraulic system are drawn using standard
symbols with their labelling. Complete documentation is required including most of the
following
Circuit diagrams.
Description of operation of the system.
Technical data of components.
Parts list of all components in the system [2].

2.1. Hydraulic circuit diagram of single double acting cylinder

b1
b2

y1 y2

0.00 Ba r

Fig.1 Hydraulic Circuit

This circuit comprise hydraulic cylinder, throttle valve, power pack, pressure relief valve,
4/3 way electric directional control valve, proximity sensors, hose pipes and connectors.
Right side solenoid of valve is designated Y1 and left side of solenoid is designated Y2.
B-port of direction control valve is connected to the throttle valve which is further
connected to the front end port of hydraulic cylinder.
A-port of direction control valve is connected directly to rear end port of hydraulic
cylinder.

Page | 39
 Pressurized fluid line is connected to P-port while return tank line is connected to T-port.
Proximity sensors are arranged near the piston, one at its desired stroke length and other
at zero stroke length.

2.2. Electric circuit of hydraulic system:

k1 s2 k1 k2 k2
s1 b1 b2

k2
k3 k1

y1 y2
k3 k3
k1
k2

Fig.2 Electric Circuit

Electric circuit comprises of relays coils and its contacts, push button switches, electric
direction control valve, proximity sensors, 24 volts DC power supply.
3 relay coils with 3 contacts of each coil respectively are used.
Relay 1 is designated as K1, relay 2 and relay 3 also designated as K2 and K3 similarly
and respectively.
Relay 1 and relay 3 are connected to power source through two ways, firstly through push
button switches S1and S2 respectively and secondly through proximity sensors switches
B1 and B2.
Solenoid Y1 and solenoid Y2 are actuated by normally open contacts of relay K1 and
relay K2 respectively.
Normally closed contacts of relay 3 are connected in between the relay 1 and relay 2.

2.3. Working of Hydraulic System

When the hydraulic power pack is actuated and 24V DC power supply is on, piston of
hydraulic cylinder is in the range of proximity sensor B1, then solenoid Y1 gets actuated
and piston moves in forward direction.
After reaching in the range of proximity sensor B2, solenoid Y2 gets actuated and piston
moves in backward direction.
This will continue as reciprocating motion till the stop push button switch S2 is pressed.
When the switch S2 is pressed, piston will stop at instant.
At this instant, solenoids Y1 and Y2 both gets deactivated.
When the switch S1 is pressed the solenoid gets actuated again and piston follows the
default reverse backward direction.
With the help of throttle valve, we can vary the speed of piston in forward stroke
depending upon the requirement of machining operation. While the speed of piston
remains constant (i.e. full throttle speed) in reverse stroke. Thus, it fulfills the different
requirements of different operations.

Page | 40
 With the variation in distance between the proximity sensors, we can easily vary the
stroke length and fix the position of starting of piston.

3. Design of Model of Complete Machine Tool

Supporting structure of complete machine tool is designed on solidworks 2018 to incorporate

the hydraulic system to perform our intended operations. Structure is divided into parts, in one
part, hydraulic system is incorporated while in other part there will be electrical system for
drilling and grinding operations.
Drill chuck
and drill bit Grinding wheel
Hydraulic piston
cylinder assembly
Table (1)

Work holding
device Motorized
screw jack

Nut screw Casted bed

Arrangement

Fig.3 3D Model of Machine tool

In one part of machine tool on leftmost side as we can see in picture, hydraulic piston
cylinder assembly is permanently fastened i.e. welded to nuts of nut screw arrangement.
Nut screw arrangement is basically comprise of two screw which rotates about its own axis

Nut screw arrangement is mounted on cast body in which both the nuts are connected to
each other and hydraulic piston cylinder assembly while one of the screw is connected to
motor through pulley wheel arrangement to make it electrically controlled.
This nut screw arrangement is used to give transverse motion to hydraulic cylinder.
In second part of machine tool i.e. rightmost side of machine tool, screw jack is mounted on
casted body which is further connected to table.
Screw rod of screw jack is connected to motor, thus it is making the vertical up and down
motion of table (1) electrically controlled.
Hydraulic power pack is kept beside the bed.
Throttle valve is mounted beside nut screw arrangement motor.
Since piston do reciprocating motion in X-axis, thus all perpendicular axes motions are
achieved in design.
On table (1), whole drill and grinder arrangement is mounted.
Work holding device for drill and grinder arrangement is mounted on piston of hydraulic
cylinder.

Page | 41
 Drill and grinder arrangement comprise of drill chuck, drill bit, shaft, motor, abrasive
grinding wheel, bearing support, bearing.
In this arrangement, a little long shaft is coupled with motor and drill chuck and abrasive
wheel is fitted on that same shaft.

4. Working of complete hydraulic based machine tool

For drilling operation, workpiece holding device is connected to piston and rotation of
drill bit is done through attached motor.
Rotating drill bit remains stationary at table (1) while table (1) do reciprocating
vertical up and down motion through screw jack.
Workpiece holding device gets the motion from piston and nut screw arrangement and
fed to drill bit to make required size of hole.
Similarly for grinding operation workpiece holding device is mounted on piston and
rotation of abrasive wheel is done through attached motor. Wheel remains stationary at
rotating table (1) while workpiece holding device gets the same motion from piston,
nut screw arrangement and screw jack as same in case of drilling machine tool to
improve surface finish.
Thus, all the intended operations are performed.

5. Conclusion

In this project the conventional single machine tools are converted into hydraulic based
machine tool by which operating time will be saved. Thus, the output will be increased.
Since this is a combination of machine tools in a single machine tool, so it also reduces the
production cost as well as the cost of machine tool.
This machine tool is converted into semi-automatic and semi-electrically controlled because
the loading and unloading of workpiece, connecting different machine tool is done manually.
It also reduces the large floor area at workplace and allows to perform the different
operations at single platform.
Since this machine tool uses the hydraulic reciprocating mechanism, so there is a very small
inertia of moving parts, therefore there are very less vibration in machine tool.
Hence here we conclude that, this project is made keeping the two things in mind that
different machine tools which are based on mostly same mechanism can be combined in one
machine tool and we can also use the different automation technique.
There is still wide scope in the area of automation to make it fully automatic to reduce the
huge idle time.
We can also add even more different machine tools.
Thus, lots of improvement can be made with the latest technology.

Page | 42
View publication stats

References

1. M. King, B. Zhu, and S. Tang (2001) (vol. 8, no. 2), pp. 520-531.
2. Bharath, Siddharam Patil, RM Lathe (2013), automation using Electro-Pneumatic devices and Plcs ,
(vol. 8).
3. Hydraulic and pneumatic manuals- Bosch Rexroth.
4. Manufacturing technology volume 2, metal cutting and machine tools by P N Rao.
5. Design of Hydraulic circuit for CNC lathe machine converted from conventional lathe machine.
6. Low cost automation.
7. Machine tools and automation by H.P. Potts.
8. Grinding: Wikipedia.
9. Drill: Wikipedia.
10. B. Suresh Kumar, N. Baskar, K. Rajaguru (2020), Drilling operation: A review , (vol. 21).

Page | 43