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Design and Dynamic Analysis of Hydraulic Press Machine for Sheet and Pipe Bending Operations

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Design and Dynamic Analysis of Hydraulic Press Machine for Sheet and Pipe Bending Operations International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017 Design and Dynamic Analysis of Hydraulic Press Machine for Sheet and Pipe bending Operations Chinthakindi Vinod, Assistant Professor, VJIT, Hyderabad. P. Chandra Kumar, Assistant Professor, VJIT, Hyderabad. CH. Sharath Reddy, Assistant Professor, JBREC, Hyderabad. Abstract: In present world industries are running into hydraulic, medical, and many other applications. automation in order to reduce human effort. In recent Tubes are measured by their outer diameter. Pipes years pipe bending and sheet bending machines are used are vessels that are used in transport systems for in industries as well as domestic purpose for bending the fluids. They are measured by their inside diameter. pipes and sheets of required angles. Types of Pipe Bending process In our project the Hydraulic Press Machine is implemented for pipe bending and sheet bending 1. Rotary draw bending operations. Hydraulic bending machine consists of 2. Compression bending Double acting cylinder, P-40 Direction control valve, 3. Ram bending Hoses, Motor, Pump, Rack and Pinion, Free wheel, 4. Roll bending bending tools and fixture. The pipe or sheet is bent by the hydraulic cylinder piston with holding the pipe or sheet in the fixture. The main advantage of our project is dual operations can be done on the machine. Designing of the machine is done in computer aided software CATIA. Structural loads are applied, so analysis of work piece and tools are done to find stress, strain, deformation, von misses stresses with the help of ANSYS software. Keywords: Hydraulic Press machine, tools, pipe and sheet bending, Hydraulic operation I. INTRODUCTION Pipes and Sheets are used in artistic ways in various fabrication works as well as in architectural works. To bend these pipes and sheets into required angles is not easy thing to be done manually. Using a Fig. Types of pipe bending methods particular machine specially developed for bending of pipes and sheets will be helpful. To design and manufacture such machines many equipment’s are 1.2 Sheet bending machine used. Bending of sheet metal is a common and vital 1.1 Pipe bending machine process in manufacturing industry. Sheet metal bending is the plastic deformation of the work over Tube and pipe bending machines are used to bend an axis, creating a change in the part's geometry. tubes and pipes in order to produce finished parts. After bending of sheet the thickness of sheet may Tubes are structural, hollow conduits which are changes a little. But in majority cases bending will used as flow lines for fluids in pneumatic, produce essentially no change in the thickness of the sheet metal. Bending is also used to impart strength and stiffness to sheet metal. Metal bending 1106 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017 enacts both tension and compression within the wall. A fluid, such as oil, is displaced when either material. piston is pushed inward. Since the fluid is Types of sheet metal bending process incompressible, the volume that the small piston displaces is equal to the volumedisplaced by the 1. Sheet metal bending with a v die large piston. This causes a difference in the length 2. Edge bending with wiping die of displacement, which is proportional to the ratio of areas of the heads of the pistons, given that volume = area × length.Therefore, the small piston must be moved a large distance to get the large piston to move significantly. 2.2 Application Hydraulic presses are commonly used for forging, clinching, moulding, blanking, punching, deepdrawing, and metal forming operations. Fig. Sheet metal bending with a V die 2.3 Material Data The materials which are used are mentioned below with their properties. 2.3.1 Properties of Gray Cast Iron Table Density 7.2e-006 kg mm^-3 Coefficient of Thermal Expansion 1.1e-005 C^-1 4.47e+005 MJ kg^-1 Specific Heat C^-1 5.2e-002 W mm^-1 C^- Fig. Edge bending with wiping die Thermal Conductivity 1 Resistivity 9.6e-005 ohm mm II. PIPE AND SHEET BENDING MACHINE Compressive Ultimate 2.1 Hydraulic Press Strength 820 MPa A hydraulic press is a device (see machine press) Compressive Yield using a hydraulic cylinder to generate acompressive Strength 0 MPa force. It uses the hydraulic equivalent of a mechanical lever, Principle The hydraulicpress Tensile Yield Strength 0 MPa depends on Pascal's principle: the pressure throughout a closed system is constant. One partof Tensile Ultimate the system is a piston acting as a pump, with a Strength 240 MPa modest mechanical force acting on a small Reference Temperature 22oc crosssectional area; the other part is a piston with a larger area which generates a correspondingly large Young's Modulus 1.1e+005 MPa mechanical force. Only small diameter tubing Poisson's Ratio 0.28 (which more easily resists pressure) is needed if Bulk Modulus 83333 MPa thepump is separated from the press cylinder. Pascal's law: Pressure on a confined fluid is Shear Modulus 42969 MPa transmitted undiminished and acts with equal force Relative Permeability 10000 on equal areas and at 90 degrees to thecontainer 1107 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017 2.3.2 Properties of Structural Steel 2.4. Construction details of hydraulic pipe and Table sheet bending machine Density 7.85e-006 kg mm^-3 The Hydraulic pipe and sheet bending machine consists of the following parts: Coefficient of Thermal 1. Base Plate Expansion 1.2e-005 C^-1 Base Plate is the base member of the machine. The Specific Heat 4.34e+005 MJ kg^-1 C^-1 entire assembly of the machine is done onto the Thermal Conductivity 6.05e-002 W mm^-1 C^-1 base plate. Base plate is structural steel (EN9). The Resistivity 1.7e-004 ohm mm pillars are mounted on to the base plate using Socket head bolts M8. Compressive Ultimate 2. Pillar Strength 0 MPa Pillar is an structural steel (EN9 vertical Compressive Yield member of the structure of the press whichis Strength 250 MPa held on to the base plate using Socket head bolts Tensile Yield Strength 250 MPa M8. The pillar is provided with holes equi-spaced Tensile Ultimate Strength 460 MPa (3 No’s ) to receive the Dowell pins which act as pivot for the die roller Reference Temperature 22oc 3. Top Fix Plate Young's Modulus 2.e+005 MPa Top plate is structural steel (EN9 horizontal Poisson's Ratio 0.3 member of the structure of the press which is held Bulk Modulus 1.6667e+005 MPa on to the top of the LH & RH_ Pillars and held in Shear Modulus 76923 MPa place by using horizontal support, M20 Hex nut, and Lock nut. Relative Permeability 10000 4. Hydraulic cylinder Hydraulic cylinder is fixed vertically at horizontal 2.3.3 Properties of Stainless Steel support rods at top place and provide thehydraulic Table cylinder piston and attached sheet and pipe press Density 7.75e-006 kg mm^-3 parts are attached to the ram of the jack which provide the automatic return after bending operation Coefficient of Thermal Expansion 1.7e-005 C^-1 is over. Specific Heat 4.8e+005 MJ kg^-1 C^-1 5. Machine properties Hydraulic press machine is 3000 kg capacity with Thermal Conductivity 1.51e-002 W mm^-1 C^-1 the following parts: Resistivity 7.7e-004 ohm mm a. Release valve Compressive Ultimate b. Base Strength 0 MPa c. Adjusting screws Compressive Yield Strength 207 MPa d. Ram Tensile Yield Strength 207 MPa e. Cylinder Tensile Ultimate Strength 586 MPa f. Oil Tight tank Reference Temperature 22oc g. Sheet and pipes bend parts Young's Modulus 1.93e+005MPa h. Pump Body Poisson's Ratio 0.31 i. Pump Plunger Bulk Modulus 1.693e+005 MPa j. Safe valve Shear Modulus 73664 MPa k. Handle. Relative Permeability 10000 1108 Chinthakindi Vinod, P. Chandra Kumar, CH. Sharath Reddy International Journal of Engineering Technology Science and Research IJETSR www.ijetsr.com ISSN 2394 – 3386 Volume 4, Issue 12 December 2017 2.5. Advantages of hydraulic pipe and sheet III. DESIGN OF PIPE CUM SHEET BENDING bending machine MACHINE 1. 5000 kg push force, makes possible bending of heavy sections possible CATIA enables the creation of 3D parts, 3D 2. Ease of operation sketches, sheet metal, tooling parts up to the 3. Gradual application of force prevents the pipe definition of mechanical assemblies. The software and sheet damage. provides advanced technologies for mechanical 4. Quick release of the ram using relief valve surfacing & BIW. CATIA offers a solution to shape makes operation fast. design, styling, surfacing workflow and 5. Ease of maintenance. visualization to create, modify, and validate 6. Less cost complex innovative shapes from industrial design. 2.6. Applications CATIA supports multiple stages of product design. 1. Automobile industry 2. Process equipment press. 3.1 Schematic diagrams 3. Industrial piping and sheet errection. 4. Small industries works. 3.1.1 Sketch of Sheet bending tool 2.7. Technical specifications of project Below are the 2-D Sketch diagrams of Sheet Table Bending tool with dimensions. All dimensions are in mm. 20mm x 1.5mm Max. Tube Capacity (Ferrous tubes UTS (D x T) 45 Kg/mm2) Min. Tube Capacity (Diameter) 6mm Min sheet capacity (mm) 0.5 mm Max. Bend Radius(CLR) 80mm Max sheet press 25mm Min.
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