International Journal of Research in Mechanical Engineering

Volume-2, Issue-2, March-April, 2014, pp. 13-22, IASTER 2014

www.iaster.com, ISSN Online:2347-5188 Print: 2347-8772

Design of Hydraulic Power Pack for

Vertical Turret Lathe
1
M. Rama Narasimha Reddy, 2D. Sreenivasulu Reddy, 1P. Sundera,
1
S. Madhusudhana
1
Department of Mechanical Engineering, SVTM (JNTUA), Madanapalli, A.P., India.
2
HOD, Department of Mechanical Engineering, SVTM (JNTUA), Madanapalli, A.P., India

ABSTRACT
The project is aimed at the Design of hydraulic power pack for vertical turret lathe. This Hydraulic
power pack is used to obtain the various motions of the Vertical Turret Lathe Clamping and
unclamping is also done with hydraulic system. Hence versatility and reliability of hydraulics is
prime importance. The power pack is an integral supply unit usually containing a pump, reservoir,
relief valve and direction control valve, Pressure control valve. For the purpose of design of
hydraulic power pack, the component are to be designed are pump, reservoir, heat exchanger and an
electric motor. Hydraulic drives and controls have become more important due to automation and
mechanization. Many of the modern and powerful machinery are controlled partly or completely by
hydraulics. Hydraulic system is less complicated and has less moving parts. Today drive and control
system engineering is inconceivable without hydraulics. Special emphasis is made on design of power
pack in which the elements, maintenance aspects and trouble-shooting methods is dealt with.

Keywords: Turret Lathe, Hydraulic Power Pack, Hydraulic Fluid Flow, Turret Indexing, Turret
Clamping, Pressure Loss.

1. INTRODUCTION
The word hydraulics is derived from the Greek word hydro means water. The term hydraulics means
the transmission and control of forces and movement by means of fluid. The power pack is an integral
power supply unit, which basically determines the working of the control unit. Power packs offer
capacities, control options and configuration for virtually any application requirement. A wide variety
of manifold options and choice of pumps enables customers to match any application requirement
with a power pack that meets his system, at the same time ensuring cost effective operation and
optimum productivity. A hydraulic power pack offers a simple method of introducing hydraulic
Operation to individual machines, with flexibility of being adaptable to other duties.

Fig 1 Line Diagram of Hydraulic Power Pack Fig 2 Circuit Diagram of Hydraulic Power Pack

It consists basically of an integral electrical motor, with associated tank. The pump or motor unit may be
mounted on the tank or separately and packs are usually available in either horizontal or vertical
configuration. Relief and check valves are normally incorporated on the tank. The basic unit may be

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piped to the cylinders or actuators through a suitable control valve. Hose assemblies are generally
preferred to rigid piping for connecting the power pack to actuators. The hydraulic power packs consist
of a reservoir / tank that house the hydraulic fluid, which is the working medium. The capacity of the
tank may vary accordingly to the requirements. The reservoir is also equipped with an air breather at the
top to maintain the pressure in the tank at the atmospheric pressure and filters the oil to 40 microns.

1.1 Working

The working of a power pack commences when the pump is initialized with the help of an electric
motor coupled to it. The oil is pumped from the reservoir along the suction line through a suction
strainer with a capability to retain the foreign particles up to 149 microns. From the suction line the oil
is forced in to the pressure line through the pump at 35 bars. There is provision to measure the
pressure, with the help of a pressure gauge. An isolator is used to measure the pressure immediately in
any line. When the set of pressure is reached, the fluid moves to the cylinder present at the fixture
(clamp). The hydraulic energy of the fluid is converted back to the mechanical energy by the cylinder.
According to the direction of the energizing of the solenoid valve, the linear movement of the clamps
(clamping and unclamping) is controlled. When the solenoid valve is energized in reverse,
unclamping of the work piece occurs. There is a return line provided so that the used fluid may be
utilized again. Due to the friction losses, total energy is not converted into the useful work so a part is
converted into the heat. So, a heat exchanger is incorporated. The return line filter has a return
capacity of 10 microns.

A vertical turret lathe works much like an engine lathe turned

up on End. The principles used to operate a vertical turret lathe
are not very different from those for a horizontal turret lathe.
The only significant difference is in the main turret. And also
feed is transferred vertically toward the headstock (down), and
at an angle. To cut a taper of less than 30 and more than with a
main turret-held tool, set the turret slide for the correct degree
of taper and use only the vertical feed for the slide. In this type
of turret lathe, the revolving turret is mounted on a ram or a
slide carried in a base which can be clamped in any position
along the bed of the machine, as shown in fig.
Fig 3 Vertical Turret Lathe
A turret lathe can perform internal or external work such as turning, boring, drilling reaming, tapping,
threading, forming, knurling, chamfering and parting off etc. the operations which are usually
performed from the hexagonal turret include: turning, boring, drilling, reaming, tapping and threading.
The operations which are done from cross slides include: facing, forming, knurling, chamfering,
recessing and paring off. Internal cuts are almost always made by tools in hexagonal turret.

Technical Specifications of Vertical Turret Lathe Component

NAME DESCRIPTION
Table diameter 1500mm.
Maximum swing diameter 1650mm.
Maximum turning height above top of table 1200mm.
speed range (Infinitely variable) 4 to 200mm.
Turret feed range 0.05 to 10mm/Rev
Vertical travel of Cross Rail 750mm.

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Vertical travel of Turret 700mm.

Distance from Tabletop to Turret face 1304mm.
Swivel of Turret Head 30 deg on either side.
Rapid traverse rate(X & Y Direction) 2000mm/min
Main Motor Power 30KW
Type of Spindle motor speed A.C Variable
Feed motor torque (X & Y axes) 18.5 N-m
Type of feed motor (X & Y axes) A.C Servo.
Power supply 415+_10% Hz+3%
Table loading capacity 2000Kg
Table stopping By Regenerative
Gross weight of machine 25 Tonnes
Total connected load 60 KVA

1.3 Different Fluids used in Hydraulics

1. Water 2. Mineral oil 3. Organic oil 4. Synthetic oil
Water was one of the most widely used hydraulic fluid in early hydraulic machinery. It has the
advantages of being inexpensive, readily available. Its disadvantages are that it is a poor lubricant, is
corrosive to steel and iron, and cannot be used below 0c unless additives are added. In spite of its
disadvantages it is still used in large central hydraulic pressure systems such as in rubber plants and
modeling plants. Mineral oil has displaced water as a hydraulic fluid in hydraulic machine design.
Mineral oil is a good lubricant and if proper oils are selected it can be used successfully at sub
freezing temperatures. Mineral oil has the disadvantages of having poor temperature, viscosity
characteristics. Various additives have been included in mineral oils to improve their viscosity
characteristics. Organics oils have received wide use as hydraulic fluids, notably in automobile
breaks. This has been brought about by the use of natural rubber for lines and packing. Organic oil do
not affect natural rubber. These oils are rapidly and must have additive to minimize these tendencies.
In recent years, synthetic oil notably, the silicons have been offered for hydraulic service. They are
excellent for this use but cost more than mineral oils. Their advantages lie in their freedom from
sludge forming components and they have very flat viscosity characteristics.

1.4 Design Considerations

1. Space Available: The available physical-space with in which a hydraulic cylinder or a fluid must
be accommodates or dictates the size of cylinder or the fluid motor.

2. Force Required: Once the piston size is decided, the force required at the actuator depends up on
the working pressure of the system. Higher the working pressure, lower is the size and weight of the
actuator, for the same force. But it results in many disadvantages. systems working pressure are
known the power of the prime mover can be easily calculated. There by the size of the reservoir, the
suction strainer, the pipelines and all other valves are determined.

3. Flow Required: The speed of the actuator determines the flow capacity of the pump.

4. Environmental Conditions: This determines whether the system should have ordinary or fire
proof hydraulic fluid in hazardous condition, shock resistance on mobile use, nonmagnetic
construction in certain applications, noise elimination arrangement in noisy atmosphere, more
filtration arrangement in a dusty atmosphere and some special designs of mountings or fittings in
typical applications is required.

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5. Economical Consideration: This is the most important factor, which must be kept in mind while
designing a hydraulic circuit. If a hydraulic machine is likely to operate only a few hours in a month,
no customer will likely to buy it, if its cost is very high. If a hydraulic machine is likely to operate 24
hours a day, the life expectancy of each component becomes an important consideration. The need of
frequent replacement of components will create maintenance problems and production losses.

2. DESIGN CALCULATIONS (DATA FROM THE MACHINE DESIGN DEPARMENT)

1 Number of Cylinders for Cross Rail Movement 2

2 Number of cylinders for cross rail support 2
3 Number of cylinders for Clamping &de-clamping chuck 1
4 Number of cylinders for ram counter balancing 2
5 Number of cylinders for turret indexing location 1
6 Number of cylinders for turret clamping 1
Total No of cylinders 9 Nos

2.1 Dimensions of Cylinders

Rate of traverse of all pistons V = 20mm/sec.

Diameter in (mm) Stroke No. of

S. No. Type of Cylinder
Length Cylinders
Bore Rod
1. Cross Rail Movement 125 70 900 2
2. Cross Rail Support 70 50 200 2
3. Chuck 120 60 320 1
4. Turret Indexing 55 20 550 1
5. Turret Clamping 90 45 600 1
6. Ram Counter Balance 63 28 850 2

Design of Circuit Diagram for Vertical Turret Lathe

Fig 4 Circuit diagram of Vertical Turret Lathe Fig 5 Block Diagram of Hydraulic Fluid Flow
with Cylinders

The circuit diagram in fig shows how to control a machine element with double acting cylinder and a
direction control valve condition the system pressure is maintained by the pressure relief valve. All
return lines from the system are bought back to the reservoir. The control valve could be actuated by
various manual, hydraulic elements as shown in fig. one of the problems of such a circuit is that the
cylinder cannot have an intermediate position.

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Design of Line Diagram for Fluid Flow Circuit Diagram for Fluid Flow

Fig 6 Line Diagram of Energy Transfer Fig 7 Circuit Diagram of Fluid Flow

The line diagram consists of various components. Design of a hydraulic system starts with the mode of
energy transfer in the system the energy transfer in the system is done by the pump which draws the oil
from the reservoir and transfers the same to the system we know that energy transfer occurs due to changes
in potential energy inside the reservoir and as the oil starts moving on wards there are further losses.

The circuit diagram in fig shows how to control a machine element with double acting cylinder and a
direction control valve condition the system pressure is maintained by the pressure relief valve . All
return lines from the system are bought back to the reservoir. The control valve could be actuated by
various manual, hydraulic elements as shown in fig. one of the problems of such a circuit is that the
cylinder cannot have an intermediate position.

In the circuit diagram the cylinder movement is controlled by a direction control valve (DCV) with
solenoid control. The electrical system used to control the solenoids could again be a simple
manual push button type or could also be made automatic by using limit switches it may be noted
here that the addition of a non return valve in the return line to provide some resistance to the
flow of oil through the return line will project.

Calculations for Pump Size and Details of Fluids

a) Working pressure of fluid = 70kg/cm.
b) Oil viscosity () = 68cst mm/sec.
c) Oil density () = 0.89 kg/m.

1) Considering Cross Rail Movement

Fluid flow rate: Q=AV = 3.141 constant.
Q = Rate of flow in l/min, A = Area of cylinder in m, V = Velocity in m/sec
A = /4[(125)-(70)] = 8423.395mm
Q1 = 8423.395 x 20 = 168467.9 mm/sec.
= 168467.9x60
1000x1000 = 10.10 l/min.
The flow rate is calculated for only one cylinder. As there are 2 cylinders, the total flow rate is
Q1 = 10.10x2 = 20.20 l/min.

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2) For Cross Rail Support

Area A = /4 x [(70) (50)] = 1884.95 mm
Flow rate Q = 1884.95 x 20 mm/sec. = 2.262 l/min.
The fluid flow rate for two such cylinders is Q2 = 4.523 l/min.

3) For Chuck
Flow rate: Q3 = /4 x [(120)-(602) ]x 20 = 169646.80 mm/sec. Q3 =10.1648 l/min.

4) For Turret indexing

Flow rate: Q4 = /4 x [(35)-(202)] x 20 = 41233.5 mm/sec.
Q4 = 2.47400 l/min.
5) For Turret Clamping
Flow rate: Q5 = /4 x [(90)-(45)] x 20 =
95425.876 mm/sec. = Q5= 5.725 l/min.

6) For RAM Counter Balance

Flow rate: Q6 = /4 x [(63)-(282)] x 20 = 50029.86 mm/sec = 3.00179 l/min.
For two such cylinders Q6 = 3.00179 x 2 = 6.4676 l/min.

Pump selected should be able to supply fluid at a flow rate required by different cylinders working at
given time, i.e. the pump flow rate is taken as maximum value among Q1, Q2, Q3,Q4, Q5 and Q6.

Therefore the flow rate of Q1 is selected. For better result it is taken 120% of the maximum value.
Flow rate of Q1 = 20.20 x 1.2
Flow rate of Q1 = 24.24 l/min

According to standards the pump of fluid flow rate 30 l/min is selected.

Calculations for Power of Electric Motor

Pump flow in l/min, Working pressure in N/m.

Geometric efficiency = 0.8 (assumed) ,
K= proportion constant in fluid flow
30 X 70
Power = ------------------ = 4.9282 KW = 5.71 HP.
612 X 0.8

The motor considering the various requirements taken the motor of 10 HP is selected.
Calculations for Tank Capacity

To provide uninterrupted supply of hydraulic fluid and to prevent vacuum inside the tank, capacity is
taken as 2.5 to 3 times of the pump capacity. Therefore the tank capacity is taken as 3 x 30=90 l/min.

But the lubrication oil is also pimped from the tank to the chuck with a 10HP motor therefore the
total capacity of the tank is 90 x 2=180 l/min.

Therefore from the standards, the tank capacity of 250 litres is selected.

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Calculation for Relative Pressure Loss

VXD
a) Reynolds No. Re =- ------------------

Where
V= velocity of fluid flow through pipe in m/sec.
= viscosity of fluid in m/sec and
D= inner diameter of pipe in mm.

b) Pressure Losses in Pipe Connected to a Cylinder

X X L X V X 10
P= ----------------------------------------
2XD
= pipe coefficient in friction, L=length of pipe (meters),
V= flow sped in the line (m/s) D= Diameter of pipe in mm,
= density of the oil in kg/m, k=valves of factor =10 (wide open).

1) Cross Rail Movement

Flow rate Q = 336935.8 mm/sec., Area A = 78.5 mm,

Diameter of hose D = 8 mm, Length of hose L= 1000 mm.
Velocity of fluid is calculated from the Bernoullis equation of fluid flow, Q= AV
V= 336935.8 mm/sec = 6703.851 mm/sec.

() Re = 6703.851 x 8 = 788.2
68
(<2300 hence the flow is laminar)
() = 64/ 788.2= 0.0812
() P = 0.0812 x 0.89 x 1000 x (6.698) x10 = = 2.02bar
2x8
2) Cross Rail Support
Q= 75398.2 mm/sec., A= 50.26 mm, D= 08 mm. (diameter of hose)
L1= 1500 mm., V= 75398.2/ 50.26 = 1501.95 mm/sec.
() Re= 1501.95 x 10 = 176.7
68
() = 64 /176.7= 0.362
() P1 = 0.362 x 0.89 x 1500 x (1.501) x 10
2x8
= 0.436 bar (RH)
P2 = 0.362 x 0.89 x 1500 x (1.501) x 10
2x8
= 0.436 bar (LH)
Total pressure loss= 0.436+0.436 = 0.872 bar.

3) For Turret Indexing

Q = 41233.50 mm/sec., Diameter of hose D = 4mm,

A= 12.566mm, L= 650mm.,
V= 41255.50 =3282.925
12.566

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(i) Re = 3282.92 x 4 = 193.144

68
(ii) = 64 / 193.14=0.811
(iii) P = 0.811 x 0.89 x 650 x 1.53 x 10 = 1.2 bars
2x4
4) For Chuck
Q = 169646.80 mm/sec., D= Diameter of hose = 8mm.
A = 50.265 mm. L = 2000mm.
V = 169646.800/50.265= 3375 mm/sec
(i) Re = 3375 x 8 = 397.176
68
(ii) = 64/397.176= 0.1609
(iii) P = 0.1609 x 0.89 x 2000 x(0.45) x 10 = 2.72/8= 0.34 bars

5) For Turret Clamping and Unclamping

Q = 95425.876mm/sec., D= Hose diameter = 8mm
A = 50.26mm L = 900mm., V = 95425.876/ 50.26= 1898.64mm/sec.
(i). Re = 1898.64 x 8 = 223.36
68
(ii) . = 64/ 223.36= 0.286
(iii). P = 0.286 x 900 x 0.89 x 1.89 x 10 =0.5168 bars
2x8
6) For Ram Balance
Q = 100059.726mm/sec., D= Hose diameter = 10mm.
A = 157mm, L = 2000mm., V = 100059.729/ 157= 637.72 mm/sec.
(i) Re = 637.72 x 10 = 93.8
68
(ii) = 64/ 93.8=0.689
(iii) P = 0.689 x 0.89 x 2000 x 1.32 x 10 = 0.255 bars
2 x 20
7) Pressure Loss between Reservoir and Hydraulic Manifold
Q = 30 l/min.
30x1000x1000 = 500000 mm/sec
60
D= Diameter of hose = 15mm, L= 7000mm, A = 176.714 mm.
V = 500000/ 176.714 = 2829.43 mm/sec.
(i) Re = 2829.43 x 15 = 624.139
68
(ii) = 64/ 624.139= 0.1025
(iii) P= 0.1025 x 0.89 x 7000 x 2.829 x 10 = 1.704 bar.
2 x 15
As the fluid is transferred from reservoir to the system through the manifold, the pressure loss of
hydraulic manifold is to be added to every system. Then the total pressure loss of every system is
given follows.
Cross rail movement = 2.02+1.704 = 3.724 bar
Cross rail support = 0.436+1.704 = 2.14 bar
For turret Index = 1.2+1.704 = 2.904 bar
Chuck = 2.72+1.704 = 4.424 bar
Turret clamping = 0.5168+1.704 = 2.22 bar
Ram balancing = 0.255+1.704 = 1.959 bar

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Calculation of Total Pressure Loss in the System

Here for effective design considerations the maximum values among the loss of pressure valves are
selected. Therefore the maximum value is 4.424 bar of chuck. There are two such lines connected to
the system so maximum loss of power in the system is given as 4.424 x 2 = 8.848 bar.

Diameter in (mm) Pressure

Stroke No. of Discharge
S.No Type of Cylinder Loss in
Bore Rod Length Cylinders In Lpm
Bar
1. Cross Rail Movement 125 70 900 2 20.20 3.724
2. Cross Rail Support 70 50 200 2 4.523 2.14
2.14
3. Chuck 120 60 320 1 10.16 2.904
4. Turret Indexing 35 20 550 1 2.47 4.424
5. Turret Clamping 90 40 600 1 5.72 2.22
6. Ram Counter Balance 63 28 1100 2 6.46 1.959

Pressure Loss through the Valves

For solenoid valve of model no. DSG 01 3C D24

N150 and flow rate 20l/min is selected from the
curves
P----A line = 1.1 kgf/cm.
B----T line = 1 kgf/cm.
P----B line = 1.1 kgf/cm.
A----T line = 1 kgf/cm.
Total pressure loss of the system = 4.2 kgf/cm. Fig 8 Losses Through Valves

Here four valves are used in the circuit at the various locations so the total pressure drop of the circuit
= 4.2 x 2 = 8.4 kgf/cm.

Total discharge in the pipeline is Q = 20.20+4.523+10.16+2.47+5.72+6.46 Q = 49.5381 l/min.

3. RESULTS

After designing and selecting the required parts of the Hydraulic Power Pack including calculations of
power requirements of motor and pump, it was found that the Hydraulic clamping system is more
efficient and economical compared to Mechanical clamping system comprising of various levers,
screws, cams etc. which are prone to overloading prevalent in many component clamping units.

= 49.5389 X 8.4 X 100 = 866.775 watts. = 1.606 HP

0.8 X 60
But 1 HP = 641.2 kcal/hr. Then 2.206 HP = 700.55 kcal/hr.
So the cooler capacity of 2000 kcal/hr is selected for heat exchanging.

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4. CONCLUSION

By employing a Hydraulic system, the advantage over Mechanical and Electrical systems are:
Possibility of automation of all types of movements. Speeds, forces can be easily and infinitely
controlled by using cylinders, and linear movements can be carried out without the use of Mechanical
components. Simple protection against overload can be made by means of pressure relief using
hydraulic. Safe control systems without electricity for use in areas where there is danger of explosion.

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