Title:

Design of hydraulic circuit and calculate main specification for a press machine with manually-
operated valves.

List of task (step to do)

Question 1:

- To define essential component of the hydraulic circuit

- Reservoir with its accessories
- Pump with prime mover mounted on reservoir
- A pressure pipeline emanating from pump
- Control valves
- Hydraulic cylinders
- Throttles
- Pipes with fitting
- Filters

Question 2:

1. To workout specification hydraulic power unit

a) Pump capacity
Calculate pump capacity Q (flow rate) for hydraulic unit by using:

Q = Q1+Q2 (m3/min)

Where;
Q1= flow rate for clamp cylinder
Q2 = flow rate for press cylinder
 Q= VA (m3/min)

Where;
V= velocity of the piston, m/min
A= working area of piston, m2

2. Working pressure

Calculation for working pressure for clamp and press cylinder of cylinder

P=

Where;

F = Force for clamp of press operation

Other parameter is as specified above

3. Calculate basic dimension for press cylinder piston

4. Power of electric motor

W= kW
600

Calculate the power W for electric motor for the ruining pump and choose the nearest
standard electric motor

Other parameter is specified above.

5. Reservoir size

The reservoir size S should be at least 4 times the flow rate of pump.
S= 4Q (m3)
Choose the nearest standard volume of reservoir
6. Present in the table basic parameter

Clamp cylinder Press cylinder

Resebult
Pump 0.0075 m3/min 0.0491 m3/min
Electrical motor 112.54W 1743W
Working process 1.193M Pa 18.476MPa
Diameter of pipe 0.04 m2 0.06m2
Diameter and length

7. Choose the accessories

Oil level gauge

A strainer and a filter
A breather filter
A pressure gauge for clamp and pressure lines
A relief valve for clamp and pressure lines
A check valve for clamp and pressure lines
Throttle
Filters
Others

8. Pipes size( internal diameter) for clamp and press cylinder

A=

Where;
V= Velocity of piston m/min
 9. Pressure drop in pipe lines with devices. Frictional losses (depends on laminar or turbulent
flow)
10. Describe work of hydraulic circuit of each component and unit in circuit.
11. Design hydraulic circuit of project and it in standard symbols
12. Provide conclusion for project

Introduction

In fluid power, hydraulics is used for the generation, control, and transmission of power
by the use of pressurized liquids. For the hydraulic machines, it was machinery and tools that
use liquid fluid power to do simple work. In this type of machine, hydraulic fluid is transmitted
throughout the machine to various hydraulic motors and hydraulic cylinders and which becomes
pressurized according to the resistance present. The fluid is controlled directly or automatically
by control valves and distributed through hoses and tubes. The popularity of hydraulic machinery
is due to the very large amount of power that can be transferred through small tubes and flexible
hoses, and the high power density and wide array of actuators that can make use of this power.
Hydraulic machinery is operated by the use of hydraulics, where a liquid is the powering
medium. A fundamental feature of hydraulic systems is the ability to apply force or torque
multiplication in an easy way, independent of the distance between the input and output, without
the need for mechanical gears or levers, either by altering the effective areas in two connected
cylinders or the effective displacement between a pump and motor.

Methodology hydraulic circuit

1) What are the specifications of the job?

Force requirement
Length of work stroke
Speed of piston and rod assembly
2) What size of cylinder is needed?

Force known. Cylinder Area & Operating

Pressure must be selected. F = PA
Standard bore and rod size cylinders

3) Cylinder Selection Reasoning?

Large or small diameter cylinder

Operates at low or high pressure
Requires bigger or smaller pump for speed give
Cylinder selected

4) What Size reservoir should be used?

2.5-3.0 times the pump capacity

What size of Electric Motor needed?
Calculate power required to run Pump
Consider efficiency of pump
Shaft size, type and electric source

Find Pressure and then select suitable pump

5) Size of pump inlet?

Inlet and outlet flow velocity

Size of Discharge tubing?
Relief valve selection
Pressure range
Valve port size
Direction Control valve
Work of the hydraulic circuit design and components

Double acting
cylinder

One way flow

control valve

Pressure
gauge

4/2 way dcv

Pressure valve normally
gauge returns with
level operated
Pump

In line return
Filter Relieve valve filter with by
pass

Figure 1: Hydraulic circuit

The function of this system is to first clamp the work piece then pressing operation is done. So
in this circuit 4/2 dcv normal return valve is use. Cylinder type used for press and clamp is
double acting type. Speed of press and clamp is control by one way control valve. The system
stat when level operated in clamping dcv is set on. Oil is supply to cylinder with desired speed
and makes the cylinder to extend. When level operated at press cylinder is set on the oil that
been eject from first cylinder is supply to second dcv valve and makes the press cylinder to
 extend. When both of the level operated is let off the dcv valve automatically retract and close
the supply of oil and makes both cylinder to retract back.

Methodology for calculation

Clamping cylinder: Pressing cylinder:

Load = 600kg Load = 100ton

Bore diameter = 80mm Bore diameter = 250mm
Clamping speed, V = 1.5 m/min Press return speed, V = 1.0 m/min

1. Pump capacity

Q = Q1+Q2 (m3/min) Q= VA

Where: Where:

Q1 = flow rate for clamp cylinder V= velocity of the piston, m/min

Q2 = flow rate for press cylinder A= working area of piston, m2

= 2 = 2
= (0.04)2 = (0.125)2
A = 0.00503 m2 (clamp cylinder) A = 0.0491 m2 (pressing cylinder)

Q = (1.5m/min x 0.00503m2) + (1.0m/min x 0.0491m2) = 0.0566m3/min

2. Working pressure

a) Clamp cylinder: b) Press cylinder:

P = (Pascal) P = (Pascal)

F = 600kg x 10 N F = 100ton (907.185kg)

= 6000N = 100ton x 907.185
= 2 = 90718.5 x 10 N
= 0.00503 m2 = 907185N
= 2
6000 = 0.0491 m2
P=
0.005032
= 1.193M Pa 907185
P=
0.0491 2
= 18.476MPa

3. Power of electric motor

a) Clampcylinder:
b) Press cylinder

W= (KW) W= (KW)
600 600
1.193 (0.0566m3 /min) 18.476 ( 0.0566m3 /min)
= =
600 600
= 112.54W = 1743W
4. Reservoir size

S = 4Q
= 4 (0.0566m3 /min)
= 0.2264 m3/min

5. Pipes size ( internal diameter)

a) Clampcylinder: b) Press cylinder:

A= A=

0.05663 / 0.05663 /
= =
1.5 / 1.0 /

= 0.04 m2 = 0.06m2

Discussion of Result

Conclusion
References