HYDRAULICALLY OPERATED PIPE CLAMP PRESSING DEVICE

Submitted in the partial fulfillment of the requirement for the award of

“DIPLOMA IN MECHANICAL ENGINEERING ”

SUBMITTED BY:

1. G.K. MANIGANDAN 4. J. DHANAJEYAN 2. B. KARTHIKEYAN 5. D. DURAIVEL 3. P. BALASUBRAMANI 6. L. PRABHU

Under guidance of

Mr. V.K. RAJENDRAN,M.E.

APRIL 2013.

DEPARTMENT OF MECHANICAL ENGINEERING

A M K TECHNOLOGICAL POLYTECHNIC COLLEGECHEM BARAMBAKKAM, CHENNAI – 602 103

A M K TECHNOLOGICAL POLYTECHNIC COLLEGECHEM BARAMBAKKAM, CHENNAI – 602 103

BONAFIDE CERTIFICATE

This is to certify that this Project work on

“HYDRAULICALLY OPERATED PIPE CLAMP PRESSING DEVICE”

submitted by …………………… ……………. Reg. No. ……………

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING

This is the bonafide record of work carried out by him under our supervision

during the year 2013

Submitted for the Viva-voce exam held on ……………..

HEAD OF THE DEPARTMENT PROJECT GUIDE

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr. R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement

and valuable advice.

we thank our Esquired Head of Department Mr R. RAJKUMAR,

A.M.I.E, M.E., for presenting his felicitations on us.

We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E.,

for guiding in various aspects of the project making it a grand success.

We also owe our sincere thanks to all staff members of the

Mechanical Engineering Department.

Ultimately, we extend our thanks to all who had rendered their co-

operation for the success of the project.

CONTENTS

CONTENTS

Chapter No. TITLE

1. INTRODUCTION

2. SYNOPSIS

3. CONSTRUCTION

4. WORKING PRINCIPLE

5. DESCRIPTION OF HYDRAULIC JACK

6. HYDRAULIC CIRCUIT DIAGRAM

7. MECHANICAL SPARE PARTS DETAILS

8. ADVANTAGES

9. SAFTY,CARE AND MAINTENANCE

10. FINISHING AND PAINTING

11. COST ESTIMATION

12. CONCLUSION

13. BIBILOGRAPHY

14. PHOTO VIEW

INTRODUCTION

INTRODUCTION

This is a self – assessment test on the part of the students to assess his

competency in creativity.

During the course of study, the student is put on a sound theoretical

foundation of various mechanical engineering subjects and of course, to a

satisfactory extent. Opportunities are made available to him to work on

different kinds of machines, so that he is exposed to various kinds of

manufacturing process.

As a students learn more and more his hold on production technology

becomes stronger. He attains a stage of perfection, when he himself is able

to design and fabricate a device.

This is the project work. That is the testimony for the strenuous

training, which the student had in the institute. This assures that he is no

more a student, he is an engineer.

This report discuses the necessity of the project and various aspects of

planning , design, selection of materials, fabrication, erection, estimation and

testing.

SYNOPSIS

SYNOPSIS

A hydraulic fluid power system is defined as a means of

power transmission in which relatively incompressible fluid is used as the

power transmitting media. The primary purpose of hydraulic system is the

transfer of energy from one location to another location and this energy into

useful work.

In this project of the fabricated model of HYDRAULIC PIPE CLAMP

PREESING MACHINE is used to bend the pipe clamp and it will describe

the working principles as well as hydraulic machines application and its

advantages. Efforts have been taken to show the path of hydraulic fluid as it

is applied and released. The Hydraulic system pressure can be generated in

the form of any physical action which result a compression over the

Hydraulic system or pneumatic pressure which is developed in the form of

air compressing externally can be applied to activate Hydraulic system.

There is a constant relation between pressure density, and volume,

According to Bernoulli’s equation. Liquids can be heated by applying high

pressure without any external heat energy supplied to them. So the specific

heat of any liquid system which is used in the hydraulic machinery must be

more than enough to with stand the pressure applied over them also viscosity

must be high enough for smooth conversion of external pressure applied

over them to hydraulic pressure.

CONSTRUCTION

CONSTRUCTION

This unit consists of

a) M.S. Fabricated stand

b) Hydraulic jack with Pressing die set

c) Handle

A ) M.S .FABRICATED STAND ;

This stand is used to hold the hydraulic jack with pressing tool and tool

guide base. The work to be pressed is placed between the male and female

die set which are mounted above jack ..

HYDRAULIC JACK

A Hydraulic Jack is a device using Hydraulic Power in its simplest possible

shape shown in figure and consists of five fundamental components.

1. pump

2. reservoir

3. cylinder

4. suction valve and

5. delivery valve

WORKING PRINCPLE

WORKING PRINCPLE

This device is worked by the principle of hydraulic lifting system..

This is operated by hydraulic power without use of man power. This unit

consists of

d) M.S. Fabricated stand

e) Hydraulic jack with pressing tool

f) Handle

The M.S. stand is used to hold the hydraulic jack with pressing tool. The

work to be pressed is placed between the die set. The male die is mounted at

top of the frame and the female die is mounted below the male die. The

female die moves up and down by the action of hydraulic jack.when the

handled is operated , the piston in the jack moved upward along with the

female die and press the work.finally the male part of the die coincide with

the female die to make the pipe clamp.

To lower the piston in the jack , the drain valve is unscrewed. The

pressurized oil under the piston returns to reservoir . hence the piston along

with the female die lowered to take the pipe clamp..

WORKING OF HYDRAULIC JACK;

A Hydraulic Jack or for that matter any device using Hydraulic Power

in its simplest possible shape consists of five fundamental components.

A. The Hydraulic Reservoir storing the Hydraulic Oil (Oil is used as the

medium to transmit force and motion-such fluids are called Hydraulic

Oils) should be thoroughly clean, whether integrally built-in or used

as a separate tank.

Pump, either of the integral or the remote control type, comprises of highly

precision engineered pump plunger, cylinder, suction and delivery valves,

safety valves with conical or steel balls matched with micron tolerances.

Very often O Rings and special seals are used, made from specially treated

leather or synthetic nitrile rubber or Teflon or other modern substitutes for

greater resistance to wear and sealing ower

It is imperative that these must function at peak efficiency by regular

cleaning and flushing of foreign particles which enter into the

hydraulic system and may clog the delicate valves, damage the seals

and affect the functioning of other elements in the hydraulic circuit.

B. A pump by itself would be useless without a system of VALVES to

govern the flow of hydraulic oil to perform the desired function.

C. The transmission of hydraulic oil from the reservoir by the pump

through the valves to Ram & Cylinder which converts the hydraulic

pressure into a mechanical force is by means of a Hydraulic Circuit

which is nothing but a network of passages in hydraulic systems.

These passages are formed with the help of Steel Tubes, Flexible

Hydraulic Hoses or through internal holes or cavities in metal blocks.

It is of the utmost importance that the circuit is always leak proof as

well as free from obstacles. Each joint or coupling must be securely

tightened or replaced forthwith. No air lock or foreign particles

should be allowed to interrupt or block the free flow of hydraulic oil.

D. All hydraulic cylinders consists of two basic elements – the outer

housing is called the Cylinder body and the inner sliding elements is

called the Ram (or piston or plunger) which actually converts the

hydraulic pressure into mechanical force and transmits to the desired

point for performing the function. The movement of Ram is always in

line with cylinder under pressure.

Hydraulic Oil is pumped into the cylinder and as more and more oil is

forced into the cylinder pressure builds up and when enough oil is

forced into the cylinder the resultant pressure will cause the ram,

plunger or piston to move and consequently lift, press, push, pull or

bend any object any object as the case may be.

The Ram and Cylinder are also precision engineered and mostly fitted

with high quality seals which give it the necessary compression

holding capacity and prevent leakages.

The five fundamental components already illustrated and described

combined together perform the specified job by a synchronous follow

through of their individual functions.

1. The release valve is closed tightly to ensure flow of oil from the pump

to the cylinder only.

2. As soon as the pump is operated oil is sucked in from the reservoir.

As the Pump Plunger is raised up oil passes from the reservoir into

the pump cylinder with the Suction Valve opening up to allow oil from

reservoir to enter into pump cylinder.

3. When the Pump Plunger is pressed down the Delivery Valve opens up

to allow the passage of oil from the pump into the cylinder, at the

same time the suction valve automatically closes to prevent oil

returning to the reservoir.

4. By repeating the above two operations successively more and more oil

is pumped into the cylinder resulting in the generation of pressure by

the action of the load being lifted.

5. When the load is desired to be lowered the pressure within the

cylinder is released by operating the Release Valve. The oil flows

back into the reservoir shown in the diagram in page 1.

6. Due to neglect or other causes pressure within the system may

continue to increase beyond the predetermined safe working limit. To

prevent damage to the system a safety relief valve is located between

the cylinder and the reservoir excessive pressure by the opening up of

the safety valve and discharge of oil into the reservoir (very often the

safety overload preventive relief valve is located in between the

reservoir and the pump – the pump automatically cuts off without

delivery of oil to the cylinder due to generation of excessive pressure

within the pump).

The simple diagram shown in page 1 shall help to understand the

working of the hydraulic system in a more graphic manner.

HYDRAULIC CIRCUIT

DIAGRAM

MECHANICAL SPARE

PARTS DIAGRAM

ADVANTAGES

ADVANTAGES

1. It eliminates complicated parts like hydraulic cylinder pipe

connections and pressure tubes.

2. Fluid Power transmitted through port so high efficient.

3. Control of system is easier

4. Maintenance cost is less

5. Can be achieved up to two ton force.

In this Hydraulic system lubricating system not necessary so that wear and

tear very low.

1. Single person is enough to operate this efficiently to make the pipe

clamp.

2. Easy and efficient handling of this unit without wastage or damage to

any other parts.

3. Increase the jack life.

4. Least maintenance of the equipment.

5. Need not require any individual work place.

6. Can be worked in the work spot.

7. Suited for making pipe clamp as well as bending.

SAFTY,CARE AND

MAINTENANCE

BASIC SAFETY RULES FOR HYDRAULIC JACKS;

The nature of lifting operation should determine the choice of jacking

equipment-integral or remote control pump type jacks. Capacity and the

hydraulic lifting stroke are vital aspects to be carefully determined before

selection.

Lifting any load calls for precise and safe jacking points. Jack should be

centrally loaded eccentric loading causes dangerous accidents and damages

beyond repair.

The world over prudent safety minded operators observe the flowing basic

safety rules :

A. To overpower the load, whether one or a dozen cylinders are used to lift

the load, the cylinder lifting capacity should be two times the weight of

the load. This allows for a reduction in the oil pressure, prevents strain

and possible break-down of the cylinder.

B. To balance the load, for large, heavy and uneven loads, it is

recommended dividing the load evenly between a number of cylinders.

These cylinders should be placed beneath the load at points providing the

best support, balance and stability. For example, to lift a 200-tonns load,

the necessary 400-tonnes capacity could be handled by four 100-tonnes

cylinders.

C. Never raise the hydraulic ram beyond the specified stroke (lift).

D. Never drop (shock) load on the hydraulic ram.

E. Never go under a load supported by hydraulic ram only.

F. Never extend the hydraulic ram by means other than the pump.

G. Never use hydraulic equipment with observed leakages.

H. Use safety lock nut type jacks for supporting load on jack for long

periods.

I. Use steel plates or heavy wooden sleepers where ground surface is soft

and yielding

J. Do not disturb the factory preset internal safety valve provided for

preventing overloading.

K. Do not load more than 50% of the rated head capacity on the toe (claw)

of toe lifting jacks.

Positioning the Jack

Jack should be centrally loaded, jack base and upper jacking point must be

in level.

Raising the Jack

Turn the release valve in clockwise direction till tight, use end of slotted

operating handles. Start pumping with a regular handle movement. Make

only few fast and rapid download delivery strokes, Jack handle slightly

downward, in case the delivery does not close instantly. Check that the

saddles rests firmly against the Jacking point.

Lowering the Jack

Turn the release valve SLOWLY anticlockwise.

Jack Storage

Retract ram completely, close oil filler, keep the Jack away in a safe clean

place.

Caution

Do not use the Jack beyond rated capacity and lift mentioned on the name

plate.

Making Jack ready for use

VANJAX Hydraulic Jacks are supplied ready for use. Unlock the release

valve half a turn and operate the pump few times to flush the hydraulic unit

free from airlocking.

DO’S AND DON’TS

Do’s Don’ts

Air venting is an important

precaution for the successful

Under no circumstances the

equipment should be used beyond

performance of any hydraulic jack

or hydraulically operated device,

equipment or system.

rated capacity or rated stroke. It is

in the interest of the user and for the

protection of his costly equipment to

ensure correct selection of the

capacity and restricting the stroke

within the rated stroke length.

All couplings and other fasteners

should be properly tightened.

Do not forcibly hammer fit

accessories if falling short by a

fraction of the required length or

spread. Use the next higher size

equipment. Abuse of accessories

and attachments are hazardous both

for the equipment and the personnel.

At all times the entire equipments

should be kept free from dust

through regular systematic cleaning.

Do not expose the equipment to

areas of excessive heat or where

dirt, dust and heavily laden fumes /

smoke are prevalent. If the

equipment is used in such areas it is

absolutely essential to service it at

once.

Check oil level each time before

use.

Do not refill without a reliable

strainer

Every time the hydraulic hose is

attached to the pump and the ram

cylinder assembly unit, it should be

thoroughly flushed.

Do not use brake fluid as refill.

Release valve to be properly

tightened by turning it in clock-wise

direction when applying load. For

releasing pressure open release

valve gradually by turning it in anti-

clockwise direction.

Do not hammer to open guide nuts.

Open by guide nut spanner.

The equipment must be centrally loaded. The pressure screw in a hydraulic puller should be absolutely perpendicular to the axis of the load.

Do not apply extra force to close the release valve. Normal hand pressure is enough.

As refill we recommend IOC Code No. Servo System 32 and 46, HPC Hydrol 0232 or any other equivalent.

Do not use fluffy cloth or cotton waste for cleaning cylinder ram, valve, pump and oil tank.

VANJAX cannot be held responsible for damage or injury caused by unsafe

use, maintenance or application of its products.

Trouble Shooting Chart for VANJAX Hydraulic Jacks and

Hydraulically Operated Equipment.

Trouble Probable cause Remedy

Jack will not close immediately

Air under Cylinder or Oil Tank

Open the oil filler plug/air breathe or open the release key and operate the pump handle few time to breath out the air the close the release valve.

Pump handle stroke partly effective

Air in pump chamber

Open release valve. Operate the pump handle rapidly several times. Close release valve.

Pump handle raise without efforts

Sticky suction and delivery valve

Remove pump, clean valve unit and reset valve unit Open release valve and operate the pump rapidly a few times.

Jack will not rise to full height

Lack of oil or leakage

Refill with fresh oil. Check for leakage.

Jack raises and falls during each stroke

Leaky suction & delivery valve

Tighten the pump and then operate. If defect still persists the remove valve body, clean properly replace the defective parts, make a fresh seat and assemble accordingly.

Jack will not raise up to specified lift

Or

Jack will not hold the rated load.

a) Pump is not properly tightened

b) Release key is not completely closed

c) Suction and delivery valve are defective.

a) Tighten the pump properly.

b) Close release key completely

c) Check inbuilt valve capsule ball seating accordingly.

PAINTING AND FINISHING

FINISHING AND PAINTING

JOB PREPARATION

Before welding, remove any bend in the L angle with the sludge

hammer on the anvil block. Then it is cut to the required length with the

hacksaw blade and fabricated to required dimensional shape with arc

welding.

FINISHING OPERATION BEFORE PAINTING

After welding, any slag on the welded area is removed with the

chipping hammer and cleaned with the metal wire brush. Then all the

surfaces are rubbed with the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the

metal primer, the second coating is applied with the paint.

COST ESTIMATION

COST ESTIMATION

1.Work holding support and pressing tool 1800,00

2. hydraulic jack 2800.00

3 . M.S. Fabricated housing unit 600.00

5. Painting cost 200.00

6. transport cost 200.00

TOTAL COST 5600.00

CONCLUSION

CONCLUSION

We make this project entirely different from other projects. Since

concepts involved in our project is entirely different that a single unit is used

to various purposes, which is not developed by any of other team members.

By doing this project we gained the knowledge of fabrication work

and how the welding is doing and material selection for particular

components etc.,

It is concluded that any fabrication work can be done with the help of

welding.

We have successfully completed the project work on using welding

work at our Institute.

Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY -HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY -R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY -S.S.MANIAN

4. JIG AND FIXTURE DESIGN - R.K.JAIN

PHOTO VIEW

PHOTO VIEW