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Development of a Manually Operated Hydraulic Press and Pull Machine

Article · September 2017

DOI: 10.46792/fuoyejet.v2i2.111

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FUOYE Journal of Engineering and Technology, Volume 2, Issue 2, September 2017 ISSN: 2579-0625 (Online), 2579-0617 (Paper)

Development of a Manually Operated Hydraulic Press and Pull Machine

Bethrand N. Nwankwojike, *Chukwunonso N. Nwogu and Godswill Kalu
Department of Mechanical Engineering, Michael Okpara University of Agriculture Umudike, Nigeria
[email protected]|[email protected]|[email protected]

Abstract— A hydraulic press and pull machine comprising of a frame, cylinder and piston, two threaded studs, hydraulic pump and hose,
pulling clamp and a workpiece support was designed, fabricated and evaluated. The machine is manually operated. The maximum shear
force, maximum bending moment and maximum displacement of the machine workpiece support were determined as 74.9491N, 16.6335N-
m and 4.367e3mm for a simulated load of 1000N. Maximum axial, bending and torsional stresses were also determined as 0.00359, 701998
and 0.00653N/m2 respectively. performance of the developed machine was determined using seven bearings of bore diameters 24, 30, 40,
50, 65, 80 and 100mm respectively, fitted into seven corresponding shafts with shaft deviation of ±0.001mm and dismantled afterwards
using three different methods: traditional hammering, the developed manual hydraulic press and pull machine and already existing
electrically powered hydraulic press. The results of the experiments showed that traditional hammering is the most time consuming method
of mounting and dismounting force fits, followed by the use of the developed press-pull machine while electrically powered hydraulic
presses are the fastest.The machine which was fabricated with local materials will reduce the time and stress associated with installation
and removal of bearings, and other forms of force fits in machine assemblies. Hence, leading to an overall improvement in the standard of
machines/equipment fabricated in Nigeria.

Keywords— Bearing, fastening, housings, machine, press fitted elements, shafts.

——————————  ——————————

1 INTRODUCTION The major advantages of hydraulic presses over the

P
ress fit or friction fit, is an interference fit fastening other types of presses (power screw and mechanical
between two parts which is achieved by friction presses) include; hydraulic press provides a more
after the parts are pushed together, rather than by positive response to changes in input pressure, the force
any other means of fastening. Typical examples of and pressure can accurately be controlled, and the entire
interference fits are the press fitting of shafts into magnitude of force is available during the entire
bearings or bearings into their housings and the working stroke of the ram travel (Butcher, 2004; Sullivan,
attachment of watertight connectors to cables. An 2000; Cockbain, 1998; Doring, 1998). Hydraulic presses
interference fit also results when pipe fittings are are preferred when very large a nominal force is
assembled and tightened. required, hence the best option for mounting and
dismounting force fits (Lange 1975). The hydraulic press
In many workshops (especially small and medium is therefore a valuable equipment in the workshop and
scaled workshops), repair and replacement of press laboratory especially for press fitting operations and for
fitted machine elements are done in a crude manner. the deformation of materials such as in metal forming
This process wastes time and consumes a lot of energy, processes and material testing for strength (Dagwa and
as well as cause harm to the environment. Also the Ighadode, 2005; Harding, 1996).
material to be replaced or the machine/plant on which
the repairs is being carried out on may get damaged in Unfortunately, all such presses are imported into Nigeria
the process. The ability of a technician to carry out his and as such, cannot be afforded by small and medium
job safely, with less time and energy application scaled workshops or artisans. Also, existing presses are
depends on the availability of the right working tools. To electrically powered, which may not be readily available
perform jobs such as Pushing, pulling, thrusting and in small workshops. It is therefore important to design
rotation, presses are required. and manufacture a manually operated low cost
hydraulic press, using locally sourced materials like mild
For instance, the installation of bearings into housings or steel bars, pipes and rods, rubbers hoses, etc.
shafts and the extraction of such from a housing or shaft
depend largely on the tools and methods used. If The development of the manually operated hydraulic
bearings are not properly installed or removed, the effect press and pull machine will bring relief to workshops
is felt on the entire assembled machine. Also improper (especially small and medium scaled) by reducing the
installation of bearing causes vibration in rotating parts time and stress associated with installation and removal
and affects the geometric precision and surface integrity of bearings, and other forms of force fits in machine
of the balls and rollers (Khurmi and Gupta, 2006). assemblies, thereby ensuring easier and cheaper
Presses can be divided into the following categories: maintenance and repair of machines and plants. Since all
Hydraulic Presses which operate on the principles of parts of the machine were built with locally sourced
hydrostatic pressure, Screw presses which use power materials, this project therefore reduces dependence on
screws to transmit power and Mechanical Presses imported goods and promotes indigenous technology.
which utilize kinematic linkage of element to transmit
power (Niebel et al, 2007; Degarmo et al, 1997; Sharma,
2005).

*Corresponding Author

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2 METHODOLOGY 2015 simulation to determine the maximum shear stress,

2.1 DESIGN CONCEPTS AND CONSIDERATIONS maximum bending moment and the displacement on the
beam when loaded to deformation. This was done by
The design, material selection and development of the
first designing the part using Solidworks design
manually operated hydraulic press and pull machine
software. After the design, the part was assigned the
were based on the following concepts and
material mild steel from the Solidworks material
considerations:
database and the ends were restrained. Force (load) was
i. The machine was designed with provisions for
then applied to the part until it deformed. Maximum
adjustment, such that bearings of different
shear stress, maximum bending moment and the
diameters can be fit into shafts or housings of
displacement on the beam when loaded to deformation
different diameters and lengths.
was then displayed by the software. Solidworks uses the
ii. The hydraulic fluid is pumped manually, thus
maximum von Mises stress criterion to calculate these
ensuring that the machine does not require electrical
parameters. This criterion states that a ductile material
energy for its operation thereby incurring no
starts to yield when the equivalent stress (von Mises
operational cost.
stress) reaches the yield strength of the material
iii. The machine was fabricated using locally sourced
(Khurmi, 2010; Dassault Systemes, 2014). The yield
and available materials for easy operation,
strength (SIGYLD) is a material property which is
maintenance and repair/replacement in case of
defined as stress at which a material begins to deform
breakdown. Also, standard components/parts were
plastically. Table 1 below shows the model with its
used where necessary to ensure low cost of
material properties. When loads are applied to a body,
production and maintenance of the machine.
the body tries to absorb its effects by developing internal
forces that, in general, vary from one point to another
2.2 DESIGN ANALYSIS AND MATERIALS SELECTION
(Khurmi, 2010). The intensity of these internal forces is
Hydraulic cylinders are tubular structures in which a called stress. The units of stress are force per unit area.
piston slides when hydraulic fluid is admitted into it. For an estimated load of 1000N, determined by adding
The design requirements include; the minimum wall the weight of the workpiece and the force (press fitting
thickness of the cylinder, the end cover plate and the force) produced by the hydraulic pump, the beam forces
flange thickness (Sumaila, 2002). The minimum wall and resultant stresses are shown in tables 2 and 3
thickness, T of the hydraulic cylinder was computed to respectively. Also, the nodal stress plot, which shows the
be 12mm using equations 1 and 2 below (Khurmi and stress distribution on the component under load and the
Gupta, 2006). static displacement plot showing displacement along the
(1) workpiece support length were generated by the
analysis. These were displayed in figures 1 and 2
(2) respectively. In figure 1, the regions in red indicate
regions that will experience maximum bending stress
Where; ri = Internal radius of cylinder = 50x10-3m while the blue regions are the regions where bending
p = Internal fluid pressure = 3.82 N/m2 stress is minimum. The green region indicate regions
t = Tangential stress = 480x106 N/m2 (Khurmi and with intermediate value. Similarly, red regions in figure
Gupta, 2006). 2 indicate regions that will experience maximum
t depends on the material from which the deflection if the beam fails whereas the blue region will
cylinder was made. experience minimum deflection. Hence, bending stress is
The cylinder end cover plate thickness Tcp, was maximum at the ends of the support beam while
determined as 9.6mm using equation 3. deflection is maximum at the centre, where the
workpiece rests.
(3)
Where; D = Diameter of end cover plate = 0.1m Table1: Material Properties (Solidworks 2015 simulation)
K = coefficient depending upon the material of plate =
0.4 (Khurmi and Gupta 2006)

The flange thickness tf may be obtained by considering

the bending of the flange about a section where the
flange is weakest in bending. Thickness of the flange was
therefore determined as 49mm using equation 4.
(4)

Where: b = width of flange at the section under

consideration
δf = shear stress of flange material
M = resultant bending moment

Stress analysis of the workpiece support which is the

major load carrying member was done using Solidworks

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Table 2: Beam forces resolution 2.3M ACHINE M ANUFACTURING PROCEDURE/DESCRIPTION

The developed machine comprises of the following

Moment1(N.m)

Moment2(N.m)
parts: frame, cylinder and piston, two threaded studs,

Torque(N.m)
Beam Name

Shear1(N)

Shear2(N)
Axial(N)
Joints hydraulic pump and hose, pulling clamp and a
workpiece support. Figure 3 shows the isometric view of
the machine with the main components identified.

- - -
- 1.66
Workpiece support

4.643 3.53 74.9 1.774

1 16.7 364e
06e- 553e 491 22e-
544 -007
006 -009 007
- -
4.671 3.26
64.9 16.6 1.69 1.788
2 08e- 339e
554 335 229e 64e-
006 -009
-007 007

Table 3: Resultant stresses

Axial(N/m^2)

Case(N/m^2)
Dir1(N/m^2)

Dir2(N/m^2)

Torsional
Bending

Bending

(N/m^2)
Joints

Worst
Name
Beam

Fig. 3: Isometric view of the Force Fit Assembling Machine

The frame (Fig. 4) is the main supporting structure upon

which other components of this plant are mounted. The
- frame is a welded section constructed from 8 mm thick
0.00357 70710 0.005884
mild steel U-channel bar to withstand direct tension
Workpiece

1 0.0065 707101
support

158 1 67
2554 imposed on the pillars. The frame provides mounting
- points and maintains proper relative positions of the
0.00359 70199 0.005985 units and parts mounted on it over the period of service
2 0.0065 701998
314 8 99 under all specified working conditions. It also provides
786
general rigidity of the machine (Acherkan, 1993).

Fig. 1: Upper bound axial and bending stress Fig. 4: Frame

The cylinder is a 50 mm diameter hollow mild steel pipe

of 12.5 mm thickness and 250 mm length. The piston is
made from 25 mm diameter mild steel rod which is in
alignment with the center line of the cylinder bore. It
slides in and out of the cylinder while the hydraulic
pump is manually pumped. The lower end of the piston
which makes contact with the workpiece has a larger
diameter of 42 mm. The action of the piston causes either
insertion or removal of force fitted assemblies. Two
pieces of threaded stud of length 525 mm and diameter
20 mm were cut and four (4) nuts and spacer washers
were screw to it (two on a stud) to hold the stud at both
ends as shown in figure 1.

Fig. 2: Static displacement

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The force required to push and pull the piston is Table 5: determination of press fitting and dismounting
generated by a manually operated hydraulic pump. The time for different bearing-shaft assemblies
pump has an arm which when moved up and down, Time required to Time required to

Press fitting force (N)

releases hydraulic fluid into the hose to force the piston mount assembly dismount assembly
(mins) (mins)

diameter (mm)
Bearing bore
down. The hose helps over-come vibration and absorb
hydraulic impulse shock. Hence, it is installed in such a

hammering

hammering
Electrically

Electrically
Traditional

Traditional
press-pull

press-pull
Hydraulic

Hydraulic
hydraulic

hydraulic
powered

powered
machine

machine
way that there must be no twists. The workpiece support

press

press
is a hollow rectangular beam with dimension 920 mm x
80 mm x 60 mm, welded to the sides of the frame (below
the threaded studs) for holding the workpiece while
pushing or pulling operation is done on it. The support 24 337 30 11 8 25 9 -
is adjustable to accommodate varying dimensions of 30 427 35 15 8 25 9 -
workpieces by means of three (3) 17 mm diameter holes 40 517 37 15 10 28 9 -
50 607 40 18 10 29 10 -
drilled on both sides of the frame.
65 742 42 20 10 29 10 -
80 877 43 21 10 32 10 -
2.4 Performance Test Procedure 100 967 47 21 12 32 10 -
To test the performance of the developed machine, seven
bearings of bore diameters 24, 30, 40, 50, 65, 80 and 100 From table 5 above, press fitting force was determined
mm respectively were fitted into seven corresponding (using equation 4) for bearing bore diameters of 24, 30,
shafts with shaft deviation of ±0.001 mm and dismantled 40, 50, 65, 80 and 100mm as 337, 427, 517, 607, 742, 877
afterwards. The mounting and dismounting of the and 967N respectively. Hence, the force required to press
various bearing-shaft assemblies were done using three fit a shaft into a bearing increases as the diameters of the
different methods: traditional hammering, using the shaft and bearing bore increase i.e., bigger shaft and
developed manual hydraulic press and pull machine bearing assemblies require larger press fitting force than
and using already existing electrically powered smaller ones. Also, of the three methods investigated, it
hydraulic press in each case. The time taken to mount can be seen that traditional hammering is the most time
and dismount the various assemblies for the three consuming method of mounting and dismounting force
methods used was recorded. Also, the force required for fits, followed by the use of the developed press-pull
press fitting the assembly was determined using machine. Electrically powered hydraulic presses are seen
equation 5 (NSK, 2008). to be the most efficient (in terms of time conservation)
(5) for mounting force fits. Finally, with issues such as non-
availability of electricity in local workshops as well as
Where:
high cost of electrically powered hydraulic presses, the
= 0.7 to 0.9 developed manual hydraulic press and pull machine is
d = nominal bearing bore diameter thus the best option for local workshops and artisans.
Di = raceway diameter of inner ring
B = nominal inner ring width
∆d = effective interference
4 CONCLUSION
E = modulus of longitudinal elasticity = 208MPa A manually operated hydraulic press and pull machine
μ = friction coefficient of the fitted surface = 0.135 was produced using locally sourced materials. The
The nominal inner ring width (B) for the various bore strength of this machine was analyzed by simulating a
diameters were obtained from table 4. load of 1000N and the corresponding values of
maximum shear force, maximum bending moment and
Table 4: Nominal width for different bearing bore maximum displacement were determined as 74.9491N,
diameters (Khurmi and Gupta, 2006) 16.6335N-m and 4.367e3mm. Also, maximum axial stress,
Bearing bore diameter (mm) Nominal inner ring width (mm) bending stress and torsional stress where determined as
24 15 0.00359, 701998 and 0.00653N/m2 respectively. The
30 19 developed machine will bring relief to small and
40 23
50 27 medium scaled workshops and artisans by reducing the
65 33 time and stress associated with installation and removal
80 39 of bearings, and other forms of force fits in machine
100 43
assemblies.

3 RESULTS AND DISCUSSION REFERENCES

The results of the experimental investigation of the Acherkan N., (1993). Machine Tool, Vol 3. Mir public. Moscow,
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FUOYE Journal of Engineering and Technology, Volume 2, Issue 1, September 2017 ISSN: 2579-0625 (Online), 2579-0617 (Paper)

Dagwa I. M. and Ighadode, A. O. A., (2005). Design and

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