CHAPTER-1
INTRODUCTION

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 fabricated model of Multipurpose Hydraulic angle forming machine will describe. Metal forming can be defined as a process in which the desired shape is obtained through the deformation of metals plastically under the action of externally applied force. The type of drive depends upon the length of the stroke needed and loads on the ram. In this project we have applied to the hydraulic force for the angle forming machine. The Hydraulic drive is used when a very heavy pressures is required on the ram this is used for drawing and forming operation .System pressure can be generated in the form of any physical action which results in a compression over the Hydraulic system.

CHAPRT-2
BASIC PRINCIPLE 2.1 PASCAL’S LAW Fig no:1 * Pascal’s law states that the pressure applied anywhere to a confined liquid it transmitted equally to every portion of the surface of the containing vessel. * Refer the above fig. When a force is applied to the liquid by a piston, the liquid transmits this force equally to all surfaces of the container.

2.2 HYDRULIC PRINCIPLES

There are certain governing principles in a hydraulic system
1. All liquids are non-compressible and can be used to transmit power.
2. Any load to be lifted offers resistance to flow of liquid. This resistance to flow is pressure.
3. If the capacity of the pump is more, then it pumps out more liquid. If it pumps out more liquid, then it makes the hydraulic actuators (hydraulic cylinder) (or) hydraulic for the speed of the hydraulic actuator.
DIAGRAM

Fig no:2
4. If the force developed in the hydraulic cylinder is more than the external load, then the actuator lifts the external load. If the force developed in the hydraulic cylinder is less than the external load, then the actuator will not lift the external load. The flow rate is nothing to do with the load carrying capacity of the hydraulic system.
5. If the operation of a hydraulic system, the liquid chooses the path of least resistance
For example, there are two passages of flow from the pump. One path is connected to the hydraulic actuator to lift the load. Another path is connected to the reservoir. The liquid will choose the path of least resistance (reservoir path) and flows back into the reservoir, without choosing the path that offers higher resistance i.e. lifting the load. Ultimately, the load remains no lifted in this case.

CHAPTER-3
DESCRIPTION OF THE HYDRAULIC COMPONENTS

3.1 HYDRAULIC CYLINDER

A Hydraulic cylinder (also called a linear hydraulic motor) is a mechanical actuator that is used to give a linear force through a linear stroke. It has many applications, notably in engineering vehicles. Contents * Operation * Parts of a hydraulic cylinder * Cylinder barrel * Cylinder Bottom or Cap * Cylinder Head * Piston * Piston Rod * Rod Gland * Other part

3.1.1 OPERATION OF HYDRAULIC CYLINDER

Hydraulic cylinders get their power from pressurized hydraulic fluid, which is typically oil. The hydraulic cylinder consists of a cylinder barrel, in which a piston connected to a piston rod moves back and forth. The barrel is closed on each end by the cylinder bottom (also called the cap end) and by the cylinder head where the piston rod comes out of the cylinder. The piston has sliding rings and seals. The piston divides the inside of the cylinder in two chambers, the bottom chamber (cap end) and the piston rod side chamber (rod end). The hydraulic pressure acts on the piston to do linear work and motion. Flanges, trunnions, and/or clevises are mounted to the cylinder body. The piston rod also has mounting attachments to connect the cylinder to the object or machine component that it is pushing. A hydraulic cylinder is the actuator or “motor” side of this system. The “generator” side of the hydraulic system is the hydraulic pump which brings in a fixed or regulated flow of oil to the bottom side of the hydraulic cylinder, to move the piston rod upwards. The piston pushes the oil in the other chamber back to the reservoir. If we assume that the oil pressure in the piston rod chamber is approximately zero, the force on the piston rod equals the pressure in the cylinder times the piston area (F=PA). The piston moves instead downwards if oil is pumped into the piston rod side chamber and the oil from the piston area flows back to the reservoir without pressure. The pressure in the piston rod area chamber is (Pull Force) / (piston area – piston rod area).

3.1.2 CUT SECTION OF THE HYDRAULIC CYLINDER

Fig no:3 3.1.3 PARTS OF HYDRAULIC CYLINDER
A hydraulic cylinder consists of the following parts: 3.1.4 CYLINDER BARREL The cylinder barrel is mostly a seamless thick walled forged pipe that must be machined internally. The cylinder barrel is ground and/or honed internally. 3.1.5 CYLINDER BOTTAM OR CAP
In most hydraulic cylinders, the barrel and the bottom portion are welded together. This can damage the inside of the barrel if done poorly. Therefore some cylinder designs have a screwed or flanged connection from the cylinder end cap to the barrel. (See "Tie Rod Cylinders" below) In this type the barrel can be disassembled and repaired in future.

3.1.6 CYLINDER HEAD
The cylinder head is sometimes connected to the barrel with a sort of a simple lock (for simple cylinders). In general however the connection is screwed or flanged. Flange connections are the best, but also the most expensive. A flange has to be welded to the pipe before machining.
The advantage is that the connection is bolted and always simple to remove. For larger cylinder sizes, the disconnection of a screw with a diameter of 300 to 600 mm is a huge problem as well as the alignment during mounting.
3.1.7 PISTON
The piston is a short, cylinder-shaped metal component that separates the two sides of the cylinder barrel internally. The piston is usually machined with grooves to fit elastomeric or metal seals. These seals are often O-rings, U-cups or cast iron rings. They prevent the pressurized hydraulic oil from passing by the piston to the chamber on the opposite side.
This difference in pressure between the two sides of the piston causes the cylinder to extend and retract. Piston seals vary in design and material according to the pressure and temperature requirements. Generally speaking, elastomeric seals made from nitrile rubber or other materials are best in lower temperature environments while seals made of Viton are better for higher temperatures. The best seals for high temperature are cast iron piston rings.

3.1.8 PISTON ROD
The piston rod is typically a hard chrome-plated piece of cold-rolled steel which attaches to the piston and extends from the cylinder through the rod-end head. In double rod-end cylinders, the actuator has a rod extending from both sides of the piston and out both ends of the barrel.
The piston rod connects the hydraulic actuator to the machine component doing the work. This connection can be in the form of a machine thread or a mounting attachment such as a rod-clevis or rod-eye. These mounting attachments can be threaded or welded to the piston rod or, in some cases, they are a machined part of the rod-end.

3.1.9 ROD GLAND
The cylinder head is fitted with seals to prevent the pressurized oil from leaking past the interface between the rod and the head. This area is called the rod gland. It often has another seal called a rod wiper which prevents contaminants from entering the cylinder when the extended rod retracts back into the cylinder.
The rod gland also has a rod bearing. This bearing supports the weight of the piston rod and guides it as it passes back and forth through the rod gland. In some cases, especially in small hydraulic cylinders, the rod gland and the rod bearing are made from a single integral machined part.

3.1.10 OTHER PARTS

* Cylinder bottom connection * Seals * Cushions
A hydraulic cylinder should be used for pushing and pulling only. No bending moments or side loads should be transmitted to the piston rod or the cylinder. For this reason, the ideal connection of a hydraulic cylinder is a single clevis with a spherical ball bearing. This allows the hydraulic actuator to move and allow for any misalignment between the actuator and the load it is pushing.

3.2 HYDRAULIC PUMP
3.2.1 PRINCIPLES AND TYPES OF THE HYDRAULIC PUMP
Hydraulic pumps are used in hydraulic drive systems and can be hydrostatic or hydrodynamic. Hydrostatic pumps are positive displacement pumps while hydrodynamic pumps can be fixed displacement pumps, in which the displacement (flow through the pump per rotation of the pump) cannot be adjusted or variable displacement pumps, which have a more complicated construction that allows the displacement to be adjusted.

3.2.2 PUMP SELECTION
Pumps are selected by considering the following factors:
1. Discharge (flow rate) requirements. (in litres/mm)
2. Operating speed (in rpm)
3. Pressure rating (in bar)
4. Performance
5. Reliability
6. Maintenance
7. Cost
8. Noise
3.2.3 TYPE OF PUMP USED In this project we have used reciprocating pump, to pump the hydraulic fluid to the piston. The working principle of reciprocating pumps is explained below.
3.2.4 AXIAL PUMP SWASH PLATE PRINCIPLE
Axial piston pumps using the swash plate principle (fixed and adjustable displacement) have a quality that is almost the same as the bent axis model. They have the advantage of being more compact in design. The pumps are easier and more economical to manufacture; the disadvantage is that they are more sensitive to oil contamination.

3.2.5 RADIAL PISTON PUMPS
Radial piston pumps (fixed displacement) are used especially for high pressure and relatively small flows. Pressures of up to 650 bar are normal. In fact variable displacement is not possible, but sometimes the pump is designed in such a way that the plungers can be switched off one by one, so that a sort of variable displacement pump is obtained.
3.3 HYDRAULIC FLUID AND ITS CHARACTERS Hydraulic fluids, also called hydraulic liquids, are the medium by which power is transferred in hydraulic machinery. Common hydraulic fluids are based on mineral oil or water. Examples of equipment that might use hydraulic fluids include excavators, brakes, power steering systems, transmissions, backhoes, garbage trucks, aircraft flight control systems and industrial machinery.
Hydraulic systems like the ones mentioned above will work most efficiently if the hydraulic fluid used has low compressibility.
1 Functions and properties
2 Compositions

3.3.1 FUNCTIONS AND PROPERTY
The primary function of a hydraulic fluid is to convey power. In use, however, there are other important functions of hydraulic fluid such as protection of the hydraulic machine components. The table below lists the major functions of a hydraulic fluid and the properties of a fluid that affect its ability to perform that function:
3.3.2 FUNTION PROPERTY * Medium for power transfer and control * Low compressibility (high bulk modulus) * Fast air release * Low foaming tendency * Low volatility * Medium for heat transfer * Good thermal capacity and conductivity * Sealing Medium * Adequate viscosity and viscosity index * Shear stability * Lubricant Viscosity for film maintenance * Low temperature fluidity * Functioning life * Material compatibility

3.3.3 COMPOSITION

Hydraulic fluids can contain a wide range of chemical compounds, including: oils, butanol, esters (e.g. phthalates, like DEHP, and adipates, like bis(2-ethylhexyl) adipate), polyalkylene glycols (PAG), phosphate esters (e.g. tributylphosphate), silicones, alkylated aromatic hydrocarbons, polyalphaolefins (PAO) (e.g. polyisobutenes), corrosion inhibitors, etc.

CHAPTER-4
DESIGN PROCETURE
4.1 PROPERTIES OF MILD STEEL
4.1.1 PHYSICAL PROPERTY * Density-7860/m3 * Melting point -1427 * Thermal conductivity – 63
4.1.2 CARBON CONTENT Low carbon (or) Mild steel – 0.15 to 0.45carbon
4.1.3 MECHANICAL PROPERTY * Elasticity * Ductility * Toughness * Weld ability

In our design, screwed spindle have a main part hence the calculation are concentrated on it.

4.2 HYDRAULIC OIL SERVO68

Hydraulic oil ISO 32 | Mineral based hydraulic oil | Property | Value in metric unit | Value in US unit | Density at 60°F (15.6°C) | 0.868 *10³ | kg/m³ | 54.2 | lb/ft³ | Kinematic viscosity at 104°F (40°C) | 32.2 | CSt | 32.2 | cSt | Kinematic viscosity at 212°F (100°C) | 5.52 | CSt | 5.52 | cSt | Viscosity index | 108 | | 108 | | Flash point | 212 | ºC | 414 | ºF | Pour Point | -33 | ºC | -27 | ºF |

Table no:1

4.3 SPECIFICATION

* Reservoir : 100 mm length and 80mm diameter * Cylinder : 100 mm length and 60mm diameter * Ram : 170mm length and 40mm diameter * Piston : 42mm diameter * Pump : 14mm diameter

4.4 DESIGN CALCULATION
4.4.1 PRESSURE INTENSITY Diameter of the piston D = 42mm Area of the piston A = (π/4) * D2 = (π/4) * 422 = 1385.4 mm2 Force = 50000 KN (designed) Maximum pressure P = F/A = 50000/1385.4 = 36.09 N/mm2

4.4.2 CYLINDER DESIGN

Hoop stress c =P*D/2t c – hoop stress P – Pressure intensify =36.09mm D – Inside diameter of cylinder = 42mm t – Thickness of cylinder = 8mm

c = 36.09*42/2*8 =94.73 N/mm
Allowable stress = 100N/mm (from design data book)
Here, Max stress is less than allowable stress
So that, Design is safe

4.4.3 DESIGN OF RAM

Diameter of ram = 40 mm
Area of ram = 1256.6mm2
Stress in ram
r = F/A = 50000/(1256.6) = 39.78 N/mm2
Allowable stress = 100 N/mm2
Here, Max stress is less than allowable stress
So that, Design is safe

4.4.4 MULTIPICATION OF FORCE

P1 = P2

F1/A1 = F2/A2

F2/F1 = D22/D12

F2/F1 = 422/142 = 9
Multiplication of force = 9 times

4.4.5 MATERIAL TO BE BENDED

Force = 50000 N

For mild steel, Yield strength of mild steel = 94Mpa

Assume cylindrical rod,

Yield strength = Force / Area

94 = 50,000/ (π/4) * D2

D = 26mm Maximum diameter of rod to be bended = 26mm Cross section area of work to be bended = 530 mm2

CHAPTER-5
2D DIAGRAM OF OUR PROJECT

Fig no:4

CHAPRT-6
CONSTRUCTION AND WORKING OF OUR PROJECT

* This machine has a hydraulic cylinder and piston assembly which works in a port type integrated hydraulic circuit. * In this circuit there is no need for separate oil pump hydraulic houses, D.C valves, Pumps etc. These all those things are integrated with the hydraulic cylinder itself. * Hydraulic cylinders (also called linear hydraulic motors) are mechanical actuators that are used to give a linear force through a linear stroke. * Hydraulic cylinders are able to give pushing and pulling forces of millions of metric tons, with only a simple hydraulic system. Very simple hydraulic cylinders are used in presses; here the cylinder consists out of a volume in a piece of iron with a plunger pushed in it and sealed with a cover. * By pumping hydraulic fluid in the volume, the plunger is pushed out with a force of plunger-area multiplied by pressure. Here hydraulic circuit is a port type integrated one. No hoses are found .oil will passes through port only and no separate sump for oil storage .oil store around the shell of hydraulic cylinder itself * The hydraulic cylinder and arrangement are attached in the frame where the dies are namely male and female die * In this machine, the male die is placed on the piston head and female die is placed on upper position of the frame * In hydraulic angle forming machine where the work piece is placed between two dies * If we apply the small force in the pump by using the external rod, it develops the pressure in the fluid * This pressure has passed to the cylinder through a valve, which is placed between pump and cylinder and lifts the piston upwards at one stage the required shape is formed. * Now. We open the key of the port or inlet valve to push the piston downwards by take out of the fluid from the cylinder to the reservoir through the port.

6.1 POWER DIE

Fig no:5 As the surfaces of the punch and die are flat; thus, the punch force builds up rapidly during shearing, because the entire thickness of the sheet is sheared at the same time. However, the area being sheared at any moment can be controlled beveling the punch and die surfaces, as shown in the following Figure. This geometry is particularly suitable for shearing thick blanks, because it reduces the total shearing force.

CHAPTER-7
MATREIAL USED

NAME OF THE COMPONENTS | MATERIALS | Cylinder | M.S rod | Piston | M.S with chromium | Ram | M.S rod | End plate | M.S plate | Hydraulic fluid | Servo 38 | Structure | M.S Plate |

Table no:2

CHAPTER-8
COST INVOLVED

S.NO | COMPONENT | QUANTITY | MATERIAL USED | COST(RS) | 1 | Hydraulic cylinder assembly | 1 | - | 1900 | 2 | Material for External structure Mild steel | 5 kg | Mild steel | 250 | 3 | Hydraulic oil | 0.15liters | Servo68 | 250 | 4 | Machining and over Head charges | - | - | 500 | 5 | Total cost | - | - | 2900 |

Table no:3

CHAPTER-9
ADVANTADES

* By changing the die the multipurpose can be obtained. * All type of sheet metal can be possible. * No extra skill is required for operating this system. * Easier maintenance * Low die wear * No damage to the surface of the sheet

CHAPTER-10
PHOTOGRAPHY

Fig no:6

CHAPETR-11
CONCLUSION
This report details with design and fabrication of multipurpose hydraulic angle forming machine.
Our project simplifies the angle forming action. We can obtain the desired angle through this. Our project is also portable. It multiplied the given force to the die, so the angle formed quickly.

REFERENCES

1. A Text Book of “Machine Design” by S.Chand and Company Ltd., 2. A Text Book of “Machine Design” by R.S.Kurumi and J.K.Gupta., 3. A Text Book of “Hydraulic Principles” by R.K.Srinivasan 4. A Text Book of “Manufacturing Technology” by R.K.Rajput 5. “Design Data” by P.S.G COLLAGE OF ENGINEERING