International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 11 Issue: 04 | Apr 2024 www.irjet.net p-ISSN: 2395-0072

Structural Design and Analysis of 100 Ton Hydraulic press

Mr. M. Balaji 1, B. Nithin Kumar 2, N. Tejeswara Rao 3, J. Veera Narayana 4, P. Venkat Charan 5, D.
Gowtham 6
1 Associate professor & HOD, Department of Mechanical Engineering, Annamacharya Institute of Technology &
Sciences, Tirupati
2 3 4 5 6 Student, Department of Mechanical Engineering, Annamacharya Institute of Technology & Sciences, Tirupati

---------------------------------------------------------------------*---------------------------------------------------------------------
Abstract - This work of paper is to develop a 3D model of press plates using finite element analysis offers methods to
hydraulic press of capacity 100 Ton by using optimization enhance press performance [6]. B. Parthiban's study on the
technique and FEA techniques. As the budget of the company is design and analysis of C-type hydraulic press structures and
limited, they need to select a machine design which can cylinders provides a detailed exploration of press
withstand high load in working condition. For making the components and their structural integrity [7]. Deepak
complete design from the beginning of process till the end Annasaheb More's work on the design, development, and
Solid Edge simulation software used. To minimize the material optimization of hydraulic presses offers strategies for
usage and money being spent on hydraulic press, the design is improving press efficiency and performance [8]. Muni
made in an optimize manner so that there is less machining Prabaharan and V. Amarnath's research on the structural
process. optimization of hydraulic presses and scrap baling presses
highlights the importance of cost reduction and topology
Key Words: Manual calculation, Finite Element Method, optimization in press design [9]. Furthermore, Sultan
Hydraulic press, Solid Edge, Analysis, Optimization. Thipprakmas and Wiriyakorn Phanitwong's study on
process parameter design in V-bending processes using the
1.INTRODUCTION Taguchi technique contributes to understanding press
forming processes [10]. Malachy Sumaila's research on the
A hydraulic press is a machine which is designed to develop design and manufacture of a 30-ton hydraulic press provides
a compressive force. It works on the bases of pascal’s law, practical insights into press manufacturing processes [11].
the pressure throughout a closed system is constant. Crown, Zhang and Wang's study on the structural analysis and
gateway, bed, and cylinder are the main components of the design of double-acting hydraulic presses offers innovative
press. In this work a hydraulic press is designed on the bases design approaches [12]. Additionally, Martin Zahalka's
of fundamental calculation, later it’s analyzed in Solid Edge research on modal analysis of hydraulic press frames and
software. An integrated approach is chosen to verify the Karel Raz and Kubec Vaclav's study on the use of hydraulic
structural performance and stress distribution are identified presses in the production of large rings provide insights into
using Solid Edge. According to the structural values the press frame dynamics and industrial applications [13, 14]. S.M.
dimensions of the structure are modified to perform better. Bapat and Dessai Yusufali's work on the design and
optimization of a 30-ton hydraulic forming press machine
2. LLITERATURE REVIEW contributes to the development of efficient press systems [15].

The design and analysis of hydraulic presses have been These research works collectively contribute to advancing
extensively explored in various research works. V.B. the field of hydraulic press design and optimization, offering
Bhandari's book "Design of Machine Elements" provides valuable insights and methodologies for improving press
fundamental insights into machine element design, which performance, efficiency, and reliability.
serves as a basis for hydraulic press design [1]. D. Ravi's study
focuses on the computer-aided design and analysis of power 3.METHODOLOGY
presses, offering valuable methodologies for optimizing
press designs [2]. O.O. Ojo's research delves into the design, In the design and analysis of a hydraulic press, various steps
fabrication, and structural analysis of a 5-ton hydraulic press are followed to ensure structural integrity and performance.
and Mold machine, shedding light on its application in These include 2D model development, fundamental
crucible production [3]. N.A. Anjum's work presents the calculations, 3D model development using Solid Edge, mesh
design, fabrication, and manufacturing of a 100-ton generation, application of boundary conditions, stimulation,
hydraulic press tailored for equal channel angular pressing, and assessment of results. If the results meet acceptable
contributing to advancements in press technology [4]. conditions, the design is concluded; otherwise, the model is
Mohammed Iqbal Khatib's study focuses on the design and re-engineered.
fabrication of a 5-ton hydraulic press machine, providing
1. 2D Model Development: The initial step involves the
insights into its construction and operation [5]. Akshay
development of a 2D model, which acts as a foundation for
Vaishnav's research on the design optimization of hydraulic
© 2024, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 614
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 04 | Apr 2024 www.irjet.net p-ISSN: 2395-0072

the subsequent 3D model. This step lays out the basic 4.1. Design Calculation of Hydraulic Press
geometry and dimensions of the hydraulic press
components. Every design begins with fundamental calculation by
applying various kid of stress development.
2. Fundamental Calculations: After the 2D model is
established, fundamental calculations are performed to Design of hydraulic cylinder:
ensure the design meets the required specifications and
The work of hydraulic cylinder is to generate compressive
safety factors. These calculations determine the required
force (F), with a pressure (P) during the forward stroke.
dimensions and load-bearing capacities of each component.

3. 3D Model Development using Solid Edge: The 2D model P=

is then utilized to create a detailed 3D model using Solid
Edge software. The 3D model allows for a more Where A = cross sectional area of piston = in mm2
comprehensive visualization of the hydraulic press
components and their assembly.
From this piston diameter or the bore of the cylinder can be
4. Mesh Generation: Following the development of the 3D determined.
model, mesh generation is carried out to divide the model
into finite elements. This step is essential for the subsequent For finding wall thickness of cylinder:
analysis using Finite Element Analysis (FEA).
Circumference failure th=

5. Boundary Conditions Applied: Boundary conditions are

applied to the model to simulate real-world operating
Longitudinal failure tl =
conditions. These conditions include loads, constraints, and
other external forces that the hydraulic press will experience
during operation. 4.2. Analysis and Testing

6. Stimulation: The model is then subjected to stimulation The components of hydraulic press are designed in Solid
using Solid Edge simulation and analysis software. This Edge software for working load of 100 Ton with the factor of
process involves analyzing the stress, strain, and safety 1.5 (i.e., designed load of 150 Ton). The following
deformation of the hydraulic press components under the details are material properties used for components in
applied loads. hydraulic press.

7. Result and Feasibility Assessment: After the Table 1: Materials used and their properties
stimulation, the results are evaluated to determine if they
meet the acceptable criteria. If the results are within the Part Material Density Yield Modulus
acceptable range, the design is concluded. However, if the Name of used Kg/m3 Strength of
results are not satisfactory, the model is re-engineered to (MPa) Elasticity
address the identified issues. (MPa)

4.Problem Identification Cylinder Aluminum 2712 275 71000

7075 T6
The main components like top plate, guide ways and bed are Piston Hard 7833 262 210000
subjected to continuous load which causes arise the and chrome
formation stress at the time of working condition. So, for this piston plated
stress distribution is obtained for each part. rod steel
Requirement: Frame Structural 7833 262 210000
steel
Cylinder working pressure: 300 Bar

Cylinder testing pressure: 450 Bar FEA is performed using Solid Edge software to determine the
stress acting in it. Below shown images are related to the
Force extracted by the cylinder: 100 Ton output from the analysis.

Stroke of cylinder: 400 mm For the analysis of the cylinder, 300 bar of hydraulic
pressure is applied inside the cylinder and by constrain at
the holder which is permanently joined by the means of
welding.

© 2024, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 615
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 04 | Apr 2024 www.irjet.net p-ISSN: 2395-0072

Figure 1: Stress analysis on cyclinder

Figure 4: Deformation of piston and piston rod

The component piston has the minimum displacement of 0

and maximum of 0.01177 mm and is considered to less
deformation. The induced stress lies in minimum of
0.000469 Mpa to maximum of 157 Mpa which is less
compared to allowable stress of 265 Mpa. So, the component
design is said to be safe.

The complete structure needs to be analyzed because after

Figure 2: Deformation of cyclinder assembly of a components or a machine there will be
different kind of moments which can’t be analysis. By this we
The component named cylinder has the minimum can also identify the weaker part and critical damages in
displacement of 0 and maximum of 0.213 mm and is machine by changing positions of specimens, and the
considered to less deformation. The induced stress lies in moments. The surface which gets contacted with the ground
minimum of 6.13 Mpa to maximum of 174 Mpa which is less is taken as the constraints.
compared to allowable stress of 275 Mpa. So, the component
design is said to be safe.

On the top of piston, a hydraulic pressure of 300 bar acts

which cases the deformation on piston and buckling on the
rod which is directly connected to the piston. For this the
constrains are made at the bottom of the piston as shown
below.

Figure 5: Stress analysis on frame

Figure 3: Stress analysis on piston and piston rod

© 2024, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 616
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 04 | Apr 2024 www.irjet.net p-ISSN: 2395-0072

REFERENCES

[1] V.B. Bhandari, “Design of Machine Elements”, Tata

McGraw-Hill Publishing Co. Ltd., New Delhi, 2008.
[2] D. Ravi, “Computer Aided Design and Analysis of Power
Press”, Middle East journal of Scientific Research
20(10):1239-1246,2014.
[3] O.O. Ojo, “Design, Fabrication and Structural Analysis of a
5 Ton Hydraulic Press and Mould Machine for Crucible
Production”, Computational Engineering Vol.3 Issue 3,
September 2020, Pg:46-58.
[4] N.A. Anjum, “Design, Fabrication and Manufacturing of
100 Ton Hydraulic Press to Perform Equal Channel
Angular Pressing”, Technical Journal, University of
Engineering and Technology (UET) Taxila, Pakistan Vol.22
No. 11-2017.
[5] Mohammed Iqbal Khatib, “Design and fabrication of 5
Ton Hydraulic Press Machine”, International Journal of
Scientific Research in Science, Engineering & Technology,
Vol.7 Issue 2, March-April 2020 Pg: 22-30.
[6] Akshay Vaishnav, “Design Optimization of Hydraulic
Press Plate Using Finite Element Analysis”, International
Figure 6: Deformation of frame Journal of Engineering Research and Applications, Vol.6
Issue 5, May 2016, Pg No. 58-66.
The complete structure is made of different material. By [7] B. Parthiban, “Design And Analysis Of C Type Hydraulic
taking the average of allowable stress its assumed maximum Press Structure And Cylinder”, International Journal Of
allowable stress as 220 Mpa. The deformation in the Research In Aeronautical And Mechanical Engineering,
complete machine is 2.58 mm as maximum and maximum Vol 2, Pg No. 47-56.
induced stress is 179 Mpa. So, the obtained values are in [8] Deepak Annasaheb More, “Design, Development And
acceptable range. So, the design is safe. Optimization Of Hydraulic Press”, IJRASET Volume 3
Issue VI, June 2015.
5.Result [9] Muni Prabaharan and V.Amarnath “Structural
Optimization of 5Ton Hydraulic Press and Scrap Baling
The following is the summary of the results obtained from Press for Cost Reduction by Topology”, International
the analysis using Solid Edge simulation software. The Journal of Modeling and Optimization, Vol 1, pp 185-190,
results are as follows: - 2011.
[10] Sultan Thipprakmas, Wiriyakorn Phanitwong (2011)
Table 2: Analysis data output “Process parameter design of spring-back and spring-go
in V-bending process using the Taguchi technique”,
Part Name Max Stress Deformation Materials and Design, Vol 32, Pp 4430-4436.
(MPa) (mm) [11] Malachy Sumaila, “ Design and Manufacture of a 30-ton
Cylinder 174 0.213 Hydraulic Press”, AU J.T. 14(3): 196-200 ,Jan. 2011.
[12] Zhang, Y., & Wang, H. (2010). Structural Analysis and
Piston and piston 157 0.0177 Design of a Double Acting Hydraulic Press. Advanced
rod Materials Research, 105-106, 664-667.
[13] Martin Zahalka, “Modal Analysis of Hydraulic Press
Frame 179 2.58
Frames for Open Die Forging”, Elsevier Science Direct,
pp. 1070–1075, 2016.
[14] Karel Raz, Kubec Vaclav, “Using of a Hydraulic Press in
6. CONCLUSIONS
Production and Manufacturing of Large Rings”, Elsevier
Science Direct, pp. 1064–1069, 2016.
As shown in the result section Max Stress are option with a
[15] S.M. Bapat And DessaiYusufali(2014|) “Design And
F.O.S of 1.5. The obtained stress is with the limit. So, the
Optimization Of A 30 Ton Hydraulic Forming Press
structural design developed for 100 Ton hydraulic press is
Machine”, International Journal For Research In Applied
safe and satisfies the conditions of engineering.
Science And Engineering Technology, Vol 10, Pp 637-646.

© 2024, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 617