1. 1. Introduction:
Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metalworking and can be cut and bent into a variety of different shapes.
Countless everyday objects are constructed with sheet metal. Thicknesses can vary significantly;
extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in)
are considered plate.
There are many different metals that can be made into sheet metal, such as aluminum,
brass, copper, steel, tin, nickel and titanium. For decorative uses, important sheet metals
include silver, gold, and platinum (platinum sheet metal is also utilized as a catalyst)Sheet metal
also has applications in car bodies, airplane wings, medical tables, roofs for buildings
(Architectural) and many other things.
Various methods and techniques are being used to complete the whole process of
fabricating metal sheets. Each method or a combination of them can create the desired
materials for a specific object. This is considered as one of the most important material that
every industry requires so that they could complete structural and engineering projects.
Embossing process involves making a contour on a metal strip. In BTP Structural (India) Pvt.Ltd.
there was a need to introduce a embossing machine which would increase productivity at
lesser time and capital investment.
1.1 Problem Overview
On the given Hot rolled strip (612*110 *4mm) there was a need to emboss letters in
three section of the strip. These emboss letters include Company Name, license number and
weight of the cylinder.
The industry was using press tool to emboss letters on the Hot rolled strip. For
completing the embossing operation on the strip it need three press tools each with its own
design.
Need of three types of embossing dies with different press housings.
Requires three different set ups for completing the embossing operation in strip.
More Handling and operation time
High capital cost involved in making press tool.

2. 1.2 Objective
Main scope of the project is to design and fabricate Horizontal Hydraulic Embossing
machine for embossing foot ring of LPG cylinders (BTP Structural Private India Ltd).
Main focus is to
To emboss three section of strip simultaneously.
To reduce work handling time and setup time.
To reduce cycle time.
To emboss four components in one cycle.
2.2.Embossing
Embossing is a metal forming process for producing raised or sunken designs in sheet
material by means of matched male and female roller dies, basically with no change in metal
thickness, or by passing sheet or a strip of metal between rolls of the desired pattern.
2.2.3. Characteristics of embossing:
The ability to form ductile metals.
Use in medium to high production runs.
The ability to maintain the same metal thickness before and after embossing.
The ability to produce unlimited patterns, depending on the roll dies
4.3.1.Calculations for hydraulic cylinder Specification
Formulae:
Pressure =
Discharge = Area*velocity in
Power = Pressure*Discharge in watts
Data Available:
Force = 29430 N
Velocity = 0.12 ms
Bore Diameter
(m)
Area
()
Pressure
()
Discharge ( Power
(watts)
Power
( HP)
0.08 5.03* 5.85* 6.04* 3531.06 4.73
0.1 7.85* 3.74* 9.42* 3523.08 4.72

3. 0.125 12.3* 2.39* 1.48* 3527.64 4.73
0.140 15.4 1.91* 1.85* 3514.4 4.71
0.160 20.1* 1.46* 2.41* 3521.52 4.72
Since Power generated considering the above 5 bore diameters is approximately equal.
Therefore considering the cost factor we have selected 80mm bore Diameter cylinder.
Since Maximum pressure acting on cylinder is 5.85 Mpa therefore Vane Pump is
recommended.
Since Maximum Power required is 4.73 HP therefore electric Motor of 5HP is
recommended.
Specification:
Bore diameter: 80mm
Stroke length : 450mm
Material: Standard.
14.3.2.Calculationsfor Column :
Critical Load for Column according to Euler’s Column Theory for one side fixed and other end is
free :-
Where E=Young’s Modulus of steel (210* I=Moment of Inertia in
L=Length of Column in mm
Inertia of Column (I) =Inertia of whole column(X)-{Inertia of Pocket 1(Y) +Inertia of Pocket 2(Z)}
Inertia(X) = = = 4.96*
Inertia(Y) = = = 0.215*
Inertia (Z) = = = 0.285*
Inertia I=Inertia X-(Inertia Y+ Inertia Z)
I=4.96*- (0.215* + 0.285*)

4. I=4.45*
Critical load for column ) =
=6.85*N
Actual Load acting on Column(=3.96*N
<
Hence Column Design is safe
Specification:
Size : 580*305*50
Material : Mild steel
4.3.4.Structural Parts: The following parts are listed below that are used in the fabrication of
Hydraulic embossing machine
Fixed Plate:
Specification :
Size : 950*950*30
Material : Mild steel
Sliding Plate:

5. Specification :
Size : 900*900*20
Material : Mild steel
Die block:
Specification :
Size : 830*110*60
Material : Mild steel
Roller:
Specification :
Size : ф 196 *1120
Material : Mild steel
4.4. Analysis in Solid Works.
4.4.1.Analysis of Hot Rolled Steel Strip:
No. Body Name Material Mass Volume
1 Strip AISI 1020 HRS 2.88565 kg 0.000365272 m^3
Material name: AISI 1045 Steel, cold drawn

6. Analysis results: The Yield Strength of hot rolled strip is 351.6MPa
Strain analysis:
Results :Maximum strain = 5.4053e-006
orizontal Hydraulic Embossing machine:

7. WORKING:
It is Hydraulic operated machine.
Workers places Dies in die Blocks.
During Operation Worker places strip on the die blocks.
When worker operates the machine the hydraulic cylinders moves the slider plate in
between the rollers.
Embossing on the strip takes place because of less clearance between rollers and dies.
Three parts of a component can be embossed at a time.
Four components can be embossed in one cycle.
POST FLOW PROCESS CHART LABOR TYPE
Chart No. Sheet No. 1 Of. 1 Summary
Subject Charted:
Hydraulic press
Activity Present Proposed Savings

8. Activity:
Embossing of strip in press tool.
Method: Present
Operation
Transport
Delay
Inspection
Store
Location: BTP structural Pvt.Ltd. Distance (m)
Charted By:Group 8 Date:
20/12/12
Approved By: BTP Pvt.Ltd.
Date:25/12/12
Time (Work-h) 0.24 hour
Cost
Total
Sl no Description
Distance
(m)
Time
(Min)
Symbol Remarks
O D
1 Loading of dies
0 1
.
2 Strip loading 0.33 .
3 Foot switch 0.17 .
4 Embossing 5 . Delay
5 Unloading the strip 1 .
6 Loading the strip 1 .
7 Embossing 3 4.17 Delay
8 Unloading the strip 1
9 Loading the strip 1 .

9. 5. Conclusion:
The proposed horizontal hydraulic embossing machine for foot ring strips helps
to emboss three sections of strips simultaneously.
Presently, press tools are used which consumes lot of time & effort in
replacement of press tool housing. On the other hand proposed machine offers
flexibility toward replacement of dies based on the letter configuration.
Total cycle time will be considerably reduced from forty five minutes to fifteen
minutes. This results in increasing in the productivity.
Proposed machine offers only replacement of dies. Hence human effort is
reduced.
Four components can be embossed at a time.
6. References:
1. “Press Tool Technology” :Nettur Technical Training Foundation 2006
2. “Design of Machine Elements” :R.S.Kurmi 2010
3. “Work Study and Ergonomics” : S Dalela and Sourabh,Chand Publisher ,
3rd
edition
4. “Finite Element Method” :J.N.Reddy, Tata McGraw Hill edition 2002
5. “Fluid Power with applications” : Anthony Esposito, fifth edition,
Pearson Education,Inc 2000