Minor project Report on DESIGN OF HYDRAULIC SHEET METAL PUNCHING MACHINE USING HYDRO-MECHANICAL LEVERAGE

MAHAKAL INSTITUTE OF TECHNOLOGY AND SCIENCE,
UJJAIN (M.P)
(Rajiv Gandhi Proudyogiki Vishwavidyalaya, Bhopal M.P.)
Session 2016-17
Minor project report
On
DESIGN OF HYDRAULIC SHEET METAL PUNCHING MACHINE
USING HYDRO-MECHANICAL LEVERAGE
Submitted towards Partial Fulfillment of the degree of
Bachelor of Engineering
Under the Guidance of- Submitted By-
Prof. Pankaj Gera Arun Singh Rathore
Assistant Professor Harshil Sehariya
MITS, Ujjain Mahendra Singh Chandrawat
Shubham Bagi
Shubham Dhaneshree
Shubham Mathur

MAHAKAL INSTITUTE OF TECHNOLOGY &
SCIENCE, UJJAIN
CERTIFICATE
This is to certify that Mr. Arun Singh Rathore, Mr. Harshil Sehariya, Mr. Mahendra Singh
Chandrawat, Mr. Shubham Bagi, Mr. Shubham Dhaneshree and Mr. Shubham Mathur.
Student of B.E. (Mechanical Engineering Department) of this college has carried out
Project DESIGN OF HYDRAULIC SHEET METAL PUNCHING MACHINE
USING HYDRAO-MECHANICAL LEVERAGE. It is submitted towards partial
fulfillment of the requirements for the award of Bachelor of Engineering in Mechanical
Engineering from Mahakal Institute of Technology & Science; Ujjain affiliated to Rajiv
Gandhi Proudyogiki Vishwavidyalaya, Bhopal (M.P.).
Prof. Pankaj Gera Prof. Santosh Vyas Prof.V.M Shah
Project Guide Head of Department Director
M.I.T.S., Ujjain M.I.T.S., Ujjain M.I.T.S., Ujjain
I

ACKNOWLEDGEMENT
The successful completion of the project is the result of dedicated efforts of many people
and this report would be incomplete without giving due credit to them. This
acknowledgement is taken of small gratitude in recognition of the help provided by them.
We wish to express our heartfelt appreciation to all the people who had contributed to this
project, both explicitly and implicitly. First to all we want to thank our projects guide
Prof. Pankaj Gera for giving us this opportunity to work under his guidance. His empathy
towards us made our work easy. Many thank to him for encouraging and supporting us to
complete this project work. We are thankful to Prof. Santosh Vyas Head of the
Department, Mechanical Engineering and Prof. V.M Shah Director Mahakal Institute Of
Technology & Science, Ujjain for understanding our problem and shorting them out. We
are thankful to staff of Mechanical Engineering Department for letting us know about
problem of industry and encouraging us to work on it. In the last but not least, we are also
thankful to all the persons and colleagues who have helped us directly or indirectly during
this project. .
Arun Singh Rathore
Harshil Sehariya
Mahendra Singh Chandrawat
Shubham Bagi
Shubham Dhaneshree
Shubham Mathur
II

ABSTRACT
Tools and simple machines are a natural extension of our mastery of physics. By putting
our knowledge to use, we are able to manipulate the world around us on a much larger
scale. Tools and machines have allowed us to build great monuments, to settle otherwise
inhospitable locations, and to launch ourselves into space. These simple machines which
work on mechanical advantage were evolved in complex machines. Out of these many
advantages hydraulics turned out to be a game changer. Hydraulics has proven to be one
of the most efficient and economical system for amplification of forces. First used by the
ancient Greeks as a means of elevating the stages of their amphitheatres, the principles of
hydraulics were explained scientifically by the seventeenth century scholars Pascal and
Boyle. The laws discovered by these two men regarding the effects of pressure and
temperature on fluids and gases in confined areas form the basis of the principle of
mechanical advantage; in other words, the "why and how" of hydraulics. Similarly,
another mechanical advantage ‘Lever’ was explained and proven by Archimedes in 3rd
century BC.
Both of these models of amplification of forces along with others were later used in
modern era of technology for the evolution of machines which made the modern world
possible. Making a similar contribution by using two mechanical advantages in a
machine, the aim of this project is to integrate the mechanical advantage of Leverage with
Hydraulic System to facilitate the ease of operation to manufacture smaller parts and to
reduce the dependence on heavy hydraulic machines for small punching operations. Thus
the production effort can be reduced as the dependence on complex hydraulic machines
will be alleviated. Hence an attempt has been made to provide the smooth and rapid
functioning of punching work with the help of hydraulic system.
III

CONTENTS Page No.
Certificate i
Acknowledgement ii
Abstract iii
CHAPTER 1: INTRODUCTION 2
CHAPTER 2: LITERATURE REVIEW 6
2.1 Leverages 9
2.2 Mechanical leverage 12
CHAPTER 3: COMPONENTS AND THEIR WORKING 14
3.1) Hydraulic fluids 14
3.2) Seals and packing 15
3.3) Reservoirs 17
3.4) Filter and strainer 18
3.5) Hydraulic cylinder 19
3.6) Direction valve 19
CHAPTER 4: DESIGN AND ANALYSIS 22
4.1 Design and analysis 22
4.2 Drawing of machine parts 31
CHAPTER 5: RESULTS AND DISCUSSION 36
Conclusion 38
Reference 39

List of figures-
Figure Description Page no.
Figure 1 Punch 2
Figure 2 Die Block 3
Figure 3 Pascal’s law 8
Figure 4 Lever system 10
Figure 5 First class lever 11
Figure 6 Second class lever 12
Figure 7 Third class lever 12
Figure 8 Lever arrangement 13
Figure 9 Relief valve 21
Figure 10 Frame 31
Figure 11 Punch 32
Figure 12 Die 33
Figure 13 Assembly 34
Figure 14 Final model 35
Figure 15 Existing proposed model 35
List of tables-
Table no. Name of table Page no.
1 Round Hole Diameter [inches] to be punched 37
CHAPTER 1

INTRODUCTION
Punching is a metal forming process that uses a punch press to force a tool, called a
punch, through the work piece to create a hole via shearing. The punch often passes
through the work into a die. A scrap slug from the hole is deposited into the die in the
process. Depending on the material being punched this slug may be recycled and reused
or discarded. Punching is often the cheapest method for creating holes in sheet metal in
medium to high production volumes. When a specially shaped punch is used to create
multiple usable parts from a sheet of material the process is known as blanking. Punching
machine type of cold working process in which punching done by the punch machine tool
and die designed to punch the sheet metal by applying mechanical force or pressure. The
punch governs the size of the hole and the clearance is provided on the die.
The components of punching machines are:
• Punch: It is the male member of the unit and kept as small as possible consistent
with required strength and rigidity. The punch made of the hard, wear resistance
metal and is finally ground to the pre-determine size providing just opium
clearance between the punch and die.
Figure 1.Punch
• Punch Retainer of punch plate: It fits closely over the body of the punch and
holds it in a proper relative position. The retainer is turn to bolt to the punch
holder.

• Punch holder: It provided a wide plate surface which face against the lower end
of the press ram and is anchored to it with help of the shank which is an integral
part of the punch holder shank exactly fits in to the ram opening, to help in
properly positioning and aligning the punch holder is made of cast steel.
• Backing plate: Whenever the punch is headless a hardness steel backing plate is
introduced between the back of the punch holder so that intensity of pressure does
not become excessive on the punch holder. Backing plate distributes the pressure
over wide area and intensity of the pressure on the punch holder is reduced to
avoid crushing.
• Die Block: it is female working member & is kept as small as possible consistent
with required strength. It is also made of hard, wear-resistant metal and finish
ground to predetermined size and tolerance.
Figure 2.Die
• Die retainer: Just like the punch retainer, the die retainer also holds the die block
at proper position with respect to punch. The retainer is mounted on the die shoe
or holder. In certain die shoe it serves as a retainer for the die block the block is
then mounted directly on to die shoe.
• Die shoe: Die shoe assembly consisting of die block and die. These in turn bolted
or clamped to the bolster plate.
• Guide posts and bushing: the punch and die makers once properly located
aligned are held in aligned are held in alignment by means of guide post and
bushing which resist movement or deflection of die members as operating

pressure increase guide post and bushing are part of the commercially available
punch and die holders.
• Stripper and stripper plate: When the punch has completed its downward
movement and start returning, the scrape strip tries to go up along with it. The
stripper plate prevents this upper movement of scrape stripes and frees and
punches of these for next stroke.
• Stock stops & Stock guide: Fixed type of stripper sometimes are used to guide
the stock are also where as stock stops locate the work material at a suitable
position in relation to previously blanked surfaced in preparation to the next
downward movement of the punch.
• Bed: The bed is the lower part of a press frame that serves as a table to which a
bolster plate is mounted.
• Bolster plate: This is thick plate secured to the press bed, which is used for
locating and supporting the die assembly. It is usually 5 to 12.5 cm thick.
• Die set: It is unit assembly, which incorporates lower and upper shoe, two or
more guidepost and guidepost bussing.
• Die: The die may be defined as a female of a complete part of a complete tool
producing work in press. It also referred to a complete tool consisting of a pair of
mating members for producing work in a press.
• Lower shoe: The lower shoe of a die set is generally mounted on the bolster plate
of a press. The die block is mounted on the lower shoe. Also, the guideposts are
mounted in it.
• Upper shoe: This is the upper part of the die set, which contains guidepost
bushing.
• Knockout: It is mechanism, usually connected to and operated by a press ram,
for freeing a work piece from a die.

• Pit man: It is connecting rod, which is used to transmit motion the main drive
shaft to the press slide.
• Shut height: It is distance from top of the bed to the bottom of a slide, with its
stroke down and adjustment up.
• Stroke: The stroke of a press is the distance of ram its up position to its down
position. It is equal to twice the crankshaft and eccentric drives but it is Variable
• on the hydraulic press.
1.2 ADVANTAGES OF HYDRAULIC PUNCHING MACHINE
1. Full power stroke - The full power of a hydraulic press can be delivered at any point in
the stroke. Not only at the very bottom, as is the case with mechanical presses.
2. Much lower original cost and operating costs - Hydraulic presses are relatively
simple, they have a significant cost advantage over mechanical presses in comparable
sizes. The numbers of moving parts are few, and these are fully lubricated in a flow of
pressurized oil.
3. More control flexibility - Hydraulic press power is always under control. The ram
force, the direction, the speed, the release of force, the duration of pressure dwell, all can
be adjusted to fit a particular job.
4. Quiet - Fewer moving parts and the elimination of a flywheel reduce the overall noise
level of hydraulic presses compared to mechanical presses.
5. Reliability- Hydraulic punching machines are more reliable in opertaion than any
mechanical punching machines.
1.3 DISADVANTAGES OF HEAVY HYDRAULIC MACHINES
1. Hydraulic machines are complex in construction.

2. Hydraulic machines have oil leakage problems.
3. They have more maintenance issues than pneumatic machines.
4. They have slower motion than pneumatic machines.
CHAPTER 2
LITERATURE REVIEW
Hydraulics is a branch of engineering concerned mainly with moving liquids. The term is
applied commonly to the study of the mechanical properties of water, other liquids, and
even gases when the effects of compressibility are small. Hydraulics can be divided into
two areas, hydrostatics and hydrokinetics. Pascal’s law states that when a confined fluid
is placed under pressure, the pressure is transmitted equally in all directions and directed
normal on all faces of the container.
Hydraulics has proven to be the most efficient and economical system adaptable to
aviation. First used by the ancient Greeks as a means of elevating the stages of their
amphitheaters, the principles of hydraulics were explained scientifically by the
seventeenth century scholars Pascal and Boyle. The laws discovered by these two men
regarding the effects of pressure and temperature on fluids and gases in confined areas
form the basis of the principle of mechanical advantage; in other words, the "why and
how" of hydraulics.
The word "hydraulic" is derived from two Greek words: "hydro" meaning liquid or water
and "aulos" meaning pipe or tubing. "Hydraulic," therefore, is an adjective implying that
the word it modifies is in some major way concerned with liquids. Examples can be found
in the everyday usage of "hydraulic" in connection with familiar items such as automobile
jacks and brakes. As a further example, the phrase "hydraulic freight elevator" refers to an
elevator ascending and descending on a column of liquid instead of using cables and a
drum. On the other hand, the word "hydraulics" is the generic name of a subject.
According to the dictionary "hydraulics" is defined as a branch of science that deals with

practical applications (such as the transmission of energy or the effects of flow) of a
liquid in motion.
The press machine Gutenberg (Johan Gensfleisch) a German invented in 1400 was
modified one from a wooden screw type press machine for squeezing olive oil and
grapes. This was exactly the root of the screw presses and all press (punching, stamping)
machines, stamping inked print boards onto sheet with the screw. This is the type of
machine to apply static pressure.
Until 1700 AD fly press were not in engineering application. Earlier open Die or
Hammers were used to produce small components .Then gradually by 1767 AD;
Small fly presses particularly for Gold smith work in ornamental work were evolved and
used effectively.
Later, in the field of hydraulics and punching machines, various contributions have been
made, of which some are:
1. Design and Fabrication of Auto Roll Punching Machine by Kundan Kumar
ISSN(Online) : 2319-8753 In their research they revealed that design and
fabrication of auto roll punching machine will make an impressing mark in the
field of small scale industries this has also reduce the cost involved in the concern
and it required task taking minimum time.
2. Improvement in design of the manual small press machine by vivek Sharma
ISSN : 2278 – 0149 In their research they revealed that machine is capable to do
work with some shear force By putting (diametrically opposite) variable
additional weights on the flywheel we can obtained that desired energy levels to
suit the maximum load required for manufacturing different types of engineering
parts. Of course it is understood that only limited variation in capacity is possible.
If at all some bigger or odd components to be manufactured one can choose the
next higher range of the flypress.It is very clear that for given press reasonable
flexibility is possible as far as energy is total load is concerned.
3. Doc Smith & Mates in 1999 work on hydraulic press machine & give conclusion
that the press work on the Hydraulic version of the press machine
4. Oseni K Owolarafe, Michael O Faborode 25 May 2000 work on press machine
& give conclusion that The comparative evaluation of the DSP system which is

being developed and the conventional hydraulic press system undertaken in this
study revealed that the DSP system has many comparatively favorable attributes
and is to be preferred to the hydraulic system.
5. Isaac Bamgboye and Morakinyo T.A An improved oil screw press has been
designed and constructed having 98.6 % efficiency and a capacity of 0.86
tons/day. Abrasion rate of screw-shafts has been reduced from 63.3% to 12.6% by
using high carbon steel material instead of low-carbon steel. Peter Beerens in
2007 gives an idea about press machine and the result is extended due to
improvement in the plate form in the design of the machine.
The hydraulics of these machines functions on very simple principle known as Pascal's
law or the principle of transmission of fluid-pressure. Pascal’s Law is a principle in fluid
mechanics that states that a pressure change occurring anywhere in a confined
incompressible fluid is transmitted throughout the fluid such that the same change occurs
everywhere. The law was established by French mathematician Blaise Pascal.
To understand this, let us consider a system of two piston and cylinders connected
together. Now,
Figure 3 Pascal’s law
The force equation for the small cylinder:

Fs = p As
Where,
Fs = force acting on the piston in the small cylinder (N)
As = area of small cylinder
p = pressure in small and large cylinder
The force equation for the large cylinder:
Fl = p Al
Where,
Fl = force acting on the piston in the large cylinder (N)
Al = area of large cylinder
p = pressure in small and large cylinder
on combining the above equations,
Fs / As = Fl / Al
Or,
Fs = Fl As / Al
The equation indicates that the effort force required in the small cylinder to lift a load on
the large cylinder depends on the area ratio between the small and the large cylinder - the
effort force can be reduced by reducing the small cylinder area compared to the large
cylinder area.
2.1LEVERAGES

In its most basic form, the lever consists of a rigid bar supported at one point, known as
the fulcrum. One of the simplest examples of a lever is a crowbar, which one might use to
move a heavy object, such as a rock. In this instance, the fulcrum could be the ground,
though a more rigid "artificial" fulcrum (such as a brick) would probably be more
effective.
As the operator of the crowbar pushes down on its long shaft, this constitutes an input of
force, variously termed applied force, effort force, or merely effort. Newton's third law of
motion shows that there is no such thing as an unpaired force in the universe: every input
of force in one area will yield an output somewhere else. In this case, the output is
manifested by dislodging the stone—that is, the output force, resistance force, or load.
Use of the lever gives the operator much greater lifting force than that available to a
person who tried to lift with only the strength of his or her own body. Like all machines,
the lever links input to output, harnessing effort to yield beneficial results—in this case,
by translating the input effort into the output effort of a dislodged stone. Proper use of a
lever actually gives a person much greater force than he or she would possess unaided.
The principle of the lever tells us that the below arrangement is in static equilibrium as
shown in fig.3, with all forces balancing, if F1D1 = F2D2.
Figure 4.Lever system
In physics, a lever (from Old French levier, the agent noun to lever "to raise", c. f.
Levant) is a rigid object that is used with an appropriate fulcrum or pivot point to multiply
the mechanical force that can be applied to another object.

This is also termed mechanical advantage, and is one example of the principle of
moments. The principle of leverage can also be derived using Newton's laws of motion
and modern statics.
• The three classes of levers
Levers are divided into three classes, depending on the relative positions of the input
lever arm, the fulcrum, and the output arm or load. In a Class I lever, such as the crowbar
and the wrench, the fulcrum is between the input arm and the output arm. By contrast, a
Class II lever, for example, a wheelbarrow, places the output force (the load carried in the
barrow itself) between the input force (the action of the operator lifting the handles) and
the fulcrum, which in this case is the wheel.
Finally, there is the Class III lever, which is the reverse of a Class II. Here, the input force
is between the output force and the fulcrum. The human arm itself is an example of a
Class III lever: if one grasps a weight in one's hand, one's bent elbow is the fulcrum, the
arm raising the weight is the input force, and the weight held in the hand—now rising—is
the output force. The Class III lever has a mechanical advantage of less than 1, but what it
loses in force output in gains in range of motion.
• First-Class levers A First-Class Lever is a lever in which the fulcrum is
located in between the Effort Force and the Resistance Force, and works by
having a force be applied by pulling or pushing onto a section of the bar, which
causes the lever to swing about the fulcrum, overcoming the resistance force.
Figure 5.First class lever

Examples:
Seesaw (also known as a teeter-totter)
Crowbar (removing nails)
Scissors (double lever)
• Second-class levers
Figure 6.Second class lever
Examples:
Wheelbarrow
Nutcracker (double lever)
• Third class lever
Figure 7.Third class lever
Examples: Human arm
2.2 Mechanical leverages

Let
W= Weight to be Lifted,
A=Force applied on the plunger,
A=Area of plunger,
Pressure intensity produce by the force F, p=F/Area of plunger=F/a
As per Pascal’s Law, the above intensity p will be equally transmitted in all directions.
Therefore, The pressure intensity on Ram =p=F/a=W/A or W=F(A/a)
Above Equation indicates that by applying a small force F on the Plunger, a large force W
may be developed by ram.
Mechanical advantage of press=A/a
If the force in the plunger is applied by a lever Which has a mechanical advantage(L/l)
then total mechanical advantages of machine=(L/l)(A/a) The ratio (L/a) is known as
Leverage of Press.

Figure 8.Lever arrangement
CHAPTER 3
COMPONENTS AND THEIR WORKING
Hydraulics now could be defined as a means of transmitting power by pushing on
confined liquid. The input component of the system is called a pump; the output is called
an actuator. While for the sake of simplicity we have shown a single small piston, most
power driven pumps incorporate multiple pistons, vanes or gears as their pumping
elements. Actuators are liners, such as the cylinder; or rotary, such as the hydraulic motor.
The hydraulic system is not source of power. The power source is a prime mover such as
an electric motor or an engine which drives the Pump. The reader might ask, therefore,
why not forget about hydraulic and couple the mechanical equipment directly to the
prime mover? The answer is in the versatility of the hydraulic system, which gives it
advantages over other methods of transmitting power.

Hydraulic systems contain mainly following parts.
(1) Hydraulic fluids.
(2) Seals and Packing.
(3) Reservoirs
(4) Filter and strainers
(5) Cylinders
(6) Pressure control valve
3.1) HYDRAULIC FLUIDS: Proper selection and care of hydraulic fluids for a
machine will have an important effect on how the machine performs and on the life of the
hydraulic components.
• PURPOSE OF THE FLUID The hydraulic fluid has four primary purposes:
(1) To transmit power,
(2) To lubricate moving parts,
(3) To seal clearance between parts, and
(4) To cool or dissipate heat.
• LUBRICANTION: In most hydraulic component, internal lubrication by the
fluid. Pump elements and other wearing part slide against each other on a film of
fluid. For long component life the oil must contain the necessary additives to
ensure high antiwar characteristics. Not all hydraulic oils contain these additives.
• QUALITY REQUREMENTS In addition to these primary functions, the
hydraulic fluid may have a number of other quality requirements. Some of these
are to:
 Prevent rust

 Prevent formation of sludge, gum, and varnish
 Depress foaming
 Maintain its own stability and thereby reduce fluid replacement cost
 Maintain relatively stable body over a wide temperature range
 Prevent corrosion and pitting
 Be compatible with seals and gaskets
 Separate out water
These quality requirements often are the result of special compounding and may not be
present in every mind.
• FLUID PROPERTIES let us now consider the properties of hydraulic fluid
which enable it to carry out its primary functions and fulfill some or its entire
quality requirement:
 Viscosity
 Pour point
 Lubricating ability
 Oxidation resistance
 Rust and corrosion protection
3.2) SEALS AND PACKING: Seals are device for closing gaps to prevent leakage or
make pressure tight joints and also to prevent entry of air and dirt from outside in to the
system. A wide variety of seals of different shapes and material are used. The material of
the seal must be compatible with the fluid medium.
• SEAL MATERIALS Seals are device for closing gaps to prevent leakage of
make pressure tight joints and also the prevent entry of air and dirt from outside
into the system. A wide verity of seals of different shapes and material are used

Synthetic rubbers (elastomers), however, are the most part quite compatible with
oil. Elastomer can be made in many compositions to meet various operating
condition. Most of the hydraulic equipment seals today are made of one of these
elastomers: Nit rile (Buna-N), chloroprene (Neoprene) Teflon.ERP/EPDM (also
known as EPM),of silicon.
• PREVENTING LEAKAGE Three general considerations in preventing leakage
are:
1. Design to minimize the possibility (back, gasket of sub-plate mounting)
2. Proper installation.
3. Control of operating conditions.
• OPRATING CONDITIONS Control over operating conditions can be very
important to seal life. A number of factor that can help prevent leakage are
discussed below.
Contamination prevention: An atmosphere contaminated with moisture, dirt or any
abrasive material shortens the life of shaft seals and a piston rod seal exposed to the air.
Protective device should be used in customized atmosphere. Equally important clean fluid
and proper filtration to avoid damage to internal seals and surfaces.
Fluid Compatibility: Some fire-resistance fluid attack and disintegrate certain elastomer
seals. Few seals, intact, are compatible with all fluids. The fluid supplier should always be
consulted when in doubt whether the change seals when in change in made in the type of
fluid. Fluid additives (added by the machines user) also may attack seals and should be
used only at the recommendation of the fluid supplier.
Temperature: At extremely low temperature, a seal may become too brittle to be
effective. At too high a temperature, a seal may harden, soften, or swell. The operating
temperature should always be kept well within the temperature range of the seals being
used.

Pressure: Excess fluid pressure puts an addition strain on oil seals and may “blow” a seal
causing a leak. Lubrication: no seal should ever be installed or operated dry. All must be
lubricated prior to installation or the seal will wear quickly and leak.
3.3) RESERVOIRS the main function of the reservoir in a hydraulic system is to store
arid supply hydraulic fluid for use by the system. The section discusses this and other
reservoir function such as heat exchange and desertion.
• FUNCTION OF A RESERVOIR Since, in addition to holding the system fluid
supply, a reservoir can also reserve several secondary functions, some system
designer feel that the reservoir is the key to effective hydraulic system. Some
examples of these functions are discussed below. By transferring waste heat
through its walls, the reservoir acts as the heat exchanger that cools the fluid
within. As the deaerator, the reservoir allows entrained air to rise and escape
while solid contaminants settle to the bottom of the tank. Making it a fluid
conditioner. These are function that can also be provided to the system by
methods that do not involved the reservoir. In some instance, the reservoir may be
used as a platform to support the pump, motor, and other system components.
This saves floor space and is a simple way to keep the is a simple way to keep the
pumps and valves at the good night the servicing.
• RESERVOIR COMPONENTS a typical industrial reservoir is constructed of
welded steel plate with end-plate extension that support the unit. To reduce the
chance of condensed moisture within the tank causing rust, the inside of the
reservoir is painted with a sealer that is compatible to the fluid maintenance, a
plug placed at the low point on the tank to allow completed drainage. The various
components that make up a reservoir are follows.
(1) Oil level gauge
(2) Breather assembly
(3) Filler opening
(4) Clean-out plates
(5) Baffle plate

(6) Line connection and fittings
• RESERVOIRE SIZING A large tank always desirable to promote and separation
of contaminants. At a minimum, the tank must store all the fluid the system will
required and maintain and high enough level to prevent a whirlpool effect at the
pump inlet opening. It this occurs. Air will be taken in with the fluid. When
determining reservoir size, it is important to consider the following factors: Fluid
expansion caused by high temperature. Changes in fluid level due to system
duration. Exposure of the tank interior to excess condensation. The amount of heat
generated in the system.
• HOW TO SPECIFY FILTERS Specifying the correct filter of strainer for a
given application requires consideration of several important factors, including:
the minimum size of particles to be trapped, the quality or weight of the particles
to be held, the flow rate capacity, the type of filter condition indicator providing,
the pressure rating, the pressure drop through the filter element, and the filter’s
compatibility with system fluid.
3.4) FILTER OR STRAINER There will probably always be controversy in the
industry over the exact definition of filter and strainers. In the past, many such devices
were named filters, but technically classed as strainers. To minimize he controversy, the
national fluid power association gives these definition:
FILTER: A device whole primary function is the retention, by some porous medium, of
insoluble contaminants from a fluid. STRAINER: A course filter, to put it simply,
whether the device as a filter or strainers, its function is to trap contaminants from fluid
flowing through it. “Porous medium” simply refers to screen or filtering material that
allows fluid to flow through it. “Porous medium” simply refers to a screen or to filtering
material that allows fluid to flow through it. But stop other materials.
3.5) HYDRAULIC CYLINDER The focus of this topic is on the output member or
actuator, a device for converting hydraulic energy in to mechanical energy. Two types of
hydraulic actuators are cylinder or motors. The type of job done and its power
requirements determine the correct type and size motor or cylinder for an application.

Cylinder and liner actuators. This means that the output of the cylinder is a straight-line
motion and/or force. The major function of the hydraulic cylinder in to convert hydraulic
power in to liner mechanical power.
TYPES OF CYLINDERS Following are the main types of cylinder.
(1) Single Acting Cylinder
(2) Ram
(3) Telescopic Cylinder
(4) Spring Return
(5) Double acting cylinder
(6) Double Rod Cylinder
(7) Tandem Cylinder
3.6) DIRECTIONAL VALVES As the same name implies, directional valves start, stop,
and control the direction of fluid flow. Although they share this common function,
directional valves very considerably in construction and operation.
There are basically three types of valves employed in hydraulic systems:
a. Directional control valves
b. Flow control valves
c. Pressure control valves
a. Directional control valves:- Directional control valves are used to control the
distribution of energy in a fluid power system. They provide the direction to the fluid and
allow the flow in a particular direction. These valves are used to control the start, stop and
change in direction of the fluid flow. These valves regulate the flow direction in the
hydraulic circuit.
Directional control valves can be classified in the following manner:

1. Type of construction:
• Poppet valves
• Spool valves
2. Number of ports:
• Two- way valves
• Three – way valves
• Four- way valves.
3. Number of switching position:
• Two – position
• Three - position
4. Actuating mechanism:
• Manual actuation
• Mechanical actuation
• Solenoid actuation
• Hydraulic actuation
• Pneumatic actuation
• Indirect actuation
b. Flow control valves: -The flow control valves work on applying a variable restriction
in the flow path. Based on the construction; there are mainly four types viz. plug valve,
butterfly valve, ball valve and balanced valve.
c. Pressure control/relief valves:-The pressure relief valves are used to protect the
hydraulic components from excessive pressure. This is one of the most important
components of a hydraulic system and is essentially required for safe operation of the
system. Its primary function is to limit the system pressure within a specified range. It is

normally a closed type and it opens when the pressure exceeds a specified maximum
value by diverting pump flow back to the tank. The simplest type valve contains a poppet
held in a seat against the spring force as shown in Figure 9.
CHAPTER 4
4.1 DESIGN AND ANALYSIS
In order to evaluate the force generated by the machine, force acting on the machine and
factor of safety, following assumptions and specifications were taken,
1. Tool Design:-
Figure 9.Relief valve

Specification and material-
Alloy Steel AISI 1020
Diameter of punch D=10mm
Length of punch=25mm
Yield Strength σο = 351.57 Mpa
Shear stress to punch a Plate τ= F/A=F/ (πdt) =150/ (3.14 x 10 x .250) =19.09 N/mm2
Where F= force Assumed
T=Thickness of sheet plate
Shear yield strength of punch = σ/2=175.78 Mpa
& Here
τ<σ/2 Hence design is safe.
2. Design of die:-
Diameter of hole=10mm
Clearance C=5% of Thickness
Thickness of sheet .250
Therefore, C=0.05x.250=0.0125mm
Thus, diameter of Die= 10+2x0.0125=10.025mm

Simulation of Punch
Date: Tuesday, November 15,
2016
Designer: Shubham Dhaneshree
Study name: SimulationXpress
Study
Analysis type: Static
Table of Contents
Description
Analysis of Punch for 150 N forces.

Model Information
Model name: Punch
Current Configuration: Default
Solid Bodies
Document Name and
Reference
Treated As
Volumetric
Properties
Document
Path/Date
Modified
Fillet1
Solid Body
Mass:0.0952514 kg
Volume:1.20571e-
005 m^3
Density:7900
kg/m^3
Weight:0.933463 N
B:PROJECTDe
signPunch.SLDP
RT
Nov 15 22:41:31
2016
Material Properties
Model Reference Properties Components
Name: AISI 1020
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises
Stress
Yield strength: 351.571
N/mm^2
Tensile strength: 420.507N/mm^2
SolidBody 1(Fillet1)
(Punch)

Loads and Fixtures
Fixture
name
Fixture Image Fixture Details
Fixed-1
Entities: 1 face(s)
Type: Fixed Geometry
Load
name
Load Image Load Details
Force-1
Entities: 1 face(s)
Type: Apply normal
force
Value: 150 N

Mesh Information
Mesh type Solid Mesh
Mesher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Element Size 2.29392 mm
Tolerance 0.114696 mm
Mesh Quality High
Mesh Information - Details
Total Nodes 11487
Total Elements 7477
Maximum Aspect Ratio 5.0427
% of elements with Aspect Ratio < 3 98.2
% of elements with Aspect Ratio > 10 0
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:02
Computer name: LENOVO

Study Results
Name Type Min Max
Stress VON: von Mises Stress 0.0502114 N/mm^2
(MPa)
Node: 11317
2.48795 N/mm^2 (MPa)
Node: 8742

Conclusion:-
Design is safe, But lower shank may be fail at higher loads.
4.2 DRAWINGS OF MACHINE PARTS

Figure 11
Figure 12
Figure 10.Frame
Figure 11Punch

Final View of model
Figure 13.Assembly

Figure 14 Final Model
As shown in above solidworks generated model. Design model is more simplified that the
previous model of same punching machine with mechanical leverages as given by
previous researches.
Figure 15 Existing model
CHAPTER 5

RESULT AND DISCUSSION
The table no. 1 shows the tons of force required for punching a single round hole in mild
steel derived by the formula: Tons of pressure required + hole size x material thickness x
constant 80. All table figures shown are tons or percentages of tons. For sizes in-between,
you can interpolate.
To calculate the tons needed for other metals just multiply number times the tons required
for punching mild steel:
Aluminum (2024-0): multiply x .36
Brass (1/4 hard): multiply x .70
Copper (1/2 hard): multiply x .52
High Carbon Steel: multiply x 1.60
A36 Steel (recycled): multiply x 1.25
Stainless Steel: multiply x 1.50
Also remember that you should never try to punch a hole that is smaller that the thickness
of the steel. This is because the concentrated load on the punch stem will shatter it very
quickly. That is why there are blank spots on the chart. Example; if the steel is 1/4 inch
thick, you should not try to punch a hole smaller than 1/4 inch diameter. You should
consider drilling the hole instead.
A hint on how to keep your punches sharp longer; spray oil on the spot before you punch
the hole. This will prevent the punch from getting dull so quickly. This is especially true
when punching holes in stainless steel or hard aircraft aluminum. Without spraying oil,
the punches will get dull twice as fast as the die, which is a good reason to buy twice as
many punches as dies.
If you are punching metric size hole diameters and want to use this chart, divide by 25.4
to convert your mm sizes into inches so that you can find the tonnage needed to punch
your hole sizes. For your convenience we have already converted some hole sizes from
inches to mm.
To convert to metric from inches, remember 1 inch = 25.4 mm, so just multiply the inch
sizes by 25.4 to get your answer in mm.
Table no. 1 Round Hole Diameter [inches] to be punched

Steel
Thickness
1/8 inch
diameter
3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16
26 gauge (.018) .18 tons .27 .36 .45 .54 .63 .72 .81 .90 .99 1.07 1.16 1.25 1.34
24 ga. (.024) .24 .36 .48 .60 .72 .84 .96 1.08 1.20 1.31 1.43 1.5 1.67 1.89
22 ga. (.030) .30 .45 .60 .75 .90 1.05 1.20 1.35 1.50 1.65 1.80 1.95 2.10 2.24
20 ga. (.036) .36 .54 .72 .90 1.08 1.26 1.44 1.62 1.80 1.98 2.15 2.33 2.51 2.69
18 ga. (.048) .48 .72 .96 1.20 1.20 1.43 1.67 1.91 2.39 2.63 2.87 3.11 3.34 3.58
16 ga. (.060) .60 .90 1.20 1.50 1.79 2.09 2.39 2.69 2.99 3.29 3.59 3.89 4.19 4.49
14 ga. (.075) .75 1.12 1.49 1.87 2.24 2.61 2.99 3.36 3.73 4.11 4.48 4.86 5.23 5.60
12 ga. (.105) 1.05 1.57 2.09 2.62 3.14 3.66 4.18 4.71 5.23 5.75 6.28 6.80 7.32 7.85
10 ga. (.135) - 2.02 2.69 3.36 4.04 4.71 5.38 6.05 6.73 7.40 8.08 8.75 9.42 10.09
3/16 (.187) - 2.81 3.74 4.68 5.61 6.50 7.48 8.42 9.35 10.29 11.22 12.16 13.09 14.03
1/4 (.250) - - 5.00 6.25 7.50 8.75 10.00 11.25 12.50 13.75 15.00 16.25 17.50 18.75
3/8 (.375) - - - - 11.25 13.13 15.00 16.88 18.75 20.63 22.50 24.38 26.25 28.13
1/2 (.500) - - - - - - 20.00 22.50 25.00 27.50 30.00 32.50 35.00 37.50
5/8 (.625) - - - - - - - - 31.25 34.38 37.50 40.63 43.75 46.88
3/4 (.750) - - - - - - - - - - 45.00 48.75 52.50 56.25
7/8 (.875) - - - - - - - - - - - - 61.25 65.63
1 inch thick - - - - - - - - - - - - - -
Below is a conversion chart that converts sheet metal gauge numbers into metal
thickness:
26 gauge
24
ga.
22
ga.
20
ga .
18
ga.
16
ga.
14
ga.
13
ga.
12
ga.
11
ga.
10
ga.
9 ga.
8
ga.
7 ga. 6 ga.
.018"
.
024"
.
030"
.
036"
.
048"
.
060"
.
075"
.
090"
.
105"
.
120
"
.
135"
.
150"
.
16
4"
.
180"
.194
.46mm
.
61m
m
.
76m
m
.
91m
m
1.2m
m
1.5m
m
1.9m
m
2.3m
m
2.7m
m
3m
m
3.4m
m
3.8m
m
4m
m
4.6m
m
4.9m
m
From above data we conclude that the designing of punching machine for lower yield
stress material like aluminum, Brass etc can be punch with small thickness of sheet metal
plates. Above data is for reference purpose only for the punching machine we design
theoretically is required how much stress to punch a hole for different-different materials
and thickness.

CONCLUSION
The project carried out by us will make an impressing mark in the field of small scale
industries. It is very usefully for the workshops to carry out the punching operations
easily on our machine. This project has also reduced the cost involved in the concern. The
project has been designed to perform the required task taking minimum time.
We have estimated the capacity of the hydraulic punching machine. From the analysis we
found that the machine will be capable to perform the operation on the aluminum sheet to
produce the punched product or for mass production of washers. This machine can be
used for multipurpose punching at a single time of stoke of ram/plunger. As a
modification and extension of the project, a motor along with a flywheel can be attached
to automate the machine in order to increase the throughput time and reduce the cycle
time of the machine according to desire.
We have seen how the Hydraulic systems allow users to accurately wield large amounts
of power with little input force. So we can say that a portable hydraulic system using
leverages is quite economical as compare to the other alternative.

REFERENCE
Research papers:-
1. Design and Fabrication of Auto Roll Punching Machine by Kundan Kumar
ISSN (Online) : 2319-8753
2. Improvement in design of the manual small press machine by vivek Sharma
ISSN : 2278 – 0149
3. Hydraulically controlled punching machine by h.schmid
4. Hydraulic punching machine by f.j cloup
5. The research of new type hydraulic breaker with strike enegy and frequency
of adjusted by gouping yang & yubao chen
Books:-
1. Basic Hydraulic and Components (Pub. ES-100-2) yuken kogyo co.
Ltd.
2. Fluid Mechanics and Hydraulic Machines - Dr. R. K. Bansal, Lp
Publication
3. Machine design R.S Khurmi J.K Gupta, Eurasia publication house
Pvt. Ltd
4. Introduction to Basic Manufacturing Processes and Workshop
Technology Rajendra Singh, New age international publication.
5. Design data handbook K.Mahadevan K.balaveera Reddy, CBS
publishers & Distributors Pvt Ltd.

Minor project Report on DESIGN OF HYDRAULIC SHEET METAL PUNCHING MACHINE USING HYDRO-MECHANICAL LEVERAGE

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