A PROJECT REPORT ON

DESIGN OF HYDRAULIC POWER PACK FOR VERTICAL

TURNING LATHE MACHINE
Submitted in partial fulfilment of the requirements for the award of the degree

of
BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
Under the guidance of
Dr.T.CHINNA PAMULETY, Ph.D
Associate Professor of Mechanical Engineering

BY
RAMAYANAM NAVEEN 16751A0326
V.HARISH 16751A0330

SREENIVASA INSTITUTE OF TECHNOLOGY AND

MANAGEMENT STUDIES, CHITTOOR-517127, A.P.
(Autonomous)
(Approved by AICTE, New Delhi & Permanently Affiliated to JNTUA, Ananthapuramu)

DEPARTMENT OF MECHANICAL ENGINEERING

(2016-2020)
 SREENIVASA INSTITUTE OF TECHNOLOGY AND
MANAGEMENT STUDIES, CHITTOOR-517127, A.P.
(Autonomous)
(Approved by AICTE, New Delhi & Permanently Affiliated to JNTUA,
Ananthapuramu)

This is to certify that the project work entitled “DESIGN OF HYDRAULIC

POWER PACK FOR VERTICAL TURNING LATHE” is a genuine work of
RAMAYANAM NAVEEN 16751A0326
V.HARISH 16751A0330
Submitted to the Department of Mechanical Engineering, in partial fulfillment of
the requirements for the award of the degree of BACHELOR OF TECHNOLOGY
in MECHANICAL ENGINEERING from Jawaharlal Nehru Technological
University Ananthapur, Ananthapuramu.

Signature of the Supervisor Signature of the Head of Department

Dr.T.CHINNA PAMULETY, Ph.D., Dr.S.RAJESH, M.E., Ph.D.,
Associate Professor, Associate Professor & HOD,
Department of Mechanical Engineering, Department of Mechanical Engineering,
Sreenivasa Institute of Technology and . Sreenivasa Institute of Technology and
Management Studies, Chittoor, A.P. Management Studies, Chittoor, A.P.

Submitted for University Examination (Viva-Voce) held on……………………

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT
A Project of this magnitude would have not been possible without the guidance
and co-ordination of many people. Predominantly my thanks to Late Sri
D.K.AUDIKESAVULU Garu Founder, SITAMS and Late Sri D.A. Satya
Prabha Garu for the extensive lab facilities provided in the college.

Our team is very much grateful to the Chairperson Sri K.Ranganatham, B.E,
E.I.E, I.E.C.Engg., Garu for his encouragement and stalwart support. Further, we
would like to express our profound gratitude to Dr.M.Saravanan, M.E, Ph.D,
Principal FAC, for providing all possible facilities throughout the completion of our
project work.

We express our sincere thanks to our Head of Department Dr. T. Chinna Pamulety,
M.Tech., Ph.D., for his co-operation and valuable suggestions towards the
completion of project work.

We express our sincere thanks to our guide Dr.T.Chinna Pamulety, M.Tech.,

Ph.D., for offering us the opportunity to do this work under his guidance.

We express our sincere salutation to all other teaching and non-teaching staff
of our department for their direct and indirect support given during our project work.
Last but not the least; we dedicate this work to our parents.

RAMAYANAM NAVEEN 16751A0326

V.HARISH 16751A0330
Course Outcomes for project work

On completion of project work we will be able to,

CO1. Demonstrate in-depth knowledge on the project topic.

CO2. Identify, analyze and formulate complex problem chosen for project work to
attain substantiated conclusions.

CO3. Design solutions to the chosen project problem.

CO4. Undertake investigation of project problem to provide valid conclusions.

CO5. Use the appropriate techniques, resources and modern engineering tools
necessary for project work.

CO6. Apply project results for sustainable development of the society.

CO7. Understand the impact of project results in the context of environmental

sustainability.

CO8. Understand professional and ethical responsibilities while executing the

project work.

CO9. Function effectively as individual and a member in the project team.

CO10. Develop communication skills, both oral and written for preparing and
presenting project report.

CO11. Demonstrate knowledge and understanding of cost and time analysis required
for carrying out the project.

CO12. Engage in lifelong learning to improve knowledge and competence in the

chosen area of the project.
 CO – PO MAPPING

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CO.2
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CO.3
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CO.4
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CO.5
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 ABSTRACT

The project is aimed at the Design of hydraulic Power pack for vertical turning lathe.
This Hydraulic Power pack is used to obtain the various motions of the Vertical
Turning Lathe Clamping and unclamping is also done with hydraulic system. Hence
versatility and reliability of hydraulics is prime importance. The Power pack is an
integral supply unit usually containing a pump, reservoir, relief valve and direction
control valve, Pressure control valve. For the purpose of design of hydraulic Power
pack, the component is to be designed are pump, reservoir, heat exchanger and an
electric motor. Hydraulic drives and controls have become more important due to
automation and mechanization. Many of the modern and Powerful machinery are
controlled partly or completely by hydraulics. Hydraulic system is less complicated
and has fewer moving parts. Today drive and control system engineering is
inconceivable without hydraulics. Special emphasis is made on design of Power pack
in which the elements, maintenance aspects and trouble-shooting methods is dealt
with.
 CONTENTS

TITLE Page No.

CHAPTER -1: INTRODUCTION TO HYDRAULIC POWER PACK
1.1 Special characteristics of Hydraulics 2
1.2 Why Hydraulic power pack? 2
1.3 Classification of Hydraulic power pack 2

1.4 Working principles of Hydraulic power pack 5

1.5 Components of hydraulic power pack 7
1.6 Working of power pack 8
CHAPTER -2: LITERATURE SURVEY
2.1 Literature Review 10
CHAPTER –3:MODELLING
3.1 Design consideration 12
3.2 Software used for Designing 12
3.3 Manufacturing of hydraulic power pack 14
CHAPTER– 4: DESIGN METHODOLOGY
4.1 Vertical turning machine 18
4.2 Definition of technical terms 20
4.3 Components of hydraulic Power pack 21
4.4 Environmental conditions 31
4.5 Selection of Components 32
CHAPTER -5: DESIGN AND VALIDATION
5.1 Design Calculations 38
5.2 Hydraulic Power Pack Layout 43
5.3 Troubleshooting Hydraulic Power Pack 52
5.4 Advantages and Disadvantages 57
5.5 Accessories 59
5.6 Hydraulic Fluid 65
5.7 Contamination And Its Control 67
CHAPTER -6: INSTALLATION 71
CHAPTER -7: RESULT & CONCLUSIONS 72
REFERENCES 73
List of figures

List of Tables
 CHAPTER - 1
INTRODUCTION TO HYDRAULIC POWER PACK

The word hydraulics is derived from the Greek word hydro means water. The term
hydraulics means the transmission and control of forces and movement by means of
fluid. The Power pack is an integral Power supply unit, which basically determines
the working of the control unit. Power packs offer capacities, control options and
configuration for virtually any application requirement. A wide variety of manifold
options and choice of pumps enables customers to match any application requirement
with a Power pack that meets his system, at the same time ensuring cost effective
operation and optimum productivity. A hydraulic Power pack offers a simple method
of introducing hydraulic Operation to individual machines, with flexibility of being
adaptable to other duties.

Fig: - 1.1. Hydraulic Power Pack

It consists basically of an integral electrical motor, with associated tank. The pump or
motor unit may be mounted on the tank or separately and packs are usually available
in either horizontal or vertical configuration. Relief and check valves are normally
incorporated on the tank. The basic unit may be piped to the cylinders or actuators
through a suitable control valve. Hose assemblies are generally preferred to rigid
piping for connecting the Power pack to actuators. The hydraulic Power packs consist
of a reservoir / tank that house the hydraulic fluid, which is the working medium. The
capacity of the tank may vary accordingly to the requirements. The reservoir is also
equipped with an air breather at the top to maintain the pressure in the tank at the
atmospheric pressure and filters the oil to 40 microns.

1
The field of hydromechanics (Fluid Mechanics) is broken down as follows: -
HYDROSTATICS: -
Hydrostatic is the mechanics of still fluid.
EXAMPLE: - Transfer of force in hydraulic.
HYDRODYNAMICS: -
Hydrodynamics is the mechanics of moving fluid.
EXAMPLE: -Conversion of flow energy in turbines in Hydroelectric Power plants.
1.1 Special characteristics of Hydraulics
 High forces with compact size, i.e., high Power density.
 Automatic force adoption.
 Movement from standstill possible under full load.
 Step less change (control or regulation) of speed, torque, stroke force etc. can be
achieved simply.
 Simple overload protection.
 Suitable for controlling fast movement proves and for extremely slow precision
movements.
 Relatively simple accumulation of energy by means of gas.
1.2 Why Hydraulic power pack?
 It eliminates the need of complicated linkages, gears, cam and leavers.
 It has a medium of power transmission of the fluid. Which is not subjected any
breakage like parts (or) mechanical transmission.
 It consists of parts, which are not subjected to great wear like the parts of then
mechanical components.
 It has a less complex construction when compared to a pneumatic system.
 It also has a noise free operation when compared to the sound generated by
compressor in pneumatic system.

1.3 Classification of Hydraulic power pack

There are many types of hydraulic power pack in the market but classification may
depend on the construction, function and size of the power pack.
Based on the construction/design: -
1. Single acting hydraulic power pack: - In single acting hydraulic cylinders, the
hydraulic fluid acts on only one end of the piston. Therefore, to push the piston
back to its original position (retraction), the cylinder uses a compressed air,
mechanical spring, a flying wheel or gravity load.

1.4 Working principles of Hydraulic power pack

 Pascal law:
When force ‘F’ acts on an enclosed fluid via surface ‘A’, pressure occurs in the fluid.
The pressure is related to the amount of force applied to the surface vertically and the
area of application of force.

2
Since the pressure is force per unit area, it has units of N/m 2 in SI system. Another
name for the SI unit of pressure is pascal (pa). 1P = 1N/m2
Pressure acts on all sides equally and simultaneously. It is equal at all points this is
valid with emission of the gravity force, which to be added to the fluid level.

Fig. 1.8: Illustration of Pascal`s law

 Bernoulli’s principle:
In fluid dynamics, Bernoulli's principle states that an increase in the speed of a fluid
occurs simultaneously with a decrease in static pressure or a decrease in the fluid 's
potential energy.

Fig 1.9. Bernoulli’s principle

3
1.4.1 Flow configurations
1. Laminar flow: laminar flow. Smooth, orderly movement of a fluid, in which
there is no turbulence, and any given subcurrent moves more or less in parallel
with any other nearby subcurrent. Laminar flow is common in viscous fluids,
especially those moving at low velocities.
2. Turbulent flow: Turbulent flow, type of fluid (gas or liquid) flow in which the
fluid undergoes irregular fluctuations, or mixing, in contrast to laminar flow, in
which the fluid moves in smooth paths or layers.

Fig. 1.10. Types of flows

1.5 Components of hydraulic power pack

The major components of hydraulic power pack include:

Fig.1.11: Hydraulic power pack

4
 Electric or diesel motors: -An electric motor is an electro-mechanical device that
converts the electric energy into mechanical energy. That is it converts electrical
energy to magnetic energy then to rotational force.
1. Tank/Reservoirs: - A hydraulic tank is a container that holds the fluid that
you’ll supply to the system to do the work.
2. Valves: - Valves are devices that control the flow of fluid in hydraulic
systems. They regulate flow by cutting-off, diverting, providing an overflow
of the hydraulic fluid, among other functions.
3. Suction filtes+sssssrs: - Hydraulic filter removes debris or impurities in the
oil before it is suctioned through the hydraulic pipe to the pump. It also helps
to keep the hydraulic system clean.
4. Manifold blocks: - A hydraulic manifold helps to regulate the fluid flow,
pressure and flow direction in hydraulic systems. It acts as a junction between
the hydraulic pump and hydraulic actuators.
5. Actuator: - A hydraulic actuator is the mechanical portion that converts
hydraulic power into useful work. This mechanical work can either be linear
motion, rotary motion or oscillatory motion.
6. Pump: - A hydraulic pump is a device that converts the mechanical energy
from the motor (rotor motion) into a hydraulic energy. The output shaft from
the electric motor is coupled to the shaft of the hydraulic pump. As the pump
rotates, it creates a pressure difference between its inlet and outlet.

1.6 Working
The working of a Power pack commences when the pump is initialized with the help
of an electric motor coupled to it. The oil is pumped from the reservoir along the
suction line through a suction strainer with a capability to retain the foreign particles
up to 149 microns. From the suction line the oil is forced in to the pressure line
through the pump at 35 bars. There is provision to measure the pressure, with the help
of a pressure gauge. An isolator is used to measure the pressure immediately in any
line. When the set of pressure is reached, the fluid moves to the cylinder present at the
fixture (clamp). The hydraulic energy of the fluid is converted back to the mechanical
energy by the cylinder. According to the direction of the energizing of the solenoid
valve, the linear movement of the clamps (clamping and unclamping) is controlled.
When the solenoid valve is energized in reverse, unclamping of the work piece
occurs. There is a return line provided so that the used fluid may be utilized again.
Due to the friction losses, total energy is not converted into the useful work so a part
is converted into the heat. So, a heat exchanger is incorporated. The return line filter
has a return capacity of 10 microns.
A vertical turret lathe works much like an engine lathe turned up on End. The
principles used to operate a vertical turret lathe are not very different from those for a
horizontal turret lathe. The only significant difference is in the main turret. And also
feed is transferred vertically toward the headstock (down), and at an angle. To cut a
taper of less than 30° and more than with a main turret-held tool, set the turret slide

5
for the correct degree of taper and use only the vertical feed for the slide. In this type
of turret lathe, the revolving turret is mounted on a ram or a slide carried in a base
which can be clamped in any position along the bed of the machine.

Fig 1.12. Vertical Turret Lathe

A turret lathe can perform internal or external work such as turning, boring, drilling
reaming, tapping, threading, forming, knurling, chamfering and parting off etc. the
operations which are usually performed from the hexagonal turret include: turning,
boring, drilling, reaming, tapping and threading. The operations which are done from
cross slides include: facing, forming, knurling, chamfering, recessing and paring off.
Internal cuts are almost always made by tools in hexagonal turret.

6
 CHAPTER – 2

LITERATURE SURVEY

2.1. Literature Review

The history of hydraulic system can be traced back to the 1646, when braise pascal
performed the first hydrostatic experiment. He used a pascal’s barrel to investigate the
effect of a force applied at one point of the fluid and how is transmitted to the other
sections within an enclosed system. The outcome of his experiments resulted in a
scientific law/principle called pascal law/pascal principle.
By 1795 Joseph bramah, a British mechanic did put pascal’s law into practice by
developing the first hydraulic press was known as Bramah press. Since then a number
of firm machineries, industrial equipment’s, tractors etc... have been developed to
facilitate various industrial processes. Take for instance, Ferguson tractors and
hydraulic power packs.
ISO Standard 4409 Defines the necessary measurements, symbols, measurement
accuracy and suggested tests for pumps and motors.
ISO Standard 8426 Presents a method of determining the actual displacement of a
pump or motor during a test. For a certain displacement set point, several pressure
measurements are used to extrapolate a line whose intercept is the actual
displacement.
Srinivas R et al. A hydraulic system is a group of hydraulic elements arranged in an
order and using these hydraulic element Powers is transmitted using a confined liquid
i.e. Oil. Hydraulic Power units are drive system for hydraulic machines.
Sridharakeshava K. B. et. al., has discussed about the General Requirements of a
Fixture which includes constraints of Deterministic location, contained deflection,
geometric constraint in order to maintain the work piece stability during a machining
process. They also discussed three broad stages of fixture design, Stage one deals with
information gathering and analysis, Stage two involves product analysis and stage
three involves design of fixture elements.
Vektec, hydraulic clamping information describes Hydraulic Systems & Circuits
which includes Power Supplies, Valves, System Types, Accumulators, Orifices,
Filtration, Flow Requirements, Line Sizing, Circuit Design; General Description,
information & Application Recommendations of Work Supports, Swing Clamps,
Cylinders & Position Sensing.
Wen Wang et al., In these study oil pump models with different gear tooth shapes
were established and the internal flow field simulation were conducted by utilizing
pump links. Especially the flow pulsation of dislocation gear pump is much lower,
than straight gear pumps.
E.A.P. Egbe Present detailed design procedure of external gear pump. And also, the
fabricating methods and their analysis and results. The design analysis, fabrication

7
and testing of an external gear pump, which will serve as a spring board for
technological transfer and development of country. The components of this gear pump
were fabricated by machining.
Dipen Rana et al., Present CFD analysis is applying for to know flow behaviour inside
the pump that cannot be captured in physical testing. This experimental simulation is
applying to simulate for 4 psi delivery pressure which is required to circulate in
punching machine.
The growth of oil hydraulics as parallel development in transportation, farm and earth
moving equipment, industrial machinery, machine tool ship control, aircraft missiles
and numerous other applications. Oil hydraulics however forms one aspects of an
overall system concept with the impact of raising cost and global shortage of fossil
fuels like coal and petroleum, the transmission system designers today are forced to
critically consider his options from the point of view of efficiency and overall
economy. These results in the introduction of oil hydraulic machine components over
the last decade, with remarkable. Increase in Power density and operating pressure,
with greater overall efficiency. This trend is likely to continue into the 1980’s with a
major breakthrough in materials and manufacturing technology.
In 1980’s we have seen the introduction of organic and synthetic fluids in a hydraulic
system on a very large scale. The coming decade shall also witness the introduction of
water based hydraulic fluids in industrial hydraulics.
The problem today is not the development of water-based fluids themselves, but in the
design of hydraulic machines and components, which uses such fluids.
The rising costs and shortages of mineral oil based hydraulic fluids will certainly
provide the incentive to switch over to water-based fluids. But various problems
which are yet to be solved, water hydraulic did not make any great impact on industry
in early half of 1990’s. However, any developments or research activities in this
sphere will be of pioneering natural and small definitely be of great help to the
organization engaged in such work. There has been specific growth in the applications
of Power during the 1960’s and 70’s. Today the application ranges from the artifices
like gigantic machine tools, injection moulding machines and presses.
These applications are likely to go proliferate further in the future. During the last two
decades oil hydraulics has made great advances in the field of farm tractors, farm
machinery and implements with world facing the challenge of feeding an ever-
increasing population, there is bound to be phenomenal growth in far mechanization.
It is the special relevance to our country where we shall have to recognize agriculture
and try to increase efficiency in cultivating large acres and producing food grains on a
large scale.

8
 CHAPTER - 3

MODELLING
3.1 Design consideration
1. Space Available: The available physical-space with in which a hydraulic cylinder
or a fluid must be accommodates or dictates the size of cylinder or the fluid motor.
2. Force Required: Once the piston size is decided, the force required at the
actuator depends up on the working pressure of the system. Higher the working
pressure, lower is the size and weight of the actuator, for the same force. But it
results in many disadvantages. systems working pressure are known the Power of
the prime mover can be easily calculated. There by the size of the reservoir, the
suction strainer, the pipelines and all other valves are determined.
3. Flow Required: The speed of the actuator determines the flow capacity of the
pump.
4. Environmental Conditions: This determines whether the system should have
ordinary or fire proof hydraulic fluid in hazardous condition, shock resistance on
mobile use, nonmagnetic construction in certain applications, noise elimination
arrangement in noisy atmosphere, more filtration arrangement in a dusty
atmosphere and some special designs of mountings or fittings in typical
applications is required.

5. Economical Consideration: This is the most important factor, which must be

kept in mind while designing a hydraulic circuit. If a hydraulic machine is likely
to operate only a few hours in a month, no customer will likely to buy it, if its cost
is very high. If a hydraulic machine is likely to operate 24 hours a day, the life
expectancy of each component becomes an important consideration. The need of
frequent replacement of components will create maintenance problems and
production losses.

3.2. Software used for Designing

AutoCAD was derived from a program that began in 1977, and then released in
1979 called Interact CD, also referred to in early Autodesk documents as MicroCAD,
which was written prior to Autodesk's (then Marin chip Software Partners) formation
by Autodesk cofounder Michael Riddle.
The first version by Autodesk was demonstrated at the 1982 Comdex and released
that December. AutoCAD supported CP/M-80 computers.As Autodesk's flagship
product, by March 1986 AutoCAD had become the most ubiquitous CAD program
worldwide.The 2020 release marked the 34th major release of AutoCAD
for windows. The 2019 release marked the ninth consecutive year of AutoCAD
for Mac. The native file format of AutoCAD is drawing. This and, to a lesser extent,
its interchange file format DXF, have become de facto, if proprietary, standards for
CAD data interoperability, particularly for 2D drawing exchange. AutoCAD has

9
included support for drawing, a format developed and promoted by Autodesk, for
publishing CAD data.
Since the introduction of CAD, design work that once used pen and paper now uses
computers. CAD software replaces the traditional drawing board and makes design
processes faster and smarter than ever before. CAD is a feature of every industry that
produces a tangible product, from fashion to architecture. No matter what you use it
for, CAD helps us explore ideas, visualize concepts, simulate designs and produce
them.
In this article, we’ll look at how the engineering industry and its sub-disciplines use
CAD. We’ll even take a quick look at examples of CAD software used in the
industry.
CAD doesn’t just help engineers create designs; it also gives them the ability to fully
analyse their designs through simulations. Engineers can measure stress
levels, simulate the flow of fluid and calculate the tolerances of their design. Essentially,
they can figure out the strengths and weaknesses of their designs without having to
manufacture them.
CAD software locates flaws and troubleshoots problems that engineers would
otherwise only discover after production. Additionally, it can also simulate how a
prototype would function in certain environments, including extreme environments
which would be difficult to replicate in the real world. CAD packages make use
of CAE applications to aid in engineering analysis tasks.
3.2.1. Design/modelling

Fig 3.1. Model preparation in Auto CAD

10
 Fig 3.2. Model preparation in Auto CAD

Fig 3.3 Model preparation in Auto CAD

3.3. Manufacturing of hydraulic power pack

1. Sand casting: -
Sand casting, the most widely used casting process, utilizes expendable sand moulds
to form complex metal parts that can be made of nearly any alloy. Because the sand
mould must be destroyed in order to remove the part, called the casting, sand casting
typically has a low production rate. The sandcasting process involves the use of a
furnace, metal, pattern, and sand mould. The metal is melted in the furnace and then
ladled and poured into the cavity of the sand mould, which is formed by the pattern.
The sand mould separates along a parting line and the solidified casting can be
removed.

11
 CHAPTER - 4

DESIGN METHODOLOGY

4.1Vertical turning machine

When market demand is high and the goods have to be supplied at shorter delivers
and lower price, the need for mass production of the components arises. To offset the
low level of mass production by conventional machine tools, it is essential to develop
machines for mass production of components demand high productivity and reliability
machine tools. The concept of vertical turning machine has been evolved to meet
these requirements.
By the advent of vertical turning machine concept, it has become possible to achieve
higher production rates by cutting down unproductive time to minimum and by
performing a greater number of operations on a component simultaneously that is
possible on conventional machine tools.

Fig 4.1. Vertical Turning Machine

The main components of vertical turning machine are: -
1. Bed: - It will be of enough deep section braced by adequate number of ribs.
Guide ways have ample bearing surface finished on CNC Machine and are
accurately hand scraped to fine limits.
2. Table: - Table will be of box section with guide ways finished on CNC
Machine to bear load & will be of long wearing quality. Adequate numbers of
T-Slots are provided to clamp the work securely.
3. Columns: - The Columns will be of rigid box section keyed firmly bolted on
the bed and will be capable of absorbing the heaviest possible shocks. Set pins
will be provided to help refit machine accurately after it is dismantled. The
matching surfaces of the VTL will be finished on CNC Machine.
4. Cross Rail: - Cross Rail will be fixed type Camel type box section heavily
ribbed with large bearing surface finished on CNC Machine.

12
 5. Clamping Jaws: - Machine will be supplied with 4 Nos. Heavy Duty Jaws to
clamp the work piece securely.
4.1.1. Layout of vertical turning lathe machine

Fig: 4.2. Layout of vertical turning lathe machine

Technical Specifications of a vertical turning machine

i. TABLE
a) Table Diameter mm 2000
b) Maximum Turning Diameter mm 2000
c) Turning height mm 2000
d) Permissible max load on table Kg. 5000
e) Power of table drive (Continuous) kw 51
f) Table speed ranges for turning Nos. 2 (Two)
g) Table speed range rpm 1 to 150 rpm
ii. CROSS RAIL
a) Max. Height under cross rail & table top surface mm 1600
b) Min. Height under cross rail & table top surface mm 800

13
 c) Vertical movement of cross rail mm 1200 in steps of 200mmhydrualically
operated.

iii. RAM HEAD

a) Vertical travel of ram (Z-Axis) mm 1200
b) Horizontal travel of ram (X-Axis) mm -1000 / +1000
c) Ram cross section mm 240 x 240 • d. Tool cross section mm 40 x 40.
1. POSITIONING ACCURACY AS PER VDI / DGQ 3441
i. For X & Z Axes
a) Positional uncertainty(P) X-axis mm 0,015
b) Positional uncertainty(P) Z-axis mm 0.010
c) Repeatability error (Ps) X-axis mm 0,008
d) Repeatability error (Ps) Z-axis mm 0.006
e) Reversal error (U) mm 0,005
ii. For C-Axes
a) Positional uncertainty(P) arc sec 10
b) Repeatability error (Ps) arc sec 06
2. LIVE SPINDLE
a) Spindle speed RPM 0 – 3000
b) Spindle taper BT50
c) Spindle power kw 25 Chip Conveyor Chip Trolley.
4.2. Definition of technical terms:
Actuator: A device used for converting hydraulic energy into mechanical energy. It
can be a motor or a cylinder.
Circuit: An arrangement of components is interconnected to perform a specific
function with a system.
Cylinder: A device that converts fluid Power into linear mechanical force and
motion.
Drain: A passage or a line, from a hydraulic component that returns leakage fluid
independently, to the reservoir or vented manifold.
Direction valve: A valve that selective directs or prevents fluid flow to desired
channels.
Flow control valve: A valve that controls the rate of oil flow through the circuit.
Pressure reducing valve: A valve that limits the maximum pressure at its outlet
regardless of inlet pressure.
Line: A tube pipe or hose that acts as conductor of hydraulic fluid.
Manifold: A fluid conductor that provides multiple connections ports.
Plunger: A cylinder shaped part that has only one diameter and is used to transmit
thrust through a ram.

14
Power pack: An integral Power supply unit usually containing a pump, reservoir,
relief valve and direction control valve.
Servo Mechanism: A Mechanism subjected to the action of controlling device, which
will operate as if it were directly actuated by controlling device.
Spool: A term loosely applied to any moving cylindrically shaped part of hydraulic
component which to direction flow through the component.
Solenoid: An electro mechanical device, which converts electrical energy into
mechanical motion, used to accurate direction valves.
Fluid: A liquid or as material which adapts the shape of the container.
Laminar flow: Fluid flow in which particles slide smoothly along lines parallel to the
wall. Resistance to flow varies directly with velocity.
Turbulent flow: Random local disturbances in the fluid flow pattern about a mean
average velocity. Resistance to flow is proportional to square of velocity.
Reynolds number: A dimensionless number relating with fluid velocity V, pipe
diameter and fluid viscosity.
4.3. Components of hydraulic Power pack
They include:
1. Electric or diesel motors
2. Hydraulic valves
3. Reservoirs
4. Hydraulic gear pumps
5. Suction filter
6. Air breathers for fill oil into Hydraulic Reservoirs
7. Central manifold blocks
8. Electrical Control systems, like buttons remote and wireless remote
It is these parts that are interconnected to form an electric driven Power unit, i.e., a
single component. Other Power units may have more components depending on the
complexity of the design.
1. AC & DC Electric Motors:
An electric motor is an electro-mechanical device that converts and electric energy to
mechanical energy. That is, it converts electrical energy to magnetic energy then to
rotational force.
Broadly, motors are classified in three main categories:
 DC motors:
Electric motors into this category include: shunt motors, separately excited
motors, series motors, permanent magnet DC motors and compound motors.

15
 AC motors:
These electric motors include induction and synchronous motors. The induction
motors are classified further as either single phase induction motors or three phase
induction motors.
 Others:
Examples of motors in this category include: stepper motors, brushless DC
motors, hysteresis motors, reluctance motors and universal motors.
For the scope of this hydraulic Power pack eBook, I will focus on AC and DC
motors.
In a hydraulic circuit, electric motors convert the electrical energy into a rotational
force that drives the pump gear.
DC motor:
 The electrical DC motors convert direct current into a rotational mechanical
energy. These motors use a direct Power supply whose voltage may vary from
DC12V, DC24V, DC48V or DC96V; depending on the design specification of the
hydraulic Power pack system.

How DCMotorsWork
These motors have the following key parts:

 A stator that provides the magnetic field. For most portable equipment, the stator
is a permanent magnet.
 An armature (also referred to as the rotor in this case) that connects to a DC Power
supply via commutator rings. It’s a coil that conducts electrical energy.
 As the current flows through the coil, an electromagnetic force is induced. This
causes the coil to rotate. Of course, this is according to the Lorentz law.
 When the coil is perpendicular to magnetic flux, the torque action will be zero.
Therefore, to ensure smooth operation, there should be more conductor coils.
 In practical applications, a DC motor has more rotor loops with different pairs of
commutators. The armature loops are always in a slot of highly permeable steel
layers.
 For large DC motors that are commonly found in large hydraulic systems, the
electric motor manufacturers use electromagnet instead of permanent magnets.
 That is, the field coil of the electromagnet is Powered from the DC source that
Powers the armature. Depending on the type of connection, you’ll have either a
shunt or series DC motor.
 The complexity of the design will depend on the type load the motor should drive.
In the case of the hydraulic Power packs, we have a hydraulic pump as the load.

Why Use DC Motors in Hydraulic Pump Applications:

Here are some of the reasons why DC motors are common in pump applications:

16
 DC motors have variable speed control.
 They have a high starting torque.

 DC motors have good transient response.

 High efficiency and Power density.
 Less maintenance.
 Simple and compact design.
 Better thermal properties and constant magnetic field.
 In the recent past, a number of hydraulic Power pack manufacturers have adopted
the permanent magnet and brushless DC motors for most pump applications. The
brushed wound field DC motors are still common in some hydraulic applications.

4.3.1. Main components of hydraulic Power pack

1. PUMP: -As stated before, pumps add energy to liquid and perform various
functions
Their functions are
 The liquid can be raised to a higher level by virtue of increase in potential energy
of the liquid.
 There would be an increase of liquid pressure.
 Increase in the velocity of liquid by virtue of increase in kinetic energy.

Fig: 4.3. Types of Pumps

1. Dynamic Pumps
Dynamic pumps are classified into different types but some of them are discussed
below like Centrifugal, Vertical centrifugal, Horizontal centrifugal, Submersible, and
Fire hydrant systems.
 Centrifugal Pumps
These types of pumps are most commonly used worldwide. The working is very
simple, described well and carefully tested. This pump is strong, efficient and fairly
cheap to make. Whenever the pump is in action, then the fluid pressure will increase

17
from the inlet of the pump to its outlet. The change of pressure will drive the liquid
throughout the system.

Fig 4.4. Centrifugal Pump

This kind of pump produces an enhancement within force by transmitting mechanical

Power from the electrical motor to the liquid throughout the revolving impeller. The
flow of liquid will enter the centre of impeller and exits along with its blades. The
centrifugal Power hereby enhances the velocity of fluid & also the energy like kinetic
can be altered to force.
 Vertical Centrifugal Pumps
Vertical centrifugal pumps are also called as cantilever pumps. These pumps use an
exclusive shaft & maintain design that permits the volume to fall within the pit as the
bearings are external to the pit. This mode of pump utilizes no filling container to
cover the shaft however in its place uses a throttle bushing. A parts washer is the
common application of this kind of pump.

Fig 4.4. Vertical Centrifugal Pump

 Horizontal Centrifugal Pumps
These types of pumps include a minimum of two otherwise more impellers. These
pumps are utilized in pumping services. Every stage is fundamentally a divide pump.

18
 Fig 4.5. Horizontal Centrifugal Pump

All the phases are in a similar shelter & mounted on a similar shaft. On a solo
horizontal shaft, minimum eight otherwise additional stages can be mounted. Every
stage enhances the head by around an equal amount. Multi-stage pumps can also be
single otherwise double suction on the first impeller. All kinds of pumps have been
providing as well as servicing this type of centrifugal pumps.
 Submersible Pumps
These pumps are also named as storm water, sewage, and septic pumps. The
applications of these pumps mainly include building services, domestic, industrial,
commercial, rural, municipal, & rainwater recycle applications

Fig:4.6. Submersible Pump

These pumps are apt for shifting storm water, subsoil water, sewage, black water,
grey water, rainwater, trade waste, chemicals, bore water, and foodstuffs. The
applications of these pipes mainly include in different impellers like closed, contra-
block, vortex, multi-stage, single channel, cutter, otherwise grinder pumps. For
different applications, there is an extensive selection is accessible which includes high
flow, low flow, low head, otherwise high head.
 Fire Hydrant Systems
Fire hydrant pump systems are also named as hydrant boosters, fire pumps, & fire
water pumps. These are high force water pumps intended to enhance the capacity of
fire-fighting of construction by increasing the force within the hydrant service as
mains is not sufficient. The applications of this system mainly include irrigation as
well as water transfer.
2. Positive Displacement Pumps

19
Positive displacement pumps are classified into different types but some of them are
discussed below like diaphragm, gear, peristaltic, lobe, and piston pumps.
 Diaphragm Pumps
Diaphragm pumps also known as AOD pumps (Air operated diaphragms), pneumatic,
and AODD pumps. The applications of these pumps mainly include in continuous
applications like in general plants, industrial and mining. AOD pumps are particularly
employed where Power is not obtainable, otherwise in unstable and combustible
regions. These pumps are also utilized for transferring chemical, food manufacturing,
underground coal mines, etc.

Fig 4.7. Diaphragm Pump

These pumps are responding pumps and include two diaphragms which are driven
with condensed air. The section of air by transfer valve applies air alternately toward
the two diaphragms; where every diaphragm contains a set of ball or check valves.
 Gear Pumps
These pumps are a kind of rotating positive dislocation pump, which means they force
a stable amount of liquid for every revolution. These pumps move liquid with
machinery coming inside and outside of mesh for making a non-exciting pumping act.
These pumps are capable of pumping on high forces & surpass at pumping high
thickness fluids efficiently.

Fig 4.8. Gear Pumps

1. Peristaltic Pumps
Peristaltic pumps are also named as tube pumps, peristaltic pumps. These are a kind
of positive displacement pumps and the applications of these pumps mainly involve in
processing of chemical, food, and water treatment industries. It makes a stable flow

20
for measuring & blending and also capable of pumping a variety of liquids like
toothpaste and all kinds of chemicals.

Fig 4.9. Peristaltic Pump

2. Lobe Pumps
These pumps offer different characteristics like an excellent high efficiency, rust
resistance, hygienic qualities, reliability, etc. These pumps can handle high thickness
fluids & solids without hurting them. The working of these pumps can be related to
gear pumps, apart from the lobes which do not approach into contact by each other.
Additionally, these pumps have superior pumping rooms compare with gear pumps
that allow them to move slurries. These are made with stainless steel as well as
extremely polished.

Fig 4.10. Lobe Pumps

3. Piston Pumps
Piston pumps are one kind type of positive dislocation pumps wherever the high force
seal responds through the piston. These pumps are frequently used in water irrigation,
scenarios requiring high, reliable pressure and delivery systems for transferring
chocolate, pastry, paint, etc.

21
 Fig 4.11. Piston Pumps
4. Reciprocating pump: -
Reciprocating Pumps are positive displacement machines typically used for low-flow,
high-pressure operations. ANSI and the Hydraulic Institute categorize reciprocating
pumps by four types. Both pistons and diaphragms are used to provide pumping
action while valves regulate flow into and out of the pump body.

Fig 4.12. Reciprocating pump

2. RESERVOIR: -
A hydraulic system must have a reserve of fluid in addition to that contained in the
pumps, actuators, pipes and other components of the system. This reserve fluid must
be readily available to make up losses of fluid from the system, to make up for
compression of fluid under pressure, and to compensate for the loss of volume as the
fluid cools. This extra fluid is contained in the tank usually called a reservoir.

22
 Fig 4.13. Reservoir
In addition to providing storage to reserve the fluid needed for the system, the
reservoir acts as a radiator for dissipating heat from the fluid and as settling tank
where heavy particles of contamination may settle out of the fluid and remain
harmlessly in the bottom until removed by cleaning or flushing of the reservoir. Also,
the reservoir allows contained air to separate from the fluid. The inside of the
reservoir generally will have baffles to prevent excessive slashing of the fluid and to a
partition between the fluid return line and the pup suction or inlet line. The partition
forces the returning of the fluid to travel further around the tank before being drawn
back into the active system through the pump inlet line. This aids in setting the
contamination and separating the air from the fluid.
Types of Reservoir: -
The various reservoir used for the SPM are broadly classified into two groups. They
are
1.) VENTED they act purely as storage tanks.
2.) SEALED they may be pressurized or non-pressurised
Vented reservoirs are more advantageous than the sealed reservoir, in that it can be
made smaller for the same fluid volume. Care should be taken to avoid over filling,
since this will reduce the air volume and produce wider ranges of pressure during
working. There are various requirements, which a tank must be taken to meet the
specifications.
Non-pressurised Reservoir: -
Hydraulic system designed to operate equipment at sea level are normally equipped
with non-pressurized reservoirs. The ends extended below the bottom of the reservoir
and serve as supports. The bottom of the reservoir is convex, and a drain plug is
incorporated at the lower point.
3. VALVES:
Valves are the devices that control the flow of fluids. The control of the flow of fluids
is itself of various types, mainly isolation, diversion, non-return and regulation. The
regulatory function can be of various types as throttling. Pressure reducing, pressure
relief. safety relief temperature regulation etc.

23
 Fig: - 4.14. Valves

Valve functioning: -Valves are used in piping system and on processing vessels or
tanks for a variety of reasons. The first step, in valve selection is to determine exactly
what is expected of the valve, i.e. what function the valve is to perform after it has
been installed. Proper evaluation of this function will determine the types of valves
suitable for that application.
 GENERAL VALVE FUNCTION
i. On-off service.
ii. Throttling service.
iii. Prevention of the reverse flow.
iv. Pressure control.
v. Sampling service.
vi. Limiting flows.
vii. Special function that includes.
viii. Direction flow control.

 Valve selection factor: -

Usually, more than one type of valve is suitable to perform a specific function. In
order to select the most appropriate valve it is necessary to investigate the factor that
effect individual valves performance and the effect that a particular-valves has on the
materials being handled.
i. Fluid properties: -The properties of the fluid being used must be known. These
properties include its specific gravity, viscosity, corrosiveness and abrasiveness.
Fluid, are used here, is a general term that means gas, vapour or slurry as well as
pure liquid material.
ii. Fluid friction losses: -Various types of valves exhibit varying degree of pressure
drops. A system requirement of pressure drop will often influence valve selection
and must be taken in to consideration.

24
iii. Operating conditions: -Corresponding and maximum and minimum pressure,
temperature must be known. A valve choice, practically in a corrosion material of
construction can be influenced greatly by these factors. This is especially true
plastic of lined valve or under consideration. Establishment of the actual
conditions of each valve simplifies valve selections procedure.
 Material for construction: -
The factor is directly related to the corrosive and abrasive of fluids. In dealing with
extremely corrosive or abrasive materials. The choice of valve is limited by
availability of valves in suitable materials of construction. at times. it is desirable to
consider the construction material to the economical. The combination of operating
pressure and operating temperature will also influence the design criteria of
characteristic will determine the permissible material of construction.
 Valve size: -
As all types are not available in a complete range of size, it is necessary to known
what valve size is required to perform a particular function.
1. DIRECTION CONTROL VALVES
Direction control valves are designed to direct the flow of fluid, at a desired time, to
the point in a fluid Power system where it will do work. The driving of a ram back
and forth in its cylinder is an example of a directional valves, such as selector valve,
transfer valve and control valve. They are ideal for machine tools, production and
material handling equipment, marine auxiliary Power controls, off-highway and
heavy construction equipment, oil field and farm equipment.

Fig 4.15. Direction Control Valves

Direction control valves may be operated by difference in pressure acting on opposite
sides of the valve element, or they may be positioned manually mechanically or
electrically. Often two or more methods of operating the same valve will be in
different phases of its action.
2. PRESSURE CONTROL VALVE
Pressure control valves are used to control and regulate pressure in fluid Power
system. The maintenance or lowering of pressure can be achieved a number of ways.
Some valves are designed to blow off pressure when a set level is reached, other times
are simply designed to send impulse to other valves are normally globe shaped and
are often designed with flanged ends to allow for ease of maintenance. Normally the

25
valves are smaller than line in which it is attached. The design feature prevents the
valve from throttling, which would cause the seat to wear too quickly. The disc is
moved by a pneumatic, hydraulic, electrical or manual operation actuation.
In hydraulic systems pressure regulator as used to unload the system and to maintain
and regulate pressure at the desired valves. When the system pressure decreases a
certain amount, the regulator will open sending the fluid to the system. When the
system pressure increases sufficiently, the regulator will close allowing the fluid from
the pump to flow through the regulator and back to the reservoir. The pressure
regulator takes the load of the pump and regulator system pressure.
4.4. Environmental conditions: Thus, determines whether the system should
have ordinary or fire proof hydraulic fluids in hazardous condition, shock resistance
on mobile use, non-magnetic construction in certain applications, noise elimination
arrangement in noisy atmosphere more filtration arrangement in a dusty atmosphere
and some special design of mounting or fitting in typical applications are required.
4.4.1. Economic considerationsThis is the most important factor, which must be
kept in mind while designing a hydraulic circuit. If a hydraulic machine is likely to
operate only a few hours in a month, no customer will likely to buy it, if its cost is
very high. If a hydraulic machine is likely to operate 24 hours a day, the life
expectancy of each component becomes an important consideration. The need of
frequent replacement of components will create maintenance problems and
production losses. If a hydraulic machine is likely to operate in a place where trained
personal is not available, any sophistication in the hydraulic circuit has to be avoided.
4.5. Selection of Components

CHECK VALVE:

Fig 4.16. Check Valve

Model No Threaded Rated flow A in mm B A/F MM Weight in

size in Bspp LPM KGS
CUT 0.25 ¼ 20 65 19 0.15
CUT 0.35 3/8 30 75 25 0.25
CUT 0.45 ½ 50 85 30 0.40
CUT 0.65 ¾ 80 100 38 0.75
CUT 0.85 1 150 115 41 0.90
CUT 10.5 1-1/4 200 130 55 1.75

26
 CUT 12.5 1-1/2 270 132 665 2.70
 7 Sizes – flow up to 270 L/min
 Max working pressure – 200 bar
 Choice of cracking pressure – 0.5/3.5 bar
 Steel poppet type construction
 Prevents flows in reserve direction

The check valve which acts as a non-return valve not allowing fluid to flow back, is
selected on the basis of pipe size connecting to the check valve in the main line which
is on the basis of flow rate in the main line which is 26 L/min, for having free flow
with no instruction check valve with flow rate more than this is used CUT 0.1-5.
 BREATHER:

Fig: - 4.17. Breather Valve

Features:
1. Chrome plated steel cap – vents underneath
2. Filtration 40 microns standard / optional 10 microns.
3. Air-flow to 25 CFM (750LPM) rugged cast aluminium housing.
4. Metal strainer
5. Hardware includes gasket.

Model Displacement Rating A B C D Weight

microns in kg

FSB 05.10 150 LPM 40 45 49 65 28 0.10

FSB 05.10 90 LPM 10
FSB .25.1 720 LPM 40 77 62 91 48 0.25
0 400 LM 10
FSB .25.1
0
As though this unit the fluid is poured into the tank, the breather selected should act as
a filter to steam unwanted material in fluid to entre in to the tank and as well it should
at as a filter. Where the air entering (during breathing) is also filtered and large
particles of dust is restrained so a breather with maximum micron rating and flow rate
is selected to have free flow of fluid and air (during breathing).

27
 OIL LEVEL GAUGE:

Fig: 4.18. Oil level gauges

Features:
1. 3 sizes 3”, 5” and 10” between bolt centres.
2. For non-pressurized tanks only
3. Can be mounted on tapped holes
4. Suitable for minerals/petroleum-based oils
5. Maximum temperature 80degree Celsius.
Selection of an oil level gauge is made depending on the height of the tank/reservoir.
In the case the reservoir model selected prompts to use an oil level gauge of
dimension 127mm.so the available LG2.05 model is selected.

Weight in
Model A B C D E
kg

LG2-03 26 37 20 34 108 0.20

LG2-05 127 76 20 34 159 0.24

LG2-10 254 203 20 34 286 0.28

A Screen
B overall C die Weight in
Model Threaded Nut A/F area (sq.
length nut cap kg’s
in BSSP cms)

E 3-005 ½ 106 49 25 400 0.20

E 3-007 ¾ 89 68 36 438 0.20

E 3-010 1 137 68 41 710 0.30

28
E 3-015 1-1/4 175 85 50 1045 0.45

E 3-020 1-1/2 206 85 59 1451 0.55

E 3-030 1-1/2 254 102 70 2193 0.65

E 3-040 2 254 102 70 2193 0.80

E 3-075 2-1/2 259 131 85 2580 1.05

E 3-100 3 300 131 85 3225 1.36

 Reliable SS100 mesh/149micron standard
 Steel cap/ support tube
 Continuous epoxy bond
 Metal working temperature 80degree Celsius
 Suitable for hydraulic / mineral oil

The flow rate of pump selected is 30 LPM, so flow rate through the suction strainer
that would be around 90 LPM (3 times should be selected).

29
 FILTERS:

Fig 4.19. Filters

Features:
 Direct tank mounting
 10 bar working pressure / maximum temperature 80
 All aluminium die cast construction
 4 sizes flow to 175 LPM
 By pass standard 1 bar
 Elements replaceable through cover
 Suitable for mineral / petroleum-based oils.
The return line filter is selected on the basis of the size of the pipe connected to it and
the filtration requirement. The pipe connected to this filter in the return line is of the
size 3/4, so model TIF2-06 IS selected.
MODEL CODE: ASSEMBLY
SERIES PORT A BSPP PORT X BSPP FILERATION INDICATOR
in micros
2- All cast 04-1/2” 06-3/4” 0.10-1 OU Q-Visual
06-3/4” 10-1-1/4” 0.25-25 U indicator

08-1”
10-1-1/4”

MODEL CODE: ELEMENT

SERIES SIZE FILTERATION in microns

TIE 04 0.1-1
06 0.25-25
08
10

30
The selection of filter element for return line filter is done on the fact that is the return
line filter is to be fine so a filter of 10 is used and a paper type element is used due to
its low cost.
1. PUMP SELECTION
Pump section depends on the factors such as:
 Working pressure
 Maximum Power rating9max. delivery, speed, rating)
 Efficiency
 Control
 Weight
 Fluid
 Noise
 Cost
 Maintenance
EFFICIENCY:
Where there is considerable variation in demand it is usually more efficient as regards
both operating and running costs, to use a variable delivery pump, although the initial
cost is high.
Efficiency may be important (where large volumes of fluids are being pumped) or
relatively insignificant (ex in a light duty system where ample input Power is
available from an inexpensive drive, or an oversize pump is to be used for a particular
reason).
SPEED:
Pump speed, governs the actual delivery operating speed limits are set by the design
of the pump, while desirable running speeds are set by the normal running speed of
the driver.
NOISE:
S.NO Quietest running pump

1 Screw
2 Lobe rotor
3 Vane
4 Cam vane
5 Gear
6 Multi piston (seated valves)
Noise generated in pump is largely the result of sudden change between suction and
outside, thus pumps which produce high localized pressures are likely to be nosier
than those providing a more gradual pressure change.
COST:
Probably in majority of applications the initial cost is of secondary importance, to
perform and other factors – pump cost, therefore only becomes a major factor for
selection after all other requirements have been met.

31
 Lowest cost first
1. simple external gear
2. Vane
3. Precision external gear
4. Rotary abutment
5. Screw
6. Multi-piston
Despite of the many factors to be considered on selection of pump, in this case the
important factors, which were considered, are the flow rate, comparatively least cost,
variable delivery requirement, and noise. So, a variable displacement vane pump
(with a flow rate of 26LPM) was selected for use.
2. SELECTION OF RESERVOIR / TANK:

Fig 4.20. Reservoir Layout

Features of selected reservoir,

 Large hole for cleaning purposes.
 Sloping tank base.
 Sand blasted and base coated with zinc paint inside and outside.
 Suitable for internal excess pressure up to 0.5 bar.
 Oil drain screw on tank base.

32
 CHAPTER - 5

DESIGN AND VALIDATION

5.1. Design Calculations

 Data from the machine design department:
 Given data

Cylinders for cross Rail Movement = 2

Cylinders for cross Rail Support = 2
Cylinders for Ram Counter balancing = 2
Total No. of cylinders = 6
Dimensions of cylinders:

S.NO TYPE OF DIAMETER STROKE NO.OF

CYLINDERS (mm) LENGTH CYLINDERS
BORE ROD

1. Cross rail movement 125 70 1100 2

2. Cross rail support 70 50 20 2

3. Ram counter 50 22 1000 2

balancing
Rate of transverse of all pistons V=20 mm/sec.
Details of fluid: -
a.) Working pressure of fluid =70 kg/
b.) Oil viscosity (ɣ) =68cst /sec.
c.) Oil density (ρ) =0.89 Kg/
List of formulae used
a) Fluid flow rate Q=A.V
Where Q=Rate of flow in 1/min.
A=Area of cylinder in
V=Velocity in m/sec.
 Calculations for pump size:
1) cross Rail Movement:
Fluid Flow Rate: Q=A.V
Π = 3.141 Constant.
A = π/4[( )- ( )]
= 8421.806
= 8421.806 ×20

33
 = 168436.125 .
= 10.10 l/min.
The flow rate is calculated for only one cylinder. As there are 2 cylinders. The total flow rate
is
= 10.10*2 = 20.20 l/min.

2) For cross rail support:

Area A= π/4[( )-
= 1884.95
Flow rate = 1884.95×20
= 37699.11 /sec.
=2.2621/min.
The fluid flow rate for two such cylinders is = 4.5231/min.
Pump selected should be able to supply fluid at a flow rate required by different
cylinders working at given time, i.e. the pump flow rate is taken as maximum value
among &
Therefore, the flow rate of is selected. For better result it is taken 120% of the
maximum value.
Flow rate of = 20.20×1.2
Flow rate of = 24.24 l/min.
According to standards the pump of fluid flow rate of 30 l/min, is selected.
 calculations for Power of electric motor

Power in Kw=

Pump flow in 1/min.

Working pressure in kg/
Geometric efficiency = 0.8 (assumed)
POWER = 30×70/612×0.8
= 4.9282 KW
= 4.9282×4/3
= 5.71 HP.
The motor considering the various requirements taken the motor of 10HP is selected.
 calculations for tank capacity:
To provide uninterrupted supply of hydraulic fluid and to prevent vacuum inside the
tank, capacity of tank is taken as 2.5 to 3 times of pump capacity.
Therefore, the tank capacity is taken as 3×30 = 90 1/min.
But the lubrication oil is also pumped from the tank to the chuck with a 10 HP motor
therefore the total capacity of the tank is 90×2=180 1/min.
Therefore, from the standards, the tank capacity of 250 litres is selected.

34
 calculations for Relative pressure loss
REYNOLDS No. Re=V×D/ɣ.
Where V=velocity of fluid through pipe in m/sec.

ɣ =viscosity of fluid in cst

D=inner diameter of pipe in mm.
 Pressure losses in pipe connected to the cylinder:

ΔP =
⅄= pipe coefficient in friction.
L=Length of pipe (meters).
V=Flow speed in the line (m/s).
D=Diameter of pipe in mm.
ρ= Density of oil in kg/ .
1. Cross Rail movement:
Given data:
Flow rate Q=336872.25
Area A=78.5
Diameter of the Hose D=12mm
Length of the Hose L=5100mm
Velocity of fluid flow is calculated from the Bernoulli’s equation of fluid flows.
Q =A*V

V= /sec
=4291.36mm/sec.
a) Re = 4291.36×10/68
=757.29(<2300 hence the flow is laminar)
b) ⅄ = 64/757.29
= 0.0845
c) ΔP = (0.0845×0.89×5100×4.29 ×10)/2×12
=2.942bar.
2. Cross rail support:

Given data: Q = 75.9×2

A=78.5
Diameter of House D =10mm
L1 =3300mm
L2 =2000mm
V=75398.2/78.5=960.4mm/sec
i. Re= (960.4×10)/68=141.26
ii. ⅄ = 64/141.63=0.453
iii. ΔP1= (0.453×0.89×3300× ×10)/2×10 =0.613 bar (L.H)

35
 iv. ΔP2= (0.453×0.89×2000× ×10)/2×10=0.371 bar (R.H)
Total pressure loss = 0.613+0.371 = 0.984 bar.
3. FOR RAM BALANCE:
Given data Q = 207795.56 /sec
Hose Diameter D =10 mm.
A =279.6
V = (207795.56)/279.5
=743.118 mm/sec.
i. Re= (743.118×12)/68
=131.13
ii. ⅄=64/131.13=0.88
iii. ΔP= (0.88×0.89×7000× ×10)/2×26=0.699bar.

 Pressure loss between reservoir and hydraulic manifold:

Given data Q = 30 l/min = 500000 /sec
Diameter D = 15 mm
Area A = 176.714
i. Re= (2829.43×15)/68 =624.139
ii. ⅄=64/624.139=0.1025
iii. ΔP= (0.1025×0.89×7000× ×10)/2×15=1.704bar

As the fluid is transferred from reservoir to the system through the manifold, the
pressure loss of hydraulic manifold is to be added to every system. Then the total
pressure loss of every system is given as follows.
1) Cross Rail Movement =2.942+1.702=4.644bar.
2) Cross Rail Support LH=0.613+1.704=2.317bar
RH=0.371+1.704=2.075bar
3) Ram Balancing =0.699+1.704=2.403bar.
 calculation of total pressure loss in the system:
Here for effective design considerations the maximum values among the loss of
pressure values are selected. Therefore, the maximum value is 4.644 bar of cross rail
movement. There are two such lines connected to the system so maximum loss of
Power in the system is given as
=4.644×2=9.288.
Pressure loss through the valves:
1) For solenoid valve of model, no DSG 01 3C4 D24 N150 and flow rate 20 /m
is selected from the curves
P-------A line =1.1 kgf/
B-------T line =1 kgf/
P-------B line =1.1 kgf/
A-------T line =1 kgf/

36
 Total pressure loss of the system is = 4.2 kgf/
Here four valves are used in the circuit at the various locations so that total pressure
drop of the circuit is = 4.2×2 =8.4 kgf/ .
For the solenoid valves of model, no DSG-01-2B2-D24-N150 of flow rate 4.52 l/mm
is given by the P------A, B-----T, P-----B, A-----T.
At chuck is 0.5×4 = 2kgf/
Then the total pressure drop is given by = 2kgf/
Total discharge in the pipeline is
Q=2020+4.523+13.5648+1.1539+17.6302+12.467
Q=69.5381 l/mm

RESULTS TABLE

EDS.NO Type of Diameter in(mm) Stroke No of Discharge Pressure

cylinder length cylinders in lpm loss in bar
Bore Rod

1 Cross rail 125 70 900 2 20.20 6.668

movement
2 Cross rail 70 50 20 2 4.523 2.447
support 2.908

3 Ram 63 28 1100 2 12.468 1.774

counter
balance

The power loss due to pressure loss =

=
= 1645.75 watts
= 2.206 HP (1HP = 746 watts)
But 1 HP = 641.2 kcal/hr
Then 2.206 HP = 1414.55 kcal/hr
So, the cooler capacity of 2000 kcal/hr is selected for heat exchanging.

5.2. Hydraulic Power Pack Layout (VTL): -

37
38
5.2.1. Symbols of hydraulic power pack: -

Troubleshooting Hydraulic Power Pack:

Let’s look at each of these problems and their solutions in this hydraulic trouble
shooting list:-
1. The Motor is Not Running: -
In case of such a scenario, you need to inspect the following key parts:
 The electric motor: -
In the case of a DC power supply, there is always a possibility of low voltage.
However, for the case of AC, there is always a high possibility that the power grid do
not match the AC motor specifications.

 The motor
You need to check if the motor is in good working condition. That is, check all the
terminals to ensure they are connected appropriately and rust free.
 Cable remote
The cable could be loose from the starter relay or broken, thus there could no
continuity.
 Wireless remote
At times, the receiver may be loose from the starter relay. You should inspect the
battery of the remote control to ensure they are in good condition.
The problem could be also be due to poor grounding. So, you have to inspect all
electrical connections.
2. The Motor is Running but in a Wrong Direction: -
You should check the following:
 The electric motor: -
For DC motors, it could be + – inversely connected, so consider reversing the
connections.
 Cable remote: -
The button may have been wired incorrectly.
 Wireless remote: -
The receiver may have been wired incorrectly
So, in both cases, you may consider reversing the terminals.
3. The Motor has Not Been Developing Proper Oil Rate: -
There are always two possibilities:
 The electric motor: -
Maybe the motor speed is not enough to create the required torque. So, so consider
adjusting the motor speed.Alternatively, there could be low voltage therefore, you
need to check your power source.
 The hydraulic pump: -

39
The pump may not be suitable for hydraulic systems or it could faulty. So, you may
consider replacing the pump.
4. The Pump Pressure is too Low: -
In such situations, you may consider the following:
 The electric motor: -
The power to the motor could too low to create the required torque to turn the pump.
That is, either the DC voltage may be too low or for AC motors, the power grid may
not match the
Specifications of the motor.
Apart from these, rust and low motor speed may hinder the electric motor from
developing the required torque.
 The hydraulic pump: -
Your hydraulic pump could be defective or it may be unsuitable for the application.
So, you may consider replacing it. Also, there could be a possibility of internal
leakage. This is mainly brought about by wear and tear.
 The manifold and valves: -
Relief valve of the hydraulic system could be defective or there could be a possibility
of manifold internal leakage.
 Filters: -
Your filters could be blocked thus preventing the sufficient amount of hydraulic from
flowing into the system.
 The hydraulic fluid: -
The viscosity of fluid could be too, and this is mainly due to very low temperatures.
Apart from all these, cylinder leakage may also cause low pump pressure.
5. specifications of the motor.
You should consider the following:
 About the hydraulic pump: -
This problem could be due a defective pump or unsuitable pump type. At times this
could also be due to internal leakages brought about by wear and tear.
 Manifold & valves: -
There could be a manifold internal leakage.
 Filter: -
The filter could be blocked.
 Connectors: -
This problem could be due to couplings wrongly aligned or leakages in the suction
pipe. At times, it may also be due to defective or loose coupling mechanism.
 Oil tank: -
The oil level could be too low or oil is not enough. Apart from these the pump may
not be developing oil when the hydraulic power unit is wrongly mounted.
6. The Cylinder Runs ON
This problem could be due to the following:
 The electric motor: -
It is common when the starter relay is bad. You may consider replacing it.
 Cable remote: -

40
The main causes include button wrongly wired from the inside, a cable is loose from
the starter relay or the switching is too fast. Also, when the cable is loose from the
solenoid coil the cylinder may run on.
 Wireless remote
This happens when the receiver is wrongly wired, switching is too fast or the receiver
is loose from the starter.
 Manifold and valve: -
It occurs whenever there is internal leakages, faulty bleeding solenoid valve is
defective, relief valve has malfunctioned or the valve is dirty. At times, this could be
due to the cylinder inlet seal leakage of cylinder rod that is worn out.
7. When the Cylinder Cannot Extend
The problem could be due to the following:
 Electric motor: -
For DC motors, the battery could be too low while in the case of AC motors, the
power grid may not match the AC motor specifications. Also, it may be due to low
motor power or thermal pressure lock.

 Cable remote: -
The cable could be loose from starter relay, there could be a thermal pressure lock or
fast witching.
 Wireless remote: -
It could be due to fast switching or the receiver may be loose from the starter relay.
 Hydraulic pump: -
The pump could be defective or unsuitable pump type. At times, the problem could be
due to internal leakages brought by wear and tear.
 Manifold & valve: -
It could be due to manifold internal leakage, directional valve not shifting properly or
solenoid valve may not have sufficient energy.
 Filter: -
The filter may be blocked.
 Connectors: -
This could be due to the coupling wrongly aligned, loose coupling, defective coupling
or leakage at the suction pipe.
 Oil tank
There could be low oil level in the tank (oil not enough). Apart from these, the
problem could be due to cylinder leakage, packing on cylinder rod worn out or
hydraulic power unit could be wrongly mounted.
8. The Cylinder Cannot Hold Load
This problem could be due to:
 Manifold & valve
There could be internal leakage or both the check valve and solenoid valves may be
defective.
The problem may also be as a result of cylinder inlet seal leakage or the rod getting
worn out.

41
9. The Cylinder Drops Too Slow or Cannot Drop
This is due to:
 Electric motor: -
For DC motors, the battery voltage could be too low while for the case of AC motors,
the power grid may not match the AC motor specifications.
At times, the power of the motor may be too low or there could be thermal pressure
lock.
 Cable remote: -
The cables could be loose from the solenoid, there could be thermal pressure or the
system switching too fast.
 Wireless remote: -
Its receiver may be loose from the solenoid or the switching may be too fast.
 Manifold & valve: -
The manifold, oil return line may be clogged from the orifice, throttle too tight, loose
inlet or solenoid valve not energized.
 Oil tank: -
It could be too full.
10. The Cylinder Drops Not Stable
The problem could be due to:

 Electric motor: -
For DC motors, the battery electric quantity may not be enough, while for AC motors,
there could be instability in the power grid. Also, the motor may have rust.
 Cable remote: -
The cable could be loose from the solenoid coil or it may be switching too fast.
 Wireless remote: -
Its receiver may be loose from the solenoid coil or the switching could be too fast.
 Hydraulic pump: -
This could be due to internal leakage as a result of wear, defective pump or unsuitable
pump type.
 Manifold & valve: -
There could be manifold oil return line leakage, throttle too loose or solenoid valve
not energized properly.
 Connectors: -
The connectors may be wrongly aligned, lose or defective. A possibility of suction
pipe leakage is also high.
At times, the problem may be due to cylinder outline seal leakage or a worn-out
cylinder rod.
11. The Start Solenoid Just Click and the Motor is Not Engaging
This is a result of:
 Electric motor: -
The DC battery electric quantity insufficient or the AC power grid does not match that
of the motor. Rust may also be a contributing factor.
 Cable remote: -

42
A cable may be loose from starter relay, there could be a thermal pressure lock or the
systems could be switching too fast.
 Wireless remote
The receiver could be loose from the starter or the switching too fast.
Noise:
The noise is due to:
 Electric motor: -
The DC voltage may be too low or the AC power grid may not match that of the AC
motor specifications. Rust is also another cause of noise.
 Hydraulic pump: -
There could be internal leakage due to wear, unsuitable or defective pump type.
 Manifold & valve: -
This could be due to internal leakages, faulty bleeding, dirty valve or defective
solenoid that may cause leakage in valves.
 Connectors: -
The coupling may be wrongly aligned, lose or defective. Leakages at the suction pipe
may also cause noise.
 Oil tank: -
Oil level may be too low.

 Hydraulic fluid: -
The viscosity may be too high due to extremely low temperature.
Apart from these, there could be a cylinder leakage or a worn-out cylinder rod.
12. An Excess Operating Temperature
The high temperature is due to:
 Electric motor: -
DC voltage may be too low while the AC power grid may not match the
specifications of the AC motor. Rust may cause overheating.
 Hydraulic pump: -
The hydraulic pump may be defective or unsuitable.
 Manifold & valve: -
The valves may be dirty or worn out.
 Filter: -
The filter may be dirty
 Connectors: -
The connectors may be wrongly aligned, lose or defective.
13. An Excess Operating Temperature
This is due to:
 Hydraulic fluid: -
There could be leakages in suction or return lines.
 Oil tank: -
The fluid level may be too low
 Hydraulic fluid: -

43
It could be unstable hydraulic fluid.Clearly, a hydraulic power pack may have simple,
but difficult to identify problems that can compromise its functionality. With all these,
I am sure you can identify the exact problem that may reduce the efficiency of the
hydraulic power pack.In the next chapter, you’ll learn how to manufacture a hydraulic
power.
5.3. Advantages and Disadvantages
Advantages of Hydraulic Power Packs: -
 The advantages of hydraulic Power units include:
 Hydraulic Power packs have high horse Power to weight ratio
 When you compare hydraulic, mechanical and electrical system with the same
Power output, say 5hp, you’ll find that the hydraulic system is small and
lightweight. In fact, you can hold it in the palm of your hand.
 They are Powerful compared to other lifting mechanisms
 Hydraulic systems can create a huge amount of lifting force by applying or using
just a small amount of force. For instance, a micro or mini Power unit, with its
lightweight, can create a high lifting Power than either electric or diesel motors.
 Convenient to use and install
Their small sizes make them easy to carry besides, you can install these Power units
in vertical or horizontal positions. They are also portable and you can mount them
with a clear layout.Hydraulic Power packs have fewer moving parts, unlike most
mechanical and electrical parts that use gear systems. This alone makes the system
easy and simple to install.
 You can easily adjust them to various speed and lifting applications
This makes Power units a perfect choice for a wide range of speeds and weight lifting
capacities in industrial processes.
 The torque and force can be held constant
Regardless of any changes in the system’s speed, a hydraulic unit can maintain a
constant force and torque throughout the operation. As a matter of fact, you can hold
either torque or force constant in any fluid transmission system. Furthermore, you can
also achieve a high torque even when the rotational speed is low. This is not always
the case for electric motors.
 Hydraulic systems are stable and rapid
Hydraulic Power packs require a short period of time to lift a heavy weight to the
required height or to exert the required amount of compressive force.
 They are safe and easy to control
Hydraulic systems come with overload protection valves. The remote-control
mechanism makes it simple and easy to control the operation of a hydraulic Power
unit.
You’ll find that most hydraulic units have multi-functional control system and the
motion can be reversed easily. They are also considered to be safe, especially during
an emergency stop conditions. Even in the hazardous environments, hydraulic
systems can tolerate high temperatures, thus, there will be no instances of
overheating.

44
Also, hydraulic systems are spark-free thereby eliminating the possibility of fire
outbreak.
 Hydraulic units are compact units
All the basic components such as electric motors, machinery, oil, pistons, cylinders,
etc. come in a compact unit, hence easy to operate, transport, install and store. .You
can easily realize a rectilinear motion with Power packs. This is mainly due to the
movement of the hydraulic piston within the cylinder. In fact, the hydraulic piston
extend and retract linearly.They are easy to design and cost effective to run after
installation
All these reduces the cost of owning a hydraulic system and subsequent maintenance
costs.
There’s a minimal loss of Power over long distances. Hydraulic Power packs can
transmit hydraulic energy over long distance or through complex machines with small
loss in Power.
Disadvantage of Hydraulic Power Pack: -
 Handling hydraulic oil can be messy
Power packs depend on hydraulic oil to generate a working force. In most cases,
handling the hydraulic oil if you’re not a professional can be messy.Moreover, at
times it can be difficult to completely eliminate the leakage.Apart from this, a
hydraulic fluid may also catch fire in case of leakages. So, avoid hydraulic fluids that
tend to be flammable.
 They are sensitive to extreme temperature
Very high temperatures may affect the stability of a hydraulic Power pack. For
example, heat can destroy the hydraulic seals, causing significant pressure drop.On
the other hand, very cold temperature will result in a slow response of the hydraulic
system since the hydraulic fluid will tend to thicken.
 Hydraulic actuators have a low operating efficiency
Their system efficiency may range between 40 to 55%. The electric actuators have a
system efficiency that ranges between 75 and 80%.Moreover, using a throttle to
change speed, especially over long distances may cause low transmission
efficiency.Again, as long as the hydraulic system is on, the Power pack must keep the
hydraulic system pressurized. This alone causes inefficiency since it uses Power.
 High maintenance and initial installation costs
 For complex systems, initial cost is likely to be high. A good example is the
standard hydraulic Power packs. Also, troubleshooting complex hydraulic systems
can be a cumbersome process. They require constant inspection to fix all sealing
problems that may cause oil pollution. Remember, a leaking Power pack may
cause damage to the skin due to fluid pressure.
 It is quite evident that the hydraulic Power units have a number of advantages
compared to the disadvantages. This does not imply that they are the best
equipment.
 You need to examine the task at hand to choose the most appropriate Power pack.
This will help you to choose the right equipment that is reliable and can operate
optimally.

45
 Troubleshooting a hydraulic system can be a cumbersome process. However, with
comprehensive troubleshooting guide, this should be a simple problem you can
handle.
 In chapter six, I will focus on how you can troubleshoot and repair simple
problems in the hydraulic Power pack systems.
5.4. Accessories:
The term accessory actually leads to a false impression, when considering the
importance of the equipment.
1. Heat Exchangers:
In a hydraulic system, part of the input is transformed into heat at various points
(valves, lines) i.e., the heats up. If the heat radiated from the tank is too low, the
induced temperature lies above the desired operating temperature, due to the amount
of heat supplied and radiated. The fluid must be cooled. The fluid must be cooled. The
cooler ensures that a certain fluid temperature is not exceeded.

Fig 5.5. Heat Exchangers

46
 CHAPTER - 6

INSTALLATION
Packages/units:
Before installation is carried out, ensure that the packages/units have not suffered
because of storage conditions. After ensuring that no damage has occurred to the
equipment, drain out the oil, which was filled for a long storing and plug the ports.
The draining should be only to take out the oil but not lose the oil film. Mount the
packages/unit in their respective locations.
Pipes/fittings/hose pipes:
For pipe lines use the seamless steel, cold drawn, precision steel tubes. Bending of
pipes should be carried out on suitable bending equipment. Fitting of cutting
type/welding type are used. When installing all the pipes and fittings must be
absolutely clean i.e. free from scale and all kinds of foreign matter.
Pipes, fittings/flanges, should be brushed from inside and edges should be deburred.
For small pipes sand blasting could be used only when there is absolutely no chance
of particles of sand remaining in blind holes/pockets. Otherwise pipes are picked
neutralized, rinsed and dried before assembly.
The pies, which are not taken up for immediate assembly, should be plugged to
prevent entry of metal chips/dirt because of drilling, tapping, welding or brazing being
carried out near the installation are any other possible source of foreign matter. The
dangerous chemicals are used in packing operation and therefore the same should be
stored in proper containers and handled with extreme care.
Inter connect the pipes using suitable fittings i.e. tees, elbows, crossers etc. between
various packages Power units, valve packages/gauges panels and actuators etc. as per
the installation manufacturers recommendation. The piping should be free of tension
and clamped properly for vibration free operation.
Layout the pipes such that they do not obstruct the passages. Also avoid overlapping
of the pipes.
For longer distribution lines:
Pipe size should be large enough so that the pressure drop between actuator and pump
does not exceed the allowable value. Suitable headers may be used wherever
advantageous.
Loose supplies:
Install all loose supply components at respective positions after proper cleaning and
rising. Fixing up the required fitting and inter connect them with suitable sized pipes
as shown in the circuit.

47
 CHAPTER - 7
RESULT & CONCLUSIONS

After designing and selecting the required parts of the hydraulic Power pack including
calculating the Power requirements of the pump, motor, it was found that the
hydraulic clamping system is more efficient and economical compared to the
mechanical clamping system comprising of various levers, screws, cams, etc. which
are prone to overloading which is prevalent in any component clamping unit.
We also recognized the necessity of a hydraulic Power pack in an SPM, as the
component which is to be clamped rigidly can be done with less wear, smooth
running, greater accuracy and less noise. So, a hydraulic system as compared to any
other systems is more effective and efficient.

Conclusions
By employing a hydraulic system, the advantages that can be utilized as compared to
the other systems are.
 Possibility of automation of all types of movements.
 All the operations can be easily and infinitely controlled by using cylinders, and
linear movements can be carried out without the use of mechanical components.
 Simple protection against overload can be made by means of pressure relief valve
using hydraulics.
 Safe control systems without electricity for the use in the areas where there is a
danger of explosion can be predicted.

48
 REFERENCES

1. Hartness, James (1910), Hartness Flat Turret Lathe Manual, Springfield,

Vermont, USA: Jones and Lamson Machine Company.
2. Roe, Joseph Wickham (1937), James Hartness: A Representative of the
Machine Age at Its Best, New York, New York, USA: American Society of
Mechanical Engineers, LCCN 37016470, OCLC 3456642,
3. H.W. Ward & Co., Ltd (1938), Operators' Hand-book (4th ed.), Dale Road,
Bournbrook, Birmingham, England: H.W. Ward & Co., Ltd.
4. Sparey, Lawrence (1947). The Amateur's Lathe. Special Interest Model
Books. ISBN 0- 85242-288-1
5. Woodbury, Robert S, (1961). History of the Lathe to 1850. Cleveland, Ohio:
Society for the History of Technology. ISBN 978-0-262-73004-4.
6. Rolt, L.T.C. (1965), A Short History of Machine Tools, Cambridge,
Massachusetts, USA: MIT Press, LCCN 6512439. Co-edition published as
Rolt, L.T.C. (1965), Tools for the Job: A Short History of Machine Tools,
London: B. T. Batsford, LCCN 65080822.
7. Hounshell, David A. (1984), From the American System to Mass Production,
1800- 1932: The Development of Manufacturing Technology in the United
States, Baltimore, Maryland: Johns Hopkins University Press, ISBN 978-0-
8018-2975-8, LCCN 83016269.
8. Ernie Conover (2000), Turn a Bowl with Ernie Conover: Getting Great
Results the First Time Around, Taunton, p. 16, ISBN 978-1-56158-293-8
9. Raffan, Richard (2001). Turning Wood with Richard Raffan. Taunton. ISBN
1-56158- 417-7.
10. D.M. Mate at all, “Formulation of Experimental Data Based Model for
Aluminium Alloy HE-15 Operation with Burnishing Tool on Lathe Machine
using Dimensional Analysis, International Journal of Research in Mechanical
Engineering, Vol.1, Issue 2, OctDec.2013, pp.80-90.
11. Marlow, Frank (2008). Machine Shop Essentials: Q & A. Metal Arts Press.
ISBN 978- 0-9759963-3-1
12. "Hints & Tips for Using a Lathe". “George Wilson‟s” Hints and Tips -
Publication date unknown. Lathes.co.uk. Retrieved 29 November 2010.
13. "Men, Women, and Recording: The History of the Office Dictation Machine"
by David Morton athttp://www.rci.rutgers.edu/~dmorton/dicta.html.
14. www.target-hydraulics.com/hydraulic-power-pack-ebook/

49
 Evaluation Rubrics for Project work:
Rubric (CO) Excellent (Wt = 3) Good (Wt = 2) Fair (Wt = 1)

Select a latest topic through Select a topic through partial Select a topic through
Selection of Topic (CO1) complete knowledge of facts knowledge of facts and improper knowledge of facts
and concepts. concepts. and concepts.

Thorough comprehension Reasonable comprehension Improper comprehension

Analysis and Synthesis (CO2)
through analysis/ synthesis. through analysis/ synthesis. through analysis/ synthesis.

Thorough comprehension Reasonable comprehension Improper comprehension

Problem Solving (CO3) about what is proposed in the about what is proposed in the about what is proposed in
literature papers. literature papers. the literature.

Incomplete literature survey

Extensive literature survey with Considerable literature survey
Literature Survey (CO4) with substandard
standard references. with standard references.
references.

Clearly identified and has Identified and has

Identified and has sufficient
Usage of Techniques & Tools complete knowledge of inadequate knowledge of
knowledge of techniques &
(CO5) techniques & tools used in the techniques & tools used in
tools used in the project work.
project work. project work.

Project work impact on Society Conclusion of project work has Conclusion of project work has Conclusion of project work
(CO6) strong impact on society. considerable impact on society. has feeble impact on society.

Conclusion of project work has Conclusion of project work

Project work impact on Conclusion of project work has
considerable impact on has feeble impact on
Environment (CO7) strong impact on Environment.
environment. environment.

Clearly understands ethical and Moderate understanding of Insufficient understanding of

Ethical attitude (CO8)
social practices. ethical and social practices. ethical and social practices.

Did literature survey and Did literature survey and

Selected a topic as
Independent Learning (CO9) selected topic with a little selected topic with
suggested by the supervisor
guidance considerable guidance

Presentation in logical
Presentation with
sequence with key points, clear Presentation with key points,
Oral Presentation (CO10) insufficient key points and
conclusion and excellent conclusion and good language
improper conclusion
language

Status report with clear and Status report with logical

Status report not properly
Report Writing (CO10) logical sequence of chapters sequence of chapters using
organized
using excellent language understandable language

Comprehensive time and cost Moderate time and cost Reasonable time and cost
Time and Cost Analysis (CO11)
analysis analysis analysis

Highly enthusiastic towards Interested in continuous Inadequate interest in

Continuous learning (CO12)
continuous learning learning continuous learning

Annexure I

50
 DESIGN OF HYDRAULIC POWER PACK FOR
Title of the Project :
VERTICAL TURNING LATHE MACHINE.
Name of the students:

RAMAYANAM NAVEEN 16751A0326

V.HARISH 16751A0330
Name of the Guide & Designation : Dr.T.CHINNA PAMULETY., Ph.D, Associatet
Professor
TABLE 1: OUTCOME ATTAINED AND ITS JUSTIFICATION

PO Justification

PO1 The knowledge hydraulic power pack was gained through this project work

PO2 Analysed the problems of machines accuracy

PO3 Designed hydraulic power pack for vertical tuning machine.

PO4 We used research based data to provide valid conclusions

We implemented our work with well appropriate techniques, good resources

PO5 modern engineering tools to uplift the project. Auto Cad is used to design
system

This solution increases the accuracy of the parts produced and Productivity
PO6
for sustainable development of the society.

This solution increases the accuracy of the parts produced. Hence reduction
PO7
in wastage of resources happens..

PO8 We followed the ethical principles..

We worked in this project function effectively as a member of the project

PO9
team.

Oral and written communication skills are improved while planning,

PO10 implementing and executing the entire project and till submission of the
report.

We demonstrated our knowledge and understanding of cost and time

PO11
analysis required for carrying out the project.

Facilitated ourselves in Lifelong learning to improve technical knowledge

PO12
and competence in the chosen area of the project.

51