DESIGN AND ANALYSIS OF HYDRAULIC POWERPACK AND PUMPS.

This paper is about design and development of hydraulic system for clamping of workpiece on Vertical Machining Center (VMC). Clamping system plays vital role in any manufacturing system it provides good clamping and also increases the production efficiency.so we made a device which overcome the drawbacks of manual clamping and provide safe clamping system. This operated on hydraulic principle Pascals law. Using this we made hydraulic clamping system which semi-automatic type clamping system. Which increase productivity and reduce the cycle time of product. We also analyze the component on ANSYS 16 software for various clamping load on component.


ISSN: 2320-5407
Int. J. Adv. Res. 7(7), 320-328 321 4. To minimize operations time per product. Problem Definition 1. In VMC (vertical machining center) whenever we clamping the job manually there are some drawbacks 2. Less Accuracy (Clamping Force) -Whenever human being applies the force manually on the clamping device it will changes time to time or human to human. Due to these the job/workpiece clamping accuracy is decreases. The human clamping force does not constant. 3. Feedback Loop -When the workpiece clamped on the VMC, the machine and worker both does not get clamping indication i.e. (job is clamped or not). 4. Time Consuming -Whenever the manual clamping is carried out it takes a lot of time for clamping and declamping. And also analyzing the clamp is fixed or not. 5. Surface Finish -When the manually clamping is carried out we does not get required surface finish. 6. Others -Whenever the manually clamping is carried out on VMC machine, if workpiece will not be clamped perfectly it will reduce the accuracy of other process that will done on VMC machine.
For manually clamping we always required qualified / skilled labor. From above problems, Maintenance as well as operating cost increases. So, such all problems related to manually clamping, we will be designing an automatic clamping system for that we will moving towards hydraulic system this more accurate also widely used in industry. So, our work is to design hydraulic power pack unit for clamping and de-clamping of workpiece on VMC machine.

O.J Bakker et al-[2]
-This paper analysis the latest studies in the field of achieve fixture design and its relationship with flexible clamping and reconfigurable fixture system. In this paper reveals that performance and flexibility are the driver behind the different fixturing contact that have been proposed. Helps to improve accessibility.

Sunny N Shahane et al-[3]
-This fixture was designed and built to hold support and locate fire tube boiler plate to ensure that it is drilled with accuracy. Which can help in improving productivity and time? This automation reduced the human effort also the design enabled vibration free operation. It increased the productivity and reduced the cycle time of 1 hour to 15 times.

Sridharkeshava K B et al-[4]
-This paper gives a brief introduction to the general and classic principles of jigs and fixtures Design for Clamping operation. The workpiece location clamping stability under dynamic machining and frictional conditions at the interface between jigs and fixtures elements and workpiece are taken into account-1. Manufacturing considerations 2. Clamping location, pool guiding and workpiece and mounting.

K.M Viramgama et al-[5]
-This paper will give brief overview if about the 3-2-1 Locating principle to design the fixture for complex parts and other clamping principle. From the study we can conclude that for designing the fixture the geometry method 3-2-1 principle is very useful for the complex component.

Srinivas R et al -[6]
-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.

Component Details
The component is Bajaj ape differential casing. A differential is device which used for obtaining two different speeds of rear wheels of vehicles while turning. This split type construction having two parts of casing which are attached by means of bolting. The fig no.1 shows the differential casing one part. The component is made up of grey cast iron (ASTM48). This is made by sand casting process. The differential is also known as secondary gearbox of vehicles.

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Operations to be performed on differential casing are drilling of four holes and tapping this hole on VMC machine. For that we develop hydraulic clamping system to increase the accuracy of production and for reduction of cycle time.

Hydraulic Circuit
A hydraulic circuit is a system which has different interconnection between many hydraulic parts in which the hydraulic liquid is flow and generate power. This power is used to achieve a specific function resulting in work being performed. Before the hydraulic circuit can be designed, the following things must be defined 1. The type and number of each type of hydraulic actuator to be used on fixture. 2. The operating pressures required. 3. The sequence of operation. 4. Type of control required.
The circuit comprises the following components: 1. Active components-Hydraulic power pack 2. Transmission lines-Hydraulic pipes 3. Passive components-Hydraulic cylinders Hydraulic pump is used of output 1.395 LPM. Hydraulic Pump is a device used to impart motion and pressure to the fluid in a hydraulic circuit. Pump is driven by 3 phase, 1hp electric motor to create flow. Pump that creates flow pushes against the piston of a hydraulic cylinder.Directional control valve is one of the most fundamental parts in hydraulic circuit. They allow fluid flow into different paths from one or more sources. Here double solenoid, spring centered and center open type D.C. valve is used. The valve is controlled by an electric current through a solenoid. At center position pressure line is connected to tank line and motor is unloaded. Due to this one can connect or disconnect quick disconnect coupling at center position. Cylinders are linear actuation devices that are typically used to keep a work piece stationary or move work piece into position. They provide axial clamping force proportional to the hydraulic pressure applied. Hydraulic clamp used is of 2.22KN force @ 15Bar, piston diameter is of 45 mm, Stroke is 58. It is important when designing a circuit that all devices including fittings, hoses, valves, tubing have a working pressure compatible with circuit pressure.
Never exceed the maximum operating pressure of any device. If the system flow requirement for clamp time is established with in the restrictions of the largest device, the addition of a flow control will be required to prevent over driving the smaller devices. Hydraulic circuit is shown in fig no.2 323 Figure no2:-hydraulic circuit diagram with different component Design Every mechanical system having some design procedure and we all know which are important things that we want to design for system and this design gives satisfactory work according to calculations. Hydraulic system consists of many parts but from that we want to calculate some important parameter like 1. Hydraulic cylinder 2. Flow rate/ discharge of system 3. Tank capacity Now for designing of our system we required some basic information, so we have following information.  . 7(7), 320-328 324 HP=0.04375 BTU/ Hrs.

Finite Element Analysis (Fea) Of Component
Finite element analysis (FEA) is a computerized method for predicting how a product reacts to real word forces, vibrations and other physical effects. Finite element analysis shows whether a product will break, wear out or work the way it was designed. Here we divide the component into small sizes known as element and collective element on the model form mesh. The computer analyses the element and shows collective result. The computer solves by the computational method provided. FEA analysis is done on ANSYS 16.0 The test results showed that the deflection was within permitted limit or not. For checking whether static and dynamic forces acting over the component are within acquired such that it will provide some of flexibility to it without causing damage to some software are used for it to simulate that designed component are safe or not also whether further improvement is needed. This is done by using ANSYS 16.0 software.

Meshing
As for analysis whole element is divided into number of parts called as nodes. These nodes are joined to each other to form elements. The process of joining these nodes is called as meshing. We can choose auto mesh mode. This meshing is shown in following figure no 3.        In the same we apply different force applied on the casing and we observe the various effect on the differential casing the various value of stress and deformation is give below form that all we can choose 225 kg force because it is recommended by industry but according to our analysis, we also can use force of 250 kg. The value of various deformations and stress are given in table no 5.