Various Applications Of Hydraulic Jack

Hydraulic jack and cylinders are the most commonly used in heavy industry and power equipment that require tremendous power to operate. You can find these hydraulic jacks in all types of heavy machinery and vehicles such as excavators, forklifts, elevators and excavators etc. These hydraulic cylinders are also found in household appliances and door frames, cars, motorcycles, etc. and other it became clear that these hydraulic jack provide a lot more functionality in terms of comfort and ease. In the operation of a hydraulic cylinder, hydraulic jack design has an important role. If you have a business which involves loading and unloading heavy parts, one can understand the importance of these hydraulic cylinders with ease. An effective hydraulic environment can do much work for you. A simple example is the car of the hydraulic jack that uses a hydraulic manipulation of the back door of his car.

Nowadays, you can also find the hydraulic brakes for motorcycles, for a number of forces to the brake pedal, which leads to a breakdown effectively. Today, two-cylinder and the slave of modern cars made of cylinders, the other takes over. This ensures greater safety of modern cars.

The hydraulic jacks are typically used for heavy loads of life in industrial processes. These connectors are used to lift cars, while replacing the flat tire. This type of jack is known as Car Jack, Floor Jack, or Garage Jack. The hydraulic jacks are also used in cranes to lift heavy loads. Some cranes are equipped with multiple takes that are designed for additional functionality.

Each company has different needs, so that the hydraulic jack can be used as needed basis. You should always consult an expert, while the installation of these connectors as proper installation of the plug will give you the desired results.

Even if you install a hydraulic piston must always consider the requirement and the available space. The installation must be such that it does not consume much space, when the industry meets the full requirement as well.

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Practical High Pressure Gear Pumps Design

We're going to use the approach of "unwrapping a piece of string from a cylinder". Consider the following diagram. We will take vectors A and B, break them into components, and add them. Note that "theta" is an arbitrary parameter, in radians, not the pressure angle of the gear.

Also note that we start the operation at the "base circle", which is the pitch circle * the cosine of the pressure angle.

The math follows from this:

So the vector B is a point on the involute, which will trace the path of the involute curve for you as parameter "theta" is varied. "Theta pressure" is the pressure angle of the gear. You can then Apply the normal gear parameters for addendum and dedendum circles out of Machinery's handbook or Shigley, etc.

Practical Hints

CAD Modeling

If you are using the CAD model to determine the displacement of the gear pump, be careful to understand that some of the gap between gear teeth does not represent the volume pumped: some of this oil volume, at the root between teeth and the mating tooth from the other gear, goes around a full 360! Ask yourself what would happen to the volume pumped if you machined a large undercut at the root of the teeth: would this increase the pump displacement? No.

Contact Ratio

The contact ratio (the average number of gear teeth in contact at any time) should be always be above 1, but as close to 1 as possible.

AGMA Quality Grade and Gear Metrology

You will need to specify an AGMA quality grade on your drawing. Instead of just calling for "AGMA 8", you should specify what aspect of the gear metrology is referred to.

Lead

For gear pumps, the most critical parameter by far is the "lead" tolerance, which is the deviation in the axial direction of the gear, in other words, how close it is to being a perfect extrusion. You might need to consult with your gear supplier since they typically "crown" their gears to compensate for deflection during loading... but this would create a leakage path when used in a gear pump!

Profile

Second up is "profile" tolerance, which is what you imagine it to be, similar to the "profile" tolerance in GD&T. The reason for this requirement is that at very high pressures, such as the contact stress of a gear mesh, the viscosity of oil increases exponentially. If there is substantial sliding motion (due to poor involute gear profiles), this will cause a large friction loss, for gear pumps operating at high loads.

Be careful to test a new supplier's gear using a professional gear metrology service: most suppliers who claim to work to your drawing will not be able to meet your AGMA spec's. Testing new suppliers is mandatory!

Contact Stress

The gear mesh contact stress causes another problem, again mainly for high pressure gear pumps: the contact stress can yield the material. Use your CAD system to determine the instantaneous radii of curvatures of the gear faces, calculate the Hertzian contact stresses, and specify material hardness accordingly. This will often require the gear to be hardened before final machining and grinding, which adds to the expense.

A few remarks about Gear Pump Housings

    * Gear shafts need to vent back to intake or reservoir, or simply locate the gear pump in the tank.
    *  Don't forget to specify "DO NOT BREAK THIS EDGE: LEAVE EDGE SHARP" on the housing drawing, 2 places, at the edges of the gear pockets, or you will have a large leakage path between inlet and outlet, due to broken edges!
    * Rotary shaft seals continuous service life depends on the PV ratio that the seal elastomer can withstand. These seals are not normally designed to take any real pressure, but select a "pressure seal" if you purge the hydraulic system using pressure!
    * It is a very good idea to integrate the seal into the pump's pressure plate, so you can hold the seal manufacturer's concentricity spec., which can otherwise be a very long tolerance stackup.
          o This can be difficult to do due to the diameter of the seal encroaching on the idler shaft. The Creavey company makes a nice little small-diameter Teflon seal energized with a stainless steel garter spring. This can also be found on McMaster-Carr.
    * If the seal is integrated into the pump's pressure plate, then ensure that the drive gear shaft bore is:
          o Stepped up to prevent the creation of an accidental journal bearing (which will create enough pressure to blow the seal!)
          o Vented to tank
    * Use a narrow washer underneath the screws which fasten the pressure plate to the gear housing, to minimize manufacturing-induced side loads on the gear shafts.
    * Housing and pressure plate flatness is more important than surface finish. For high-pressure gear pumps, these surfaces can be lapped.

 

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Directional Control Valve

 

Directional control valves are critical and they come in many forms. A valve's flow-directing elements may be spools, poppets or plungers. Designs for the valve operators, which produce the force to move the valve, are migrating from manual systems to electro-hydraulic systems. The latter allows the operator to interface with the hydraulic system at a distance. If still more room is required for improved safety or efficiency, directional control valves are operated via radio control.

Trends for Directional s

Anthony J. Welter is product manager, global lead for mobile valve at Eaton's Hydraulics Operations in Eden Prairie, MN. He sees four major trends in directional controls:

1. Electro-hydraulic control:-

Customers are going from manual or hydraulic pilot control to electro-hydraulics. CAN bus control is also a high priority for many of our customers as it reduces the amount of wiring and provides a communication channel for diagnostics. The electro-hydraulic migration has enabled enhanced functionality improving control and productivity, while reducing operator fatigue.

2. Reduced parasitic losses:-

The wider adoption and advancement of closed-center load sense systems has improved the efficiency of the hydraulic system which results in reduced fuel consumption. In addition, better analytic tools like computational fluid dynamics (CFD) and control modeling tools have enabled engineers to develop more efficient solutions that reduce throttling losses around meter surfaces and provide for better overall control.

3. Increased performance:-

Whether it's increased response, fine implement control, or overall stability, vehicle manufactures are demanding these features to help differentiate their vehicles over their competition.

4. Flexibility:-

Manufacturers are developing more customized machines focused on specific markets and are launching new products faster. These factors require greater flexibility to tune performance or quickly apply the valves into customized solutions.

Directional Control Valve Features

   1. Directional control valve is compact construction and low pressure drop.
   2. Directional control valve is long service life and high efficiency.
   3. Depend on your requirement can choose various operation methods of control valves, such as manual, pneumatic, hydraulic, and electro-hydraulic control.
   4. Depend on your requirement can choose various ports and circuit valves.
   5. The directional control valve is spring return.
   6. High accuracy spool is hardened for long term accuracy.
   7. The valve is sub-plate mounting.
   8. Directional control valve can use handle shift operation.

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Steel Casting Manufacturing Process

Today steel is widely used in Big construction site like River bridge, Bib Building. They are use predefined shape of steel casting and fits different steel shape and making one big constructions. For predefined steel shape many casting foundries in the world use casting process with steel alloy, which is known as alloy steel casting process in which you can get you desired and solid shape.

You can find alloy steel casting process through above video . Then after you know how to get desired or necessary steel shape or parts using steel casting. As per my way today, steel casting manufacturer in India use latest casting methods for making high quality steel products

Homemade Metal Casting

Casting metal is a practice that has been around for thousands of years. Today, it is used in a number of fields in everything from engineering to jewelry. A number of methods can be used to cast metal. One such process, called investment casting or lost wax casting, can be done in the home. It involves building a wax sculpture of the piece that you wish to make and then pouring investment (a plaster-like material) over it to make a mold, melting out the plastic and then pouring molten metal into the mold.

Follow step by step Instruction

1. Carve a wax sculpture of exactly what you want your final product to look like. Use an X-Acto knife.
2. Attach a wax spur to the bottom of your sculpture by melting the tip of it with a candle. Once the wax is melted out of the investment casting the metal will flow through this spur into your mold.
3. Place a glob of moldable wax onto a rubber base. The rubber base must be about the same size of the can that you plan to use. Attach the wax spur that is on the sculpture to this glob of wax.
4. Remove the bottom of the can with a cut-safe can opener. The can opener removes the bead on the can instead of leaving a sharp edge.
5. Place the can on top of the rubber base with the sculpture inside. Ensure a good seal between the can and the base with masking tape.
6. Mix investment material with water according to the manufacturer's specifications. Pour the investment into the can, completely covering your wax sculpture. Let the investment dry to the manufacturer's specifications.
7. Remove the rubber base from the can and place the can in a furnace that is as close as you can be to the melting temperature of the metal that you plan to cast without exceeding the can's melting temperature. Make sure the end with the spur is facing down. Leave the can in the furnace overnight, allowing the wax to drain from the mold.
8. Melt the metal that you plan to invest in a crucible with an oxyacetylene torch.
9. Keep the oxyacetylene torch on the metal and have someone else remove the can from the furnace. Have this assistant turn the can over so the hole where the spur was is available for you to pour the metal into it.
10. Turn off the torch and pick up the crucible with metal tongs. Pour the metal as fast as you can, without spilling, from the crucible into the hole in the investment.
11. Place the can into a bucket of water using the crucible. The water in the bucket may boil from the heat.
12. Shake the can back and fourth while still under water. This will loosen up the investment and remove it from the metal casting. After a couple of minutes the metal should be cool enough to touch.

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Overview of Investment Casting Process

Investment casting is widely known as lost wax investment casting and one of the best precision casting process used for fabricated metal parts for any types of alloy. In past investment casting widely used for complex component manufacturing.

Investment casting process start with fabrication of a sacrificial pattern with basic geometrical shape for finished cast part. Generally this patterns are made by investment casting wax and injected into metal wax die. When wax pattern is designed then its assembled with other metal wax components to form metal delivery system which is known as gate and runner system. Now this whole wax assembly is dipped into ceramic slurry, for dry and this process is repeated until shell of 6 mm is applied.

When ceramic has dried the take entire assembly in steam to remove most of the wax. Then after remain portion of burned wax remove from furnace. Now preheated this mold with specific temperature and pure with molten metal for creating metal casting. When casting is cooled then chipped away mold shell from the casting. Now cuts gates and runners from casting for finishing the casting. This is one of the quick cast processes.

Through investment casting, you can make high quality patterns without cost and time with fabricating injections mold dies. In addition, this pattern fabricated by CAD through which we make complex pattern. As per my way most of casting foundries in India used investment casting for fabricating complex and solid industrial shape while other casting process are time consuming and costly. In addition, you can make small parts through investment casting

Investment Castings Importance or Benefits

Casting is a process known as precision casting, which gives the piece a finished condition very good, sometimes it does not require any machining for delivery to the customer, because the tolerances are very strict handling, other great advantage is that it can be done in almost any metal, these conditions have marked its growth, displacing machined parts in many industries, especially those that require significant production of components such as automotive, arms industry, especially the related to so-called Hand guns, textile, etc.

Additionally it is a very flexible, which allows great freedom in design with intricate geometries, unfortunately requires a strong infrastructure and do not allow the manufacture of large, which is necessary and conventional casting processes.

This process uses the formation of a «vessel» very fine sand carried in special bonded, in which the metal is strained as is evident if the geometry is very intricate, there is always the possibility that the metal does not cover all parts of why mold is subjected to a centrifugal (centrifugal casting) making it the complete filling of the mold regardless of its geometry. See below various casting products by leading Investment casting foundry in India.

The secret of investment castings is in the formation of the containers described above, it begins with obtaining a model which is used to manufacture various molds, which give rise to identical reproductions of the piece to be manufactured, made in wax these reproductions are joined to a generally cylindrical central element, which on top has a funnel shape, are assembled in a similar way to a tree branch, this element is also manufactured with wax and once they are embedded in wax models, was performed immersion in a mixture of refractory powder and a colloidal binder, forming a housing to which a ceramic powder is sprinkled, depending on the thickness of the walls is required, the dive must be performed as often as necessary, then removed interior wax, heating the mold in an oven, making it melt and easily evacuate, the mold is ready pour the metal which solidifies gravity, to meet this requirement shell is removed by mechanical methods.

Should be considered, as in all casting, metal contraction as it cools, and the ceramic powder particle size, since smaller particle sizes, smooth surfaces were obtained, but the mold are becoming more sensitive.

We need a careful design, as regards the size of the piece, nerves (thick), solid parts, preventing pores, combination of walls, changes in section should not be abrupt, sharp corners removed, the use of male is also an important consideration, since they must be perfectly placed, and its use is justifiable only when the piece is very large hole in the casting as it helps to solidification.

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