Research
Design of Air Booster for 1200 Ton Mechanical Press
A mechanical press is used for pressing of sheet metals to give it the desired shape. Mechanical press is a machine that changes the shape of the work piece by applying tones of load on it for accurate output. Mechanical punch presses fall into two distinct types, depending on the type of clutch or braking system with which they are equipped. Generally older presses are "full revolution" presses that require a full revolution of the crankshaft for them to come to a stop. This is because the braking mechanism depends on a set of raised keys or "dogs" to fall into matching slots to stop the ram. It is a 1200T mechanical press. It consists of a ram, upper die, lower die and cushion. For pressing upper die is pressed on sheet metal and lower die. At that time the cushion gets activated and it holds the lower die. The cushion is supported by hydraulic and pneumatic pressure. The press is a try-out press. It requires pressure up to 7 bar. The pressure provided by the company compressor is 5bar. To increase the pressure there are two options. One is to use compressor for which we have to compress air from atmospheric pressure. So it will consume more power. Moreover the space required for it very large. The another option available for it is to use a compact and power saving device. Such a device is called booster. A booster is a double acting cylinder. It has two chambers. One chamber has bigger area which consist of piston end. Another chamber has small area and it consists of rod end. Large force is applied to piston end by pressurized air. This force is transmitted to rod end of piston. The area at this end is small and hence the air at this end is compressed to very high pressure. Thus pressure rise is obtained.
Thickness and Shape Optimization of Filter Sheet by Non-Linear FEA
Filter Sheets are non standard components and hence the guidelines for design are loose under the ASME and the TEMA code. The usual engineering practice is to extend the ever current design is available with an increased factor of safety. However this results in excessively heavy designs, resulting in increasing costs (e.g. Material, transport, assembly and installation).Hence in such designs there is maximum scope for optimization. Optimization goals are focused on Installing maximum possible filter tubes in a single plate thus increasing the capacity – Shape Optimization and Designing an optimal thickness for filter sheet assembly component for maximum economy – Material optimization. The Project execution phases consist of Analyzing a proposed for both Shape and Material optimization and submission of reports to clients, (In this phase we analyze only 1/6th portion of the assembly) Based on approval and feedback of client, designing the entire assembly and submitting drawings and models for approval) On approval of client proceed with analysis of the entire model created in phase 2. Performing actual hydro tests on the assembly after manufacturing, and evaluating effectiveness of FEA analysis. Preparing Information sheets and guideline processes for future project implementation. The challenges for FEA validation are Performing Shape Optimization and making filter pattern in accordance with manufacturability and ergonomic evaluations. FEA validation should certify a FOS of 5, as required by the guidelines of the Saudi Arabia Oil Code. FEA validation being comparable in case of Hydro Test performance on actual installation of assembly. The outputs of FEA work shall be a shape Optimized Filter Sheet assembly, with maximum productivity and maximum economy. Deformation and Stress Certification for performance in Hydro Test which shall take place at 2.5 times the actual working conditions.
