How to Build a 20 Ton Hydraulic Press

Hydraulic presses are one of the premier tools for metal shaping and deformation, due to their immense force and versatility that allow it to meet specific production requirements.

This study explored the design of a motorized constant temperature hydraulic press to form metal ducts, using relevant mathematical expressions for each part of its construction and performing spring analysis.

Hydraulic Cylinder

Hydraulic cylinders serve as the "muscles" of any system; lifting, lowering and moving heavy objects with linear force. Each one consists of a barrel, piston rod and mounting attachments for ease of installation and use.

A cylinder barrel is typically constructed from honed steel; this process creates an inner surface with smooth contours that can withstand high pressure. Both ends of this device are sealed off using a cylinder head and piston rod to maintain pressure within.

Damage to a piston head can result in fluid leaks and overheated equipment, but quality replacement hydraulic cylinder heads are available that can easily be installed and can withstand extreme temperatures and working pressures.

Motor

A motor converts electrical energy to motive energy or mechanical energy for mechanical work. The input electricity is known as current while its mechanical output is known as torque. Part of that conversion energy becomes heat during its journey from electricity to motion.

To generate torque, the rotor must first be magnetized and rotated by currents passing from brushes through a commutator. As one armature winding interacts with PMs or another winding (field coil), they produce opposing magnetic fields whose gap creates rotational force.

Hydraulic Pump

Hydraulic pumps convert mechanical energy into fluid energy, enabling hydraulic machinery to lift heavy loads with ease. They're popularly found in applications spanning automotive and woodworking workshops alike.

Hydraulic pumps come in various varieties, from gear, piston, and vane pumps to radial piston pumps suited for high pressure/low flow applications. Each type offers distinct efficiency levels and displacement capacities. Radial piston pumps may be particularly beneficial in such situations.

Hydraulic pumps use energy to move fluid from a lower potential to a higher one, making this step essential for hydraulic systems that rely on both pressure and flow for operation.

Hydraulic Reservoir

Reservoirs play many roles in hydraulic systems, from dissipating heat to conditioning fluid and filtering out contaminants for improved fluid quality. Furthermore, reservoirs supply the hydraulic pump with fluid as well as providing an area where accumulators and cylinders can charge.

Most reservoirs feature five ports: pump suction, return, pressurizing, overboard drain and bleed port. Most models feature a bleed valve to depressurize the reservoir for easier servicing; tall and narrow designs save space while offering adequate surface area for heat transfer.

Hydraulic Hoses

Hydraulic hoses serve as conduits for transporting hydraulic fluid. As such, they must be durable enough to withstand extreme pressure and temperature while being flexible enough to accommodate its contents - all while being chemically compatible with its contents.

Selecting the ideal hydraulic hoses can be daunting. Gaining knowledge of their three main components - inner tube, reinforcement and outer cover - will make the search for your perfect hose easier.

Control Valve

Control valves regulate flow by moving a valve plug relative to ports located within their body, and can be controlled manually, pneumatically, or electrically. They can be managed manually, pneumatically or electrically for ease of use. Their body must permit actuator thrust transmission while being resistant to media and meeting all standards for connection to piping systems - this includes providing either linear, equal percentage, or modified flow characteristics as per customer preference.

Control valves feature arrows cast into their bodies to indicate flow direction. Depending on their size, control valves may feature sweat (soldered), screwed, or flanged connections for easy installation and servicing.

Pneumatic Tubing

Pneumatic tubing distributes compressed air to valves, actuators and other pneumatic components. When designing for its environment, factors such as temperature resistance and OD tolerances must always be taken into account.

Plastic tubing such as polyurethane and polyvinyl chloride (PVC) are among the most frequently used options, providing flexibility, kink resistance, gas permeability and chemical and oxidation resistance. Copper is often chosen when rigidity and durability are required - such as in fuel lines or other fluid circuitry applications.

Platens

These shop press plans are highly adaptable, both in terms of height and power source. While a hydraulic jack was demonstrated in the video, nearly any source can provide adequate force.

Upper and lower plates of this press are constructed from heavy gauge steel to resist flexing under pressure, while its frame contains bolt holes for attachment to a stable table for use.

Frame

This shop press features an adjustable steel frame designed to be flexible. With adjustable height settings, this press can be utilized at virtually any level imaginable. Furthermore, its flexible nature enables a variety of power sources such as hydraulic and electric jacks to be utilized.

Build the main frame using 700 mm U-profile parts and 105 mm pieces and weld them together, taking care that all vertical bars are straight.