Hydraulic Press

Baileigh 30 Ton Hydraulic/Air Press

Make: Baileigh

Model: 30T Air Press

Ace: Nathan Hayward (nhayward21@georgefox.edu).

Location: Machine Shop

Description

A hydraulic press is a machine tool that uses a hydraulic cylinder to generate a compressive force. They are often used in shops to press interference fit parts together, such as gears onto shafts or bearings into housings. Some of the other uses include bending and forming metal. Some presses use a manual pump to produce the force while others use compressed air or a power unit driven by an electric motor.

Here is an example of this piece of equipment being used.

Documentation

Terminology

• Pressure Gauge- An indicator that uses a needle to indicate the amount of force being applied to the work piece.
• Release Valve Handle- This is the control handle for releasing the hydraulic pressure in the system. Turn the handle clockwise prior to charging the hydraulic system and counter-clockwise when releasing pressure.
• Table Holding Pin- 4 removable pins support the table and allow for height adjustment.
• Ram- This is is the end of the hydraulic cylinder rod that moves and pushes against your work piece.
• Pump Handle Socket- This is the location for handle placement while pumping up the hydraulic system.

Training

Overview

The press consists of a pump and hydraulic ram that moves down towards the table as the handle is cycled. The hydraulic press has a 58 mm diameter ram and can produce 30 tons of force. Some of the many uses including installation and removal of press fit parts as well as metal forming and punching. The ram can also be powered using compressed shop air, but should never be attempted without the shop techs supervision. The ram can be adjusted laterally as need to accommodate a specific part. As long as the ram keeps moving the force will remain fairly low. When the cylinder stops moving the hydraulic pressure in the system will start to build. As the force increases so does the risk. Pieces that are subjected to a high amount of force can shatter or explode. Make sure you are aware of what is happening and don't keep pumping on the handle and increasing the force without knowing what is occurring.

Make sure you have a full understanding of what you are attempting to accomplish before possibly getting into a risky situation. Ask a supervisor if you have any questions. Its important to properly set up the press before performing a job. It is good practice to observe the setup from various angles to ensure part alignment. If there is any risk something could fall on the floor during the process have a box or padding to catch the part. The table needs to be moved to the proper height to accommodate the work piece and ram travel. You want to avoid extending the ram farther than needed to prevent material from tipping over. Always make sure you will have enough ram travel to perform the task at hand. The release valve handle will need to be turned fully clockwise to allow the system to build pressure. It is imperative that you keep the work piece from tipping or slipping to the side while applying force to prevent flying parts and or damage. You should use a guide when pressing in a pin to prevent the pin or rod from slipping while installation. Keep an eye on the force gauge to verify your work piece is not sticking or hanging up. When the piece is pressed to its maximum travel pressure will start to build and could cause damage if you keep cycling the handle. Be aware that a part or piece could bottom out and avoid applying more force at the end of your parts travel than needed.

Demonstration

Demonstrate you can setup the press and safety install a pin with a press fit. You will also press the pin out after insertion. The pin, plate, and guide will be provided. Remember the guide will help keep the pin straight during installation. You will also need an extra person to help adjust the table height.

General Procedure

Pin Insertion

1. Place the plate you will be pressing the pin into on the top of table frame support blocks.

2. Set the dowel pin into the guide and make sure the table frame and support plates are high enough for the ram to be within an inch of the top of the pin.

3. If you need to adjust the table frame height remove the safety clips from the pins supporting the table and remove the table plates and assembly pieces. The table plates are heavy so don't drop them.

4. To move the table frame down you will remove the two upper pins and reinstall them in the correct holes below.

5. You will need a second person to help lift the table frame slightly while removing the remaining two pins and slowly lower the table onto the pins below.

6. Reinstall the top two pins and safety clips.

7. To move the table frame up you will leave the lower pins installed and remove the two upper pins. The lower pins will help prevent the table from accidentally dropping to the floor while making an adjustment.

8. You will need a second person to help lift the table frame while installing the two removed pins in the 2 lower positions.

9. Install the 2 remaining top pins and safety clips.

10. Place table support plates and assembly pieces back onto the table.

11. Place the dowel pin into the guide and align the pin with the hole in the plate. Its good practice to keep the dowel pin centered on the ram so the force is centered.

12. Make sure the pressure relief handle has been turned clockwise to allow pressure to build.

13. Insert the pump handle into the handle socket.

14. Slowly pump the handle while watching the force gauge and the pin. Make sure pressure is not building.

15. If the pin starts at an angle do not continue to apply force as this will most likely bend the pin and cause damage.

16. When the pin is at the bottom of its travel it will stop moving and you will see the force increase on the gauge and this is a good time to stop cycling the handle.

Pin Removal

1. Place the plate with the installed pin on top of the table support plates. You will need to leave a gap between the plates for the pin to press though.

2. Check the distance between the end of the pin to be pressed and the ram. If the gap is too large the ram will run out of travel before pressing out the pin.

3. If you need to adjust the table frame height remove the safety clips from the pins supporting the table and remove the table plates and assembly pieces. Remove everything from the table to prevent accidentally dropping items on your feet.

4. To move the table frame down you will remove the two upper pins and reinstall them in the correct holes below.

5. You will need a second person to help lift the table frame slightly while removing the remaining two pins and slowly lower the table onto the pins below.

6. Reinstall the top two pins and safety clips.

7. To move the table frame up you will leave the lower pins installed and remove the two upper pins. The lower pins will help prevent the table from accidentally dropping to the floor while making an adjustment.

8. You will need a second person to help lift the table frame while installing the two removed pins in the 2 lower positions.

9. Install the 2 remaining top pins and safety clips.

10. Place table support plates and assembly pieces back onto the table.

11. Make sure the pressure relief handle has been turned clockwise to allow pressure to build.

12. Insert the pump handle into the handle socket.

13. Slowly cycle the handle while watching the force gauge and the pin. Make sure the pin is starting to move.

15. You will continue to press the pin until the pin is flush with the top of the material.

16. When the pin is flush it will stop moving and you will see the force increase on the gauge and this is a good time to stop cycling the handle.

17. At this point you will need another piece of material slightly smaller than the pin to assist in the final removal of the pin.

18. Using the guide will help keep the material straight while pushing on the dowel pin.

19. As the dowel pin approaches the bottom of plate get ready to catch it to prevent it from falling on the floor.

20. Turn the pressure relief handle counterclockwise to retract the ram.

21. Reset the space.

Safety

When operating a hydraulic press be aware that extremely dangerous forces can be produced which could cause parts to shatter and fly like bullets. It's very important to keep an eye on the force gauge while increasing force and to be aware of the dangers of flying parts. Always keep you hands away from the ram and parts being pressed. Keep stacked parts as short as possible to prevent tilting or buckling. If you have questions make sure to ask a supervisor prior to attempting something that could be potentially dangerous. Be aware that you may be working with heavy material located several feet above the floor and there is potential to drop metal on your feet.

Certification

Foxtale Quiz

Troubleshooting

If you pump the handle and the ram doesn't move try tightening the release valve knob.

Maintenance

General maintenance

Keep the press clean. The hydraulic oil level and hoses should be checked by the tech on a regular basis.

Specific Maintenance Tasks

Maintenance Procedure	Frequency	Done By
Sample	Sample	Sample