Design and Finite Element Analysis of an Integrated Hydraulic Press for Industrial Applications

Abstract

Hydraulic presses are essential in various industrial manufacturing processes such as forging, molding, punching, and assembling due to their high force capability and precision control. This study focuses on the design and finite element analysis (FEA) of an integrated hydraulic press tailored for diverse industrial applications. The integration aims to optimize structural integrity, operational efficiency, and safety while minimizing material costs and weight. The design phase involves defining critical parameters including load capacity, frame geometry, cylinder specifications, and safety factors. CAD modeling is performed to generate detailed geometries of the press components, such as the frame, hydraulic cylinder, ram, and base plate. Finite Element Analysis using software such as ANSYS is employed to simulate the press under operational loading conditions, assessing stress distribution, deformation, and factor of safety across the structure. The results highlight critical stress concentrations and potential deformation zones, allowing for design optimization by modifying geometry or material selection. Von Mises stress criteria are used to ensure the structural components operate within permissible limits under maximum load. Modal analysis is conducted to evaluate the natural frequencies and avoid resonance during operation. The integrated hydraulic press design demonstrates a balance between robustness and cost-effectiveness, ensuring operational reliability. The study concludes that FEA is a powerful tool for pre-emptive failure analysis and structural optimization in hydraulic press design. Future work includes prototype fabrication and experimental validation, as well as exploring advanced materials and automation integration.