Design and Analysis of Ferrule Crimping Machine

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1 Design and Analysis of Ferrule Crimping Machine Umesh S Badakundri* Prof. A.A.Kulkarni** *PG Student, M.Tech (Machine Design), Mechanical Engineering, KLS Gogte Institute of Technology, Belgaum, India **Professor, Mechanical Engineering, KLS Gogte Institute of Technology, Belgaum, India Abstract - Crimping work is the most popular worldwide among all the devices of joining metal and even some non-metals. The importance of the crimping is proper working of crimping machines, in order to increase their performance and productivity hence proper design is very essential. The use of crimping machine is very much essential in all type of hydraulic industries. The main objective of the project is to design and analyze the ferrule crimping machine for different outside diameter of ferrules. The characteristics of forces have to be analyzed thoroughly for the proper design of crimping machine We decided to design crimping machine, which is cost effective and advantages has following, such as reduce errors, fast and safe crimping operation, grease free portable device, assembly, with mounting option and easily detachable tools. The present study is used as a starting point for an optimization procedure on crimping machines. Keywords: Crimping machine, ANSYS. ***** I. INTRODUCTION Crimping work is the most popular worldwide among all the devices of joining metals and even some non-metals. The great importance of the crimping is proper design of crimping machines, in order to increase their performance and productivity proper design is very essential. The performance of hydraulic crimping machines depends upon the behavior of its operation. The main aim of the project is to design of ferrule crimping machine working condition. Crimping machine has a various parts involved such as hydraulic cylinder, hand pump, tool holing blocks, ferrule crimping component, and base plate. Hydraulic cylinder has working pressure of maximum 400bar. Hand pump of 400 bar + 2 meter hose and the end fitting coupling. Tool holding blocks are for different ferrule size of 16mm to 42mm. Ferrule crimping component to crimp required ferrule size. Using crimping machine we can crimp different size of ferrules by changing ferrule crimping component. The ANSYS Finite Element software system is used as a tool to analysis the critical part of machine, and compering analysis results with analytical results. Crimping and crimping machine Crimping is a technique which is easy, fast and cost effective method for joining and forming two or more parts. Crimping machine is machine of joining two or more parts. Crimping machines are more reliable, accurate and flexible machines with easy and fast set up times and multiple cost effective tooling options than any other joining machines, these factors to be made machines well accepted among manufactures in number of industries worldwide. The crimping process can be made more and more efficient by automating the individual process steps involved in machining. Machine which plays vital role in market will placing increasing pressure on their strategic partners to optimize installation times. Crimping machines is equipped with a universally adjustable stripping mechanism and a user-friendly touch screen. They also feature longer servicing intervals and machine lifespans. And, there is no need to change tools. Crimping machines are manufactured using the art of manufacturing equipment and technology. The precision manufacturing parts together with the engineering and assembly expertise, it should be combined with quality control. By using crimping machine we can achieve more accuracy in joining process then manually. And it reduces the time consuming for joining process, labor cost and number of labors. The crimping machine is portable as per working condition or working environment. II. 1. Design the parts of crimping machine. 2. Assembling as per the design requirement. 3. Analysis of the critical parts of machine using ANSYS. III. OBJECTIVES METHODOLOGY After systematically analyzing the problem statement in order to meet the above listed objectives following methodology is carried out in sequential manner. 1. Finalize the concept of crimping machine. 2. Note down the different forces used for calculations. 3. Design analytically all the parts. 4. Create the CAD model of all parts using modeling software (solid works). 5. Analyze the critical parts using analysis software (ANSYS-14). 19

Accessories Hydraulic cylinder with Hand pump Hand pump which is used to supply required pressure to the hydraulic cylinder.

2 6. Assemble all the parts as per drawing 7. Release bill of material. The ferrule crimping has the following major parts. IV. DESIGN: i. Hydraulic cylinder with Hand pump (pressure supply unit) Supporting block for hydraulic cylinder i V-block and caps Hose Nipple v. Pressure pad vi. Supporting block v Union nut vi Tie-rods ix. Accessories Hydraulic cylinder with Hand pump Hand pump which is used to supply required pressure to the hydraulic cylinder. The minimum pressure is about 200bar and maximum pressure is about 500bar used in the machine. Hydraulic cylinder used to push the connecting component to crimp the ferrule and pipe. The maximum working pressure is about 500bar. Hose Nipple The Hose Nipple used to crimp the ferrule and pipe. It is used for different ferrules by required dimension. Pressure pad The pressure pad which helps to support to crimping pipe for different outside diameter. Supporting block This is used as a support part for pressure pad. Union nut Union nut helps to crimp as loading part for connecting component. Accessories The accessories of the mashies are like pins, bolts etc. 1. Design drawing of Hose nipple Fig 1 Design drawing and solid model of Hose nipple 2. Assembly of ferrule Crimping machine 20

The Fig 2 Shows the assembly model of ferrule crimping machine. Working of machine Fig 2 Assembly of ferrule crimping machine Ferrule crimping machine works on the bases of hydraulic system.

3 The Fig 2 Shows the assembly model of ferrule crimping machine. Working of machine Fig 2 Assembly of ferrule crimping machine Ferrule crimping machine works on the bases of hydraulic system. Ferrule is to crimp by using this machine, the pipe and ferrule are of same outer diameter (OD). By taking 42mm outside diameter pipe and ferrule as example, lock the front bush to cylinder piston using lock pip. And Hose Nipple is the lock to Front Bush by using lock pin. Then on the 42mm outside diameter pipe, ferrule is kept where it to be crimp and then it is kept to crimp in pressure pad and insert the union nut on ferrule to support for crimp. After that it pumps the pressure up to 390bar for 42mm outside diameter. The Hose Nipple is crimping the ferrule on pipe, and then release the relief valve for return stroke. The crimped ferrule is checked by visually. V. CALCULATION AND ANALYSIS: Machine design is the art of planning or better-quality machines to achieve specific determinations. In overall, a machine contains a arrangement of several different mechanical elements correctly designed and arranged for work together, as a one. Throughout the primary planning of a machine, important decisions must be consider to concerning loading, type of kinematic elements be used, and correct application of the properties of materials. Financial considerations are usually of prime importance when the design of new machinery is commenced. In this chapter calculations are carried out to obtain pressure, stresses and deflections for critical component of the hydraulic crimping machine. The yield stress of the mild steel EN8 is 330 N/mm 2. The stresses obtain from these calculations should not exceed the yield stress in order to avoid yielding of the material. Also the factor of safety of 1.5 is taken in consideration which is using the company. Considering the FOS, maximum working stress is calculated. If the stresses induced in the machine components are less than the maximum working stress then the design is said to be safe. Therefore, Maximum working stress = = 330/1.5 = 220 N/mm 2 The hydraulic crimping machine consist of different assemblies like two tie rod assembly, block assembly, and frame assembly and cylinder-ram assembly. These assemblies in turn consist of different parts. All these parts are subjected to different static loads. Each part are their own manner of loading and deformation. In this chapter the major part are analyzed for their type of loading and suitable results are obtained for stresses and deflections. Specifications of the hydraulic crimping machine are given by the company which is noted. Later these calculations are compared with the ANSYS results for validation. The whole hydraulic crimping machine body is made up of mild steel EN8 material. Pressure calculation for hydraulic ferrule of mild steel and stainless steel to crimp The pressures mentioned is based on calculation carried out in accordance with DIN2413 (technical standards originating in Germany and used internationally). The calculation are carried out by assuming the boundary conditions for straight tubes and do not take into consideration any special condition of a real hydraulic system. Therefore only intended to assist in preliminary selection and do not release the user from his obligation to carry out in design calculation. The scope of application of the above standard shall be observed. Pressure calculation as described in ISO

4 Load case I- mainly static: Design calculation pressure Load case III- pulsating: Design calculation pressure Nomenclature D a = outer dia of ferrule in mm T= Ferrule thickness in mm P= Pressure in bar K=Strength parameter N/mm S= Safety factor C 1 = Reduction factor for thinner ferrule walls Table 1 Constants to be considered for mild steel EN8 and stainless steel (E235 and E355) Load case I-static Load case III-rising E235 (EN8) E355 E235 (EN8) E355 K=235 K=355 K=225 K=230 S=1.5 S=1.58 S=1.5 S=1.5 C 1 =0.9 C 1 =0.9 C 1 =0.9 C 1 =0.9 *For E235 and E355: a value of 10 N/mm 2 shall be subtracted for D a 30mm and T 3mm Calculation for OD42 (E235) Load case I-mainly static: Pressure Load case III-pulsating: Pressure Tabular column Table 2 Tabular column Ferrule dimensions Design calculation pressure (bar) Load case I Load case III D a (mm) D i (mm) T(mm) E235 (EN8) E355 E235 (EN8) E Table 2 shows the pressure for load I and load III for different ferrule dimension. The maximum pressure is about 500 bar and minimum about 200bar for (E235). We have to consider for design. Design of hydraulic cylinder Pressure P= 390 bar 22

5 Stroke length L=70mm Bore diameter D= 52 mm Double acting cylinder Area Crimping machine parts calculations Back support i V-Block i Moment of inertia I= Caps Moment of inertia I mm i Moment of inertia I= Supporting block mm Moment of inertia i I= Pressure pad i Moment of inertia I= Supporting bock plate 1 i Moment of inertia I= Supporting block plate 2 23

6 (6.32) (6.33) i Moment of inertia I=.(6.34)..(6.35) Base plate..(6.36)...(6.37) i Moment of inertia I=...(6.38).(6.39) Stresses on hose nipple component (Critical part of machine) Specifications of the component [19] i. Material used for manufacturing the component: Mild steel Carbon content of the mild steel: 0.40 i Density : 7870Kg/m 3 Ultimate tensile strength of the mild steel:410 N/mm 2 v. Young s modulus:2x10 5 N/mm 2 vi. v vi ix. Poisson s ratio:0.3 Coefficient of thermal expansion:12 x10-6 / 0 C Thermal conductivity:43.3 W/m-K Operating temperature: C Calculations for Hose Nipple x. Maximum pressure acting on the component: 390bar xi. Yield strength : 330 N/mm 2 Hose Nipple The stresses acting on Hose Nipple hoop stresses. Given data:- i. Diameter of Hose Nipple d= 42mm Length of Hose Nipple L= 53 i Pressure acting on Hose Nipple P= 390bar Thickness is t = 4mm v. Outer diameter d o =49mm vi. Inner diameter d i= 45mm Hoop stress on Hose Nipple i. i According to Barlow s equation Results obtained:- 24

1. Since the load acting on each Hose Nipple i.e 41.6KN is very less than the critical load i.e 82.8KN, therefore under given loading condition. 2. The induced stress in hose nipple is 204.75 N/mm 2.

7 1. Since the load acting on each Hose Nipple i.e 41.6KN is very less than the critical load i.e 82.8KN, therefore under given loading condition. 2. The induced stress in hose nipple is N/mm 2. Since, < Maximum working stress i.e. 220 N/mm 2, design is safe. Deformation of Hose Nipple Analysis by ANSYS The ANSYS14 has many finite element capabilities, ranging from a simple linear static analysis to a complex, nonlinear, transient analysis. A basic theory of ANSYS is explained in previous chapter. In project, I have used ANSYS for analysis of the critical machine part Most of the machine components are meshed as free mesh and element used is solid 45 nodes 8. Solid works12 were used for the 3D modeling of solid model. The element is defined by eight nodes having three degrees of freedom at each node of element: x, y, and z directions. Import file Model is crated in solid works and to analysis is done using ANSYS 14. Fig 3 Import step file of Hose Nipple Fig 4 Meshing of Hose Nipple Fig 5 Stress on Hose Nipple Fig 6 Deformation Hose Nipple Element used is solid 45 element (8 node with 3 DOF/ node) to mesh the model of the Nipple hose. Analysis is done for internal circumference of Hose Nipple by assuming that load acting throughout circumference. Meshed view of Hose Nipple The Hose Nipple is fixed in all DOF at one end. The Pressure is distributed on circumference of Hose Nipple of 390bar pressure. The load is compressive in nature. Stress on Hose Nipple Results obtained:- The maximum stress on Hose Nipple is about = N/mm 2 Minimum stress on Hose Nipple is about = N/mm 2 Deformation of Hose Nipple Results obtained:- The maximum deformation is about = mm The minimum deformation is about = 0mm VI RESULTS AND DISCUSSION The design of ferrule crimping is done as per industry requirement, the main aim of project is to provide the design drawings to industry to manufacture and use it for proper crimping of ferrule. Bill of material Table 3 Bill of material SL NO NAME CAMPONENT OF RAW MATERIAL FINISHED MATERIAL SIZE (L B H)mm PRICE INR 1 BACK SUPPORT EN QTY 25

8 2 V-block EN Cap 1 EN Cap 2 EN Front hose EN8 Ø52 length 55mm Hose Nipple EN8 Ø52 length 53mm Springs EN8 *********** Tie rods EN8 Ø20mm 209.1mm Length Pressure Block EN8 *********** Pressure pad EN Supporting block EN Plate 1 EN Plate 2 EN Pin (Ø10) EN8 Ø10 length 54mm Pin (Ø16) EN8 Ø16 length 90mm Pressure Block pin EN8 Ø15 length 100mm Bolts (Ø10) EN8 Standard Bolts (Ø5) EN8 Standard Base plate EN TOTAL The Table 3shows the bill of material with finished dimension, the total approximate cost of manufacturing is about rupees The following results have been obtained by ANSYS and theoretical calculations for critical part of Hydraulic crimping machine and the results are compared. ANSYS Results Table 4 Stress and deflection results Component ANSYS results Theoretical results Maximum stress in N/mm 2 Maximum deflection in mm Maximum stress in N/mm 2 Maximum deflection in mm Hose Nipple Table 4 shows the ANSYS results. The stresses are on radial circumference is about N/mm 2. In the component linear deflection is about Since the stresses induced are fine under the yielding stress of the material. The material is safe. Percentage error From the Table 9.2 we see that the deflections for the Hose Nipple is very less, even less than 0.01 mm, hence such a small deflection in a this machine is negligible. Therefore the percentage of error is calculated for the maximum stress induced, after comparing both theoretical and ANSYS results. The percentage error in the analysis of Hose Nipple is as follows. Table 5 Percentage error for stress analysis Component ANSYS results Theoretical results Maximum stress in N/mm 2 Maximum stress in N/mm 2 Hose Nipple % Percentage error The percentage error is less than 10& therefore it will be considered as safe design. VII CONCLUSION After analyzing the specified problem we decided to design crimping machine with cost effective and efficacy. By using this crimping machine company will get more benefit in design, cost and efficacy. It reduces human efforts as compared to manual crimping and also it saves the time The critical part is analyzed using ANSYS-14 and same is compared with analytically, the stress acting on the component is well bellowed the working stress and the error is less than 10% by comparing this with analytical answer. 26

9 Crimping is an easy, fast and cost operational method for connection and forming parts. Crimping machines are reliable, precise and elastic machines with easy and fast set up times and multiple cost effective tooling options. These issues have made machines well accepted among manufactures in many industries worldwide. Among all manufacturing process, Crimping technology has special place because it helps to produce parts of superior mechanical properties with minimum wastage of material. In crimping, the starting material has a relatively simple geometry, which is plastically deformed between tools, to obtain the desired final configuration. By using design we can easily fabricate and install the ferrule crimping machine. Using this machine we can achieve the more efficiency of crimping. It is easy to handle and portable machine. REFERENCE: [1] Festo Didactic GmbH and co. K G Denkenderf/Germany,2003 by D. Merkle B. Schrader, M Thomes [2] Hydraulics and Pneumatics Fluid power control By A C Niranjan 3 rd Edition, 2014 Pooja Publication Page no 1,2,3,4 [3] Hydraulic Decre and company service publication Moline Illinois 1997 [4] Industrial hydraulic manual Vickers, Training center Rochester Holls Michigan 1993 [5] Par, Andrew (2001) Hydraulic and pneumatics a technical and engineering guide page no 38 [6] Management of Hazardous Energy: Deactivation DC-Energization, Isolation and Lockout, Thomas Neil MC Manus, page no 678, Aug 8, 2012 by CRS press Reference 942 Pages-273 B/W Illustration, IBN [7] Maximization cylinder performance A checklist of design guidance ensures the best hydraulic cylinder for an request Aug 20, 199 Kenneth Korane, Machine design publication. [8] Fluid power design manual Third edition page 112 By Frank Yeaple CRC journalists 1995, 854 page ISBN [9] Ferrules and Eyelets Trans-matic manufacturing Inc. Retrieved 18 April 2014 [10] Lillbacka Powerce. Ltd USA, Inc.-Finn Power crimping machine Page no: 1 [11] Parker Catalogue 4400/UK Karry Krimp 2 85CE / P Hastkrimp 89CEParkrimp fittings 26, 43, 46, 48, 70, 71, 73, 77 and 78 series [12]EATON ET5040 Crimp Machine E-EQCR-TT001-E1 May 2014 page no:2&11 [13]Voss fluid GmbH- Germany crimping machine Catalog Voss Fluid GmbH 2013 [14] Automatic machines by Weidmuller Page no:1.2 [15] Monolex industrial crimp quality hand book order no page no:3 [16] Fluid power ivtinternational.com Off-Highway 2014 paoloseghi [17] Power crimp 707 crimper safety & operation manual (Ind AG) [18] H.G. Patil, machine design data hand book, fourth edition, [19] Vishwas Agarwal "Steel Hand book Vishwas Techno Publications edition. [20] K. J. Bathe, finite element procedures, Englewood Clis, NJ: Prentice hall,

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