forging tools‎ > ‎

"Two in One" Hydraulic Press

Well, after several years of research and three design revisions I think I finally got it right! 
This is the "Two in One" hydraulic press because you can press from front to back and from side to side. 

When pressing front to back the 2" dies draw out the billet. When pressing side to side the 12" dies straighten and flatten. It really is like having two presses. A third benefit is that when idle it locks the workpiece like a vise (by means of a check valve) that locks the flow of hydraulic fluid and the ram cannot move.

My design goals were:
- Simple and safe to operate: foot control, pull down operation, dies at chest-level, low profile. 
- Press from front to back and side to side for drawing out, straightening and flattening.
- Quiet operation: power unit with submerged pump and low speed motor.
- Compact and portable: manifold, modular valves,  short hoses, quick connects.
- 35 Tons of force.
- 1/2 inch per second travel speed, multiple pressings in one heat.
- 2500 PSI max operating pressure.
- Cylinder should lock the workpiece like a vise when in neutral idle position.

I made a cover to keep the scale from falling on the hoses and power unit.

The power unit sits on an angle iron base that is bolted to the base of the press. With the quick disconnect it can be easily separated and ready for transport. The quick disconnect is a high quality Dixon that does not introduce air into the lines when connected or disconnected.

 I wrapped the hoses with a protective outer lining. 

Hydraulic valves, filter and pressure gauge are integrated into a single manifold. 

The directional control valve operated by 120V solenoids switched by foot pedals.

I started out by making the frame out of 3/8" x 4" square tube:  42" tall x 24" wide.

The first set of press bed plates are: top and bottom 1/2" x 4.5" x 12" and the sides 1/4" x 4" x 12"

The steel rods are 1" diameter x 48" long, Grade 8 rated at 150,000 psi. 
The steel nuts are 1" tall extreme strength, extra wide Grade 9. 

Cross plates are 1" x 8" x 12". I bolted down the forging dies for now until I can come up with a good method to make them quickly interchangeable. I hate having dies moving around while you're pressing. Another benefit is that that you can adjust the cross plates up and down to accommodate larger forging dies, tooling, or work pieces.

The press bed is further reinforced on all sides with a second set of plates:  top and bottom 1/2" x 5.5" x 12" and the sides 1/2" x 5" x 8". 
The threaded rod guides are 1/8" tubing x 10" x 1" inner diameter. 
Click on the image to zoom in.

The cylinder is mounted upside down and the base mount is connected by pins 1.5" diameter x 4" long through the 1/2" x 2" steel tube collars. The pins are only 4 inches long so they can slide outward and the cylinder can be removed. They are held in place by 1/2" bolts threaded through the collars. 
Click on the image to zoom in.

The bottom rod mount is connected by a 1.5" diameter x 9" long pin passing through both tube collars. It's held in place by a 1/2" bolt threaded thru one of the tube collars. 
Click on the image to zoom in.

The frame sits on 1/8" x 2" x 2" x 22.5" angle iron and 4" swivel casters with brakes. 
Click to zoom in.

Press Features:

- 6” diameter cylinder, 3” rod, 8” stroke.
- 7.5 HP motor, 1725RPM, 220V, single phase.
- High pressure pump submerged in 10 gallon tank for quiet operation.
- Power unit with integrated manifold (D03 pattern) and return filter.
- 120V solenoid actuated directional control valve. 
- Check valve on return port B to lock the workpiece.
- Operating at max 2500 PSI it produces 35 tons of force.
- Ram travel is 1/2” per second.
- Non flammable hydraulic fluid. Short hoses. 

Hydraulic Formulas and Flow Diagrams

Good luck with your build! 

Questions and comments welcome:
web stats