Design and Modeling of Fluid Power Systems

ME 597/ABE 591 - Lecture 7

Dr. Monika Ivantysynova

MAHA Professor Fluid Power Systems

MAHA Fluid Power Research Center

Purdue University
Content of 6th lecture

The lubricating gap as a basic design element of displacement machines

Gap flow calculation. Gap with a constant gap height

Gap with variable gap height (slipper)

Gap between piston and cylinder, numerical solution of gap flow equations

Non-isothermal gap flow

Aim: Derivation of basic equations for gap flow and calculation of

Gap flow parameters (pressure and velocity distribution, load ability,
gap flow and viscous friction)

Basic knowledge about the gap design and simulation models

Design and Modeling of Fluid Power

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Lubricating Gap

Basic Design Element of Displacement Machines

Design & operating

parameter

Gap height

Gap flow

Load ability

Leakage Performance & Losses

Viscous friction
Design and Modeling of Fluid Power
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Lubricating Gaps -examples
Swash plate axial piston machine
Gaps seal the displacement chamber
QSK QSB
Movable Piston Rotating cylinder block
pi
QSG
Qr
Valve plate
(fixed)
Displacement chamber

Gaps between:
piston and cylinder
slipper and valve plate
cylinder block and valve plate

Swash plate (fixed or with adjustable angle)

Design and Modeling of Fluid Power
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Gap Flow Calculation
Aim: High load carrying ability
Low friction Low leakage flow

Gap height lies in a range of some micrometers, whereas all other

dimensions are in a range of millimeters

Laminar flow of an incompressible fluid in the gap can be described using

Navier-Stokes-Equation:
y
z
h=f(x,y)
movable surface
Assumptions:
p2
- neglecting mass forces p 1
h
- assuming steady state flow,
- change of fluid velocity only in direction of gap height x
- pressure is not a function of gap height h fixed surface

Pressure Force + Viscosity Force = 0

Design and Modeling of Fluid Power
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Gap with constant gap height

Pressure field Forces applied on a fluid element:

∂v
with τ = µ⋅
∂z
after double integration velocity yields:

1 ∂p 2
v= ⋅ ⋅ z + c1 ⋅ z + c 2
2 ⋅ µ ∂x
boundary conditions:
z=0 … v=0
h

p z=h … v=0

1 ∂p 2
v= ⋅ ⋅ (z − h ⋅ z)
2 ⋅ µ ∂x

Design and Modeling of Fluid Power

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6 Systems, ME 597/ABE 591
Gap with constant gap height
h
1 ∂p
Gap flow: Q = b ∫ v ⋅ dz = − ⋅ ⋅ b ⋅ h3
0 12µ ∂x
p2 − p1
for pressure: p= ⋅ x + p1
l
∂v z = 0h
Shear stress on surfaces: τ = µ ⋅

h
∂z z = 0h
Δp h Δp h
τ z= 0 = ⋅ τ z= h = − ⋅ l
l 2 l 2
1 ∂p 2
with: v= ⋅ ⋅ (z − h ⋅ z)
2 ⋅ µ ∂x
Viscous friction: Fv = τ ⋅ b ⋅ x
1 Δp 2

Power loss due to gap flow: PSQ = Q ⋅ Δp = ⋅ b ⋅ h3 ⋅

12 ⋅ µ l
Design and Modeling of Fluid Power
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Gap with constant gap height
boundary conditions: z
p1=p2
z=0 … v=0 x=0 … p=p1 v0
z=h … v=v0 x=l … p=p2

h
p1 p2
x
l
b >> h
Flow velocity:

Shear stress on surfaces: ∂v

τ = µ⋅
h h
∂z
v0 v0 h 2 v0
Gap flow: Q = b ∫ v ⋅ dz = b ⋅
h
∫ z ⋅ dz = b ⋅ ⋅
h 2
= b ⋅
2
⋅h
0 0
v0
Viscous friction: Fv = τ ⋅ l ⋅ b = µ ⋅ ⋅ l ⋅ b
h
l⋅b 2
Power loss due to viscous friction: PSv = Fv ⋅ v 0 = µ ⋅ ⋅ v0
h
Design and Modeling of Fluid Power
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Gap with constant gap height
Boundary conditions:
z=0 … v=0 x=0 … p=p1 p1 p2
z=h … v=v0 x=l … p=p2
∂p ∂ 2v z
Flow velocity: = µ⋅ 2 v0
∂x ∂z
1 ∂p 2 +
( z − h ⋅ z) + ⋅ z

h
v0 p1 p2
v=
2 ⋅ µ ∂x h x
Gap flow: l
h
1 ∂p
Q = b ∫ v ⋅ dz = −
h b >> h
⋅ ⋅ b ⋅ h 3 +v 0 ⋅ ⋅ b
0 12µ ∂x 2
∂v p2 − p1 1 v0
Shear stress on surfaces: τ = µ⋅ = ⋅ (2 ⋅ z − h ) + ⋅ µ
∂z l 2 h
Power losses: Ps = PSQ + PSv = Q ⋅ Δp + Fv ⋅ v 0
1 Δp 2 v 2
Ps = ⋅ b ⋅ h3 + µ 0 ⋅ b ⋅ l
12 ⋅ µ l h
Design and Modeling of Fluid Power
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Radial Gap with constant gap
height
r
r

h
p1 p2
x

l d

Gap width: b=π⋅d

Equations from gap with constant gap height can be applied:

h
π ⋅ d ∂p 3
Gap flow: Q = b ∫ v ⋅ dz = − ⋅h
0 12µ ∂x

Design and Modeling of Fluid Power

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Gap with variable gap height
Hydrodynamic force
Boundary conditions:
z=0 … v=v0 x=0 … p=p1
z=h … v=0 x=l … p=p2
∂v
with τ = µ⋅
∂z
z
∂p ∂ 2v
p1=p2=p0= 0 = µ⋅ 2
∂x ∂z
Flow velocity:
1 ∂p 2
( z − h ⋅ z) +
vv00
v= − ⋅⋅zz+ v 0
2 ⋅ µ ∂x hh

Gap flow:

h
1 ∂p
Q = b ∫ v ⋅ dz = −
h
⋅ ⋅ b ⋅ h +v 0 ⋅ ⋅ b
3

0 12µ ∂x 2
Design and Modeling of Fluid Power
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 Gap with variable gap height

Pressure distribution in x-direction:

p F
(1)

from
h
1 ∂p x
= b ∫ v ⋅Qdz = −
h
⋅ ⋅ b ⋅ h 3 +v 0 ⋅ ⋅ b (2)
0 12µ ∂x 2
we obtain:
v0
∂p 12µ ⋅ Q 6µ ⋅ v 0
=− + (3)
∂x b⋅ h 3
h2

⎛ 6µ ⋅ v 0 12µ ⋅ Q ⎞
p( x ) = ∫ ⎜ 2 − 3 ⎟
dx (4) with: (5)
⎝ h b⋅ h ⎠

Design and Modeling of Fluid Power

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Gap with variable gap height

⎛ 6µ ⋅ v 0 12µ ⋅ Q ⎞
p( x ) = ∫ ⎜ 2 − 3 ⎟
dx (4) with: (5)
⎝ h b⋅ h ⎠
using:
(6)

in our case: (7)

where n=-2 for the first term in Eq. (4) and n= -3 for the second term in Eq. (4)
and after integration:
6µ ⋅ v 0 1 12µ ⋅ Q 1
p( x ) = ⋅ − ⋅ 2 + c (8)
h2 − h1 h2 − h1 h2 − h1
⋅ (−1) ⋅ x + h1 b ⋅ ⋅ (−2) ⎛⎜ h2 − h1 ⋅ x + h ⎞⎟
l l
h
l ⎝ l 1
⎠
h
Boundary conditions: x=0 p=p0
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Gap with variable gap height

6µ ⋅ v 0 1 12µ ⋅ Q 1
p( x ) = ⋅ − ⋅ 2 +c
h2 − h1 h2 − h1 h2 − h1 ⎛ − ⎞ (8)
⋅ (−1) ⋅ x + h1 b ⋅ ⋅ (−2) ⎜ 2 1 ⋅ x + h ⎟
h h
l l h l ⎝ l 1
⎠
6µ ⋅ v 0 ⋅ l 6µ ⋅ Q ⋅ l
c = p0 + − 2 (9)
( 2 1) 1
h − h ⋅ h b ⋅ ( 2 1) 1
h − h ⋅ h (11)

6µ ⋅ l ⎛ v 0 Q v0 Q ⎞ l
p( x ) = ⋅ ⎜− + + − 2⎟
+ p0 (10) h2 − h1 = ( h − h1 ) ⋅ (12)
( h2 − h1 ) ⎝ h b ⋅ h h1 b ⋅ h1 ⎠
2
x

(13)

finally we get: Boundary conditions: x=0 p=p0

6µ ⋅ x ⎛ h + h1 Q ⎞
p( x ) = ⋅ ⎜v 0 − ⋅ ⎟ + p0 (14)
( h ⋅ h1 ) ⎝ h ⋅ h1 b ⎠
Design and Modeling of Fluid Power
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Gap with variable gap height

6µ ⋅ x ⎛ h + h1 Q ⎞ p F
p( x ) = ⋅ ⎜v 0 − ⋅ ⎟ + p0 (14)
( h ⋅ h1 ) ⎝ h ⋅ h1 b ⎠
x
Using boundary conditions for x=l is
p1=p2=p0=0
p=p0 and h=h2 from Eq. (14) follows :

h1
p1

h2
v0 p2
v 0 ⋅ b ⋅ h2 ⋅ h1 (15)
Q= x
h2 + h1
Substituting Eq. (15) into Eq. (14) the pressure p(x) yields:

6 ⋅ µ ⋅ x ⋅ v 0 h − h2
p( x ) = ⋅ + p0 (16)
h 2
h2 + h1
No load ability!
when h=h1=h2 p(x)=p0
Design and Modeling of Fluid Power
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Gap with variable gap height
Load capacity due to hydrodynamic
pressure field generated in the gap: 6 ⋅ µ ⋅ x ⋅ v 0 h − h2
p( x ) = ⋅ + p0 (16)
l h 2
h2 + h1
F= ∫ ( 0)
b ⋅ p − p ⋅ dx (17)
0
p F
l
h − h2
F = b ∫ 6 ⋅ µ ⋅ v0 ⋅ 2 x ⋅ dx (18)
0 h ( h2 + h1 )
x
6 ⋅ µ ⋅ b ⋅ l 2 ⎡ h1 h1 − h2 ⎤ p1=p2=p0=0
F= 2 ⋅ ⎢ln
−2⋅ ⎥ ⋅ v 0 (19)

h1
( h1 − h2 ) ⎣ h2 h1 + h2 ⎦ p1

h2
v0 p2
Maximum pressure force for h1/h2=2.2 yields: x

6 ⋅ µ ⋅ l2 ⎡ 2.4 ⎤ 0.16 ⋅ µ ⋅ l 2
Fmax = 2 2 ⋅ ⎢ln2.2 − ⎥ ⋅ v0 = ⋅ v0 (20)
1.2 ⋅ h2 ⎣ 3.2 ⎦ h2 2

Design and Modeling of Fluid Power

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Example

A gap between two circular plain and parallel surfaces with a central inflow
as shown in Fig.1 is given. Both surfaces are fixed. The inner radius is R1
and the outer radius is R2.
Calculate the flow Q through the gap for a given gap height h, when the
pressure at the inner radius is p1 and the pressure at the outer radius is p2.
And determine the pressure on the radius r= 15 mm.
The following parameters are given:
p1=20 MPa R1=12 mm
p2=0.5 MPa R2=25 mm p1
h = 20 µm
Dynamic viscosity of the fluid: p2 p2
µ =0.0261 Pa· s r
Boundary conditions:
z=0 … v=0 r=R1 … p=p1
z=h … v=0 r=R2 … p=p2
r Fig.1
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Example
From force balance on a fluid element follows:
∂p ∂τ ∂v Boundary conditions:
= with τ = µ ⋅
∂r ∂z ∂z z=0 … v=0 r=R1 … p=p1
After double integration the velocity yields: z=h … v=0 r=R2 … p=p2
1 ∂p 2
v=
2 ⋅ µ ∂r
( z − h ⋅ z) (1)
h
Gap flow: Q = ∫ 2 ⋅ π ⋅ r ⋅ v ⋅ dz = − π ⋅ r ⋅ h 3
∂p
⋅ (3)
0 6⋅ µ ∂r p1
∂p 6⋅ µ⋅ Q
Therefore: =− (4) p2
∂r π ⋅ r ⋅ h3 p2
p2 R2
6⋅ µ⋅ Q r
and
∫ dp = ∫ π ⋅ r ⋅ h 3 ⋅ dr
− (5)
p1 R1

(6) r

Design and Modeling of Fluid Power

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Example

(6)

From Eq. (6) follows for the gap flow: (7)

For the pressure distribution in radial direction we obtain integrating Eq. (4):

(7) (4)
And using boundary conditions for c follows:

(8) (9)

Design and Modeling of Fluid Power

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Example
The pressure distribution in radial direction yields:

(9)
p1
Substituting the volume flow equation Eq. (7)
into Eq. (9) we obtain: p2 p2
(7) r

Design and Modeling of Fluid Power

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Gap between piston & cylinder

Axial and radial piston motion cylinder

p2 p1>p2
RZ
p1 vp
ω·Rz RK

Unrolled gap in Cartesian co-ordinates system

p2

Gap height
p1 gth
len
p
Gap c
ircum Ga
Gap height due to inclined piston position ferenc
e

Design and Modeling of Fluid Power

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Gap height function

cylinder

Design and Modeling of Fluid Power

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Gap between piston & cylinder
After double integration flow velocity yields:

Boundary conditions:
z=0 … vx=0 vy=0
z=h … vx=ω·Rz vy=vp

1 ∂p 2 z
vx = ⋅ ⋅ (z − h⋅ z) + ω ⋅ Rz ⋅
2 ⋅ µ ∂x h

Design and Modeling of Fluid Power

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Gap between piston & cylinder

Considering the continuity equation for incompressible fluid:

After substituting the mean velocities the Reynolds-equation can be derived:

and taking into account time dependent change of gap height

the Reynolds equation becomes:

This partial differential equation has to be solved numerically

Design and Modeling of Fluid Power

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Numerical solution of gap flow
Applying the method of finite differences the j
Reynolds equation can be written:

i
(1) i, j

Δx
(2) Δy
Different methods available:
-finite differences
(3) (4) -finite volumes
-finite elements

Substituting Eq. (1), (2), (3) and (4) into the Reynolds- equation we obtain:

(5)

Iterative solution of Eq. (5) to calculate the pressure pi,j

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Numerical solution of gap flow

The gap grid

Gap height
Gap height

Gap circumference Gap

length

Design and Modeling of Fluid Power

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Gap Parameter

Pressure field between piston and cylinder

Load capacity of the gap

p [MPa]

Ga e
pl
en fe re n c
gth c ircum
Gap

with:

Design and Modeling of Fluid Power

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Contact between piston and swash
plate
Support by slippers Increase of volumetric losses
Hydrostatically balanced Hydrodynamically balanced

Additional hydrodynamic effect usable

Requires oil filled case

Special surface geometry

can support hydrodynamic
effect

Lower loading of piston-cylinder

Suitable for high pressure and high speed
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Slipper Design

BG… slipper balance (0.95 – 0.99)

Gap flow assuming constant

gap height

FGF
(1)

Flow from displacement chamber to slipper pocket

Through a small orifice or laminar throttle (3)

(2)

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Slipper Design
DG/dG= 1.2 ÷ 1.3
Load ability FGF due to pressure field under the slipper
(1)

(2) FGF

DG/dK= 1.2 ÷ 1.3

Viscous friction force: Losses due to friction:

Losses due to gap flow: Power loss:

Design and Modeling of Fluid Power

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Slipper Motion
Gap flow simulation requires the determination
of gap height

HP HP HP
Pressure field

LP LP LP

Operating parameter:
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Slipper
Slipperhold down
hold down device
using springs

Inside the Outside the piston

piston

Slipper hold down by cylinder block spring Slipper hold down device
Cylinder block spring

Slipper hold down spring

Design and Modeling of Fluid Power
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Slipper hold down device
Slipper hold down using springs

Slipper hold down device

Slipper hold down spring Slipper hold down spring

Design and Modeling of Fluid Power

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 Slipper hold down device

Fixed slipper hold down

Slipper hold down spring

Spacer

Design and Modeling of Fluid Power

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