Proceedings of ASME Turbo Expo 2009: Power for Land, Sea and Air

Proceedings of GT2009
ASME Turbo Expo
June2009:
8-12, Power for Land,Florida,
2009, Orlando, Sea andUSA
Air
June 8-12, 2009, Orlando, Florida, USA

GT2009-59287
GT2009-59287

ANALYTICAL PREDICTION TECHNIQUE FOR INTERNAL LEAKAGE IN AN

EXTERNAL GEAR PUMP

Abdul Wahab
Institute of Space Technology
Department of Aerospace Engineering
44000 Islamabad
Pakistan
Email: abdul.wahab@ist.edu.pk

ABSTRACT QIdeal Ideal Flow Rate

Gear pumps are commonly found in Aero-engine high QPredicted Predicted Flow Rate
pressure part of fuel system. Their objective is to start the QLeak Leakage Flow Rate
engine, to provide take off flow at the required pressure and to D0 Outer Diameter of Gear
prime a fuel system. Development of Electric Fuel Metering DR Root Diameter of Gear
Pumps for micro turbine has optimized the fuel system by DB Base Diameter
eliminating the need for control valves. The correct prediction DP Pitch Diameter
and control of tip leakage flow rate in a gear pump is crucial for C Center Distance
efficient fuel metering. In this paper, an approach has been t Tip clearance
presented for obtaining the above prediction in a simple ω Angular Velocity of Gear
analytical and explicit method. Orifice equation is incorporated Ф Pressure Angle
to predict leakage flow rate at different inlet/outlet pressure CD Discharge Coefficient
differences. A variable pressure ratio positive displacement CV Velocity Coefficient
pump test rig is utilized to conduct experiments on micro CC Contraction Coefficient
turbine gear pump. The results obtained with proposed method ρ Density of Fluid
compare favorably with the one obtained by experimental μ Fluid Absolute Viscosity
techniques. In many cases, there is hardly a distinction between T Fluid Temperature
prediction and the experimental results. P Fluid Pressure
Re Reynolds Number
NOMENCLATURE Rt Transition Reynolds Number
SG Surface Area of Gear Face B Height of Orifice
N Number of teeth on driving and driven gear W Width of Orifice
w Thickness of Gear
AD0 Area of Circle with Outer Diameter Main Subscripts
Aetr(G) Entrapped Area per Gear 1 Driving Gear
Vetr(G) Entrapped Volume per Gear 2 Driven Gear
Aetr(T) Entrapped Area per tooth In Inlet
At Tip Area Out Outlet
AInlet Area before Orifice
VD Volumetric Displacement Greek Letters
∆ Difference

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 INTRODUCTION PUMP DESCRIPTION
External gear pump is a positive displacement pump. It Figure 1 shows the nomenclature for the two meshed gears.
consists of two meshed gears, suitably housed with a shaft Gears used in the analysis are spur gears with involute teeth.
attached to one of the gears. Close tolerances are held between The number of teeth on gear 1 is given by N1 and the number of
housing, gear sides and the periphery to prevent excess leakage. teeth on gear 2 is given by N2. In the analysis that follows, the
Fluid is transported in the spaces between the teeth in the number of teeth on each gear is equal and therefore the two
periphery of both gears, and the meshed segment of the gears gears will be identical. Outside diameter will be identified
serve as a seal between inlet and outlet [1]. Unlike by D0 1,2 , root diameter by DR 1,2 , Base diameter by DB 1,2 , and
Rotodynamic pump which produces constant pressure with flow
rate depending on the restriction downstream, a gear pump pitch diameter is given by DP1,2 . The center distance between
produces constant flow rate with pressure depending on the the driving and driven gear is given by C. The thickness of the
restriction downstream. gears is given by the dimensions w (not shown in figure). The
Gear pump has now become the main choice of fuel system subscript 1 and 2 denote the driving and driven gear
designer due to its long life, minimum maintenance, high respectively. The driving gear rotates at an angular velocity 1 .
reliability, ability to operate on low lubricity fuel, low heat input The driven gear rotates in the opposite direction at an angular
to fuel, small size and low weight. velocity 2 .
Its use as a fuel pumping and metering device is common in
small turbine engines. For fuel metering, it is important to study External gear pump consists of two spur gears separated by
different parameters that affect gear pump output a distance equal to pitch diameter. Pressure angle is selected on
characteristics. Internal Clearance and Cavitation are the a basis of number of teeth on the driving and driven gear. Shaft
contributing factors in the deviation of gear pump ideal curve. is connected to one gear while the other gear rotates due to
In Gear Pump there are three internal leakage paths: the tips of meshing of gears. Both the gears rotate within the housing. A
the gear teeth and the cavity wall, where the gears mesh and clearance is made between tip of the gears and the housing
close, and the mating surfaces of the gears, the pump body and which is known as tip clearance.
the end cap [2].
In order to improve the design for fuel metering, a good
first step is to develop mathematical model for ideal flow rate
and tip leakage. Prediction of Ideal flow rate has been studied
by El-Bahloul and Yasser Ali [3,4]. In their research only the
gears with circular-arc tooth profile are discussed. Manring and
Kasaragadda [5] presented a simple approach to find a solution
for the instantaneous length of action for the two contacting
teeth in order to study the flow ripple of an external gear pump
as it varies using different combinations of teeth for the driving
and driven gear. In this paper average flow rate for one flow
pulsation is mentioned which can help in predicting ideal flow
rate. A cavitation phenomenon also disturbs the ideal behavior
of gear pump. Borghi at al. [6] analyzed the influence of the
fluid modeling on cavitation and aeration detection and motors
inter-teeth volumes during the gears meshing process. In a Fluid
Power steady state simulation package MATLAB/SIMULINK
[7] the leakage flow is determined based on the assumption that
it is linearly proportional to the pressure differential across the
pump and is computed by the Hagen-Poiseuille formula. In this
method, however, leakage flow rate is calculated in terms of
volumetric efficiency which is determined by experiments.
Though all of this work has been valuable in and of itself,
none of this work has considered predicting the internal leakage
without experimentally determined Volumetric Efficiency. The
present study is aimed at developing an analytical model for
determining the actual flow rate with non-cavitating operating
conditions. The model predicts both the ideal flow rate and tip Figure 1. Meshing Gears Nomenclature
leakage flow rate.

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 External gear pump is operated by filling the space LEAKAGE FLOW RATE MODEL
surrounded by three sided wall (gear teeth and housing) with the Consider an external gear pump with equal number of teeth
fluid. The pump then imparts momentum to the fluid due to the (N1=N2) on both the driving and driven gear. When gear pump
rotational motion of gears. The fluid is then discharge at a rotates the restriction downstream creates a pressure difference
constant flow rate when one of the sides (housing) opens up. between inlet and outlet. Due to this pressure difference a
The meshed portion in the middle separates the high pressure leakage occurs through the internal clearances. There are three
region on the outlet to the low pressure region in the inlet and is sources of internal leakages:
not used for imparting momentum to the fluid.  Through the tips of the gear teeth and the cavity wall.
 Through the center where the gears mesh and close.
IDEAL FLOW RATE MODEL  Between the mating surfaces of the gears and the end
Gears used in the study are spur gears with involute teeth. caps.
Geometric calculations of gears are carried out on an In this paper the internal clearance is modeled as a narrow
ANSI/AGMA standard [8,9]. The gears are hobbed out of gap. The dimension of this narrow gap is calculated from tip
standard gear cutter. Gap between gear teeth and casing is gap. For metering application, gear pump parts were machined
maintained at a known value with a tolerance of ±3 microns. with a tight tolerance. This results in the negligibility of other
Both driving and driven gear has equal number of teeth. internal clearances (mentioned above) as compared to tip
Standard Pressure Angle and metric module is selected for the clearance. They are therefore neglected in this paper. The total
gears. Gears are modeled on Pro-Engineering Wildfire 3D CAD tip clearance is of the order of 100 microns.
software [10]. Surface Area (S) of the gear is measured using The fluid flow in a gear pump is steady-state and therefore
Analysis Module of CAD software. Area entrapped by single the leakage flow rate through a narrow gap is constant. The
gear teeth was evaluated by subtracting total circular surface leakage flow rate depends on the viscosity of fluid, internal
area by Gear teeth surface area. Volumetric displacement for a clearance, pressure difference between inlet and outlet etc. The
single gear is found out by dividing total entrapped volume per flow through a narrow gap is streamline or potential flow and
gear by the angle in radians the single gear move to discharge therefore justifies the use of Bernoulli’s equation [1];
total entrapped volume. The procedure is as follows:
2
Surface Area of Single Gear evaluated by CADsoftware  SG Q  CD At (P  P ) (8)
 Out In
Number of Teeth  N  N1  N 2
Thickness of Gear  w Where At is the area of the orifice. It is determined by
Outer Dimeter  D0 product of tip clearance (t) and thickness (w) of the gear,
2
D 
Area of Circle with Outer Diamter  AD 0    0  (1) At  t  w (9)
 2 
Total Entrapped Area per gear  Aetr (G )  SG  AD 0 (2) CD is the Discharge coefficient. Due to viscous friction,
Total Entrapped Volume per gear  Vetr (G )  Aetr (G )  w (3) the fluid velocity downstream of orifice is slightly less than the
Entrapped Area in a tooth  Aetr (T )  Aetr ( G ) / N (4) ideal and therefore coefficient of discharge is introduced to
account for this discrepancy. The Discharge coefficient is given
Entrapped Volumein a tooth  Vetr (T )  Aetr (T )  w (5)
by
N Vetr (T )
Volumetric Displacement  VD  2   (6)
2  CV CC
CD  (10)
2
 A 
Ideal Flow rate is then calculated by the product of 1  CC2  t 
Volumetric Displacement and angular velocity and is given by  AInlet 

QIdeal  VD   (7) Where AInlet is the area upstream of the orifice. CV and
CC are velocity and contraction coefficient respectively. They
Flow rate calculated using this method has a linear relation are difficult to compute but solutions have been made by
with rotational speed. This model is independent of the pressure several investigators for round and slit type sharp-edged orifices
difference between gear inlet and outlet. [11,12].

If the flow is turbulent and At<<AInlet then the theoretical

value of

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  difference can be maintained across the pump. A heat exchanger
CC   0.611 (11) is installed in the facility to maintain a constant temperature of
 2
24°C. Figure 2 shows the Computer Aided Drafting Model of
is used for all sharp edged orifices, regardless of the particular Positive Displacement Pump Power Transmission System.
geometry. In the present paper it is shown that the above
analysis is greatly simplified when one considers a constant Pressure Sensor Ports
Gear Pump Unit Gearbox
discharge coefficient CD=0.6 for turbulent tip leakage flow. The Electric Motor
orifice equation takes the familiar form:

2 P
QLeak  0.6 At (12)


This simplification occurs without any significant reduction

in the accuracy of the prediction. For very small tip clearance
and small pressure differences across gear pump one can
assume the flow to be laminar. Orifice equation for sharp edge
rectangular slit having a laminar flow has been determined
theoretically by West [13]. The leakage flow rate for a laminar
flow through clearance is given by
Figure 2. Gear Pump Test Rig
 b2 w
QLeak  ( POut  PIn ) (13)
32  TEST PROCEDURE
During machining, total radial clearance of the order of 100
where height(b) << (w)thickness. Discharge coefficient has microns between gear tip and housing for both the gears served
been found to be directly proportional to the square root of to ensure that the turbulent flow is established through tip
Reynolds number by many investigators and is given by clearance. The gears inlet pressure was set high enough in order
to avoid cavitation. Liquid Hydrocarbon Fuel is used for
experimentation. The pressure difference across the gear pump
Cd   Re (14)
was varied by changing the load pressure in the output line. The
load pressure was varied by a proportional valve. Initially the
Where quantity  depends on geometry and is called the pump was run from 0 to 10,000 RPM with no load pressure at
laminar flow coefficient. It is taken to be 0.157 for sharp-edged the exit. Due to frictional losses in the output line, the pressure
rectangular orifice. The transition Reynolds number (Rt) is difference across the pump was found to vary from 0.35 MPa to
determined by the intersection point of the two asymptotes 0.58MPa. Therefore, the pump was tested with different
Cd   Re and Cd  0.611 , pressure differences ranging from 0.6 MPa to 4.8 MPa. From
0.6 MPa to 0.8 MPa, pressure differences tests were conducted
2 with an increment of 0.1 MPa and from 1.3 MPa to 4.8 MPa,
 0.611 
Rt    (15) pressure differences tests were conducted with an increment of
   0.5 MPa. The rotational speed was varied from 1000 RPM to
10,000 RPM for a pressure difference ranging from 0.6 MPa to
Predicted Flow Rate can then be calculated by the 1.3 MPa , 1500 RPM to 10,000 RPM for a pressure difference
subtraction of ideal flow rate with the leakage flow rate for both of 1.8MPa, 2000 RPM to 10,000 RPM for a pressure difference
the gears. of 2.3 MPa to 3.3 MPa and 2500 RPM to 10,000 RPM for a
pressure difference of 3.8 MPa to 4.8 MPa. The reason for this
QPredicted  QIdeal  QLeak1  QLeak2 (16) increase in rotational speed with pressure difference is due to
the output line frictional loses and inability of proportional
EXPERIMENTAL SETUP valve to maintain constant pressure difference at lower
The facility used for the present study is the positive rotational speeds. For all cases, rotational speed was varied with
displacement pump facility with different adaptation for various an increment of 500 RPM. In order to get the readings for 0
types of pump. Variable Frequency Drive and Power MPa pressure difference, a gear was made having the same
transmitting system can rotate pump from 0 to 16000 RPM with geometry but with reduce gear thickness. Since reducing
a maximum torque of 120 N-m. Fluid inlet pressure to pump thickness will reduce the discharge flow rate and hence pressure
can be varied from 0 to 0.6 MPa. Maximum of 7MPa pressure loss in output line will be lower.

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 RESULTS AND DISCUSSION compared to ideal flow rate. This is due to the inclusion of
Figure 3 shows the gear pump characteristic curves of flow internal leakage in an experimental data. Furthermore, internal
rate (Q) against shaft rotational speed (  ) at a pressure leakage increases with the increase in pressure difference which
difference (∆P) of 0.0 MPa. Two curves are shown, one is an shows strong dependability of internal leakage on pressure
ideal curve determined by Ideal Flow Rate Model Approach. difference across the pump.
Second dotted curve is experimentally determined on a positive
displacement test rig. Scale is chosen to be 1000 RPM on x-axis 1700
and 20 LPH on y-axis. As is clear from the figure that for zero 1500
pressure difference, experimental results are in close agreement ∆P = 0.7 MPa
1300
with the ideal results. Therefore ideal flow rate model can be

Flow Rate, LPH

implemented in predicting performance curve of gear pump for 1100
zero pressure differences. Maximum relative error between 900
ideal and experimental data is found to be 18% at 7500 RPM. 200 LPH
700
Ideal
160 500 Predicted
Experimental
140 300
∆P = 0.0 MPa
120 100
2000 3000 4000 5000 6000 7000 8000 9000 10000
Flow Rate, LPH

100
Rotational Speed, RPM

80 Figure 5. Gear Pump Characteristic Curves at ∆P=0.7 MPa

20 LPH
60
1700
40 Ideal
Experimental
1500
20 ∆P = 0.8 MPa
1300
0
Flow Rate, LPH

1100
0 1000 2000 3000 4000 5000 6000 7000 8000
Rotational Speed, RPM 900
200 LPH
Figure 3. Gear Pump Performance at ∆P=0.0 MPa 700
Ideal
500 Predicted
Figure 4 to Figure 14 shows flow rate against rotational Experimental
speed at pressure differences of 0.6 MPa ~ 4.8 MPa. Ideal flow 300

rate curve is in direct proportion to rotational speed. Predicted 100

flow rate curve obtained by deducting tip leakage flow rate 2000 3000 4000 5000 6000 7000 8000 9000 10000
from ideal flow rate also shows linear behavior but with Rotational Speed, RPM

different ordinate intercept. Figure 6. Gear Pump Characteristic Curves at ∆P=0.8 MPa
1700
1800
1500
∆P = 0.6 MPa 1600
1300 ∆P = 1.3 MPa
1400
Flow Rate, LPH

1100
Flow Rate, LPH

200 LPH 1200

900
1000
700 200 LPH
Ideal 800
500 Predicted Ideal
Experimetal 600 Predicted
300 Experimental
400
100
2000 3000 4000 5000 6000 7000 8000 9000 10000 200
Rotational Speed, RPM 2000 4000 6000 8000 10000 12000
Rotational Speed, RPM
Figure 4. Gear Pump Characteristic Curves at ∆P=0.6 MPa
Figure 7. Gear Pump Characteristic Curves At ∆P=1.3 MPa
Experimental data is represented as dotted line. Scale is
At low pressure difference and low rotational speed,
chosen to be 1000 RPM on x-axis and 200 LPH on y-axis.
predicted flow rate is in close agreement with the experimental
Experimentally determined flow rate is found to be lower as

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 results. At high rotational speeds, predicted results deviates RPM. Ideal approach on the other hand overestimates the
from experimental data. This is due to the inclusion of internal experimental data. At low rotational speed and high pressure
leakages occurring between gears and end faces, and where the difference, the predicted results underestimate while ideal
gears mesh together. These internal leakages are neglected in results overestimate the experimental results. The predicted
proposed leakage model. results underestimates in a way no worse than the
overestimation of ideal results.
1800

1600 1700
∆P = 1.8 MPa
1400 1500
∆P = 3.3 MPa
Flow Rate, LPH

1200 1300
1000

Flow Rate, LPH

1100
200 LPH
800 900
200 LPH
600 Ideal 700
Predicted
400 500
Experimental Ideal
200 Predicted
300
2000 4000 6000 8000 10000 12000 Experimental

Rotational Speed, RPM 100

2000 4000 6000 8000 10000 12000
Figure 8. Gear Pump Characteristic Curves At ∆P=1.8 MPa
Rotational Speed, RPM

1800
Figure 11. Gear Pump Characteristic Curves At ∆P=3.3 MPa

1600
1700
∆P = 2.3 MPa
1400
1500
∆P = 3.8 MPa
Flow Rate, LPH

1200
1300
1000
Flow Rate, LPH

1100
200 LPH
800
900
200 LPH
600 Ideal 700
Predicted
400 500
Experimental
Ideal
200 300 Predicted
2000 4000 6000 8000 10000 12000 Experimental
Rotational Speed, RPM 100
Figure 9. Gear Pump Characteristic Curves At ∆P=2.3 MPa 2000 4000 6000 8000 10000 12000
Rotational Speed, RPM

1700 Figure 12. Gear Pump Characteristic Curves At ∆P=3.8 MPa

1500
1700
∆P = 2.8 MPa
1300
1500
∆P = 4.3 MPa
Flow Rate, LPH

1100
200 LPH
1300
900
Flow Rate, LPH

1100
700
900
500 200 LPH
Ideal
700
Predicted
300
Experimental 500 Ideal
100 Predicted
2000 4000 6000 8000 10000 12000 300
Experimental
Rotational Speed, RPM
100
Figure 10. Gear Pump Characteristic Curves At ∆P=2.8 MPa 2000 4000 6000 8000 10000 12000
Rotational Speed, RPM

As it can be seen that for any pressure differences the Figure 13. Gear Pump Characteristic Curves At ∆P=4.3 MPa
analytical approach used in this paper agrees very well with the
experimental data for rotational speed between 4000 ~ 8000 Also from the figure 9 to figure 14, it is clear that for high

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 pressure difference and high rotational speed, the comparison CONCLUSIONS
between leakage flow rate model and experimental data is very In the present study, orifice equation is implemented to
satisfactory while the ideal flow rate model overestimates the predict the Internal Leakage of an external gear pump. The
experimental data. The relative error between predicted and dimensions of rectangular orifice are determined from gear tip
experimental data for pressure differences ranging 0.6 MPa ~ narrow gap. The leakage flow rate model is determined based
4.8 MPa is found to be within 13% at a rotational speed of on the assumption that it is proportional to the square root of the
10,000 RPM. pressure differential across the pump. Experiments are
1700 conducted on positive displacement pump test rig at different
pressure differences and rotational speeds. Liquid Hydrocarbon
1500
∆P = 4.8 MPa fuel is used in the experimentation. At zero pressure difference
1300 across the pump, ideal flow rate model can be used to predict
performance of gear pump. Maximum relative error between
Flow Rate, LPH

1100
200 LPH predicted and experimental data is found to be 18% for 1000 ~
900
7500 RPM. At high pressure difference across the pump,
700 leakage flow rate model in addition to ideal flow rate can be
500 Ideal implemented for predicting the performance of an external gear
Predicted pump. Maximum relative error between predicted and
300
Experimental experimental data is found to be within 13% for 4000 ~ 10,000
100 RPM. From experimentation, it is concluded that internal
2000 4000 6000 8000 10000 12000
leakage is also dependent on rotational speed and increases with
Rotational Speed, RPM
the increase in rotational speed.
Figure 14. Gear Pump Characteristic Curves At ∆P=4.8 MPa
ACKNOWLEDGMENTS
Figure 15 shows the leakage characteristics of an external gear The author would like to thank Afzaal Azghar and Tauqeer
pump at a pressure difference of 0.6 ~ 4.8 MPa and rotational Ahmed for their assistance during experimentation of gear
speed of 4000 ~ 10,000 RPM. The rotational speed is plotted pump. The author would also like to thank the Institute of Space
with an increment of 2000 RPM. Scale is chosen to be 1 MPa Technology for the permission to carry out the described
on x-axis and 200 LPH on y-axis. Predicted results are investigation.
represented by solid line while experimental results are
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