22ME404

Hydraulics and Pneumatics

R.Isaac
 Unit I
Fluid Power Principles and
Hydraulic Pumps
Basic Methods of Power Transmission
Electrical Power Transmission
Mechanical Power Transmission
Fluid Power Transmission
Fluid Power
To convert, Transmit, Control and Apply fluid
energy to perform useful work.
A fluid can be either a liquid or a gas.
Fluid Power System = Hydraulic + Pneumatic
Systems Systems
Hydraulics employs pressurized liquid and
Pneumatics employs compressed air.
Why Fluid Power?
Easy and Accuracy of control.
Multiplication of Force.
Constant Force or Torque.
Safety and economy.

Automatic protection against overloads.

Easy of Shock absorption.
Application of Fluid Power,
Agriculture: Tractors and farm equipment's like ploughs,
movers, chemical sprayers, fertilizer spreaders.
Aviation: Fluid power equipment's like landing wheels on
aeroplane and helicopter, aircraft trolleys, aircraft engine test
beds. https://www.techno-press.org/content/?page=article&journal=scs&volume=33&num=2&ordernum=5

Building Industry: For metering and mixing of concrete

ingredients from hopper.
Construction Equipment: Earthmoving equipment's like
excavators, bucket loaders, dozers, crawlers, and road graders.
Defence: Missile-launch systems and Navigation controls.
Application of Fluid Power,
Entertainment: Amusement park entertainment rides like
roller coasters.
Fabrication Industry: Hand tools like pneumatic drills,
grinders, bores, riveting machines, nut runners.
Food and Beverage: All types of food processing equipment,
wrapping, bottling.
Foundry: Full and semi-automatic moulding machines, tilting
of furnaces, die casting machines.
Material Handling: Jacks, Hosts, Cranes, Forklift, Conveyor
system.
Types of Fluid Power
Based on Fluid,
Hydraulic System
Pneumatic System
Based on Control System,
Open loop system
Closed loop system
Based on the Type of Control
Fuzzy logic control
Electrical control
Electronic control
Properties of Fluids,
Density
Specific Gravity
Specific Volume
Viscosity : is a measure of the fluid’s internal
resistance offered to flow.
Properties of Fluids,
If the viscosity of the hydraulic oil is higher than
the recommended,
The viscous oil may not be able to pass through
pipe.
The working temperature will increase because
there will be internal friction.
The consumption of power will increase.
Properties of Fluids,
If the viscosity of the hydraulic oil is lesser than
the recommended,
The internal and external leakage will increase.
It cannot lubricate properly and will lead to
rapid wear of the moving parts.
Properties of Fluids,
Viscosity Index,
a number indicating the effect of a change in
temperature on viscosity.
The lower the viscosity index, the greater the
variation in viscosity with changes in
temperature and vise versa.
Properties of Fluids,
Oxidation Stability,
Oxidation is caused by a chemical reaction
between the oxygen of the dissolved air and the
oil.
The oxidation of the oil creates impurities like
sludge, insoluble gum and soluble acidic
products.
The rise of system temperature accelerates the
oxidation.
Below 55°C, the oxidation low. But above 65°C,
for every 9°C rise in the system temperature the
Properties of Fluids,
Demulsibility,
The ability of a hydraulic fluid to separate
rapidly from moisture and successfully resist
emulsification.
Lubricity,
To avoid more wear, the hydraulic fluid will be
able to lubricate the moving parts efficiently.
Properties of Fluids,
Rust Prevention,
The moisture entering into the hydraulic
system with air causes the parts made ferrous
materials to rust.
The additives named Inhibitors are added to
the oil to keep the moisture away from the
surface.
Pour Point,
It is of great importance in cold countries where
the systems are exposed to very low
temperatures.
Properties of Fluids,
Neutralisation Number,
a number is measure of the acidity or alkalinity
of a hydraulic fluid.
Cohesion and Adhesion,
Intermolecular attraction between molecules of
the same liquid is called Cohesion.
The attraction between the molecules of a
liquid and the molecules of a solid boundary
surface in contact with the liquid.
Properties of Fluids,
Cavitation,
when the fluid pressure is dropped below the
vapour pressure due to a flow phenomenon,
then there will be local boiling and a vapour
bubbles will form.
Surface Tension
Compressibility
Cloud Point
Flash Point and Fire Point
Compatibility
Selection of Hydraulic Fluid,
Chemical stability to prevent formation of
sludges, etc.,
Free from acidity so that the fluid is non corrosive
to the metals in the system.
Lubricating properties to avoid wear in moving
parts.
Viscosity and Viscosity Index.
Minimum Toxicity.
Good Demulsibility.
Selection of Hydraulic Fluid,
Better fire resistance.
Good heat dissipation capability.
Good Oxidation stability.
Better rust and corrosion preventive properties.
Types of Hydraulic Fluid,
Petroleum-based fluid
Water
Glycol
Water glycol
Emulsions
Synthetic fluids
Vegetable oils
Biodegradable hydraulic fluids
Types of Fluid,
Petroleum Oils,
The characteristic of petroleum based hydraulic
oils are controlled by the type of crude oil used
Naphthenic, Aromatic, Paraffinic
Naphthenic oils have low viscosity index so it is
unsuitable where the oil temperatures vary too
widely.
Aromatic have a higher presence of benzene
and they are more compatible with moderate
temparture variation.
Paraffinic oils have a high viscosity index and they
Types of Fluid,
Advantages of Petroleum Oils,
Excellent lubricity.
Non Corrosive.
Good heat dissipation capability.
Longer life.
Disadvantages of Petroleum Oils,
Tendency to oxidise rapidly.
Not fire resistance.
Types of Fluid,
Water,
Water is treated with chemicals before being
used in a fluid power system.
This treatment removes undesirable
contaminants.
Advantages,
Fire resistant.
Inexpensive and Rapidly available.
Disadvantages,
No lubricity.
Corrosive and Temperature limitations.
Types of Fluid,
Glycols,
Organic compounds belonging to the alcohol
family. Polyglycols, Polyalkylene glycols.
Advantages,
Good lubricity,
High flash point, High viscosity index and low
volatility.
Disadvantages,
Not good fire resistance
Poor high temperature oxidation
Types of Fluid,
Water Glycols,
Solution of water and glycol.
Contain 35% to 55% of water.
Advantages,
Good fire resistance.
Inexpensive, Compatible with most pipe
compounds and seals.
Disadvantages,
Not good for high bearing loads
Poor corrosive resistance.
Types of Fluid,
Water oil emulsion,
Contain 40% of water, rest is oil, emulsifier and
other additives.
The water dispersed in microscopic droplets
surrounded by a film of oil.
Advantages,
Good fire resistance.
Inexpensive, Compatible with most pipe
compounds and seals.
Disadvantages,
Not good for high bearing loads & Poor corrosive
resistance.
Types of Fluid,
Phosphate Esters,
Organic alcohols attached to a phosphorous atom.
They have high thermal stability.
Prevent building-up of sludge.
Advantages,
Excellent fire resistance.
Good lubricity.
Non corrosive.
Disadvantages,
Fairly Expensive.
Basics of Hydraulics,
Relationship between Pressures,
Basics of Hydraulics,
Laminar flow & Turbulent Flow,
Basics of Hydraulics,
Continuity Equation,
Basics of Hydraulics,
Bernoulli’s Equation,
Basics of Hydraulics,
Darcys’ Equation & Chezy’s Equation,
Basics of Hydraulics,
Darcys’ Equation & Chezy’s Equation,
Basics of Hydraulics,
Pascal's Law,
The pressure or intensity of pressure at a point in
a static fluid is equal in all directions.
Basics of Hydraulics,
Application of Pascal's Law,
Basics of Hydraulics,
Application of Pascal's Law,
Basics of Hydraulics,
Application of Pascal's Law,
Basics of Hydraulics,
Application of Pascal's Law,
A hydraulic press has a ram of 30 cm diameter
and a plunger of 4.5 cm diameter. Find the
weight lifted by the hydraulic press when the
force applied at the plunger is 500N.

A hydraulic press has a ram of 20 cm diameter

and a plunger of 3 cm diameter. It is used for
lifting a weight of 30 kN. Find the force required
at the plunger.
Basics of Hydraulics,
Application of Pascal's Law,
Consider the arrangement similar to that shown in figure.
The piston diameter of the small cylinder is 25 mm and the
large cylinder is 100 mm. The force needed at the large
cylinder piston is 2000 N. a.Calculate the amount of force
applied at the small cylinder piston. b.How far the large
piston will move if the small piston moves 100 mm.
Basics of Hydraulics,
Work,
Whenever a force acts on a body and the body
undergoes a displacement in the direction of the
force then the work is said to be done.
WD = Force x Distance moved N-m or J
Power,
Power is rate of work done or workdone per unit
time.
Power = Workdone / Time taken J/s or Watt
Sources of hydraulic power,
Pumping Theory,
The positive displacement hydraulic pump is a device that
converts mechanical energy into hydraulic energy.
When driven by its motor (prime mover), it basically
performs two functions.
Firstly, it creates a partial vacuum at the pump inlet port.
This vacuum enables the atmospheric pressure to force
fluid from the reservoir (tank) into the pump.
Secondly, the mechanical action of the pump traps this
fluid within the pumping cavities, transports it through the
pump, and forces it into the hydraulic system.
Sources of hydraulic power,
Classifications of Pumps,
Hydrodynamic or Non-positive
displacement pumps
For Low pressure and High volume of flow.

Hydrostatic or Positive displacement pumps

Discharges fixed quantity of fluid per
revolution of the pump shaft.
Discharge of fluid is not dependent on system
pressure.
Suitable for Fluid Power System.
Sources of hydraulic power,
Classifications of Pumps,
Sources of hydraulic power,
Classifications of Pumps,
Sources of hydraulic power,
External Gear Pumps
Gear Internal Gear Pumps
Lobe Pumps
Pumps Screw Pumps

Vane Unbalanced Vane Pumps

Balanced Vane Pumps
Pumps

Piston Axis Design

Bent Axis
Pumps Swash Plate Type
Radial Design
Hydraulic pumps – External Gear
Pump,
Hydraulic pumps – External Gear
Analysis of External gear pumps,
Pump,

𝜋
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑉 𝐷 = ( 𝐷𝑜 − 𝐷 𝑖 ) 𝑏 𝑚
2 2 3
4

b = Width of the gear in m m = Module of gear

Z = No. of teeth in driver or driven gear N = rpm of pump
α = Pressure angle of the gear
Do & Di = Outside & Inside dia. of gear teeth in m
Di = Do – 2 (addendum + dedendum)
Hydraulic pumps – External Gear
Pump,
Hydraulic pumps – External Gear
Pump,
Hydraulic pumps – External Gear
Pump,
The gears in the gear pumps can be of Spur gear, Helical
gear, Herringbone gear.
For Low capacity Spur gear pumps are used,
For higher capacity helical or herringbone gear pumps
used. Both helical and herringbone rear pumps used for
high viscosity oils.
Spur gear pumps used for below 5bar pressure
application.
Helical gear pumps used for below 15bar pressure
application.
Herringbone gear pumps used upto 200bar pressure
Hydraulic pumps – External Gear
Pump,
Advantages of External gear pumps,
Self Priming
Constant discharge with negligible pulsations for a
set of rotor speed.
Volumetric efficiency is high.
Small space required and light in weight.
Disadvantages of External gear pumps,
The fluid to be pumped must be clean.
Depend on the liquid pumped to lubricate the
internal moving parts and can be damaged if run dry
Hydraulic pumps – Internal Gear
Pump,
Hydraulic pumps – Internal Gear
Pump,
External gear pump Internal gear pump
Two identical gears positioned Operates a “gear within a gear”
side by side, rotating into one principle, whereby one gear (the
another. One gear is driven by idler) is positioned inside another
the motor and in turn moves the gear (the rotor).
other gear.
Works to higher pressures upto Works to moderate pressures upto
200 bar. 7 bar.
Compact construction and less Bulkier construction, more
expensive design. expensive design.
For medium/low temperature Can handle high temperature
fluids. fluids. Often supplied with a
heating jacket to maintain the
fluid temperature
Larger outlet sizes and high Smaller outlet sizes and Low
capacities. capacities.
Bi-directional if spur gears are Always bi-directional flow.
Hydraulic pumps – Gerotor Pump,
Hydraulic pumps – Lobe Pump,
Hydraulic pumps – Screw Pump,
Hydraulic pumps – Unbalanced Vane
Pump,
Hydraulic pumps – Unbalanced Vane Pump,
Analysis of Unbalanced vane pumps,

𝜋 3
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑉 𝐷 = ( 𝐷𝐶 + 𝐷 𝑅 ) 2𝑒 𝑚𝑎𝑥 𝐿𝑚
4

DC = Diameter of the cam ring in m

DR = Diameter of the rotor in m
L = Width of the rotor in m
N = Rotor speed in rpm
e = Eccentricity in m
Hydraulic pumps – Balanced Vane Pump,
Hydraulic pumps – Balanced Vane Pump,
Hydraulic pumps – Axial Piston
Pump Bent Axis
Type
Hydraulic pumps – Axial Piston
Pump Swash
Plate Type
Hydraulic pumps – Radial Piston
Pump
Comparison between pumps,
Gear Pump Vane Pump Piston Pump

֍ If consists of two gears in ֍ It consists of a cylindrical ֍ It consists of a cylinder block

mesh with each other, rotor with radial slots, vanes with axial or radial bores,
mounted inside a closed are inserted in the slots. pistons are inserted in the
casing. ֍ The rotor is mounted with an bores.
֍ One is driver and the other offset in casing. ֍ One end of the piston is
Construction is driven. connected to rotating
component.

֍ When the driver is rotated ֍ Rotation of cylindrical rotor ֍ Rotation of the moving
by means of any prime causes the size of the pockets component causes the
mover, driven will also to grow continuously on one pistons to reciprocate in the
rotate. side and to reduce on the bores.
Working ֍ Thus the oil is sucked, other side. ֍ Half rotation of the cylinder
Principle surrounded between gear ֍ This causes filling of oil on block causes suction of oil
teeth and casing, carried suction side and delivery of oil into the bores and the next
from inlet to outlet. on the other side. half causes discharge.
Comparison between pumps,
Gear Pump Vane Pump Piston Pump

Working Up to 200 bar 70 to 140 bar 140 to 850 bar

Pressure

Discharge Up to 45 m3/hr Upto 20 Upto 45

Speed of Upto 2500 rpm 1200 to 1800 rpm 1200 to 3000 rpm
the pump

Volumetric 80 % to 90 % 90 % to 95 % 95 % to 98 %
Efficiency
Hydraulic pumps – Graphical
symbol
 Unit II
Hydraulic Actuators and
Control Components
Hydraulic Actuators
The fluid discharged by the pump is directed to
the ‘Hydraulic actuator'.
The actuator converts the pressure energy of
the fluid into mechanical energy.
Linear motion or Rotary motion.
Hydraulic Actuators
Basic types of hydraulic actuator,
Rotary (continuous rotation) motion-hydraulic
motor

Rotary (limited angle of movement) motion-semi-

rotary actuator

Linear motion-hydraulic cylinder

Hydraulic Motors
Instead of pushing on the fluid as pumps do,
motors are actuated by the fluid.
The fluid forces the motor to create a rotary
motion.
This rotary motion of the motor is mechanically
linked to the workload.
Hydraulic motors develop torque and produce
continuous rotary motion.
Hydraulic motor converts hydraulic energy into
mechanical energy, which is just opposite to the
Classification of Hydraulic Motors,
Gear type motors
Vane type motors
Piston type motors
Axial piston motors
Swash plate type
Bent axis type
Radial piston motors
Eccentric cam shaft type
Multi lobe cam type
Semi Rotary Actuators,
Vane type actuators
Single vane
Double vane
Rack and pinion semi-rotary actuator
Lever arm semi-rotary actuator
Chain and sprocket semi-rotary actuator
Helical screw semi-rotary actuator
Linear Motion ,
Hydraulic Cylinders
Classification of Hydraulic Motors,
Radial piston motors
Eccentric cam shaft type
Multi lobe cam type
Semi Rotary Actuators,
Vane type actuators
Single vane * *
Double vane
Rack and pinion semi-rotary actuator *
Lever arm semi-rotary actuator
Chain and sprocket semi-rotary actuator
Helical screw semi-rotary actuator
Hydraulic Cylinders ,
Fluid power into linear mechanical force and
motion.
Types of hydraulic cylinders,
Single acting cylinder
Double acting cylinder
Special type cylinders,
Double rod cylinder
Tandem cylinder
Telescoping cylinder
Single Acting Cylinders ,

Graphical Symbol
Double Acting Cylinders ,

Graphical Symbol
Double Rod Cylinders ,

Graphical Symbol
Tandem Cylinders ,

Graphical Symbol
Telescoping Cylinders ,

Graphical Symbol
Cylinder Cushioning ,
Mounting Configurations of
Cylinders ,
Fixed Centerline Mounts,
Mounting Configurations of
Cylinders ,
Fixed Non - Centerline Mounts,
Mounting Configurations of
Cylinders ,
Pivoted Centerline Mounts,
Control Components
Direction Control Valve
Flow Control Valve
Pressure Control Valve
Valve Actuating Methods
Direction Control Valve
Classification of Direction Control Valves
(DCV),
As per Construction,
Poppet Valves or Seat Valves
Spool Valves
Rotary Spool Valves
Shuttle Valve
As per Function,
2/2 way Valve
3/2 way Valve
4/2, 4/3, 5/3 way Valve
Check Valve or Non-Return Valve,
Shuttle Valve,
2/2 way valve,
3/2 way valve,

3/2 way valve,

4/2 way valve,
4/3 way valve,
5/2 way valve,
Rotary Spool valve,
Flow Control valve (FCV),
Non-pressure compensated
Gate FCV
Globe FCV
Needle FCV
Pressure compensated
Gate valve - FCV,
Globe valve - FCV,
Needle valve - FCV,
Pressure compensated - FCV,
Pressure Control valve,
Pressure relief valve
Pressure reducing valve
Unloading valve
Counterbalance valve
Pressure sequence valve
Pressure relief valve,
Compound pressure relief valve (pilot
operated pressure relief valve),
Pressure reducing valve,
Unloading valve,
Counter balance valve,
Pressure sequence valve,
Servo Valves
Servo Valves – Single stage servo
valve
Servo Valves – Two stage servo
valve
Proportional Control Valve
Proportional pressure reducing
valve
Fluid Power ANSI Symbols
Fluid Power ANSI Symbols
Fluid Power ANSI Symbols
Fluid Power ANSI Symbols
Fluid Power ANSI Symbols
 Unit III
Hydraulic Circuits and Systems
Accumulators,
A hydraulic accumulator is a device that stores
the potential energy of an incompressible fluid
held under pressure by an external source
against some dynamic force.
This dynamic force can come from three different
sources,
Gravity
Mechanical
Compressed Gas
Accumulators,
The stored potential energy in the accumulator is
a quick secondary source of fluid power capable of
doing useful work as required by the system.
Classification of Accumulators,
Weight loaded or Gravity type
Spring loaded
Gas loaded type
Non-separator type
Separator type
Piston type
Diaphragm type
Bladder type
Application of Accumulators,
Application of Accumulators,
Weight loaded or Gravity type
Accumulator,
Spring loaded Accumulator,
Gas loaded Accumulator – Non-separator
type,
Gas loaded Accumulator – separator -
Piston type,
Gas loaded Accumulator – separator -
Diaphragm type,
Gas loaded Accumulator – separator -
Bladder type,
Intensifier,
Application of Intensifier (Pressure Booster
Circuit),
Speed Control Circuits or
Meter-In, Meter-Out, Bleed Off Circuits
Dual Pump Hydraulic System
Regenerative Circuit
Synchronizing Circuit with Cylinder in
Series
Synchronizing Circuit with Cylinder in
Parallel
Sequencing Circuit
Fail - Safe Circuit
Pump – Unloading Circuit
Reciprocation Circuit
Air over Oil Circuit
Hydrostatic Transmission System,
Hydrostatic Transmission System,