Design and Modeling of Fluid Power Systems

ME 597/ABE 591 - Lecture 2

Dr. Monika Ivantysynova

MAHA Professor Flud Power Systems

MAHA Fluid Power Research Center

Purdue University
Contents

1. Introduction and overview of components, circuit and system design methods

2. Fluid properties, modeling of transmission lines, impedance model of lines

3. Displacement machines design principles

4. Steady state characteristics, measurement methods and modeling

5. Gap flow models

6. Flow and pressure pulsation

Design and Modeling of Fluid Power

© Dr. Monika Ivantysynova 2
Systems, ME 597/ABE 591
Fluid Power System Design

• Choose max operating pressure

• Size the hydraulic motor
• Calculate flow requirement
• Select type of control, in case of valve control select type
and size of control valve
• Select pump size based on flow requirement and speed
of prime mover
• Calculate required line diameter
• Add additional components like pressure relief valve,
logic elements, filter, reservoir, accumulators

Design and Modeling of Fluid Power

© Dr. Monika Ivantysynova 3
Systems, ME 597/ABE 591
Fluid Power System Design
Example

φ
φ

φ
φmax /s
φmaxmax
Flight /s
max Flight
M
l
during FmaxmaxFlight
Flight

Design and Modeling of Fluid Power

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Systems, ME 597/ABE 591
MAHA
Fluid Distance Learning
Properties

Density Compressibility Viscosity

Properties of Fluids

Change of density with pressure Viscosity - temperature behavior

Change of density with temperature Viscosity - pressure behavior

•Oxidative, hydrolytic and thermal stability •Air/Gas absorption

•Foaming (release air without forming emulsions) •Pour Point
•Lubricity (boundary lubricating property) •Flash point/ fire point
Design and Modeling of Fluid Power
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Systems, ME 597/ABE 591
Fluid Properties
Compressibility of a real fluid
Density is defined: and
Change of fluid volume with pressure and temperature:

Isothermal coefficient of compressibility

dV = -V ⋅ βp ⋅dp

Bulk modulus is defined as reciprocal

of compressibility coefficient

Therefore we can write: ⋅dp

Design and Modeling of Fluid Power

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17 Systems, ME 597/ABE 591
Fluid Properties
Bulk modulus
Fluid can be compressed isothermally or isentropically (adiabatic process)

Isothermal bulk modulus K Adiabatic bulk modulus KA

⋅ dp
1
V1
⋅ (p2 - p1)

V
2
V2
p1 p2
p
In practice secant bulk modulus KS is often used!

Design and Modeling of Fluid Power

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Influence of entrapped air

Due to entrapped air the compressibility of the fluid (fluid-air mixture) changes.

For the bulk modulus of fluid – air mixture K* can be derived:

p0 … atmospheric pressure
In a simplified way for the change of volume of the
fluid – air mixture dVM we can derive:

For isothermal process follows:

simplified:

Change of air volume with pressure: and for the change of fluid volume:

Design and Modeling of Fluid Power

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Influence of entrapped air

(1) and (2)

Due to VAir << VF we can make the following simplification: VF=V

then
(3)

Substituting Eq. (3) in Eq. (1) and (2) follows:

Example: Calculate how the bulk modulus of the fluid – air mixture with 0.5%
undissolved air at p = 100 bar=107 Pa is changed. The bulk modulus of the fluid
is K=2·109Pa.

Design and Modeling of Fluid Power

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Viscosity of a real fluid
The viscosity of a fluid is the measure of
its resistance to flow or of its internal y
p1=p2
friction. v0
According to Newton’s law the shearing v

h
stress between adjacent layers of a p1 p2
viscous fluid is proportional to the rate of
shear in the direction perpendicular to the x
fluid motion (flow direction).
µ … dynamic viscosity [Pa·s=N·s/m2]

are empirical constants for a given fluid, whereas

Typical values for mineral oil:

Design and Modeling of Fluid Power

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Viscosity of a real fluid
Kinematic viscosity

Kinematic viscosity: [m2·s-1] or [cSt]

ISO Viscosity Grades for mineral oils (ISO 3448)

ISO VG 10 mean value at 40°C 10 mm2·s-1 , (cSt)

ISO VG 22 22 mm2·s-1

ISO VG 32 32 mm2·s-1

ISO VG 46 46 mm2·s-1

ISO VG 100 100 mm2·s-1

Design and Modeling of Fluid Power

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Systems, ME 597/ABE 591
Viscosity-Temperature

Viscosity-temperature diagram

Ordinate: lg lg (ν+0.8)
Kinematic viscostiy [mm2/s]

Abszissa: lg T

Skydrol (Phosphate ester)

ISO viscosity grade reference temperature

Temperature [°C]
Design and Modeling of Fluid Power
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Systems, ME 597/ABE 591
Types of Hydraulic Fluids

Petroleum based fluids (mineral oils) usually with additives to

-prevent oxidation and corrosion HL
-reduce foaming
-improve lubricity HLP
-increase viscosity index HV
Water
Fire resistant fluids
- oil – water emulsions (20% H2O) - HFA
- water in oil emulsion (about 40% H2O) - HFB
- Polymer solutions with H2O - HFC
- water free synthetic fluids ( Phosphate ester) - HFD
Biodegradable fluids
-Vegetable oil base HTG
-Polyglycol base HPG
-Synthetic ester HE

Design and Modeling of Fluid Power

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Water versus Mineral Oil

50% reduction of
Viscosity 30 lower
pressure loss
Viscosity-temperature dependency 14 lower

Specific heat 2.3 higher Better cooling-

ability
5 times higher thermal conductivity

50% higher bulk modulus

Higher stiffness
Air –release ability 30times better

but Higher vapor pressure

Design and Modeling of Fluid Power

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Systems, ME 597/ABE 591
Vapor Pressure of Water

Vapor Pressure Water

Pressure [bar]

Water

Vapor

Temperature [°C]
pV H2O=0.1133 bar @ 50°C
pV mineral oil= 0.053Pa = 0.53 µbar @ 50°C
Design and Modeling of Fluid Power
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Fluid Properties

Thermal properties Specific heat c [ J/kg ·K]

Thermal conductivity λ [W/m ·K]

Solubility of gas Henry’s law

Cavitation

Design and Modeling of Fluid Power

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