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Analysis of the turbulence in the suction chamber of an external gear pump using
Time Resolved Particle Image Velocimetry
R. Castilla a, , J. Wojciechowski b , P.J. Gamez-Montero a , A. Vernet c , E. Codina a
a
LABSON - Department of Fluid Mechanics, Technical University of Catalonia, ES-08222 Terrassa, Spain
Institute of Aeronautics and Applied Mechanics, Technical University of Warsaw, Nowowiejska 24, PL- 00-665 Warsaw, Poland
ECOMMFIT, Department of Mech. Eng., Rovira i Virgili University, Avinguda dels Paisos Catalans, 26 Campus Sescelades ES-43007 Tarragona Catalonia, Spain
article
info
Article history:
Received 22 November 2007
Received in revised form
21 May 2008
Accepted 20 June 2008
Keywords:
Time Resolved Particle Image Velocimetry
External gear pump
Two-dimensional turbulence
Autocorrelation function
Integral timescale
a b s t r a c t
The use of air bubbles for the analysis of the turbulence in the suction chamber of a gear pump with
Time Resolved Particle Image Velocimetry (TRPIV) is considered. It is the first time, as far as the authors
know, that the flow inside a gear pump is observed with a non-intrusive technique. Although there are
drawbacks of using air bubbles as flow tracers, it is the only option available in this case, since solid
particles and water drops could drastically damage the steel-made gears. It is shown that if the bubbles
are small enough (around 100 m), the buoyancy is not a significant problem for the typical velocities
involved in the experiments. On the other hand, if the number of particles per interrogation area is
between 10 and 20, as is normally suggested in the literature, the modification of the speed of sound and,
hence, the danger of having a compressible flow, is also negligible. Using air bubbles as tracers for the
TRPIV, the turbulence for three experiments, at different diameter-based Reynolds numbers, is analysed.
The time series of the velocity at different distances to the gearing zone of the gear pump are considered,
as well as the wavenumber distribution of the density of energy, calculated from the vorticity field. The
results show that for high enough Reynolds number the integral timescale of the turbulence, obtained
from the autocorrelation function, is approximately the same as the gearing period. Also, the spectral
distribution in frequency show an energy transport to large scale, as well as the spectral distribution in
wavenumber. This latter shows also an stepper range related to the enstrophy cascade towards the small
scales. That suggests the two-dimensionality of the turbulence created in the suction chamber.
2008 Elsevier Ltd. All rights reserved.
1. Introduction
A gear pump uses the meshing of gears to pump fluid by
displacement. In a gear pump, this displacement is fixed, which
means that it pumps a constant amount of fluid per revolution.
There are two main types: external gear pumps which use two
external spur gears and internal gear pumps which use an external
and an internal spur gear. The present work is focused on the
performance of the external gear pumps.
As the gears rotate, they separate on the intake side of the pump,
creating a void and suction which is filled by oil. The fluid is carried
by the gears to the discharge side of the pump, where the meshing
of the gears displaces the fluid (see Fig. 1). The compact and simple
design of the gears and housing allows the pumping of the oil at
very high pressure, usually up to 300 bars.
Cv
2
(1)
378
Fig. 1. Scheme of an external gear pump. One of the wheels are driven by the other.
The fluid is transported from the suction chamber to the impulsion one. In this case,
from left to right.
Fig. 2. Schematic drawing of the test bench. The two hydraulic circuits are shown,
as well as the laser sheet, the high velocity digital video camera and the computer
for processing the images. The methacrylate test pump is displayed as a white box.
the oil from the tank and impulses it through a pressure fall of
typically 510 bars back to the tank again. This pump is driven by
an oleohydraulic motor, which is a component of the secondary, or
driver, circuit (under the table in Fig. 2). This motor is in turn driven
by an hydraulic power-pack. This scheme allows easy modification
of the rotational velocity of the test pump acting on the flow rate of
the driver circuit, but has the disadvantage that it is not possible to
select a certain velocity with precision and, furthermore, it is rather
unstable.
The high velocity digital camera used in the experiments was
a Photron Ultima APX-RS with 17.5 m square pixels in a 1024
1024 pixel sensor. This camera can record up to 3000 frames per
second at full resolution and 250 000 fps at limited resolution, and
has a buffer memory of 2 GB. We have made tests at full resolution
at 500 fps and 1000 fps, since it was the limit admissible frequency
of the laser used. This was a pulsed green laser (526.5 nm) with 1 mJ
of energy per pulse externally synchronised. The camera was used
as master time-base, but its behavior was rather unstable. Some
similar problems with the output syncronisation signal with this
camera have been also reported by Wernet [8]. As noted by Wernet,
it is advisable the use of an external pulse generator.
The collected images have been processed with the open source
software gpiv [9]. The images were obtained with maximum
resolution, i.e. 1024 1024 pixels at 500 Hz and 1000 Hz with
an 105 mm objective. The buffer memory of the camera allows
recording up to 2048 images per experiment, with a duration of
slightly more than 4 and 2 s, respectively.
2.2. Flow seeding
Most PIV experiments reported in the literature use small solid
particles for flow seeding. However, in this case, the use of solid
material is ill-considered, since the metal-metal contact between
the teeth can produce material erosion and, eventually, damage the
transparent surface of methacrylate. The use of water drops has
been also discarded, since it can produce oxidation of the steelmade gears. It has been decided to use air bubbles, in spite of some
disadvantages: (a) the size of the bubble is not easily controllable,
(b) the density ratio is very large ( 600), (c) the presence of gas
in a liquid can reduce the velocity of sound and, hence, can make
the flow becoming compressible at relatively low velocity [6]. The
first item refers not only to the setting of the bubbles size, but also
to the uniformity of this size in one experiment. As pointed out by
Raffel et al. [7], a large variability in the size of the particles can
379
make difficult the estimation of the velocity lag. But, in the present
case, it is not an important factor, since the air bubbles have a very
low inertia.
The second issue could be important because of buoyancy
effects in the particles, which can make the bubble to leave the
laser light sheet before it reaches the end of the test section. But,
as it is shown below, it actually has a secondary significance.
From the Stokes law the drag force over the bubble of diameter
Db is
FD = 3 Db vz
(2)
vz =
1 D2b g l
18
(3)
hvy i
(4)
1 D2b g l
18 hvy i
(5)
1 D3b l2 g
18
(6)
Fig. 3. Ratio of vertical deviation and test section length in function of mean
horizontal velocity for several bubble diameter. The limit value for this case, H /L
0.025, is indicated as an straight horizontal line.
the bubbles are formed only by the action of the buoyancy force,
the relation
d0 =
D3b l g
(7)
is obtained [12,13]. For the mineral oil used, the superficial tension
is = 28.9 N/m. That gives, for Db 0.15 mm, a hole of diameter
d0 0.17 m. It is difficult to obtain a capillar of this diameter and,
also, it should be needed a large quantity of them. Microporous
ceramics with some tenth of microns large pores, normally used
for filtering the water in aquaria, are currently being tested with
compressed air.
Finally, we consider the effect of gas-liquid mixture on the sonic
speed of the flow. According to Brennen [6], a sufficiently high
volume fraction of air could reduce the sonic speed down to 20
m/s. For low values of the pressure and considering that the gas
maintains its temperature constant, the expression for the sonic
speed c is
s
c=
l (1 ) + g
,
(8)
,
(9)
4M 2 D3b nb
3N 2 e
(10)
380
In summary, the use of air bubbles, which is the only option for
these experiments, has been grounded. It has been argued that if
the size of the bubbles is smaller than 0.3 mm and the quantity does
not exceed the number of 15 to 20 bubbles per interrogation area,
the effects of buoyancy and compressibility are not important.
2.3. Experimental results
Results for three experiments, at different rotational velocity
and, hence, different diameter-based Reynolds number, ReD , are
presented here. This Reynolds number is defined as
D2
ReD =
.
(11)
clearly seen in the two upper corners. For space saving, it is only
shown here the sequence for ReD = 2400 (experiment 2).
In Fig. 7 the profiles of the streamwise component of the
velocity are plotted for different distances for experiment 1 (Re
= 520). These are mean profiles for all the temporal series, and
they are normalised with the reference velocity D (see Table 1).
If we consider the total y mean velocity (i.e. spatial as well as
temporal mean) hvy it , from the definition (1) and with the cross
section of the chamber, it is easy to theoretically calculate its
normalised value, hvy it /D = 0.123. The experimental results
are exposed in Table 1. For experiments 1 and 3 the mean value
measured is slightly lower, about 0.105. For experiment 2 it is
about 0.150. The difference in this latter experiment can explained
because the laser sheet is centered in the z direction, and it is
expected the velocity magnitude to decrease in both z directions,
because of the boundary layers in the upper and lower surfaces.
Some measurements in the yz plane should be performed in
order to confirm this point. More disconcerting is the low values
for the first and the third experiments. It could be due to a
poor estimation in the wall zones. A faster filming compared
to the others experiments and an inadequate illumination could
be responsible of this underestimation of the mean velocity for
experiments 1 and 3.
Velocity time series in the center line of the flow have been
analysed for the three experiments, at different distances d from
gearing zone. This distance is related to the diameter of the
gearwheels, D. In Fig. 8 the spectral density of energy is shown
for all experiments and distances. The points of measurements are
those displayed in Fig. 5, separated by a distance 0.1 D. Spectra
are calculated, as usual, as the square of the Discrete Fourier
Transform of velocity [14]. Frequencies are normalised with the
angular velocity of the experiment. In all the experiments the peaks
associated to gearing cycles are visible at f 2 / = 11, as well
as the first harmonic in 22 for the two firsts experiments. The
slope 5/3, corresponding to Kolmogorovs law in homogeneous
and isotropic turbulence, is shown for the purpose of comparison.
It seems that, as typical of two-dimensional turbulence [15,16],
for high enough Reynolds number, energy is being transferred
from the stirring scale to bigger ones. The smaller scales are not
properly resolved and thus numerical noise is visible instead of
the enstrophy cascade. It is suspected that this is because of
experimental uncertainty at high frequencies. For low Reynolds
number (experiment 1) there is no energy transferred to bigger
scales and the slope to lower scales is shyly observed for a small
range.
If the attention is paid at low frequencies (big scales), it is clearly
observed that the transfer of energy is lower with low rotational
velocity (low Re) and farther out.
The autocorrelations of velocity have been calculated as well. It
is defined, as usual [17], as
v 0 (t )v 0 (t + )
Rt ( ) =
v 0 (t )2
(12)
(a) t = 0.00 s.
381
Table 1
Description of experiments
Exp.
n (rpm)
ReD
D (m/s)
hvy i
D
1
2
3
55
245
365
520
2400
3400
0.31
1.37
2.04
1000
500
1000
16 16
32 32
64 64
630 322
494 258
494 258
0.105
0.150
0.105
382
Z
TI =
Rt ( )d
(13)
383
Fig. 10. Spectral density of energy in wavenumber for the three experiments.
(high k) and energy to big scales. For experiment 3 the slope of the
direct enstrophy cascade is even bigger than 3, as reported usually
in DNS experiments [21] and in experiments [16]. The separation
region between the direct and the inverse cascades corresponds to
the stirring scale, which is approximately, between one and two
tenth of D, i.e., the size of the teeth.
3. General discussion and conclusions
The possibility of using air bubbles to investigate, with TRPIV,
the flow inside the suction chamber of a gear pump is being
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