GeneralFluidProperties

Four Functions of Hydraulic Fluid

1.

2.

3.

4.
 Fluid Power Systems
Principles learned in fluid dynamics are the
foundation for fluid power systems

Pascals Law
Pressure exerted anywhere in a confined
incompressible fluid is transmitted equally in all
directions throughout the fluid such that the pressure
ratio (initial difference) remains

Additional concepts
Static pressure, viscosity, conservation of mass,
momentum, continuity, Bernoullis equation, head loss

New methodology is used, but no new concepts

are introduced
 Review
Hydrostatic Pressure
 Review
Specific Gravity
 Pressure
Pressure measurements can be referenced to atmospheric
pressure (14.696 psi at sea level) or zero pressure (a vacuum
and no positive pressure).

Gage
pressure
Pressure

Atmospheric pressure

Barometric Absolute or
Pressure Total Pressure
Absolute reference

Pabs = Patm + Pgage

Conservation of Mass
Working Fluid
 Heat Energy
The main heat source is not friction but the conversion of fluid energy
to heat energy when there is a pressure drop across a restriction
along a conductor, and no mechanical work is done.
Viscosity
 Viscosity
If you use an oil with too low a viscosity
It can result in a loss of pump (and motor) efficiency due to
increased internal leakage (clearances are not sealed)
It can cause increased component wear due to breakdown of the
lubrication film
At high operating speeds and high operating pressures, the
lubrication film can break down completely, which will cause the
moving parts to spot weld together and cause a complete failure
(seizure)

If you use an oil with too high a viscosity

Pump cavitation the oil is so thick that it does not flow readily
into the pump. The pump is filled partly with oil and partly with
air.
High pressure drops occur due to friction in the lines

Always use an oil that meets specifications of the pump (or

motor) manufacturer, and make sure operating temperature is
controlled within the range required to keep viscosity within
the specified range
Bulk Modulus
Thermal Expansion
 Vapor Pressure
Vapor Pressure
Pressure at which a liquid
will boil (evaporate)
Increases with increase of
oil temperature
Can lead to __________
Formation and collapse of
vapor cavities
Bubble collapse within a
pump can result in high
pressures (up to 7000 bar),
which cause the erosion of
the pump elements
 Oxidation
Reaction between oil and oxygen
Compounds formed are referred to as resins or sludges
Rate of formation increases with the amount of oxygen
(water contamination) and temperature
Rate doubles every 18 oF above 140 oF
Reduces the life of the oil, increases the cost for
replacement and used oil disposal
Can plug orifices or cause moving parts to stick

Reduce oxidation
Keep sources of oxygen out of the system
Remove particulates with a good filtration system. These
particulates can act as sites for the oxidation reaction to
occur
Avoid the use of cadmium, zinc, and copper in contact with
hydraulic oil. For example, never use galvanized pipe or
fittings. These metals can react as catalysts that promote
the oxidation reaction.
 Properties
Compatibility
The oil should not react chemically with any other
materials used in the system, including bearings,
seals, paints, etc.
Should also be compatible with materials which will
come into contact with leaked oil (electrical lines,
mechanical components, etc)

Acidity
Ideal hydraulic liquid should be free from acids (may
become this way as it deteriorates)

Toxicity
Manufacturers try to produce liquids without toxins
May cause sickness or death
Some fire-resistant liquids are toxic
Corrosion and Rust Resistance
Corrosion:
Chemical reaction between the fluid and a metal
surface
Rust:
Oxidation of a ferrous metal
Typically takes place in the reservoir above oil level

Corrosion and rusting can be minimized by

Limit, to the maximum degree possible, the
introduction of air, water, and chemicals into the
hydraulic fluid
Select a fluid with a good oxidation and rust inhibiting
additives (these oils are sometimes referred to as R
and O oils)
Provide filtration to remove by-products of rusting and
corrosion
 Cleanliness: Air Contamination
Definitions
Free air: Air that is trapped in the system but not in
total contact with the fluid. It is entrapped example is
an air pocket that could be bled.
Entrained air: Air that is suspended in fluid and
normally exists. Filters/screens may be able to
remove.
Dissolved air: Within the fluid solution neither free
nor entrained. Does not follow Boyles law (i.e. gas
law) it instead follows Henrys law. It can be removed
by subjecting fluid to a reduced pressure and/or
raising the fluid temperature.
Henrys Law: The weight of gas dissolved in a liquid is
proportional to the pressure of the gas.
 Cleanliness: Air Contamination
Entrained air: minor significance

Undissolved air causes problems:

Reduction of the bulk modulus
Reduction in fluid density
Slight increase in viscosity
Noise

Foaming
Mineral-based oil can contain up to 10% dissolved air
Dissolved air is liberated as discrete bubbles
Liberation increases with increased temperature or
decreased pressure
Most hydraulic fluids contain foam-depressant
additives that cause rapid breakdown of the foam
 Cleanliness: Air Contamination
Free air bubbles passing through a pump
T1 = 288 K, P1 = 100 kPa (abs), k = 1.4
 Bubbles/Air in Hydraulic Systems
Causes/Sources
Liberation of air (formation of bubbles) due to local
pressure drop
Air leakage in suction lines, connections, etc.
Free air entrained at reservoir (splashing at reservoir)
Low fluid reservoir levels
Bad design of tank/reservoir
Improper fluid maintenance
 Effects of air on hydraulic systems
Spongy control: reduction in
stiffness

Loss of horsepower: Additional

power is consumed to
compress the air before the
onset of actuator motion

Loss of bulk modulus:

Compressibility increases
considerably with increase in
entrained air (figure)

Loss of system fluid: lower

reservoir levels (cavitation)
 Effects of air on hydraulic systems
Relatively low air pressure force substantial volumes of air into solution with
MIL-H-5606 fluid. | Effect of vacuum over MIL-H-5606 fluid that is saturated
with air. The vacuum withdraws large quantities of dissolved air. Higher
temperatures release more air.
Effects of air on hydraulic systems
Dissolved air
Adsorption: thin films of gas adhere to the surface
of the fluid
Rate of adsorption of entrained bubbles is a
function of their size
Ex: ~25 mil bubble dissolve at ~100 psi

Fluid holds more dissolved air as pressure

increases (Henrys law)
Remove dissolved air in the presence of a vacuum
Cannot vacuum the reservoir (induced pump
cavitation)
Use a deaerator!
 Effects of air on hydraulic systems
Released air collects in
upper part of chamber,
deaerated fluid returns to
the system.
As fluid level in chamber
falls a float valve closes
the port to stop deaeration
process (until tank fills with
aerated fluid).
Air is vented to
atmosphere
Can only reduce until rate
of deaeration equals rate
of readsorption.
Effects of air on hydraulic systems
Solutions:
Spongy control: incorporate as many bleed points in the
system as possible to vent trapped air. Purge at a high flow
rate to aspire air pockets. Rotate systems to encourage air
migration. Vacuum fill (evacuate system of air before filling).
Loss of horsepower: Use larger pumps or actuators
Loss of system fluid: Monitor reservoir levels continuously.
Change from a closed to an open system to make the fluid
level constantly visible.
Foaming: Add antifoaming agents. Incorporate baffles to
reduce sloshing. Submerge return lines. Place fine mesh
screens over suction lines.
Temperature Effects: Oversize the system
Erosion and Caviaton: Pressurize the reservoir with gas or a
bootstrap piston. Use harder materials in system components.
 Cleanliness: Water Contamination
Sources of water contamination
Condensation from humid air (absorption increases
with humidity)
Leakage from oil-water heat exchangers
Fluid itself was contaminated (bad storage)
Harmful effects
Formation of rust
Rust particles cause additional damage
Formation of sludge (via oxidation)
Minimize moisture content
Drain water/sludge from lowest point of reservoir
Fluid should have good demulsibility properties
Filter (remove limited amounts of water)
One simple way to remove water from hydraulic oil

Oil becomes cloudy when its contaminated

with water above its saturation level
Typ. 200 to 300 ppm at 68 oF for mineral oil

Head space flush

Introduce desiccant dry air through reservoir
continuously

Prevention is cheaper than removing it

Major point of ingression is through he

reservoir breather
Replace with hydroscopic breather
 GPM Hydraulic Consulting, Inc.
Oil samples taken from a 500-gallon reservoir with oil that was badly
contaminated and had high water content (left to right) before flushing, after
one pass through flushing machine, after 4 hours of flushing and after 16
hours of flushing

http://gpmhydraulic.com/hydraulicsystemflushing/
 Why Water and Oil Dont Mix
This graph shows the effect of water concentration on bearing life. Bearing
life is normally derived assuming lubricating oil contains 100 ppm of water.
Reducing water concentration to 25 ppm increases bearing life by nearly
150%
Understanding hydraulic fluid contamination

Water in hydraulic fluid

depletes some additives and reacts with others to form
corrosive by-products which attack some metals
reduces filterability and clogs filters
increases air entrainment ability
increases the likelihood of cavitation occurring
reduces lubricating film-strength, which leaves critical
surfaces vulnerable to corrosion and wear.

Levels above 500 ppm is sufficient to spawn

micro-biological contamination
(with other conditions present)
Understanding hydraulic fluid contamination

Measuring and removing water

Karl Fischer Volumetric Reagent Method
Karl Fisher Method, Karl Fisher Titration

Changing oil may be most cost-effective method

(smaller systems)
Water removal filters
Coalescing filters: contains water absorbent fibers,
collected water coalesce and drain into a collector
Polymeric filters: absorptive (chemical) or adsorptive
Neither remove dissolved water

Vacuum distillation
Water boils at 56 oC under partial vacuum (846 mbar)
water can be removed without damaging oil
 Thermal Properties
__________ the temperature 3 oC above the
temperature at which the fluid ceases to flow

__________ is the lowest temperature at

which vapors rising from the oil surface will
ignite in the presence of an open flame
Insufficient to sustain the flame
Varies from 150 oC to 265 oC

__________ is the point at which the vapors

will support combustion for five seconds in
the presence of an open flame
Approximately 50 oF higher
 Thermal Properties
_________________________ is the temperature
at which the fluid will burst into flame in the
absence of an ignition source
Usually at a much higher temperature

_______________ is the quantity of heat required

to raise the temperature of one unit of mass of
substance by one degree
kJ/kg per K or kcal/kg per oC
Cp: specific heat at constant pressure

_______________ is the ability to transmit heat,

normally expressed in units of W/m per K
For mineral oils, k = 0.12 W/m per K
TypesofHydraulicOils&Additives
Classification of Hydraulic Fluids
Typically used hydraulic fluids
Noninhibited refined mineral oil
Refined mineral oil with improved anti-rust and anti-
oxidation properties
Refined mineral oil with improved anti-rust, anti-oxidation,
and viscosity-temperature properties
Refined mineral oil with improved anti-rust, anti-oxidation,
anti-wear, and viscosity-temperature properties
Synthetic fluids with no specific fire-resistant properties
High water-based fluid (up to 20% combustible materials +
min 80% water)
Chemical solution in water (more than 80% water content)
Water-in-oil, water droplets in a continuous oil phase (60%
oil + 40% water)
Water/polymer water glycol (35% to 80% water)
Pure chemical fluids; water-free
Chlorinated hydrocarbons
Mixture of phosphate esters and chlorinated hydrocarbons
Classification of Hydraulic Fluids
Mineral Oils
Most widely used hydraulic fluid

Relatively inexpensive, widely available, offered in

suitable viscosity grades, good lubricity, noncorrosive,
and compatible with most sealing materials (except
butyl rubber)

Chemical breakdown at higher temperatures

Premium grade mineral oils contain additives

Disadvantages
Flammability
Excludes them from use in hazardous areas like in molding, coal
mines, and near furnaces
Increase in viscosity at high pressures

M.G.Rabie
 Fire-Resistant Fluids
Oil-in-Water Emulsion
Consists of tiny droplets of oil dispersed in a
continuous water phase

Dilution is normally 2% to 5% oil in water

Characteristics are more similar to water than oil

Advantages
Extremely fire-resistant
Highly incompressible
Good cooling properties

Disadvantages
Poor lubricity
Low viscosity
 Fire-Resistant Fluids
Water-in-Oil Emulsion
Most popular fire-resistant fluid

Continuous oil phase in which tiny droplets of water

are dispersed

Lubrication properties are reduced

Dilution is normally 60% oil + 40% water

Operating temperatures should not exceed 25 oC, but

intermittent operation up to 50 oC is permissible
Avoid evaporation

For idle systems, oil and water tend to separate

Pump will re-emulsify the fluid
 Fire-Resistant Fluids
Water-Glycol Fluids

Developed primarily for use in aircraft

Advantages
Very low flammability characteristics
Suitable for low-temperature applications

Disadvantages
Cannot be used at high temperatures
Attack most paints
 Fire-Resistant Fluids
Synthetic Oils
Good fire-resistance properties
Lubricating ability is similar to that of mineral oil
Certain metals and most paints are susceptible to attack for some
synthetic oils

Superior to mineral oil-based fluids

Thermal stability
Oxidation stability
Viscosity-temperature properties
Low temperature fluidity
Operational temperature limits
Fire resistance

Mineral oil-based fluids are advantageous

Hydrolytic stability
Corrosion protection
Toxicity
Compatibility with elastomers and construction materials
Solubility of additives
Frictional characteristics
Cost and availability
 Additives
Largest class of hydraulic fluids consists of refined hydrocarbon
base oils (petroleum oils) with suitable additives
Oxidation inhibitors improve the ability of liquid to withstand
chemical reaction with oxygen/air and avoid subsequent
degradation. They are of prime importance when operating at
elevated temperatures
Corrosion inhibitors form molecular layers that are bound to the
surface by electrostatic forces and form an effective barrier against
penetration by oxygen and water, which is necessary for rust-
forming electrochemical reactions
Antifoaming agents, which form small heterogeneous areas within
the bubble walls of surface foam. Due to their low surface tension,
these small areas are weak spots and result in bubble bursting
Anti-wear additives of high thermal stability
Viscosity index improvers
Pour point depressants
Friction modifiers are necessary under certain conditions to ensure
smooth operation, free from juddering (stick/slip)
Detergents are substances providing a cleaning action with respect
to the surface deposits
 Requirements
Satisfactory flow properties throughout the
entire range of operating temperatures
A high viscosity index that ensures moderate
viscosity variation in relation to the
temperature fluctuations
Good lubricating properties are a prerequisite
to reduce wear and increase the service life
of the system
Low vapor pressure to avoid cavitation
Compatibility with system materials since the
fluid should not react chemically with any of
the used materials or deteriorate their
physical properties
 Requirements
Chemical stability is necessary to increase the
service life of liquid to avoid performance
deterioration
Corrosion protection by adding effective corrosion
inhibitors
Rapid de-aeration and air separation
Good thermal conductivity is required to rapidly
dissipate the heat generated due to friction
between elements and due to hydraulic losses
Fire resistance is essential in some applications
Electrically insulating properties can be significant
in a number of modern designs
Environmental acceptability
 Environmentally Acceptable Hydraulic Oils
An oil leak may result in considerable pollution
Mineral oils are composed of stable
hydrocarbons (break down very slowly)

80%biodegradablewithin21days
ISOVG 32/46 Viscosityat100oC 7.3cSt
Viscosityat40oC 40.1cSt Viscosity Index(VI) 149
SpecificGravity 0.965 FlashPoint 256oC
FirePoint 282oC PourPoint 56oC
 Example

VG32 VG68
Density(at15oC),kg/m3 869 878
Pourpoint,oC 45 36
Flashpoint,oC 212 252
Minimumstartup temperature,oC 32 21
Estimatedoperatingrange,oC 14to67 0to87
Kinematicviscosity, at 40oC 32.2 67.9
cSt at 100oC 6.4 10
Viscosityindex 156 132
 Hydraulic fluids incorporate fluorescent safety additive

July 16, 2015: Spectronics Corp. and Quaker Chemical Corp. have signed a strategic
supply-and-market-development agreement for the global expansion of Quakers fire-
resistant hydraulic fluids that incorporate FluidSafe, Spectronics unique fluorescent
safety additive. Along with the new partnership, Spectronics is merging its Alerton
subsidiary with the parent company and adopting FluidSafe under its Spectroline
brand

Image: FluidSafe confirms a fluid injection injury by its bright fluorescent glow under
blue light, minimizing surgical intervention
Temperature&HeatTransfer
 Temperature Control
Keep oil temperatures below 160 oF to prevent

Oxidation of the oil

Formation of insoluble gums, varnishes, and

acids

Deterioration of seals

Loss of lubricity

Changes in viscosity
 Temperature Control
Design to remain below 140 oF
Characteristics:
Temperature Control
Article
Article
 Heat Transfer Cundiff

Sometimes the reservoir is main source of heat exchange

Heat Transfer Cundiff
Heat Transfer Cundiff
 Heat exchangers
Reservoirs/lines may be enough for heat transfer
Heat exchanger may be necessary if:
A specific oil temperature limitation is necessary
Cycle swell time is a major portion of duty cycle,
especially in systems with fixed displacement pumps
There is a history of problems from hot oil, or
shortened oil or seal life

Heat transfer mechanisms (influencing U)

Convective heat transfer from fluid to wall
Increases with turbulent and high velocity flow
Thermal conductance through the tube wall
Convection of heat from tube wall to cooler fluid
Deposits/Scale decreases heat transfer
 Heat exchangers
Tube-pass configurations
Can come in 1-, 2-, and 4-
pass configurations
Turbulators used to disrupt
laminar flow
 Methods for Cooling
Shell-and-Tube exchanger
Tubes made of various metals
Arranged to promote turbulent flow
Contains baffle system
 Methods for Cooling
Finned Tube exchanger (air cooling)
Air movement and fin design increase transfer
 Heat exchangers
Newer Designs
Extended surface designs: many fines to the external sides of
tubes
My have a spring-loaded pressure-surge protector

Brazed plate: Series of stainless steel plates each stamped with

corrugated pattern and stacked.
Fluids are in alternate parallel channels
Compacted, rugged, high heat transfer, induce turbulent flow, prevent
fouling

Plate-fin heat exchanger:

More cooling per cubic inch
Design flexibility
 Heat exchangers
Determine the temperture limits of the system and
fluid components
Estimate total system heat output before building
the system
Consider where to place heat exchangers
Information for heat exchanger
Oil heat load (BTU/min)
Oil flow (gpm)
Maximum oil temperature
Ambient air temperature during system operation
Environmental contaminants that can affect the
system
Maximum allowable pressure drop
Water inlet temperature and flow rate (if applicable)
Heat Exchangers
Heat Exchangers
 Heat Generation Cundiff

Merritt (1967) gives the following empirical expression for

estimating the heat generated by a hydraulic system
 Heat Generation Cundiff

Example: Pump/Motor system, eom = eop = 0.875,

1000 psi, flow delivered by the pump is 8 GPM
Heat Generation Cundiff
DesignExample:
Cundiff
Ifacoolerisneeded,whatrateofheatexchangeisrequired?
Amobilemachinehasthreehydraulicpumps.PumpAisapistonpump,anditsuppliesflowtoa
closedcircuithydrostatictransmission.Thispumphasadisplacementof2.3in3/revandis
drivenat1885rpm.Thechargepumpdisplacementis0.33in3/rev,andthechargereliefvalveis
seton150psi.PumpBisagearpumpmountedontheauxiliarypumpmountofPumpA;thusit
isalsodrivenat1885rpm.DisplacementofPumpBis1.25in3/rev.PumpCisdrivenwithabelt
driveat2000rpm.Itsdisplacementis1.21in3/rev.BothpumpsBandCsupplyopencircuits.

Thereservoirisconstructedfrom0.125in.thickmildsteelandisrectangular,6 30 36in.The
specificgravityofthehydraulicfluidis0.85,andthespecificheatis1.5Btu/lbmF.Maximum
fluidtemperatureis140F,andmaximumambienttemperatureis95F.

Thevarioussubsystemsonthemachinearewidelyseparated;thus,therearesomelongrunsof
hydrauliclinesthatprovideampleopportunityforheatexchangefromthePumpBandPumpC
circuitstothesurroundings.

ThefunctionalrequirementofthePumpBcircuitwasanalyzed,andtheoperatingpressurewas
calculatedtobe400psi.Itisestimatedthatthepeakpressurerequirementwillbeperhaps2.5
timesthenormalpressure,or1000psi.Thispeakisexpectedtooccuronly10%ofthetotal
operatingtime.

AnalysisofthePumpCcircuitrevealedthatnormaloperatingpressurewouldbe650psi.Peak
pressuresupto1500psiareexpected,anditisestimatedthatthesepeakswilloccur20%ofthe
operatingtime.
 Design Example Notes Cundiff

Pump B & Pump C are open

Pull from reservoir
Pump A is closed
Charge pump replaces fluid
Assume (for now) all charge pump flow goes across its relief
valve (150 psi)
 Design Example Cundiff

The functional requirement of the Pump B circuit was analyzed, and

the operating pressure was calculated to be 400 psi. It is estimated
that the peak pressure requirement will be perhaps 2.5 times the
normal pressure, or 1000 psi. This peak is expected to occur only
10% of the total operating time.

Analysis of the Pump C circuit revealed that normal operating

pressure would be 650 psi. Peak pressures up to 1500 psi are
expected, and it is estimated that these peaks will occur 20% of the
operating time.
Design Example Cundiff
Design Example Cundiff
Design Example Cundiff
Design Example Cundiff
Design Example Cundiff
 Design Example Cundiff

Reevaluate Pump A
Pump A is a variable displacement axial piston pump that delivers flow to
an axial piston motor. Pressure in the main circuit will generally be less
than 2000 psi, so the overall efficiencies of both pump and motor will be
greater than 90%. The volumetric efficiency of both pump and motor is
95%. The displacements of both pump and motor are 2.3 in3/rev.

PumpA: FlowRate:

Pressure:

TotalInputPower:
 Design Example Cundiff

PumpAinputpowerconvertedtoheat

Outputpowerofmotor(neglectotherlosses)

Motorpowerconvertedtoheat

Totalheatgenerated(pump&motor)
 Design Example Cundiff

Whatamountofflowisdeliveredtotheloopduetoleakage?(RecallQcharge =2.69gpm)
Leakageofpump(95%volumetricefficiency)

Leakageofmotor(95%volumetricefficiency)

Flowacrosschargereliefvalve

Heatgenerateacross150psireliefvalve
 Design Example Cundiff

TotalheatgeneratedfromPumpAclosedcircuit:

Totalheatgeneratedfromthesystem:

Assume50%dissipatedforB&C(opensystems)and25%dissipatedforA(closedsystem)
 Design Example Cundiff

Additionalcoolingneeded:

Forexample:
Obtainafinnedtubeheatexchangerratedat9500BTU/hat24gpm withT=45oF
Contamination&Filtration
 Contamination
There are three types of failure in a fluid power
system.

The performance of the component _______________

over time as surfaces wear, clearances increase, and
leakage increases.

Valves stick and then break loose such that operation

is _______________.

_______________ failure occurs when a major

component breaks apart. Often, debris causes the
failure of other components, and a total replacement of
the circuit is required.
 Contamination
There are four sources of contamination in hydraulic fluid:
 Contamination Damage
Internally generated contamination causes damage in the
following ways:
Contamination Damage
Contamination Damage

Damage to valve plate of hydraulic pump

Understanding hydraulic fluid contamination
Additive depletion
Occur via physical removal or by chemical reaction.
Additive may not be effective when base degrades, is
in the presence of water/particulates

Table2:Effectsofparticulatecontaminationandwateronhydraulicfluids
Fluidbreakdown Cause Effectonsystem
a. Agglomerationandprecipitationof componentwear
particulatecontamination cloggingofjets,nozzles,and
Physicalproperties b. Oxidation/hydrolysisproducts orifices;valvejamming
c. Reactionsinvolvingadditives systemmalfunctiondueto
d. Freewater icingoffreewater
Basestock a. Oxidation corrosionandsurface
degradation b. Hydrolysis degradationofcomponents
a. Precipitationofadditives
lossofcomponentprotection
b. Adsorptionbyparticulates
Additivedepletion increasedcomponentwear
c. Reactionsinvolvingadditives
andcorrosion
d. Abnormaldegradationofbasestock
Understanding hydraulic fluid contamination

Monitoring contaminants

On-line monitors
Particle counters particle size distribution
Contamination monitors operate on principle
of mesh blockage
Humidity monitors water sensors

Samples can be extracted and sent to the

lab
Standardtocountparticles:ISO4406

Rangecodeat4m/6m/14m
NOT:15m/5m/2m(inCundiff)
Contamination: Pumps Cundiff
Contamination: Pumps Cundiff
Contamination: DCV
 Contamination
Pressure Controls

Flow Controls
Cleanliness Level Cundiff
 Cleanliness Level
From Target ISO Cleanliness Codes
 Cleanliness Level
Step One
Use cleanliness code chart to determine the cleanest
fluid required for any component in the system

Step Two
Set one code lower if the fluid is not 100% petroleum oil

Step Three
Set one code lower if one or more of the following
conditions are experienced by the system:
(i) Frequent cold starts (0 oF);
(ii) Intermittent operation with fluid temperatures over 160 oF;
(iii) High shocks to the system;
(iv) Critical dependence on system operation sequence, ex:
manufacturing;
(v) Malfunction will endanger to operator or others
Filter Efficiency Cundiff
Filter Efficiency Cundiff
 Filter Efficiency
under system operating conditions
 Filter Location
Pressure Line
 Filter Location
Return Line
 Filter Location
Off-line
 Filter Location
Additional Protection
Servo valves, and other close-tolerance spools
 Filter Location
Closed Circuits
 When to change a filter
After a certain number of hours?
 Filters
www.daerospace.com
 Return Line Filter
1. Housing
2. Cover
3. Connection to clogging
indicator
4. Filter element
5. Contamination retaining
basket
6. Clogging indicator
7. Bypass

CourtesyofBoschRexrothAG.
 High Pressure Filter
1. Filter heat
2. Filter housing
3. Filter element
4. Clogging indicator
5. Bypass valve

CourtesyofBoschRexrothAG.
 Contamination
Keep a record of filter performance/lifetime

Flush new system components

Sometimes a low-viscosity fluid is used at
high velocities

Confirm and monitor cleanliness level

Collect a sample during operation and later
send it to a laboratory
Some companies have published
guides/procedures
Understanding hydraulic fluid contamination
At work in the real world
One U.S. airline studied the impact of contamination on
performance in the hydraulic systems of its aircraft ground-support
equipment, such as mobile cargo loaders, container rotators,
aircraft bridges, and nose docks.
This equipment operates outdoors and is exposed to dirt and
weather extremes. Initial investigations revealed high particulate
levels - 20/16 on the ISO 4406 scale - and water contamination in
excess of 1,000 ppm. These conditions required fluid changes
every two to three months. In spite of these relatively frequent
changes, equipment failure was common.
The airline initiated a comprehensive program of contamination
control. It included installing high-efficiency fine filtration and the
use of portable fluid purifiers. The result: hydraulic-fluid service life
was extended to more than eleven months. The water
concentration in the fluid was held consistently below the
manufacturer's recommended 200- to 400-ppm level. Particulate
levels were reduced to 13/11 on the ISO 4406 scale. The
associated benefits were improved performance and less
downtime.
RelevantFluidMechanics
 Pascals Law
Multiplication of force
Pressure applied to a confined fluid is transmitted
undiminished in all direction throughout the fluid
and acts perpendicular to the surfaces in contact
with the fluid
Hydraulic Jack
Hand-Operated Hydraulic Jack
An operator makes one complete cycle per second interval using the
hydraulic jack on the previous slide. Each complete cycle consists of two
pump cylinder strokes. The pump cylinder has a 1 inch diameter piston and
the load cylinder has a 3.25 inch diameter piston. If the average hand force
is 25 lb during the power stroke,
a) How much load can be lifted?
b) How many cycles are required to lift the load 10 inches assuming no oil
leakage? The pump piston has a 2 inch stroke.
c) What is the output (in hp) assuming 100% efficiency? 80% efficiency?
 Air-to-Hydraulic Pressure Booster
Converts shop air into higher hydraulic pressure
needed for operating hydraulic cylinders
Requiring small to medium volumes of high pressure oil.
A type of hydraulic intensifier

Relatedconcept:
 Application: Hydroforming
Sheet or Tube hydroforming

Shaping of metals using highly pressurized fluid to form metal

Choice of material is key

~20,000 psi to 100,000 psi

http://www.totalmateria.com/
 Conservation of Energy
Continuity equation

Bernoulli's equation
 Bernoullis Equation: Venturi
Consider a venturi nozzle
For the hydraulic system shown, the following is given
The pump is adding 5 hp to the fluid
The pump flow is 30 gpm
The pipe has a 1 inch inside diameter
The specific gravity of the oil is 0.9
Find the pressure available at the inlet to the hydraulic motor (station
2). The pressure at station 1 in the hydraulic tank is atmospheric. The
head loss due to the friction between stations 1 and 2 is 30 ft of oil
 Bernoullis Equation
Torricellis Equation
Fluid Dynamics
 Minor Losses
Results from rapid variation of magnitude or
direction of the oil velocity
Expansions and Contractions
Loss in Pipe Flow
MoodysDiagram
 Losses: Roughness
For turbulent flows, f is a function of Reynolds number
and the relative roughness of the conductor
Relative roughness = (/ D)
= surface roughness
 Head Loss Cundiff

Loss in pressure due to friction

hL = head loss (ft)
f = friction factor (unitless)
D = conductor inside diameter (ft)
L = conductor length (ft)
2
v = average fluid velocity (ft/s)
g = gravitational constant (ft/s2)
 Losses Example
A hydraulic motor powers a conveyor on a harvesting machine. Oil flows in a
16-ft hydraulic hose from the pump to the motor. The oil properties are Sg = 0.9
and = 36.5 cS. Flow rate is Q = 15 GPM, and the hose inside diameter is 0.75
in. What is the pressure drop between the pump and the motor?
Losses Example
 Losses in Fittings Cundiff

Usually, pressure loss across conductors are less significant than

the pressure drops through other components (valves, fittings, etc)
Losses in fittings are proportional to the square of the fluid velocity

Fitting K Factors
Standardtee 1.8
Standardelbow 0.9
45o elbow 0.42
Return bend(Uturn) 2.2

The previous problem illustrated why there are recommendations

on maximum fluid velocity. Larger components generally cost
more, but have lower operating costs (lower pressure loss)
Note: The next few chapters do not consider pressure drops for
individual conductors or fittings, only total p for sections are given
Internal Leakage in Hydraulic Elements
Internal Leakage in Hydraulic Elements
Relationship between leakage and pressure (refer
to book for derivation)

Power loss due to leakage

 Additional Geometries
Eccentric Mounting Long-Thin-Slot
Radial Clearance Orifice
 Additional Geometries
Clearance between a circular nozzle and a plane surface

Viscous friction and damping effect

 Orifice Equation Cundiff

Q = flow (in3/s)
C = orifice coefficient (unitless)
A = area (in2)
= specific weight of fluid (lb/in3)
g = gravitational constant (386 in/s2)
p = upstream pressure downstream pressure (psi)

2 /

Allvalvesformsometypeoforificeintheline
Manufacturerstypicallysupplyacurve(p vs Q)
 Orifice Equation

Contraction coefficient, Cc = A2/A0

Velocity coefficient, Cv
Discharge coefficient, Cd
Orifice Equation
Contraction Coefficient
Transmissions,Hoses,andLosses
Reservoirs
Reservoir Construction Cundiff
Reservoir Construction Cundiff
Reservoir Construction Cundiff
 Reservoir Construction Cundiff

Thorough mixing within the reservoir

 Reservoir Construction Cundiff

Pressurized Reservoir
 Bootstrap Hydraulic Reservoir
Military and commercial aircraft
21.5 to 3119 in3
System pressures 3000 to 5000 psi
Operation
Pump supplies system pressure
High pressure piston conversion to low pressure
application in reservoir
Ex: 3000 psi to 85 psi
Bootstrap Hydraulic Reservoir
 Bootstrap Hydraulic Reservoir

www.daerospace.com
 Piston Spring Type
Spring provides a fairly constant (low) reservoir
pressure

www.daerospace.com
 Emergency Reserve
Emergency reserve (feed backup/critical system)

www.daerospace.com
 Two System Feed
Feed two systems (ex: if one leaks)

www.daerospace.com
HydraulicTransmissionLines
 Transmission Lines
Performance:




Selection:
 Recommendations
Rigid Pipes
2 to 6 m/s for pressure line
0.6 to 1.6 m/s for suction, return, and low pressure lines
Hose
2.1 to 4.6 m/s for pressure line
0.6 to 1.2 m/s for suction, return, and low pressure lines

Inner diameter
Tube: Nomogram (Fig. 3.1)
Hose: Nomogram (Fig. 3.5)

Working pressures
Pipe: Table 3.1
Hose: Table 3.2
 Cundiff

100SUSfluid
0.5intube/hose

Saybold universalsecond:
Time60cm3 toflow
throughcalibratedtube
at38oC

100or400SUSfluid
0.5intube/hose
Pipe Cundiff
 Hydraulic Tubing Cundiff

Pressure Ratings
SAE Standard J1065 Jul95
Table 9.4: Service Ratings
Appendix A9, Table A9.1 based on A Service Rating
Design Factor
Ratio of (Burst Pressure) / (Working Pressure)
Derating Factor
Based on working conditions
Value less than 1.0
(Burst Pressure) / (Working Pressure) / (Derating Factor)
i.e. increases overall factor
Cundiff
A press is used to form bladders for truck brakes. Sheets of reinforced elastomer
material are placed in the mold and the press closes. A combination of pressure and
temperature is used to form the part. The procedure calls for a bump cycle where
pressure is cycled for several cycles. Operating temperature is 320 F. The relief
valve for the press circuit is set on 2000 psi, and 0.75 OD carbon steel tubing has
been selected. Find the wall thickness required.
1. Innersyntheticrubbertube,resistanttooilsandhydrocarbons.Theoperating
temperaturerangesfrom40C to120C andthehosemayhaveaninternal
dressinglayerofViton.
2. Highabrasionresistantmetallicscreenlayers.
3. Closelybraidedhightensilesteelwirelayersseparatedbyantifrictionrubber
layer.
4. Abrasionresistantsyntheticrubbercover.
5. Textilelayer.
Hydraulic Hose Cundiff
 Hydraulic Hose Cundiff

Pressure Ratings
Table A9.2

Hose Fittings
 Hydraulic Tubing Cundiff

Seamless carbon steel or seamless

stainless steel

Fitting Type #1: Flared

Hydraulic Tubing Cundiff
 Hydraulic Tubing Cundiff

Fitting Type #2: Flareless

Fitting Type #3: Welded

Severe applications / extremely high pressures
 Connections Cundiff

Dash number: number of sixteenths of an inch in the

nominal size
 Connections Cundiff

Valves, motors, and pumps usually purchased

with straight-thread
37o flare adapter can be added
 Connections Cundiff

Fittings are available that can

swivel 360

These fittings are more expensive,

but sometimes they are needed to
prevent a hose from twisting as it
moves to follow an actuator.

American Hoses & Fittings, Inc.

 Tube Mounting
Should be (properly) bent whenever possible
to reduce the number of fittings
Symmetrical design
Avoid straight-line connections
Eliminate tube stress mounting/brackets
Form tubes to assemble with true alignment
Hose Mounting
Cundiff
 Manifolds & Cartridges
Manifolds: more robust than connecting directly to component

Vonberg flowregulatingvalves,directionalvalves,
velocityfuses,flowlimiters,pressurecontrols,
hydraulicmanifolds
 Quick Disconnect
Single shut-off
Double shut-off
 Installation of Lines
Influence of line choice:
Friction factor
Cost
Heat exchange
Compliance
Actuator movement (rigid vs. flexible)
External vibration
 Design Life
Environmental
Corrosion, UV light, temperature, etc.

Failure
Routine
Pinhole
Burst