[PPT] - A NALYSIS OF THE L UBRICATION S YSTEM IN A H IGH P RESSURE P ISTON W PowerPoint Presentation

SLIDE 1

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA
Dept. of Sciences and Methods for Engineering

University of Modena and Reggio Emilia, Italy

ANALYSIS OF THE LUBRICATION SYSTEM IN A HIGH PRESSURE PISTON WATER PUMP

D. Bottazzi2, D. Galloni1, M. Milani2, L. Montorsi2

1 - Comet S.p.A.

Reggio Emilia, Italy

2 - HYDRAULIC SYSTEMS DESIGN

RESEARCH GROUP

SLIDE 2

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA
Task: avoid overheating for long time operation -

Comet Product Divisions

Numerical Analysis and Optimization of the Lubrication System

SLIDE 3

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Test rig thermal analysis -

CLW (aluminium crank case) 66 l/min (1000 rpm) @ 140 bar 1 – Oil 2 – Water 3 – Air (ambient) 4 – Needle-bearing on the joint side 5 – Needle-bearing on the other side 6 – Crank case, front position 7 – Crank case, close to the valves Thermocouple measurements

SLIDE 4

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA
spectral range: 7.5 - 13 µm
temperature range: -20 °C - 900 °C
optical resolution: 160 x 120 pixel
picture repetition frequency: 120 Hz

– Test rig thermal analysis -

CLW (aluminium crank case) 66 l/min (1000 rpm) @ 140 bar

a) b) c) d)

Optris PI 160

SLIDE 5

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

–Mesh construction, from 3D to 2D -

2D - 300000 cells 1 mm 0.5 mm 3D – millions of cells Only one piston is simulated

SLIDE 6

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Moving mesh construction -

Point B position –

Rod big end position

Generic point J

 

      t r x

c B

sin

 

      t r z

c B

cos

BJ v v

B B trans J tot

       

 

        t r x

c B

cos 

 

         t r z

c B

sin 

    

              t t

B

     

2 2 sin

1 cos 

   

 

t t r z

c A

             

2 2 sin

1 ) / 1 ( cos ) / 1 1 (

Point A position – Rod small end position
Overset mesh (rod motion) -
Morphing (piston motion) -

SLIDE 7

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– VOF – air&oil-

W. Habchi, P. Vergne, S. Bair, O. Andersson, D. Eyheramendy, G.E. Morales-Espejel - Influence of pressure and temperature

dependence of thermal properties of a lubricant on the behaviour of circular TEHD contacts, Tribol. Int. 43 (2010) 1842–1850.

Oil properties, T & p dependence -

     

   

6 . 7 3 _ _ _ 1

/ / 101 . 1 /



      

ref

il
il

ref

il
il

ref

il
il
il

V V T T V V C C k

   

 

il

ref

il
il

ref

il
il
il

p

V V T T C C c  / / /

4 _ _ 3 2 

   

SLIDE 8

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

 

fring fjb frse frbe fnb hm hyd ftot

P P P P P P P           3 2 1 

Friction evaluation -

 

hm vol suc mech hyd tot

M p p Q P P           

max max

  

  

4 / 2 3 /

2 p c vol

d r Q         

Needle bearings -

 

2 / 4 /

2 max p p nb

n d p F     

nb nb f fnb

F d C M     5 .

J.B. Heywood - Internal Combustion Engine Fundamentals, 1st ed., McGraw-Hill, Inc., New York, 1988.

 

rbe rbe rbe

il

rbe rbe

il

rbe rbe frbe

c l d c d l d F                           

2 2

2 /

rbe frbe frbe

d F M  

  

frbe frbe

M P

35% 65%

SLIDE 9

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA
Heat transfer -

K.A. Brucker, J. Majdalani - Effective thermal conductivity of common geometric shapes, Int. J. Heat Mass Transf. 48 (2005) 4779–4796.

 

wall wall wall ext wall wall cond

k s S T T W / /

int _ _ int _

  

 

ext wall ext wall env ext wall conv

h S T T W

_ _ _

   

   

env ext wall env ext wall ext wall ext wall

f k l h Nu Pr , Re /

_ _ _ _

  

 

9 / 4 16 / 9 4 / 1 _ _

Pr 67 . 1 67 . 68 .



    

env ext wall ext wall

Ra Nu Dissipated thermal power

Conduction & convection -

SLIDE 10

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Selected physical models & field functions -

Eulerian Multiphase → Volume Of Fluid (immiscible fluid mixtures)
Segregated Multiphase Temperature
k-ε Turbulence
Oil thermo-physical properties function of temperature and pressure

   

 

     

il
il

cell cell

il
il

cell cell cell

il

tot

VF V VF V T T  

_ _ _

Monitoring field functions

   

 

     

air air cell cell air air cell cell cell air tot

VF V VF V T T  

_ _ _

Air Oil

SLIDE 11

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Moving mesh -

Overset mesh (rod motion) -
Morphing (piston motion) -

SLIDE 12

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Temperature -

Oil Air

SLIDE 13

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Oil fraction & Dynamic Viscosity -

Oil Air

SLIDE 14

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Velocity -

Oil Air

SLIDE 15

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

Different oil levels …

High oil level

Std. oil level

Low oil level

Oil Air

SLIDE 16

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

High oil level, 800 rpm High oil level, 1000 rpm High oil level, 1200 rpm

Std. oil level,

1000 rpm

Std. oil level,

800 rpm

Std. oil level,

1200 rpm Low oil level, 1200 rpm Low oil level, 1000 rpm Low oil level, 800 rpm

… and various operating conditions -

SLIDE 17

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

High oil level, 800 rpm High oil level, 1200 rpm High oil level, 1000 rpm

Std. oil level,

800 rpm

Std. oil level,

1200 rpm

Std. oil level,

1000 rpm Low oil level, 800 rpm Low oil level, 1200 rpm Low oil level, 1000 rpm

Oil Air

… and various operating conditions -

SLIDE 18

STAR Global Conference 2014 - Vienna

HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP

DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA

– Work in progress -

… Three pistons … … From 2D to 3D …