d. bottazzi2, d. galloni1, m. milani , l. montorsi...
TRANSCRIPT
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
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
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
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
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
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
trx cB sin
trz cB cos
BJvv BBtransJtot
trx cB cos
trz cB sin
t
tB
22 sin1
cos
ttrz cA 22 sin1)/1(cos)/11(
• Point A position – Rod small end position
- Overset mesh (rod motion) -
- Morphing (piston motion) -
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 -
6.73
___10 //101.01/
refoiloilrefoiloilrefoiloiloil VVTTVVCCk
oilrefoiloilrefoiloiloilp VVTTCCc ///4
__32
STAR Global Conference 2014 - Vienna
HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP
DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA
fringfjbfrsefrbefnbhmhydftot PPPPPPP 321
- Friction evaluation -
hmvol
suc
mech
hyd
totM
ppQ
P
P
max
max
4/23/2
pcvol drQ
- Needle bearings -
2/4/2
max ppnb ndpF
nbnbffnb FdCM 5.0
J.B. Heywood - Internal Combustion Engine Fundamentals, 1st ed., McGraw-Hill, Inc., New York, 1988.
rbe
rberbeoil
rbe
rbe
oilrberbefrbec
ld
c
dldF
22 2/rbefrbefrbe dFM
frbefrbe MP
35% 65%
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.
wallwallwallextwallwallcond ksSTTW //int__int_ extwallextwallenvextwallconv hSTTW ___
envextwallenvextwallextwallextwall fklhNu Pr,Re/ ____
9/416/9
4/1
_
_
Pr67.01
67.068.0
env
extwall
extwall
RaNu
Dissipated thermal power - Conduction & convection -
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
oiloilcellcell
oiloilcellcellcell
oiltotVFV
VFVTT
_
_
_
Monitoring field functions
airaircellcell
airaircellcellcell
airtotVFV
VFVTT
_
_
_
Air Oil
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) -
STAR Global Conference 2014 - Vienna
HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP
DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA
– Temperature -
Oil
Air
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
STAR Global Conference 2014 - Vienna
HYDRAULIC SYSTEMS DESIGN RESEARCH GROUP
DEPT. OF SCIENCES & METHODS FOR ENGINEERING – UNIV. OF MODENA & REGGIO EMILIA
– Velocity - Oil
Air
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
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 -
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 -
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 …
Thank you very much
for your kind attention!