Meike Ernst Advisor: Formerly Dr. Ivantysynova Currently Dr. Vacca 6/6/2019 Maha Fluid Power Research Center 1500 Kepner Dr. Lafayette, IN 47905 Pushing the Performance Limits of the Lubricating Interfaces in Axial Piston Machines
Meike Ernst
Advisor:
Formerly Dr. Ivantysynova
Currently Dr. Vacca
6/6/2019
Maha Fluid Power Research Center
1500 Kepner Dr.
Lafayette, IN 47905
Pushing the Performance Limits of the Lubricating Interfaces in Axial Piston Machines
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Micro Surface Shaping
Shaping the component surfaces that form the lubricating interfacesShape is on the order of microns in height
Fluid Film
Surface Shape
u
Component A
Component B
3From the work of Andrew Schenk (2014)
FluidSlipper Solid Body
Swashplate Solid Body
Translation
Tilt
Relative motion of components builds
hydrodynamic pressure.
Load support
Translation and tilt can increase leakage
Load Support and Power Loss at the Interfaces
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Table of Contents
I. Three main lubricating interfacesII. Slipper-swash plate interfaceIII. Cylinder block-valve plate interfaceIV. Piston-cylinder interfaceV. Conclusions
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1. Slipper-swash plate interface2. Cylinder block-valve plate interface3. Piston-cylinder interface
These lubricating interfaces have two important functions:
• Bearing function• Sealing function
The Lubricating Interfaces of Axial Piston Machines
Slipper
Piston Swash PlateCylinder Block
DC Valve Plate
1
2
32 1
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
a piston pump CAE toolF TI
6
Slipper
Piston Swash PlateCylinder Block
DC Valve Plate
1
1
Slipper-Swash Plate Interface
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
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The Slipper
Slipper
Piston Swash PlateCylinder Block
DC Valve Plate
1
1
Slipper-Swash Plate Interface
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
Sealing Land
Piston
Slipper Swash Plate
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Trace 1
Trace 2Trace 8
Trace 3
Trace 4
Trace 5
Trace 6
Trace 7
Measuring Slipper Wear
Hei
ght
[m
]Normalized Distance along Trace
0 1
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
From the work of Ashkan Darbani (2019)
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Variables:v0, v1, x0
𝑠1 = 𝑎1𝑥2 + 𝑏1𝑥 + 𝑐1
𝑠2 = 𝑎2𝑥2 + 𝑏2𝑥 + 𝑐2
x0
v0
v1
Slipper Surface Shaping
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Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
From the work of Ashkan Darbani (2019)
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Variables:v0, v1, x0
𝑠1 = 𝑎1𝑥2 + 𝑏1𝑥 + 𝑐1
𝑠2 = 𝑎2𝑥2 + 𝑏2𝑥 + 𝑐2
x0
v0
v1
From the work of Ashkan Darbani (2019)
Slipper Surface Shaping
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50 % Decrease in Power Loss
at 450 bar, 3,600 rpm, 100% Displ.
Optimized Profile
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
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Optimization Results (Cont.)
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
From the work of Ashkan Darbani (2019)
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Slipper
Piston Swash PlateCylinder Block
DC Valve Plate
1
2
2
Cylinder Block-Valve Plate Interface
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
13
12
Cylinder Block Valve Plate
Figure from Baker (2008)
Circumferential Sine Wave Surface Shape
Circumferential Sine Wave Surface Shape:
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
From the work of Rene Chacon (2014)
14From the work of Rene Chacon (2014)
Results
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
~40% reduction in power loss
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The Lubricating Interfaces of Axial Piston Machines
Slipper
Piston Swash PlateCylinder Block
DC Valve Plate
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Piston-Cylinder Interface
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
Half-Barrel
Axial Sine Wave
Waved Barrel
Circumferential Sine Wave
Piston Surface Shaping to Increase Efficiency
“Flat”
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
From the work of Ashley Wondergem (now Dr. Busquets) (2018)
Half-Barrel
Waved Barrel
Operating Condition:350 bar, 1,500 rpm, 20% Displacement
Over 50% reduction in power loss
Over 20% reduction in power loss
75 cc UnitNominal clearance reduced to
~60% of original unit
Piston Surface Shaping to Increase Efficiency
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
From the work of Ashley Wondergem (now Dr. Busquets) (2018)
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Water Hydraulics
Why Water???
Green (sustainable resource) Cheap Widely available
Water Hydraulics
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
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Bushing
Cylinder Block
zK
Pump Case
External Forces on Piston Head
Piston During the High-Pressure Stroke
Metal-Metal Contact
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
Pt. A
Pt. B
DC Fluid
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Piston Deformation during the High-Pressure Stroke
DC Pressure
Current Work
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
External Forces on Piston Head
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Piston Deformation during the High-Pressure Stroke
DC Pressure
Current Work
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
External Forces on Piston Head
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Piston Deformation during the High-Pressure Stroke
DC Pressure
Current Work
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
External Forces on Piston Head
xpr
ypr
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Conclusions
• The Maha Fluid Power Research Center in-house model:o State of the art multi-physics simulation toolo Today’s presentation focused on its virtual prototyping
capabilities
• Well-designed surface shaping can:o Drastically reduce power losso Increase achievable load support for low-viscosity fluids
• Surface shaping is the FUTURE:Advances in manufacturing allow for more complex shaping
Overview Slipper-Swash Plate Cylinder Block-Valve Plate Piston-Cylinder Conclusions
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Questions?
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ReferencesBusquets, A. (2018). An Investigation of Micro-Surface Shaping on the Piston/Cylinder Interface of Axial Piston
Machines, PhD thesis, Purdue University.Chacon Portillo, R. (2014). Cylinder Block/Valve Plate Interface Performance Investigation through the Introduction of Micro-
Surface Shaping, Masters thesis, Purdue University.Darbani, A. A. (2019). An Investigation in Slipper-Swashplate Interface of Axial Piston Machines, Masters thesis,
Purdue University.Ernst, M. and Ivantysynova, M. (2018), ‘Axial Piston Machine Cylinder Block Bore Surface Profile for
High-Pressure Operating Conditions with Water as Working Fluid’. 2018 Global Fluid Power Society PhD Symposium (GFPS). Samara, 18-20 July.
Ivantysyn, J., and Ivantysynova, M., 2003, Hydrostatic Pumps and Motors, Tech Books International, New Delhi, pp. 134-141, Chap. 4.
Ivantysynova, M., Garrett, R. A. & Frederickson, A. A. (2012), ‘Positive Displacement Machine Piston with Wavy Surface Form’. Lasaar, R. (2003), Eine Untersuchung zur mikro- und makrogeometrischen Gestaltung der Kolben-/Zylinderbaugruppe von Schraegscheibenmaschinen, VDI Verlag GmbH, Duesseldorf.URL: http://www.sciencedirect.com/science/article/pii/S0257897205008807
Lasaar, R. (2003), Eine Untersuchung zur mikro- und makrogeometrischen Gestaltung der Kolben-/Zylinderbaugruppe von Schraegscheibenmaschinen, VDI Verlag GmbH, Duesseldorf.
Pelosi, M. (2012), An Investigation on the Fluid-Structure Interaction of Piston/Cylinder Interface,PhD thesis, Purdue University.
Schenk, A. (2014). Predicting Lubrication Performance between the Slipper and Swashplate in Axial Piston Machines, PhD thesis, Purdue University.