Applied Hydraulics and Pneumatics: Unit - I Fluid Power Systems and Fundamentals

APPLIED HYDRAULICS AND PNEUMATICS
UNIT-- I
FLUID POWER SYSTEMS AND FUNDAMENTALS
Introduction to fluid power, Advantages of fluid power, Application of fluid power system. Types of fluid power systems, Properties of hydraulic fluids General types of fluids Fluid power symbols. Basics of Hydraulics-Applications of Pascals Law- Laminar and Turbulent flow Reynolds number Darcys equation Losses in pipe, valves and fittings.
R.GANESA MOORTHY,ASSO.PROF/MECH
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Fluid power is the use of confined fluid flowing under pressure to transmit power from one location to another. It is a controlled, flexible muscle that provides power smoothly, efficiently, safely and precisely to accomplish useful work. Fluid power steers and brakes automobiles, launches space craft, moves earth, harvests crop, coal mine, drive machine tools, control airplanes, processes food and even drills teeth. Fluid power technology deals with the conversion, generation, control and transmission of fluid energy (power) using pressurized fluids to do some useful work.
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Advantages of Fluid power system

1.Fluid power system can readily start, stop, speed up or slow down and position very high forces with close tolerances using simple levers and push buttons. 2. Fluid power can simply performs work by achieving greater forces through the multiplication of smaller forces efficiently. 3. Fluid power provides constant torque at infinitely variable speeds in either direction with smooth reversals. 4. Fluid power systems are simple to maintain and operate. Hence maximum safety, compactness and easy installation is assured.
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5. High accuracy in controlling small or large forces with instant reversible motion is possible
6. Since the medium is fluid, these systems are not subjected to any breakage of parts as in mechanical systems. 7. Fluid power is efficient, economical, dependable, and readily available and provides predictable performance. 8. Hydraulic fluid power systems have the provision of automatic lubrication for less wear.
9. It easily provides infinite and step less variable speed control.

10. Automatic protection against overload is possible in Fluid power systems.
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Disadvantages of Fluid power system

1. Hydraulic oils are messy. 2. It is impossible to eliminate the leakages completely. 3. Improper design of Hydraulic lines can burst and results in injuries to the operator. 4. Prolonged Exposure to loud noise.
5. Leakage of most of the hydraulic oils in hot equipment area causes fire, as they are highly flammable.
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Applications of Fluid power systems

Some of the areas applying Fluid power are given below. 1. Agriculture : Hydraulically driven farm equipment 2. Automobile : Fluid power steering and braking systems. 3.Automation : Hydraulically powered robotic dexterous arm, Transfer machine, machine tools, Pneumatically operated indexing, holding, gripping and feeding devices. 4.Aviation : Hydraulic retractable landing wheels. 5. Domestic Applications : Hydraulic powered brush drive to clean roads, floors.
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6. Construction: Excavators, Earth movers, Concrete mixing equipments.

7. Defence: 8. Fabrication: Missile Launch Systems, navigation controls. High speed pneumatic riveter, Injection moldings machine, pneumatic hand tools, Hydraulic controlled Goliath (forging press). Industrial Lift trucks, Rear crawler shovels, Hydraulic jacks. hydraulic rams, onveyor systems, pneumatically operated packing, wrapping and butting equipments.
9.. Material Handling:
10. Transportation: Hydraulically powered overhead sky tram.
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Types of Fluid Power Systems

Based on the type of fluid used, the fluid power systems can be classified into two systems. 1. Hydraulic system [Fluid - Liquid] 2. Pneumatic system [Fluid - Compressed air]
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Hydraulic system
Hydraulic systems are power - transmitting assemblies employing pressurized liquid as a fluid for transmitting energy from energy generating source to energy use area to accomplish work. Figure shows the simple circuit of a hydraulic system with basic components.
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Hydraulic Actuator is a device used to convert the fluid power into mechanical power to do useful work. Actuators may be linear type or rotary type to provide linear or rotary motion respectively. Hydraulic pump is used to force the fluid to the rest of the hydraulic circuit from the reservoir. By converting the mechanical energy into hydraulic Energy. Valves are used to control the direction, pressure and flow rate of a fluid flowing through the circuit. External power supply(Motor) is required to drive the pump. Reservoir is used to hold the hydraulic liquid usually hydraulic oil. Piping system carries the hydraulic oil from one place to another. Filters are used to clean the hydraulic oil used in that circuit. Pressure regulator regulates i.e., maintains the required level of pressure in the hydraulic fluid.
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Advantages of Hydraulic system

1. Large load capacity with almost high accuracy and precision.
2. Smooth movement.
3. Automatic lubricating provision to reduce wear.
4. Division and distribution of Hydraulic power is simpler and Easier than other forms of Energy.
5. Limiting and balancing of Hydraulic forces are easily performed.
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Disadvantages of Hydraulic system 1. Hydraulic Elements needs to be machined to a high degree of precision. 2. Leakage of Hydraulic oil poses a problems to hydraulic operators. 3. Special treatment is needed to protect them from rust, corrosion, dirt etc; 4. Hydraulic oil may pose problems ifit disintegrates due to aging and chemical deterioration. 5. Hydraulic oils are messy and almost highly flammable.
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Pneumatic systems
Pneumatic system carries power by employing compressed gas generally air as a fluid for transmitting the energy from an energy generating source to energy - use area to accomplish work. Figure shows the simple circuit of a pneumatic system with basic components.
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Functions of the components

Hydraulic Actuator is a device used to convert the fluid power into mechanical power to do useful work. Actuators may be linear type or rotary type to provide linear or rotary motion respectively. Hydraulic pump is used to force the fluid to the rest of the hydraulic circuit from the reservoir. By converting the mechanical energy into hydraulic Energy. Valves are used to control the direction, pressure and flow rate of a fluid flowing through the circuit. External power supply(Motor) is required to drive the pump. Reservoir is used to hold the hydraulic liquid usually hydraulic oil. Piping system carries the hydraulic oil from one place to another. Filters are used to clean the hydraulic oil used in that circuit. Pressure regulator regulates i.e., maintains the required level of pressure in the hydraulic fluid
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Advantages of pneumatic system

1. Low inertia effect of pneumatic components due to light density of air 2. System is light weight 3. Comparatively easy operations of valves 4. Power losses and leakages are less in pneumatic systems 5. Low cost
Disadvantages of pneumatic system

1. Suitable only for light loads or small loads. 2. Availability of the assembly components is doubtful
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S.No.
1.
Hydraulic System
It employs a pressurized liquid usually air as a fluid. Generally, Hydraulic systems designed are designed as closed system. System get slow down if leakage system much occurs. Valve operations are difficult.
Pneumatic System
It employs a compressed gas as a fluid. Pneumatic systems are usually as open system. Leakage does not affect the more. Easy to operate the valves.
2.
3. 4.
5.
6.
Heavier in weight.
Pumps are used to provide pressurized liquid.
Light in weight
Compressors are used to provide compressed gas.
7.
8.
System is unsafe to fire Hazards.

Automatic lubrication is provided.
System is free from fire hazards

Special arrangements are made for lubricating the parts.
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Requirements / Characteristics of a hydraulic Fluid

A Good hydraulic fluid should possess the following characteristics 1. High corrosive resistant properties. 2. Good lubrication properties to reduce friction and wear. 3. Good sealing properties 4. Good Heat transfer capabilities. 5. Not effected by temperature changes. 6. Free from acidity and should be non-toxic. 7. High Flash point and low pour point. 8. Chemically and environmentally stable. 9. Less volatile. 10. High degree of incompressibility. 11. Ideal viscosity. 12. Good Fire and Foam resistant properties. 13. Low density. 14. Readily available. 15. Inexpensive.
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Functions of a Hydraulic Fluid

1. To transmit fluid power efficiently to perform useful work.
2. To lubricate the moving parts to minimize wear and friction.

3. To absorb, carry and dissipate the heat generated within the system. 4. To seal the close clearances between mating parts against leakage. 5. To prevent the rusting or corrosion. 6. To rapidly settle and separate the insoluble contaminants and abrasion.
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Properties of Hydraulic Fluid 1. Specific Gravity or relative density Specific gravity of a fluid is the ratio of the specific weight of a liquid to the specific weight of water 2. Viscosity Viscosity is the most important property of a hydraulic fluid, as it determines the ability of a fluid to be pumped and transmitted through the system 3. Viscosity Index Viscosity Index (V.I) is a relative measure of change in viscosity for a given change in temperature
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4. Neutralization Number The Neutralization number is a measure of the acidity or alkalinity of a hydraulic fluid And referred as PH factor of the fluid.
Neutralization Number = (Total ml of titrating solutionX5.61) /Weight of sample used
5. Lubricity A good hydraulic fluid must lubricate all the integral moving parts of the system. 6. Demulsibility Demulsibility is the ability of a fluid to resist emulsification by separating it from moisture(water). 7. Oxidation Another important property of hydraulic fluid is the oxidation stability. Oxidation is caused by the chemical reaction between the oxygen of the dissolved air and the oil
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8. Corrosion
Rust is the chemical reaction between iron or steel and oxygen. Corrosion is the chemical reaction between a metal and acid. 9. Defaming Foaming is the result of entrainment of air in oil. Typically, an oil can contain up to 10% by volume of dissolved air. 10. Pour point, Flash point and Fire point Pour point is the lowest temperature at which a fluid will flow. Flash point is the Temperature at which the oil gives sufficient vapour at the surface to ignite when a test flame is passed over the surface. Fire point is the temperature at which the oil will release sufficient vapour to support combustion
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Types of Fluids Generally, Fluids are broadly categorized into two major groups. 1. Gases 2. Liquids 1. Gases Gases are used as a fluid in pneumatic systems, preferably air. In gases, the relative spacing between the molecules is too large. Gases have definite mass, but no volume and definite shape. 2. Liquids Liquids are used as a fluid in hydraulic systems, preferably oils. In liquid, the relative spacing between the molecules is much less. Liquids have definite mass and volume but no definite shape The liquids may fall on the following categories.
a) Water b) Petroleum oil c) Fire resistant fluids
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a) Water Water was the first fluid used for the transmission of power. It is treated with chemicals before use to remove undesirable contaminants. b) Petroleum - base Fluids Petroleum - base fluids are refined from selected crude oils and blended with additives to prevent wear, rust, oxidation and Foaming c) Fire resistant fluids In many fluid power applications, hazardous conditions and safety requirements dictate the use of a fire resistant fluid.The commonly used fire resistant fluids are i)Water-in-oil Emulsion (invert Emulsion) ii) Water Glycol Emulsion ill) Synthetic fluids iv) High water content fluids (HWCF).
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Fluid power symbols Fluid power symbols are used to draw the hydraulic/ pneumatic circuit for easy understanding. They are used worldwide in design. Operation and maintenance of fluid power systems.
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Basic of Hydraulics
According to Pascal's law "The pressure generated on a confined fluid at rest is transmitted equally undiminished in all directions throughout the fluid and acts at right angles to the containing surfaces". Here, a force is being applied to a piston which in turn exerts a pressure on the confined fluid which is equal everywhere and at right angles to the containing surfaces According to Pascal's law P1 = P2 (F1/A1) = (F2/A2) 100/10 = F2/100 F2 = 1000N
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Applications of Pascal's law Any fluid power system works on the basis of pascal's law. Here, we discuss the applications of pascal's law employed in two simple systems. Hand operated Hydraulic Jack This system uses a piston-type hand pump to power a hydraulic load cylinder for lifting loads as shown in figure .It consists of handle ABC, pivoted about point C and a piston rod is pinned to it atpoint B. When handle is pulled up at A, the piston rises and valve creates a vacuum in the space below it thus draws the oil from the tank through check value 1. This check valve allows flow to pass in only one direction, as indicated by the arrow.
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When the handle is pushed down at A, the pump cylinder ejects the oil to the load cylinder through check valve 2. Pressure builds up below the load piston and thus lifts the load. Bleed valve is a hand-operated valve, which opened to lower the load by bleeding the oil from the load cylinder back to the oil tank.
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Air-to-Hydraulic pressure Boosters This device uses shop air to increase hydraulic pressure needed for operating hydraulic cylinders requiring small to medium volumes of higher - pressure oil. It consists of a large air piston cylinder driving a small hydraulic piston cylinder to clamp a work piece to a machine tool table by supplying highpressure oil as shown in figure
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Laminar and Turbulent flow Conditions due to the construction or operation of hydraulic machinery may effect the flow characteristics of the fluid in the system. There are two type of fluid flow in a hydraulic system. 1)Laminar or streamline flow Laminar or streamline flow is characterized by the smooth flow of liquid particles in even layers with minimum frictional losses. Laminar flow continues only in low velocity on the same direction. This Fluid flow type is called stream line flow as all the fluid particles moves in a parallel path.
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Turbulent Flow Turbulent flow is characterized by the irregular flow of liquid particles due to the collision of fluid particles. Figure shows the random or erratic pattern of a fluid flow, creating inefficiencies, high energy losses due to friction, more resistance to flow and pressure drop. Turbulent flow may lead to premature wear, cavitations and pitting on valve surfaces
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Reynold's Number Osborne Reynolds in 1833 has given a dimensionless number for predicting the nature of flow (laminar or turbulent) in a given situation and expressed as Re = (v D / ) = (v D/ v)
where, v- Fluid velocity, m/sec d- Pipe Inside diameter, m -Fluid Density, kg/m3 - Absolute Viscosity, N.S/m3 v - Kinematic viscosity, m2/sec
For laminar flow, Re value is less than 2000. For turbulent flow, Re value is greater than 4000. For critical flow, Re value varies between 2000 and 4000 and assumed as turbulent flow for calculations. This is an unpredictable flow type. To avoid greater losses, hydraulic systems are usually designed to operate in the laminar flow region. This can be made by increasing the pipe diameter.
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Darcy's Equation Darcy's Equation can be used to calculate the head loss due to friction in pipes for both laminar and turbulent flow and expressed as HL=fLv2/2Gd--- Darcy Weisbach formula where HL = Head loss in pipe due to friction, m f = Friction factor, dimensionless L = Pipe length, m V = Fluid velocity, m/sec g = Acceleration due to gravity, m/sec2 D = Pipe inner diameter, m For Laminar flow f = 64 / Re HL= (64Lv2/Re2gD) =(32Lv2/ Re g D) =(32Lv2 ) /(v D g D)= 32Lv2 / v D 2 g=32Lv / D 2 g =32vLv/ D 2 g
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Pipe roughness depends on the pipe material and the method of manufacture. Re1ative Roughness = Surface roughness (E)/Diameter of pipe (D) The friction factor (f) may also be taken from the Moody diagram for both laminar as well as turbulent flow.
Losses in pipes, valves and Fittings When fluid is pumped through a fluid power system, a portion of its energy is lost due to friction. Major losses occur as the fluid flows through pipe, hoses and tubing. These losses can be calculated using thumb rules for a given length of pipes. Minor losses occur at valves, fittings, bends, enlargements, contractions and orifices.
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Losses in pipes Losses in pipes are due to the friction i.e., rubbing action between the boundary surface and fluid. This friction builds up the heat and results in energy loss. In addition to this, pressure drop may occur during the flow. In hydraulic systems, pressure drop should be kept as low as possible to obtain high transmission efficiency. This may be done by increasing the design value of diameter of one pipe to some extent. In other words, large diameter pipes reduces the pressure drop across the flow.
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Losses in valves and Fittings Minor losses occur as the fluid undergoes sudden expansions or contractions, or as the fluid flows through the pipe fittings, valves and bends. For many fluid power applications, majority of energy losses are due to change in cross-section of the flow path and the change in flow direction which are usual in these valves, fittings, tees, elbows and bends. Head losses are found to be proportional to the square the velocity of the fluid. HL= kv2/2g The head loss through the minor losses is equal to the loss through some length of straight pipe. Minor HL=Major HL kv2/2g=f L v2/2Gd L=D(k/f)
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Applied Hydraulics and Pneumatics: Unit - I Fluid Power Systems and Fundamentals

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APPLIED HYDRAULICS AND PNEUMATICS

FLUID POWER SYSTEMS AND FUNDAMENTALS

Advantages of Fluid power system

9. It easily provides infinite and step less variable speed control.

Disadvantages of Fluid power system

Applications of Fluid power systems

6. Construction: Excavators, Earth movers, Concrete mixing equipments.

9.. Material Handling:

10. Transportation: Hydraulically powered overhead sky tram.

Types of Fluid Power Systems

Advantages of Hydraulic system

Functions of the components

Advantages of pneumatic system

Disadvantages of pneumatic system

System is unsafe to fire Hazards.

System is free from fire hazards

Requirements / Characteristics of a hydraulic Fluid

Functions of a Hydraulic Fluid

2. To lubricate the moving parts to minimize wear and friction.

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