The Significance of Piston/Cylinder Surface

Shaping on the Performance of Axial Piston

Machines

Ashley Wondergem
Dr. Monika Ivantysynova
Purdue University

October 16, 2015

Outline

Introduction
Axial Piston Machines

Theory
Previous Research

Method
Fluid Structure Interaction Model
Simulation Study First Phase
Simulation Study Second Phase

Simulation Study Results

Conclusion
Next Steps

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Introduction

Overview of Main Tribological Interfaces of Axial Piston Machines

Piston & Cylinder

Goal: ODC (Outer

Dead Center)
Investigate how to reduce energy dissipation
between the piston and the cylinder through
IDC (Inner
surface shaping of the piston Dead Center)

Cylinder Block & Valve Plate

Slipper & Swash Plate
Functions
Dissipations
Bearing Function Main source of
Load Carrying Viscous Friction energy
Sealing Function Leakage flows dissipation

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 Previous Work Surface
Shaping
Yamaguchi (1976)
Numerical analysis: tapered piston increased efficiency

Ivantysynova (1983)
ProposedLoss reductions
a barrel strongly dependent on
like piston
operating condition
Kleist (1997)
Surface shaping reduces friction forces
Study made with incomplete models
Lasaar (2003)
Barrel piston (analytical and experimental)
Volumetric losses reduced
Friction forces reduced

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Fluid Structure Interaction Model

Macro & Micro Motion

Kinematics / Dynamics

Lubricating Fluid Film

Heat Transfer Pressure Field

Pressure Deformations
Thermal Deformations Surface Profile

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Micro Surface Shaping
-Geometries Under Investigation
[]
=0.29 MRC
[]
MRC [] A
= 0.4
A []
Baseline: 1 [] 3 [] R1 LApex R2 R3
= 0.9993 = 0.9989
wear-in piston-cylinder from
Standard 2 []
[]
2 []
Sine
75 cc stock unit:
[]
=0.4167
[] MRC = 0.96 Waved Barrel
=0.29
[]
[] MRC max wear
= 0.4
[] MRCR max wear
2 []
MRC = 0.96 R1 LApex =0.29
R3 []
[]
= 0.167
Barrel []
1 [] MRC = 0.96
= 0.9996
2 []
MRC 3 []
A = 0.9984
2 [] CircSine
[]
max []

Bushing wear: =0.4167
=1.21 MRC
[]
[]
Flat MRC
Piston
max []
wear: = 0.96 =0.1
[]
[]
=0.29 MRC = 1.64
[]
MRC = 0.96

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Simulation Studies

First phase:
4 different designs compared to baseline for moderate
operating conditions in pumping mode only

Results published in:

Wondergem, A, and M Ivantysynova. 2014. "The Impact of the
Surface Shape of the Piston on Power Losses." Proceedings of the
8th FPNI PhD Symposium. Lappeenranta, Finland.

Second phase:
5 different designs compared to baseline for extreme operating
conditions in pumping and motoring mode

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 Simulation Study
Pumping Mode - 1000 rpm, 400 bar LP
HP
Baseline Barrel Flat
Lf 1 Lf 1 Lf 1
Fluid Film
Gap Height 0.5 0.5 0.5
(m)
0.1 0.1 0.1
7
6 0 360 0 360 0 360
4
3
1
0

Pressure
(bar)
2000

1500
Lf Lf
1000 Lf
360 360
360
500 0
0 0

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Simulation Study
Pumping Mode - 2800 rpm, 400 bar LP
HP
Baseline Barrel Sine
Lf 1 Lf 1
Fluid Film Lf 1

Gap Height 0.5 0.5

(m) 0.5

7 0.1 0.1 0.1

6 0 360 0 360 0
4 360

3
1
0 Case

Pressure
(bar)
2000

1500

1000 Lf
Lf Lf DC
360 360
360
500 0
0 0

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Simulation Study
Pumping Mode Energy Dissipation

Circ sine and waved barrel Up to 40%

outperform at LP reduction
Flat fails at(flat)
high
Up to 30% decrease Sine also fails at high
speeds/pressures
for barrel speeds/pressures
Barrel best,
especially at HP

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Simulation Study
Pumping Mode Leakages

Around
Up to 60%
70% reduction
reductionBUT fails at some
(barrel)
(flat); Based on 40%
operating conditions
Around 40% in
reduction clearance
reduction at
higher speed/pressures

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Simulation Study
Pumping Mode Overall

: : ** Simulation failure was

100
: penalized 1.5*baseline

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Simulation Study
Motoring Mode - 2000 rpm, 225 bar LP
HP
Waved
Baseline Barrel Barrel
Lf 1 Lf 1 Lf 1
Fluid Film
Gap Height 0.5 0.5 0.5
(m)
7 0.1 0.1 0.1
6 0 360 0 360 0 360
4
3
1
0
Case

Pressure
(bar)
2000

1500

1000 Lf
Lf Lf DC
360 360
360
500 0
0 0

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Simulation Study
Motoring Mode Energy Dissipation

Waved barrel and circ sine

outperforms
almost barrel in
30% decrease
motoring mode

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Simulation Study
Motoring Mode Leakages

Trend in energy dissipation

Flat and circrelies
sine results in
on reduction in leakages
almost 50% decrease
-Based on reduction in
Waved barrel and circ sine
clearance
results in larger decrease
than barrel

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Simulation Study
Motoring Mode Overall

: : ** Simulation failure was

100
: penalized 1.5*baseline

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Simulation Study
Overall Pumping & Motoring Mode

: : ** Simulation failure was

100
: penalized 1.5*baseline

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Conclusion

Piston Surface Shaping

Better understanding of how piston shape effects machine operation
and fluid film generation under various conditions

Increased load support allows for reduction in clearance between the

piston and the cylinder
Improve/maintain reliability of machine

Improvements in the efficiency of the machine are shown over a wide

range of operating conditions
Largely due to decreased leakages based on decreased clearances

Overall barrel surface profile performs best under conditions studied

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Next Steps
Investigate at machine limits

Manufacture prototype

Test on Steady State test rig

Measure overall losses Tribo Test Rig

Test on the Tribo test rig Case

Measures the friction forces at the Swashplate

Shaft
piston/cylinder interface
Main Pistons

Test on the EHD test rig Cylinder Block

Measure the pressure and
temperature distribution as the
swashplate rotates
EHD Test Rig

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 Questions

Contact Information
Monika Ivantysynova - mivantys@purdue.edu
Ashley Wondergem awonderg@purdue.edu

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