NumericalSimulationofFluidStructure InteractionintheDesignProcessforaNew HydraulicAxialPump

BettinaLandvogt Leszek Osiecki TomaszZawistowski Bartek Zylinski FraunhoferSCAI,Germany GdanskUniversityofTechnology,Poland SpaceResearchCenterofthePolishAcademyof Sciences,Poland Bandak Engineering,Norway

Content
Introduction HydraulicAxialPumps VariableDisplacementPumps PressurePeaks CompensationChamber CoupledFEAandCFDSimulation SimulationModels SimulationResults SummaryandOutlook
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HydraulicAxialPumps

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HydraulicAxialPumps
ResearchprojectintheDepartmentof HydraulicsandPneumaticsatGdansk UniversityinPoland. Anewaxialpumpwithacamdriven commutationunit(calledPWKpump) wasdeveloped. Constantdisplacementpumpwith verygoodperformance: Workingpressureupto55MPa Efficiencyof94% Goodpowerdensity
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HydraulicAxialPumps
Tocontrolthefluidamountvariabledisplacementpumpsareused, whichusuallyhavetobecontrolledbyacomplicatedhydraulic servomechanism. Themainadvantageofthenewpumpisthatitcanbecontrolledby alowenergyactuator. Reducespumpscostanddimensionsdrastically. Fordisplacementcontrolaspecialplanetarygearboxwasdeveloped toprovidecontroloverfastrotatingparts.
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VariableDisplacementPumps

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HydraulicAxialPumps
Mainelementsofthepump:

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HydraulicAxialPumps

Prototypeshavebeenbuiltandtested,e.g.inlifting devicesonshipsinanextremetemperatureenvironment.

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PressurePeaks

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PressurePeaks
Whenthecylinderchamberis disconnectedfromthe outtakeandintakechannels harmfulpressurepeakswere observedinthepump.

HighNoiseEmission DamageofthePump

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PressurePeaks
Averagepumping pressure Displacement adjustment

Oilcompressibility

Amplitudeof PressurePeaks

Rotationalspeed

Volumeofthefluid inthechamber Deformationof pumpselements

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Leakage

Temperature
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PressurePeakCompensation

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PressurePeakCompensation
CompensationChamber: Shortensperiodof disconnectionandgivesfluid moreroom.

PressurePeakreductionby 50%,notaffectingthepumps efficiency. Optimizeshape,elasticityand volumeofthechamberwhile minimizingpressurepeaks.

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CoupledCFDandFEASimulation

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CoupledCFDandFEASimulation

CADmodelofapumpwithsevenchambers(right)andasymmetricmodelof asimplifiedpumpwithtwochambers(left).Movablepartsareshowninred.
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CFDmodelinFLUENT
Hexahedralelementsanddynamiclayeringmethod formovingmeshbetweenthepistons. Motionofthepistonsandthebridge(connecting thecylindervolumewiththeintakeorouttake channels)isrealizedviauserdefinedfunctions. Thehydraulicoilisassumedtobeslightly compressible. Acoupledsolver(forpressureandvelocity)andthe SpalartAllmarasturbulencemodelareused. Highpressure10MPa,lowpressure0.2MPa. (pressurein andoutlet). Twocyclesofthepump(dependingonthe configuration)take0.08s. Timestepsizeis1e05or5e06.
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CFDmodelinFLUENT

Onecylinderchamber inFluent:wallsare coloredblue,interfaces greenandsymmetry planesyellow. Thetwopistonsare quiteclosetoeach otherleadingtoasmall volumeofthecylinder chamber.

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FEAmodelinAbaqus
ShellmodelofthemembranewithS4 elements. Boundaryconditions:leftandright sidesofthechamberwallarefixedin space. Thicknessofelasticwall:1.5mm Isotropicelasticmaterialwith Youngsmodulus: E=2.1e09Pa =0.35 Poissonratio: Density: =7800kg/m

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FEAmodelinAbaqus
Solidmodel(consistingof hexahedralelements)ofthepump wasdevelopedaswellfor comparisonwithshellresults. SolvedwithAbaqus/Explicit (nonlineargeometry)withafixed timeincrement. Abaqusloadsarerampedlinearly overthetimestep.

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FluidStructureInteraction
Hydraulicoilexerts wallforceonthe membrane. Position WallForce Membranedeforms underload.

ModeledinFluent.

SimulatedinAbaqus.

FSIcouplingwith MpCCI
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FluidStructureInteraction
MpCCI FraunhoferSCAIsMulitphysics CodeCouplingInterface:
Automaticandfastcouplingmethods Orphanfilling Flexible:manysupportedcodes,API Usageoffastsocketcommunication Underrelaxationofquantities Visualizationofresults EasyusageviaGUIorbatch

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SimulationResults
Pressurecontoursonthe CFDmodelduringtwo pumpcycles. Thepressurechangein thecompensation chambercanbeseen whenthechamberis connectedtothe channels.

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SimulationResults
Displacementofthe FEMmodel(shells modeledinAbaqus).

Theforceexertedby thehydraulicoil leadstoaslight deformationofthe membranewall.

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SimulationResults
VonMises Stresson theFEMmodel(shell elementsinAbaqus)

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SimulationResults
VonMises Stressonthe FEMmodel(displaced volumeelementsin Abaqus)

Theboundaryconditions, i.e.thefixationofthe compensationchamber,is showninthispicture.

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SimulationResults

CFD(FLUENT) PressurePlotsatthreediscretepointsofthepump.
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SimulationResults

CFD(FLUENT)

FSI (AbaqusMpCCIFluent)

PressurePlotsatthreediscretepointsofthepump.
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SimulationResults

TimesensitivityoftheFSIsolution:timestepsize1e04
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SimulationResults

TimesensitivityoftheFSIsolution:timestepsize3e05
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Summary
FSIsimulationduringthedesignprocessofthenewaxial hydraulicpump: Muchbetterunderstandingofoccurrenceofpressurepeaks. Helpedinfindinganoptimaldesignforthecompensation chamber. SignificantdifferencesbetweenCFDstandaloneandFSI simulations:FSIsimulationsagreedconsiderablybetterwith experimentalresults. Thankyouforyourattention. Anyquestions? Furtherinvestigations: Includeleakageinthenumericalsimulation. Fatiguesimulationofpump.
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Summary
FSIsimulationduringthedesignprocessofthenewaxial hydraulicpump: Muchbetterunderstandingofoccurrenceofpressurepeaks. Helpedinfindinganoptimaldesignforthecompensation chamber. SignificantdifferencesbetweenCFDstandaloneandFSI simulations:FSIsimulationsagreedconsiderablybetterwith experimentalresults. Thankyouforyourattention. Anyquestions? Furtherinvestigations: Includeleakageinthenumericalsimulation. Fatiguesimulationofpump.
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