Analyzing Two Different Fluids in Hydraulic · PDF fileInternational Journal of All Research Education and Scientific Methods (IJARESM) ISSN: 2455-6211, Volume 5, Issue 6, June- 2017,

International Journal of All Research Education and Scientific Methods (IJARESM) ISSN: 2455-6211, Volume 5, Issue 6, June- 2017, Impact Factor: 2.287

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Analyzing Two Different Fluids in Hydraulic

Retarder

Timur Choban Khidir1, Abbas Mohammed Ismael

2, Ali Hasan Abdulla

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1,2Kirkuk University / College of Engineering - Mechanical Dept. 3Kirkuk University / College of Engineering - Petroleum Dept.

ABSTRACT

The three-dimensional geometric model of hydraulic retarder is built based on an enterprise production

as reference prototype by SOLIDWORKS with the three-dimensional entity model of the hydraulic

retarder. The internal flow in the retarder use two type of fluids first gear oil and the second is

intercooler bio-green, we will analyze two types of fluid so that getting best one to use in retarder which

has blade angle 43 degree. The simulation results show that there were some problems such as vast

vortexes and wall flow separations which added braking torque losses. In order to improve the braking

simulation using different fluids and get the best optimization scheme. We also selected the material of

retarder blade as (Steel, normalized at 870 ° C) and analyzed it.

Key Words: hydraulic retarder, gear oil, intercooler bio-green, blade metal.

I. INTRODUCTION

Hydraulic retarder is as a kind of an auxiliary brake, is applied to stabilize vehicle speed in long slope road. Commonly driving in mountainous areas and mining road for heavy duty truck causes overload brake. It is hard

to meet drivers using only traditional brake system in these roads. The hydraulic retarder is widely applied in

heavy vehicle due to it has high and continuous braking performance with a compact structure[1]. A retarder is

usually consists of rotor, stator, cooling system and control system, and it is always locates between convert and

transmission. During the working the rotating mechanical energy is transferred into heat energy and the heat is

brought to outside atmosphere by cooling system, at the same time the brake torque is generated and work at

tires to slow down the vehicle speed[2]. The structure parameter of hydraulic retarder is an important factor that

affects the braking performance[3].

In this research, the three-dimensional geometric model of hydraulic retarder is built in Solid works program

based on an enterprise production as reference prototype, onCFD platform. The stress analysis of rotor retarder

studied and in order to improve the brake performance the internal flow is simulated and the influence of fluid on the internal flow is analyzed for two different fluids.

II. SPECIFICATIONS

A- Retarder specification

1- Rotor

Fig. 1: Isometric view of Rotor


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Dimensions:

Value Description No.

170mm Rotor inner Diameter 1

292mm Rotor Diameter out 2

18 Rotor blade Number 3

7 mm Rotor blade thickness 4

43° Rotor blade Wedge angle 5

2- Stator

Fig. 2: Isometric view of Stator

Dimensions:


170mm Stator inner Diameter 1

295mm Diameter out Stator 2

16 Stator blade Number 3

7mm Stator blade thickness 4

43° Stator blade Wedge angle 5

10 Stator Oil inlet Number 6

B- Shaft specification

Fig. 3: Isometric view of Shaft


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C- Gear specification

1- Large Gear

Fig. 4: Isometric view of large Gear

Dimensions:


2.5 Module 1

56 Number of teeth 2

45° Helix angle 3

Left hand Helix Direction 4

20° Pressure angle 5

30mm Face Width 6

120mm Nominal Shaft Diameter 7

202mm Out Diameter 8

120mm Inner Diameter 9

2- Small Gear

Fig. 5: Isometric view of Small Gear

Dimensions:


2.5 Module 1

28 Number of teeth 2

45° Helix angle 3

Right hand Helix Direction 4

20° Pressure angle 5

30mm Face Width 6

100mm Nominal Shaft Diameter 7

103mm Out Diameter 8

65.44mm Inner Diameter 9


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D- The properties of the metal are used in retarder

Steel, normalized at 870 °C

unit value Property

N/m^2 2.05e+011 Elastic Modulus

N/A 0.285 Poisson's Ratio

N/m^2 8e+010 Shear Modulus

kg/m^3 7850 Mass Density

N/m^2 731000000 Tensile Strength

N/m^2 460000000 Yield Strength

W/(m.k) 42.5 Thermal conductivity

J/kg.k 477 Specific Heat

III. METHODOLOGY

A. CAD-Models:

B.

Fig. 6: Isometric view of CAD model of retarder

B. Design of retarder:

To design a retarder for (Steel, normalized at 870C), Speed1200 r.p.m, brake Torque 433.66N.m, Static pressure

2.5Mpa, mass flow rate 0.22 kg/m.

C- Study Simulation for Rotor retarder:

1- Meshing of Rotor retarder:


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Fig. 7: Meshing of Rotor retarder

2- Analysis

Test of Rotor retarder (Von Misesstress, shear stress, Strain, deformation) Test by applying pressure at

(P=2Mpa).

- Von Mises

Fig. 8: Von Misesstress of Rotor retarder

- Strain

Fig.9: Strain of Rotor retarder


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- Deformation

Fig.10: deformation of Rotor retarder

- Shear Stress

Fig.11: Shear Stress of Rotor retarder

3. Flow Simulation Study for retarder:

We will study now two types of fluids in order to compare between two fluids and choose the best to use in

Retarder.

3.1- Gear Oil

Its specification is as the following:

The density and viscosity is respectively defined as ρ=860 kg/m3 and μ=0.006 kg/ms, Specific Heat (cp) 1884

J/(kg.k), Thermal conductivity 38 W/(m.k).

pressure

Fig.12: Pressure analysis of retarder


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Relative Pressure

Fig.13: Relative Pressure analysis of retarder

Rate Velocity

Fig.14: Rate Velocity analysis of retarder

Velocity X-axis

Fig.15: Velocity X-axis analysis of retarder

Velocity Z-axis

Fig.16: Velocity Z-axis analysis of retarder


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Turbulent Viscosity

Fig.17: Turbulent Viscosity analysis of retarder

Turbulent Time

Fig.18: Turbulent Time analysis of retarder

Temperature Fluid

Fig.19: Temperature Fluid analysis of retarder

Thermal Conductivity

Fig.20: Thermal Conductivity analysis of retarder


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Prandtl Number

Fig.21: Prandtl Number analysis of retarder

Specific Heat (cp)

Fig.22: Specific Heat (cp) analysis of retarder

Flow Simulation Pressure Curve Study for retarder(Gear Oil):

Fig.23: Pressure curve Study

3. 2- Intercooler bio- Green

Bilateral alcohol (hydroxyl glycols)

Its preparation:

The pure of this compound is non-colored, non-volatile and viscous fluid, its molecular weight is 76.09 Ib

/(IbMole) mixable with water in any proportion, its boiling point is 197 °C and the density is 1.050 g/ cm3 at 20


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°C. This compound is obtained by inserting two molecules or two sets of hydroxyl into propane. It is prepared

by hydrolysis the alkyl halides binary halogen, which attends from alkines [4].

The pure of this compound has high boiling point allowing it to withstand high temperatures generated in

turbines without evaporating up to 187.3°C also has good heat conduction which is enough to loss in the heat

exchanger of this high temperature that acquires after rotating turbines, and because of this property named as

(Intercool Bio-green). So it is considered as a good solvent to distribute the heat inside internal combustion engines as well as a non-oxidizing material. Its vapor pressure is less than 0.1 mm Hg at 20 °C (atmospheric

pressure 780 mm Hg) and because of its accepted molecular weight which keeps it in liquid condition even in

high pressure and high temperature, and it is easily dissolves in water, alcohol and ether. And its melting degree

is (-60 °C).

Its specification as below:

The density and viscosity is respectively defined as ρ=1050kg/m3 and μ=0.024 kg/ms, Specific Heat (cp) 3602

J/(kg.k), Thermal conductivity 0.374 W/(m.k). By analyzing which we did for intercooler bio- green fluid we

obtained the results of the analysis as shown in the table.

unit Value Description No.

pa 2500000.1 Pressure 1

pa 2398675.075 Relative Pressure 2

m/s 0.006 Rate Velocity 3

m/s 0.006 Velocity X-axis 4

m/s 0.002 Velocity Z-axis 5

Pa.s 5.1865e-005 Turbulent viscosity 6

S 762.146 Turbulent time 7

k 293.2 Fluid Temperature 8

W/m.k 0.0385 Fluid Thermal conductivity 9

Prandtl Number 10 2245.4ـــــــــــــ

J/kg.k 3602 Specific Heat (cp) 11

Flow Simulation Pressure Curve Study for retarder(Intercooler bio- Green):

Fig. 24: Pressure curve Study


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IV. RESULT AND DISCUSSION

If we look to the figures 23 and 24 we will see difference in pressure values and the reason for this is the

properties of two fluids, first is Gear oil and the second is Intercooler bio- Green, especially the difference in

density. By checking figure 23 we will see the pressure increase along its length and until it reach to the rotor,

(in case of gear oil). And the reason is the fluid temperature. As we know the relation of density with the temperature, by increasing fluid temperature the density will decrease and the pressure will increase.

While in case of Intercooler bio- Green the water will evaporate with heat exposure and will lose its property to

obstacle the rotation of rotor, (reverse of gear oil). So we see in figure 24 the pressure decrease when the

Intercooler bio-green reaches to the rotor, and as we know the rotor temperature is high.

CONCLUSION

In this study we have used two types of fluid and by analyzing the result with SOLIDWORKS program software

we found that the Gear Oil has a relative pressure of 2,563,700.2pa, While the Intercooler bio- Green fluid has

relative pressure 2,398,675.075 pa, The pressure difference between the two fluids is 165,025.125pa,this means

that the Gear Oil fluid is better than Intercooler bio- Green fluid. Also, there is a difference in the amount of flow velocity between the two liquefied Gear oil and Intercooler bio- Green, the speed of Gear oil is 1.017 m/s

while the speed of flow of Intercooler bio- Green0.006 m/s the reason for the difference in velocity between the

two fluids is due to the difference in the amount of viscosity. The other analysis of blade like von misses stress,

shear stress, strain and deformation all of them are in the safe value for two different fluids.

REFERENCES

[1]. WeiW, Yan Q D. Study on Hydrodynamic Torque Converter Parameter Integrated Optimization Design System Based

on Tri-Dimensional Flow Field Theory [J]. SAE 2008-01-1525. [2]. Wu Chao, Xu Ming, Li Huiyuan, et al. Analysis of Characteristic and Development of Vehicle Hydraulic Retarder[J].

Vehicle and Power Technology, 2011(01): 51-55. [3]. XieRong, Shan Yujiao, Wang X iaofang. Numerial Simulation on Flow Performance and Blade Profile Optimal

Design of Mixed-flow Pump Impeller [J]. Journal of Drainage and Irrigation Machinery Engineering, 2010, 28(4):

296-299. [4]. Organic chemical, Dr. Abdul karimabd mohammed, Dr. Helmihasanhusani.

Documents

Analyzing Two Different Fluids in Hydraulic · PDF fileInternational Journal of All Research Education and Scientific Methods (IJARESM) ISSN: 2455-6211, Volume 5, Issue 6, June- 2017,