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
3
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
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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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:
Value Description No.
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
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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C- Gear specification
1- Large Gear
Fig. 4: Isometric view of large Gear
Dimensions:
Value Description No.
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:
Value Description No.
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
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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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:
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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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
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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- 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
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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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
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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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
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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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
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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°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
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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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
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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.