SUBJECT : FLUID POWER SYSTEMS (17ME72 )

MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Fluid Power:
Fluid Power is the technology that deals with the generation, control, and transmission of
power using pressurised fluids. Fluid power is used to push, pull, regulate or drive virtually
all the machines of modern industry. For example, fluid power steers and brakes automobiles,
moves earth, harvests crops, mines coal, controls airplanes, launches spacecrafts, drives
machine tools and processes food.
Fluid power is called hydraulics when the fluid is a liquid and is called pneumatics when the
fluid is a gas. Thus fluid power is the general term used for both hydraulics and pneumatics.
Hydraulic systems use liquids such as petroleum oils, synthetic oils and water. Though water
was the first to be used because of its easy availability, nowadays it is not preferred. This is
because water is a poor lubricant, freezes easily and tends to rust metal components.
Pneumatic systems use air as the gas medium because air is very abundant and can be readily
exhausted into the atmosphere after completing its assigned task.
Fluid power is designed specifically to perform the work. The work is accomplished by a
pressurised fluid bearing directly on an operating cylinder or fluid motor. A fluid cylinder
produces a force resulting in linear motion whereas a fluid motor produces a torque resulting
in rotary motion. These cylinders and motors are called actuators.
Liquids provide a very rigid medium for transmitting power and can thus operate under high
pressures to provide huge forces and torques to drive loads with accuracy and precision. On
the other hand, pneumatic systems exhibit spongy characteristics due to the compressibility
of air. However pneumatic systems are less expensive to build and operate. In addition,
provision can be made to control the operation of the pneumatic actuators that drive the loads.
Thus pneumatic systems can be used effectively in applications where low pressures can be
used because the loads to be driven do not require large forces.
Advantages of fluid power:
Fluid Power helps in automation in industries through direct and remote control of production
operations, manufacturing processes and material handling. The following are the advantages
of fluid power:
1. Ease and accuracy of control: By the use of simple levers and push buttons, the
operator of a fluid power system can readily start, stop, speed up or slow down forces
that provide any desired horse power to close tolerances.
NOTES BY SANDESH M PRABHU,
ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 1
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

2. Multiplication of force:
A fluid power system (without using gears, pulleys and levers) can multiply forces
simply and efficiently from a few grams to many tons.
3. Constant force or torque:
Only fluid power systems are capable of providing constant force or torque regardless
of speed changes.
4. Simplicity, safety and economy:
In general fluid power systems use fewer moving parts than comparable mechanical
or electrical systems. Thus they are simple to operate and maintain. This in turn
maximises safety, compactness and reliability.
Additional benefits of fluid power systems include instantly reversible motion, automatic
protection against overloads and infinitely variable speed control. Fluid power systems have
the highest power to weight ratio.

Limitations of fluid power:

1. Hydraulic oils are messy and complete elimination of leakage is impossible.
2. Hydraulic lines can burst which in turn can cause injuries to people due to high-speed
oil jets and flying pieces of metals if proper design is not implemented.
3. Prolonged exposure to loud noise can result in loss of hearing.
4. Most hydraulic oils can cause fires if an oil leak occurs in the area of a hot equipment.
5. In pneumatic systems, components such as compressed air tanks and accumulators are
potentially explosive if the pressure is allowed to increase beyond safe design limits.

Applications of fluid power:

1. It drives high-wire overhead tram.
2. It is applied in harvesting.
3. It is made use of in power brush drives for cleaning roads, floors, etc. in industrial
applications.
4. It drives excavators and other earth moving equipment.
5. It is the muscle in industrial lift trucks.
6. It powers the robotic arm
NOTES BY SANDESH M PRABHU,
ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 2
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Components of Hydraulic system:

Figure 1

A hydraulic system has six basic components:

1. A tank (reservoir) to hold the hydraulic oil
2. A pump to force the oil through the system.
3. An electric motor or other power source to drive the pump.
4. Valves to control oil direction, pressure and flow rate.
5. An actuator to convert the pressure of the oil into mechanical force or torque to do
useful work. Actuators can either be cylinders to provide linear motion or hydraulic
motors to provide rotary motion.
6. Piping which carries the oil from one location to another.

Components of Pneumatic system:

A pneumatic system also has six basic components:

1. An air tank to store a given volume of compressed air.

2. A compressor to compress the air that comes directly from the atmosphere.
3. An electric motor or prime mover to drive the compressor.
4. Valves to control air direction, pressure and flow rate.
5. Actuators which are similar in operation to hydraulic actuators.
6. Piping to carry the pressurised air from one location to another.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 3
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Figure 2

Transmission of power at static and dynamic states:

A hydrostatic system uses fluid pressure to transmit power. Hydrostatics deals with the
mechanics of still fluids and uses the theory of equilibrium conditions in fluid. The system
creates high pressure, and through a transmission line and a control element, this pressure
drives an actuator (linear or rotational). An example of pure hydrostatics is the transfer of
force in hydraulics.
Hydrodynamic systems use fluid motion to transmit power. Power is transmitted by the
kinetic energy of the fluid. Hydrodynamics deals with the mechanics of moving fluid and
uses flow theory. An example of pure hydrodynamics is the conversion of flow energy in
turbines in hydroelectric power plants.

Pascal’s law and it’s applications:

Statement:
The pressure applied on a confined fluid is transmitted undiminished in all directions
throughout the fluid and acts perpendicular to the surfaces in contact with the fluid.
Pascal’s law explains why a glass bottle filled with a liquid can break if a stopper is forced
into its open end. The liquid transmits the pressure created by the force of the stopper
throughout the container. For example, if a force of 10N is applied to the stopper whose

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 4
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

surface area is 1cm2 , then every cm2 of the bottle wall the force acting is 10N. If the bottom
of the bottle has an area of 10 cm2 , then the entire bottom receives a force of 100N.
Pascal’s law applies only to hydrostatic systems.
Applications:
1. Hydraulic jack:
Refer to the figure below.

Figure 3

A force of 10N applied on an area of 1cm2 develops a pressure of 10N/cm2 . This

pressure remains the same throughout the continuous fluid and also acts on the piston
of larger area 10cm2 thereby developing a force of 100N. In other words, the fluid can
balance a load of 100N.

Problem 1 (15ME72-Aug/Sep 2020):

Define Pascal’s law and solve the following problem.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 5
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Solution:

The above principle is applied to the hand-operated hydraulic jack shown in fig. 4

Figure 4
A hand force is applied at point A of handle ABC, which pivots about point C. The
piston rod of the pump cylinder is pinned to the input handle at point B. The pump
cylinder contains a small diameter piston, which is free to move up and down. The
piston and rod are rigidly connected together. When the handle is pulled up, the piston
rises and creates a vacuum in the space below it. As a result, atmospheric pressure
forces oil to leave the oil tank and flow through check valve 1 to fill the void created
below the pump piston. When the handle ABC is pushed down, oil is ejected from the
small diameter pump cylinder and flows through check valve 2 and enters the bottom
end of the large-diameter load cylinder. The load cylinder is similar in construction to
the pump cylinder and contains a piston connected to a rod. Pressure builds up below
the load piston and the value of this pressure is same as that generated by the pump
NOTES BY SANDESH M PRABHU,
ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 6
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

piston as per Pascal’s law. The product of this pressure and the area of the load piston
gives the magnitude of load that can be lifted. Each time the input handle is cycled up
and down, a specified volume of oil is ejected from the pump to raise the load piston a
given distance. The bleed valve is a hand-operated valve, which when opened, allows
the load to be lowered by bleeding oil from the load cylinder back to the oil tank.
2. Air-to-Hydraulic pressure Booster:
This device is used for converting shop air into the higher hydraulic pressure needed
for operating hydraulic cylinders requiring small to medium volumes of higher
pressure oil. An example for such a requirement is supplying higher pressure oil to a
hydraulic cylinder whose short piston stroke is used to clamp a workpiece to a
machine tool table.
Refer to the fig. 5

Figure 5
Let a pressure of 10N/cm2 be acting on the air piston of area 10 cm2 so that the force
developed is 100 N. This force in turn acts on the booster’s hydraulic piston exerting a
pressure of 100 N/cm2 if its area is 1 cm2 . According to Pascal’s law, this produces

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 7
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

100 N/cm2 oil at the short stroke piston of the hydraulic clamping cylinder mounted
on the machine tool table. The pressure ratio obtained is 10:1

Fluids for hydraulic systems:

A hydraulic fluid is the transmitting medium of a hydraulic system. It performs the following
functions:

1. Power transmission: To transmit power, which is the primary function.

2. Lubrication: To lubricate various parts, so as to avoid metal-to-metal contact and reduce

friction, wear and heat generation.
3. Sealing: To seal the moving elements to avoid leakage.
4. Cooling: To carry away the heat generated in the system and to dissipate the heat through
a reservoir or a heat exchanger.

5. Contaminant removal: To carry along the contaminations to the tank, where they can be
removed through filters.

Properties of hydraulic fluids:

For a fluid to perform efficiently, it must possess certain properties. The various properties
required for an ideal hydraulic fluid are as follows:

1. Ideal viscosity.
2. Good lubrication capability.
3. Demulsibility.
4. Good chemical and environmental stability.
5. Incompressibility.
6. Fire resistance.
7. Low flammability.
8. Foam resistance.
9. Low volatility.
10. Good heat dissipation.
11. Low density.
12. System compatibility.
NOTES BY SANDESH M PRABHU,
ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 8
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

It is almost impossible to achieve all these properties in a hydraulic fluid. Although we can
select a good fluid with desirable properties, some of the characteristics of a fluid change
with usage. For example, it is common for the temperature of a fluid to rise due to friction in
the system, which reduces the viscosity of the fluid, which in turn increases leakage and
reduces lubrication ability. A fluid gets oxidized and becomes acidic with usage.
1. Ideal viscosity: The most basic desirable property of a hydraulic fluid is optimum
viscosity. It is a measure of a fluid’s resistance to flow. When viscosity is low, the
fluid flows easily. On the other hand, when viscosity is high, the fluid flows with
difficulty. The viscosity of a fluid should be high enough to seal the working gap
between the parts and prevent leakage but should be low enough to cause easy flow
throughout the system. Therefore the hydraulic fluid should have an optimum
viscosity.
2. Lubrication capability: Hydraulic fluids must have good lubricity to prevent friction
and wear between the closely fitted working parts. The film formed by the fluid
should be strong enough that it is not wiped out by the moving parts.
3. Demulsibility: The ability of a hydraulic fluid to separate rapidly from moisture and
successfully resist emulsification is known as “demulsibility.” If an oil emulsifies
with water, the emulsion promotes the destruction of lubricating and sealant
properties. Highly refined oils are basically water resistant by nature.
4. Good Chemical and Environmental Stability (Oxidation and Corrosion
Resistance): Most fluids are vulnerable to oxidation, as they come in contact with
oxygen in air. Mineral oils or petroleum-based oils (widely used in hydraulic systems)
contain carbon and hydrogen molecules, which easily react with oxygen. The
oxidation products are highly soluble in oil and being acidic in nature they can easily
corrode metallic parts. The soluble acidic products cause corrosion, whereas insoluble
products make the operation sluggish.
5. Incompressibility: The incompressibility of a fluid is a measure of its stiffness and is
given by its bulk modulus. The fluid should have high bulk modulus so that its
compression will not be much due to increasing pressure.
6. Fire resistance: There are many hazardous applications where human safety requires
the use of a fire-resistant fluid. Examples include coal mines, hot metal processing

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 9
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

equipment, aircraft and marine fluid power systems. A fire-resisting fluid is one that
can be ignited but does not support combustion when the ignition source is removed.
7. Low flammability: Flammability is defined as the ease of ignition and ability to
propagate the flame. This is tested through flash point and fire point tests. The higher
are the flash point and fire point values, lesser is the flammability.
8. Foam resistance: The hydraulic fluid should have the ability to release air absorbed
by it without foaming, so that components like the pump will not be affected by
cavitation.
9. Low volatility: The hydraulic fluid should have low vapour pressure or high boiling
point characteristics. High vapour pressure may cause high back pressures or vapour
lock resulting in lack of adequate flow.
10. Good heat dissipation: The hydraulic fluid should have a high heat dissipation
capability. This will prevent its overheating which would otherwise cause damage to
seals, reduction in fluid viscosity as well as reduction in fluid life due to oxidation.
11. Low density: This is important in designing the layouts of pumps and reservoirs
especially in aircraft applications.
12. System compatibility: A hydraulic fluid should be inert to materials used in or near
the hydraulic equipment. If the fluid in anyway attacks, destroys, dissolves or changes
the parts of hydraulic system, the system may lose its functional efficiency and may
start malfunctioning.

Additives in hydraulic fluids:

Some of the commonly used additives and their purposes are as follows:
1. Pour point depressant: A pour point is the temperature at which a fluid ceases to
flow. The minimum operating temperature in a hydraulic system should be at least
10°C above the pour point. Pour point depressants inhibit the formation of wax
crystals in the mineral oils and hence enhance the pour points.
2. Viscosity index improvers: These additives are long-chain polymers that stay in a
coiled form in the hydraulic fluid. At a low operating temperature, they have no effect
on viscosity. But when the temperature rises, these polymers uncoil and intermesh

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 10
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

causing a thickness effect in the fluid, thereby not allowing the viscosity to drop
down.
3. Defoamers (anti-foam additives): Certain additives, such as silicon polymer, act as
defoamers. They cause a rapid breakdown of the foam by removing the entrained air
bubbles.
4. Oxidation inhibitors: Oxidation causes the chemical reaction and formation of acidic
products that leads to corrosion problems. The oxidation rate increases with
temperature. Certain additives having greater affinity for oxygen are added so that
they easily react with them than with oil.
5. Corrosion inhibitors: These additives form a thin film on the metal surface and
shield it from coming in direct contact with the chemicals/acids in the fluid, thereby
preventing corrosion problems.
6. Anti-wear additives: These are either long-chain polymer or extreme pressure (EP)
additives. The long-chain polymers are adsorbed on the metal surfaces, causing a high
local temperature and polish the surface. This helps in reducing the surface roughness,
hence the wear problem.
7. Additives increasing Load-carrying capacity: The load-carrying capacity of a
hydraulic fluid is a measure of the oil’s capability to maintain a film of lubricant
between two metal surfaces under extremes of load or pressure. All hydraulic oils
have a natural load-carrying capacity that can be enhanced by special additives known
as EP additives. These additives help reduce wear especially in hydraulic pumps and
motors by providing lubrication when almost all the oil film has been squeezed out
under heavy load conditions.

Types of hydraulic fluids:

1. Petroleum based fluids
2. High Water Content Fluids (HWCF)
3. Bio-degradable oils.
1 Petroleum based fluids:
Mineral oils are the petroleum-based oils that are the most commonly used hydraulic
fluids. Basically, they possess most of the desirable characteristics: they are easily

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 11
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

available and are economical. In addition, they offer the best lubrication ability, least
corrosion problems and are compatible with most seal materials. The only major
disadvantage of these fluids is their flammability. They pose fire hazards, mainly from
the leakages, in high-temperature environments such as steel industries, etc. Mineral
oils are good for operating temperatures below 50°C, At higher temperatures, these
oils lose their chemical stability and form acids, varnishes, etc. All these lead to the
loss of lubrication characteristics, increased wear and tear, corrosion and related
problems.

2. High Water Content Fluids (HWCF):

These are basically fire-resistant fluids. Some of them are:
a) Oil-in-water emulsions: This emulsion has water as the main phase, while
small droplets of oil are dispersed in it. Generally, the oil dilution is limited,
about 5%; hence, it exhibits the characteristics of water. Its limitations are
poor viscosity, leading to leakage problems, loss in volumetric efficiency and
poor lubrication properties. These problems can be overcome to a greater
extent by using certain additives. Such emulsions are used in high-
displacement, low-speed pumps (such as in mining applications).
b) Water-in-oil emulsions: Water-in-oil emulsions, also called inverse
emulsions, are basically oil based in which small droplets of water are
dispersed throughout the oil phase. They are most popular fire-resistant
hydraulic fluids. They exhibit more of an oil-like characteristic; hence, they
have good viscosity and lubrication properties. The commonly used emulsion
has a dilution of 60% oil and 40% water. These emulsions are good for
operations at 25°C, as at a higher temperature, water evaporates and leads to
the loss of fire-resistant properties.
c) Water-glycol solution: This is another non-flammable fluid made up of water
and glycol in the ratio of 1:1. It generally has a low lubrication ability as
compared to mineral oils and is not suitable for high-temperature applications
as the water in it can evaporate. However, it is very good for low-temperature
applications as it possesses high antifreeze characteristics. Because of its

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 12
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

aqueous nature and presence of air, it is prone to oxidation and related

problems. It needs to be added with oxidation inhibitors.
d) Phosphate-Esters: These are suitable for high-temperature applications, since
they exhibit good viscosity and lubrication characteristics. They not suitable
for low-temperature applications. In addition, they are not environmental-
friendly. They also attack aluminum and paints.
3. Biodegradable hydraulic fluids: Biodegradable hydraulic fluids, alternatively
known as bio-based hydraulic fluids use sunflower, rapeseed, soybean, etc., as the
base oil and hence cause less pollution in the case of oil leaks or hydraulic hose
failures. These fluids carry similar properties as that of a mineral oil–based anti-wear
hydraulic fluid.
Factors Influencing the Selection of a Fluid :
The selection of a hydraulic fluid for a given system is governed by the following factors:
 Operating pressure of the system.
 Operating temperature of the system and its variation.
 Material of the system and its compatibility with oil used.
 Speed of operation. - Availability of replacement fluid.
 Cost of transmission lines.
 Contamination possibilities.
 Environmental condition (fire proneness, extreme atmosphere like in mining, etc.).
 Lubricity.
 Safety to operator.
 Expected service life.

Seals:
Any hydraulic system is associated with a major problem, that is, leakage. This reduces
efficiency and increases the power losses. Hence, sealing devices play a vital role in a
hydraulic system by increasing the efficiency and decreasing the power losses. Leakage can
be overcome by proper maintenance of the system and proper selection of seals and sealing at
the design stage.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 13
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Leakage in a hydraulic system can be classified as follows:

1. Internal leakage: This occurs in hydraulic components built with operating clearances.
Moving parts need to be lubricated and leakage path may be designed solely for this purpose.
Internal leakage does not cause loss of fluid because the fluid returns to the reservoir. This
leakage increases the clearances between mating parts due to wear. If the entire system
leakage becomes large enough, the actuators do not operate properly.
2. External leakage: External leakage represents loss of fluid from the system. It also
represents a safety hazard. Improper assembly of pipe fittings is the most common cause of
external leakage. Over-tightened fittings may become damages or vibrations can cause
properly tightened fittings to become loose. Failure to connect drain lines, excessive
operating pressure and contamination might cause the fluid to externally leak.
Functions of Seals:
 They prevent leakage – both internal and external.
 They prevent dust and other particles from entering into the system.
 They maintain pressure.
 They enhance the service life and reliability of the hydraulic system.
Classification of Seals:
Seals can be classified as follows:
1. According to the method of sealing:
a. Positive seal: A positive seal prevents even a minute amount of oil from getting past. A
positive seal does not allow any leakage whatsoever (external or internal).
b. Non-positive seal: A non-positive seal allows a small amount of internal leakage, such as
the clearance of the piston to provide a lubrication film.

2. According to the relative motion existing between the seals and other parts:
a Static seals: These are used between mating parts that do not move relative to one another.
Typical examples are flange gaskets and seals, o-rings, etc. These are relatively simple. They
are essentially non-wearing and usually trouble-free if assembled properly.
b Dynamic seals: These are assembled between mating parts that move relative to each other.
Hence, dynamic seals are subject to wear because one of the mating parts rubs against the
seal. Commonly used dynamic seals include O-rings, compression packings, piston
cup packings, piston rings and wiper rings.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 14
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

O-ring seal:
O-ring is the most widely used seal for hydraulic systems. It is a moulded synthetic rubber
seal that has a round cross-section in its free state. O-ring can be used for the most static and
dynamic conditions. It is compressed in one direction when installed. Application of pressure
causes the ring to be compressed at right angles to give a positive seal against two annular
surfaces and one flat surface. It gives effective sealing through a wide range of pressures,
temperatures and movements with the added advantages of sealing pressure in both directions
and providing low running friction on moving parts.

Figure 6: O-rings

Compression packings:
Compression type seals are used in virtually all types of reciprocating motion applications.
These include rod and piston seals in hydraulic and pneumatic cylinders, press rams, jacks
and seals on plungers and pistons in reciprocating pumps. These packings (which can be
moulded into U-shapes or V-shapes) are normally installed in multiple quantities for effective
sealing. These packings are compressed by tightening a flanged follower ring against them.

Figure 7

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 15
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

V-ring seal U-ring seal

Figure 8

Piston cup packing:

Piston cup packings are designed specifically for pistons in reciprocating pumps and
pneumatic and hydraulic cylinders.Sealing is accomplished when pressure pushes the cup lip
outward against the cylinder barrel. The backing plate and retainers clamp the cup packing
tightly in place, allowing it to handle very high pressures.

Figure 9: Piston cup packing

Figure 9: Piston cup packing in action

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 16
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Piston rings:
Piston rings are seals that are universally used for cylinder pistons. These offer less
opposition to motion than do rubber seals. These may be metallic or non-metallic. Metallic
rings are made of cast iron or steel and may be coated with zinc phosphate or manganese
phosphate to prevent rusting and corrosion. Non-metallic rings are made out of
tetraflouroethylene (TFE) which has very low coefficient of friction and can be run dry.

Figure 10: Piston rings

Wiper rings:
Wiper rings are seals designed to prevent foreign abrasive or corrosive materials from
entering a cylinder. They are not designed to seal against pressure.

Figure 11: Wiper rings

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 17
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Seal materials:
Natural rubber is rarely used as a seal material because it swells and deteriorates with time in
the presence of oil. In contrast, synthetic materials are compatible with most oils. The most
common types of materials used for seals are leather, Buna-N, silicone, neoprene,
tetraflouroethylene, viton and also metals.
Leather:
Leather is rugged and inexpensive. It can operate well at cold temperatures up to -60°F, but
cannot operate above 200°F, which is inadequate for many hydraulic systems.
Buna N:
This material is rugged and inexpensive and wears well. It has a wide operating temperature
range (-50°F to 230°F) during which it maintains good sealing characteristics.
Silicone:
This material has a very wide temperature range (-90°F to 450°F) during which it maintains
its good sealing characteristics. It is therefore used for rotating shaft seals and static seals
where a wide operating temperature range is expected. It is not used for reciprocating seal
applications because it has low tear resistance.
Neoprene:
This material has a temperature range of -65°F to 250°F. Beyond 250°F, it is unsuitable
because of its tendency to vulcanize.
Tetraflouroethylene:
This is a plastic material which is tough, chemically inert and a waxy solid. It has excellent
resistance to chemical breakdown up to 700°F and has a low coefficient of friction. It
however has a drawback to flow under pressure, forming thin, feathery films, which may be
overcome by adding certain filler materials like graphite, asbestos and glass fibres.
Viton:
This material contains about 65% flourine. It operates in the temperature range of -20°F to
500°F.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 18
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Compatibility of seals with fluids:

Table below gives the compatibility of seals with the fluid during static and dynamic
applications.

Fluid Preferred for Preferred for Not to be used at all

static application dynamic application
Petroleum oil Neoprene, Polyeurathane and Ethylene propylene
Flourocarbon and Teflon and Silicone
Nitrile
Water glycol Nitrile Ethylene propylene, Leather
Nitrile and Teflon
Phosphate Ester Butyl Ethylene propylene, Neoprene, Nitrile
Teflon and Viton and polyeurathane

Pipes:
In a hydraulic system, the fluid flows through a distribution system consisting of conductors
and connectors which carry the fluid from the reservoir through the operating components
and back to the reservoir. These conductors are called pipes in a broad sense while the
connectors are called fittings.
Pipes include tubes and hoses. If the conductor is specified in terms of the nominal bore size
(NB), then it is called a pipe. If the conductor is specified in terms of outside diameter (OD)
then it is called a tube. A hose means plastic or synthetic rubber tube.
Four different types of pipes or conductors are used in a hydraulic system:
1. Steel pipes
2. Steel tubing
3. Plastic tubing
4. Flexible hoses
1. Steel pipes:
Steel pipes are still extensively used in fluid power systems, although they are rapidly
being supplemented by steel or plastic tubing. Their greatest advantage is their
mechanical strength and particularly the ability to withstand abuse. A hot- or cold-
NOTES BY SANDESH M PRABHU,
ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 19
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

drawn seamless pipe is recommended for use in a hydraulic system and must be
internally free from rust scale and dirt. The major disadvantages of steel pipes are their
weight and the large number of fitting requirement for connection. Steel piping in fluid
power systems is most often joined by threaded connections.
2. Steel tubing:
Seamless steel tubing is the most widely used material for hydraulic system conductors.
One major reason of its popularity is the fact that it can be easily formed to fit irregular
paths so that fewer fittings are required thereby minimising the chances of leakage.
Tubing is easier to handle the pressure and flow requirements with less bulk and
weight. However, tubing and its fittings are more expensive. Tubing is not sealed by
threads but by special fittings called compression fittings.
3. Plastic tubing:
Plastic tubing has gained rapid acceptance in the industry because it is inexpensive and
extremely easy to use. It can easily be formed to fit around obstructions without special
tools; it is light and easy to handle. It is also available in colours so the different circuit
lines can be colour coded, especially in chemical industries. Because of its resilience, it
is highly resistant to damage crushing although it can be fairly easily cut. It may also be
used where flexing or vibration can damage steel tubing. The materials for plastic
tubing include nylon, polyethylene, polypropylene and PVC. Plastic tubing is used for
pneumatic systems because air pressures are low. However, being compatible with
most hydraulic fluids, it can be used in low-pressure hydraulic applications.
4. Flexible hoses:
Flexible hoses are used when hydraulic components such as actuators are subjected to
movement. For example, in portable power units, mobile equipment and hydraulically
powered machine tools. A hose is fabricated in layers of elastomer (synthetic rubber)
and braided fabric or braided wire which permits operation at higher pressures. The
outer layer is normally a synthetic rubber or neoprene to protect the braid layer. There
can be more than one braid layers to handle higher pressures. The inner layer is made of
materials like nylon, Teflon, PVC, butyl or nitrile so as to be compatible with the
hydraulic fluid.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 20
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Figure 12
Hoses offer the following advantages:
 Flexibility
 Higher capacity to withstand shock and vibration
 Easy to install or dismantle
 Can take up high pressures
However, the following are the disadvantages:
 Higher initial cost
 Poor abrasion resistance and can get damaged with incompatible oil.
 Poor weathering resistance

Quick couplings:
Quick connect (QC) couplings or Quick acting couplings are devices which permit the rapid
connection or disconnection of pipes or hoses, generally without the use of tools. A QC
coupling usually comprises a plug and socket arrangement that provides a leak-proof joint
when two parts are connected together, and that can be released easily without the use of
tools. Each half of the coupling contains a spring-loaded ball or poppet that automatically
closes on disconnection, so that two completely leak-free joints are obtained. Leaking during
the process of disconnecting or connecting coupling is negligible.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 21
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Filters and Strainers:

For proper operation and long service life of a hydraulic system, oil cleanliness is of prime
importance. Hydraulic components are very sensitive to contamination. Contamination is
any foreign material in the fluid that results in detrimental operation of any component of the
system.
Sources of contamination:
Contamination may be in the form of a solid, liquid or gas and can be caused by any of the
following:
1. Built into the system during component maintenance and assembly: Contaminants
here include metal chips, bits of pipe threads, tubing burrs, shreds of plastic tape, bits
of hose and seal materials, welding beads and dirt.
2. Generated within the system during operation: Contaminants here include moisture
due to condensation inside the reservoir, entrained gas, scale caused by rust, bits of
worn seal materials, particles of metal due to wear, and sludges and varnishes due to
oxidation of the oil.
3. Introduced into the system from external environment: The main source of
contamination here is due to the use of dirty maintenance equipment such as funnels,
rags and tools. Disassembled components should be washed using clean hydraulic
fluid before assembly. Any oil added to the system should be free of contaminants
and poured from clean containers.
Contamination control:
Strainers and filters are designed to remove foreign particles from the hydraulic fluid.
Strainer:
A strainer is a device whose function is to remove large particles from a fluid using a wire
screen. The smallest sized particle that can be removed by a strainer is as small as 0.15 mm
Filter:
A filter is a device whose primary function is the retention of insoluble contaminants from
fluid , by some fine porous medium. The porous medium refers to a material that allows fluid
to flow through it but stops other materials (contaminants). Particles as small as 1µ can be
stopped by a filter.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 22
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Types of filters:
Filters are classified in three ways:
1. Method of filtering
2. Size of pores in the filtering material
3. Location of the filter
4. Depending on the proportion of oil flow through filter.
1. Method of filtering: According to the method of filtering, there are three types of
filters:
(a) Mechanical filters: This type normally contains a metal or cloth screen or a
series of metal disks separated by thin spacers. These filters are capable of
removing only relatively coarse particles from the fluid.
(b) Absorption filters: These filters are porous & permeable materials such as
paper, wood pulp, cloth, cellulose and asbestos. Paper filters are impregnated
with a resin to provide added strength. In this type of filter, the particles are
actually absorbed as the fluid permeates the material. Hence these filters are
used for extremely small particle filtration.
(c) Adsorbent filters: Adsorption is a surface phenomenon and refers to the
tendency of particles to cling to the surface of the filters. Thus the capacity of
such a filter depends on the amount of surface area available. Adsorbent
materials used include activated clay and chemically treated paper.
2. Size of pores in the filtering material: Taking into consideration the size of the pores
in the filtering material, there are two types of filters:
(a) Surface filters: These are nothing but simple screens used to clean oil passing
through their pores. The screen thickness is very thin and dirty unwanted particles
are collected at the top surface of the screen when the oil passes. These filters are
considered as strainers.
(b) Depth filters: These contain thick walled filter medium through which the oil is
made to flow & the undesirable foreign particles are retained. Much finer particles
are arrested and the capacity is much higher than surface filters.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 23
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

3. Location of the filter: A filter can be in any of the three locations:

(a) Intake or inline filter: These are provided first before the pump to protect the
pump against contaminations in the oil. These filters are designed to give a low
pressure drop. Otherwise the pump will not be able to draw the fluid from the
tank. To achieve low pressure drop across the filters, a coarse mesh is used. These
filters cannot filter out small particles.

Figure 13
(b) Pressure line filter: These are placed immediately after the pump to protect valves
and actuators and can be finer & smaller mesh. They should be able to withstand
the full system pressure. Most filters are pressure line filters.

Figure 14
(c) Return line filter: These filters filter the oil returning from the pressure relief
valve or form the system i.e. actuator to tank. It is generally placed just before the
tank. They may have a relatively high pressure drop & hence can be fine mesh.
These filters have to withstand low pressure only and also protect the tank &
pump from contamination.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 24
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

Figure 15
4. Depending on the proportion of oil flow through filter:
There are two types of filters:
(a) Full flow filter: In this type, complete oil is filtered. Full flow of oil must enter
the filter element at its inlet and must be expelled through the outlet after crossing
the filter element fully. This is an efficient filter. However, it incurs large pressure
drops. This pressure drop increases as the filter gets blocked by contamination.

Figure 16
(b) Proportional filter (by-pass filter): In some hydraulic system applications, only a
portion of oil is passed through the filter instead of entire volume and the main flow is
directly passed without filtration through a restricted passage.

Figure 17
NOTES BY SANDESH M PRABHU,
ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 25
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

As the main flow passes through a venturi, a localised low pressure is created. This
pressure differential across the filter influences it to draw a proportion of the fluid
through the filter.

Heat exchangers:
Heat is generated in hydraulic systems because no component can operate at 100%
efficiency. Significant sources of heat include the pump, pressure-relief valves and flow
control valves. Heat can cause the temperature of hydraulic fluid temperature to exceed its
normal operating range of 35–70° C hastens the oxidation of the hydraulic oil and causes it to
become too thin. This promotes deterioration of seals and packing and accelerates wear
between closely fitting parts of hydraulic components of valves, pumps and actuators. The
steady-state temperature of fluid of a hydraulic system depends on the heat-generation rate
and the heat-dissipation rate of the system. If the fluid operating temperature in a hydraulic
system becomes excessive, it means that the heat-generation rate is too large relative to the
heat-dissipation rate. Assuming that the system is reasonably efficient, the solution is to
increase the heat-dissipation rate. This is accomplished by the use of coolers, which are
commonly called “heat exchangers.”
There are two main types of heat exchangers – air coolers and water coolers
In the air cooler type heat exchanger, hydraulic fluid is pumped through tubes banded to fins.
Special devices called turbulators present in the tubes mix the warmer and cooler oil for
better heat transfer.
In the water cooler type heat exchanger, water is made to flow around the tubes containing
the hydraulic fluid.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 26
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

QUESTION BANK
1. Define fluid power. What are the types of fluid power systems?
2. Give a comparison between a hydraulic system and a pneumatic system.
3. In a fluid power system how does a cylinder differ from a motor?
4. What are the advantages of fluid power systems?
5. What are the limitations of fluid power systems?
6. List some applications of fluid power.
7. Outline the components of a hydraulic system with a neat sketch.
8. Outline the components of a pneumatic system with a neat sketch.
9. Define Pascal’s law. Explain the significance of Pascal’s law in applying fluid power.
10. Explain the working of a hand-operated hydraulic jack with a diagram.
11. Explain with a diagram how the Air-to-Hydraulic pressure Booster works in the
clamping of a workpiece on a machine table.
12. What are the functions of fluids used in hydraulic systems?
13. List and explain the properties of hydraulic fluids.
14. Write a note on the different additives used in hydraulic systems.
15. Write a note on the different types of hydraulic fluids.
16. List the factors involved in the selection of hydraulic fluids.
17. How does an external leakage of fluid in a hydraulic system differ from that of
internal leakage?
18. Differentiate between:
(a) Positive seal and non-positive seal
(b) Static seal and dynamic seal
19. Write short notes on:
(a) O-ring seal
(b) Compression packings
(c) Piston cup packings
(d) Piston rings
(e) Wiper rings
20. Write a note on seal materials.
21. Differentiate between pipes, tubes and hoses.

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 27
 SUBJECT : FLUID POWER SYSTEMS (17ME72 )
MODULE 1: INTRODUCTION TO FLUID POWER SYSTEMS

22. Write a note on the different types of pipes (conductors) used in hydraulic systems.
23. What is a quick coupling? How does it work?
24. What are the sources of contamination of hydraulic fluids?
25. How does a filter differ from a strainer
26. How are filters classified? Explain.
27. Draw neat sketches to show the positioning of in-line filters, pressure-line filters and
return-line filters.
28. With a neat sketch, explain the working of full-flow filter.
29. With a neat sketch, explain the working of by-pass filter.
30. Write a note on heat exchangers used in hydraulic systems.
--------------

NOTES BY SANDESH M PRABHU,

ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING. SRINIVAS INSTITUTE OF TECHNOLOGY,
VALACHIL, MANGALURU Page 28