ME 453

Hydraulics & Pneumatics

Department of Mechanical Engineering

College of Engineering, KNUST

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 Course Objectives

 Be able to identify and describe the basic operation of Hydraulic

/ Pneumatic systems.
 Be able to identify and describe the basic equipment used in
Hydraulic / Pneumatic Systems.
 Be able to identify and interpret Hydraulic / Pneumatic terms
and symbols.
 Be able to design and build simple Hydraulic/Pneumatic
System.
 Be able to maintain and troubleshoot Hydraulic / Pneumatic
equipment.

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 Instruction Format

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 Assessment

 Random and unannounced quizzes

 Assignments
 Attendance
 Mid Semester Examination
 End of Semester Examination

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 Class Regulations
 No lateness beyond 10 minutes: Student
will be turned out
 No mobile phone use in class: the phone
will be confiscated for one week on first
offence and for the semester on second
offence.

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 References

 Basic Hydraulics and Pneumatics for

Practicing by Y.A.K. Fiagbe
 Fluid Power: Hydraulics and Pneumatics
by James R. Daines
 www.wisc-online.com

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 Course Schedule
Week Date Topic Note
1 Introduction
2 Hydraulic Fluids
3 Circuit and Symbols
4 Hydraulic and Pneumatic Power Units and symbols
5 Hydraulic and Pneumatic Actuators
6 Hydraulic and Pneumatic Valves
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8 Other Components of Hydraulic and Pneumatic Mid Sem
systems Exam
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10 Hydraulic circuit design

11 Maintenance of Hydraulic and Pneumatic Systems

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13 Exam
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15 Exam
 Assignment 1

Write a brief history about development of

hydraulic and pneumatic systems.

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 Introduction

9
 Log Splitter

10
 Backhoe

Excavator

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 Forklift

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13
 Hydraulic Drill

14 Hydraulic Jack
 Sky-tram

Sky tram is unique. It is self-propelled and

travels on a stationary cable. Because the tram
moves instead of the cable, the operator can
stop, start, and reverse any one car completely
independently of any other car in the tram
system. Integral to the design of the Sky-tram
drive is a pump (driven by a standard eight-
cylinder gasoline engine) which supplies
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pressurized fluid to four hydraulic motors.
 Pneumatic Drill

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 Hydraulic Stacker
Hydraulic Press
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18
 Assignment 2

Select one hydraulic and one pneumatic equipment

and write briefly on how it operates

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 Fluid Power
 Technology that deals with generation, control and
transmission of power, using pressurized fluids
 Both Hydraulics and Pneumatics are Fluid Power
systems
 Hydraulics – when the fluid is liquid (petroleum oils,
synthetic oils and water).
 Pneumatics – when the fluid is gas (air - very abundant
and can be readily exhausted into the atmosphere
after completing task)

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 Fluid Power

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 Fluid Power

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 Application of Hydraulics

Mobile Hydraulics Stationary Hydraulics

Using manual Using electro-

hydraulics to control hydraulics to control
•Crane •Press machine
•Excavator •Molding machine
•Back-hoe •Lathe machine
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 Advantages of using Hydraulics

1. Very high force despite small components (if

pneumatics, bigger components are needed for high
force, thus, incur high cost as well as wastage of
compressed air)
2. Very slow and linear movements (if pneumatics, too
slow will create jerking on the cylinder)
3. Very exact positioning (stops exactly on a point).
Compared to pneumatics, there’s a tolerance and if a
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load is given, it will move a little.
 Advantages of using Hydraulics

4. Start-up under heavy loads (Possible to start

the motor & process a job with a load
attached to it. This is because there is oil in
the actuator though the pump is idling).

5. Simplicity, safety, economy

In general, fluid power systems use fewer
moving parts than comparable
mechanical or electrical systems. Thus, they
are simpler to maintain and operate. This, in
turn, maximizes safety, compactness and
25 reliability.
 Disadvantages of using Hydraulics
1. Slow movement of actuators, heavy work is slower (Pneumatics are
faster)
2. Messy (Leakage may occur and if not bothered, the surrounding area
could be messy. However, constant cleaning could avoid messy.)
3. heavier equipment
4. Dangerous!
i. It produces extreme pressure and if there’s a leakage, oil will be
forced out. Stopping the flow with bare hand would result in a
punctuated wound.
ii. While in process, oil became hot and flammable (though not easily
happened). Therefore, it is advisable to control the temperature by
26 limiting it (turning off the machine if the limit is exceeded).
 Applications of Pneumatics
 Paintball Guns
 Torque Wrenches
 Nail Guns
 Truck Suspensions
 Automotive Air Bag

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 Advantages of Pneumatics

 only one power source is required

 endless supply of air
 relatively clean depending on the environment
 able to operate at high speeds
 lower component costs
 lighter component weights

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 Disadvantages of Pneumatics
 not capable of heavy work
 construction crews rarely fix air leaks
 there is a minor loss of energy due to
friction and exhausting
 higher operating costs with electric
compressors

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30
 Fluid Power Systems

Power Supply Control System Work Actuator

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 Components of Hydraulic Systems
All industrial hydraulic systems will have:
◼ A fluid, usually oil.

◼ A tank, or reservoir, to hold a supply

of the fluid.

◼ A pump to cause the fluid to flow.

◼ An electric motor, or engine, to

drive the pump.

◼ Hoses or tubing to carry the fluid.

◼ Valves to control fluid flow, direction

and pressure.

◼ One or more actuators, usually cylinders or hydraulic motors, to do the

work where mechanical movement occurs.
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Basic Principles
 Pressure and Force
Pressure is defined as force per unit area.
Hence, pressure is the amount of force acting over a
unit area

Pressure (P) = Force (F) / Area (A)

Example of P at 100 kPa and A at 20 m²,

F = P x A, so F = 100 kPa x 20 m²
F = 2000 kN.
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 Example
 A lifting is to lift a load of 15kN and is to have a system
pressure of 75 bar. How large does the piston surface
need to be?

Solution:
P = F/A
A = F/P
= 15000N/(75x105 Pa)
= 0.002 m2

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 Basic working principle
 Hydraulic systems operate according to
Pascal's Principle - Pressure is transmitted
undiminished in an enclosed static fluid.

 Illustration of force multiplication by

applying pressure according to Pascal's
principle, which for the two pistons implies
P1 = P2

 Therefore, with the automatic hydraulic lift,

heavy load can be lifted with a small force.
Of course, assuming in an ideal case with no
frictional loss, work cannot be multiplied:
Winput = Woutput

Slide-36
 F2=10 kN
d2=3 m
d1=0.5 m
S2=0.5m
F1 = ?
S1
S1 = ?
 F1/A1 = F2/A2
A1 = 0.1963 m2  W = F.s
A2 = 7.0686 m2 F1s1 = F2s2
F1 = (F2/A2) x A1 0.278 x s1 = 10 x 0.5
= (10 kN / 7.0686 m2) x 0.1963 m2 s1 = 17.986 m
= 0.278 kN
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Flow
 Flow is the movement of a hydraulic fluid caused by a
difference in the pressure at two points.
 In a hydraulic system, flow is usually produced by the
action of a hydraulic pump- a device used to
continuously push on a hydraulic fluid.
 The two ways of measuring flow are velocity and flow
rate.
Velocity
 Velocity is the average speed at which a fluid's particles
move past a given point, measured in meter per second
(m/s). Velocity is an important consideration in sizing
the hydraulic lines that carry a fluid between the
components.
Flow Rate
 Flow rate is the measure of how much volume of a liquid
passes a point in a given time.
 Flow rate determines the speed at which a load moves
and, therefore, is important when considering power.
Pressure Transfer Medium
 Pressure Transfer Medium
 There are 2 media types
 Liquid
 Gas

 Form of liquid used

 Oil, when surrounding is not hot (car brake system)
 Water, when surrounding is hot / very hot. To avoid
corrosion and to have better lubrication, water is usually
mixed with some additives (food processing, semiconductor
process, paper manufacturing, construction works, medical
and welfare appliances).

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 Pressure Transfer Medium

Gas Vs. Liquid

•Compressible, both in • Not compressible in

theory and practical theory, however, is
compressible up to 0.7%
•Pressure is storable in practice
•Pressure is not storable.
Released when the pump
stops.
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 Physical differences between liquids and gases

Parameter Liquid Gas

Volume Has its own volume Volume is determined

by container

Shape Takes shape of container Expands to completely

but only to its volume fill and take the shape
of the container

Compressibility Incompressible for most Readily compressible

engineering applications
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 PROPERTIES of Hydraulic Fluid
For the fluid to perform well some properties or characteristics are
required.
 COMPRESSIBILITY: Liquids are very difficult to squeeze into a smaller
volume. If air is mixed with the fluid it becomes slightly compressible and
loses this property.
 VISCOSITY: The viscosity of a fluid determines how easily it flows.
Fluids with a low viscosity such as water flow easily but fluids with a high
viscosity such as thick oil, flows with some difficulty and this results in a
loss of pressure in the pipes and fittings. The preferred units are centi-
Stokes but many other units exist such as Redwood Seconds.
 VISCOSITY INDEX: The viscosity of a fluid usually decreases as it gets
hotter. Oil with a low viscosity index will change very little but one with
a high index will change a lot.
PROPERTIES
 AIR ABSORPTION AND RELEASE: Liquids will absorb gas
under pressure and release it when the pressure is released. A
good hydraulic fluid will not absorb air easily and will release
it quickly without causing froth and foam.
 OXIDATION: Oxidation is chemical combination of elements
in the fluid with oxygen. This causes the oil to thicken and
produce varnishes which stain the components surface. The
life of the oil is much reduced.
 CORROSION: Hydraulic fluids can cause corrosion of
metals. This is avoided by using compatible materials.
PROPERTIES
 WEAR: Chemicals may be added which cause the fluid to deposit
a surface film at places where surfaces are pressed together such as
on the flanks of gears in gear pumps and motors. This prevents
wear taking place.
 POUR POINT: The pour point is the lowest temperature at which
the fluid will flow from a beaker when tipped up. It is possible to
add chemicals to reduce this temperature for working in cold
climates.
 FLASH POINT: The flash point of a fluid is the temperature of
the fluid at which vapour given off will ignite on contact with a
naked flame. The apparatus to measure this is called a Pensky-
Martens apparatus.
 Hydraulic Fluids

The primary purpose of hydraulic fluid is to transmit force from one

place to another.
However, hydraulic fluids are also
required to:
◼ Lubricate contact surfaces within the
system.
◼ Provide sealing of components,
where tight clearances are involved.
◼ Remove heat generated within the system.
◼ Protect system components against rust, oxidation and corrosion.
◼ Prevent foaming when subjected to turbulence.
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 Hydraulic Fluids
When selecting a hydraulic fluid for an application, consideration must be given to the
pressure, temperature and materials of the system.

Improper selection can lead to:

◼ Inadequate system performance.

◼ Premature failure of
components.

◼ The potential for fire.

◼ Environmental pollution in the event of

loss of containment.

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 Hydraulic Fluids

The main types of hydraulic fluid are:

Petroleum based fluids:
Most common type of fluid.

Synthetic fire resistant fluids:

Used where fire hazards or environmental
pollution are a concern.
Water based fire resistant fluids:
Used where fire hazards or environmental
pollution are a concern.

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 Hydraulic Fluid Safety

Generally, hydraulic fluid:

◼ Can cause skin and eye irritation.
◼ Can cause medical problems. If
ingested; seek medical attention
immediately.
◼ May cause medical problems,
if repeatedly inhaled.
◼ May be corrosive.
◼ Must be disposed of according
to Environmental regulations.
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 Fluid Selection
A hydraulic fluid has the following 4 primary functions:-
1. Transmit power
2. Lubricate moving parts
3. Seal clearance between mating parts
4. Dissipate heat

In addition a hydraulic fluid must be inexpensive and readily available.

A hydraulic fluid should have the following properties:-
1. Good lubricity
2. Ideal viscosity
3. Chemical stability
4. Fire resistance
5. Low density
6. Foam resistance
7. Non toxicity
8. Low volatility
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