Applied Pneumatics and Hydraulics - H1: This Work Covers Part of Outcome 2 of The Edexcel Standard Module
Applied Pneumatics and Hydraulics - H1: This Work Covers Part of Outcome 2 of The Edexcel Standard Module
Applied Pneumatics and Hydraulics - H1: This Work Covers Part of Outcome 2 of The Edexcel Standard Module
OUTCOME 2
The series of tutorials provides an extensive overview of fluid power for students at
all levels seeking a good knowledge of fluid power equipment.
On completion of this tutorial you should be able to do the following.
1.
INTRODUCTION
The purpose of seals is to contain the working fluid within the hydraulic or pneumatic unit and to
keep external contamination out. They may be classified as one of the following.
2.
Static seals,
Sliding seals
Rotary seals.
STATIC SEALS
Static seals are placed between surfaces which do not move. Some form of pressure must be exerted
to squeeze the surfaces together and force the seal material into the small imperfections in the
surfaces. The following is a description of some static seals.
GASKETS
Gaskets are cut out of thin sheets of
material and placed between mating
surfaces which are then squeezed
together by screws or bolts. The
materials used are paper, copper,
brass, rubber and so on. Typical
applications are between flanges on
pipes and flanges on the fluid port
of a pump or motor.
Figure 1
RINGS
Rings are placed in grooves between the mating
surfaces and stand proud of the groove so that they
are squeezed when the surfaces are pulled together.
The rings are usually circular in section and are then
called O rings but they may have rectangular sections
also.
Figure 2
The most common materials are natural or
synthetic rubber and polymers (plastics) such
as Viton and PTFE. They are used on
applications such as flanges, cylinder end
caps and motor bodies.
Figure 3
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WASHERS
Sealing washers are placed under the head of screwed fittings with parallel threads to prevent fluid
leaking up the thread and escaping under the head. Plastic washers are sufficient for pneumatic
applications and copper washers are also often used.
DOWTY (Bonded) WASHERS
These are used for containing high pressure
fluids. They are usually aluminium rings
with a rubber seal glued to the inner surface.
The shape of the seal is such that fluid
leaking up the thread presses the rubber
firmly against the sealing surfaces.
Figure 4
Figure 5
3.
SLIDING SEALS
Sliding seals are mainly used with cylinders to
prevent fluid escaping around a piston rod or
from passing from one side of a piston to the
other. All sliding seals are rings but many
different types exist. These may be solid rings
such as O rings or rings with rectangular
sections. For more demanding applications,
more sophisticated designs are used with lips
or cups to make the seal fan out and fill the
gap between the sliding parts.
Figure 6
Common types are U ring, Cup, Flange,
Chevron, O ring and T ring
The diagram left shows a U ring seal on
a piston to prevent fluid passing from
the top to the bottom of the piston. Two
seals placed back to back would be used
for a double acting cylinder. U ring seals
may be used for piston rods also and
there is a large variety of shapes for
shapes for different applications.
Figure 7
Figure 8
Figure 9
The diagram above left shows a cup seal which is suitable for simple single acting cylinders with
low pressure. The fluid pressure forces the cup out against the cylinder walls.
The diagram above right shows a flange seal which is used on the piston rod. The flange is
tightened down and squeezes the seal into the gap between the rod and the cylinder end.
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Figure 10
Figure 11
The diagram above left shows another piston rod seal. The seal is made up of chevrons embedded
in a softer material. They are forced into the gap by the screwed ring and the chevrons spread out
and form a seal.
The diagram above right shows a wiper ring. The wiper ring is not strictly a seal. Its purpose is to
remove oily dirt from the rod as it is drawn into the cylinder. The action is similar to that of a car
wind screen wiper.
4.
ROTARY SEALS
Rotary seals are used on pumps and motors to
prevent fluid leaking out through the gap
between the shaft and the shaft bearing. They
are designed with a spring loaded lip which
presses to the shaft. Oil leaking into the space
behind the seal will force the lip even tighter
but this space should be drained to prevent
the seal being blown out by pressure.
Figure 12
Figure 13
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5.
SEAL REPLACEMENTS
Great care must be exercised when replacing seals. Clean components and clean hands are essential.
When a seal has to be expanded in order to fit into a groove, such as on a piston, the correct tool
tapered assembly tool should be used.
Avoid using screw drivers to lift seals over edges.
When sliding a rod through a gland seal, be careful not to cut the seal with the sharp shoulders on
the rod. Use a tapered assembly tool as shown.
Figure 15
6.
MATERIALS
Seals must be compatible with the fluid and this is shown below.
Seal Material
Designation
Compatable Fluids
Acrylonitrile butadiene
NBR
Air,Oil,Water/Glycol
Polyacrylate rubber
ACM
Air, Oil
Polyurethane
AV,EV
Air, Oil
Fluorocarbon rubber
FPM
Silicone
FMQ
Styrene butadiene
SBR
Air,Oil,Water/Glycol
EPDM
PTFE
Ethylene Propylene Diene rubber (EPDM) :This polymer is a terpolymer of ethylene, propylene and some Diene as the termonomer.
Moulded parts and seals from EPDM have good resistance to :1. Ozone, ageing and weathering
2. Water and steam
3. Dilute acid, alkalies, ketones, alcohols and polar organic media.
4. Phosphate ester based hydraulic fluids
Normal services temperatures of this polymer is -40oC to +135oC
VAKO's EPDM compounds include:1. Compounds with high modulus and low compression set.
2. Compounds for electrical insulations.
3. Compounds for contact with drinking water.
4. Compounds for high temperatures applications upto 160oC.
5. Compounds for general purpose applications.
Polyacrylic rubber (ACM):This polymer is a co-polymer of Ethyl acrylate or Butyl acrylate and a small amount of monomer
which facilitates vulcanization.
ACM has excellent resistance to heat, hydrocarbon oils, mineral oils, oxidation and ozone, but poor
resistance to water, steam, acids and alkalis.
Normal service temperature of ACM is -25oC to 175oC.
Ethylene Acrylate rubber (EAM) :This terpolymer of Ethylene, Methyl acrylate and a cure site monomer is commonly referred to as
Vamac.
This polymer has better heat resistance than ACM. Other Properties include good low temperature
flexibility, good resistance to weathering, sunlight, oxygen, ozone and good flame resistance. It has
good resistance to Paraffin based mineral oils, water and refrigerants. Normal service temperature
of AEM is -4OoC to 175oC.
Vamac is the registered trademark of Dupont Dow elastomers IIc
Silicone rubbers (VMQ, PVMQ):These are high molecular weight poly organo siloxanes. VMQ has both Vinyl and Methyl
substituent groups on the polymer chain, while PVMQ has an additional Phenyl substituent group
on the polymer chain.
These polymers have excellent cold flexibility as well as high thermal resistance. They have
excellent di-electric properties and very good resistance to attack by oxygen, ozone and sunlight.
They however have moderate resistance to mineral oils . The most admirable property of this
polymer is it's very wide service temperature range i.e -65oC to 250oC.
VAKO's Silicone compounds include: 1. Compounds for very high temperature apphcatons upto 300oC.
2. Compounds for very low temperature applications upto - 120oC.
3. Compounds with very low compression set.
4. Transparent compounds.
5. Compounds with good oil resistance.
6. Compounds for medical applications .
7. Compounds for general applications.
Fluorosilicone (FVMQ):FVMQ has a similar polymer stucture as that of VMQ and has an additional Fluoro substituent
group on the polymer chain.
These polymers have very good fuel, oil and solvent resistance in addition to the regular properties
of silicones. They are used for special applications.
Fluorocarbon rubber (FKM):These versatile range of polymers which are commonly referred to as Viton are used for a vast
range of sealing applications due to its resistance to a broad spectrum of chemical and oil media and
a wide range of temperatures. The co-polymer types of FKM are co-polymers of Hexa
fluoropropylene (HFP) and Vinylidine difluoride (VF2) (Fluorine content = 65-66%) While the
terpolymers have Tetra fluoroethylene (TFE) as the Termonomer (Fluorine content = 67-71%).
Some terpolymers have an additional cure site monomer which are used for very speciality
applications.
FKM's exhibit excellent resistance to mineral oils, fuels, steam, alcohols, alcohol containing fuels,
aliphatic and aromatic hydrocarbons. Chemical and oil resistance improve as the fluorine content of
these polymers increase. However the co-polymer types of FKM give the best compression set
resistance. Normal service temperatures for FKM is -20oC to 250oC.
VAKO's FKM compounds are used for abroad range of applications they include :1. Compounds with very low compression set.
2. Compounds for high temperature (upto 275oC) dynamic sealing applications.
3. Compounds for low temperature applications (upto -35oC)
4. Compounds for general purpose applications.
Viton is a registered trademark of Du pont Dow elastomers IIc
Tetrafluoroethylene propylene co-polymers (TFE/P):This is a copolymer of Tetra fluoro ethylene and propylene. It shows much better resistance than
FKM in high pH caustics, Brine solutions, amines engine oils, engine coolants, power steering
fluids, corrosion inhibitors and gamma radiation.
It also exhibits less sensitivity to changes in chemical enviroments. They have good electrical
insulation properties. Normal service temperatures of this polymer is - 10oC to 280oC.
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VAKO's TFE/P compounds go into various special applications which include automotive, oilfield,
aerospace and industrial environments.
Chloro sulphonated Polyethylene (CSM):This polymer based on polyethylene has chlorine side groups and chloro sulphonated side groups
on the main chain. It is commonly referred to as HYPALON.
Vulcanizates of this polymer have very good resistance to flame, heat, ozone and weathering.
They also have good resistance to swelling in hot water, steam, acids, bases, ketones, polar organic
media and oxidising media.
Normal service temperatures of this polymer is -20oC to 150oC .
Hypalon is a registered trademark of Du pont Dow elastomers IIc.
Ethylene oxide - Epichlorohydrin rubber (ECO):This is a co-polymer of Epichlorohydrin and Ethylene oxide.
ECO vulcanisates have very low permeability to gases and good resistance to weathering and
ozone. They exhibit good resistance to mineral oils, greases, vegetable oils, aliphatic hydrocarbons,
petroleum and water.
Normal service temperature of this polymer ranges form -40oC to 150oC.
Carboxylated Nitrile rubber (XNBR):These are terpolymers of butadiene, acrylonitrile and methacrylic acid. As these polymers have
caboxylic acid side groups they are referred to as Carboxylated Nitrile rubber.
Moulded products of XNBR have very high tensile strength, tear strength and above all improved
abrasion resistance than NBR. Normal temperatures of these polymers range from -25oC to 120oC.
Hydrogenated Nitrile rubber(HNBR or HSN):The elimination of double bonds from the polymer chain of NBR, either partially or completely by
hydrogenation gives Hydrogenated Nitrile rubber.
These polymers have much improved heat resistance than NBR (heat resistance depends on the
degree of hydrogenation).
HNBR has outstanding resistance to heat, ozone, weathering, mineral oils, crude oils with amines,
fuels, greases, aliphatic hydrocarbons and industrial chemicals HNBR has very good mechanical
properties and excellent wear resistance. Normal service temperatures of these polymers are -30oC
to 150oC.
VAKO's HNBR compounds include:1. Compounds with very low compresssion set.
2. Compounds for low temperature applications (upto -40oC)
3. Compounds for oil drilling applications.
2.
Name 2 seal materials which are not compatible with PHOSPHATE ESTER hydraulic fluids.
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3.
4.
Identify each seal shown in cross section and state its main purpose. A is done as an example.
A. Wiper ring.
B. ________________________________________________________________________
C
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5.
The diagram shows cross sectional drawings of seals used in hydraulic and pneumatic
equipment and a cross section of a typical cylinder.
Select and name the seal from the previous diagram that would be suitable for the following
items.
Items 5, 7, 10, and 11.
6.
a.
Describe a simple test method to determine if the piston seals on a pneumatic cylinder are
leaking.
b. A double acting pneumatic cylinder in operation becomes slow and weak on the retraction
stroke. State two possible causes for this.
c.
A double acting pneumatic cylinder in operation develops jerky and erratic motion on the
extension stroke. State two possible causes for this.
ANSWERS
5.
6.
Disconnect pipe on one side and apply pressure to the other side and look for air leaving by the
disconnected port.
Leaks through the piston seals
Leaks from the rod seal.
Leaks through the piston seal.
One way restrictor on front port faulty or not adjusted correctly.
Directional control valve not operating correctly.