Formulae Book
Formulae Book
Formulae Book
b. Pneumatic Formulae
1. Velocity of sound 32.
2. Boyle’s law 32.
3. Charle’s law 32.
4. Amonton’s law 32.
5. Dalton’s law 33.
6. Work done 33.
7. Efficiency 33.
8. Reciprocating compressor 33.
9. Screw compressor 33.
10. Receiver design 34.
11. Pneumatic Cylinders 36.
12. Cylinder design 36.
13. Pneumatic valves 38.
14. Pneumatic Motor 39.
c. References 40.
2
Knots Metre per second (m/s) 5.14773 X 10-1
Centimeter per minute (cm/min) Metre per second (m/s) 1,66667 x 10-4
Average Total distance travelled in specific direction (S) m km
Aerage velocity (v) = or
velocity Total time of travel (t) s h
Instantaneous d2 m
Acceleration Instantaneous Acceleration (a) = (S )
dt 2 s2
Acceleration Final velocity (v 2 ) − Initial velocity(v1 ) m
Acceleration (a) =
Time interval over whcih change occoured (t) s2
Linear
acceleration v
Linear Acceleration (a) =
t
3
Hydraulic Hydraulic power (P) = Pressure (P) × Flow Rate (Q) J/s or Watt
Power Pressure (in N/m ) × Flow Rate (in m /s)
2 3
Hydraulic power (in kW) =
1000
Pressure (in psi) × Flow Rate (in GPM)
Hydraulic power (HP) =
1714
Mechanical 2πNT J/s or Watt
Mechnical Power (P) =
power of a 60
rotating object where N = rotation speed in RPM, and T = Torque in N-m
Pressure Pressure transmission
transmission P A
1
= 2
P2 A1
4
Viscosity Shear Stress due to viscous force N
m2
or,
Ns/m2
Following chart gives conversion table for converting absolute viscosity from one unit to
other.
where
β = Bulk modulus (N/m 2 orPascal)
ΔP = Change in Pressure (N/m 2 or Pascal)
∆V = Change in volume when ∆P is applied (m 3 )
V = Original volume (m 3 )
Compressibility 1 m2/N
Compressib ility =
Bulk Modulus
Effective Bulk Effective Bulk Modulus of oil with air N
Modulus of
1 1 VT − V AIR 1 V AIR m2
oil with air = +
β e β OIL VT β AIR VT
V AIR / VT << 1
Because
1 1 V 1
= + AIR
β e β OIL VT β AIR
VT = VOIL + VAIR
Natural Spring rate of a fluid column
frequency of a Aβ m
fluid column K=
l
Natural frequency of the fluid column
1 Aβ A
n= l
b
2π ml
where, K = spring rate b = Bulk Modulus
A = area of fluid column L = Length of the fluid column
m = moving mass
Reynolds Reynolds Number for flow in a circular pipe
Number
6
Friction head Frictional head loss in a fluid conductor is given by
loss
where,
h L = Head loss (m), f = Friction Factor (dimensionless),
L = Conductor length (m), D = Conductor inside diameter (m),
v = Average fluid velocity (m/s) , g = graviational acceleration (m/s 2 )
Friction factor for laminar flow
Ref. [1]
Pressure In general, pressure losses in fittings can be given by
Losses in Kv 2
Fittings hL =
2g
Where
hL = head loss (m)
v = fluid average velocity (m/s)
g = graviational acceleration (m/s 2 )
Typical K factors for common fittings are given by Esposito (1988).
7
Pressure Pressure loss due to sudden expansion
Losses 2
d 2 ρvi2
P = K e 1 − i2 ----------Ref [2] di do
d o 2
where
K e = inlet coefficient, d i = inlet diameter
d o = outlet diameter, vi = inlet velocity
Inlet condition Ke
Well rounded 0.04 Ref: “Hydraulic System Analysis”; by
George W Keller
Slightly Rounded 0.23
Sharp Edged 0.485 – 0.56
Inward projecting Pipe 0.62 -0.93
Pressure loss due to Sudden Contraction
d o2 ρvi2
1 − 2
di 2
P= ; N R ≥ 5000
2
Ref [3]
Pressure loss due to gradual Expansion
ρvo2 ρvo2
P = 0.04 or P = K
2 2
--- (Ref - 4)
------- (Ref - 5)
-------- (Ref - 6)
8
--- (Ref - 7)
--- (Ref - 9)
9
--- (Ref - 11)
Resistance coefficients due to abrupt changes in the cross-section and due to geometry of
pipe entrance and exits.(Ref-13 )
Resistance Resistance coefficient for pipe bends
coefficient for
pipe bends
10
Resistance coefficient for pipe bends (Ref –[ 14])
Pressure loss Pressure loss in tubing bends
in tubing
l ρv 2
bends ∆P = f + cK B --------------- (Ref - 15)
d 2
(Ref - 16)
-----(Ref - 18)
11
(Ref - 19)
-----(Ref - 20)
(Ref - 21)
12
------ (Ref - 22)
Flow area and For a poppet valve the flow area, Av, is described by the following
flow of a expression:
conical
poppet valve
(Ref - 23
Discharge flow through the poppet valve
13
Leakage Flow No flow, one plate stationary one moving V
(Laminar u
y
flow) Velocity (u) = V Q
b y
wb 3
Flow (Q) = ∆P ; w >> b
12 µl
Steady laminar flow, one stationary flat plate, one moving
w
y 1 ∆P 2 b 2 V
Velocity (u) = + V + y − Q
µ
b 2 2 l 4 y u b
Vb b 3
Flow (Q) = w − ∆P ; w >> b
2 12 µl
Steady laminar flow through square tubes
a4 a
Flow (Q) = ∆P
28.4 µl
14
Steady laminar flow through Elliptical tube a
b
πa b 3 3
Flow (Q) = ∆P
(
4 µl a 2 + b 2 )
Steady laminar flow through Equilateral Triangle tube
a4 a
Flow (Q) = ∆P
185µl
Steady laminar flow through Right angle Triangular tube (Ref - 25)
2πRb 3 ∆P
2
3e
Flow (Q) = 1+ R
12 µl 2b
or
πdb3 ∆P 3 e
2
Flow (Q) = 1+
12µl 2 b Where b = Radial clearance between tubes
Laminar flow through Rectangular passage, w/h,i.e., w is greater diameter (Ref - 26)
Orifice
Equation Q = C d A ( 2 g∆P / γ (Valid only for turbulent orifice flow)
Q = Flow (m 3 /s)
Cd = Orifice constant (decimal)
A = Area (m 2 )
g = graviational acceleration (m/s 2 )
∆P = Pressure (N/m 2 )
γ = Specific weight of the fluid (kg/m 3 )
or
Q = k ∆P where k = C d A 2 g / γ
So, ∆P = Q / k = k eq Q
2 2 2 2
15
Fig. Orifice Coefficient for turbulent Flow Fig. Orifice Coefficient for Laminar Flow
Contraction
coefficient for
round and slot
type orifice
(Ref- 27)
16
Orifice area
of a circular
port in a flat
plate (Ref - 29)
Fig. Orifice area Vs Valve spool displacement for a circular port in a flat plate.
Lateral Force Lateral Force acting on the tapered piston
acting on the
tapered piston
(Ref - 30)
Where, C is the radial clearance at the large end of the piston and spool centered.
Hydraulic Locking force
Forces in
flapper nozzle
valves(Ref -
31
)
17
Single jet
flapper valve
(Ref - 32)
Design Criteria
Fig. Single jet flapper valve with Piston load
Double jet
Flapper valve
(Ref - 33)
18
Leakage or centre flow at null
and
So,
Note: For detailed Flapper Valve design, Refer “Hydraulic Control Systems”, Herbert E Merritt.
Stresses in Pressure rating of the pipe (thin tubes)
pipe and tubes
(Ref - 34)
19
For Copper Pipes
For 180o Bends the minimum thickness required is given by (ASTM A 566-65)
20
Maximum
Working
pressures for
imperial tubes
as per BS
3602 CDS23
(Ref - 35)
Maximum
Working
pressures for
metric tubes
as per BS
3602 CDS23
(Ref - 36)
American
Hydraulic
pipe sizes
(Ref - 37)
21
Hydrostatic Circular step thrust bearing
bearings Pressure distribution
(Ref - 38) ln(r/R2 )
P = PS
ln(R1 /R2 )
Frictional torque
T =
πµω 4
2h
(
R2 − R14 )
Flow rate requirement
πh 3 dP πh 3 PS
Q = 2πr − =
12μ dr
6μ ln (R2 /R1 )
Load carrying capacity
W = πR P + 2π ∫ rPdr =
2
R2
(
πPS R22 − R12 )
2 ln(R2 /R1 )
1 S
R1
or
W =
(
3 µQ R22 - R12 )
h3
Thus, Load carrying capacity of such a bearing varies with the flow rate and film thickness.. For
Example, doubling the load will decrease the film thickness by 38%, indicating a stiff film.
Hydrostatic system power loss
E total = E f + E P
Fluid friction power loss
E f = Tω =
πµω 2 4
2h
R2 − R14 ( )
Pumping power loss
πh 3 PS2
EP =
6η P μ ln (R 2 /R 1 )
where hp = efficiency of the pump
d
1 1 1 1
1 1
− − − h2
h c-e e
h 2 h12 µlv h
h1 h2 x h h1
p = p1 + ( p1 − p2 ) +6 l
1
−
1 t 1 1
+
h22 h12 h
2 h1
Lateral force (f) acting on a taper (conical) piston
Lateral force (f) or lateral bearing force in a dimensionless form can be given as
F T 2+T 24VL ( 1 + T )2 − E 2 − 1 − E 2 2+T
= − 1 − −
L E ( 2 + T )2 − 4 E 2 TE T ( 2 + T )2 − 4 E 2
where
T = t/c, E = e/c, L = l/d, F = f/0.25π/ 2 (p 2 − p1 ), V = µdv/c 2 (p 2 − p 1 )
t = 0.5(d 2 − d 1 ) = taper
22
Leakage flow through gap between cylinder and piston annulus
πc 3 ∆ p 2 ( 1 + T ) 2 3 T4 2+T
q= + ( 2 + T )E 2 + − 1
12 µL ( 2 + T ) 4 8( 2 + T ) ( 2 + T )2 − 4 E 2
which can be approximated as
πc 3 ∆p 1 + 1.75T + 1.5( 1 + 0.5T )E 2
q=
12 µL L
Sizing of Single Rod Double Acting Hydraulic Cylinder
Hydraulic
cylinders Cylinder Demand:
Q = Ae L
where D d
Cylinder Force:
πD 2 π (D 2 - d 2 )
Cap End Area (ACE ) = = Piston Area (AP ) Rod End Area (ARE ) =
4 4
π 2
Rod Area (AR ) = d
4
Force developed by Cylinders
Force Extension = Cap End Area × pressure at cap end - Rod End Area × pressure at rod end
FR = ACE × PC - ARE × PR
if rod end pressure PR (back pressure) is zero, then
Force Extension = Cap End Area (ACE ) × pressure at cap end (Pc )
FR = ACE × PC
Force Retraction = Rod End Area × Pressure at rod end - Cap End Area × Pressure at cap end
FR = ARE × PR - ACE × PC
if Cap end pressure PC (back pressure) is zero, then
Force (Retraction) = Rod End Area × Pressure at rod end
FR = ARE × PR
Force under regeneration
Extension Force with Regeneration = Rod Area × pressure
Stress in rod
F
σ = D d
π 2
d
4
Critical load capacity to avoid bucking of rod
P
π 2 EI
Pcr =
( KL )2
Where E = modulus of elasticity,
I = area moment of inertia,
L = unsupported length of column,
K = column effective length factor, whose value depends on the conditions of end support of the
column, as follows.
For both ends pinned (hinged, free to rotate), K = 1.0.
For both ends fixed, K = 0.50.
For one end fixed and the other end pinned, K = 0.699....
For one end fixed and the other end free to move laterally, K = 2.0.
23
Cylinder Speed:
Velocity at any instant
dx pA − ( Fr + f )
= t
dt m
Where p is pump pressure, A area, Fr resistance opposing the motion and, f frictional and fluid
losses at exhaust port.
A =ACE, for extension of rod; A = ARE for retraction of the rod.
24
Flowrate per minute(Q)
N(RPM) =
Displacement per Revolution
Volumetric efficiency
DN
ηv = × 100
Qa
where
D= Volumetric displacement of motor per revolution(in m3/REV)
N = Speed of the motor in Revolutions per second
Qa = Actual flow required by the motor(in m3/s)
Or
If the accumulator volume is Vf and pressure is pf, when filled with desired amount of fluid,
and Ve and pe are the volume and pressure when it is empty
Vs
Ve = 1
β β = 1.24 for Bladder type accumulators
pe
n β = 1.11 for Piston type accumulators
;
1−
pf
25
Bladder accumulators- Refer Annexure - 1 for selection of the bladder accumulators
26
Hydraulic
pumps Table : Useful formulae for the displacement of positive displacement pump (Ref- 41)
27
Filters Bubble Point Test
Bubble point is based on the fact that liquid is held in the pores of the filter by surface
tension and capillary forces. The minimum pressure required to force liquid out of the
pores is a measure of the pore diameter.
Beta Ratio
Number of particles of size x or higher in the upstream line
βx =
Numbe of particles of size x or higherin the downstream line
Filtration Efficiency
1
η fx = 1 −
βx
Sizing A Hydraulic Filters
Refer Manufactures catalogue for sizing filter for given application.
Refer Annex- 2 for example.
Heat Heat generated in the hydraulic system
exchanger - Due to inefficiency of transmission
selection and - Due to leakage through relief valve
sizing - Due to pressure drop across valves, pipe friction, bends, fitting, filters and
other components
Where
28
Specific Heat Dissipation rate
(Ref - 42)
(Ref - 43)
29
Fig. Leakage flow of an incompressible fluid through an axial bush at various shaft eccentricities (Ref - 44)
30
---- ( Ref - 46)
Optimum design and performance prediction of
Viscoseal (Ref - 47)
The optimum design varies with Reynolds number [(Re) = Vcp/η]] for turbulent flow; in particular
a smaller helix angle than the optimum laminar value is better. Eccentricity will lower the sealing
pressure with laminar flow but may raise it for turbulent flow.
Application
oriented
For Lifting the load
(Ref – 48)
31
Where
Boyle’s law
Charle’s law
Amonton’s
law
32
Dalton’s law
Efficiency
where –
Screw
compressor
33
Theoretical Power
where
Design Stress
34
35
Normal thickness
Pneumatic
Cylinders
Cylinder
design
36
For dynamic applications
Cylinder thrust
The thrust available from an air cylinder is given by:
‘F’ is in Newton’s, P is the gauge pressure in bar and ‘A’ is the effective
37
piston area in mm2, ‘f’ is the cylinder efficiency, taking into account seal
friction. ‘f’ is usually taken as 0.75 (75% efficiency).
Air consumption of a cylinder
where
q is in litre/s (free air), P is the absolute pressure in bar,
L is the stroke in mm, A is the cross-section area in mm2
N is the frequency of operation in cycle/s.
For single-acting cylinders (no return air), A = piston area;
For double-acting cylinders, A = piston area + the return area.
Piston velocity
Pneumatic
valves
Kw is the flow in litres of water which passes through it with a pressure drop of 1 bar.
As per BS 5793, equation for flow through a valve is given by the pair of equations:
38
P1 and P2 are the upstream and downstream pressures respectively in bar (absolute) and
q is the flow rate in litre/s. The value C is known as the conductance with units of litre/(s
bar). b is the critical pressure ratio. Note that C is not the same as Cv.
Where Cv or Kv are quoted but not C, the value may be obtained from
b=0.53
Pneumatic The theoretical torque output of pneumatic motor given by
Motor ∆PD
Torque ( T ) =
2π
where
D P =pressure drop across motor = P s= System Pressure
D= Volumetric displacement of motor per revolution
Speed of the pneumatic motor
Flowrate per minute(Q)
N(RPM) =
Displacement per Revolution
Pneumatic Power
Overall efficiency
Actual power output
ηo =
Theoretica l power output
Mechanical Efficiency
ηo
ηm = × 100
ηv
39
References :
(A) Particular references for Formulae
[1]
“Hydraulic control systems, Herbert E. Meritt, John Wiley & Sons Inc., Page no. 37.
[2]
“Hydraulic System Analysis”; by George W Keller, page 54
[3]
“Hydraulic System Analysis”; by George W Keller, page 55
[4]
“Handbook of Hydraulic Resistance”, Idelchik Page 222-224
[5]
“Handbook of Hydraulic Resistance”, Idelchik Page 222-224
[6]
“Handbook of Hydraulic Resistance”, Idelchik Page 222-224
[7]
“Handbook of Hydraulic Resistance”, Idelchik Page 222-224
[8]
“Handbook of Hydraulic Resistance”, Idelchik Page 222-224
[9 ] “
Handbook of Hydraulic Resistance”, Idelchik Page 522, Diagram 8.6.
[10 ]
“Handbook of Hydraulic Resistance”, Idelchik Page 523, Diagram 8.6.
[11 ]
“Handbook of Hydraulic Resistance”, Idelchik Page 526, Diagram 8.6.
[12 ]
“Handbook of Hydraulic Resistance”, Idelchik Page 526, Diagram 8.6.
[13]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 46
[14]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 48
[15]
“Hydraulic System Analysis”; by George W Keller, page 51
[16]
“Fluid power design handbook”, Franklin D. Yeaple, 3rd Edition, page no.
[17]
“Fluid power design handbook”, Franklin D. Yeaple, 3rd Edition, page no.
[18]
“Fluid power design handbook”, Franklin D. Yeaple, 3rd Edition, page no.
[19]
“Fluid power design handbook”, Franklin D. Yeaple, 3rd Edition, page no.
[20]
“Fluid power design handbook”, Franklin D. Yeaple, 3rd Edition, page no.
[21]
“Fluid power design handbook”, Franklin D. Yeaple, 3rd Edition, page no.
[22]
“Fluid power design handbook”, Franklin D. Yeaple, 3rd Edition, page no.
[23]
“Hydraulic Component Design and Selection”, Dr. E.C. Fitch and Dr. I. T. Hong, page no. 209,210.
[24]
“Hydraulic Component Design and Selection”, Dr. E.C. Fitch and Dr. I. T. Hong, page no. 182.
[25]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 34.
[26]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 34.
[27 ]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 42.
[28]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 43
[29]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 114
[30]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 109
[31]
“Hydraulic and electro-hydraulic control systems”, By Ronald B. Walters, page no. 171
[32]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 118
[33]
“Hydraulic control systems”, Herbert E. Meritt, John Wiley & Sons Inc., page no. 122
[34]
“Hydraulic handbook”, R H Warring, 8th Edition, page no. 180-184
[35]
“Hydraulic handbook”, R H Warring, 8th Edition, page no. 177
[36]
“Hydraulic handbook”, R H Warring, 8th Edition, page no. 178
[37]
“Hydraulic handbook”, R H Warring, 8th Edition, page no. 178
[38]
“Applied Tribology”, Michael M. Khonsari, E. Richard Booser, page 302 - 306
[39]
“Analysis, Synthesis & Design of Hydraulic Servo Systems and pipelines”, Taco J. Viersma, Page no. 233.
[40]
“Hydraulic handbook”, R H Warring, 8th Edition, page no. 158-165
[41]
“Oil Hydraulic Systems”, S R Mazumdar, TMH Publication, Page no. 129-130.
[42]
“The Tribology Handbook”, M. J. Neale, 2nd Edition, Butterworth-Heinemann publication, page – B22.1.
[43]
“The Tribology Handbook”, M. J. Neale, 2nd Edition, Butterworth-Heinemann publication, page – B22.1.
[44]
“The Tribology Handbook”, M. J. Neale, 2nd Edition, Butterworth-Heinemann publication, page – B22.2.
[45]
“The Tribology Handbook”, M. J. Neale, 2nd Edition, Butterworth-Heinemann publication, page – B22.5.
[46]
“The Tribology Handbook”, M. J. Neale, 2nd Edition, Butterworth-Heinemann publication, page – B22.5.
[47]
“The Tribology Handbook”, M. J. Neale, 2nd Edition, Butterworth-Heinemann publication, page – B22.6.
[48]
“Principles of hydraulic System Design”, Peter J. Chapple
[49]
“Pneumatic Handbook”, Antony Barber, 8th Edition,
(B). General references
a. “Fluid Power & Controls”, John F Cundiff.
b. “Design of Hydraulic control Systems”, Ernest E Lewis and Hansjoerg Stern
40
c. “Fluid Power Systems & Circuits”, Russel W Henke
d. “The Control of Fluid Power”, D McCloy and H R Martin
e. Hydraulic Trainers, Vol. 1,2,3,4,6 , Rexroth
f. Practical Hydraulic Systems, Ravi Doddannavar and Andries Barnard
Websites:
www.hydraulicspneumatics.com
www.boschrexroth.com
www.parker.com
www.google.com
41
42
Annexure – 1
Selection of
Accumulators
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Annexure – 2
Selection of Filters
Í×Æ×ÒÙ ØÇÜßÝ Ú×ÔÌÛÎ ßÍÍÛÓÞÔ×ÛÍ
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Annexure – 3
Selection of Heat
Exchanger
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