Professional Documents
Culture Documents
Zeeshan Ahmad
(132090007)
Under the Guidance of
Dr. V.M.Phalle
Associate Professor & TPO
Contents
1.
Introduction
Problem definition
Objective
Summery
2.
Literature review
3.
Methodology
Tribological Evaluation of Hydraulic Fluids
Gamma Irradiation of Hydraulic Fluids
4.
5.
6.
1.Introduction
1. Objective
Study of different types of hydraulic fluids and their properties and selection of fire resistant
hydraulic fluid based on previous data available and system requirements.
Study of tribological behaviour of different hydraulic fluid and selection of standard method
of evaluating tribological properties based on our requirements.
Preparation and submission of report on tribological behaviour of hydraulic fluids.
Conclusion based on experimental data of both the hydraulic fluids.
Planning and preparation of sample for gamma radiation of hydraulic fluids inside a gamma
chamber located at ISOMED, south side of BARC.
Measurement of viscosity, viscosity index of radiated oil samples at different temperatures
and conclusion based on experimental data.
2. Summery
a) Literature Reviewed
Study of different types of hydraulic fluids
Selection of fire resistant hydraulic fluid
Study of properties of hydraulic fluids and their effect on system performance
Study of different tribological test methods as per ASTM and ISO standards
Study of effect of gamma radiation on properties of hydraulic fluids
2.Literature Survey
Sr. No.
Literature
Fire-Resistant
Sr. No.
Literature
Charles Spar, Hydraulic Fluids and Their Relative radiation resistance of various
Applications, ASME Publication 64 hydraulic fluids.
WA/LUB-14.
R.O .Bolt and J.G. Carrol, Effect of Change of properties of lubricant because
radiation on aircraft lubrications and of gamma irradiation
fuels, California Research Corporation,
WADC Technical Report No 56- 646, Part
II, ASTIA Document No. AD 151176.
April 1958.
Zeeshan
Ahmad,
P.K.Mishra, Tribological data of gamma irradiation on
Determination of Effect of Gamma hydraulic fluids.
Radiation on Petroleum based Hydraulic
Fluid - ENKLO-68 RTD Report, BARC,
Mumbai
Literature
Timken Tester
Federal Test Method 6505
Almen Tester
Falex Tester
Federal Test Method 3807 & Federal Test
Method 3812
A cylindrical rod is rotated between two hard Vshaped bearing blocks which are pressed against
the rod
Four-ball Tester
ASTM D-2596-67T, Federal Test Method
6514 & ASTM D-2266-64T
SAE Tester
Federal Test Method 6501
ASTM
Designation
G133-05(2010),
Standard Test Method for Linearly
Reciprocating Ball-on-Flat Sliding Wear,
ASTM International, West Conshohocken,
PA, 2010, www.astm.org
3.Methodology
1. Tribological testing of hydraulic fluid
Objective:
This test has been carried out at Refueling Technology Division (RTD), BARC Mumbai
A reciprocating sliding wear and friction machine (Plint and Partner TE-70) was used based on
ASTM G133 Procedure B
Bearing steel plate SS-52100 and bearing steel balls SS-52100 of 1/2 inch (12.7 mm) diameter
were used as fixed specimen and moving specimen respectively.
Temperature (C)
Oil-A
FRHF
65
POE
Oil-B
65
Mineral
Oil-A
FRHF
90
POE
Load(N)
Frequency (Hz)
Sliding
Stroke Length
Distance (M)
(MM)
15
10
400
20000
15
20
400
10000
25
10
400
20000
15
10
400
20000
15
20
400
10000
25
10
400
20000
15
10
400
20000
15
20
400
10000
25
10
400
20000
Test Procedure:
Load
Time (Sec)
Test Parameters:
Sr.
No.
1
2
3
4
Parameter
200 N
4.76 mm
10 mm
sliding Distance 400 m
Frequency of oscillation
10 Hz
10,20,10 Hz
40 to 60 %
60%
8
9
Ambient Temperatures
Medium
150 2C
Lubrication
65C
Lubrication
Owing to the nature of this type of test, the wear on ball specimen may not be circular or flat
always therefore refer the following which applies.
If the ball appears flat but not circular, the average of the maximum and minimum
dimensions of the scar is taken as effective ball scar diameter (D).
Pin scar measurement may be made by removing the ball specimen holder and placing the
wear scar portion under the microscope. A calibrated ocular or a photo-micrograph of known
magnification may be used to measure scar dimensions.
As per ASTM G99-05(2010) Volume loss of Ball in mm3 is calculated using following formula
( . , )4
, =
64 ( , )
4
= 64
Vb= Wear volume for ball scar of diameter D in mm3
D = Ball scar diameter in mm
R = Ball radius in mm
3
Where
Note: This is an approximate geometric relation that is correct to 1 % for (wear scar diameter/ball radius) <0.3, and is correct to 5
% for (wear scar diameter/ball radius) <0.7. The exact equation is as given below.
=
( 103 )
Where
Where
Coefficient of Friction
1.
OIL-B
0.09
0.08
0.07
Regime 1 Regime 2
0.06
Regime 3
0.05
0
0.05
0.1
0.15
0.2
*V/P(Stribeck Parameter)
0.25
0.3
0.35
Friction Characteristics
Effect of Temperature on Coefficient of Friction
15 N / 20 Hz
0.081
0.08
Oil-A
0.089 0.088
0.09
0.081
Oil-B
0.079
0.07
0.06
0.05
Oil-A
0.1
0.095
0.095
0.096
0.092
0.089
0.076
0.063
0.05
27
65
90
27
Oil-B
0.086 0.086
0.077
0.08
0.073
0.073
0.07
0.06
0.05
27
65
Temperature (C)
65
Temperature (C)
Temperature (C)
Coefficient of Friction
0.102
Coefficient of Friction
Coefficient of Friction
90
90
Oil-B
Wear Characteristics
1. Ball Wear
Load Vs. Wear Rate of Ball
27C /10 Hz
10-7
1.50
OIL-A
OIL-B
0.90
0.83
0.60
0.38
0.36
0.30
0.00
15
Load (N)
OIL-A
25
Wear Rate(mm/Nm)
Wear Rate(mm/Nm)
1.20
1.20
OIL-B
1.20
0.90
0.87
0.86
0.60
0.30
0.22
0.21
0.00
15
25
Load (N)
Plate Wear
Load Vs. Wear Rate of Plate
27C /10 Hz
OIL-A
4.79
5.00
OIL-B
4.00
3.00
2.00
2.82
1.81
1.36
1.00
0.00
15
Load (N)
25
5.00
Wear Rate(mm/Nm)
Wear Rate(mm/Nm)
6.00
OIL-B
4.00
3.53
3.00
2.21
2.00
1.00
1.45
0.56
0.00
15
Load (N)
25
Sample Preparation
0.90
Density (g/cm)
0.80
0.70
Density Vs Temperature
0.60
0.50
0.40
0.30
0.20
283
303
323
343
Temperature (K)
363
383
5 MRad
25 MRad
50 MRad
100.0
100 MRad
300 MRad
10.0
1.0
283
303
323
343
Temperature (K)
363
383
Viscosity index
100
90
80
70
60
50
0
50
100
150
200
250
300
350
1. Density:
Density (g/cm)
Following graph gives the variation of density in g/cm3 for fresh as well as
irradiated oil samples with respect to temperature in range of 15-100 C (288K to
373K).
Fresh
5 MRad
25 MRad
50 MRad
100 MRad
300 MRad
0.2
283
303
323
343
Temperature (K)
363
383
Fresh
Oil
Sampl
e
5
MRad
25
MRad
50
MRad
100
MRad
300
MRad
500
Fresh
5 MRad
Viscosity mm/s
25 MRad
50 MRad
100 MRad
300 MRad
50
5
270
290
310
330
Temperature K
350
370
Viscosity Index
150
148
146
VI
144
142
0
50
100
150
200
250
300
The tribological evaluation for qualifying hydraulic Oil-A and Oil-B has been done on sliding
friction and wear machine TE-70. Friction and wear were the major candidate for qualifying
the oils.
As discussed in previous chapter, the friction characteristics of the two oils are almost same.
The stribeck curve shows that both Oil-A and Oil-B have similar operating conditions in
hydrodynamic regime.
The wear characteristics shows that the wear rate of ball and plate under Oil-A lubrication is
high as compared to Oil-B but the order of wear rate is very low for both oils and is of order
10-7, which is condition of mild wear. Hence it can be acceptable.
Based on tribological experiment it can be concluded that both hydraulic oils are similar in
tribological behaviour, Oil-A has the advantage of being fire resistant. There for Oil-B can be
replaced by Oil-A if there is chances of fire hazard or the operating temperature is high.
2. Radiation Resistant
There is approx. 5.92% decrease in the density of the ENKLO 68 and 6.02% decrease in the
density of the POE 68 from 15 to 100 C
The density of both ENKLO-68 and POE-68 oil has been found to be resistive to radiation
levels up to 300 MRad for same temperature as the radiation level increases Density is not
much affected.
The viscosity of the ENKLO-68 has been found to be more resistive to radiation levels and is
affected by 12-13% only where as POE-68 oil has been found to be less resistive and is
affected by 50-60% for same temperature.
It is found that the percentage change in viscosity for both oil samples is higher in lower
temperature range as compared to that in higher temperature range with respect to unirradiated fresh oil sample.
The viscosity index of the ENKLO-68 oil has not improved because of radiation and remains
constant, where as VI of POE-68 oil has improved.
The appearance of hydraulic oil ENKLO-68 has changed after exposure to Gamma radiation,
where as the appearance of hydraulic oil POE-68 Remains unchanged.
Analysis of Total Acid Number (TAN) and Total Base Number (TBN) may give the change in
acidic or basic content in the oil. This may be helpful to decide the effect of irradiated oil on
the components of hydraulic system.
Based on above discussion it is concluded that up to 50 MRad radiation level Oil-A can be
used as hydraulic fluid in replacement of Oil-B in nuclear industry when the operating
temperature is high.
Future Scope
The test procedure discussed in this report for sliding friction and wear measurement can be
used for general purpose friction and wear test under lubricated or dry condition.
The data available in this report can be used for selection of hydraulic oils for other
applications also.
The properties of hydraulic oils will required to be evaluated at more radiation levels, for this
purpose it is planned to irradiate hydraulic oils at 5, 25, 100, 200, 300, 400 and 600 MRad
radiation levels.
The appearance of oil is not a major concern in this report but in future the oil has to be
further analysed for presence of oxidation compounds using TAN and Oxidation Stability test.
Change-over of a system from one hydraulic oil to another can create problems unless
consideration is given to circuit and component design.
For this purpose, a Fire Resistant Hydraulic Fluid Test Facility (FRHTF) will be developed by
RTD at Engineering Hall 3. In this facility hydraulic performance, compatibility with existing
hydraulic components, and high temperature operability will be tested by evaluating the
changes in properties of the hydraulic oils after being used in this facility test setups.
The test facility will be designed to be operated without any operator.
A man machine interface (MMI) will be required to design to run this test facility 24x7
without any operator assistance.
References
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
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