CURSO HIDRAULICA BÁSICA

ROQUET presentation on:
WP6-Testing
(and related: T1.1 Risk analysis, T1.2 Definition of
categories, T2.1 Structural design, T2.2 Fluid
dynamic design, T3.1 Cast iron, T3.2 Seals, T3.4
Coatings, T4.1 Honing and T4.2 Welding, )
4th Reporting Period General meeting ,
VIC (Barcelona-Spain),
on 26th and 27th May 2008
PROHIPP-4th Reporting Period General Meeting - VIC (Barcelona) on 26th and 27th May 2008
Page : 1
Research performed – 4th RP- stress lab tests results
95 stress lab tests have been carried out in the Roquet’s stress test
benches during the 4th Reporting Period.
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25 Cast iron cylinders (provided by FRoda)
15 MAG welded Tubes as oil port. (samples)
11 MAG welded Oil ports.(samples)
7 MAG welded Rods.
4 Friction welded Rods (provided by Scaglia).
3 Laser welded Oil ports (provided by ISQ).
3 Electron beam welded Oil ports (provided by ISQ).
2 different Test benches
2 Hybrid welded Rods (provided by ISQ).
10 complete cylinders in Stress Test bench nº2 (oil ports and rod ends)
15 ceramic rupture disks – fatigue tests
Partners involved: Roquet, FRoda, Scaglia, ISQ, BCE
MAG
MAG
MAG
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
NEW ! On 4th RP
Ceramic rupture disks
Friction
Laser , Electron Beam
Cast iron
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Research performed – 4th RP- crack propagation
Roquet has carried out an experimental investigation on the crack
propagation on the oil port zone under different pressures.
Partners involved: Roquet, Cenaero
Crack evolution
CRACK EVOLUTION PHF-314
12
11
10
9
CRACK (mm)
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8 samples and 200 inspections by now (still going on)
With the purpose of finding the first indications of crack, having previously
calculated his estimated life by means of other experimental results, and by
means of CFD simulations (crack propagation – CENAERO).
2 samples Ø45xØ52 with oil port at 440 bar
2 samples Ø45xØ52 with welded tube at 440 bar
2 samples Ø45xØ52 with welded tube at 275 bar
2 samples Ø50xØ57 with welded tube at 275 bar
8
7
Crack A
6
Crack B
5
4
3
2
1
0
105.000
110.000
115.000
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
120.000
CYCLES
125.000
130.000
135.000
Graphic of sample Ø50xØ57
welded tube 275 bar..
Stress cracks revealed by the inside
bore, under the oil port hole.
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Research performed–4thRP-Metallurgical Laboratory reports
80 Metallurgical Laboratory reports have been done.
Analysing: breakages, cracks, welds, seals, etc.
Partners involved: Roquet, FRoda, Scaglia, ISQ
Insert type “A” cast and then
friction welded
Rod weld analysis
Rod weld breakage
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008Stress
crack in oil port
Oil port weld
Page : 4
Research performed – 4th RP- Roundness distortion
measurements on bore with different welding procedures
Roquet carried out 10 tests, measuring the bore roundness before and after different
welding procedures.
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2 -Laser welding
2 -Electron beam welding
2 -Stud welding
4 -MAG welding
It has been necessary to modify the
Roquet manufacturing process,
in order to measure the
roundness distortion produced
by the MAG welding process.
First honing, then welding
(Not current process).
Partners involved: Roquet, ISQ
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 5
Research performed –4th RP- Fatigue tensile test
Objective: Obtaining real S-N curves from smooth samples , traction loaded.
During the 4th reporting period, Roquet designed and built a new fatigue tensile test bench.
In order to obtain real and accurate data from different material properties, several tests
have been carried out. Tractioning test pieces to different pressures. (38 tests).
Iron test piece Ø5
(CK-45)
Cast iron test piece Ø8
(GGG 40.3)
Iron test piece Ø5
(CK-15)
19 different tests
11 different tests
8 different tests
NEW ! On 4th RP
Fatigue tensile test bench
Partners involved: Roquet, FRoda
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 6
Research performed- 4th RP- Cushioning tests
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Roquet and UPC-Labson carried out many experimental cushioning tests in 3
different types of cushioning:
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TYPE I. Piston grooves
30 Lab cushioning tests. Varying the
number of grooves and its depth,
but also the geometry and the
piston length.
-2 types of grooves (rectangular and triangular)
-10 different piston designs - prototypes
-Part num. 2972/8/4, 4599, 4601,
4896, 2652/25.
Triangular grooves
-Part num 2535.
Grooves in both sides
-Part num. 2972/8/2
Triangular grooves
Opened grooves: 1-2.
-Part num. 2283
Rectangular grooves
Opened grooves: 2-3.
Partners involved: Roquet, UPC-Labson, Imamoter
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
-Part num. 2972/8/1
Triangular grooves
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Research performed – 4th RP- Cushioning tests
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Roquet has carried out tests in 3 different types of cushioning:
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TYPE II. Metallic Ring
24 Lab cushioning tests. Roquet has investigated in order to
improve the cushioning by adding a 2nd metallic ring. The
metallic ring plays a check valve role.
- 3 types (1 metallic ring, 2 metallic rings,
progressive cushioning (single ring))
- 8 prototypes
Partners involved: Roquet,
UPC-Labson, Imamoter
-Part num. 2377
Progressive cushioning
(single ring)
1 metallic ring
-Part num. 2377
2 metallic rings
-Type a)
-Type b)
-Type c)
-Type d)
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 8
Research performed- 4th RP- Cushioning tests
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Roquet and UPC-Labson have carried out tests in 3 different types of cushioning:
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TYPE III. Conic cushioning
49 Lab cushioning tests
-Part num. 3215 version 1
Short Guiding bush. Conic part fixed
-Part num. 3215 version 2
Long Guiding bush. Conic part fixed
- 15 prototypes (different designs)
-Part num. 3215 version 4
Check valve function backward. Conical part
movil.
-Part num. 2720.
By floating ring and floating
conical cushion part
-Part num. 3215 version 5
Check valve function frontal. Conical part movil
-Part num. 4909.
Cushioning by floating ring
-Part num. 3215 version 3
Check valve function backward.
-Part num. 2697
Cushioning by floating ring
Partners involved: Roquet,
UPC-Labson, Imamoter
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 9
Research performed – 4th RP- Cushioning tests
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Cushioning tests: The cylinders are tested in the cushioning testing bench,
monitoring the displacement, speed and pressure within both chambers . All
cushioning tests have been recorded for pressures 100, 200, 270 Bar.
New ! (4th RP)
3 Test benches on cushioning – 2 NEW ! (4th RP)
5 fatigue-cushioning tests
New ! (4th RP)
Partners involved: Roquet, UPC-Labson , Imamoter
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 10
Research performed – 4th RP- Cushioning tests
Performed cushioning Bond-graph simulations: Partners involved: Roquet, UPC-Labson , Imamoter
Performing also the necessary comparative between simulation
and Lab experimental tests results.
-Software simulating piston grooves
cushioning (triangular – rectangular)
TYPE I
-Software simulating metallic ring
cushioning (single – doble)
TYPE II
-Software simulating conic cushioning
TYPE III
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 11
Research performed – 4th RP - on wearing dynamic bench
50 tests to evaluate the seals, the bushing and the honing results
Partners involved: Roquet, Trelleborg, Honingtec, UPC
-32 Tests dynamic bench
-6 Tests new dynamic bench
-12 Tests alternative dynamic bench
-Dynamic test bench
-Alternative dynamic test bench
Wynseal seal tested
Mainly focused on getting real
characteristics on developed
seals but also on developed
honing processes (honing but
also plateau-honing)
Glydring seal tested
In order to obtain more experimental
data to investigate in seals and
bushing wear, an alternative
dynamic bench has been
developed (designed and built)
-New dynamic test bench
New ! (4th RP)
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 12
Work performed – 4th RP – Designing and manufacturing
cylinders prototypes (other than the ones for fatigue tests)
30 Cylinders with cushioning system for Lab and in field tests:
- 10 cushioning Type I
Several have been tested in field.
- 8 cushioning Type II
Partners involved: Roquet, UPC- 12 cushioning type III
Labson, Hidrar and Sempere.
31 Cylinders for buckling tests:
- 2 for “in field” buckling tests (loader – BMH/Hidrar)
- 4 for Lab buckling tests on back-hoe (UPC-Labson/Hidrar)
- 25 rods (and tubes as rods) for Lab buckling tests (UPC-Labson) –
(several diameters and thickness)
Partners involved: Roquet,
UPC-Labson, Hidrar.
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 13
0,0
B5 + B5 ESPECIAL (with B46)
ROQUET (estándar) (G)
RODILLADA (W)
RODILLADA (G)
HONINGTEC B91 + B20 (4 Strokes) (W)
HONINGTEC B64 + B20 (6 Strokes) (W)
HONINGTEC B64 + B20 (6 Strokes)
HONINGTEC B64 + B20 (6 Strokes) - Tap guia
30.10
HONINGTEC B64 + B20 (6 Strokes) -Tap guia
30.15
HONINGTEC rough:B64 finish:6strokes B20
HONINGTEC rough:B64 finish:2strokes B20
B5 + B5 ESPECIAL (with B46)
HONINTEC rough B-64 + (2 min.) B20
FINISHED
Honing method
ESPECIAL ROQUET B5
ESPECIAL ROQUET B5
ESPECIAL ROQUET B5
ESPECIAL ROQUET B5
ESPECIAL ROQUET B5
STANDARD ROQUET
STANDARD ROQUET
STANDARD ROQUET
STANDARD ROQUET
HONINGTEC B91 + B20 (2 Strokes) (G)
HONINGTEC B64 + B20 (4 Strokes)
HONINGTEC B64 + B20 (4 Strokes)
HONINGTEC B64 + B20 (2 Strokes)
HONINGTEC rough:B64 finish:4strokes B20
HONINGTEC rough:B181 finish:3strokes B20
HONINGTEC rough:B181 finish: 3 strokes B20
HONINGTEC rough:B64 finish:2strokes B20
HONINGTEC rough:B181 finish:5strokes B20
HONINGTEC rough:B181 finish:9strokes B20
Km
Research performed- 4th RP - Honing methods tests
Roquet has carried out an investigation in honing methods (honing and Plateau-honing), this graphic is a summary
of the results, (32 tests).
All tests done in the dynamic test bench have been recorded and analyzed.
700,0
600,0
500,0
400,0
300,0
200,0
100,0
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Partners involved: Roquet, Trelleborg, Honingtec
Page : 14
Research performed – 4th RP - Corrosion tests –
NSS (Neutral Salt Spray)- CASS
300
275
250
225
200
175
150
125
100
75
50
25
0
Induction hardened rods (Ck 45)
1100
1000
Hours in salt mist chamber
900
800
700
600
500
400
300
200
Ø50.e=33
Ø30.e=37,7
Ø30.e=37,7
Ø30.e=37,7
Ø30.e=26,1
Rod diam eter and chrom ed thickness
Rod diameter and chromed thickness
Ceramic rods
Oxinitrocarburized rods
900
900
800
800
700
Ø30. Thickness=191µm
600
Ø30. Thickness=168µm
500
Ø30. Thickness= 575µm
400
Ø30. Thickness=16,4µm
Ø30. Thickness=20,7µm
300
Ø30. Thickness=20,7µm
200
100
Hours in salt mist chamber
Hours in salt mist chamber
Ø30.e=34,1
Ø30.e=29,1
0
Ø25. e=35,4
Ø50.e=33
Ø50.e=33
Ø40.e=30,5
Ø40.e=30,5
Ø40.e=26,2
Ø35.e=30
Ø35.e=29,5
Ø35.e=31,4
Ø25.e=25,3
Ø25.e=24
100
Ø25.e=25,7
Hours in salt mist chamber
Chrom ed rods (Ck-45)
700
-NSS test chamber.
600
500
400
300
sample1,2
200
sample 3,4,5
100
0 PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
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0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85
0 5
% rust
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
% rust
Partners involved: Roquet, HEF
Page : 15
Research perform – 4th RP - Corrosion as “in field” tests
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Roquet carried out (but still going on) tests in several rod samples (40) to
evaluate the corrosion in different field environments.
Rods treatments
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Environment (field simulation)
-Induction hardened chromed rods
-Buried in saline earth
-Chromed rods
-Saline earth atmosphere
-Oxinitrocarburized rods
-Marine environment
6 Induction hardened chromed rods Buried in saline earth.
5 Induction hardened chromed rods in Saline atmosphere
6 Induction hardened chromed rods in Marine environment
-Saline earth
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3 Chromed rods Buried in saline earth.
3 Chromed rods in Saline atmosphere
3 Chromed rods in Marine environment
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3 Oxinitrocarburized rods Buried in saline earth
3 Oxinitrocarburized rods in Saline atmosphere
8 Oxinitrocarburized rods in Marine environment
Partners involved: Roquet, HEF, UPC-Labson
-Marine atmosphere
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 16
Research perform – 4th RP- Field tests
Partners involved: Roquet, Hidrar,UPC-Labson
5 Field tests – 48 recorders – 48 cycle counting
The Cycle-counting program is an analysis program
of the signal spectrum by the “Rainflow”
analysis.
method, which besides showing the
spectrum, it finds the Normal distribution,
Lognormal, Exponential and Weibull that
better adjusts to the discreet spectrum, to
transform it into a continuous spectrum.
Hydraulic solar panels
Loader
Back-hoe
PROHIPP- 4 Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
th
Page : 17
Research performed –4th RP- Thermographic analysis
In order to investigate the possibility of monitoring the heating evolution in any part of a
cylinder, Roquet has taken 60 thermal photos.
Slave cylinder 2 min working
Slave cylinder 10 min working
Oil port 1 min working
Oil port 10 min working
Guiding bush 1 min working
Guiding bush 11 min working
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 18
Research perform – 4th RP- Cylinder’s calculation program
Roquet developed a cylinder’s calculation program to design
correctly and efficiently, as well as to evaluate the load,
buckling and stress in any critical part of a cylinder.
Data entrance
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 19
THANKS FOR YOUR ATTENTION
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 20
Research perform Important parameters of roughness for the study of
honing and plateau-honing surfaces
The figure below shows as after the
honing process, the valley and plateau
region is modified improving the
tribological and bearing characteristics.
HONED SURFACE
Bearing area ratio and the height
distribution of honing bore surface
The
figure below shows the
differences with the previous process
in volume of valley region where the
lubricant is deposited.
PLATEAU-HONED SURFACES
Bearing area ratio and the height
distribution of plateau honing
surface
PROHIPP- 4th Reporting Period General Meeting – VIC (Barcelona) on 26th and 27th May 2008
Page : 21