Tutorials for hydraulic circuit design and analysis

1) Design a car crushing system. The crushing force required is such that a 15 cm
diameter cylinder is required at a working pressure of 126.5 kg/cm2. Time for
crushing is about 10 s and the stroke required to flatttten the car is 254 cm.
Compare
the power required by the circuit without and with accumulator.
Accumulator details:
It is a gas-loaded accumulator
Time taken for charging =5 min
Inititial pressure of charging (pre-charged), p1 = 85 kg/cm2
Charged pressure of accumulator, p2= 210 kg/cm2
Minimum pressure for crushing, p3= 126.5 kg/cm2

The circuit to do the crushing can be seen in figure above

 2) A pump delivers oil at a rate of 18.2 gallons/min into the blank end of a cylinder of
diameter 75 mm (Fig below). The piston contains a 25 mm diameter cushion plunger
that is 25 mm ; therefore, the piston decelerates over a distance of 25 mm at the end
of the suction stroke. The cylinder drives a load of 7500 N that slides on a horizontal
bed with coefficient of friction = 0.1. The pump relief valve pressure setting is 5.5
N/mm2. What is the pressure acting due to cushioning deceleration?

1 gallon = 3.785 L

3) A double-acting cylinder is used in a regenerative circuit as shown in Figure below.

The relief valves is set at 7.5 N/mm2, the piston area is 150 cm2, the rod area is 40
cm2 and the flow is 20 gallons/min. Find the cylinder speed and load-carrying
capacities for various DCV.

4) Two double-acting cylinders are to be synchronized connecting them in series as shown in figure
below. The load acting on each cylinder is 4000 N. Cylinder 1 has the piston diameter 50 mm and rod
diameter 20 mm. If the cylinder extends 200 turns in 0.05 s, find the following :

(a) The diameter of the second cylinder.

(b) The pressure requirement of the pump.
(c) The capacity of the pump assuming the efficiency of the pump to be 85% and overall efficiency of
the system as 90%.

5) A high–low circuit uses a low-pressure pump of 1.4 N/mm2 and a high-pressure pump of 12.6
N/mm2. The press contains eight cylinders and the total load of the press is 5600 kN. The length of
cylinder is 200 mm whereas the punching stroke is only for 6 mm. The time for lowering is 0.05 s and
the time for pressure build-up and pressing is 0.03 s. Determine the following:
(a) The piston diameter of cylinder.
(b) Pump flow rates.
(c) Total motor capacity.
(d) If a single pump of 12.6 N/mm2 is used, find the kW capacity required.

6) A high–low circuit with an unloading valve is employed for press application. This operation
requires a flow rate of 200 LPM for high-speed opening and closing of the dies at the maximum
pressure of 30 bar. The work stroke needs a maximum pressure of 400 bar, but a flow rate between 12
and 20 LPM is acceptable. Determine the suitable delivery for each pump.

7) A press with the platen weighing 5 kN is used for forming. The force required for pressing is 100
kN and a counterbalance valve is used to counteract the weight of the tools. The cylinder with a piston
diameter 80 mm and a rod diameter 60 mm is used. Calculate the pressure to achieve 100 kN pressing
force.

8) In a meter-in circuit, a cylinder with 100 mm bore diameter and 70 mm diameter is used to exert a
forward thrust of 100 kN, with a velocity of 0.5 m/min. Neglect the pressure drop through the piping
valves. If the pump flow is 20 LPM, find the following :
(a) Pressure required at the pump on extend.
(b) Flow through the flow-control valve.
(c) Relief-valve setting.
(d) Flow out of the pressure-relief valve.
(e) System efficiency during extend.

9) A hydraulic intensifier is meant to enhance the fluid pressure from 50 to 200 bar. Its small-cylinder
capacity is 23 L and has a stroke of 1.5 m. Find the diameter of the larger cylinder to be used for this
intensifier.

10) A punch press circuit with five stations operated by five parallel cylinders is connected to an
intensifier. The cylinders are single-acting cylinders with spring return and the piston diameter of the
cylinder is 140 mm. The cylinders are used for punching 10 mm diameter holes on sheet metal of 1.5
mm thickness. The ultimate shear strength of sheet material is 300 MN/m2. The punching stroke
requires 10 mm travel. If the intensification ratio is 20 and the stroke of the intensifier is 1.3 m,
determine the following:
(a) Pressure of oil from the pump.
(b) Diameter of small and large cylinders of intensifier.

11) A double-acting cylinder is hooked up in a regenerative circuit for drilling application. The relief
valve is set at 75 bar. The piston diameter is 140 mm and the rod diameter is 100 mm. If the pump
flow is 80 LPM, find the cylinder speed and load-carrying capacity for various positions of direction
control valve.

12) Two double-acting cylinders are to be synchronized by connecting them in series. The load acting
on each cylinder is 4000 N. If one of the cylinders has the piston diameter 50 mm and rod diameter 28
mm, find the following:
(a) The diameter of the second cylinder. (b) Pressure requirement of the pump.
(c) Power of the pump in kW if the cylinder velocity is 4 m/s.

13) A flow control valve has a controlled flow Cv of 10.5 LPM/ bar and a free flow Cv of 32.4 LPM/
bar. Determine the pressure drop across the valve in both the controlled flow and free flow directions.
The system has a flow rate of 19 L/min and uses standard hydraulic oil of specific gravity 0.9.

14) A cylinder has to exert a forward thrust of 150 kN and a reversible thrust of 15 kN (Figure below).
The retract speed should be approximately 5 m/min utilizing full pump flow. Assume that the
maximum pump pressure is 150 bar. Pressure drops over the following components and their
associated pipe work are as follows :
Filter = 3 bar
Direction control valve (each flow path) = 2 bar
Determine the following:
(a) Suitable cylinder (assume 2:1 ratio; piston area to rod area).
(b) Pump capacity.
(c) Relief-valve setting pressure.