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1

Reducing aeration and cavitation effect in shock absorbers using uid-structure interaction simulation

Czop P., Gniłka J.

Computer Assisted Methods in Engineering and Science

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2016

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Vol. 23, no. 4

171--189

EN

This paper presents a fluid-structure interaction simulation applicable for evaluating and optimizing hydraulic valve designs. A special emphasis is placed on shim stack valve commonly used in automotive and railway shock absorbers. For simplicity, the problem was effectively reduced to a two-dimensional (2D) problem. This was accomplished by introducing section-lines along which the pressure profile was computed to find and evaluate the global minimum. The global minimum was then treated as the design ranking measure. This ranking function provided a means to choose an optimal design from a set of available design variants. In the presented results, the ranking is problem-specific as it identifies and localizes low pressure zones that are the root causes of both aeration and cavitation effects. The damping force performance was experimentally evaluated for both the baseline and optimized valve design using a shock absorber level test on a servo-hydraulic test rig.

2

Numerical models of a valve system used in railway hydraulic dampers

Woźniak M.

Journal of Achievements in Materials and Manufacturing Engineering

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2015

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Vol. 73, nr 2

190--198

EN

Purpose: The aim of this paper is to develop and validate a linear and nonlinear numerical 2/3D models of the spring washer stack and a system model of an entire hydraulic damper. Design/methodology/approach: Three types of numerical models are investigated. Linear and non-linear 2D models developed in Matlab program, and 3D nonlinear model developed in Ansys software. Findings: The system model of entire hydraulic damper and detail numerical 2/3 D model of the spring washers stack including the boundary conditions for simplified and advanced analysis were developed. Research limitations/implications: It is important to provide a model functionality allowing for calculation of spring washer stacks groups having the opening limiter. Spring washer stack stress and opening characteristics vs. applied pressure are determined with simplified analytically derived model and full 2D model including almost all significant forces and moments in a stack of circular plates. An advantage of a simplified spring washer stack model is possibility of its rapid engineering calculations, e.g. performed in Matlab. Practical implications: The valve model allows to determine the critical von Misses stress level and fatigue critical limit in elastic components of a valve system. Damper force and valve durability expressed in life-cycles are the optimization criteria considered during selection and tuning of a valve system. Originality/value: A new valve system was developed in two versions, i.e. simplified and advanced. The model allows durability prediction at the design stage reducing the testing costs of low-performance valve systems.

3

A computational fluid flow analysis of a disc valve system

Czop P., Śliwa P., Gniłka J., Gąsiorek D., Wszołek G.

Journal of KONES

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2011

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Vol. 18, No. 1

117-122

EN

Noise concerns in shock absorbers can be divided into two categories. The first is fluid flow noise, or “swish noise”, caused by the oil being forced through openings in the valves. The type and temperature of the oil, its velocity and the orifice geometry all have an effect on this. In addition, the structural design of the shock absorber shell may either reduce or amplify the noise. The second type of shock absorber noise is often described as regular operational noise or “chuckle noise”. It can be observed in vehicles during low-displacement, higher-frequency events, such as driving over a slightly rough road. This effect measurable as a force discontinuity into the vehicle and can come from a number of sources in the shock absorber, e.g. hydraulic transitions. It is often traceable to the valve discs closing and opening, but can also be caused by cavitation/aeration in the oil and air being pulled through the valves. The work on noise improvement reported in this paper has been started using conventional shock absorbers to be extended and will cover in the future variable damping shock systems as well. The paper gives an overview about the configurations of a typical valve system including three basic regimes of operation, which correspond to the amount of oil flowing through a valve cavity. The aim of this work was to propose a finite element fluid flow model, which can be used in order to reduce the velocity of fluid flow through a cavity of a shock absorber valve. High flow velocity can cause high-content frequency vibrations and, in turn, audible noise. The model will be used for initial screening of new valve concepts and on the other hand to improve the currently use ones.

4

Simplified and advanced models of a valve system used in shock absorbers

Czop P., Sławik D., Śliwa P., Wszołek G.

Journal of Achievements in Materials and Manufacturing Engineering

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2009

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Vol. 33, nr 2

173-180

EN

Purpose: The aim of this paper is to develop a model of a valve system applicable for strain and stress prediction. Design/methodology/approach: The analytical and numerical approaches are presented to provide an overview for available methods and prediction accuracy. Findings: An equivalent numerical model of a disc valve system of different complexity was developed and discussed. Research limitations/implications: It is important to provide a model functionality allowing for calculation of disc stacks supported by a coil spring and stack settings having the opening limiter. Disc stack stress and opening characteristics vs. applied pressure may be determined with simplified analytically derived model and full 2D model including almost all significant forces and moments in a stack of circular plates. An advantage of a simplified disc stack model is possibility of its implementation in an environment supporting matrix operations, e.g. Matlab. Practical implications: A valve system has to withstand the cyclic pressure load across the piston. The number of discs, their diameters and thicknesses directly affect durability of a valve system. Damper force and valve durability expressed in life-cycles are the optimization criteria considering during selection and tuning of a valve system. Originality/value: A new valve system was developed in two versions, i.e. simplified and advanced. The model allows durability prediction at the design stage reducing the testing costs of low-performance valve systems.