Dissertationen zum Thema „Cavitation in hydrodynamic machine“

To increase profitability for biogas production, new innovative substrates and condition of operations needs to be implemented. At the current state, fats, oils and greases (FOGs) represent a promising substrate even though it brings operational challenges to the anaerobic digestion process. By utilizing hydrodynamic cavitation (HC) as a pre-treatment of the FOGs, the efficiency of FOGs’ co-digestion with wastewater sludge can be significantly improved. Preliminary experiments conducted on oil and water demonstrates that the HC pre-treatment improves the oil solubilisation as well as forms stable oil and water emulsion that last for several hours. The pre-treatment also improved the soluble chemical oxygen demand (COD) of biosludge (BiSl) by up to 115% and the initial degradation rate by up to 35%. In a semi-continues system, this allowed a significant increment in the specific methane yield depending on the organic loading rate (OLR) applied1. With sufficient process optimization, the HC-pre-treatment may prove to be an energy efficient and effective pre-treatment of FOGs.

Process industries are cornerstones in today’s industrialized society. They contribute significantly in the manufacturing of various goods and products that are used in our day-to-day life. Our society’s paradigm of consumerism accompanied by a rise in global population drives an ever increasing demand for goods. One of many strategies developed to satisfy these demands and at the same time improve production capabilities is known as process intensification. As an example, this can be accomplished by implementation of devices using the principle of hydrodynamic and acoustic cavitation. High-intensity cavitation in the ultrasonic range can change the physical and chemical properties of a wide range of substances and hence, improve the production rate or quality. Despite the generally accepted benefits of hydrodynamic and acoustic cavitation, applications in the process industry are yet limited. The reasons are that the method requires extensive optimization, which depends on multiple process parameters and encounters problem in the implementation on a larger scale. Scalable cavitation reactor concepts for industrial applications need to meet challenges like stability and robustness, energy efficiency and high flow rates. This thesis focuses on the methodology for the design and optimization of a flow through cavitation reactor. An ultrasound reactor concept has been developed and tested for two different applications: i) Fibrillation processes typical for paper and pulp industry; ii) Metal leaching of mineral concentrates. Simulations were carried out using a commercially available software for multiphysics modeling which combines acoustics, structural dynamics, fluid dynamics and piezoelectrics. However, the optimization procedure requires extensive experimental work in parallel with multi-physical simulations. In general, the application leads to hydrodynamic initiation of small gas bubbles in the fluid to be excited and collapsed by high-intensity ultrasound. This transient collapse of the cavitation bubbles provides both mechanical and chemical effect on materials. The developed reactor has a power conversion efficiency of 36% in batch mode and is well suited for a scale-up. In flow-through mode, the cavitation effect improves extensively and provides stable results. Energy efficiency requires hydrodynamic initiation of cavitation bubbles, high acoustic cavitation intensity by multiple excitation frequencies adapted to the optimized reactor geometry, as well as optimal process pressure and temperature with respect to the materials to be treated. The impact of flow conditions and hydrodynamic cavitation is significant and almost doubles the yield at the same ultrasonic power input. In the case of fibrillation of cellulose fibers, results obtained indicate that generated cavitation intensity changes the mechanical properties of the fiber wall. In the case of leaching, experiments show that six hours of exposure gave a 57% recovery of tungsten from the scheelite concentrate at 80°C and atmospheric pressure. Future research will focus on different types of excitation signals, extended reactor volume, increased flow rates and use of a higher process temperature.

Includes bibliographical references.<br>Hydrodynamic cavitation is a novel method for microbial cell disruption, mediated by intense pressure fluctuations caused by cavity oscillation and collapse. Selective release of intracellular microbial products is desirable to reduce the cost involved in their downstream processing. A study of the process variables that affect microbial cell disruption by hydrodynamic cavitation is presented in order to ascertain the conditions required for a selective release. Two model systems were considered (yeast and E. coil). Enzymes from different locations of the cell were studied and the release compared with other methods of disruption.

Cavitating flow through five perforated plates with different number of holes with preserved constant flow cross-section area in sum were experimentally examined. Dynamic characteristics such as dependence of pressure amplitudes and dominant frequencies on cavitation number in all regimes of cavitating flow: incipient cavitation, partial cavitation, fully developed cavitation and supercavitation are obtained. For determination of dominant frequencies several pressure transducers in two regimes of measurement were used. Results were validated with frequency spectra obtained from picture analysis based on high-speed camera records.

Renewable energy sources have been proposed as a viable option to mitigate the consumption and the dependence of fossil fuels. Among the available alternatives, lignocellulosic biomass has shown great potential for bioenergy generation, and biofuels as ethanol can be obtained by fermentation from sugars present in cellulosic and hemicellulosic fractions of biomass. However, for the efficient release of fermentable sugars during the enzymatic hydrolysis step, a pretreatment process is required to modify the material in its structure and composition. In this context, hydrodynamic cavitation (HC) was proposed in this work as a new and promising alternative for pretreatment of sugarcane bagasse. Firstly, the variables NaOH concentration, solid/liquid (S/L) ratio and HC process time were optimized in HC assisted pretreatment. In optimized conditions (0.48 mol/L of NaOH, 4.27% of S/L ratio and 44.48 min), high lignin removal (60.4%) and enzymatic digestibility of cellulose fraction (97.2%) were obtained. Based in those results, new variables (inlet pressure, temperature, alkali concentration) were included for evaluation in a second stage of the study aiming to reduce the HC pretreatment time. In this case, temperature and álcali concentration showed more significance on lignin removal and hydrolysis yield of carbohydrate fraction in pretreated biomass. No significant difference in pretreatment efficiency was observed in 20 and 30 min of process time in the best conditions (70 °C, 3 bar of inlet pressure and 0.3 mol/L of NaOH). The dimensionless cavitation number influence also was evaluated in two levels (0.017 and 0.048), resulting higher efficiency using low cavitation number which was obtained using orifice plate with 16 holes (1 mm of diameter). Using the last optimized conditions and lower temperature (60 °C instead 70 °C) in order to avoid the foam formation when black liquor is reused, other alkalis (Ca(OH)2, Na2CO3, KOH) were evaluated in combination with HC and compared to the use of NaOH. High enzymatic conversions of carbohydrate fraction were observed in biomass pretreated using KOH-HC and NaOH-HC; additionally, NaOH black liquor was reused in 10 sequential batches. The pretreated biomass using fresh and reused black liquor were mixed and used for simultaneous saccharification and fermentation process (SSF) in interconnected column reactors, resulting in 62.33% of hydrolysis of total carbohydrate fractions and 17.26 g/L of ethanol production (0.48 g of ethanol/g of glucose and xylose consumed). Finally, the addition of oxidant agent (H2O2) in the alkali HC-process was optimized. In selected conditions (0.29 mol/L of NaOH, 0.78 % v/v of H2O2 and 9.8 min), 95,43% and 81.34% of enzymatic hydrolysis yield of cellulose and hemicellulose fraction were achieved respectively, using 5% of solid loading (S/L) in the hydrolysis process. When packed bed flow-through column reactor using 20% of S/L was used, 74.7% cellulose hydrolysis yield was reached. Sugars present in hydrolysate were also fermented into ethanol in bubble column reactor resulting in a yield value of 0.49 g/g and 0.68 g/L.h of productivity. By analyzing the results as a whole, HC was shown as a promising technology to accelerate the pretreatment time under mild conditions, showing advantages as simplicity of system and possibility to application in industrial scale.<br>O uso de fontes de energia renováveis tem sido proposto como uma alternativa viável para reduzir o consumo e a dependência de combustíveis fósseis. Entre as alternativas disponíveis, a biomassa lignocelulósica apresenta grande potencial para geração de bioenergia, sendo que biocombustíveis como o etanol podem ser obtidos por fermentação a partir de açúcares presentes em suas frações celulósicas e hemicelulósicas. No entanto, para a liberação eficiente de açúcares fermentáveis na etapa de hidrólise enzimática, é necessário um processo prévio de pré-tratamento para modificar a estrutura e composição do material. Neste contexto, no presente trabalho a cavitação hidrodinâmica (CH) foi proposta como uma nova e promissora alternativa para o pré-tratamento do bagaço de cana-de-açúcar. Em uma primeira etapa, as variáveis concentração de NaOH, relação sólido/líquido (S/L) e tempo de processo foram otimizadas no pré-tratamento assistido por CH. Em condições otimizadas (0,48 mol/L de NaOH, 4,27% de relação S/L e 44,48 min), elevados valores de remoção de lignina (60,4%) e digestibilidade enzimática da fração de celulose (97,2%) foram obtidos. Com base nesses resultados, novas variáveis (pressão à montante, temperatura e concentração de álcali) foram incluídas para avaliação em uma segunda etapa do estudo com o objetivo de reduzir o tempo de pré-tratamento com CH. Neste caso, a temperatura e a concentração de álcalis foram as mais importantes na remoção de lignina e influenciaram na hidrólise das frações carboidrato da biomassa pré-tratada. Não houve diferença significativa na eficiência do pré-tratamento em 20 e 30 minutos de tempo de processo nas melhores condições (70 ° C, 3 bar de pressão a montante e 0,3 mol/L de NaOH). A influência do adimensional -número de cavitação? também foi avaliada em dois níveis (0,017 e 0,048), resultando em maior eficiência usando o número de cavitação mais baixo, que foi obtido usando placa de orifício com 16 furos (1 mm de diâmetro). Usando estas condições otimizadas e menor temperatura (60 ° C ao invés de 70 ° C) para evitar a formação de espuma quando o licor negro é reutilizado, outros álcalis (Ca (OH)2, Na2CO3, KOH) foram avaliados em combinação com CH e comparados com o uso de NaOH. Conversões enzimáticas elevadas das frações carboidrato foram observadas em material pré-tratado utilizando KOH-CH e NaOH-CH; além disso, o licor negro de NaOH foi reutilizado em 10 bateladas sequenciais. As biomassas pré-tratadas com licor negro reutilizado e fresco foram misturadas e utilizadas em processo de sacarificação e fermentação simultâneas (SSF) em reatores de coluna interligados, resultando em 62,33% de hidrólise das frações carboidrato e 17,26 g/L de produção de etanol (0,48 g de etanol/g de glicose e xilose consumidos). Finalmente, a adição de agente oxidante (H2O2) no processo alcalino-CH foi otimizado. Nas condições selecionadas (0,29 mol/L de NaOH, 0,78% v/v de H2O2 e 9,8 min), 95,43% e 81,34% de rendimento de hidrólise enzimática das frações de celulose e hemicelulose, respectivamente, foram obtidos utilizando 5% de carregamento de sólidos (S/L) no processo de hidrólise. Quando foi utilizado reator de coluna de leito fixo com 20% de S/L, atingiu-se 74,7% de rendimento de hidrólise de celulose. Os açúcares presentes no hidrolisado também foram fermentados em etanol em um reator de coluna de bolhas, resultando em um valor de rendimento de 0,49 g/g e 0,68 g/L.h de produtividade. Analisando-se os resultados de uma forma global, demonstrou-se que a CH é uma tecnologia promissora para acelerar o tempo de pré-tratamento em condições amenas, mostrando vantagens como simplicidade do sistema e possibilidade de aplicação em escala industrial.

Tato disertační práce se zabývá experimentálním a výpočtovým výzkumem přídavných účinků od proudu kapaliny na obtékaný hydraulický profil. Dynamická odezva profilu byla analyzována pro dva typy buzení: buzení odtržením mezní vrstvy a Kármánových vírů a dále buzení pomocí externího budiče připojeného k lopatce. Experimentální měření dynamické odezvy profilu na oba typy buzení bylo provedeno pro lopatku umístěnou v kavitujícím a nekavitujícím proudění. Získané výsledky byly použity pro verifikaci přídavných účinků stanovených s využitím numerického modelování.

Les instabilités hydrauliques et les efforts radiaux générés par la cavitation partielle sur un inducteur de turbopompe ont été étudiés en eau pour les inducteurs des turbopompes à hydrogène et à oxygène du moteur VULCAIN d’ARIANE 5. Nous avons pu établir une méthode d’identification et d’analyse des instabilités à l’aide de la synchronisation de films rapides avec des mesures d’effort, sur l’axe et avec des signaux de pression instationnaire en paroi. Des fréquences caractéristiques du phénomène de cavitation instationnaire ont alors été identifiées à différents points de fonctionnement. Cette analyse démontre clairement l’évolution des efforts radiaux avec le nombre de cavitation : (1) constant, (2) rotatif supersynchrone, (3) chaotique, (4) constant. L’évolution de la charge radiale apparaît corrélée avec les configurations cavitantes. Les instabilités des inducteurs cavitants à 4 pales ont été expliquées qualitativement et les déséquilibres ont été estimés en terme d’efforts et de longueurs de cavités. Cette étude a été complétée par une modélisation théorique de l’inducteur basée sur la théorie des semi-disques d’action dans laquelle le volume cavitant est le paramètre principal. Une méthode de mesure de ce volume dans l’inducteur tournant a alors été proposée et expérimentée<br>Hydraulic loop instabilities and radial forces generated by partial cavitation on a turbopump inducer were investigated in water with the 4-bladed inducers of the ARIANE 5 VULCAIN engine liquid hydrogen and oxygen turbopumps. With the help of the synchronization of high speed movies with radial load measurements on the inducer shaft and with the dynamic pressures signals, we could establish an identification method and an analysis approach to the instabilities in a turbopump cavitating inducer. Characteristic frequencies of unsteady cavitation phenomenon were identified at various operating points. This analysis clearly demonstrates the evolution of radial loads with cavitation number : (1) constant, (2) rotating and supersynchronous, (3) chaotic, (4) constant. The evolution of radial load is strongly related to cavitation configurations. Instabilities of cavitating 4-bladed inducer have been explained qualitatively and imbalances have been estimated in terms of radial loads and cavity lengths. This study has been completed by a theoretical model of the inducer based on the actuator disk theory in which the cavitating volume appears to be the main parameter. A measuring method of the cavitating volume in the rotary inducer is therefore proposed which could give results with a 90% accuracy

As expectativas dinâmicas de um mundo de inovações tecnológicas, consubstanciados por explorações menos agressivas ao meio ambiente, dirigidas a um mercado consumista emergente, representam desafios para soluções de problemas de engenharia dirigidos para diversos segmentos da sociedade. Com o desenvolvimento do concreto compactado com rolo (CCR), a partir dos anos 70, o emprego de vertedouros em degraus em barragens de gravidade tornou-se uma solução atrativa, visto que, proporciona, simultaneamente, o aumento da dissipação da energia do escoamento e a redução do tempo e dos custos de implantação dessas obras. Atualmente, têm-se usado como restrições ao seu emprego de vertedouros em degraus valores máximos de vazões específicas que, sem um limite consensual, vêm tolhendo suas potencialidades. A macrorugosidade da calha acelera o processo de aeração do escoamento, se comparado com um vertedouro de soleira lisa, protegendo, para a zona aerada, os degraus contra erosão por cavitação. Entretanto, para o trecho não aerado do escoamento, existem riscos desse processo se estabelecer. As descontinuidades da fronteira sólida propiciam a sucessiva separação da camada limite nos cantos externos dos degraus. Nessa região são geradas pressões muito baixas. O presente estudo, realizado no Instituto de Pesquisas Hidráulicas, objetivou, através de medições experimentais, descrever, caracterizar e modelar pressões hidrodinâmicas nas soleiras dos degraus, estabelecendo limites para incipiência à cavitação no trecho não-aerado do escoamento. Três calhas escalonadas com declividade 1V:0,75H e alturas de degraus iguais a 0,03 m; 0,06 m e 0,09 m foram projetadas e construídas para a investigação. As amostras de pressões registradas com transmissores de pressão a 50 Hz e duração de 3minutos e 12 horas possibilitaram caracterizar o campo de pressão identificando zonas críticas, bem como, avaliando o comportamento estatístico dessas solicitações. As maiores flutuações de pressões foram registradas nas extremidades externas dos degraus e na seção de afloramento da camada limite, chegando a valores negativos de 0,69 vezes a distância vertical entre a crista e a seção analisada. Determinaram-se freqüências dominantes compreendidas entre 7-18 Hz, com valores máximos situados nos patamares dosdegraus. Os números adimensionais de Strouhal, calculados com as freqüências predominantes e as profundidades equivalente do escoamento, diminuíram de 0,40 a 0,04 no sentido do fluxo. Quanto aos limites de incipiência à cavitação, as vazões especificas mais restritivas ao emprego de vertedouros em degraus ficaram na faixa entre 11,3 e 15,6 m²/s com velocidades médias da ordem de 17 m/s, obtidas para a seção de afloramento da camada limite.<br>Hydraulic researchers have to accomplish the technological and construction materials innovations to new security design project criteria compatible to low costs requirement. At 70’s years, with the development of the Roller Compact Concrete (RCC), the use of stepped spillways has become an attractive solution for gravity dams. In steeply sloping stepped spillways, the large step macro-roughness promotes the occurrence of negative pressures on the step cavity, particularly near the external edge of the vertical step face. Consequently one may expect the occurrence of sub-atmospheric pressure conditions capable to induce cavitation for velocities lower than those observed in smooth chute spillways. Predicting cavitation damage is more complex than predicting cavitation inception. Flow conditions leading to the onset of cavitation are generally conservative in predicting damage. The severity of damage that may be expected is related both to intensity of cavitation and time of exposure. There is still no consensus on the maximum unit discharge or flow velocity which assures cavitation safe design of stepped spillways.The study carried through in the Institute of Hydraulic Research (UFRGS - Brazil), had the main goal: described, characterized and modeled experimental measurements of hydrodynamic pressures on the faces of the steps and established limits of incipient cavitation. Three stepped chutes with declivity 1V:0.75H and 0.03 m; 0.06 m and 0.09 m steps heights were projected. The samples of pressures were registered with pressure transmitters with 50 Hz and 3 minutes duration. Long-duration test were also conducted (12 hours sample size) that permitted characterize the pressure field, identifying critical zones, as well as, evaluating its statistical behaviour. The largest fluctuating pressures had been registered in the outer corner on the steps and at the inception point of air entrainment. At this last position can be expected negative pressure values close to 0.69 times the vertical distance between the crest and the analyzed section. The dominant frequencies found varied between 7-18 Hz. The dimensionless number of Strouhal calculated with the predominant frequencies and the clear equivalent depth, had diminished of 0.40 the 0.04 in the direction of the flow. The pressure measurements indicated specific discharge between 11.3-15.6 m²/s and average velocity in order of 17 m/s to inception cavitation process near the inception point.

The effect of acoustic and hydrodynamic cavitation on the precipitation of inorganic catalytic materials was investigated. The overall objective was to understand the fundamental factors involved in synthesizing nanometer-size catalytic materials in the 1-10 nm range in a cavitating field. Materials with grain sizes in this range have been associated with enhanced catalytic activity compared to larger grain size materials. A new chemical approach was used to produce titania supported gold by coprecipitation with higher gold yields compared to other synthesis methods. Using this approach, it was determined that acoustic cavitation was unable to influence the gold mean crystallite size compared to non-sonicated catalysts. However, gold concentration on the catalysts was found to be very important for CO oxidation activity. By decreasing the gold concentration from a weight loading of 0.50% down to approximately 0.05%, the rate of reaction per mole of gold was found to increase by a factor of 19. Hydrodynamic cavitation at low pressures (6.9-48 bar) was determined to have no effect on gold crystallite size at a fixed gold content for the same precipitation technique used in the acoustic cavitation studies. By changing the chemistry of the precipitation system, however, it was found that a synergy existed between the dilution of the gold precursor solution, the orifice diameter, and the reducing agent addition rate. Individually, these factors were found to have little effect and only their interaction allowed gold grain size control in the range of 8-80 nm. Further modification of the system chemistry and the use of hydrodynamic cavitation at pressures in excess of 690 bar allowed the systematic control of gold crystallite size in the range of 2-9 nm for catalysts containing (2.27 ± 0.17)% gold. In addition, it was shown that the enhanced mixing due to cavitation led to larger gold yields compared to classical syntheses. The control of gold grain size was gained at the loss of CO activity, which was attributed to the formation of non-removable sodium titanate species. The increased mixing associated with cavitation contributed to the activity loss by partially burying the gold and incorporating more of the sodium titanate species into the catalysts. This work produced the first evidence of hydrodynamic cavitation influencing the gold crystallite size on titania supported gold catalysts and is the only study reporting the control of grain size by simple mechanical adjustment of the experimental parameters. Despite the low activity observed due to sodium titanate, the methodology of adjusting the chemistry of a precipitating system could be used to eliminate such species. The approach of modifying the chemical precipitation kinetics relative to the dynamics of cavitation offers a general scheme for future research on cavitational processing effects.

Une zone de constriction dans un micro-canal fluidique peut générer, si le débit est suffisant, un écoulement bi-phasique. Ceci est l’origine de la cavitation hydrodynamique. Les échanges de chaleur latente générés par l’apparition et l’implosion des bulles impliquent une variabilité importante de la température dans les zones au-delà de la constriction. En ajoutant des sondes de température nanométriques dans le fluide et en utilisant un microscope confocal on peut déterminer la température en un point. Ainsi on a pu établir des cartographies thermiques en 2 et 3 dimensions à l’intérieur d’un écoulement stationnaire bi-phasique. La technique permet en outre d’avoir accès à la quantité de gaz ce qui permet de corréler les gradients de température avec les zones de transitions de phases. Des zones de très forts refroidissements sont observées après la constriction, là où les bulles apparaissent. Par contre on n’observe pas les zones d’échauffement attendu à cause de la condensation. Une méthode complémentaire, moins sensible, utilisant la spectroscopie Raman a aussi été utilisée pour confirmer ce résultat. Par ailleurs une nouvelle classe de matériaux luminescents sensible à la température et la pression a été étudiée. Enfin une étude de la production de radicaux lors de l’implosion des bulles a été menée en utilisant la chimiluminescence du luminol. La technique utilisée par comptage de photons a permis de quantifier cette production et une cartographie de l’émission du luminol a permis d’associer celle-ci avec la zone d’implosion des bulles<br>A constriction in the microchannel can be used to establish a two-phase flow, when a sufficient liquid flux is introduced. This is known as hydrodynamic cavitation. The latent heat resulting from the growing and collapsing vapor bubbles makes it interesting to observe the temperature conditions in the flow downstream of the constriction. Using fluorescence microscopy, with the addition of temperature sensitive nano probes into the working fluid, we can determine the temperature at a single point, averaged over the integration time. Coupled with a confocal microscope, we were able to produce two and three dimensional temperature maps of the steady state flow in the microchannel by the use of ratiometric intensity measurements. This technic allows us to observe temperature gradients in two-phase flow as well yielding the void fraction information. Areas of substantial cooling are observed downstream the constriction in the two-phase flow, linked to the bubble growth, while heating regions due to condensations are missing. A complementary, yet less sensitive probe-less technique using the inherent Raman scattering signal of the liquid, was used to confirm the findings. A separate study evaluating a new group of luminescent materials for optical temperature and pressure probes is performed and discussed herein. Finally, the luminol chemiluminescent reaction with radicals produced by the cavitating flow, is used to obtain a corresponding photon yield. By counting the photons produced, an estimate on the radical yield can be obtained. Additionally, rudimentary mapping of the chemiluminescence signal allows the localization of the bubble collapse regions

To avoid the large amount of damage that floods can cause, spillway tunnels are used to control water levels. To ensure the safety of water transportation through spillway tunnels, the behaviour of the water throughout the tunnel is important to know. Physical experiments are time consuming and expensive, hence CFD simulations are a profitable option for investigating the performance of the spillway tunnel. In this project, simulations of water flow in a spillway tunnel were executed. A three dimensional model of the spillway tunnel in Zipingpu Water Conservancy Project was created in the software ANSYS Gambit. A coarse, middle and fine mesh with both hexahedral- and tetrahedral elements were also created for the model in ANSYS Gambit. The meshes were imported to ANSYS Fluent where the simulations, and a convergence analysis were made. The water flow was set to be described by the Reynolds-Averaged Navier-Stokes model, using the pressure solver, k-epsilon model and the VOF model. Physical experiments had previously been performed, and the simulated results were compared to these, in an attempt to find the parameters to replicate the experimental results to the greatest extent possible. The inlet velocity of the tunnel was known and the inlet boundary was set as a velocity inlet. The ceiling of the tunnel was set as a pressure inlet, the floor and walls were set as wall, and the outlet was set as pressure outlet. The simulated results showed similar behavior as the experimental results, but all differed from the experimental results. The grid convergence index, estimating the results' dependency on the mesh was 6.044 %. The flow was analyzed, and where the flow had unfavorable characteristics, such as a high cavitation number, the geometry of the spillway was altered in ANSYS Gambit to investigate if an improved geometry for the spillway tunnel could be found. The water flow in the revised geometry was simulated in ANSYS Fluent, and results showing flow with lower cavitation numbers was found.

Master's thesis deals with possibility of simplifying calculation hydraulic machines by converting the three-dimensional geometry in the plane. The aim is to create modifications of a trailng edge and determine their effect of the hydraulic parameterso of the machine.

Orientador: Celso Eduardo Tuna<br>Resumo: A agroindústria nacional brasileira dispõe de uma grande variedade de unidades agrícolas que geram elevada quantidade de resíduos como o bagaço de cana-de-açúcar. Mesmo diante da crescente utilização desse material, o excedente ainda é da ordem de milhões de toneladas, causando problemas de estocagem e poluição ambiental. Devido a sua estrutura complexa e sua recalcitrância, a etapa de pré-tratamento representa o desafio mais crítico para a viabilização da utilização do bagaço de cana-de-açúcar dentro do contexto de uma biorrefinaria. O pré-tratamento busca facilitar o acesso aos componentes estruturais da biomassa, permitindo sua utilização na cadeia produtiva. Existem diferentes métodos de pré-tratamento como os físicos, químicos e biológicos ou uma combinação de todos esses, de modo que a geração de resíduos ambientalmente perigosos e/ou altos insumos energéticos é o gargalo. Neste sentido, rotas tecnológicas alternativas vem sendo estudadas e a cavitação hidrodinâmica desponta-se como uma promissora rota para o pré-tratamento de biomassa liberando grandes magnitudes de energia e induzindo a transformações físicas e químicas, favorecendo o rompimento da matriz carboidrato-lignina. Neste contexto, este trabalho empregou a cavitação hidrodinâmica para potencializar o pré-tratamento alcalino do bagaço de cana-de-açúcar. Para isto, projetou-se um reator de cavitação hidrodinâmica com tubo de Venturi utilizando como base uma abordagem computacional para a dinâmica dos fluidos. ... (Resumo completo, clicar acesso eletrônico abaixo)<br>Abstract: The Brazilian national agroindustry has a large variety of agricultural units that generate high amounts of waste such as sugarcane bagasse. Even with the increasing use of this material, the surplus is still in the order of millions of tons, causing problems of stocking and environmental pollution. Due to its complex structure and recalcitrance, the pretreatment stage represents the most critical challenge for the feasibility of using sugarcane bagasse within the context of biorefinery. Pretreatment seeks to facilitate access to the structural components of biomass, allowing its use in the production chain. There are different pretreatment methods such as physical, chemical, physicochemical and biological or a combination of all of these, so that the generation of environmentally hazardous waste and / or high energy inputs is the bottleneck. In this sense, alternative technological routes have been studied and hydrodynamic cavitation emerges as a promising route for biomass pretreatment releasing large energy magnitudes and inducing physical and chemical transformations, favoring the rupture of the carbohydrate-lignin matrix. In this context, this thesis employed hydrodynamic cavitation as a physical means to improve the alkaline pre-treatment of sugarcane bagasse. The hydrodynamic cavitation reactor with Venturi tube was modeled by a computational approach to fluid dynamics, in order to evaluate the influence of the pressure ratio, the length and diameter of the throat and ... (Complete abstract click electronic access below)<br>Doutor

La compréhension et la modélisation d'un contact lubrifié en présence de texturation nécessitent une description physique très fine pour comprendre les analyses contradictoires et pour expliquer les résultats très différents en terme de performance présentés dans la littérature internationale. De nombreuses études théoriques et expérimentales ont montré que la texturation des surfaces pourrait améliorer les caractéristiques tribologiques des contacts. La capacité de charge, le coefficient de frottement et la résistance à l'usure sont les principales caractéristiques susceptibles d'être améliorées. La texturation de surface fait appel à de nombreux paramètres géométriques, qui peuvent agir de façon très différente selon le contact. Enfin, les phénomènes supposés expliquer l'apport de la texturation ne font pas l'unanimité dans la communauté scientifique. Ainsi, les différentes contradictions font que ce domaine de recherche est en pleine évolution. Dans ce contexte scientifique, l'objectif principal de cette thèse est de conduire, à travers une étude théorique et numérique approfondie, vers une meilleure compréhension des effets induits par la texturation dans un contact lubrifié. Les paramètres géométriques, essentiels par rapport aux phénomènes physiques générés, font l'objet d'une analyse étendue. Les éléments théoriques obtenus à travers cette étude permettront une optimisation opérationnelle de tous types de dispositifs fonctionnant dans un milieu lubrifié. Parmi ces nombreuses applications, la butée en régime hydrodynamique a été choisie afin d'illustrer la pertinence des résultats de nos recherches.

This master’s thesis describes the influence of conformity on friction in rolling bearings. The coefficient of friction is measured on an experimental machine - Mini Traction Machine 2 – using ball-on-disc method. The results are plotted in graphs which showing the dependence of the coefficient of friction at spin-to-roll ratio for specific conformity, normal load and speed in the contact area. The influence of load, speed or different lubricant viscosity is verified for a given value of conformity. Experimentally obtained data are compared with the mathematical model developed in MatLab, within this thesis.

Les rotors sont excités non seulement par le balourd tournant mais aussi par les différents mouvements de leur support : turbocompresseurs de véhicules, turbomoteurs aéronautiques, pompes à vide portées en sont des exemples industriels. Ainsi la conception de rotors robustes capables de bien fonctionner sous de telles conditions (excitations extrêmes) est nécessaire pour éviter des instabilités, source de défaillance catastrophique. Le présent travail a pour objectif de prévoir le comportement dynamique d’un rotor embarqué monté sur des paliers rigides ou élastiques hydrodynamiques et soumis à des excitations du support rigide. Les énergies cinétiques et de déformation ainsi que le travail virtuel des composants d’un rotor flexible tournant sont calculés. Le modèle proposé de rotor embarqué est basé sur les éléments finis de poutre de TIMOSHENKO. Il contient les effets relatifs à l’inertie de rotation des sections droites, à l’inertie gyroscopique, à la déformation de cisaillement d’arbre et à la dissymétrie géométrique de l’arbre et/ou du disque rigide et considère six types de mouvements déterministes (rotations et translations) du support. Suivant le type d’analyse utilisé pour le palier, les forces de rappel hydrodynamiques agissant sur l’arbre et calculées avec l’équation de REYNOLDS sont linéaires/non linéaires. L’utilisation des équations de LAGRANGE fournit les équations différentielles linéaires/non linéaires du mouvement du rotor embarqué en flexion par rapport au support mobile supposé rigide, qui représente un système de coordonnées non inertiel. Les équations du mouvement contiennent des termes paramétriques périodiques en raison de la dissymétrie géométrique du rotor et des termes paramétrique variables dans le temps en raison des rotations du support. Ces termes paramétriques sont considérés comme des sources d’excitation intérieure et conduisent à une instabilité dynamique latérale. Dans les applications numériques proposées, trois configurations de rotor embarqué sont analysées. Tout d’abord, un rotor symétrique monté sur des paliers rigides est soumis à un balourd combiné avec des mouvements de rotation constante et de translation sinusoïdale du support. Ensuite, un rotor avec une dissymétrie géométrique du disque monté sur des paliers rigides est excité par l’effet de balourd et par des mouvements combinés de rotation constante et de translation sinusoïdale du support. Enfin, un rotor symétrique monté sur des paliers hydrodynamiques est soumis au balourd et aux excitations sinusoïdales de rotation ou de translation du support<br>Rotors are excited not only by the rotating mass unbalance but also by the different motions of their support: vehicle turbochargers, aircraft turbo-engines, carried vacuum pumps, are different industrial applications. Thus the design of robust rotors able to run well under such conditions (extreme excitations) and to avoid catastrophic failure is required. The present work aims to predict the dynamic behavior of an on-board rotor mounted on rigid or elastic hydrodynamic journal bearings and subjected to rigid support excitations. The kinetic and strain energies as well as the virtual work of the rotating flexible rotor components are computed. The proposed on-board rotor model is based on TIMOSHENKO beam finite elements. It includes the effects relative to the rotating inertia, the gyroscopic inertia, the shear deformation of shaft as well as the geometric asymmetry of shaft and/or rigid disk and considers six types of deterministic motions (rotations and translations) of the support. Depending on the type of analysis used for the bearing, the restoring fluid film forces acting on the shaft and computed with the REYNOLDS equation are linear/non-linear. The use of LAGRANGE’s equations yields the linear/non-linear differential equations of vibratory motion of the on-board rotor in bending with respect to the moving rigid support which represents a non-inertial reference frame. The equations of motion contain periodic parametric coefficients because of the geometric asymmetry of the rotor and time-varying parametric coefficients because of the support rotations. These parametric coefficients are considered as sources of internal excitation and can lead to lateral dynamic instability. In the proposed numerical application examples, three rotor configurations are studied. Firstly, a symmetric rotor mounted on rigid bearings is subjected to rotating mass unbalance combined with constant rotation and sinusoidal translation of the support. Secondly, a rotor with geometric asymmetry due to the disk mounted on rigid bearings is excited by the mass unbalance effect and by the combination of a constant rotation and a sinusoidal translation of the support. Thirdly, a symmetric rotor mounted on linearized/non-linear hydrodynamic bearings is subjected to the excitation due to the mass unbalance and to the sinusoidal rotational or translational excitations of the support

Le palier hydrodynamique est une solution de guidage en rotation particulièrement appréciée pour ses caractéristiques d’amortissement à hautes vitesses de rotation. Cependant les performances des machines tournantes lubrifiées par un film fluide sont impactées par des effets non linéaires difficiles à analyser. La prédiction du comportement du système par la simulation nécessite une modélisation avancée de l’écoulement de lubrifiant dans le palier hydrodynamique. Enfin, l’état de surface semble avoir un impact important sur l’écoulement du fluide lubrifiant, lui-même agissant sur les caractéristiques statiques et dynamiques des parties tournantes. Cette étude vise à améliorer les modèles numériques liés à l’impact de l’état de surface des paliers hydrodynamiques sur la dynamique de ligne d’arbre. La méthode d’homogénéisation multi-échelles a été utilisée à cet effet dans un algorithme multi-physiques pour décrire l’interaction entre la structure flexible en rotation et les films fluides des supports de lubrification. Différents modèles ont été utilisés pour prendre en compte la présence de zone de rupture de film lubrifiant. Des méthodologies non-linéaires fréquentielles ont été mises en place afin de permettre l’étude paramétrique des solutions périodiques d’un tel système et de leur stabilité. Afin de confronter ce modèle complexe à la réalité, un banc d’essai miniature a également été conçu. Différents échantillons présentant des états de surface modifiés par ablation à l’aide de LASER femto-seconde ont été testés. L’étude expérimentale a permis de vérifier certaines tendances prévues par la simulation. Des améliorations des performances des paliers hydrodynamiques par rapport aux vibrations auto-entretenues du système ont été démontrées pour certaines textures. En revanche toutes les améliorations ne sont pas prédites par les algorithmes d’homogénéisation multi-échelles. La présence de recirculation dans les aspérités du motif a été mise en évidence à partir de la résolution locale des équations de Navier-Stokes. Ce résultat participe à la remise en question des hypothèses classiques utilisées en texturation, et peut justifier les améliorations obtenues expérimentalement avec les paliers texturés<br>The hydrodynamic bearing provides good damping properties in rotating machineries. However, the performances of rotor-bearings systems are highly impacted by nonlinear effects that are difficult to analyze. The rotordynamics prediction requires advanced models for the flow in the bearings. The surface of the bearings seems to have a strong impact on the lubricant flow, acting on the static and dynamic properties of the rotating parts. This study aims to enhance the simulation of the bearings’ surface state effect on the motion of the rotating shaft. The flexible shaft interacts with textured hydrodynamic bearings. Multi-scales homogenization is used in a multi-physics algorithm in order to describe the fluid-structure interaction. Different models are used to account for the cavitation phenomenon in the bearings. Nonlinear harmonic methods allow efficient parametric studies of periodic solutions as well as their stability. Moreover, a test rig has been designed to compare predictions to real measurements. Several textured shaft samples modified with femto-seconds LASER surface texturing are tested. In most cases the experimental study showed similar results than the simulation. Enhancements of the vibration behaviors of the rotor-bearing system have been revealed for certain texturing patterns. The self-excited vibration, also known as "oil whirl" phenomenon, is stabilized on a wide rotating frequency range. However, the simulation tool does not predict well the enhancements that are observed. Vortices in surface texturing patterns have been revealed numerically with Navier-Stokes equation resolution. These results are opposed to the classical lubrication hypothesis. It is also a possible explanation of the enhancements that are experimentally measured with textured bearings

De nombreuses hypothèses sont classiquement utilisées pour décrire le comportement du fluide dans un contact lubrifié : film continu, viscosité constante dans l'épaisseur, film mince, fluide newtonien... Or, certaines s'avèrent erronées dès lors que l'on s'intéresse aux contacts Elasto- HydroDynamiques fortement glissants ou à la répartition du lubrifiant en sortie de contact. Une approche numérique originale, basée sur un retour aux équations de la mécanique des fluides générale et prenant en compte le couplage fluide/solide et les effets thermiques sont proposés ici dans le but d'apporter des éléments physiques supplémentaires aux modélisations usuelles. Dans un premier temps, l'influence des effets thermiques sur l'évolution du frottement dans les contacts Thermo-EHD est mise en évidence. La présence d'un minimum de frottement pour le cas du glissement pur est expliquée par l'analyse des transferts thermiques entre le lubrifiant et les solides. L'origine des modifications locales d'épaisseur de film observées et l'existence même d'une épaisseur de film lubrifiant pour les cas de vitesse d'entraînement nulle sont alors reliées à la présence d'un fort gradient de viscosité dans l'épaisseur de film. Une comparaison qualitative avec des éléments expérimentaux de la littérature est réalisée, validant les tendances obtenues. Dans un second temps, l'écoulement à surface libre du lubrifiant en périphérie du contact est étudié expérimentalement puis numériquement par une méthode à interface diffuse. Le rôle des effets capillaires est analysé et les résultats numériques confrontés à des résultats issus de la littérature. Un bon accord est obtenu tant qualitativement que quantitativement. Validé par l'étude numérique diphasique (air/lubrifiant) réalisée, un modèle analytique simplifié est alors développé, prédisant une loi de répartition du lubrifiant en sortie de contact. La zone de sortie des contacts EHD est ensuite traitée par un modèle de cavitation vaporeuse et la prise en compte nécessaire de l'air environnant est discutée. Enfin, une première modélisation tridimensionnelle de l'écoulement à surface libre du lubrifiant autour d'un contact ponctuel est réalisée mettant en avant l'influence des effets capillaires et la faisabilité d'une telle approche.

This thesis describes an investigation into the effect of fluid and flow parameters on cavitation dynamics and cavitation erosion. A rotating disc test apparatus was developed fo: dow-type cavitation studies. A vibratory test device was also developed to study the role of cathodic and anodic potentials applied to cavitating bodies. Some major results are given below. Erosion "peaksat about 50°C in water, but under certain conditions material degradation caused by increased corrosion rate cancels out thermodynamic effects at higher temperatures. An erosion peak is also observed as a function of static pressure. Damage increases with velocity until cavitation is fully developed, at which stage the influence of velocity becomes negligible. The changes in erosion zone geometry and mass loss caused by temperature, velocity and pressure variations may be correlated with the effect these parameters have on the cavitation pressure profile. Efforts are described to develop a system for measuring this profile in the rotating disc device. Water quality including dissolved ions, as well as solid and gas impurities, influences both cavitation inception and the amount of cavitation damage caused. The synergism between cavitation erosion and corrosion causes high damage rates in corrosive, cavitating liquids. Solid impurities at medium concentrations may enhance or retard cavitation damage substantially, depending on the physical properties of the solid. Below the saturation level, increasing concentration of dissolved air in water results in a slight decrease in damage, but damage can be almost completely eliminated by the release of air bubbles into the cavitation region. Another important result is that the gas developed by the application of external potentials to a cavitating body provides protection against cavitation erosion through a gas cushioning mechanism. Cathodic protection of cavitating bodies will thus serve to decrease damage rates even in the case of corrosion-resistant materials like stainless<br>GR 2016

<p>The valve plate/cylinder block interface in an axial piston pump is often subject to extreme pressures, which can cause wear of the valve plate and ultimately, failure of the pump. The purposes of this study were to: a) experimentally investigate the film thickness generated between a floating valve plate and cylinder block in situ using proximity probes, b) develop a model which can predict the motion, film thickness and pressures of the floating valve plate and corroborate with experimental results, c) investigate surface pockets to provide additional lubricant at the valve plate interface by measuring the flow velocities and cavitation areas in a thrust washer bearing, d) numerically investigate surface modifications of the floating valve plate to observe any changes in lubricant pressure, temperature, cavitation, or valve plate deformation. Two different test rigs were designed, developed and used to investigate the performance of axial piston pumps and surface pockets. The axial piston pump test rig (APTR) was designed to operate and measure the steady state conditions of an axial piston pump. The APTR utilizes three non-contact proximity probes to measure the valve plate motion and film thickness between the cylinder block at various speeds and pressures. A thrust washer test rig (TWTR) was developed to measure the cavitation areas and flow velocities of lubricant in a pocketed thrust washer using μPIV. Through a novel interpolation approach, the depths of the micro-particles in the bearing pocket were determined using an analytical model. Using this approach, the μPIV measured 2D velocity field was employed to develop a 3D velocity field, which illustrates the fluid motion inside a pocketed thrust bearing at various speeds and viscosities. A dynamic lubrication model was developed using the thermal Reynolds equation augmented with the JFO boundary condition and the energy equation to determine the pressure, cavitation regions and temperature of the lubricant at the valve plate cylinder block interface. The lubricating pressures were then coupled with the equations of motion of the floating valve plate to develop a dynamic lubrication model. The stiffness and damping coefficients of the floating valve plate system used in the dynamic lubrication model were determined using a parametric study. The elastic deformation of the valve plate was also considered using the influence coefficient matrix approach. The experimental and analytical motion of the valve plate were then corroborated and found to be in good agreement. 4 and 8 pocket designs were then added as surface modifications to the floating valve plate in the dynamic lubrication model. The addition of surface modifications improved the lubricating conditions at the valve plate/cylinder block interface and resulted in increased minimum film thicknesses and lowered lubricant temperatures at the same operating conditions.</p>

The presence of hydrodynamically generated air bubbles has been observed to enhance fine particle flotation in a high intensity agitation (HIA) flotation cell. In this study, the cavitation in an HIA cell, used in our laboratory, is studied by hydrodynamic computational fluid dynamics. Different types of impellers are studied to obtain flow characteristics such as velocity and pressure distributions and turbulent dissipation rate in a two-baffled HIA cell. A cavitation model in conjunction with a multiphase mixture model is used to predict the vapor generation in the HIA cell. Cavitating flow is simulated as a function of revolution speed (RPM) and dissolved gas concentration to understand the dependency of hydrodynamic cavitation on these operating parameters. For comparison, cavitation in a pressure driven flow through a constriction is also modeled. A population balance model is used to obtain bubble size distributions of the generated cavities in a flow through constriction.<br>Chemical Engineering

Understanding the mechanism of bubble-particle interactions plays a critical role in advancing flotation technology. In this study, submicron size bubbles with an average diameter less than 1 μm and a life time of at least several hours were generated using a novel hydrodynamic cavitation method. Effect of mechanical force and water chemistry on generation and stability of submicron size bubbles is investigated. With recent development in measuring zeta potential distributions of colloidal systems, interactions of bubbles and fine solid particles in various electrolyte, surfactant and frother solutions as well as in industrial process water were studied using the stable submicron size bubbles generated by hydrodynamic cavitation. The outcome of this study provides not only a better understanding of bubble-particle attachment mechanism and its role in flotation, but also a direct evidence of armour-coating of bubbles and enhanced bubble-particle interactions by in situ gas nucleation.<br>Chemical Engineering

<div>Positive displacement machines are used in a wide variety of applications, ranging from fluid power where they act as a transmission of power, to lubrication and fluid transport. As the core of the fluid system responsible for mechanical--hydraulic energy conversion, the efficiencies of these units are a major driver of the total efficiency of the system. Furthermore, the durability of these units is a strong decider in the useful life of the system in which they operate.</div><div><br></div><div>The key challenge in designing these units comes from understanding their working principles and designing their lubricating interfaces, which must simultaneously perform a load carrying and sealing function as the unit operates. While most of the physical phenomena relevant to these machines have been studied previously in some capacity, the significance of their mutual interactions has not. For this reason, the importance of these mutual interactions is a fundamental question in these machines that this thesis answers for the first time. In analysis of two different machine types, it is confirmed that mutual interactions of both physical phenomena and neighboring fluid domains of the unit contribute significantly to the overall performance of the machine. Namely, these analyses demonstrate load sharing owing to mutual interactions on average of 20% and as high as 50%, and mutual flow interactions of at least 10%.</div><div><br></div><div>In this thesis, the behavior of the thin films of fluid in the lubricating interfaces of the units, the bodies that make up these films, and the volumes which interface with them will be considered. The resulting coupled problem requires a model that can consider the effects of motion of all floating bodies on all films and volumes, and collect the resulting loads applied by the fluid as it responds. This will require a novel 6 degree of freedom dynamics model including the inertia of the bodies and the transient pressure and shear loads of all interfaces of the body and the fluid domain.</div><div><br></div><div>During operation, fluid cavitation and aeration can occur in both the displacement chambers of the machine and its lubricating interfaces. To capture this, a novel cavitation algorithm is developed in this thesis, which considers the release of bubbles due to both gas trapped within the fluid and vaporization of the operating fluid in localized low pressure regions of the films. In the absence of cavitation, this model will also be used to find the pressures and flows over the film, communicating this information with the remainder of the fluid domain.</div><div><br></div><div>Due to the high pressures that form in these units, the bodies deform. The resulting deformation changes the shape of the films and therefore its pressure distribution. This coupled effect will be captured in one of two ways, the first relying on existing geometric information of the unit, and the other using a novel analytical approach that is developed to avoid this necessity. In either case, the added damping due to the shear of the materials will be considered for the first time. Additionally in regions of low gap height, mixed lubrication occurs and the effects of the surface asperities of the floating bodies cannot be neglected. Accurate modeling of this condition is necessary to predict wear that leads to failure in these units. This work will then develop a novel implementation for mixed lubrication modeling that is directly integrated into the cavitation modeling approach.</div><div><br></div><div>Finally, effort is made to maintain a generic tools, such that the model can be applied to any positive displacement machine. This thesis will present the first toolbox of its kind, which accounts for all the mentioned aspects in such a way that they can be captured for any machine. Using both multithreaded and sequential implementations, the tool will be capable of fully utilizing a machine on which it is run for both low latency (design) and high throughput (optimization) applications respectively. In order to make these applications feasible, the various modules of the tool will be strongly coupled using asynchronous time stepping. This approach is made possible with the development of a novel impedance tensor of the mixed universal Reynolds equation, and shows marked improvements in simulation time by requiring at most 50% of the simulation time of existing approaches.</div><div><br></div><div>In the present thesis, the developed tool will be validated using experimental data collected from 3 fundamentally different machines. Individual advancements of the tool will also be verified in isolation with comparison to the state of the art and commercial software in the relevant fields. As a demonstration of the use of the tool for design, detailed analysis of the displacing actions and lubricating interfaces of these same units will be performed. These validations demonstrate the ability of the tool to predict machine efficiencies with error averaging around 1% over all operating conditions for multiple machine types, and capture transient behavior of the units. To demonstrate the utility as a virtual optimization tool, design of a complete external gear machine design will be performed. This demonstration will start from only analytical parameters, and will track a route to a complete prototype.</div>

<div><p>Water is inflammable, non-toxic, environmentally friendly--- desirable traits, for a hydraulic fluid. However, its extremely low viscosity diminishes the load-bearing and sealing capacity of lubricating interfaces. Case in point: axial piston machines of swash plate design are compact, highly efficient positive displacement machines at the heart of hydraulic systems in forestry, construction, aerospace, and agricultural equipment, as well as industrial applications (presses, etc.); however, the three main lubricating interfaces decisive to the performance of such units in terms of both component life and efficiency are challenged by the use of water as working fluid. Especially during high-pressure operation, this low-viscosity lubricant can cause the these interfaces to fail in carrying the imposed load, resulting in severe wear, or even pump failure. The piston-cylinder interface is particularly challenging to design for water because it stands under obligation to carry the heavy side load that acts on the pistons of these machines, which increases with operating pressure. Furthermore, the architecture of axial piston machines of swash plate design does not allow this interface to be hydrostatically balanced.</p> <p> </p> <p>Through the development of a methodology that separates the fluid pressure fields of the three main lubricating interfaces of axial piston machines into their hydrostatic and hydrodynamic components, the present work enables a direct comparison of these interfaces in terms of how they support load. A case study of a 75 cc unit running on hydraulic oil conducted via this methodology at three different operating conditions (low pressure/low speed, low pressure/high speed, and high pressure/low speed) demonstrates that in the piston-cylinder interface, the force from hydrostatic pressure reaches such high magnitudes over the high-pressure stroke that less than half of it is needed to counter the load. The excess force from hydrostatic pressure then becomes the load. Consequentially, hydrodynamic pressure must counter a force from hydrostatic pressure that exceeds the original load. In the other two interfaces, by contrast, over half the load is being carried by hydrostatic pressure, thus significantly diminishing the amount of hydrodynamic pressure the interfaces are required to generate in order to achieve full load support. Moreover, nearly all of the moment on the piston is countered by hydrodynamic pressure, while less than half of the moment on the block is countered by hydrodynamic pressure, and the moment on the slipper is negligible by comparison.</p> <p> </p> <p>While this case study only investigates one pump, it shows how critical hydrodynamic pressure can be to load support in the piston-cylinder interface. The use of a low-viscosity fluid, e.g. water, reduces the hydrodynamic pressure that is generated in this interface, which, at challenging operating conditions, can lead to metal-to-metal contact. However, the performance of the interface can be improved via micro surface shaping, i.e. by giving the surface of the piston, or the bore that it moves through, a shape on the order of microns in height. The aim of present work is to pursue design trends leading to surface shapes that will enable this interface to function at higher pressures than currently achievable. </p> <p> </p> <p>This pursuit takes the form of systematic virtual design studies, an optimization procedure, and an algorithm developed specifically for tailoring the bore surfaces through which the pistons travel to piston tilt and deformation. From this emerges not only a set of design trends corresponding to the dimensions of two particularly powerful types of micro surface shaping, but also a profound insight into the behavior of the water-lubricated piston-cylinder interface fluid film, and how that behavior can be manipulated by changing the component surfaces that constitute its borders. Furthermore, in collaboration with Danfoss High Pressure Pumps, a physical prototype of a 444 cc axial piston pump with surface shaping generated via the aforementioned algorithm has been constructed and tested, achieving a total pump efficiency roughly 3% higher than that achievable by the commercial unit that the geometry of the prototype is based on.</p><br></div>