Chapter 2 : Hydraulic fluid In principle, any liquid can be used to transfer pressure energy.

However, as in hydraulic installation, other characteristics are also required of hydraulic fluids, the number of suitable fluids is considerably restricted. As a hydraulic fluid, water causes problems related to corrosion, boiling point, freezing point and low viscosity. Hydraulic oil with a mineral oil base also known as hydraulic oil fulfill most normal requirements (e.g for machine tools). They are used very widely. Hydraulic fluids with low inflammability are required for hydraulic system with high of fire such as, for example: Hard coal mining Die-casting machine Forging presses Control units for power station turbines And steel work and rolling mills. In all these applications, there is a risk that hydraulic fluids based on mineral oil will catch fire on intensively heated metal parts. Oil mixtures containing water synthetic oil are used here in place of standard oils. Task for hydraulic fluids The hydraulic fluids used in hydraulic installation must fulfill very varied task: Pressure transfer Lubrication of the moving parts of devices Cooling i.e. diversion of the heat produced by energy conversion (pressure losses), Cushioning of oscillations caused by pressure jerks, Corrosion protection, Scuff removal Signal transmission Types of hydraulic fluid Within these two groups hydraulic oil and hydraulic fluids with low inflammability there are various types of fluid with different characteristics. These characteristics are determined by a basic fluid and small quantities of additives. Hydaulic oils In DIN 51524 and 51525 hydraulic oil are divided according to their characteristics and composition into three classes: Hydraulic oil HL Hydraulic oil HLP

Hydraulic oil HV

The designations for these oil are composed of the letter H for hydraulic oil and the additional letter for the additives. The code letter is supplemented by a viscosity code defined in DIN 51517 (ISO viscosity classes) Designation HL Special Characteristics Increased corrosion protection And ageing stability Area of application System in which high termal demands are made or corrosion through immersion in water is possible. Increased wearing protection Like HL oil, also for use in system where variable high friction occurs owing to design or operating factors. Improved viscosity- Like HLP oil, for use in widely temperature characteristics fluctuating low ambient temperatures. H : hydraulic oil L : with additives to increase corrosion protection and / or ageing stability HLP 68 P : with additives to reduce and/or increase load carrying ability 68 : Viscosity code as defined in DIN 51517

HLP

HV

Hydraulic fluids with low inflammability Where these hydraulic fluids are concerned, a distinction is made between hydrous and anhydrous synthetic hydraulic fluids. The synthetic hydraulic fluids are chemically composed so that their vapour is not flammable. The table shown here provides an overview of hydraulic fluids with low flammability (HF liquids). They are also described in VDMA standard sheets 24317 and 24320. Abbreviated Code HFA HFB HFC HFD VDMA standard sheet no. 24 320 24 317 24 317 24 317 Composition Oil-water emulsions Water-oil emulsions Hydrous solutions, e.g. water-glycol Anhydrous liquid, e.g. phosphate ether Water content in % 80 .98 40 35 .. 55 0 . 0.1

For hydraulic oils to be able to fulfill the requirment listed above, they must exhibit certain qualities under the relevant operating conditions. Some of these qualities are listed here: Lowest possible density; Minimal compressibility; Viscosity not too low (lubricating film); Good viscosity-temperature characteristics; Good viscosity-pressure characteristics; Good ageing stability; Low flammability; Good material compatibility;

In addition, hydraulic oils should fulfill the following requirment: Air release; Non-fronthing; Resistance to cold; Wear and corrosion protection; Water separable. The most important distinguishing feature of hydraulics is viscosity. Viscosity The word viscosity can be defined as resistance to flow. The viscosity of a liquid indicates its internal friction, i.e. the resistance which must be overcome to move two adjacent layer of liquid against each another. Thus, viscosity is a measure of how easily a liquid can be poured. The internatioal system of standards defines viscosity as kinematic viscosity (unit: mm2/s) It is determined by a standardized procesdure, e.g.: DIN 51562: Ubbelohde viscometer DIN 51561: Vogel-Ossag Viscometer The ball viscometer can also be used to determine kinematic viscosity. IT can be used to measure values precisely across a broad area. Measurments are made to determine the speed with which a body sinks in a liquid under the influence of gravity. To find the kinematic viscosity, it is necessary to divide the values determined using the ball viscometer by the density of the fluid. Refer to the Ball Viscometer.

One important method of identifiying hydraulic oils is the specification of viscosity class. The ISO standard and the new draft of DIN 51524 explain the viscosity classes lay down the minimum and maximum viscosity of hydraulic oils at 40 degree Celcius.
ISO Viscosity classes ISO VG 10 ISO VG 22 ISO VG 32 ISO VG 46 ISO VG 68 ISO VG 100 kinemaic viscosity (mm2/s) at 40 degree celcius max min 9 11 19.8 24.2 28.8 35.2 41.4 50.6 61.2 7408 90 110

Viscosity classes (DIN 51502) Thus, six different viscosity classes are available for the various types of hydraulic oil HL, HLP and HV. The table below specifies areas of application for the different viscosity classes; it is necessary here to match the viscosity class to the ambient temperatures. For storage reasons, high-grade motor or gear lubricating oil is also used in hydraulic installations. For this reason, the SAE viscosity classification is also listed here. However, this classification allow fairly large tolerance zones as can be seen from a comparison between the two methods of classification.
SAE classes 30 20, 20W 10W 5W ISO-VG Areas of application

100 68 46 32 22 15 10

stationary installations in closed areas at high temperature

at normal temperatures

for open air applications - mobile hydraulics in colder areas

SAE viscosity classification In practice viscosity margins play an important role:

When viscosity is too low (very fluid), more leakage occur. The lubricating film is thin and, thus able to break away more easily resulting in reduced protection against wear. Despite this fact, fluid oil is preferred to viscous oil since pressure and power losses are small owing to the lower friction. As viscosity increase, the internal friction of the liquid increase and, what that, the pressure and power loss cause by the heat also increase. High viscosity results in increased friction leading to excessive pressure losses and heating particulary at throttle points. This makes cold start the seperation of air bubbles more difficult and, thus, leads to cavitation. Kinematic viscosity 10 mm2/s 15 to 100 mm2/s 750 mm2/s

Lower limit Ideal viscosity range Upper limit

When using hydraulic fluid, it is important to consider their viscosity temperature characteristics, since the viscosity of the hydraulic fluid changes with changes in temperature. These characteristics are shown in the Ubbelohdes viscosity-temperature diagram. If the values are entered on double logarithm paper, a straight line is produced.

The viscosity index (VI) is used as a reference value for viscosity- temperature characteristics. It is calculated in accordance with DIN ISO 2902. The higher viscosity index of a hydraulic oil, the less the viscosity changes or the greater the temperature range in which this hydraulic oil can be used. In the viscosity-temperature diagram, a high viscosity index shown as a level characteristic line. Mineral oils with a high viscosity index are also referd to as multi grade oil. They can be used anywhere very changeable operating temperature arise; such as for mobile hydraulics, for example. Where oils with a low viscosity index are concerned, a distinction must be made between summer oils and winter oils: Summer oils: with higher viscosity so that the oil does not become too fluid causing the lubricating film to break up. Winter oils : with lower viscosity so that the oil does not become too thick and a cold start is possible. The viscosity-pressure characteristics of hydraulic oils are also important since the viscosity of hydraulic oils increase are also important since the viscosity of hydraulic oil increase with increasing pressure. These characteristics are to be noted particularly in the case of pressure from a p of 200 bar. At approx 350 to 400 bar the viscosity is generally already double that at 0 bar. If the characteristics of hydraulic fluids described in this chapter are summarized the following advantages of hydraulic fluids with low flammability result when compared to hydraulic oils on a mineral oil base:
Advantages and disadvantages of hydraulic fluids with low flammability Advantages Disadvantages Greater density Difficult intake condition for pumps Kow Compressibility Unfavaorable air venting properties Limited operating temperature Favourable viscosity temperature characteristics Hydraulic oil less fluid Higher presssure peaks possible Increase dwell time in reservior by using larger reseviors 50 C may not be exceeded as otherwise too much water vaporises In the case of HFC liquids, HFD liquids of HFD liquids, the viscosity changes less the viscosity changes with temperature sharply in case of temperature fluctuations. fluctuation HFD liquids erode conventional bunan seals, accumulator diaphragms and hoses.

Wearing properties

Price

Characteristics of HFD HFD liquids are more liquids correspond to those of expensive than hydraulic oils. hydraulic oil when appropriate cooling and heating equipment is use.