Session: 11-02-03: CFD Applications for Optimization and Control II

Paper Number: 166227

Computational Fluid Dynamics Based Modeling of Relief Valves: Validation With Lab Data and Performance Comparison to One-Dimensional Approaches 

The design and functionality of poppet relief valves in hydraulic systems depend on a comprehensive understanding of flow behavior and the forces acting within the valve. These valves play a crucial role in maintaining system pressure, preventing over-pressurization, and ensuring the reliability of hydraulic circuits across various industrial applications. A thorough understanding of the flow forces within the valve is essential for optimizing performance and mitigating undesirable effects such as instability, noise, and excessive vibration, all of which can impact system efficiency, reliability, and longevity. Effective valve design requires a balance between performance optimization and practical constraints, making predictive modeling an essential tool in the engineering process.

This study presents an investigation utilizing both a transient dynamic Computational Fluid Dynamics (CFD) model and a simplified one-dimensional (1D) model to evaluate their effectiveness in predicting flow-induced forces. The 3D CFD model provides a high-fidelity representation of transient flow characteristics, capturing intricate details such as pressure fluctuations, velocity fields, and turbulence effects. By resolving fine-scale flow structures, this approach offers deeper insights into the forces acting on the poppet, which is critical for refining valve geometry and improving overall system performance. However, full-scale CFD simulations require significant computational resources, making them impractical for early-stage design iterations or real-time applications where rapid evaluations are necessary.

In contrast, the 1D model offers a faster and more cost-effective alternative for preliminary valve performance assessments. By simplifying governing equations and reducing computational demands, the 1D approach enables quicker evaluations while still providing valuable insights into pressure dynamics, poppet lift, and resultant flow forces. Although it lacks the spatial resolution and detailed turbulence modeling of CFD, its efficiency makes it highly practical for iterative design processes and real-time simulations, particularly in engineering applications where computational resources are constrained or where parametric studies are required.

Key parameters analyzed in this study include transient pressure distributions, poppet displacement, and the corresponding flow-induced forces. A comparative analysis of CFD and 1D models was conducted to assess their accuracy, with simulation results validated against experimental data. This study will investigate the strengths and limitations of each approach, assessing the extent to which CFD provides detailed insights and whether the 1D model remains useful in engineering applications where computational efficiency is a key consideration.

By integrating CFD and 1D modeling techniques with experimental validation, this research enhances confidence in analytical models used for valve analysis and design. The insights gained have significant implications for improving the reliability, efficiency, and longevity of hydraulic systems in industries such as oil and gas and off-highway vehicles. Ultimately, this study contributes to the ongoing optimization of hydraulic valve performance, offering engineers a more comprehensive framework for designing robust and efficient flow control solutions that meet industry demands.

Presenting Author: Jenna Watts Parker Hannifin

Presenting Author Biography: Jenna Watts is a master's student in mechanical engineering at Cleveland State University, expecting to graduate in May 2025. She has research interests in fluid dynamics and computational modeling. She is currently an intern at Parker Hannifin in Elyria, Ohio, gaining industry experience in engineering applications. Her work focuses on optimizing fluid flow systems and applying computational techniques to solve real-world engineering challenges.

Authors:

Jenna Watts Parker Hannifin
Bipin Kashid Parker Hannifin
Maryam Younessi Sinaki Cleveland State University