MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Important Instructions to examiners:

1) The answers should be examined by key words and not as word-to-word as given in the
model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try
to assess the understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more
Importance (Not applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the
figure. The figures drawn by candidate and model answer may vary. The examiner may give credit for any
equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant
values may vary and there may be some difference in the candidates answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidates understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.

Q. 1 Attempt any four of following: (4x4=16)

a) Define Viscosity Index and Neutralization Number

Viscosity Index: A number describing how the viscosity of a fluid changes with temperature. Fluids affected by
temperature extremes have a low viscosity index, while fluids that maintain viscosity have a high viscosity
index.
Neutralization Number The neutralization number is a measure of the acid or alkaline content of new oils and
an indicator of the degree of oxidation degradation of used oils. This value is ascertained by titration, a standard
analytical chemical technique, and is defined as the number of milligrams of potassium hydroxide required to
neutralize one gram of the lubricant. (2 marks each)

b) Give classification of rotary pumps. Explain why only rotary pumps are preferred for oil hydraulic systems.

Rotary Pump

Gear Vane Screw

Fixed Variable
External gear
Displacement Displacement

Unbalanced
Internal gear
vane pump

(2 + 2 marks)
Balanced
Gerotor
Vane pump

Following points will justify the use of rotary pumps in oil hydraulic systems.
1) Power to weight ratio is satisfactory
2) Simpler Construction

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

3) Direct coupling to motor (el).

4) Continuous pulsation-free supply of oil.

c) What is accumulator? Why it is necessary for every huge hydraulic press? (1+3)

Accumulator: It is a device which stores the pump delivery when it is not required by the system and makes available to the
system whenever required.

Necessity of accumulator for every huge hydraulic press:

Oil requirement of the system is not continuous but intermittent. A hydraulic press needs the oil only during the lifting
operation. While, during the lowering of load, holding the load or during idle period, it doesnt not require any supply of oil.
During such period, the hydraulic pump has to stop or delivered oil must be drained back to the sump. But frequent starting and
stopping of pump is not desirable as it reduces the pump life. Also, draining the pressurized oil is wastage of power which reduces
the system efficiency.
The remedy to above problem is to use accumulator in the system.

d) Give the functions of hydraulic seals. Differentiate between static seal and dynamic seal. (2+2 marks)
Functions:

1) To stop leakage of oil

2) To maintain the pressure
3) To keep out contamination in the system
4) To enhance the working life of the system
5) To enhance the functional reliability of components over a longer period.

Static Seal Dynamic Seal

1 Used to seal two mating parts which are not moving 1 Used to seal two mating parts which are having
or which are not having any relative motion between relative motion between them.
them.

2 These seals are stationary 2 These seals are moving

3 Life of seal is more 3 These seals need to be replaced as they get worn out
due to excessive pressure.

4 Example: Sealing end covers of DA cylinder 4 Example: Cup Seal

e) With neat sketch, explain the functioning of simple pressure relief valve.

Working: Simple pressure relief valve is also a Direct operated pressure relief valve. It
consists of Poppet, spring, pressure setting knob and valve body.

It is normally closed valve connected between pressure line and the oil reservoir when
inlet oil pressure is less than the spring force; it means that it is insufficient to overcome the
spring force, the valve remains closed. The pressure of oil is safe for the system. When the oil
pressure is greater than spring force, it pushes the poppet against the spring force and unseated
the poppet. Now the valve opens and oil flow from inlet port to the reservoir. The valve will
remain open until the excessive pressure is diverted to the tank.

Cracking pressure: the pressure at which the valve first opens is called the cracking pressure. It is essential for every
hydraulic system to provide pressure relief valve as a safeguard against the pressure. (2+2 marks)
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

f) Give the detailed classification of hydraulic actuator:

Hydraulic
Actuator

LInear Rotary
Actuator Actuator

Single Acting Double Acting Telescopic Gear Motor Vane Motor Piston Motor

Piston Type Ram Type Single End Rod Radial

Double End
Spring Return Gravity Return Axial
Rod

Kicker Cylinder
Gravity Return Tandem
Return

Q. 2 Attempt any three of following: (3x6=18)

a) List any three merits and three demerits of hydraulic systems with reasoning. (3+3 marks)

Merits:

1) We can generate very high pressures in hydraulic system. Due to this nature of hydraulic system we can use this power to
lift, hold, press very heavy loads
2) Weight to power ratio of a hydraulic system is comparatively less than that of an Electro-Mechanical System. Electric
motor weigh appropriately 8.5 Kg/kW whereas, same power hydraulic motor weighs 0.85 kg/kW only.
3) The speed control of linear as well as rotary actuators can be achieved with ease. By merely adjusting small flow control
valve, wide range of speed and feed can be obtained.

Demerits:

1) Elements of hydraulic system have to be machined to high degree of precision which increases manufacturing cost of
system.
2) The hydraulic system, due to oil leakages is dirty and we cannot use this system in food and pharmaceutical industry.
3) Petroleum based hydraulic oils can create fire hazards if the temperature of the system goes beyond its flash point

b) With a neat sketch, explain the functioning of lobe pump. Give any four advantages of gear pumps.

( 2+2+2 marks)

Fig shows Lobe pump. The lobe pump operates on the same principle as the external
gear pump. But unlike the external gear pump, both lobes are driven externally so that they do
not actually contact each other. Hence they are quieter than other types of gear pumps.

Each lobe has only three mating teeth those are much wider and more rounded than
those found on a regular external gear pump. Due to the smaller number of mating elements,
the lobe pump output will have a somewhat greater amount of pulsation, although its
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

volumetric displacement is generally greater than that for other types of gear pumps. They have relatively low pressure capability.

Advantages of gear pump:

1) High Speed
2) High pressure
3) No overhung bearing loads
4) Relatively quiet operation
5) Design accommodates wide variety of materials
6) Ability to handle wide range of viscosity
7) Less sensitive to cavitations

c) Sketch the two positions of 4/2 rotary spool type DCV and explain in brief. (3+3 marks)

Explanation: A rotary spool valve consists of a rotating spool which

aligns with ports in stationary valve casing, so that fluid is directed to
required port. A/B/P/R is the ports in casing. The port P is a pressure
port though which pressurized oil is coming in the valve. R port is the
port through which used oil is returning to oil tank.

d) The pressure at no load conditions during extension of DAC is 150 and that during retraction is 250 .
Diameter of piston rod is 2.5 cm.

Calculate:

1) Bore diameter of cylinder

2) Packing friction between piston and cylinder

Given Data: Pe = 150

Pr = 250

d= 2.5 cm
Assuming packing friction same for extension and retraction stroke

F = Pe x A = Pr x (A - a)

150 x = 250 x

3 =5 - 5 x 6.25
2 = 31.25
D = 3.95cm = Bore diameter . (03)

F = 150 x .
F = 1838.13 N . (03)

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Q. 3 Attempt any two of following: (2x8=16)

a) Sketch and explain meter-in hydraulic circuit to control the speed of extension of DAC. Explain why meter-in
circuit is not preferred for over-running loads.

(Sketch: 2 Marks)

Explanation: (3 marks)
Fig shows meter-in speed control circuit. The flow control valve with integral check valve is placed before the actuator in
the pressure line so that oil flow rate at the inlet of the actuator can be regulated.
Flow control valve is the main component in this circuit which is used to reduce the sped of actuator. When pressurized
oil flows through the circuit, it passes through D.C. valve and enters in the flow control valve. The entering of FCV is reduced to
decrease the oil flow rate. Now, the less quantity of oil will enter in the cylinder through inlet A. it will push the piston in the
forward direction. As the flow rate is reduced, the movement of piston is slow.
When flow control valve opening is increased by changing the needle position, more flow of oil will enter in the cylinder
from face side inlet and increases the speed of piston. The check valve is provided along flow control valve to prevent oil flow in
the reverse direction.

Meter-in circuit is not preferred for over-running loads: (3 marks)

Over-running load is the load which tries to move some distance without applied input force. Meter-in circuits provide
accurate control only when the load is opposing the actuator movement. If there is a tendency for the direction of the load to
reverse, i.e. is act in the direction of motion or to over-run, then the meter in circuit losses control.This circuit gives smooth
motion of piston for the resistive load (acting in opposite direction of feed). When load is negative (acting in the same direction of
feed) it causes jerky motion of the actuator. Thats why meter-in circuits are preferred for resisting loads and not for over-running
loads.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

b) With the help of neat circuit diagram, explain the functioning of hydraulic shaper.

(4 + 4 Marks)

Working:

The cutting stroke is required for cutting of material using forward stroke of ram of shaper machine. The oil from pump P
enters in the cylinder through inlet A and moves the piston connected to ram in the forward direction. The flow rate of oil coming
out of cylinder is adjusted using flow control valve located in the return line.
The meter-out circuit is used to vary the speed of ram during forward cutting stroke.
When forward stroke of ram is completed the lever of D.C. valve hits the shaper dog C and changes the position D.C.
valve. Now the port P B and A R are connected.The pressurized oil will enter from inlet b and pushes the piston towards
the right end and completes the return stroke. The return movement of ram should take less time than that of cutting stroke as it is
non productive stroke. It is quicker as there is free flow during oil leaving out of the cylinder.
When return movement of ram is completed. It will hit the shaper dog D to obtain position of D.C. valve for forward
stroke.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

c) Draw hydraulic circuit for punch press. Explain how the use of unloading valve can save power. If pressure
settings of relief valve and unloading valves are 500 bar and 5 bar respectively, and pump discharge is 0.04 ,
Calculate:
i. Power consumption without unloading valve in circuit
ii. Power consumption with unloading valve in circuit
iii. Percentage saving in power by adopting unloading valve.
(Take 1 bar= )

(4 + 4 Marks)

Case I: Power consumption without unloading valve in circuit= Pmax X Qmax

= (500 X 105)X 0.04
= 2000KW

Case II: Power consumption with unloading valve in circuit= Pmin X Qmax
= (5 X 105 ) X 0.04
= 20KW

Case III: Percentage saving in power by adopting unloading valve. =

= 99%
From the calculation it has been observed that about 99% of power consumption can be saved by using the unloading valve.

Q.4 a) Draw general layout of pneumatic system and label the components (2 + 2 Marks)

1 Intake filter and silencer 2 Compressor 3 Aftercooler 4 Separator 5 Pressure switch

6 Relief valve 7 Receiver tank 8 Filter, Regulator, Lubricator 9 Control valve 10 Actuator

Q4 b) Give detailed classification of air compressors

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Q4 c) Three main types of control valves and purpose of each in pneu.system (2 + 2 Marks)

Pressure control: Maintains pressure below safe limit, Controls the pressure as per requirement.
Direction control: Controls the direction of flow for forward and reverse motion of actuator, Allows the flow in one
direction and blocks in the reverse direction.
Flow control: Controls the quantity of air going to actuator to control its speed.

Q4 d) 4/2 DCV Vs 5/2 DCV

4/2 and 5/2 DC valve are similar in functionality only difference is that 5/2 DC valve contains one more port which is
additional exhaust port. In hydraulic circuit return oil is taken back to tank while return air is exhausted to atmosphere
in pneumatic circuit. To ensure easy exhaust additional exhaust port is provided in pneumatic system while it is not
provided in hydraulic system to save extra return line to tank.
Q4 e) FRL unit and Time delay valve (2 + 2 Marks)

FRL unit Time delay valve

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Q4 f) FAD

It is the actual volume of the air delivered by the compressor, when reduced to normal temperature and pressure condition.

Given Data: = 12 bar

= 0.15

Assume T1= 2980K

Assuming NTP conditions:

=
0
= K

And =
.
= =

= 0.0295

= 1.77

Q5 a) Merits and Demerits of Pneumatic system (3 + 3 Marks)

Merits

1. Pneumatic system provides cheaper and light weight equipments as they work on air which is freely available and no
robust construction is required. Also no return lines are required.

2. Pneumatic system is fire proof, explosion proof and non-reactive thus a safer system. Hence can be used in fire prone
area.

3. Pneumatic system is clean as air is dry. Hence it is widely used in food processing, electronic and automation industry

Demerits

1. The pneumatic system can be used only up to 10 bar and hence not suitable for heavy duty applications

2. Due to compressible nature of air, pneumatic system is not highly accurate and precise hence cannot be used in precision
machines.

3. It makes lot of noise which makes it irritating for the workers.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Q 5 b) Liquid ring vane compressor (3 + 3 Marks)

The action of liquid ring vane compressor is similar to vane type

employing in addition water or other low viscosity liquid to compress the gas
trapped between the blades and casing wall. There is no metal contact
between blades and walls, therefore no lubrication or wear at these points.
These single stage compressors are available for a wide range of flow
capacities, with compression ratios up to five. Special arrangement has to be
made to maintain a constant liquid level. Maximum speed is limited due to
cavitation erosion of mechanical parts.

Q 5 c) Problems due to moisture (4 + 2 Marks)

If the moisture in the air is not removed and thus gets condensed in the system, it will cause corrosion of pneumatic equipment
like valves, actuators etc. This will affect the smooth working of these equipments and will also reduce their life. Various types of
air dryers used to remove moisture are as follows:

Absorbent dryers, Adsorbent dryers, Refrigeration drying

Q 5 d) Two positions of 3/2 DCV (3 + 3 Marks)

3/2 DCV consists of 3 ports namely P, R and A which can be interconnected with 2 different positions. It is generally used for
actuation of SAC or a pilot operated DCV. In normal position port P is blocked and port A is connected to port R. Thus pressure
in A is released. When the spool is actuated as shown in position 2, P port is connected to port A and R is blocked. This brings the
forward stroke of the SAC or actuation of another DCV.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Q 6 a) Meter out to control retraction speed of DAC (4 + 4 Marks)

When 4/2 DCV is operated, air is supplied at the blind end of the
cylinder through check valve. As the FCV is bypassed, piston moves
forward with full speed. When 4/2 DCV is released, air is admitted
into the cylinder from rod end. But the air leaving the cylinder has to
pass through the flow control valve. Thus speed of the actuator is
controlled as per the setting of the FCV

Q 6 b) Actuating DAC using two 3/2 DCV (4 + 4 Marks)

Figure shows control of DAC using two 3/2 DCV, VA and VB which
are shown in their normal position. When VA is shifted to position 1,
air is admitted to piston side. Since rod side air is exhausted through
position 0 of VB, forward strike of piston takes place. For return stroke
of the piston, VB is shifted to position 1 and VA is released to position
0.

This circuit is used for special applications using cylinders of long

stroke. To reduce the piping run and air consumption, DCVs may be
placed near each port.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
SUMMER 14 EXAMINATION
Subject Code: 12242 Model Answer
__________________________________________________________________________________________________

Q 6 c) Time delay valve circuit (3 + 3 + 2 Marks)

When valve 1.2 is manually actuated, pilot operated

valve 1.1 is shifted in position 1 which brings the forward
stroke of the DAC A. The end of the forward stroke is sensed
by the roller operated valve 1.4 which can start the return
stroke of the piston by shifting valve 1.1 to 0 position.
However the return stroke is delayed by time delay valve 1.3
by certain time which can be adjusted. As soon as the signal
pressure in the time delay valve reaches the adjusted value of
spring force of air operated 3/2 DCV, the valve opens and
passes the signal to main pilot operated DCV 1.1 which resets
and cylinder retracts after a particular dwell time.

Applications:

1) Bottle filing system

2) Small component assemblies

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