The importance of a full 3D fluid dynamic analysis to evaluate the flow forces in a hydraulic directional proportional valve

Purpose – The purpose of this paper is to present a full 3D Computational Fluid Dynamics (CFD) analysis of the flow field through hydraulic directional proportional valves, in order to accurately predict the flow forces acting on the spool and to overcome the limitations of two-dimensional (2D) and simplified three-dimensional (3D) models. Design/methodology/approach – A full 3D CAD representation is proposed as a general approach to reproduce the geometry of an existing valve in full detail; then, unstructured computational grids, which identify peculiar positions of the spool travel, are generated by means of the mesh generation tool Gambit. The computational grids are imported into the commercial CFD code Fluent, where the flow equations are solved assuming that the flow is steady and incompressible. To validate the proposed computational procedure, the predicted flow rates and flow forces are compared with the corresponding experimental data. Findings – The superposition between numerical and experime...