Q.1. What is a Hydraulic circuit ?

Ans : A hydraulic circuit is systematic arrangement (with interconnection) of various

hydraulic components to perform a specific task. Obviously every hydraulic application will
have a different circuit, but basically there are certain circuits, which are meant to perform
certain tasks in the complete circuitry

e.g. sequencing circuit, speed (flow) control circuits etc

Q.2. Explain with sketch Basic structure of

Hydraulic circuit .
Ans
: A hydraulic circuit comprises of main three groups of elements.

1) Drive assembly :This accomplishes the transformation of energy. A drive assembly

consists of a pump, actuating motor (or prime mover) and tank. It
also includes a safety valve, filter, cooler etc.

2) Control system : They modulate and control the fluid power. Essential components are
the various valves and connections between them.

3) Loads and consumers These are usually hydraulic cylinders or hydraulic motors,
which transform hydraulic energy into mechanical energy.
Q.3. Draw the circuit of control of single acting and
double acting(DA) hydraulic cylinder with
manually operated valve.
Q.1. Explain with sketch hydraulic circuit for the
Milling machine.
Ans: Hydraulic circuit for a milling machine is comparatively different from the former two
circuits, because the table movement in millingoperation is comparatively slower. As well,
different feeds (adjustable) are required for milling different type of work. Hence, in the
hydraulic circuit for milling machine in addition to other
elements a flow control valve (graduated in terms of feeds) is incorporated in the circuit.
Figure depicts the hydraulic circuit formilling machine. It has a main pump, which is a low
pressure, and high discharge pump, and one booster pump, which is a low discharge high
pressure pump. The function of the booster pump is to boost the
hydraulic pressure to a level above that of provided by main pump ( this combination saves
the power as well as use of a high flow and high discharge pump is avoided).There are two
sets of flow control valve and check valve, fitted in both supply and return line to cylinder, to
achieve speed control in both directions. A manually operated spool valve decides the
direction of flow to the cylinder
Q.2. Explain with sketch hydraulic circuit for the
GRINDING machine.
Ans : Hydraulic circuit for a surface grinding machine is depicted in sketch below. It consists
of a power pack to supply pressurised oil, one pilot operated direction control valve which
decides the direction of flow of pressurized oil.The piston rods on both sides are
mechanically coupled with the table of the machine. There are two
roller actuated pilot valves, which are actuated by cams fitted to the table ( cams not shown
in diagram). These valves provide pilot impulse to the main valve, thus deciding the position
of main valve and hence the direction of motion of the cylinder ( and consequently the table).
Every time either of the pilot valves is pressed by the cam. The cam positions are adjustable,
which decides the strokelength movement of the table. Whenever the work-piece to be
ground is changed the operator is required to change the position of the cams to suit the
length of work-piece.
Q.3. Explain with sketch hydraulic circuit for the
SHAPING machine.
Ans : Figure below depicts the hydraulic circuit for shaping machine. The circuit utilizes a
double acting cylinder with single piston rod and spool type directional control valve, which
is shifted by a reversing lever.Hydraulic power-pack supplies the pressurised oil to the spool
valve. The position of spool valve
decides whether the pressurised oil should go the head end or the piston rod end of the
cylinder. The cylinder is mounted in such amanner that the forward stroke occurs when the
oil is supplied to the head end of the cylinder and reverse stroke occurs when oil is supplied
to piston rod end of the cylinder. Due to the difference in
annular areas of head end and piston rod end, the return stroke is faster than the forward
stroke. The stroke length of the ram can beadjusted by changing the positions of the
adjustable dogs, i.e. closer the adjustable dogs shorter the stroke length and vice-
versa.Several additional controls may be added to this basic circuit to
enhance its performance and to have precise control over operation.
Hydraulic/Pneumatic circuits Faults and remedies
Q.1.Enlist the common Faults and causes in the
Hydraulic system
Ans : Following are the common faults in Hydraulic systems

1. Reduced speed of travel of machine tool elements

2. Slow response to controls

3. Excessive loss of system pressure

4. Excessive leakage in the systematic

5. Rise in the oil temperature

6. Non-uniform or jerky movement of actuators

7. Increased noise in the systematic

8. No supply or less supply from pump

9. Cavitation due seal failure

10. High rate of seal failure

11. Poor oil life

12. High degree of contamination level of system medium.

Following are the common causes of hydraulic system breakdown

1.Inadequate supply of oil in the reservoir

2. Clogged or dirty oil filters

3. Leaked seals

4.Loose inlet lines that cause the pump to take in air

5.Incorrect type of oil

6. Excessive oil temperature

7. Excessive oil pressure

Q.1. Explain with sketch Regenerative circuit.

Ans : A circuit is said to be operating on re-generative principle when the fluid returning
from other end of cylinder is forced into the head end of cylinder. Obviously, some energy is
consumed to force out the fluid from piston-rod end when cylinder is extending. The re-
generative circuit enables to utilize this part of energy, which would have otherwise
wasted. The net result of re-generation is increase in cylinder speed, with same discharge of
pump.The circuit in fig. depicts a typical re-generative circuit with solenoid operated 4/3
directional control valve. The circuit is similar to the previous linear circuit except
the change in cent

When the valve is in central position the cylinder extends, with about twice the normal
speed, thus effecting the re-generative function. When the valve shifts to right position, the
regenerative effect is nullified and cylinder moves with normal speed (as decided by pump
flow).When the valve shifts to left, the
cylinder retracts. The regenerative principle can be applied to any motion i.e. extending or
retracting.
Q.2. Explain with sketch Counter balance Hydraulic
circuit .
Ans : Counterbalance valves are commonly used to counterbalance a weight or external force
or counteract a weight such as a platen or a press and keep it from freefalling.Figure1.16
illustrates the use of a counter balance or back-pressure valve to keep a vertically mounted
cylinder in the upward position while the pump idles, that is, when the DCV is in its center
position. During the downward movement of the cylinder, the counterbalance valve is set to
open at slightly above the pressure required to hold the piston up (a check valve does not
permit flow in this direction). The control signal for the counterbalance valve can be
obtained from the blank end or rod end of the cylinder. If derived from the rod end, the
pressure setting of the counterbalance valve equals the ratio of the load to the annulus area
of the piston. If derived from the blank end, the pressure etting equals the ratio of load to
the area of piston. This pressure is less and hence usually it has to be derived from the blank
end. This permits the cylinder to be forced downward when pressure is applied on the top.
The check valve is used to lift the cylinder up as the counterbalance valve is closed in
this direction. The directional control valve unloads the pump

Q.3. Explain with sketch Sequencing circuit .

As the name suggests the sequencing ciruit is used when two or more operations are to be
sequenced one after another, means the second operation should not start until the first
operation is not completed. This is needed in lot of applications like automation and
processing.The sequencing circuits can be travel dependent or pressure dependent, means
the next circuit gets oil when either the first circuit completes the travel or the pressure
builds above certain level. Following circuit is Pressure dependent sequencing circuit
As shown in th diagram the first cylinder is operated first, when the piston of first
cylinder reaches its end point, the pressure starts building, when the pressure builds to
the set point of sequence control valve, the valve opens and the oil is supplied to the
next cylinder.

Q.4. Explain with sketch Synchronizing circuit .

A synchronizing circuit is used when we need the synchronized movement of two or more
cylinders(or motors). Means we need that the both cylinders move exactly at same time and
at same speed. This is required in several applications. Synchronization can be achieved by
mechanical means of coupling also. The following diagram depicts the synchronizing circuit

with the use of flow dividers. Flow dividing valves can be used effectively to obtain the
synchronized motion. As shown in fig below flow dividing valves divide the flow into two
equal parts
irrespective of load. One point should noted that flow dividing valve synchronize extension
stroke only (in case of circuit diagram shown),if synchronization is required in the return
stroke also, then additional flow divider in top line must be installed.

`
Q.5. Explain with sketch two pump unloading
circuit .
A two pump unloading circuit is used in situation where some part of the piston travel is
required at high speed and low pressure and some small part is required at High pressure
and low speed. For such purpose it is uneconomical to use a very high pressure and high
volume pump. Instead the unloading circuit is used which uses two pumps for two purposes.
When the motion is required with less force(pressure) both of the pumps discharge in the
cylinder, and when the motion is required with high force(pressure) only the high pressure
pump discharges to the cylinder and low pressure pump returns back oil to tank through
unloading valve. Application: This circuit finds application in machine tools like punching
machine and other cutting machines.

Q.1. Explain with sketch Meter in Circuit and explain its

working?
Ans : The fig.below illustrates the circuit connections of a meter-in circuit, in which the flow
control valve is placed in the primary line, directly before
the load. Following pressure measures are taken at three different points. In meter-in-circuit
speed control is achieved by changing the
flow adjustment of the flow control valve, which controls the oil going to the head end of
cylinder. It should be noted that flow
control in given circuit is achieved in forward direction only i.e. in return stroke the return
flow from head of cylinder bypasses through check valve.

Advantages of Meter-in-circuit :

The chief advantage of meter-in circuit is that the cylinder undertakes one-sided pressure
with a value corresponding to the real load. The relatively small friction (due to pressure on
one side, decided by load) of the piston sealing ensures its long life. Uniform motion of the
piston rod even at very slow speed.
Flow rate estimation is made based on the large piston area, which is significant advantage
when very small piston rod speeds are to be achieved.

Disadvantage of meter-in circuit :The major disadvantage of this circuit lies in the fact
that there is no pressure on the piston rod side of cylinder, due to this the load actuated by
the piston rod is not held firmly in position. This means that in case of "Pulling” type loads if
the load suddenly collapses, the piston rod
shoots forward causing an uncontrolled shift. Special counter balance measures are to be
taken if above circuit is to be used for such applications.

Applications of meter-in circuit :

Meters in circuits are generally used when the load characteristics are constant and
positive. If the load is erratic or negative, the actuator will have jerky motion. Hence, meter-
in circuits are ideally applied on surface grinder, milling machines etc.

Q.2. Explain with sketch Meter Out Circuit and

explain its working?
Ans : The Circuit diagram below illustrates the circuit connections of a meter-out circuit, in
which the flow control valve is connected in the secondary line, directly
after the load. The following measures of pressure are taken at various pressure gauges.

Pressure
gauge P1 : Indicates the Pmax as set by the pressure relief valve. This pressure is formed on
the left side volume of the cylinder, irrespective of the load; hence sealing in this side is
always subjected to maximum pressure.
Pressure gauge P2
: Indicates the pressure P2, which is determined by the difference between pressure Pmax
and the load pressure. This difference depends on

the ratio of the two-piston areas.

Pressure gauge P3 :Pressure in the return stroke is always equal to 0 . In a meter-out-circuit

speed control is achieved by changing the flow adjustment of the flow control valve, which
controls the flow coming out

from the piston rod end of cylinder. Here also it should be noted that in a given circuit, flow
control is in forward direction only i.e. in return stroke the flow of pump to the piston rod
end of cylinder is bypassed through check valve.
Advantage of meter-out circuit : The load is always under pressure from both sides i.e.
it is counter balanced.Even when the load changes direction (e.g. starts pulling). No
uncontrolled jerk motion occurs.

Disadvantages of meter-out circuit : The left side of the cylinder is always under
maximum pressure even with a minimum load. Due to continued pressure on both sides,
there is more friction and less seal life.

Applications : Meter-out type circuits are found successful in operations like drilling,
boring, reaming etc, where the drills and mills passing through the work piece often tend to
drag the entire tool unit foreword, in such situation meter-out circuit is the best solution.
Q.3. Explain with sketch Bleed-Off Circuit and
explain its working
Ans: This is the third basic circuit, which controls neither the flow going to the actuator not
flow returning from the actuator but controls the diverted part of fluid to control the flow. In
this type of circuit flow control valves are placed in the by-pass line. The cylinder speed in
this case is determined by the difference between the pump deliver flow and the flow being
directed to the tank
through the flow control valve. The bleed-off valve may be in the

pressure line or in the cylinder line.

Advantage of bleed-off circuit : Unlike in the meter-in and meter-out circuit there is
no excess flow going through the pressure relief valve, hence the system ismore efficient and
energy saving as well the hydraulic fluid is not heated due to flow through relief valve.

Disadvantages of bleed-off circuit : Bleeds off circuits provide less accuracy in speed
control because in these circuits metered flow goes to tank rather than to cylinder. In such
type of circuits an individual pump should power each cylinder. A bleed-off circuit is not
sensitive enough to compensate for very small flow such as those encountered in precise
boring operation

Applications :Bleeds off circuits are applied where pressure is reasonably constant and
precise speed control is not the prime requirement. These circuits are widely used in
broaching
machines, shapers, planers etc., where a large quantity of fluid is to be used, and small
percentage is by passed.
Maintenance of hydraulic and
pneumatic system
Maintenance of Hydraulic system
Most of the hydraulic systems are designed to have very minimum or no maintenance
required during its use. But with the passage of time the seals worn out due to friction,
pumps lose their efficiency, hose pipes lose their flexibility and
oil goes on becoming unusable due to decomposition. So the hydraulic system needs to be
repaired to restore it to the original state. Maintenance is carried out at different levels such
as routine check-ups, weekly/monthly or Annual
maintenance.

A. Operator tasks { Daily operation }

* Visual inspection of all components for leakage or damage

* Visual examination of fluid level in reservoir and fluid condition

*Visual check of operating pressure, filter conditions.

* Check for unusual sound and proper operation.

B. Periodic Maintenance (Weekly or monthly)

*Check fixing of all units

*Check pump noise level and pressure levels

*Check actuators for damage wear of seals etc.

*Check hose connections for leakages.

C. Annual Maintenance

* Empty fluid reservoir and check fluid condition.

* Clean reservoir internally and externally and examine for rust

* Examine electric motor

* Examine all hoses, pipe works and fittings for damage,wear and leakages.

* Check or replace filtering elements if required.

*Clean filter bowl

* Check all seals of pumps and cylinders and replace if required.

List any four causes of Hydraulic system breakdown.
Ans : Following are the common cause of hydraulic system breakdown

1. Inadequate supply of oil in the reservoir

2. Clogged or dirty oil filters

3. Leaking seals

4. Loose inlet lines that cause the pump to take in air.

5. Sticky valves which do not move easily.