Experimental and dimensional characterization of a prototype piston-cylinder unit and validation using finite element analysis (FEA)

A prototype piston-cylinder unit, covering a pressure range of 0.5–35 MPa in the hydraulic mode, and its assembly was designed and manufactured. The effective area and the elastic distortion coefficient (lambda) of the piston-cylinder unit was determined both experimentally using cross-floating method and dimensionally and validated using finite element analysis. Pressure distributions and gap profiles along the clearance between piston and cylinder were determined using elastic distortions of piston and cylinder. In this study, a short summary for the design and the manufacturing processes of the device was explained. Results presented a good agreement between experimental and analytical value of the effective area as an order of 8 ppm difference and the 3% on the lambda.