Evaluation of the flow forces on a direct (single stage) proportional valve by means of a computational fluid dynamic analysis

The aim of this paper is to investigate the fluid dynamic behaviour of a commercial hydraulic proportional valve in order to evaluate and justify its global performances and, in particular, to analyze the effects of some additional design features on the reduction of the force required to maintain the valve open. The proposed analysis has been performed by applying the commercial computational fluid dynamics (CFD) code, Fluent, to the solution of the three dimensional turbulent flow field through a circumferential sector of the entire valve for different spool strokes. The reliability of the employed modelization is demonstrated by the comparison between the computed flow rate curve and the corresponding experimental data provided by the manufacturer. With regard to the metering edge design, it is shown that the cylindrical hole provided on the top of the hemi-spherical notch to improve metering at small valve openings has no influence on the flow force balance. The presented results also demonstrate that compensation techniques based on an adequate spool profiling are effective in balancing the flow forces mainly at medium and large valve openings, thanks to the pressure difference on the compensation profile; which also results in an increased axial momentum at the inlet of the high pressure chamber. The benefits of its presence are amplified by the adoption of two grooves machined on the valve body, which modify the flow field so as both to increase the axial momentum at the inlet of the high pressure chamber and to reduce it at the outlet.