Failure prediction in an axial piston pump

Abstract

This research is about the analysis of internal leakage occurs in the axial piston pumps particularly the impact of varying annular gap sizes between the piston and cylinder on pump performance. A mathematical model is developed using the Conservation of momentum (Navier–Stokes) and Conservation of mass (continuity Equation) to identify leakage flow characteristics, calculating for both pressure-driven (Poiseuille) and shear-driven (Couette) flow components. Controlled clearances of 50 μm, 80 μm, 100 μm and 180 μm were introduced to simulate wear, and the theoretical predictions were validated through experimental measurements. The study reveals that pressure-driven flow is the primary contributor to leakage, while shear-driven flow becomes significant at higher operating speeds. Sensitivity analysis of the swashplate angle further clarifies its role in displacement control. The model demonstrates high accuracy in predicting discharge and leakage behavior by early detection of wear and enabling effective predictive maintenance. This work contributes to enhancing the efficiency, reliability and operational life of hydraulic systems employing axial piston pumps.