Cha pter No.1 Introduction 1 CHAPTER # O1 INTRODUCTION 1.1) Hydraulic fluid: Hydraulic fluids, also calledhydraulic liquids, are the medium by which power is transferred inhydraulic ma chinery. Common hydraulic fluids are based on mineral oilor water. Examples of equipment that might use hydraulic fluids include excavators and backhoes, hydraulic brakes, power steeringsystems, transmissions, garbage trucks, aircraft flight control systems, lifts, and industrial machinery. s like the ones mentioned above will work most efficiently if the hydraulic fl uid. Hydraulic syste m use d has ze ro com press ibi li ty. 1.1.1) Functions and properties: Th e p rim a ry fu nc ti on o f a hy d rau lic flu id is t o convey power. In use , h owe v er, there are o ther important functions of hydrauli c fluid such as prote ction of the hy draulic machine components. The table below lists the major functions of a hydraulic fluid and the properties of a fluid that affect its ability to perform that function. Table 1.1) Functions and prope rti e s of Brake Fl uids. Function Property Medium for power transfer and control Non compressible (high bulk modulus) Fast air release Low foaming tendency Low volatility Medium for heat transfer Good thermal capacity and conductivity Sealing Medium Adequate viscositya nd viscosity index She ar stability Lubricant Viscosity for film maintenance Low temperature fluidity Th ermal and oxida tiv e s ta b ilit y Hydrolytic sta bili ty / wa te r tolera nce
1.1) Hydraulic fluid:
Hydraulic fluids, also called hydraulic liquids, are the
medium by which power is
transferred in hydraulic machinery. Common hydraulic
fluids are based on mineral oil or
water. Examples of equipment that might use hydraulic fluids
include excavators and backhoes, hydraulic
brakes, power steering systems,
transmissions, garbage trucks, aircraft flight control
systems, lifts, and industrial
machinery. s like the ones mentioned above will work most
efficiently if the hydraulic
fluid. Hydraulic system used has zero compressibility.
1.1.1) Functions and properties:
The primary function of a hydraulic fluid is to convey power.
In use, however,
there are other important functions of hydraulic fluid such as
protection of the hydraulic
machine components. The table below lists the major functions of a
hydraulic fluid and
the properties of a fluid that affect its ability to perform that
function.
Table 1.1) Functions and properties of Brake Fluids.
Function Property
Fast air release
Low foaming tendency
Sealing Medium
Adequate viscosity and viscosity index
Shear stability
Low temperature fluidity
leakage
Biodegradability
1.1.2.1) Base stock:
The original hydraulic fluid, dating back to the time
of ancient Egypt, was water.
Beginning in the 1920s, mineral oil began to be used more
than water as a base stock
due to its inherent lubrication properties and ability to
be used at temperatures above
the boiling point of water. Today most hydraulic fluids
are based on mineral oil base
stocks.
Natural oils such as rapeseed (also
called canola oil) are used as base stocks for
fluids where biodegradability and renewable
sources are considered important.
Other base stocks are used for specialty applications, such as for
fire resistance
and extreme temperature applications. Some examples include:
glycol, esters,
organophosphate ester, polyalphaolefins, propylene glycol, and
silicone oils.
1.1.2.2) Other Components:
Hydraulic fluids can contain a wide range of chemical compounds,
including oils,
butanol, esters (e.g. phthalates, like
DEHP, and adipates, like
bis(2-ethylhexyl)
adipate), polyalkylene
glycols (PAG), organophosphate (e.g. tributylphosphate),
silicones,
inhibitors (incl acid scavengers),
anti-erosion additives, etc.
1.1.3) Trade names:
Arnica,
Tellus,
Durad,
Fyrquel,
Houghto-Safe,
Hydraunycoil,
1.2.1) Background:
One of the most important hydraulic applications on the modern
automobile is
the brake system. The first motor vehicle having hydraulic brake
system employed raw
hide seals and flexible hoses to transmit hydraulic pressure from
the master cylinder to
the cylinders on the front wheels.
Non-Petroleum hydraulic fluids which have no effect on rubber and
leather were used
in these systems. This selection set the precedent for the type of
brake fluids that still
exist today.
The earliest brake fluids were solution of sugar and water or
glycerin with water
or alcohol. However all of these fluids were unsuitable because
they caused corrosion
and gumming of brake parts. Rapid deterioration of the pistons and
cylinders resulted
in the leakage of the fluid. Leather seals were replaced by natural
rubber brake cups and
improved fluids of castor oils and alcohols replaced the older
fluids, but corrosion and
gum problems, although lessened, persisted due to formulation of
acidic oxidation and
hydrolysis of castor oil. The addition of cystic was found use full
as a partially effected
corrosion inhibitor for these fluids.
In order to keep up with the increase temperature demands of the
newer brake
system, higher alcohol such as butanol and diacetone alcohol
gradually supplanted the
ethanol and water type fluids.
Ethylene glycol monoethylene ether was the first glycol used in
brake fluids this
diluent started the trend towards the higher boiling points fluids.
The use non
crystalizing poly glycol lubricants made possible the preparation
of brake fluids capable
of operating at extremely low temperature. Fluids implying glycol
ethers such as cello
solve and carbitol (Diethylene glycol mono ethyl ether) as
diluents, with glycols as
lubricants, made it possible to operate at ambient temperatures
ranging from 125oF to -
40oF,
1.2.2) Definition:
Brake fluid is a type of hydraulic fluid
used in hydraulic brake and hydraulic
clutch applications
in automobiles, motorcycles, light trucks, and
some bicycles. It is used
to transfer force into pressure, and to amplify braking
force. It works because liquids are
5
not appreciably compressible in their natural state the
component molecules do not
have internal voids and the molecules pack together well, so bulk
forces are directly
transferred to compress the fluid's chemical bonds.
1.2.3) Classification:
Most brake fluids used today are glycol-ether based, but
mineral oil (Citroën liquid
hydraulique mineral (LHM) and silicone (DOT 5) based
fluids are also available.
1.2.4) Standard Specifications:
Brake fluids must meet certain requirements as defined by various
standards set
by organizations such as the SAE, or local government
equivalents. For example, most
brake fluid sold in North America is classified by the US
Department of
Transportation (DOT) under its own ratings such as "DOT
3" and "DOT 4". Their
classifications broadly reflect the concerns addressed by the SAE's
specifications, but
with local details - Alaska and the Azores
have different normal temperature and
humidity ranges to consider, for example; many countries defer
explicitly to the SAE
specifications, or simply refer to "best practice" which in
application would defer to SAE
standard.
Table 1.2) TYPICAL TECHNICAL PROPERTIES of Break-In Oil SAE 30) -
BRK
TYPICAL TECHNICAL PROPERTIES of Break-In Oil SAE 30) BRK SAE
30
Kinematic Viscosity at 100oC, cSt (ASTM D-445) 11.4
Kinematic Viscosity at 40oC, cSt (ASTM D-445) 91.6
Viscosity Index (ASTM D-2270) 112
Flash Point oC (oF) (ASTM D-92) 236 (457)
Fire Point oC (oF) (ASTM D-92) 254 (489)
Pour Point oC (oF) (ASTM D-97) -36 (-32)
Four-Ball Wear (ASTM D-4172)
Para 1 (40 kg, 75ºC, 1200 rpm, 1 hr), Scar, mm 0.45
High-Temperature/High-Shear Viscosity (ASTM D-5481 at 150ºC, 1.0
x
106 S-1), CP 3.5
Brake fluids must have certain characteristics and meet certain
quality standards
for the braking system to work properly.
1.2.5.1) Boiling point:
Brake fluid is subjected to very high temperatures, especially in
the wheel
cylinders of drum brakes and disk brake calipers. It must have
a high boiling point to
avoid vaporizing in the lines. This vaporization is a problem
because vapor is highly
compressible relative to liquid, and therefore negates the
hydraulic transfer of braking
force.
Quality standards refer to a brake fluid's "dry" and "wet" boiling
points. Wet
boiling point, which is usually much lower (although above most
normal service
temperatures), refers to the fluid's boiling point after absorbing
a certain amount of
moisture. This is several (single digit) percent, varying from
formulation to formulation.
Glycol-ether (DOT 3, 4, and 5.1) brake fluids
are hygroscopic (water absorbing), which
means they absorb moisture from the atmosphere under normal
humidity levels. Non-
hygroscopic fluids (e.g. silicone/DOT 5-based formulations),
are hydrophobic, and can
maintain an acceptable boiling point over the fluid's service life,
although at the cost of
potential phase separation/water pooling and freezing/boiling in
the system over time -
the main reason single phase hygroscopic fluids are used.
Table 1.3) Characteristics of common braking fluids:
Type Dry boiling point Wet boiling
point
Viscosity limit Primary constituent
DOT 2 190 oC (374 oF) 140 oC (284 oF) ? Castor
oil/alcohol
DOT 3 205 oC (401 oF) 140 oC (284 oF) 1500
mm2/s Glycol
Ether/Benzoate Ester
DOT 4 230 oC (446 oF) 155 oC (311 oF) 1800
mm2/s Glycol Ether/Borate
Ester
DOT 5 260 oC (500 oF) 180 oC (356oF) 900 mm2/s
Silicone
DOT 5.1 260 oC (500 oF) 180 oC (356 oF) 900
mm2/s Glycol Ether/Borate
Ester
1.2.5.2) Viscosity:
For reliable, consistent brake system operation, brake fluid must
maintain a
constant viscosity under a wide range of temperatures, including
extreme cold. This is
especially important in systems with an anti-lock braking
system (ABS), traction control, and
stability control (ESP), as these systems may use a valve with a
time-based approach,
rather than measuring pressure or volume to control the amount of
fluid transferred.
1.2.5.3) Corrosion:
Brake fluids must not corrode the metals used inside components
such as calipers,
wheel cylinders, master cylinders and ABS control valves. They must
also protect against
corrosion as moisture enters the system. Additives (corrosion
inhibitors) are added to
the base fluid to accomplish this.
The advantage of the Citroën LHM mineral oil based brake
fluid is the absence of
corrosion. Seals may wear out at high mileages but otherwise these
system have
exceptional longevity. It cannot be used as a substitute without
changing seals due to
incompatibility.
1.2.5.4) Compressibility:
Brake fluids must maintain a low level of compressibility that
remains low, even
with varying temperatures.
1.2.6) Service and maintenance:
Most automotive professionals agree that glycol-based brake fluid,
(DOT 3, DOT
4, and DOT 5.1) should be flushed, or changed, every 1 2 years
under non-racing
conditions. Many manufacturers also require periodic fluid
changes to ensure reliability
and safety. Once installed, moisture diffuses
into the fluid through brake hoses and
rubber seals and, eventually, the fluid will have to be replaced
when the water content
becomes too high. Electronic testers and test strips are
commercially available to
measure moisture content, however moisture test strips were taken
off the market
because they absorb moisture in the air before they can be used.
The corrosion inhibitors
also degrade over time. Degraded inhibitors cause corrosion in the
braking system. The
first metal to corrode is copper. You can determine when it is time
to replace brake fluid
8
when copper ions hit 200ppm. New fluid should always be stored in a
sealed container
to avoid moisture intrusion.
DOT 5 is silicone fluid and the above does not apply. Ideally,
silicone fluid should
be used only to fill non-ABS systems that have not been previously
filled with glycol
based fluid. Any system that has used glycol based fluid will
contain moisture; glycol
fluid disperses the moisture throughout the system and contains
corrosion inhibitors.
Silicone fluid does not allow moisture to enter the system, but
does not disperse any that
is already there, either. A system filled from dry with silicone
fluid does not require the
fluid to be changed at intervals, only when the system has been
disturbed for a
component repair or renewal. The United States armed forces have
standardized on
silicone brake fluid since the 1990s. Silicone fluid is used
extensively in cold climate,
particularly in Russia and Finland.
A small drop in brake fluid level in the master cylinder reservoir
can be "topped
up" but if the level consistently drops, the cause should be
investigated and repaired.
Brake fluid level in the master cylinder will drop as the linings
(pads or shoes) wear and
the calipers or wheel cylinders extend further to compensate.
Overspill from pushing
back pistons should be avoided, because glycol based fluid will
quickly lift or strip paints
and other coatings on contact (it can be removed by quickly washing
with water, not
wiping). Brake fluid level may also be low because of a leak, which
could result in a loss
of hydraulic pressure and consequently a significant loss of
braking ability. Modern cars
have redundant hydraulic circuits (two separate
circuits) to ensure against total
hydraulic failure.
1.2.7) Mixing and replacement:
Brake fluids with different DOT ratings cannot always be mixed. It
must be of the
same type, and at least the same rating. DOT 5.1 can replace DOT 4
and 3, DOT 4 can
replace DOT 3. DOT 5 should not be mixed with any of these as
mixing of glycol with
silicone fluid may cause corrosion because of trapped
moisture.
1.2.8.) Toxicity:
Brake fluid is toxic and combustible and can damage painted
surfaces.
Castor oil
Alcohol, usually butanol (red / crimson
fluid) or ethanol (yellow fluid)
b) Glycol-based DOT 3, 4, 5.1)
Alkyl ester
Aliphatic amine
Diethylene glycol