Hydraulic Cylinder Failure Analysis and Redesign

This solved assignment focuses on hydraulic cylinder failure analysis and redesign. It delves into the causes of seal failures, including manufacturing defects, improper installation, and contamination. The student demonstrates their understanding of failure analysis methods and applies them to identify root causes. They present a redesigned system with documented solutions and sketches, highlighting their collaborative approach and adherence to project deadlines.

CE 2.1 Project Information
Name of the project: Design Evaluation, Failure Analysis & Re-design of a Hydraulic
cylinder sealing
Location of the project: (Please fill)
Project Duration: (Please fill)
Organization: (Please fill)
Role and Designation during the time: Team Member
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
The project work is based on design, analysis of failure and re-design of hydraulic
cylinder sealing. I conducted this study to identify the causes of failure of seals into the hydraulic
cylinder. Hydraulic cylinders are those which convert power into linear mechanical movement. I
also determined that causes of failures are manufacturing defects which are required to be
modified by performing failure analysis on existing model. I observed that the seals were failed
due to improper installation, contamination and expose to higher temperature in the
manufacturing process. I conducted this project to redesign the hydraulic cylinder sealing using
results of failure analysis. Proper analysis of failures eliminated the potential along with future
problems. I analyzed that seals were playing a key significant role into the hydraulic cylinders
which contain of fluid.

CE 2.2.2 Objectives developed for the project
Following are the project objectives:
 To identify cause of failure of seals into hydraulic cylinder
 To suggest modifications by doing failure analysis
 To redesign of hydraulic cylinder sealing based on failure analysis results
CE 2.2.3 My Area of work
In this project work, I was involved into identifying the root causes of failure of seals
into the hydraulic cylinder. I identified that manufacturing defects were the main causes of
failure. Then, I performed a failure analysis and optimized a root cause to implement in re-design
of hydraulic cylinder which increases life cycle of component. When carrying out this project, I
came to know that 25% of the mechanical equipments were failed due to design failure. I
followed some design considerations at the time of selecting seals for hydraulic cylinder. Based
on the application parameter, information gathered from the operating conditions of the cylinder,
I selected the right seal. While selecting the seals, I investigated some considerations such as
fluid pressure range, range of temperature of fluid along with cylinder, velocity of piston rode
stroke, type of fluid for efficiency of seal. I also investigated the hardware dimensions like rode,
bore dimension, seal groove, gaps and entire length of cylinder. I verified the application of
cylinder such as its installation and exposure to inconsiderate situations.

CE 2.2.4 Project Group
Figure 1: People involved in the project
CE 2.2.5 My responsibilities throughout the project
I involved into design of the mechanical products for the hydraulic cylinder and system
by developing and analyzing the failures. I evaluated the mechanical systems by conducting
research programs and applied of principles of failure analysis. I confirmed the capabilities of
system by designing a feasibility study on hydraulic cylinder. I maintained technical knowledge
by attending of the educational workshop and reviewing the specialized publications. I
contributed towards team efforts by accomplishment of related results. While performing the
failure analysis, I maintained and modified equipments to make sure about its safe and reliability.

CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
I inspected the hydraulic cylinder after performing the failure analysis which provided
indications of root causes of failure. All seals were inspected for changes into appearance as
compared to new seals. I performed the failure analysis to identify the top most failures.
Improper installation is main causes of failures of hydraulic seals. I observed the cleanliness,
protection of seal from cuts and lubrication during installation of seal. I provided a solution to
this problem by taking reasonable care while assembling. Contamination of hydraulic system
was also a factor which is caused by dirt, dust, internal contamination from circulation of metal
chips and other system components. I indicated the contamination by scored rod, cylinder bore
surfaces with leakages. I observed the chemical breakdown of the seal materials and there was a
change into hydraulic system fluid. Breakdown of chemical was resulted to loss of seal lip
interface and excessive swelling. Degradation of heat was suspected when there was failed of
seal. I inspected that heat degradation resulted into loss of seal lip effectiveness throughout
compression set and loss of seal materials.
Figure 2: Diagram of Hydraulic Cylinder

I determined that hydraulic cylinder was being actuated by the hydraulic fluid at higher
pressure. Failure of the cylinder caused explosion and ejection of higher velocity of oil. I took
precautions to design the hydraulic cylinder after analyzing the possible failures. I analyzed that
hydraulic system comprised of cylinder barrel where a piston is linked with the piston rod moves
back as well as forth. This piston consisted of seals. Those piston rods are available in length that
is cut to outfit with application.
Design of cylinder tube:
While designing of the cylinder tube, I calculated the inside diameter along with
thickness of wall. Both of these factors were based on capacity of cylinder as well as working
pressure. I decided that the capacity of cylinder was based on what are the purposes it should be
used. Its capacity is based on size, thickness along with mechanical property of the materials. I
set the working pressure to minimum of 700Bar and more. It was based on some of the factors:
size off cylinder and type of valves as well as pump into the system.
CE 2.3.2 Engineering Knowledge and Skills applied in the project
I have key knowledge to use of failure analysis method to determine reliability of
hydraulic system and effect of failure on the hydraulic cylinder seals. I have both theoretical as
well as practical aspects of designing the hydraulic cylinder. I have hard skills to understand the
failures and causes of hydraulic cylinder. I have soft skills into analytical thinking along with
good communicational skills to interact with the team member.
CE 2.3.3 Accomplishment and task performed
Mechanical materials for cylindrical tube, piston rod along with end connections are
delivered with inspection of certificate type 3.1 as per latest edition of ISO 10474. In order to

measure thickness of material of 6mm, I performed an impact testing to carry out agreed
temperature. I dimensioned the cylindrical tube, piston rods with pressure into the rod based on
standards. I measured the value of wall thickness tube as well as piston rod with pressure into the
rod by following formula:
t= p . R
10−σt . e−0.5 . p +c
Where, t = required thickness of wall; p = design pressure; σt = allowable stress; e =
welding factor; R = internal radius of cylinder tube and c = corrosion allowance.
CE 2.3.4 Identified issues and their solutions
CE 2.3.4.1 Issues
There are issues regarding the hydraulic pressure of cylinder. It is the pressure between
sealing element and guideline components causes seal deformation beyond the pressure of
system. The system is on danger when there are exceeded of air limit on the normal pressure.
Under the limit saturation related to vacuum created air from the system oil with evaporation
along with seal is damaged.
CE 2.3.4.2 Solutions
When there is need of problematic cylinder seals, then there is need of inspection. It is
carried out to design the seal while removing of seal from the cylinder. Replacement of seal
elements should solve this problem.

CE 2.3.5 Plan to produce creative and innovative work
I designed innovative hydraulic solutions for most of challenging applications. I
identified that redesign of the cylinder is reliable means to accomplish the efficiency. Failure
analysis reflects a difference into energy efficiency, breakdown as well as increase into good
production. New and innovative components aimed to improve durability as well as function of
the components which made changes into engineering design.
CE 2.3.6 Collaborative work
I had completed the project work on scheduled time and budget. I followed a team
working approach to conduct this project work. I communicate with one of my team members,
project lead and project supervisor to discuss requirements of the project. With help of the team
member and project leader, I documented with plots and sketches of the hydraulic cylinder
sealing for better re-design than before.
CE 2.4 Project Review
CE 2.4.1 Project overview
Hydraulic cylinder used to provide unidirectional force throughout unidirectional stroke.
Those cylinders get power from pressurized hydraulic fluid that is oil. I identified that
manufacturing process defects, improper installation, exposure to high temperature and
contamination into the process are the main causes of failure into the hydraulic cylinder sealing.
Based on the results of failure analysis, I re-designed the hydraulic system.

CE 2.4.2 My contribution to work
I studied the problems in the hydraulic cylinder sealing and then input the finalized data
as input to perform the failure analysis. I performed a feasibility study to analyze the quality of
the system. I identified the different causes of seal failure and sorted the root cause failures
which are raised due to manufacturing process. I re-designed and re-evaluated each of the failure
causes into the hydraulic cylinder. Finally, I documented with plots and sketches and result the
study observation.