Effects of poppet cone angle on pressure relief valve performance using experimental and FSI analysis

Abstract

Pressure relief valves (PRVs) are crucial for the safe and efficient operation of a hydraulic system, where response time and sensitivity are the key performance factors. The present study investigates the impact of poppet cone angle on the PRV's performance using a fluid-structure interaction (FSI) framework. The framework incorporates Navier–Stokes equations based on the arbitrary Lagrangian–Eulerian (ALE) method, strongly coupled with the Lagrangian equilibrium equations of the structure, ensuring an accurate representation of the complex interactions. A partitioned implicit solution approach is implemented and further enhanced to address the coupled FSI problem effectively. Validation studies were performed using experimental data of flow visualization on two different poppets shaped PRV model, demonstrating close agreement between numerical predictions and experimental results. The study also explored the cavitation phenomenon for different cone-shaped geometries, shedding light on how poppet design influences the flow stability and performance. Analysis of the validated models of PRV includes pressure override, total fluid flow, and Von Mises stress. Intriguingly, the cone angle is found to significantly affect the fluid pressure distribution and flow rate at different port opening. A novel 3D graph illustrated the dynamic interplay between fluid flow reaction forces and static forces acting on the valve, emphasizing the critical role of poppet geometry in achieving optimal performance. This research underscores the importance of integrating design precision with computational analysis to operate the PRV with comparatively lesser cavitation pressure and faster response.