Analytical modeling and experimental verification of churning torque for cam guide rails of 2D piston pump

For 2D piston pump the churning torque of its cam guide rails at high speed is one of the main sources of mechanical efficiency loss. To conveniently calculate the churning torque and also provide guidance for future optimization of churning torque reduction, an accurate analytical model of constant acceleration and constant deceleration cam guide rail assembly of the stacked-rollers 2D piston pump is established, where the whole churning torque is divided into the peripheral churning torque, the pushing flow churning torque, and the end face churning torque. Then the analytical model is verified by CFD simulation preliminarily. Analytical modeling shows that at 16,000 rpm, the churning torque reaches about 0.826 N m, where the peripheral churning torque, the pushing flow churning torque, and the end face churning torque account for about 55.4%, 37.3%, and 7.3% of the total torque respectively, indicating that the structural parameters related to the pushing flow torque should be optimized with first priority at high rotational speed. Finally, the churning torque at 1000–16,000 rpm was experimentally measured and the influence of oil temperature was considered. The experimental results are in good agreement with the results of analytical modeling and CFD simulation, thus verifying the correctness of the proposed analytical model.