This article presents computational fluid dynamics (CFD) modeling of the flow processes at a certain specimen of an external gear pump. The purpose of the developed two-dimensional (2D) CFD model is to carry out a numerical study to obtain the main characteristics of the pump flow rate, especially the flow rate as a function of the pressure and the flow rate as a function of the time. A numerical study was carried out at forty-two different operating modes that were expressed as a variation of two parameters: rotational frequency (950–1450 min⁻¹) and pressure (5–150 bar). The validation of the numerical results was carried out through an experimental study. For this purpose, a laboratory experimental setup equipped with a modern data acquisition (DAQ) system was designed and implemented. It allows the gear pump to be tested at the same operating modes as the numerical study. A validation analysis was performed by comparing the numerical and experimental results using the average relative error index (FIT). A detailed description of the 2D CFD model development (CAD model, mesh, general settings, boundary conditions, etc.) is provided. Based on the 2D CFD model, an original methodology was proposed to take into account the influence of the discharge channels on the displacement volume of the pump by adjusting the face width of the gears. Despite the limitations of the simple 2D CFD model, which are discussed in this article, a very good match between numerical and experimental results is analyzed by calculating the FIT level, which is in the range of 93–97%.

The article presents an advanced two-dimensional (2D) computational fluid dynamics (CFD) model of an external gear pump which considers relief grooves. Relief grooves are limiting design features for the flow process of this type of pump, and their influence in existing studies is considered by a three-dimensional (3D) model only. The structural modification proposed by the authors is beyond the possibilities of real implementation, but it gives the possibility to precisely model the pump’s design features. In contrast to the existing studies (using 3D CFD), the proposed advanced 2D model requires significantly fewer computing resources. Numerical experiments were carried out using the 2D model at different pump operating modes depending on the rotation frequency (950–1450 min⁻¹) and pressure load (5–150 bar). The numerical results were validated by a real-world experiment for the same pump operating modes using an existing laboratory experimental setup. An analysis of the CFD model and real experiment results was carried out by determining a quantitative index of match (FIT), which varies in the range of 97.93–99.82%. This proves the performance of the proposed CFD model, which can be further used as a part of more complex hydraulic systems models.

Metal structures corrosion is a problem of global economic importance. Typically, the corrosion process runs slowly, which requires accelerated methods for corrosion behaviour examination. The conditions when accelerated methods are used differ from the real ones, which affects the results obtained. One of the methods that relatively successfully reproduces corrosion in a natural atmosphere is included in the standard EN ISO 11130:2018 – Alternate immersion test in salt solution. Unlike other widespread methods, uneven corrosion occurs here, including spots and pits, which greatly affect the mechanical behaviour of the material. The commercial devices for such tests are quite expensive. This justifies the development and production of one’s own equipment as the one presented in this paper. The design, construction and production of a low-cost device are hereby described. The first results of the tests performed with this machine are also given. The corrosion rate of rods, 6 mm in diameter, from widely used steel grades – S235JR and S235JRC – was determined. The duration of the test was 42 days. The results were compared with those from another corrosion test method with the same duration – immersion in a solution of 3.5% NaCl.

The paper presents a numerical and experimental study of the radial gap influence on the external gear pump performance. The numerical study is performed with a two-dimensional (2D) computational fluid dynamics (CFD) model developed and advanced in previous authors’ works. The experimental study is carried out on a laboratory test bench. The presented numerical results are accurate in the entire operating range (500–3500 RPM) of the pump, which is confirmed by comparisons between the CFD results, experimental data, and manufacturer’s technical documentation. The comparative analysis shows that the differences obtained during the verifications are in the range of −6.44% to 2.48%. An original methodology has been developed that allows us to obtain the volumetric efficiency and overall efficiency characteristics as a function of the rotation frequency of the pump at different values of the radial gap, using the manufacturer’s data for the same characteristics at a nominal radial gap and the results of CFD simulations. The analysis of the numerical and experimental results shows that a gap size of 0.04 mm is close to the limit value for the investigated pump, if it is not operated at a rotational frequency above the nominal. The presented methodology can also be applied to other types of hydraulic displacement pumps in order to evaluate their performance in the wear process and to predict the maximum allowable value of a specific design parameter under different operating modes.

The mutual twisting of steel wires is widely used in construction, engineering, and everyday applications, as it is relatively easy to perform and imparts new and useful properties to the wires. Since the process involves large deformations and high stress levels, understanding the mechanical behavior of twisted pairs is essential for both their manufacturing and in-service performance. This study provides a detailed analysis of the stresses and deformations that arise during the twisting of two galvanized steel wires with a diameter of 4 mm. Comprehensive information is presented on the development and validation of a suitable finite element model, with emphasis on geometry definition, the selection of appropriate initial and boundary conditions, and the meshing strategy. Special attention is devoted to the material properties, which are obtained and processed based on original tensile and torsion tests. Both the maximum and residual stresses are investigated. It is found that, for small twist pitches, the equivalent stresses during twisting can exceed the material’s yield strength by a factor of two or more, posing a risk of failure. The residual equivalent stresses show complex spatial distributions that vary with pitch, yet their average magnitudes remain within a narrow range, indicating a consistent residual stress level across different twisting configurations.