Axial piston pumps are key components in hydraulic systems used for industrial applications to extract oil from boreholes. Based on various experimental studies, such a pump has been developed. We have focused on the drive section of the pumping unit. Due to a number of geometrical constraints and demanding operating conditions, the discussed pump has a customised structure where the pump pistons and the thrust plate are in direct contact. The contact pair was closely examined and the contact pressure and sliding velocity in contact were monitored. In this way, we were able to calculate the wear coefficient, which is used to determine the optimum design of the piston. Numerical analysis was performed in the chosen software environment MSC Adams. Different pump piston designs were produced, where the size and position of the contact surface was varied. Experimental measurements using a high-speed camera were also performed to verify the simulation. This allowed us to confirm the correctness of the numerical analyses performed. By monitoring the wear coefficient, we then found the optimum design of the piston to ensure reliable pump performance and minimise wear at the observed critical point, which has a positive impact on the service life of the pump.
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