This research examines different techniques and proposes a Computational Fluid Dynamics (CFD) model as a robust tool for flow characterization of load leveling valves. The load leveling valve is a critical component of an air suspension system since it manages air spring pressure, a key function that directly impacts vehicle dynamic performance in addition to maintaining a static ride height. Efficiency of operation of a load leveling valve is established by its flow characteristics, a metric useful in determining suitability of the valve for application in a truck-suspension configuration and for comparison among similar products. The disk-slot type load leveling valve was chosen as the subject of this study due to its popularity in the heavy truck industry. Three distinct methods are presented to model and evaluate flow characteristics of a disk-slot valve. First is a theoretical formulation based on gas dynamic behavior through an orifice; second is an experimental technique in which a full pneumatic apparatus is used to collect instantaneous pressure data to estimate air discharge; and third is a CFD approach. Significant discrepancies observed between theoretically estimated results and experimental data suggest that the theoretical model is incapable of accurately capturing losses that occur during air flow. These variations diminish as the magnitude of discharge coefficient is altered.

A detailed CFD model is submitted as an effective tool for load leveling valve flow characterization/analysis. This model overcomes the deficiencies of the theoretical model and improves the accuracy of simulations. A 2-D axisymmetric approximation of the real fluid domain is analyzed for flow characteristics using a Realizable k-ϵ turbulence model, scalable wall functions, and a pressure-based coupled algorithm with a second order discretization function. The CFD-generated results were observed to be in agreement with the experimental findings. CFD is found to be advantageous in the evaluation of flow characteristics as it furnishes precise data without the need to experimentally evaluate a physical model/prototype of the valve, thereby benefitting suspension engineers involved in the development and testing of load leveling valve designs. This document concludes with a sample case study which uses CFD to characterize flow in a modified disk-slot load leveling valve, and discusses the results in light of application on a heavy truck.