Volumetric Efficiency Prediction of External Gear Pumps Using a Leakage Model Based on Dynamic Clearances

External gear pumps are widely used in industrial hydraulic systems, but their volumetric efficiency can deteriorate significantly because of internal leakage, especially under high-pressure operating conditions. Conventional lumped parameter models typically assume fixed clearances and therefore cannot accurately capture the leakage behavior associated with pressure-induced deformation and wear. In this study, a dynamic clearance model for an external gear pump is developed and experimentally validated. Radial and axial clearances are measured in situ using eddy-current gap sensors over a range of operating conditions, and empirical correlation equations are identified as functions of pressure and rotational speed. These correlations are embedded into a tooth-space-volume-based lumped parameter model so that the leakage flow is updated at each time step according to the instantaneous dynamic clearances. The proposed model is validated against experimental measurements of volumetric efficiency obtained from a dedicated test bench. At 800 rev/min, the average prediction error of volumetric efficiency is reduced to 1.98% with the proposed dynamic clearance model, compared with 9.43% for a nominal static-clearance model and 3.35% for a model considering only static wear. These results demonstrate that explicitly accounting for dynamic clearance variations significantly improves the predictive accuracy of volumetric efficiency, and the proposed model can be used as a design tool for optimizing leakage paths and enhancing the energy efficiency of external gear pumps.