Hydraulic valve block manifolds are complex components in which many of the pipes come together and intersect. Traditionally, the cross manifold of the hydraulic manifold is machined by cross drilling. However, due to the limitation of machining angle, on the one hand, fluid efficiency cannot be optimized most efficiently. It is often necessary to add a plug inside the flow channel to adjust the flow rate. On the other hand, the machining process also faces the challenge of co-location precision.
We have introduced Renishaw's solution for hydraulic block optimization. Now, based on the hydraulic block that has been slimmed down by half the material volume, Renishaw has further optimized it to slim down to the end, and this time, it has lost half of the material. volume…
Before the new story begins, let's review together how the initial optimization of the hydraulic block is done:
Phase I: slimming half
Figure: First design iteration
The image shows a 90 degree vertical cross-over structure inside the fluid channel, and the fluid direction is bent 90 degrees, which is machined by cross-drilling and has a terminal plug in one section of the fluid block.
Figure: a 90 degree sharp turn of fluid
Computer fluid dynamics (VFD) analysis shows that some areas face small flow problems, while others face turbulence. In order to adjust the manifold, a further internal plug is required, but adds complexity and does not change the situation in which the fluid must pass a sharp turn. From a fluid mechanics point of view, there is much room for improvement in the traditionally designed hydraulic manifold design, but at the time we did not have the flexibility of 3D printing technology .
Figure: To solve the patency of the fluid on the left, the right figure adds a built-in plug
Selective laser melting additive manufacturing technology that produces products by melting metal powder layer by layer allows us to pre-optimize the flow path inside the design fluid while reducing unnecessary valve body weight.
Step 1: Extract the fluid path
The first step is to extract the fluid path, including those that are cross-drilled, which is different from traditional machining from a solid metal block. This step requires the traditional machining fluid not to pass through, but only for the hole that is drilled for processing needs. This part of the design was removed. Leave the pipes through which the fluid will pass, and the functional manifold. The final extracted design is shown on the right.
Figure: Extract the path through which the fluid on the left is drawn, and get the design on the right.
Step 2: Optimize the manifold
Now, we are beginning to reduce and simplify the fluid flow path without the design constraints of cross-drilling, and we can change the sharp angle to a circularly curved design to reduce turbulence. The image shows a flow path concept that determines flow separation and stagnation. Area.
Figure: Locally optimized manifold
Step 3: Determine wall thickness and support structure
Once the fluid path is optimized, we need to determine the wall thickness and support structure and use the finite element analysis (FEA) stress model to calculate and analyze the hydrodynamic pressure.
Figure: Further optimization for additive manufacturing
Finally, the support structure acts as a stand to hold the components together and serves as a build support and anchor during the build process.
Figure: 50% weight loss
This great example not only reduces the weight of the hydraulic valve body by 50%, but also improves the efficiency of fluid flow, avoids further assembly needs, and improves valve body performance and stability.
Phase II: Continue to slim down half
Figure: Secondary design iteration
The secondary design iteration takes into account that the valve blocks are used in series. If one of the valve blocks is broken, it needs to be disassembled and repaired separately. Therefore, these valve blocks need to be easily disassembled. Another consideration is the need to increase the stiffness of the part to avoid chattering of the valve block during finishing, so the material is replaced from aluminum alloy to stainless steel during the second design iteration.
The second iteration brings about a 79% reduction in material volume, and because the time required for additive manufacturing is largely determined by how much material needs to be melted, this allows the time for additive manufacturing to be greatly reduced, and the savings come from two sources: material resolution And processing time and processing cost savings.
Figure: 1 iteration and 2 iterations
Not only that, the performance of the valve block has been significantly improved, the flow efficiency has increased by 60%, and is compatible with existing designs. Due to the use of stronger materials, the probability of valve block failure is greatly reduced.
The next step of exploration may bring more fun, including the manifold design of integrated pipe joints to reduce part count and assembly costs, and additive manufacturing technology is providing a practical way to realize these explorations.
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