AM's additive manufacturing and design offers the advantages of a hydraulic system for traditional manufacturing processes

Industrial users continue to use additive manufacturing, involving aerospace, medical, manufacturing and many other industries. In a recent case study, engineering firm GKN demonstrated how AM's additive manufacturing and design can provide the advantages of a hydraulic system for traditional manufacturing processes.

In the case study, GKN studied how to redesign the interior of AM's existing hydraulic block to provide benefits and enable manufacturers to overcome the technical barriers specific to traditional processes, including internal channel leakage, loss of efficiency, and more.

Traditional restrictions

The hydraulic block plays an important role in the hydraulic system. The components themselves are usually similar to external blocks, but they contain complex internal channels that help control oil distribution in large machines such as agricultural or construction vehicles.

Traditionally, hydraulic blocks have been manufactured using a subtractive machining process, which means that they start with solid steel blocks, which are milled and drilled to form internal passages. As GKN explained on his blog: “First drill a hole from above and then drill a hole from below. Finally, the two holes are connected horizontally. Then the thread must be cut. To prevent oil from escaping from the side, use the belt There are threads for the grub screws to close the horizontal connection."

In addition to generating high costs, the use of a subtractive process creates a series of problems in the final part, resulting in inefficient oil flow. First, the sharp edges in the channels created by the borehole create burrs that cannot be removed. These joint areas can also cause "large losses and inefficiencies when oil flows through them under high pressure."

Other risks listed by GKN include the formation of a dirt reservoir that may cause a malfunction, a leak in an adjacent passage, and a decrease in the OEE of the hydraulic system when the hydraulic block fails and must be replaced.

Redesigning the hydraulic system

When redesigning the hydraulic block for additive manufacturing, the GKN ensures that the block passage hole structure is identical to the original design - making it adaptable to existing hydraulic systems.

The redesign process enables the team to create lighter parts and achieve better oil flow. After printing the hydraulic block, GKN found many other significant advantages. First, the weight reduction of 3D printing hydraulic blocks is as high as 80% (from 30 kg to 5.5 kg), which means lower material costs and easier operator operation.

Second, the redesigned section eliminates dead or sharp corners and reduces the risk of dirt collection. Also, the oil flow through the block is further optimized by getting rid of sharp corners and forming a smooth passage.

3D printing blocks can also be redesigned to include more complex channels. As GKN explains: “With more complex hydraulic blocks, the length of the oil path can be adjusted to each other. The longer the oil passage, the more friction and loss of the wall. The shorter passage means less friction and less leakage. Risk.” It added, “In the future, the block will be able to further adapt to faster reactions, more stability and higher energy efficiency.”

From a production point of view, additive manufacturing also provides greater freedom for GKN to adjust and adjust the design of the hydraulic block. It's worth noting that this freedom also requires companies to not have to change tools for every design update, significantly reducing manufacturing costs.