Most of us in the world rely on hydraulics to drive many of the different machines and larger electronics we use, from pump to cylinder to actuator to valve, and the hydraulic system is responsible for controlling various electronic devices.
But as the industry develops, more modern technologies are needed to further advance hydraulic technology. Entering metal 3D printing not only has better technology, but it also allows designers and engineers around the world to create types of parts that were previously impossible. Hydraulic components can also be printed in small batches in 3D, often with unique features. All the benefits of 3D printing can be achieved from low cost, easy to create (and able to make changes), increasing productivity and speeding up manufacturing. The use of 3D printers in the field can dramatically change the production method and time-cycle framework, making it easy for people to understand why many people see this technology as a new revolution in the industry.
3D printed hydraulic components can be printed in 3D with a variety of materials, including:
Stainless steel AISI 304
Stainless steel AISI 316L
aluminum
titanium
Inconel Nickel Alloy (718)
Aidro, based in northern Italy, is at the forefront of metal 3D printing manufacturing hydraulic components. Managing Director Alberto Tacconelli said that their most suitable type of 3D printing is powder bed fusion. This is mainly used in direct metal laser sintering (DMLS) and selective laser melting (SLM) processes.
3D printing hydraulic valve block
For those who want to know if hydraulic metal 3D printing is right, Tacconelli recommends this technique if you want to print in small quantities, especially on-demand parts. If you rely heavily on prototyping or want to do more, 3D printing lets you create your own designs on the spot instead of waiting for third-party delivery. 3D printing also lets you choose from a wider range of metal materials. In the case of Aidro's metal 3D printing, Tacconelli said that they usually use aluminum and stainless steel. He also found that these materials are the same, even better than bar metals.
Tacconelli said: "With a good design approach, we can 3D print a hydraulic manifold that can withstand the peak pressure of the system without any problems. "We can increase the wall thickness and change the finite element analysis to indicate the channel shape of the potential failure. .
In addition to the 3D print manifold and testing at the Aidro Hydraulic Additive Manufacturing Solutions Center (SCAMH), they further expanded their component evaluation with the support of experts from the Polytechnic of Milan.
Tacconelli said: "After careful evaluation, we chose the direct metal laser sintering process to ensure higher accuracy and smoother surface finish in the case of hydraulic products.
Some examples of Aidro's hydraulic components for 3D printing on metal are as follows:
Stainless steel hydraulic valve block controls single-acting cylinders - internal channels are optimized for better flow and lower pressure loss, eliminating external leakage problems.
Improved stackable hydraulic valve - 3D printed stainless steel with a 60% reduction in weight, the structural wall is still strong compared to conventionally manufactured parts.
Hydraulic manifold used in agricultural machinery - Double acting cylinders are driven by two solenoid valves and two pilot operated check valves. With metal 3D printing, it is half the size of a traditional printer and 75% lighter.
Spool with new hole form - This new design replaces the typical round hole, allowing for greater oil flow and less pressure drop.
The image below allows for comparison of traditional Aidro manifolds with their 3D printed versions.
“This manifold is exactly the same as his predecessor: it controls a double-acting cylinder with two solenoid valves and two pilot-operated check valves. The Aidro team said: “A new solution compared to traditional manifolds. It achieved 75% weight reduction and half the size.
Aidro was founded in 1982 by hydraulic engineer Paolo Tirelli. Today, they use metal 3D printing to create custom designs with complex geometries, lightweight components and rapid prototyping. Their SCAMH provides a factory base where engineers can create new components specifically designed to meet the needs of industry customers, including design, production, testing, measurement, CNC machining and any post-processing. Aidro uses an EOS 3D printer for direct metal laser sintering.
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