Additive manufacturing has garnered significant attention due to its ability to replace conventional casting methods, resulting in cost reduction while meeting the increased demands for performance and cost-effectiveness in hydraulic valve bodies within the industry. Binder jet print (BJP), an additive manufacturing technique applicable to metal materials, presents new opportunities for innovating valve system production methods. This approach also allows for the redesign of electro-hydraulic systems traditionally limited by casting processes. Conventional methods often struggle to fabricate multifunctional parts without compromising functional performance or requiring additional supporting structures for manufacturability. However, the advancement of additive manufacturing technologies enables integrated actuator design and manufacturing, liberating them from these conventional constraints. These technologies facilitate the achievement of enhanced performance and multifunctional requirements for actuators, merging design and manufacturing into a cohesive domain where material and structure considerations are integrated.
In this research, we propose a compact valve system supporting body structure, considering material properties, functionality, limitations of binder jet print, dimensions, and manufacturing shrinkage. Binder jet print offers the possibility of replacing two die-casting parts with a single additive manufacturing part, necessitating the rearrangement of the possible spacer plate. Additionally, spool valves and pilot solenoids are redesigned to fit the new valve body housing. To streamline the assembly process and mitigate the drawbacks of BJP technology, spool valve sleeves are innovatively introduced into the transmission valve body design. The newly designed spool valves, assembled in the BJP valve body, aim to deliver equal or superior static response performance. This research also discusses special designs for additional components such as pressurized vents, check ball valves, and mounting parts.
This study represents a pioneering attempt to apply binder jet print to the complex industrial valve body system, with the goal of redesigning a lighter, smaller, and more cost-effective valve body. The valve actuator supporting shell is redesigned for one-step molding, and the hydraulic path is reconfigured while preserving functionality. Material considerations for the valve actuator supporting shell are addressed to mitigate deformation caused by post-processing, which may lead to the leakage issues arising from the porosity of the valve body shell. By integrating all orifices into spool valve sleeves, we achieve the same or improved pressure drop control.
Moreover, the application of binder jet print in valve body manufacturing provides an opportunity to explore new material compositions and structural designs that were previously infeasible with traditional casting methods. This flexibility allows for the incorporation of advanced features such as optimized fluid flow channels, enhanced thermal management, and reduced weight, all of which contribute to the overall efficiency and performance of the hydraulic system. The integration of these features is critical for meeting the demanding operational requirements of modern industrial applications, where reliability and precision are paramount.
To validate the feasibility and advantages of the binder jet print valve body, this research includes a comprehensive comparative analysis of the static response performance. Additionally, we explore the potential for further enhancements in valve body design through iterative testing and optimization, paving the way for future advancements in the field of hydraulic valve systems.
In conclusion, this research demonstrates the significant potential of binder jet print as an innovative manufacturing method for hydraulic valve bodies. By addressing the limitations of conventional casting and offering new design possibilities, binder jet print stands to revolutionize the production of hydraulic components, leading to more efficient, cost-effective, and high-performance systems. This work lays the foundation for future studies and applications of additive manufacturing in the industrial sector, highlighting the transformative impact of this technology on traditional manufacturing processes.
