Design of a Hydraulic Block for Additive Manufacturing

Abstract

This thesis is about design of a hydraulic block for additive manufacturing, which focuses on the current technology, quality and performance improvements based on available literature. Conventionally the hydraulic blocks were produced using machining. The fluid paths in blocks produced by machining are steps of straight path holes and upon change of direction the fluid loses some of its power. With additive manufacturing, however, smooth manifolds can be designed based on optimization of fluid paths to minimize the fluid pressure loss. It also allows different material selection. In this study, the advantages and disadvantages and challenges with conventional and additive manufacturing methods as well as hybrid methods are discussed. The challenges of manufacturing and improving the quality of the produced block in both small- and large-scale production are addressed. The manufacturing method selection is discussed, based on costs, quality, performance requirements and the scale of production. It turns out that large scale production has the potential of manufacturing higher quality products with much lower costs than in small production scale.