Additive Manufacturing in Hydraulics: Design Methodologies for Manifolds

Abstract

Additive Manufacturing (AM) has established itself as a promising technology in the field of hydraulics, offering new opportunities for the design and optimization of components [1].For converting classic designs into AM-compatible models, there are guidelines and methodologies available, including even specific approaches for manifolds [2].However, the guidelines are usually very vague and provide limited concrete design specifications.In addition to this challenge, the available software solutions for the rapid creation of asymmetrical or bionic geometries are quite limited.Although there is a variety of software solutions on the market for designing AM components, their functionalities are not tailored to the requirements of AM.While conventional computer-aided design (CAD) is based on 2D sketches evolving into volumetric bodies, there is an increasing demand for advanced software solutions that facilitate freeform spatial design and provide constructive guidelines to enhance flow-optimized designs.This paper compares and evaluates various software and design methodologies to assess their suitability for additively manufactured hydraulic components.In this paper we perform an analysis of the entire design process, including a comparison of pressure losses.The primary objective is to establish specific methodologies for the design of AM components.Results indicate significant shortcomings in conventional CAD software, which often limits designers' capabilities.To address these challenges, this study introduces an innovative design configurator implemented in the software Rhinoceros 3D® according to the approach of Biedermann [3].This configurator facilitates the automated creation of manifolds by adjusting channel geometries to minimize pressure losses in hydraulic channels.

Authors 5

1. Zita Tappeiner Aachen Institute for Fluid Power Drives and Systems

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University , Institute for Fluid Power Drives and Systems (ifas) , Campus- Boulevard 30 , 52074 Aachen

2. Moritz Nieder Aachen Institute for Fluid Power Drives and Systems

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University , Institute for Fluid Power Drives and Systems (ifas) , Campus- Boulevard 30 , 52074 Aachen

3. Robin Schulze Raestrup
4. Felix Spickenheier Aachen Institute for Fluid Power Drives and Systems

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University , Institute for Fluid Power Drives and Systems (ifas) , Campus- Boulevard 30 , 52074 Aachen

5. Prof. Katharina Schmitz Aachen Institute for Fluid Power Drives and Systems

   RWTH Aachen University

   Affiliation as printed

   RWTH Aachen University , Institute for Fluid Power Drives and Systems (ifas) , Campus- Boulevard 30 , 52074 Aachen