Introduction to the Production Process of Hydraulic Parts

Hydraulics are used in a wide range of heavy equipment, such as construction machinery and cars. Their low cost and ability to generate a high amount of power make them a popular choice.

They transmit a great deal of power through small tubes and hoses without the use of gears or shafts, which can cause significant losses. They are also safer to use, as they don’t create sparks.

Design

Design for hydraulic parts is a very complex process, involving consideration of multiple factors that will influence the overall performance of the part. These factors include materials, coatings, seals and other specialist parts that will need to be used.

Safety must be a priority in hydraulic system design. Components, such as fluid filters, need to be located in an accessible place so routine maintenance can be performed safely and efficiently.

Positioning of monitoring devices and service ports is also critical to maintenance-savings with precision casting parts. On mobile applications, it is important to know how high and low the unit can be mounted, so that a suction port is still submerged when the vehicle is in a vehicle-tilted or low-level position.

Pressure control valves are another key component in a hydraulic system. They control the flow of oil through the circuit to regulate movement speed.

Material selection

Hydraulic hoses and fittings are subject to high pressures and must be able to withstand them. This means selecting the correct material for both a fitting and a tube or hose.

Fittings come in various materials including aluminum, stainless steel and carbon steel for precision metal parts. PDI's stainless steel adapters undergo passivation to remove microscopic foreign particles, making them suitable for any application where cleanliness is a concern.

Stainless steel and carbon steel are also corrosion resistant, meaning they can withstand the harsh conditions of hydraulic systems and their environment. This type of fitting is a common choice for heavy equipment and industrial applications.

The selection of a hydraulic cylinder material depends on a number of factors, including the intended application, the required duty level and cost. This can be difficult, as a wrong material can result in reduced performance and even premature failure. Fortunately, RAM's engineering team is well versed in the selection of hydraulic cylinders for different duty levels.

Machining

The machining process is used to shape parts and components from metals, plastics, or other materials. It can add holes, remove burrs, and finish shaping a product.

Hydraulic parts may need to be shaped into various forms and sizes with a variety of tolerances in order to fit their specific applications. These parts must be made with precision and with the least amount of waste.

The machining process for hydraulic parts can range from simple cutting operations like parting off a tube stock to more complicated internal turning and finishing. Each operation requires a different tool and slightly differing speed and feed settings.

Assembly

Assembling hydraulic parts is one of the most time-consuming, labor-intensive tasks. The assembly process can also be a source of safety issues.

To solve these problems, OEMs are continually seeking manufacturing improvements and efficiencies with alloy steel. They seek to reduce production line rework and time loss, particularly in difficult-to-work areas such as the hose and tube assemblies.

Hydraulic plug-in connections are an excellent example of a technology that can improve installation time and efficiency. As an alternative to traditional nipple-and-coupling connections, hydraulic plug-in connections are installed by production line operators at a step where they have more room to work.

Once the WEO nipple and the appropriate WEO coupling or cartridge have been installed, they are held in place with the assembly stop clip attached. A simple pull test is then performed to verify the connection has been made. This method reduces the risk of failure and helps extend the service life of a hose and its related components.