Component of Hydraulics, Arrangement having a Portion of the Component, and Method for Joining Together the Component

Abstract

A component of hydraulics, via which a pressure medium connection or flow can be controlled, includes a first portion which is additively manufactured at least in part and on which there is formed at least one control geometry for controlling the pressure medium connection or flow, and a second portion joined thereto.

Claims

1. A component of hydraulics configured for controlling a pressure medium connection or pressure medium flow, the component comprising: a first portion which is additively manufactured at least in part and on which at least one control geometry is formed, the at least one control geometry configured for controlling the pressure medium connection or pressure medium flow; and a second portion which is joined to the first portion by friction welding.

2. The component according to claim 1, wherein the component is configured as a housing, a housing portion, or an element configured to be received in the housing and that is movable in the housing.

3. The component according to claim 1, wherein the first portion includes a clamping region configured for attaching a clamping device for the friction welding.

4. The component according to claim 3, wherein the clamping region extends at least in part over an outer circumference and/or axially at an end.

5. The component according to claim 3, wherein the clamping region is divided into circumferentially spaced apart and/or axially spaced apart clamping portions.

6. The component according to claim 3, wherein the clamping region is formed at least in part by an inserted semi-finished part or insert.

7. The component according to claim 1, wherein materials of a first friction-welded region of the first portion and a second friction-welded region of the second portion are the same or are different.

8. The component according to claim 1, wherein the first portion is a hollow body.

9. The component according to claim 1, wherein the first portion is optimized in respect of weight and strength and/or in respect of weight and flow resistance.

10. The component according to claim 1, wherein the component is a valve plunger for a hydraulic valve.

11. The component according to claim 10, wherein the valve plunger is a valve slide and the hydraulic valve is of slide construction.

12. The component according to claim 3, wherein the clamping region is formed on at least one radial collar.

13. An arrangement comprising: a loose first portion of a component of hydraulics, wherein the loose first portion is configured to be joined by friction welding to a loose second portion to form a component, wherein the first portion is at least partially additively manufactured and has at least one control geometry configured for controlling a pressure medium connection or pressure medium flow, and wherein the first portion includes a clamping region configured to absorb a clamping force and/or a clamping moment during the joining by friction welding.

14. The arrangement according to claim 13 wherein the second portion is manufactured at least in part additively or in an alternative way.

15. The arrangement according to claim 13 further comprising: a clamping device configured to clamp the first portion, wherein an inner lateral surface of the clamping device contacts or is configured to be brought into contact at least in part with the clamping region.

16. The arrangement according to claim 15, wherein the clamping device is a clamping sleeve.

17. The arrangement according to claim 13, wherein the clamping region is divided into clamping portions, which include at least one circumferential clamping portion and/or at least one end clamping portion.

18. The arrangement according to claim 15, wherein: the clamping region is divided into clamping portions, which include at least one circumferential clamping portion and/or at least one end clamping portion; and (i) at least one circumferential portion of the inner lateral surface contacts or is configured to be brought into contact with the at least one circumferential clamping portion and/or (ii) at least one end portion of the inner lateral surface contacts or is configured to be brought into contact with the at least one end clamping portion.

19. The arrangement according to claim 13, wherein each of the first portion and second portion includes a friction surface, and the friction surface of at least one of the first and second portions is planar or protrudes axially or is axially depressed.

20. A method for joining a first portion and a second portion of a component of hydraulics to form said component, wherein the first portion is at least partially additively manufactured and includes (i) at least one control geometry configured for controlling a pressure medium connection or pressure medium flow and the (ii) a clamping region configured for attachment of a clamping device, the method comprising: clamping the first portion at the clamping region; clamping the second portions; positioning the first and second portions relative to and/or against one another; and joining the first portion to the second portion by friction welding to form a material-bonded connection between the first and second portions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Exemplary embodiments of a component of hydraulics according to the disclosure, of an arrangement according to the disclosure and of a method according to the disclosure are shown in the drawings. The disclosure will now be explained in greater detail with reference to the figures of those drawings.

[0054] In the figures:

[0055] FIG. 1 shows an arrangement of portions of a component of hydraulics in the form of a valve plunger before joining, according to an exemplary embodiment,

[0056] FIGS. 2a-2d each show a second portion of the valve plunger according to FIG. 1 that is to be joined, in each case having a different friction surface,

[0057] FIG. 3 shows the arrangement according to FIG. 1 with a short clamping portion and a force flow on joining by friction welding,

[0058] FIG. 4 shows the arrangement according to FIG. 1 with a longer clamping portion and a clamping sleeve,

[0059] FIGS. 5a-5c show different exemplary embodiments of a component of hydraulics of joined first and second portions, and

[0060] FIG. 6 shows an exemplary embodiment of a method according to the disclosure for manufacturing the component of hydraulics by friction welding.

DETAILED DESCRIPTION

[0061] FIG. 1 shows a component of hydraulics, which is in the form of a valve plunger 1, joined together according to the disclosure, in a partially cutaway side view. The valve plunger 1 has a first portion 2, which has been additively manufactured in part, and a second portion 4 joined thereto by friction welding. The latter portion is configured as a turned part in the form of an actuating pin. The first portion 2 is divided into an additively manufactured plunger portion 6 with a complex outer and inner geometry and an insert 8 additively joined to the portion 6. The insert is fused onto the portion 6 during the additive manufacture. In the region between the portions 2 and 4 there is provided a friction-welded joint 10 according to the disclosure.

[0062] Additive manufacture makes it possible for the valve plunger 1 to be designed so that it is optimized for low pressure loss, low weight and high compressive strength. This results in the comparatively complex inner and outer geometry. The portion 6 has along its central axis 12 a series of axially spaced apart radial collars 14, at which control geometries in the form of control edges for controlling pressure medium connections of the hydraulic valve, for which the valve plunger 1 is provided, are controllable.

[0063] The portion 6 has a substantially cylindrical basic shape, wherein the radial collars 14 represent a maximum outside diameter of the valve plunger 1. Between the radial collars 14, the portion 6 has in each case a radial constriction 16 between two axially spaced apart control edges. The control edges are each underspanned in the region of the constriction 16 by a passageway 18, which approximately has the shape of a hyperbola or ellipse rotated about the central axis 12.

[0064] The additively manufactured portion 6 is rotationally symmetrical with respect to the central axis 12 at least as far as its radial collars 14 and radial constrictions are concerned. Furthermore, it is mirror-symmetrical with respect to a midplane 20 which intersects the central radial collar 14 and the normal of which is the central axis 12. The central radial collar 14 has radial mouths 22 of the two passageways 18 on both sides of the plane of symmetry 20. The two radial collars 14 arranged distally starting from the central radial collar 14 correspondingly have the distal radial mouths 24 of the two passageways.

[0065] The passageways 18 are delimited towards the central axis 12 by additively manufactured material of the portion 6. This results in the substantially hyperboloidal or ellipsoidal form of the passageway 18, which is formed fluidically without dead spaces.

[0066] The additively manufactured portion 6 of the first portion 2 further has in the region of each of the radial collars 14 a hollow space 26 which extends rotationally symmetrically around the central axis. The hollow spaces can each have a discharge cutout (not shown) to the outer circumferential surface of the portion 6, through each of which cutouts non-solidified powder of the additive manufacture can be discharged.

[0067] The hollow spaces 26 and the passageways 18 are separated in the radial direction by additively manufactured walls 28 of the portion 6.

[0068] FIGS. 3 and 4 show two exemplary embodiments of an arrangement 30; 130 with indicated clamping forces F.sub.a (axial force) and F.sub.r (radial force) during an operation of friction welding of the first portion 2 with the second portion 4. The friction-welded joint 10 shown in FIG. 1 is thus produced. The second portion 4 is thereby firmly clamped in a clamping device, not shown, and a friction surface 32 of the second portion 4 is brought into contact with a friction surface 34 of the first portion 2.

[0069] At the first portion 2, in particular at the radial collar 14 thereof that is proximal to the second portion 4, a clamping means (not shown) engages a circumferential clamping portion, in particular a circumferential clamping surface, with the radial force F.sub.r.

[0070] The same or an additional clamping means engages an end clamping portion of the insert 8 of the first portion 2 with the axial force F.sub.a.

[0071] By means of a drive (not shown), which in the exemplary embodiment is an oscillating drive, the first portion 2 is moved in an oscillating manner about the central axis 12 during joining by friction welding. The frictional force thereby results from the axial clamping force F.sub.a. The clamping means of the second portion 4 thereby absorbs the negative, axial clamping force −F.sub.a. Accordingly, there is established within the valve plunger 1 so manufactured a force flow from the clamping portion 36, via the walls 28 of the portion 6 of the first portion 2, to the second portion 4, which force flow is shown by a broken line according to FIG. 3. The walls 28 are thereby configured with the wall thickness and shape or topology necessary therefor, so that the portion 6 and thus the valve plunger 1 does not suffer any damage and in particular any deformation during the friction welding.

[0072] FIG. 4 shows the same valve plunger 1 as in FIG. 3 and FIG. 1, but in an arrangement 130 that is modified compared to FIG. 3. In a departure, the clamping means for clamping the first portion 2 is here in the form of a slotted clamping sleeve 38. The first portion 2 is inserted into the clamping sleeve until the end clamping portion 36 strikes a sleeve base 40 of the clamping sleeve 38. An interior 42 of the clamping sleeve, which receives the first portion 2 according to FIG. 1, is thereby slightly shorter than the first portion 2. The clamping sleeve 38 is thereby prevented from clamping any portion, even only a short portion, of the second portion 4.

[0073] Unlike in the exemplary embodiment according to FIG. 3 of the arrangement 30, the arrangement 130 is now able to distribute the radial clamping force F.sub.r evenly over a plurality, in particular all, of the radial collars 14 of the first portion 2, so that a plurality of radial forces F.sub.ri are obtained, which add up to the radial force F.sub.r. Consequently, the first portion 2 can be subjected to a radial force F.sub.r with a more even distribution and additionally receives support from radially outwards during the friction welding, so that the axial clamping force F.sub.a can be larger, with an otherwise identical portion 6, or, conversely, with an identical axial clamping force F.sub.a, the walls 28 can be made thinner. In this manner, the valve plunger 1 can be made lighter.

[0074] FIGS. 2a to 2d show different forms of the friction surface 32 of the second portion 4 before the friction welding. According to FIG. 2a, the friction surface 32 is smooth. Thus, although a second portion 4 that is simpler in terms of device technology is provided for joining, it does not experience self-centering during the oscillating or rotating friction welding.

[0075] According to FIG. 2b, the friction surface 32 is provided with a groove or partial groove over its entire circumference, so that an upset bead of a melt that forms during the friction welding can be accommodated.

[0076] According to FIG. 2c, the friction surface 32 is in the form of a prominently protruding, flat cylinder. If the friction surface 34 of the first portion 2 is in a correspondingly negatively matched form, self-centering can thereby take place during the friction welding, so that the process reliability and simplicity thereof is increased.

[0077] An analogous situation is shown in FIG. 2d, wherein the friction surface 32 is in the form of a truncated cone. Here too, self-centering is made possible with a correspondingly negatively matched friction surface 34 of the first portion 2.

[0078] FIGS. 5a to 5c show, schematically, different components of hydraulics 101; 201; 301. According to FIG. 5a, the component 101 is configured with an additively manufactured first portion 2 with in particular high thermal conductivity and a flow-optimized design. The second portion 4 joined thereto is manufactured from an inexpensive material in a conventional manner by turning.

[0079] Accordingly, the component 101 represents a focus on the chosen materials of the portions 2, 4, wherein the friction-welded joint 10 increases the degree of freedom of the materials to be chosen compared to conventional welded joints, since it is possible with this joining method to join very different portions of similar materials or different materials.

[0080] According to FIG. 5b, a component 201 is shown which has, in the middle, an additively manufactured first portion 2 which has a complex inner and/or outer geometry. Centrally between the friction-welded joints 10, it is joined between two in particular symmetrical second portions 4. These have a comparatively simple geometry and are manufactured conventionally, in particular by turning or milling.

[0081] This exemplary embodiment of the component 201 shows that, in addition or alternatively to focusing on the material to be chosen, the friction-welded joint 10 supports the focus on the geometries to be joined.

[0082] The component 301 according to FIG. 5c combines by friction welding an additively manufactured first portion 2, wherein the first portion has high electrical conductivity and a heat-dissipating design, with a second portion 4 with poor electrical and thermal conductivity. This can be manufactured either additively or in an alternative way, for example by turning or milling.

[0083] The component 301 is thus manufactured with a focus on the function of the individual portions 2, 4.

[0084] Joining the additive first portion 2 by friction welding to a second portion manufactured additively or in an alternative way or conventionally opens up hitherto unused technical and economic potentials for components of hydraulics, especially owing to the combinations of function and material that are possible as a result.

[0085] FIG. 6 shows a method according to the disclosure for joining together a component of hydraulics in the form of a valve plunger, wherein the valve plunger is formed according to the preceding description. First of all, the method comprises a step of “clamping the first portion 2 at its clamping region” (44). Then, or in the reverse order, there is a step of “clamping the second portion 4 (46)”. This is followed by a step of “positioning the portions 2, 4 relative to and/or against one another (48)”. Finally, there is a step of “joining by a material-bonded connection by means of friction welding (50)”. This contains steps of “applying an axial and/or radial clamping force F.sub.a (52)” and “imparting a rotating or oscillating movement to at least one of the portions 2, 4 (54)”. Finally, there is a step of “positioning the portions exactly relative to one another under high pressure (56)”.

[0086] A geometry of the portion manufactured additively at least in part can be symmetrical or unsymmetrical.

[0087] A material pairing of the portions can be reproduced by a work sample.

[0088] There is disclosed a component of hydraulics via which, on its own or in conjunction with another component of hydraulics, a pressure medium connection or flow can be controlled. In particular, a valve plunger for a hydraulic valve is disclosed. The component is joined together from at least two portions by means of friction welding, wherein at least the portion that has a control geometry is additively manufactured or 3D printed. There is additionally disclosed an arrangement having at least the additively manufactured portion as a semi-finished part for the component, wherein this portion has a clamping portion for absorbing a clamping force necessary for the friction welding. There is additionally disclosed a method for joining together the component from the first portion and at least one further portion by friction welding.

LIST OF REFERENCE NUMERALS

[0089] 1; 101; 201; 301 Valve plunger [0090] 2 First portion [0091] 4 Second portion [0092] 6 Additively manufactured portion [0093] 8 Insert [0094] 10 Friction-welded joint [0095] 12 Central axis [0096] 14 Radial collar [0097] 16 Radial constriction [0098] 18 Passageway [0099] 20 Plane of symmetry [0100] 22 Radial mouth [0101] 24 Radial mouth [0102] 26 Cavity [0103] 28 Wall [0104] 30; 130 Arrangement [0105] 32, 34 Friction surface [0106] 36 End clamping portion [0107] 38 Clamping sleeve [0108] 40 Base [0109] 42 Groove, partial groove [0110] 44 Clamping the first portion [0111] 46 Clamping the second portion [0112] 48 Positioning the portions [0113] 50 Friction welding [0114] 52 Applying a clamping force [0115] 54 Oscillating or rotating movement [0116] 56 Positioning under pressure [0117] F.sub.a, −F.sub.a axial clamping force [0118] F.sub.r, F.sub.ri radial clamping force