Over the years, 3D printing has proven to be a very convenient technique for manufacturing replacement and mechanical components such as manual pumps, gearboxes, gears and valves. This year, the title of the master's thesis titled "3D Print Safety Valve Analysis and Verification", John Anthony Dutcher III, a student of the University of Iowa's Department of Technology, used SLA 3D printing to make a pressure relief valve for an internal prototype positive displacement pump.
The abstract states that “additive manufacturing allows for faster, lower cost product development, including customization, point-of-use printing, and low cost per batch.†The study used Stereolithography's prototype to develop improvements to existing products. , that is, the internal pressure reducing valve of the positive displacement pump. Four 3D printed prototype components were developed and tested in this study. The pressure relief valve assembly consists of pressure vessel components manufactured from additive manufacturing, post-treated, and mounted on a positive displacement pump without additional processing. The prototype design was analyzed using computational fluid dynamics simulation to increase the flow through the valve. The simulation was verified by performance testing to reduce cracking to the valve's full bypass pressure range. By reducing this operating range of the valve, the power requirements of the pump drive system can be reduced, thereby increasing the energy efficiency of the pump drive system.
The performance test of the 3D printed safety valve measures the pump flow, the poppet motion within the valve, and the discharge pressure under operating conditions similar to existing applications. The Stereolithography prototype assembly performed very well, indicating a 56% reduction in pressure differential from valve cracking to full bypass. This study demonstrates the short-term ability of additive manufacturing manufactured parts to replace existing metal parts in pressure vessel applications. The power requirements of the pump drive system can be reduced, thereby increasing the energy efficiency of the pump drive system.
The gears inside the positive displacement pump developed more than a century ago can overcome the existing performance limitations, but it is by no means perfect. These pumps require an internal safety valve to prevent excessive pressure; if the discharge flow is reduced, the overpressure system may fail.
“The main focus of this study was to study the performance of internal safety valves for positive displacement pumps, and proposed flow conditions based on flow simulation to improve valve cracking to full bypass pressure range and to improve 3D printed prototypes by verifying performance.†Dutcher Written.
SLA parts production For many years, the design of internal safety valves in these positive displacement pumps has not changed much. But by using computer simulation, the design can be modified and optimized to make the part more efficient. As he wrote in his paper, Dutcher's research validates 3D printed prototypes, using computational fluid dynamics simulations and performance tests, "in the design development of improved existing products", and also shows that both cost and time can pass Use 3D printing to make the valve.
“Additive manufacturing has a custom-made advantage that allows design changes,†wrote Dutcher.
“Developing customizable end-use components that can be manufactured at point of use, allowing the production of products for specific applications for pressure vessel applications.â€
Prototypes of valves that use SLA technology for 3D printing have been shown to reduce the amount of cracking that completely bypasses the stage pressure differential required to operate the internal safety valve. FDM 3D printing is used to make a mounting bracket that attaches the LVDT sensor to the valve prototype; this sensor measures the movement of the poppet valve (the internal device is in the safety valve that seals its surface) during the test.
Assembled reference valve expansion
In his paper, Dutcher wanted to determine if 3D printing could be successfully used to produce test valve assemblies for positive displacement pumps, if the valve geometry could be optimized for flow conditions to reduce cracks, and if the 3D printed prototype valve Performance is the same as existing traditional manufacturing methods. In the end, although he did answer these questions and proved that 3D printing does have applications in developing new products, his research provides a viable proof of concept for improving the existing design of the product.
“The development of 3D printing prototypes was to reduce the cost and delivery time of prototype testing,†wrote Dutcher.
“The flexibility of additive manufacturing allows custom design alignments to provide the opportunity to verify multiple product designs in parallel.â€
The SLA support structure creates prototypes using 3D printing, and Dutcher is able to develop several different design concepts simultaneously without being plagued by conventional barriers created by traditional manufacturing methods. SLA 3D printing also produces parts with “machined part dimensional tolerances†that help speed up prototype development.
“This study demonstrates that SLA 3D printing can reproduce existing machined metal parts,†concludes Dutcher. “Although the extended performance test is not the purpose of this study, the 3D printed pressure vessel valve assembly performs very well in performance testing. Without additive manufacturing, it is impossible to develop a design change in time for the manor. Tests show that by reducing cracks Valve performance has improved with full bypass pressures from 52.0 psi to 22.8 psi. Improved performance testing of existing products demonstrates the effectiveness of SLA 3D printing prototype components."
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