Research on optimization design method of parallel flow channel structure for hydraulic cartridge valve blocks in additive manufacturing

This study proposes an optimization design method for parallel flow channels in hydraulic cartridge valve blocks manufactured via additive manufacturing (AM), with the dual objectives of minimizing pressure loss and pipeline length. Based on the structural characteristics of parallel flow channels, optimization models for both direct and deviated configurations were developed. Using computational fluid dynamics (CFD) simulations, fitting equations relating structural parameters to pressure loss were established. A response particle swarm optimization (RPSO) algorithm was then applied to optimize the flow channel design, and the reliability of the optimization results was verified experimentally. The results indicate that, for direct-connected flow channels, pressure loss is minimized when the main flow axis is tangent to the valve chamber; under this condition, the volume of an 8 mm diameter flow channel was reduced by 25.84%, and the pressure loss decreased by 3.97%. For the optimized deviated flow channel, the volume was reduced by 8.4%, and the pressure loss decreased by 10.58%. This work provides an effective optimization approach for the design of parallel flow channels in additively manufactured hydraulic valve blocks, laying a foundation for further development and application of AM-based hydraulic systems.