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Manufacturing of Hydraulic Cylinders: The Birthplace of Hydraulic Power

Manufacturing of Hydraulic Cylinders: The Birthplace of Hydraulic Power


Hydraulic Cylinder Manufacturing: The Birthplace of Hydraulic Power

Hydraulic cylinders, an indispensable power source in modern industry, generate linear mechanical force in a wide range of applications, from construction machinery and agricultural equipment to industrial facilities and crane systems. However, the engineering details behind this power are often overlooked. In this article, let's take a look at the birth process of a hydraulic cylinder, namely its manufacturing stages.

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  1. Design: Every Powerful Machine Begins with a Good Plan
    The manufacturing process begins with determining the application-specific requirements. Numerous technical details, such as cylinder stroke length, cylinder tube diameter, shaft diameter, sealing structure, pressure resistance, and connection types, are finalized at this stage. Based on this information, initial technical drawings are created using CAD (Computer-Aided Design) software.

    The following criteria are generally considered in the design process:

    Push/pull force required by the application
    Mounting conditions
    Hydraulic system pressure values
    Ambient conditions (temperature, dust, chemical exposure, etc.)

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  1. Raw Material Selection: Durability Begins Here
    Correct material selection is one of the primary factors directly affecting the performance and lifespan of a cylinder. The following parts and materials are preferred for hydraulic cylinders:

    Cylinder tube: High-strength seamless steel tube made of ST52 material, with an internal surface honed to H8 Standard
    Piston rod: Chrome-plated, ground steel shaft made of CK45 material
    Piston and covers: ST52 or 1040 high-strength steel, cast, or CNC-machined steel parts
    Sealing elements: High-strength rubber-based materials such as polyurethane, PTFE, and NBR
    Machining: The Stage Where Precision Meets Perfection
    The parts to be manufactured are machined to precise measurements on CNC machines. During this stage, all details, such as the piston, cover, shaft end, and connecting parts, are shaped according to the tolerances in the technical drawings. The shaft surface is ground, and a minimum 70-micron chrome coating is applied to increase corrosion resistance.

    Likewise, the inner surface of the cylinder tube is honed to H8 Standard and brought to a level of smoothness where the sealing elements can work efficiently.

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  1. Welding and Assembly: Parts Come Together
    Processed parts are joined using TIG or MIG welding techniques, if welded joints are required, in accordance with the WPS (Welding Procedure Specification) instructions, which are individually prepared for each product. The weld sample is checked with the necessary micro and macro tests. All parts are then assembled on the assembly line, along with seals, bearings, bushings, and pistons, in assembly rooms where dust reports are regularly collected. At this stage, cleanliness and attention to detail are as crucial as workmanship, as even the slightest contaminant can lead to future system failures.

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  1. Testing Process: Ensuring Safety and Quality
    Each assembled cylinder is tested on hydrostatic test benches under high pressure, based on the hydraulic cylinder's operating pressure. These tests identify potential sealing faults or mechanical problems before the product is shipped to the field.

    The testing process typically includes the following steps:

    Static seal testing (at 1.5 times the standard operating pressure)
    Dynamic testing (piston movement and performance control)
    Visual inspection and dimensional checks

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  1. Painting and Packaging: The Final Touch
    Cylinders that successfully pass the tests are coated with corrosion-resistant industrial paint. After customer logos, part numbers, and technical labeling are completed, they are packaged in special protective coatings and prepared for shipment.

hydraulic cylinder

The Underside of Power

It's impossible to judge a hydraulic cylinder solely by its appearance. The true value lies in the engineering, material selection, and manufacturing precision within. At Hidroman, we treat every cylinder as a safety and performance agreement, offering long-lasting solutions tailored to specific industry needs.

If you need high-performance hydraulic cylinders tailored to your business, contact us. Because power lies in the details.