This paper demonstrates a novel numerical procedure for a synthesis of electro-hydraulic pressure relief valve performance starting with the performance requirements from a functional specification. Results of this methodological approach are the unknown demands for the solenoid with regard to control orifice concepts and the solenoid geometry itself fulfilling the requirements. The developed modeling approach comprises two major solution steps. At the beginning the displacement-dependent

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... id-spring force characteristic is calculated from the intended pressure-flow rate characteristic map without the use of optimization tools. This new algorithm performs an inverse simulation of a single stage pressure valve. The next solution step deals with the determination of the geometrical shape of the solenoid. Here steady state FEM computations are used in combination with response surface methodologies to predict the desired geometrical shape. At the end robustness verification is done by means of Monte-Carlo simulation for the uncertainties of the valve assembly. Starting point for the inverse calculations are different control orifice concepts causing varying demands on the solenoid. As a result of this benchmark the most favorable control orifice concept is used for determination of the solenoid geometry. This is performed within several iterations also considering the spring force. Afterwards the robustness of the valve assembly is examined. The verification of the modeling attempt is done on the basis of prototype parts for the solenoid and the control orifice. Measurements confirm the accuracy of the novel simulation strategy for a standalone virtual product development.