Large series with solid and adjustable tools

Valve housing EN-GJS-400-15 – spool bore and compensator bore

Initial situation at the customer

Valve-block

  • Large-scale series
  • Tool setting desired
  • High machine hourly rates
  • High costs for subsequent single pass honing

Special features of this solution

  • Ideally matched separate tools guarantee optimum preconditions for a reduced honing process
  • The honing process can be eliminated with certain part requirements

Spool bore

MAPAL Boring

1. Boring
  • Optimum results in the pre-machining due to a coordinated piloting and boring process
  • Optimum chip flow and extended regrinding options through multicut technology and perfect coolant supply
  • No ring formation in the cavities due to special bore geometry → no costs for removal of rings

Control edge machining

2. Control edge machining
  • Solid carbide profile tool
  • Highest accuracy and surface finish of control edges
  • Defined control edges without macroscopic flaws

Fine boring

3. Fine boring
  • Fine boring tool with EasyAdjust system and guide pads
  • Reliable precision machining with easy handling
  • Best cylindrical forms due to optimum guidance

Compensator bore

Boring

1. Boring
  • Solid carbide boring tool with six margin lands and special lead geometry
  • Straight bore, ideal chip flow und guide across the entire bore length
  • Reduced non-productive times due to two machining operations in one tool

Fine boring

2. Contour machining
  • Double edge boring tool with form cutting edges
  • Reliable machining of the contour
  • Easy handling with low cutting material costs

Fine boring

3. ファインボーリング加工

  • EasyAdjustシステムとガイドパッド付きファインボーリングツール
  • ホーニングが不要な容易な取り扱いで頼性の高い仕上げ加工
  • 理想的なトラッキングによる最適なシリンダー形状

PRODUCTION COSTS PER SPOOL BORE

利点

  • 費用の高いスプール穴のホーニング工程を短縮
  • 加工穴当たりのツールコストが低減
  • お客様との連携で巧みなエンジニアリングによる生産外時間の短縮
  • 流量制御穴のホーニング加工が不要になり、大幅なコストダウンが可能 

ANNUAL PRODUCTION COSTS OF THE COMPENSATOR BORE [€]