Axial piston pump – cylinder Block

Cylinder block 42CrMoS4 / CuZn35Mn2Si
 

Initial situation at the customer

Machining cylinder block

  • Medium to high quantities
  • High costs incurred when manufacturing defined surfaces and high qualities
  • High fluctuation due to general lack of skilled workers with a simultaneous increase in production quantities

Special features of this solution

  • Demanding parts quality met with certainty
  • Reliable manufacturing of defined surfaces for the piston bore
  • Spot facing and boring processes no longer required thanks to Tritan-Drill and OptiMill-Uni-HPC Pocket technologies
  • LAT/EAT enable flexible implementation of the machining concept in other parts varieties

Piston bore

  • Machining cylinder block

    Stepped drilling

    Step drills
    • Optimal premachining of piston bores without additional spot facing
    • Deburring process of the bottom of the bore with sharp cutting edge no longer necessary

  • Machining cylinder block

    Fine boring

    Fine boring tool
    • Fine boring tool ensures perfect bore quality before pressing brass bushes
    • MAPAL HX inserts – six cutting edges for low cutting material costs and great economic efficiency

  • Machining cylinder block

    Actuating

    Actuating tool
    • LAT facing head for precision machining of the defined surface specifications of piston bores
    • Precision-fit machining of insertion contours of brass bushes without additional processing steps

  • Machining cylinder block

    Actuating

    Actuating tool
    • EAT eccentric facing head for applications with high spindle speeds for maximal efficiency when machining brass bushes (premachining and fine machining)

Machining kidneys

  • Machining cylinder block

    Milling

    Milling cutter
    • OptiMill-Uni-HPC Pocket supports the required drilling process with inclined plunging when machining inlet and outlet openings (kidney-shaped holes)
    • The production process of pressure and suction kidneys of the corresponding control plate can be performed efficiently and without further tools

MACHINING TIME PER CYLINDER BLOCK [SEC.]

Vantaggi

  • La tecnologia di movimentazione interna consente una “lavorazione non presidiata” efficiente e altamente automatizzata, grazie a cicli di misura e regolazione automatici durante la lavorazione
  • Riduzione dei tempi di processo e dei tempi non produttivi, possibilità di un efficiente funzionamento a più macchine grazie a soluzioni di utensili altamente tecnologiche
  • La tecnologia di movimentazione interna consente significativi risparmi sui costi di utensili e tempi di lavorazione, poiché la prelavorazione e la lavorazione di precisione del foro del pistone e della boccola in ottone non richiedono ulteriori strumenti
  • Processi accuratamente calibrati tra prelavorazione e lavorazione di precisione