• Excavator

Hydraulic valve housing

Everything depends on the main bore. Manufacturing valve housings is the supreme discipline in the world of fluid power. For years, MAPAL’s expertise has been in demand for the spool bore. The gap dimension with the spool depends on the accuracy of this bore, so that the hydraulic oil can only flow in the required direction without leaking. This is very narrowly defined in modern hydraulic valves. The roundness, cylindrical form, straightness and surface finish of this bore are therefore crucial.
Valve block

Machining requirements

  • Fluctuating cast allowance situation
  • Heavily interrupted cuts
  • Avoid ring formation during boring and ensure safe chip removal from the housing
  • Avoid macroscopic flaws on the control edges in the boring process
  • Very high demands on form and position tolerance
  • Constant stock removal before honing
  • Take part variance and limited tool storage places in the machining concept into account

Control valves
Les vannes à voies sont des vannes à commande mécanique ou électronique avec plusieurs positions de commutation. Selon la position prédéfinie du tiroir de commande le long des arêtes de commande, un débit volumétrique est réglé pour le fonctionnement des appareils de travail raccordés. La balance de pression individuelle (BPI) régule une chute de pression de charge constante au-dessus de l'arête de commande d'alimentation du tiroir de commande, de manière à obtenir une commande de débit indépendante de la pression de charge sur toute la plage de réglage, même en fonctionnement parallèle (compensation de charge). Le système doit être exempt de fuites afin d'éviter toute descente accidentelle de la charge, même en cas de fonctionnement en parallèle.

Perçages et alésages

Solutions d'application

1 – Petites et moyennes séries avec outils fixes

Situation initiale du client

MAPAL Application solution 1

Corps de valve EN-GJS-400-15 – Alésage de tiroir

  • Commandes individuelles, petites et moyennes quantités
  • Pas de possibilité de régler l’outil
  • Temps de passage moindre requis
  • Taux horaire élevé des machines
  • Processus de pierrage d’expansion stable disponible
  • Concept d'outil adapté à plusieurs variantes de composants

Détails
2 – Grande série avec outils fixes et ajustables

Situação inicial no cliente

MAPAL Application solution 2

Corpo da válvula EN-GJS-400-15 – Furo do carretel e furo do compensador

  • Produção em grande escala
  • Configuração da ferramenta desejada
  • Altas taxas de hora da máquina
  • Altos custos para posterior brunimento em passe único

Detalhes
3 – Lotes de pequenos tamanhos – Redução da troca de ferramentas por meio de ferramentas combinadas

Situação inicial no cliente

MAPAL Application solution 3

Corpo da válvula EN-GJL-300 – Furo do carretel

  • Lotes de pequenos tamanhos
  • Opção para configuração de ferramenta disponível
  • Muitas ferramentas e trocas frequentes
  • Altas taxas de hora da máquina
  • Alto esforço devido ao processo de brunimento de passagem única

Detalhes
4 – Brunimento flexível no centro de usinagem

Situação inicial no cliente

MAPAL Application solution 4

Corpo de válvula EN-GJS-400-15 – Furo do compensador/brunimento

  • Requisito para reduzir custos dos acessórios
  • Centro de usinagem existente convertido para TOOLTRONIC
  • Brunimento para construção de protótipos, bem como produção em pequena e média escala
  • Requisito para salvar o processo de brunimento em uma máquina separada

Detalhes
5 – Gerenciamento de ferramentas

Situação inicial no cliente

MAPAL Toolmanagement

Corpo da válvula EN-GJS-400-15 – Usinagem completa

  • Altos estoques
  • Processos na área de preset de ferramentas não otimizados, e qualidade de dados incompleta
  • Transparência de custos não é suficiente
  • Alta oscilação devido à falta geral de trabalhadores
  • Problemas com quebra de ferramentas
  • Altos custos de ferramentas

Detalhes

Soluções de ferramentas

Piloting and boring
  • Pilotieren

    Solid carbide boring tool

    • Six margin lands for perfect roundness and straightness
    • Optimum chip flow and extended regrinding options through multicut technology and suitable coolant supply

  • Boring

    Solid carbide boring tool

    • Three cutting edges, six margin lands and special lead geometry
    • Straight bore, ideal chip flow und guide across the entire bore length

  • Boring

    Solid carbide boring tool

    • 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

  • Piloting and boring

    Multi-stepped boring tool

    • Radial and tangential indexable inserts
    • Pre-machining spool bore and completion of contours in one processing step

  • MAPAL Boring

    Double edge boring tool

    • Form cutting edges
    • Reliable machining of the contour
    • Easy handling with low cutting material costs

Control edge machining
  • Control edge machining

    Solid carbide circular milling cutter

    • Significant cycle time savings
    • Defined control edges without macroscopic flaws

  • Control edge machining

    Solid carbide profile tool

    • Highest accuracy and surface finish of control edges
    • Defined control edges without macroscopic flaws

Reaming and fine boring
  • Reaming

    Multi-bladed reamer

    • High cutting data
    • Perfect chip control due to left-hand twist and optimum coolant supply

  • Fine boring

    Fine boring tool

    • EasyAdjust system and guide pads
    • Reliable precision machining with easy handling without subsequent honing
    • Best cylindrical forms due to optimum guidance

  • Fine boring

    Fine boring tool

    • Indexable inserts and guide pads
    • Ideal for bar machining of highly accurate and long bores

Fine machining with honing
  • TOOLTRONIC

    MAPAL TOOLTRONIC

    • Significant shortening of production and cycle times
    • Greater contour accuracy

Milling
  • NeoMill-16-Face

    NeoMill®-16-Face

    • 16-edge indexable insert / 45°
    • First choice for cast iron and heat-resistant cast steel
    • ø area 63-200 mm / ap max. 4 mm
    • Low cutting forces despite a negative shape
    • Maximum economic efficiency for face milling

  • NEOMILL-8-CORNER

    NeoMill®-8-Corner

    • Eight-edge indexable insert / 90°
    • First choice for cast iron
    • ø area 50-200 mm / ap max. 8 mm
    • Maximum economic efficiency for shoulder milling

  • NEOMILL-4-CORNER

    NeoMill®-4-Corner

    • Four-edge indexable insert / 90°
    • Highly suitable for steel, stainless steel, cast iron and heat-resistant cast steel
    • ø area 25-100 mm / ap max. 10 mm
    • Multipass milling of high shoulder dimensions
    • Very low cutting forces despite a negative shape

Clamping
  • UNIQ Mill Chuck

    UNIQ Mill Chuck

    • Highly thermal stability from 80 °C even with very long milling cycles (over 240 minutes)
    • For high-performance milling operations up to max. 33,000 revolutions per minute
    • Highest process reliability

  • UNIQ DReaM CHUCK 4.5°

    UNIQ DReaM Chuck, 4.5°

    • Hydraulic chuck with the original dimensions of a shrink chuck (DIN contour with 4.5°)
    • Application-oriented system design
    • Maximum process reliability and tool life
    • Faster und highly precise tool change

  • HB MILL CHUCK SIDE LOCK CHUCK

    HB MILL CHUCK SIDE LOCK CHUCK

    • Easy to handle thanks to use of a differential screw
    • Maximum economic efficiency and precision
    • Axial tool positioning can be defined using spring system
    • Optimum positioning of profile tools for control edge machining