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. Usinagem com controle de borda

  • Ferramenta para mandrilamento de duplas facas com geometria especial
  • Usinagem confiável do contorno e segurança no processo
  • Fácil manuseio com baixo custo de material de corte

Fine boring

3. Acabamento fino

  • Ferramenta para acabamento fino com sistema EasyAdjust e guias
  • Usinagem fina confiável com fácil manuseio, sem brunimento subsequente
  • As melhores formas cilíndricas devido a ótima orientação

PRODUCTION COSTS PER SPOOL BORE

Vantagens

  • Processo de brunimento de alto custo no furo do carretel diminuído
  • Baixos custos de ferramentas por furo
  • Tempos não produtivos mais curtos devido à engenharia inteligente em cooperação com o cliente
  • Economia significativa de custos, devido a eliminação do processo de brunimento no furo do compensador

ANNUAL PRODUCTION COSTS OF THE COMPENSATOR BORE [€]