• 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

Control valves are mechanically or electronically actuated valves with several switch positions. Depending on the specified position of the spool along the control edges, a volume flow is set for operating the connected working equipment. The individual pressure compensator adjusts a constant load pressure drop via the supply control edge of the spool, so that a load pressure-independent volume flow control is achieved across the whole adjusting range, also in parallel operation (load compensation). The system must be leakage-free, to prevent accidental dropping of the load, even with parallel operation.

Bore machining

Application solutions

1 – Small and medium series with fixed tools

Initial situation at the customer

MAPAL Application solution 1

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

  • Individual orders, smaller and medium quantities
  • No option for tool setting
  • Short cycle times required
  • High machine hourly rates
  • Stable oscillating honing available
  • Tool concept adapted to several part versions

2 – Large series with solid and adjustable tools

Initial situation at the customer

MAPAL Application solution 2

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

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

3 – Small lot sizes – Reduced tool changes due to combination tools

Initial situation at the customer

MAPAL Application solution 3

Valve housing EN-GJL-300 – spool bore

  • Small lot sizes
  • Option for tool setting available
  • Too many/frequent tool changes
  • High machine hourly rates
  • High effort due to single pass honing process

4 - 在加工中心上的灵活珩磨

客户的初始情况

MAPAL Application solution 4

阀门外壳 EN-GJS-400-15 - 压力天平孔/珩磨加工

  • 减少额外成本的要求
  • 现有加工中心改装为 TOOLTRONIC
  • 用于原型样板件制造以及中/小批量的珩磨加工
  • 要求将珩磨流程对单独的机床不采用

5 - 工具管理

客户的初始情况

MAPAL Toolmanagement

阀门外壳 EN-GJS-400-15 - 完整加工

  • 库存量高
  • 刀具预调间中的工艺流程并非最优的和数据质量不完整
  • 成本透明度不足够
  • 专业人员普遍短缺造成较大的人力波动现象
  • 发生断刀的问题
  • 刀具成本高

刀具解决方案

打导向孔和镗孔
  • Pilotieren

    整体硬质合金镗刀

    • 六个导向倒角可实现完美的圆度和直线度
    • 得益于多倒角技术和合适的冷却剂导向装置实现优化的切屑流动和扩展的精磨削选项

  • Boring

    整体硬质合金镗刀

    • 三个切削刃、六个导向倒角和特殊切口几何形状
    • 直孔,理想的切屑流和整个孔长度的导向

  • Boring

    整体硬质合金镗刀

    • 六个导向倒角和特殊切口几何形状
    • 直孔,理想的切屑流和整个孔长度的导向
    • 通过在一个刀具中进行两次加工操作来减少非加工时间

  • Piloting and boring

    多级镗刀

    • 径向和切向可转位刀片
    • 一次装夹即可完成滑块钻孔的预加工和轮廓

  • MAPAL Boring

    双刃镗刀

    • 成形切削刃
    • 工艺可靠的轮廓加工
    • 操作简单,切削材料成本低

控制刃口加工
  • Control edge machining

    整体硬质合金圆盘铣刀

    • 显著节省加工循环时间
    • 定义的控制刃口无破裂现象

  • Control edge machining

    整体硬质合金型材模具

    • 最高精度和控制刃口的表面质量
    • 定义的控制刃口无破裂现象

铰削和精镗
  • Reaming

    多刃铰刀

    • 高切削值
    • 通过左旋和最佳冷却剂导向实现完美的切屑控制

  • Fine boring

    精镗刀具

    • EasyAdjust-系统和导向板条
    • 工艺可靠的精加工,易于操作,无需进行后续的珩磨
    • 通过理想跟踪获得最佳圆柱形状

  • Fine boring

    精镗刀具

    • 可调转位刀片和导向板条
    • 很适合非常精确和长孔的腹板加工

通过珩磨实现精加工
  • TOOLTRONIC

    MAPAL TOOLTRONIC

    • 显着减少制造和流程时间
    • 更高的形状保真度

铣削
  • NeoMill-16-Face

    NeoMill®-16-Face

    • 带有16个切削刃的可转位刀片 / 45°
    • 使用铸铁和耐热铸钢时的首选
    • ø-范围 63-200 mm / ap 最大 4 mm
    • 尽管有阴模形状,但切削力低
    • 平面铣削时实现最高的经济性

  • NEOMILL-8-CORNER

    NeoMill®-8-Corner

    • 带有八个切削刃的可转位刀片 / 90°
    • 使用铸铁时的首选
    • ø-范围 50-200 mm / ap 最大 8 mm
    • 方肩铣削时实现最高的经济性

  • NEOMILL-4-CORNER

    NeoMill®-4-Corner

    • 带有四个切削刃的可转位刀片 / 90°
    • 非常适合钢、不锈钢、铸铁和耐热铸钢
    • ø-范围 25-100 mm / ap 最大 10 mm
    • 高方肩尺寸的逐行铣削
    • 尽管有阴模形状,但切削力非常低

夹紧
  • UNIQ Mill Chuck

    UNIQ 铣削液压刀柄

    • 即使在很长的(超过240分钟)铣削循环状态下,也能实现抵抗80℃高温的性能
    • 用于高效铣削加工,最高转速达33,000 转/每分钟
    • 最高的工艺可靠性

  • UNIQ DReaM CHUCK 4.5°

    UNIQ 钻铰液压刀柄,4.5°

    • 液压刀柄带有热缩刀柄的原始尺寸(采用4.5°的DIN标准轮廓)
    • 以应用为导向的系统设计
    • 最高的工艺可靠性和使用寿命
    • 快速和高精度的刀具更换

  • HB MILL CHUCK SIDE LOCK CHUCK

    HB-平面刀柄 MILL CHUCK

    • 通过差动螺钉实现简易的安装操作
    • 最高的效率和精度
    • 通过弹簧系统实现定义的轴向刀具定位
    • 用于加工控制刃口的型材模具的最佳定位