Hydraulic valve housing

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

Bore machining

Spool bore

Spool bore

The relative movement of the spool along the control edges controls the flow direction of the fluid.

Compensator bore

Compensator bore

Despite different loads on agricultural and construction machinery, the volume flow for the lifting and lowering speed on an excavator shovel, for example, must remain constant. If a low load is present, the spring-preloaded pressure compensator releases a smaller cross section, to keep the volume flow constant. With high loads, a larger cross-section is released. The working speed of the hydraulic cylinder connected to the excavator shovel thus always remains the same.

Additional bore machining

1__Tie rod hole 2__O-ring bore 3__Oil bore 4__Thread bore 5__Port hole 6__Check valve hole

• 
  1 / 6

  Tie rod hole

  Bore for tie rod, which keep the individual valve blocks together.
• 
  2 / 6

  O-ring bore

  Countersink for O-rings for sealing the plane surfaces between
  individual modules.
• 
  3 / 6

  Oil bore

  Oil channel for distributing the oil in the part.
• 
  4 / 6

  Thread bore

  Bores for fastening attachments.
• 
  5 / 6

  Port hole

  Bore for connecting the individual consumers to the valve block.
• 
  6 / 6

  Check valve hole

  Check valves for blocking a volume flow.

• 1__Tie rod hole 1__Tie rod hole
• 2__O-ring bore 2__O-ring bore
• 3__Oil bore 3__Oil bore
• 4__Thread bore 4__Thread bore
• 5__Port hole 5__Port hole
• 6__Check valve hole 6__Check valve hole

Application solutions

1 – Small and medium series with fixed tools

Initial situation at the customer

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

Details

2 – Large series with solid and adjustable tools

Initial situation at the customer

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

Details

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

Initial situation at the customer

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

细节

4 - 在加工中心上的灵活珩磨

客户的初始情况

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

细节

5 - 工具管理

客户的初始情况

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

细节

刀具解决方案