• Excavator

液压阀外壳

这一切都取决于主孔。阀门外壳的制造是流体技术领域的“最高学科”。多年来，对MAPAL公司在滑块钻孔方面的专业知识的需求一直很高。与滑块的间隙尺寸取决于该孔的精度，因此液压油只能无泄漏地沿着所需方向流动。现代液压阀对该尺寸的定义非常狭窄。因此，非常重视该孔的圆度、圆柱形状、直线度和表面质量。
Valve block

加工要求

  • 波动的铸铁加工余情况
  • 超强中断的切削口
  • 镗孔时避免环圈的形成，并确保从外壳中安全排出切屑
  • 避免在镗孔流程中控制刃口上出现破裂现象
  • 对形状和位置公差的要求非常高
  • 珩磨之前的恒定加工余量
  • 在切削加工方案中考虑组件差异和有限的刀具储存器位置

方向控制阀
方向控制阀是具有多个开关位置的采用机械或电子方式操作的阀门。根据控制滑块沿着控制刃口的指定位置，设置体积流量以运行连接的机具。独立压力天平（IDW）调节控制滑块流入控制刃口上的恒定负载压力梯度，从而在整个调节范围内实现独立于负载压力的体积流量控制，即使在并联运行（负载补偿）时亦是如此。系统必须无泄漏，以防止负载意外下降，即使在并联运行时亦是如此。

钻削加工

应用解决方案

1 – 使用固定刀具实现中、小批量

Situación inicial del cliente

MAPAL Application solution 1

Carcasa de la válvula EN-GJS-400-15 – Perforación

  • Pedidos individuales, pequeñas y medianas cantidades
  • No es posible ajustar la herramienta
  • Requiere poco tiempo de entrega
  • Altas tarifas por hora de las máquinas
  • Proceso estable de expansión y deshuesado disponible
  • Concepto de herramienta adaptado a diversas variantes de componentes

Detalles
2 - 使用固定和可调刀具实现大批量

客户的初始情况

MAPAL Application solution 2

阀门外壳 EN-GJS-400-15 – 滑块钻孔和压力天平孔

  • 大批量
  • 需要设置刀具
  • 每小时的机床费率高
  • 后续刀杆珩磨的成本高

细节
3 - 小批量 - 通过使用组合型刀具减少刀具更换次数

客户的初始情况

MAPAL Application solution 3

阀门外壳 EN-GJL-300 – 滑块钻孔

  • 小批量
  • 可以设置刀具
  • 刀具更换次数过多/太频繁
  • 每小时的机床费率高
  • 由于刀杆珩磨流程而需付出较高的费力

细节
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

细节
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

细节

Tool solutions

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