• 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

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

Details
2 – Großserie mit festen und justierbaren Werkzeugen

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

Details
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

Details
4 – Flexible honing on the machining centre

Initial situation at the customer

MAPAL Application solution 4

Valve housing EN-GJS-400-15 – Compensator bore / honing

  • Request for reduction of ancillary costs
  • Existing machining centre re-tooled to TOOLTRONIC
  • Honing for prototype manufacture, as well as small and medium-scale production runs
  • Requirement for saving the honing process on separate machine

Details
5 – Tool management

Situación inicial del cliente

MAPAL Toolmanagement

Carcasa de la válvula EN-GJS-400-15 – Mecanizado completo

  • Niveles de existencias elevados
  • Los flujos de procesos en la sala de configuración no son óptimos y la calidad de los datos es incompleta
  • Transparencia insuficiente de los costos
  • Alta fluctuación debido a la escasez general de trabajadores cualificados
  • Problemas de ruptura de herramientas
  • Costos elevados de las herramientas

Detalles

Soluciones de mecanizado

Pilotaje y taladrado
  • 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

    Fresa circular para metal duro macizo

    • Ahorro considerable de tiempos de ciclo
    • Bordes de control definidos sin astillas

  • Control edge machining

    Herramienta de perfil en metal duro

    • Precisión y calidad de superficie máxima de los bordes de control
    • Bordes de control definidos sin astillas

Escariado y taladrado de precisión
  • Reiben

    Mehrschneiden-Reibahle

    • Hohe Schnittwerte
    • Perfekte Spankontrolle durch Linksdrall und optimale Kühlmittelführung

  • Feinbohren

    Feinbohrwerkzeug

    • EasyAdjust-System und Führungsleisten
    • Prozesssichere Feinbearbeitung mit einfachem Handling ohne nachfolgendes Honen
    • Beste Zylinderformen durch ideale Nachführung

  • Feinbohren

    Feinbohrwerkzeug

    • Einstellbare Wendeplatten und Führungsleisten
    • Ideal für Stegbearbeitungen von sehr genauen und langen Bohrungen

Fertigbearbeitung durch Honen
  • TOOLTRONIC

    MAPAL TOOLTRONIC

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

Milling
  • NeoMill-16-Face

    NeoMill®-16-Face

    • Inserto a fissaggio meccanico a 16 taglienti / 45°
    • Prima scelta per ghisa e acciaio fuso resistente al calore
    • Range di ø 63-200 mm / ap max. 4 mm
    • Forze di taglio ridotte nonostante la forma negativa
    • Massima redditività nella fresatura a spianare

  • NEOMILL-8-CORNER

    NeoMill®-8-Corner

    • Inserto a fissaggio meccanico a otto taglienti / 90°
    • Prima scelta per ghisa
    • Range di ø 50-200 mm / ap max. 8 mm
    • Massima redditività nella fresatura a spallamento retto

  • NEOMILL-4-CORNER

    NeoMill®-4-Corner

    • Inserto a fissaggio meccanico a quattro taglienti / 90°
    • Particolarmente indicato per acciaio, acciaio inossidabile, ghisa e acciaio fuso resistente al calore
    • Range di ø 25-100 mm / ap max. 10 mm
    • Fresatura di spallamenti alti
    • Forze di taglio molto ridotte nonostante la forma negativa

Sistemi di serraggio
  • UNIQ Mill Chuck

    UNIQ Mill Chuck

    • Resistente a temperature di 80 °C anche in cicli di fresatura molto lunghi (oltre 240 minuti)
    • Per lavorazioni di fresatura ad alte prestazioni fino a un max. di 33.000 giri al minuto
    • Massima sicurezza dei processi

  • UNIQ DReaM CHUCK 4.5°

    UNIQ DReaM Chuck, 4.5°

    • Mandrino a serraggio idraulico con le dimensioni originali di un mandrino a calettamento termico (profilo DIN con 4,5°)
    • Progettazione di impianto orientata all’applicazione pratica
    • Massima sicurezza dei processi e durata
    • Cambio utensile più rapido e più preciso

  • HB MILL CHUCK SIDE LOCK CHUCK

    MANDRINO DI SERRAGGIO A CONTATTO HB MILL CHUCK

    • Facile utilizzo grazie alla vite differenziale
    • Massima redditività e precisione
    • Posizionamento assiale dell’utensile definito grazie al sistema a molla
    • Posizionamento ottimale degli utensili di profilatura per la lavorazione dei punti di intersezione di comando