Pompe à pistons axiaux – Bloc-cylindres

Bloc-cylindres 42CrMoS4/CuZn35Mn2Si – Alésage de pistons et de chambres

Situation initiale du client

Machining cylinder block

  • Moyennes à grandes quantités de pièces
  • Coûts élevés pour la réalisation de surfaces définies et l'obtention d'une qualité élevée
  • Taux de rotation élevé en raison d'un manque général de personnel qualifié alors que le nombre de pièces augmente

Particularités de la solution

  • Qualités optimales du composant garanties
  • Fabrication fiable de surfaces définies de l'alésage de piston
  • Élimination du lamage et du perçage grâce aux technologies Tritan-Drill et OptiMill-Uni-HPC Pocket
  • Outils LAT/EAT permettant une application flexible des concepts d'usinage à d'autres variantes de composants

Alésage de piston

  • Machining cylinder block

    Stepped drilling

    Step drills
    • Optimal premachining of piston bores without additional spot facing
    • Deburring process of the bottom of the bore with sharp cutting edge no longer necessary

  • Machining cylinder block

    Fine boring

    Fine boring tool
    • Fine boring tool ensures perfect bore quality before pressing brass bushes
    • MAPAL HX inserts – six cutting edges for low cutting material costs and great economic efficiency

  • Machining cylinder block

    Actuating

    Actuating tool
    • LAT facing head for precision machining of the defined surface specifications of piston bores
    • Precision-fit machining of insertion contours of brass bushes without additional processing steps

  • Machining cylinder block

    Actuating

    Actuating tool
    • EAT eccentric facing head for applications with high spindle speeds for maximal efficiency when machining brass bushes (premachining and fine machining)

Machining kidneys

  • Machining cylinder block

    Milling

    Milling cutter
    • OptiMill-Uni-HPC Pocket supports the required drilling process with inclined plunging when machining inlet and outlet openings (kidney-shaped holes)
    • The production process of pressure and suction kidneys of the corresponding control plate can be performed efficiently and without further tools

MACHINING TIME PER CYLINDER BLOCK [SEC.]

Advantages

  • Actuating technology allows efficient and high-automized “unmanned manufacturing” through automatic measuring and adjustment cycles during machining.
  • Reduces process and non-productive times and allows efficient multi-machine operation through high-tech tool solutions
  • Considerable savings in tool costs and machining time are achieved through actuating technology as the piston bore and brass bushes are premachined and fine machined without additional tools
  • Precisely coordinated processes between pre- and fine machining