Solutions for Fluid Technology

Tractor with baler at work in the field.
For the materials often used in fluid technology, cast iron, steel, stainless steels and non-ferrous metals, MAPAL offers economical process solutions through a high level of expertise in both bore machining and milling applications. Customers have relied on MAPAL's expertise for many years, particularly for demanding machining operations for hydraulic parts in a wide range of dimensions.

Everything depends on the main bore

Manufacturing valve housings is the supreme discipline in the hydraulics world. For many years, MAPAL’s expertise has been in demand for the spool bore. The gap dimension with the slide depends on the accuracy of this bore, which is very narrowly defined in modern hydraulic valves, so that the hydraulic oil can only flow in the required direction. The roundness, straightness and surface finish of this bore are also crucial.

The first machining step takes the varying quality of the blank parts into account. Since the pre-cast bores are relatively imprecise, a precise pilot bore must first be created in the first ridge. This lays the foundation for creating a good cylindrical form in the subsequent machining steps. Next, a solid carbide tool or, in the case of larger parts, a tool with indexable inserts passes through the entire bore. What the pilot drill has created for the first ridge is now produced along its entire length. To prevent ring formation in the hollow chambers due to chips, MAPAL ensures a soft cut during machining by using tangential technology. This can eliminate the need for a separate washing cycle in the process.

MAPAL fine boring tool with an adjustable cutting edge and guide pads

After this pre-machining, the classic fine boring tool is used, finishing the bore extremely precisely. It has an adjustable cutting edge and guide pads, which prevent the tool from being displaced from ridge to ridge. This produces a high degree of straightness and an exact cylindrical form.

The bore quality can usually be improved to such an extent that the sometimes still necessary three-stage honing process can be reduced to a one- or two-stage honing process, or honing can even be eliminated altogether. However in cases where three stages are still needed, this process is considerably faster thanks to the good pre-machining.

標準ツールによる高い費用対効果

油圧部品の加工では、利用可能な標準的なラインナップで経済的な加工を可能にすることにも重点を置いています。例えば、フェースミーリング用のNeoMillシリーズやTritan-Drill-Reamerは、ボーリングとミーリングを一度に行うことができ、新しいUNIQ DReaM Chuck 4.5°との組み合わせで、最高のドリル加工結果を保証します。

タンジェンシャルボーリングツ ールによる効率的な加工

Tangential boring tool with indexable inserts

部品はG G G 5 0 ( 球状黒鉛鋳鉄) の500x500mmの大きさのバルブブロックで、3つのピストン穴を両側から加工します。その取り代は、直径16mmにまで達しています。交換式のインサートを備えたタンジェンシャルボーリングツールは、短い不連続チップを生成して、リングが隙間に押し込まれるのを防ぎますが、これを取り除くには多大な労力を費やします。部品あたりの加工時間は、15.33分短縮できます。このタイプのハウジングは500個生産されており、これは合計で128時間の時間を節約したことになります。