Large series with solid and adjustable tools

Valve housing EN-GJS-400-15 – spool bore and compensator bore

Initial situation at the customer

Valve-block

  • Large-scale series
  • Tool setting desired
  • High machine hourly rates
  • High costs for subsequent single pass honing

Special features of this solution

  • Ideally matched separate tools guarantee optimum preconditions for a reduced honing process
  • The honing process can be eliminated with certain part requirements

Spool bore

MAPAL Boring

1. Boring
  • Optimum results in the pre-machining due to a coordinated piloting and boring process
  • Optimum chip flow and extended regrinding options through multicut technology and perfect coolant supply
  • No ring formation in the cavities due to special bore geometry → no costs for removal of rings

Control edge machining

2. Control edge machining
  • Solid carbide profile tool
  • Highest accuracy and surface finish of control edges
  • Defined control edges without macroscopic flaws

Fine boring

3. Fine boring
  • Fine boring tool with EasyAdjust system and guide pads
  • Reliable precision machining with easy handling
  • Best cylindrical forms due to optimum guidance

Compensator bore

Boring

1. Boring
  • Solid carbide boring tool with 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

Fine boring

2. Contour machining
  • Double edge boring tool with form cutting edges
  • Reliable machining of the contour
  • Easy handling with low cutting material costs

Fine boring

3.精镗

  • 带有EasyAdjust-系统和导向板条的精镗刀
  • 工艺可靠的精加工，易于操作，无需进行后续的珩磨
  • 通过理想跟踪获得最佳圆柱形状

PRODUCTION COSTS PER SPOOL BORE

优点

  • 缩短了滑块钻孔中昂贵的珩磨流程
  • 每孔的刀具成本低
  • 通过与客户合作的巧妙工程设计缩短非加工时间
  • 由于消除了压力天平孔中的珩磨流程，显着节省了成本

ANNUAL PRODUCTION COSTS OF THE COMPENSATOR BORE [€]