油圧バルブハウジング
すべてはメイン穴の加工品質に依存します。流体技術部品の加工において、バルブケースの製造は、最も高い精度が要求される分野です。ここでは長年にわたってマパールのスプール穴加工に関する技術ノウハウが必要とされてきました。スプールとスプール穴のギャップは、加工穴の精度に左右され、作動油は一定の方向にしか流れないようになっています。 最近の油圧バルブ穴は、加工公差の幅が非常に狭くなっています。そのため、加工穴の真円度、真直度、円筒度、仕上げ面精度はきわめて重要になっています。
機械加工条件
- 鋳鉄の取り代の変動状況
- 大きく中断する切削
- ボーリング時のリング形成の防止、ハウジングからの確実な切り屑搬出
- ボーリングプロセスでのコントロールエッジの破損の防止
- 形状と位置公差に対する非常に高い要求
- ホーニング前の一定の取り代
- 製造部品のばらつきや限られたツール収納スペースを考慮した機械加工コンセプト
方向切換弁
As válvulas direcionais são válvulas acionadas mecânica ou eletronicamente com várias posições de comutação. Dependendo da posição especificada da bobina ao longo das bordas de controle, um fluxo com volume é definido para operar o equipamento conectado. O compensador de pressão individual ajusta uma queda de pressão com carga constante através da borda de controle de alimentação do êmbolo, de modo que um controle de fluxo com volume independente da pressão de carga seja obtido em toda a faixa de ajuste, também na operação paralela (compensação de carga). O sistema deve estar livre de vazamentos, para evitar quedas acidentais da carga, mesmo nas operação em paralelo.
Usinagens de furos
Application solutions
1 – Small and medium series with fixed tools
Initial situation at the customer
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
2 – Large series with solid and adjustable tools
お客様の初期の加工状況
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
3 – Small lot sizes – Reduced tool changes due to combination tools
Initial situation at the customer
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
4 – Flexible honing on the machining centre
Initial situation at the customer
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
5 – Tool management
Initial situation at the customer
Valve housing EN-GJS-400-15 – complete machining
- High inventories
- Processes in the tool-setting area not optimal, and incomplete data quality
- Cost transparency is not sufficient
- High fluctuation due to general lack of skilled workers
- Problems with tool breakage
- High tool costs
Tool solutions
Piloting and boring
Control edge machining
Reaming and fine boring
Fine machining with honing
Milling
Clamping
