• 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

加工ソリューション

1 – ソリッドツールを使用する中小規模生産

お客様の初期の加工状況

MAPAL Application solution 1

バルブケース EN-GJS-400-15 - スプール穴

  • 個別受注・小ロット・中ロット
  • ツール調整機能なし
  • ツールのリードタイムが短い
  • 高い機械稼働率
  • 安定した拡張ホーニングが可能
  • 複数部品のバリエーションに適応するツールコンセプト

詳細
2 – ソリッドツールとアジャスト可能ツールを使用する大量生産。

Situation initiale du client

MAPAL Application solution 2

Corps de valve EN-GJS-400-15 – Alésage de tiroir et de compensation

  • Grande série
  • Réglage des outils souhaité
  • Taux horaire élevé des machines
  • Coûts élevés pour les pierrages suivants

Détails
3 – Petits lots – Diminution des changements d'outils grâce aux outils combinés

Situation initiale du client

MAPAL Application solution 3

Corps de valve EN-GJL-300 – Alésage de tiroir

  • Petits lots
  • Possibilité de régler l’outil
  • Changement d'outil trop fréquent/fréquent
  • Taux horaire élevé des machines
  • Frais élevés en raison du processus de pierrage

Détails
4 – Rodage flexible sur le centre d'usinage

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

Initial situation at the customer

MAPAL Toolmanagement

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

Details

Tool solutions

Piloting and boring
  • 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

    Solid carbide circular milling cutter

    • Significant cycle time savings
    • Defined control edges without macroscopic flaws

  • Control edge machining

    Solid carbide profile tool

    • Highest accuracy and surface finish of control edges
    • Defined control edges without macroscopic flaws

Reaming and fine boring
  • Reaming

    Multi-bladed reamer

    • High cutting data
    • Perfect chip control due to left-hand twist and optimum coolant supply

  • Fine boring

    Fine boring tool

    • EasyAdjust system and guide pads
    • Reliable precision machining with easy handling without subsequent honing
    • Best cylindrical forms due to optimum guidance

  • Fine boring

    Fine boring tool

    • Indexable inserts and guide pads
    • Ideal for bar machining of highly accurate and long bores

Fine machining with honing
  • TOOLTRONIC

    MAPAL TOOLTRONIC

    • Redução significativa nos tempos de produção e de ciclo
    • Maior precisão de contorno

Fresamento
  • NeoMill-16-Face

    NeoMill®-16-Face

    • Inserto intercambiável com 16 arestas / 45º
    • Primeira escolha para ferro fundido e aço fundido resistente ao calor
    • Faixa de ø de 63 a 200 mm/ap máx. 4 mm
    • Baixas forças de corte apesar de uma geometria negativa
    • Máxima eficiência econômica para faceamento

  • NEOMILL-8-CORNER

    NeoMill®-8-Corner

    • Inserto intercambiável de oito arestas / 90°
    • Primeira escolha para ferro fundido
    • Faixa de ø de 50 a 200 mm/ap máx. 8 mm
    • Máxima eficiência econômica para fresamento 90°

  • NEOMILL-4-CORNER

    NeoMill®-4-Corner

    • Inserto intercambiável de quatro arestas / 90°
    • Adequado para aço, aço inoxidável, ferro fundido e aço fundido resistente ao calor
    • Faixa de ø de 25 a 100 mm/ap máx. 10 mm
    • Fresamento de parede lateral, aplica-se multipasses
    • Forças de corte muito baixas apesar de uma geometria negativa

Fixação
  • UNIQ Mill Chuck

    UNIQ Mill Chuck

    • 非常に長いミーリングサイクル（240分以上）でも80℃の高い耐熱性
    • 最大33,000rpmの高性能ミーリング加工
    • 最高の工程信頼性

  • UNIQ DReaM CHUCK 4.5°

    UNIQ DReaM Chuck, 4.5°

    • シュリンキングチャック (4.5°のDIN輪郭)の原寸のハイドロチャック
    • アプリケーション指向のシステム設計
    • 最大限の工程信頼性と工具寿命
    • 高速・高精度なツール交換

  • HB MILL CHUCK SIDE LOCK CHUCK

    HBサーフェスチャック MILL CHUCK

    • デファレンシャルスクリューによる簡単な操作
    • 最高のコスト削減効果と精度
    • スプリングシステムにより設定された軸方向ツール位置決め
    • コントロールエッジ加工におけるプロファイルツールの最適な位置決め