PRECISION SOLUTIONS THAT MEET A VARIETY OF REQUIREMENTS
Highly economical machining of hydraulic valve housings
The production of hydraulic valve housings is the supreme discipline in the world of fluid technology. Great attention is paid to the quality of the main bore.
Manufacturing hydraulic valve housings is the supreme discipline in the world of fluid power technology. As a technology partner, MAPAL supports customers with regard to complete process design. The experts pay particular attention to the cost drivers here, which can often be found in functionally relevant bores. Based on the respective honing procedure, the part requirements and lot sizes, MAPAL designs the perfect machining strategy in dialogue with the customers.
Based on the applications already implemented for existing customers, MAPAL has developed specific solutions. They reflect many customer and component requirements. After all, when it comes to spool bores, MAPAL’s expertise has been in demand for years. The gap dimension with the spool depends on the accuracy of this bore so that the hydraulic oil can only flow in the required direction without leaking. This is very narrowly defined in modern hydraulic valves. The roundness, cylindrical form, straightness and surface finish of this bore are therefore crucial.
Clear best practice examples each deal with specific production situations. MAPAL designs the tools for these in a way that always results in the most cost-efficient process. That includes completing pre-machining and semi-finishing swiftly – all while keeping an eye on subsequent processes further down the line, such as honing.
APPLICATION SOLUTIONS FOR EVERY SITUATION
The first of the solutions presented for the machining of a hydraulic valve housing is rather unusual for MAPAL, as it does not include a fine boring tool for finishing. After piloting, boring and circular milling of the spool bore, in this instance, a multi-bladed reamer performs the final machining step before honing. With the tool selection, MAPAL shows that finding the optimal solution for the customer is the main drive. The concept is particularly suitable for smaller and medium quantities.
If large quantities and high levels of accuracy are sought in series production, the second application solution is the right blueprint. The key difference is the fine boring tool used for fine machining. It meets the high standards for spool bore and compensator bore production. The EasyAdjust-System and guide pads offer reliable fine machining with easy handling. As the customer’s technology partner, MAPAL agrees with them the extent to which a concluding honing process can be scaled down or even omitted.
Dear business partners,
dear readers,
The year 2022 was marked by drastic geopolitical and economic events. The war in Ukraine, inflation and the ongoing disruptions to global supply chains have had a significant impact on our work, and certainly on yours, and have made it a bit more unpredictable.
Encouragingly, the economic mood in our industry improved during autumn 2022. This was certainly helped by the fact that in-person encounters were possible once again as Covid-19 transitioned from pandemic to endemic – for instance, at the AMB in Stuttgart, which was a huge success. We presented our consistent focus on the market segments automotive/ electric mobility, die & mould, aerospace and general machining to our customers and interested parties there for the first time. The positive feedback confirms our decision to continue on this path.
In the current issue of Impulse, we present our strategies, solutions and applications in electric mobility, aluminium machining and tool management. We began at a very early stage to develop the processing of strategically important components of electric mobility in terms of processes and products. As a result, we are in a position to offer our customers sophisticated and cost-effective processes today. There is no one-fits-all approach. Instead, we focus on the requirements of the component and offer various solutions depending on the production lot size and component features. In this way, we remain true to our core principle: the customer and their needs are the be-all and end-all of what we do. With the increasing popularity of electric drive solutions, this approach is now also coming to bear in practice.
With tailored tool management solutions, we support our customers in focusing on their core competencies and enter into a close, trusting relationship with them. Integrating digital solutions from our subsidiary c-Com gives our tool management range a new quality. For new projects in particular, installing digital tool management is now standard, and the cloud has also become established and accepted as an intermediary between different process components. We have made significant progress in this area in recent years – with plenty of associated benefits for our customers. In this respect, all our efforts draw on the ideas, skills and personal commitment of our employees. They are the foundation of all we do. This is why we attach such great importance here at MAPAL Group to training the skilled workers of tomorrow ourselves – with great commitment and a sustainable approach. I’m especially delighted that 85 apprentices graduated at the MAPAL Group again in 2022. With great success: the 2022 world champions in the field of “Robotic Systems Integration” and the best industrial mechanic in Baden-Württemberg come from MAPAL. Almost all graduates have accepted our offer of employment and are now an integral part of the workforce.
So I am – and we are – optimistic going into 2023 and looking ahead with positivity. We look forward to many opportunities for in-person interactions with you and working together on your challenges.
Have a good read!
Yours,
Dr. Jochen Kress
