Valve is a control component in the fluid transportation system. It has the functions of cutting off, regulating, guiding flow, preventing reverse flow, stabilizing pressure, diverting flow or overflow pressure relief. From the simplest stop valve to various valves used in extremely complex automatic control systems, their varieties and specifications are quite wide.
In the past two or three decades, industries such as petroleum, chemical industry, power stations, metallurgy, shipbuilding, nuclear energy, and aerospace have developed rapidly, which has put forward higher requirements for valves. For example: Ball valves used in the petroleum industry are used under harsh working conditions with high corrosion resistance, heat resistance, pressure resistance and oxidation resistance, so the products are required to have higher durability and reliability. In order to meet these high quality requirements, it is necessary to select machining tools that can achieve stable and high-precision machining. Today, the editor will introduce to you the industrial valve processing solutions from Tungaloy, EMAG and Stutt.
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Tungaloy knives
>>>Company introduction
Tungaloy is part of the IMC Group of Berkshire Hathaway, which is run by Warren Buffett. It provides comprehensive services to customers around the world in the fields of automobiles, construction, aerospace, medical, power, infrastructure and heavy industry. products and services.
>>> Introduction to processing technology and solutions
Tools selected ensure stable tool life even when machining forged surfaces that can cause insert chipping
Boring tools make it easy to fine-tune the tool diameter even on the machine tool
Use a thread milling cutter for thread cutting to prevent unexpected problems such as sudden tool breakage and achieve stable thread processing
Efficient grooving for stable chip generation and discharge
Tool selection for high precision and reliability in large diameter drilling
Reduce tool set-up and tool management time with interchangeable-head tools
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>>> Processing methods adopted
Rough milling end face
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Precision boring
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Thread milling
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Milling slots
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Precision turning inner hole
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drilling
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>>>Processing examples and conclusions
Knife: DrillForce-Meister
Parts: valve
Material: SUS304/X5CrNi18-9
Drill body: TIS300F40-5
Drill tip: SMP300
Material: AH725
Processing conditions: vc = 60m/min; f = 0.25mm/rev; vf = 160mm/min; H = 120mm
Machine Tool: Horizontal Machining Center
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>>>Tool advantages and effects
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>>>Tool or processing video
Video material, WiFi is recommended to watch
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EMAG machine tools
>>>Company introduction
As a global machine tool manufacturer, EMAG Group's products cover all processes of soft and hard metal processing. To do this, EMAG uses a variety of process technologies – from turning, drilling, milling, gear hobbing, grinding and grinding, to laser welding, shrink-fit assembly, to electrolytic machining.
>>> Introduction to processing technology and solutions
Piston pump cylinder processing - EMAG VL200 inverted single-spindle high-precision lathe and EMAG VSC400DD inverted single-spindle customized machine tool.
As a typical product of the EMAG inverted turning center, the VL200 machine tool is suitable for turning, milling, drilling and other combined processing of disc parts with a diameter of <200mm, including roughing and finishing of hydraulic piston pump cylinders in engineering machinery. As a customized product of the EMAG inverted turning center, the VSC400DD machine tool is suitable for complex processing of turning, milling, drilling and other processing of disc parts with a diameter of <340mm, including the precision boring process of hydraulic piston pump cylinders in engineering machinery.
>>>Difficulties in workpiece processing
High-precision dimensional and geometric tolerance requirements
Efficient parts processing cycle time
Highly integrated process processing
>>> Processing methods adopted
Relying on excellent machine tool rigidity, unique inverted structural design, and high stability and precision, VL200 can achieve stable production with IT6 level precision.
Each VL series machine tool is a complete production unit with a unique inverted spindle structure. In addition to processing workpieces, the spindle is also used for automated external loading and unloading, which saves expenses, floor space and unnecessary External automation equipment has the characteristics of high efficiency and high economy.
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Relying on excellent machine tool rigidity, unique inverted structural design, and high stability and accuracy, VSC400DD can achieve high-precision processing of φ25 size +0.01 and roundness/straightness 0.003.
Each machine tool in the VSC series is a complete production unit with a unique inverted spindle structure. In addition to processing workpieces, the spindle is also used for automated external loading and unloading, which saves expenses, floor space and unnecessary External automation equipment has the characteristics of high efficiency and high economy. At the same time, its special bed design can be equipped with various independent spindles as needed to complete more and more complex processing techniques.
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>>>Processing examples and conclusions
Processed parts: plunger pump cylinder
Processing machine tool: VL200
Processing type: rough and fine turning
Complete all turning of parts in 250 seconds (including loading and unloading)
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Processed parts: plunger pump cylinder
Processing machine tool: VSC400DD
Processing type: Precision boring
Complete the finishing of the plunger hole of the part in 180 seconds (including loading and unloading)
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Video material, WiFi is recommended to watch
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Stutt internal grinding machine
>>>Company introduction
Fritz Stutt specializes in the production of universal internal and external cylindrical grinding machines. Its products are mainly used in the machine tool industry, automotive engineering, tool and mold industry, aerospace industry, pneumatic/hydraulic, electronic/electrical engineering, medical technology, watchmaking and other industries. Stutt S131 is its latest generation internal arc grinder. Its unique technical features are widely used in the engineering hydraulic industry, especially for the grinding of spherical and arc workpieces and the inner hole taper surface of hydraulic valve sleeves.
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Stutt S131 internal arc grinder
>>>Product Description
Studer S131 internal arc grinder brings together many technical points, such as: patented Granitan artificial granite bed, revolutionary StuderGuide rail system, 0.4 micron live spindle roundness workpiece headstock, and high precision using linear motors Linear drives and direct-driven fully automatic B-axes, etc. Through the interpolation and linkage grinding process of the B axis and the X and Z axes, conical and arc surfaces can be ground to polished surfaces. It can perform linked interpolation processing of various complex parts such as arcs and cones from -60° to +90° in one clamping operation.
>>>Successful Case: Hydraulic Valve Sleeve
Tooling: Power chuck
Grinding wheel: ceramic corundum
Processing methods: end face positioning, cylindrical clamping, end face grinding, inner hole and inner tapered hole
Processing difficulties: reduce deformation and ensure cylindricity of 2 microns
Machine tool performance: fast programming, convenient compensation, repairing shaped grinding wheels, multiple grinding wheels, coarse and fine grinding
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Center height 150mm
X-axis travel 350mm
Z-axis travel 400mm
B axis +60°~-91°
Process Description
1. Parts: Hydraulic valve sleeve
2. End face positioning, outer circle clamping
OP 1 External bevel grinding wheel for end face grinding
OP 2 Internal Grinding Wheel for Internal Hole Grinding
OP 3 internal chamfer grinding wheel for internal cone grinding
3. Grinding wheel: ceramic corundum
4. Trimming: electric spindle diamond disc
