Description
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Lineup long life tool to satisfy the customers with high quality standards. Patented technology “Ring Free Machining” solve the remaining ring that occurs in the inner diameter intermittent part in the drill and reaming.
Features:
- Patented technology “Ring Free Machining”
- Diverse lineup such as drill, tap, groove and cutter
Introduction
Hydraulic valve bodies in many varieties are one of the most widespread industrial components in cast iron. The majority of manufacturers of these components often face the same challenges in the machining process.
Cutting tool solutions for hydraulic valve bodies
This brochure focuses on tooling solutions for the machining of hydraulic valve bodies in cast iron. KYOCERA
UNIMERCO strives to constantly be at the forefront of product development and to meet the increased customer requirements of high quality and long tool life.
Ring-free machining™
Rings produced in the bore by the rough pass reamer is a common problem when machining spool bores. The following manual removal of these rings prior to finishing/assembly is a time consuming and costly process. A new patented process and tool technology eliminates the rings, and results in considerable savings for our customers.
At the cutting edge
Our intensive research and development continuously improve the tool solutions for the benefit of our customers. Therefore make sure to keep in close contact with your sales technician to benefit from the latest technological developments that will keep your unit costs at a minimum.
Competitiveness through reduced production costs
Through higher product quality and reduced machining time, we can lower your production costs. Learn more about our unique tool solutions, which are known to significantly increase productivity.
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Optimising the process strategy
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Increasing cutting data with helix tools
One of the general optimisation principles is to replace straight fluted tools with helix tool solutions. Combined with the C7 PLUS™ coating it is often possible to increase the cutting speed considerably while maintaining the same tool life time and machine wear.
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Revealing the potential
Measuring the thrust force of each solution when running at the same cutting parameters reveals the optimisation potential. Applying the same cutting parametres, the thrust force is much lower when using the twist drill than the straight fluted drill. However, the correct runnning in of the tools is a precondition for getting the optimum benefit of the improved tool solution.
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Increasing the cutting data
The cutting parameters of the twist drill are increased until the thrust force is equivalent to the original straight fluted solution. The result is that the cutting data can be increased by up to 248% (Vf 3081 mm/min. / Vf 1241 mm/min.)
Even though the cutting parametres are increased by 248% the thrust force is now at the equivalent level of the original tool solution.
Examples of tool solutions
SPOOL BORE HOLES
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Objective
To eliminate rings produced in the bore by the rough pass reamer. In the typical process these rings need to be removed manually prior to finishing/assembly.
Result
- Excellent size consistency
- A straight hole free of rings
- Huge cycle-time reduction (50%)
- 15 minutes saved per part
CAVITY HOLES
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Objective
To reduce the number of tools needed by combining more operations in one. Machine without vibration to obtain narrow diameter tolerance and perfect surface roughness.
Result
Reinforced core diameter and extra guide pads on the solid carbide drills with helix perform extremely well.
- Reduced machining time
- No vibration
- Safe process
- Surface quality: Ra 0.8
- Hole tolerance: H7-H8
- A straight hole
SHOCK VALVE HOLES
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Objective
A fast and reliable process ensuring that the tolerances are achieved in the most efficient way. A typical challenge is to meet the demands for a good surface quality.
Result
One shot drill with extra guide pads and C7 PLUS™ coating creating a straight hole with excellent surface quality while maintaining high feed and a long tool life. The C3 coated thread milling cutter ensures a reliable threading process.
PORT HOLES
Kyocera Tooling for Hydraulic Valve Body (Cast Iron) Machining – PT. Ikimura Indotools Center
Objective
The large diameter must be created in a drilling operation. Must be machined without vibration to obtain narrow diameter tolerances and perfect surface roughness.
Result
The step drill in pre-form carbide with special internal coolant and centre point makes it possible to increase cutting speed.
- Reduced machining time
- No vibration
- Safe process
- Excellent surface quality
- Long tool life
English 
Indonesian