Based on the applications already implemented for existing customers, Mapal has developed tailor-made solutions for fluid technology. Mapal's expertise lies in the spool bore. The gap dimension with the spool depends on the accuracy of this bore so that the hydraulic oil can only flow in the desired direction without leaking. This is very narrowly defined in modern hydraulic valves. Accordingly, great attention is paid to the roundness, cylinder shape, straightness and surface quality of this bore.

Illustrative best-practice examples address specific manufacturing situations. Mapal designs the tools in such a way that the most economical process is always achieved. This includes not only completing pre-machining and semi-finishing quickly, but also keeping an eye on downstream processes such as honing.

The first of the solutions presented for machining a hydraulic valve housing is rather atypical for Mapal, as it does not require a fine boring tool for finishing. After piloting, boring and circular milling of the spool bore, a multi-bladed reamer is used for the final machining step before honing. With this tool selection, Mapal demonstrates that some tasks can be solved with high precision even without an adjustable special tool. The concept is particularly suitable for small and medium quantities.

If the component has to be machined from two sides due to its dimensions, the third solution comes into play. Mapal uses a multi-stage boring tool with radial and tangential indexable inserts for piloting and boring. It completes the pre-machining of the slide bore and the finishing of the contours in one shot. A solid carbide profile tool machines the control edges in a defined manner and without chipping. The downstream fine boring tool with adjustable indexable inserts and guide pads eliminates the axial offset caused by machining from two sides. This would not be possible with a multi-bladed reamer of this quality.

Application solution 4 brings the flexibility to fluid technology that is required above all for small series and prototype construction. The Tooltronic mechatronic tool system makes it possible to carry out the honing process via an additional axis on the machining center. This means that the entire machining process can be carried out in one clamping operation on one machine. Machining with the Tooltronic achieves high surface quality and dimensional accuracy with the tightest manufacturing tolerances and high flexibility. In addition, burr-free and rounded transitions are produced and reclamping errors due to retooling on the honing machine are eliminated. For low quantities, a classic single-bladed reamer from the standard portfolio can be used for bore machining instead of a special tool. In this case, the quick availability and lower tool costs compensate for the slightly longer machining time.