single stage hydraulic servo valve

SINGLE STAGE HYDRAULIC SERVO VALVE


Manufacturing Alliance Associates, Inc.
720 Maple Road, East Aurora, New York 14052-1012   716-652-4510
.
Since 1993 implementing technology for businesses where resources are non-existent or during a growth initiative. [ YouTube Video]

INCIDENT: improve the capabilities of the developing source in China by creating a process-in-control outside of OEM existing US facilities.
CONSTRAINTS:  develop and debug a turn-key metric process for manufacturing hydraulic servo valves in Shanghai, China; utilize similar and compatible machinery (develop local job shop) and inspection equipment (no cmm) to the machinery and gauging actually used at the existing facility in the Free Trade Zone in Shanghai, China;  increase through-put to increased inventory turns; and,  prepare the process for shipment.
POINT: improve the cost, quality, delivery and reliability.
BENEFIT: see the METHODS COMPARISON table below.
HYDRAULIC VALVE BODY
MACHINING OPERATIONS PROCESS FOLDER
.
PRECISION MACHINING WITH PROGRESSIVE FIXTURING
[ COMPLETE DETAILED PROCESS ILLUSTRATION]
INDIVIDUAL BLUEPRINT VIEWS
BLUEPRINT INCH
NOMENCLATURE INCH
BLUEPRINT METRIC
NOMENCLATURE METRIC
METHODS COMPARISON



Current 
New
Reduction Percentage
Method: Europe/Asia U.S.A. .
Issue material 52. x 52. x 63. MM 56. x 56. x 63. .
Mill surface -F- inprocess 
Drill & ream mounting holes
Drill locating pin hole
CNC vertical machining center 3-axis 
Meldas 0M mcu
OPERATION 10 .
Twin mill surfaces -B & E- inprocess Twin mill OPERATION 20 .
Twin mill surfaces -A & D- Twin mill OPERATION 30 .
Mill surface -C- inprocess Knee mill OPERATION 40 .
-E- machine I.D. features w/ 
inprocess flow edges
CNC lathe 2-axis 
Fanuc compatible mcu
OPERATION 50 .
-B- machine c'bore features CNC lathe 2-axis 
Fanuc compatible mcu
. .
Drill & ream E2 angle hole Gang drill w/drill jig . .
Drill & ream F1 angle hole Gang drill w/drill jig . .
Drill & ream F2 angle hole Gang drill w/drill jig . .
Drill & ream F3 angle hole Gang drill w/drill jig . .
Drill & ream F4 angle hole Gang drill w/drill jig . .
Drill & ream C1 angle hole Gang drill w/drill jig . .
Drill & ream C2 angle hole Gang drill w/drill jig . .
Drill & ream C3 angle hole Gang drill w/drill jig . .
Drill & ream C4 angle hole Gang drill w/drill jig . .
Surface -C- inprocess 
C'bore o-ring holes 
Drill locating pin hole
CNC vertical machining center 3-axis 
Meldas 0M mcu
. .
Grind surface -E- Surface grind . .
Grind surface -B- Surface grind . .
Grind surface -C- Surface grind . .
Grind surface -F- Surface grind . .
Deburr & polish Bench Bench .
Hone main bore per b/p Manual hone Manual hone .


Setup standard hours 36.0 5.0 93.0%
Run standard hours 2.750 0.750 93.0%
Number of operations 23 8 97.0%
Shrinkage (scrap) 40.0% 5.0% 92.0%


Lot size 500 50 90.0%
.
MACHINE PARAMETERS
PARAMETERS
CONSTRAINTS:
LEADWELL MCV-0 VERTICAL MACHINING CENTER

MELDAS M0 MACHINE CONTROL UNIT (FANUC 0MA COMPATIBLE)
400 IPM RAPID, 200 IPM CUT
BT40 16 TOOL MAGAZINE
66-6000 RPM 3HP CONTINUOUS 5HP 15 MINUTES
AC BRUSHLESS SPINDLE MOTOR
FLOOD COOLANT
8 FIXTURE OFFSETS, 100 TOOL OFFSETS
OPERATION 0005
ISSUE AND INSPECT MATERIAL.
Issue material GGG40 (ductile iron 65-45-12).
Condition of saw cut raw material issued before machining in operation 1.
.
52. x 52. x 63. MM EUROPE

56. x 56. x 63. U.S.A.
OPERATION 0010
CNC MACHINING
SEE OP10 SHOP FOLDER FOR PROGRAM AND SETUP INSTRUCTIONS.
NOTE: 0.10-0.12 INPROCESS STOCK ON SURFACES B, E & F.
OP10 MACHINE TOOL SETUP INSTRUCTIONS
OP10 TOOL ASSEMBLY INSTRUCTIONS
OP10 MACHINING SEQUENCE INSTRUCTIONS
OP10 CNC PROGRAM
OP10 INSPECTION INSTRUCTIONS
OPERATION 0020
CNC MACHINING.
SEE OP20 SHOP FOLDER FOR PROGRAM AND SETUP INSTRUCTIONS.
NOTE: 0.10-0.12 INPROCESS STOCK ON SURFACE F.
OP20 MACHINE TOOL SETUP INSTRUCTIONS
OP20 TOOL ASSEMBLY INSTRUCTIONS
OP20 MACHINING SEQUENCE INSTRUCTIONS
OP20 CNC PROGRAM
OP20 INSPECTION INSTRUCTIONS
OPERATION 0030
CNC MACHINING.
SEE OP30 SHOP FOLDER FOR PROGRAM AND SETUP INSTRUCTIONS.
NOTE: 0.10-0.12 INPROCESS STOCK ON SURFACE F.
OP30 MACHINE TOOL SETUP INSTRUCTIONS
OP30 TOOL ASSEMBLY INSTRUCTIONS
OP30 MACHINING SEQUENCE INSTRUCTIONS
OP30 CNC PROGRAM
OP30 INSPECTION INSTRUCTIONS
OPERATION 0040
CNC MACHINING.
SEE OP40 SHOP FOLDER FOR PROGRAM AND SETUP INSTRUCTIONS.
NOTE: 0.10-0.12 INPROCESS STOCK ON SURFACE F.
OP40 MACHINE TOOL SETUP INSTRUCTIONS
OP40 TOOL ASSEMBLY INSTRUCTIONS
OP40 MACHINING SEQUENCE INSTRUCTIONS
OP40 CNC PROGRAM
OP40 INSPECTION INSTRUCTIONS
OPERATION 0050
CNC MACHINING.
SEE OP50 SHOP FOLDER FOR PROGRAM AND SETUP INSTRUCTIONS.
NOTE: 0.10-0.12 INPROCESS STOCK ON SURFACE F.
OP50 MACHINE TOOL SETUP INSTRUCTIONS
OP50 TOOL ASSEMBLY INSTRUCTIONS
OP50 MACHINING SEQUENCE INSTRUCTIONS
OP50 CNC PROGRAM
OP50 INSPECTION INSTRUCTIONS
OPERATION 0060
DEBURR COMPLETE.
OP60 DEBURR
OPERATION 0070
HONE AND WIRE BRUSH MAIN BORE.
OP70 HONE
OPERATION 0080
BLACK OXIDE.
.
OPERATION 9999
STOCK.
©1996-2011: mfgaa.com®  All rights reserved. Subject to change without notice.[ Home ]