Single stage hydraulic servo valve body lean manufacturing process.

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]

Bill Moog - the inventor, the pioneer and the entrepreneur.

Similar Business Interests:
.

Bendix Chandler Evans Double A Dowty Hamilton Standard Lucas Moog National Waterlift
Oil Gear Parker Hannifin Pegasus Rexroth Sun Hydraulics Vickers Woodward Govenor

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]

0.00040 flatness 24 Ra surface finish on valve mounting surface (face milled)
0.4921 +0.00020/-0.00000 diameter bore 0.000120 cylindrically (hone stock) for bore fit to spool with 0.00040 diametrical clearance
0.7480 +.00080/-0.00000 diameter c'bores 2 places
32 Ra surface finish on o-ring sealing surfaces with machined edge breaks 4 places
0.00120 total positional tolerance of meter edges 6 places from datum surface
9 angle holes

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.

OPERATION 0070
HONE AND WIRE BRUSH MAIN BORE.

OP70 HONE

OPERATION 0080
BLACK OXIDE.
.
OPERATION 9999
STOCK.