For an Aluminum Hydraulic Manifold Block with 80 Deep Holes and 5mm wall thickness, AAK got the order for 300 pcs qty after the first samples

For a 6061-T6 aluminum hydraulic manifold block with 80 deep cavities and a wall thickness of 5MM, Brody asked 3 hydraulic manifold block manufacturers to make samples, but they all failed. AAK used 7075-T6 aviation aluminum to replace the conventional 6061-T6, breaking through the limitations of traditional processing, with guaranteed accuracy, reaching Ra0.2μm surface finish. We skillfully used abrasive flow processing technology to 100% remove burrs and helped Brody get out of trouble.

Brody, a hydraulic customer from the United States, needed to develop a hydraulic manifold recently, which has high requirements on the hydraulic manifold block. The inner chamber is deep. There are 80 deep holes on the side of the inner wall, and there are many long and thin holes. It has big difficulty on process and requires high precision. Brody knew that this hydraulic manifold block was not simple, so he specially arranged 3 trustworthy hydraulic manifold block manufacturers to make samples at the same time, but the results were not satisfactory, either the scrap was high, or the inner hole stayed at Ra1.6μm. Brody didn't want to give up this order.

Brody checked with 20 hydraulic manifold block manufacturers online and offline, but they were either silent or could not afford the difficulty of processing. Brody considered giving up. His friend Smith, also an old friend of AAK, recommended AAK to him. According to the drawing of the hydraulic manifold block sent by Brody, AAK engineers first responded that it was difficult. 3 days later, the processing process of the hydraulic manifold block was completed, but only 90% was sure. Brody did not hesitate and paid the development cost. 4 weeks later, AAK sent 3 hydraulic manifold block samples. 6 weeks later, Brody sent the PO for 300 pcs of hydraulic manifold blocks.

On the premise of ensuring dimensional accuracy, AAK broke through the limitation of traditional machining, and replaced 6061-T6 with 7075-T6 aviation aluminum material, which is not only good in toughness, but also more impact resistant in processing. The high strength can solve the hidden danger of 5mm wall thickness. In terms of inner hole finish, abrasive flow machining technology and semi fluid medium containing silicon carbide abrasive are used to guide the flow through the surface to be machined of the workpiece under a certain pressure, so that the abrasive can squeeze the material and remove it slightly. The operating parameters are adjusted as follows: machine pressure 14~224kg/cm ²； Silicon carbide sand particles with a diameter of 0.005~1.5mm shall be selected as the abrasive particles; The diameter of abrasive cylinder is 150~600mm.

New processing operation parameters ensure that the cutting uniformity of the abrasive flow on the machined surface is kept within 10% of the cutting amount, and the surface finish value can be reduced to about 1/10 of the original, reaching Ra0.2μm surface finish and low scrap rate.

AAK aluminum hydraulic manifold block, high-precision, burr free, welcome to try!

AAK HYDRAULIC VALVES (425) 11-29-22