Case Study: SDF Solid Carbide End Mills in the Hydraulic System – Aluminum Servo Valve Block Lightweight Structure Machining

Industry Background and Machining Challenges:

Aluminum servo valve blocks are critical components in hydraulic systems, often used in aerospace, automotive, and industrial automation. These blocks are characterized by complex internal passages and high-precision external features, requiring advanced machining capabilities to achieve lightweight designs without compromising structural integrity. The typical manufacturing process involves multi-axis milling, drilling, and contouring to meet tight tolerances and surface finish requirements, which are essential for the sealing and performance of hydraulic systems.

However, the machining of aluminum valve blocks poses several challenges. Aluminum is a relatively soft material, but when machined with high precision and deep cavity structures, the risk of work hardening, burring, and chatter increases. Additionally, the high aspect ratio of internal channels demands excellent chip evacuation. Standard tools often struggle with maintaining surface quality and tool life due to the combination of high-speed cutting and thermal softening of the workpiece material.

Technical Requirements for End Mills in This Industry:

• Excellent chip evacuation: to prevent chip clogging in deep cavities and thin-walled structures.
• High surface finish capability: to meet the stringent requirements of hydraulic fluid pathways and sealing surfaces.
• Low vibration performance: for maintaining tool stability and minimizing workpiece deformation.
• Wear resistance and long tool life: to reduce downtime and tooling costs in high-volume production.
• Effective chip control: to ensure smooth cutting without re-cutting of chips.
• Thermal stability: to sustain performance in high-speed and high-temperature conditions.
• Chip load and tool rigidity: to avoid edge chipping during heavy cuts.

SDF’s Product Solution:

SDF has developed a series of high-performance solid carbide end mills tailored for the machining of aluminum servo valve blocks. These tools are engineered to balance precision, speed, and tool life. Key features include:

• Optimized flute design: A variable helix and variable pitch geometry reduce harmonics and vibration, leading to a smoother cutting process.
• Advanced coating technology: Utilizing PVD-based nanocomposite coatings, SDF tools offer enhanced wear resistance and thermal stability, suitable for high-speed machining of aluminum alloys.
• High-quality carbide substrate: The carbide grade used in SDF end mills is specifically selected to provide the ideal combination of hardness and toughness for aluminum machining.

Below is a performance comparison of SDF solid carbide end mills with those of a certain international brand in key parameters and tool life testing:

Typical Customer Application Case:

A major manufacturer of hydraulic components was experiencing frequent tool wear and suboptimal surface finish when machining 6061 aluminum servo valve blocks with internal flow paths and thin-walled cavities. The production process required high-speed milling at 8000 RPM with a 0.05 mm depth of cut to maintain tight tolerances and surface quality. However, the existing tooling solution failed to meet the required tool life, with an average of only 3000 parts before tool failure.

SDF’s technical team conducted a detailed analysis of the customer’s machining conditions and recommended a specific model of solid carbide end mill. The tool was tested in the customer’s production line for one week, with data collected on tool life, surface finish, and machining efficiency.

After implementation, the results showed a significant improvement. The following table summarizes the performance improvements:

Conclusion and Brand Value Summary:

SDF’s solid carbide end mills demonstrate superior technical performance in the machining of aluminum servo valve blocks. The combination of innovative flute geometry, advanced coating, and high-grade carbide material enables SDF tools to deliver exceptional tool life, surface finish, and process stability. These attributes make SDF a strong alternative to traditional international brands, offering comparable performance at a significantly better cost-to-benefit ratio.

As the demand for lightweight, high-precision hydraulic components continues to grow, SDF is positioned to lead with its R&D-driven approach and deep understanding of customer-specific challenges. The brand is committed to advancing its cutting tool solutions, ensuring that it remains at the forefront of the global manufacturing industry.