Case Study: SDF Ball End Mill Solutions for Hydraulic Systems – Multi-Face Machining of Splitter Valves

Industry Background and Machining Challenges:

In the hydraulic system industry, splitter valves are key components used for distributing flow in high-pressure environments. These valves often require multi-face machining, where complex 3D contours and tight tolerances are processed in a single setup using an integrated fixture. This setup typically involves ball end mills to achieve smooth surface finishes and precise geometry.

Manufacturers face several challenges during this process. The materials used for splitter valves are often hardened steels (e.g., HRC 45–50) or corrosion-resistant alloys, which are difficult to machine. Surface finish requirements are typically below 1.6 µm Ra, demanding stable cutting and minimal tool wear. Additionally, the need for high production efficiency and consistent part quality under complex tool paths and high axial depths of cut puts pressure on tool life and reliability.

Technical Requirements for End Mills in the Industry:

• Complex contour processing: The ability to handle multi-axis tool paths with high shape accuracy.
• High precision: Tool dimensional stability is crucial to maintain form accuracy and tool path consistency.
• Surface finish performance: The end mill must provide excellent chip control and minimal vibration to ensure fine surface quality.
• Wear resistance: Long tool life is essential to reduce downtime and tooling costs.
• Chip control and heat dissipation: Efficient chip evacuation and thermal stability prevent tool damage and improve machining consistency.
• Edge toughness: Resistance to edge chipping under interrupted cutting and high load variations is required.

SDF Product Solution:

SDF developed a series of high-performance ball end mills specifically tailored for the machining of hydraulic splitter valves. These tools feature a micro-grain tungsten carbide substrate, ensuring excellent wear resistance and mechanical strength. The cutting edges are precisely ground with a 5-axis CNC grinding system to maintain tight tolerances and excellent shape fidelity.

Advanced coating technology is applied, including multi-layer TiAlN-based coatings with nanocrystalline structures. This provides enhanced thermal stability and friction reduction, enabling the tools to perform consistently at high cutting speeds and feed rates, even in difficult-to-machine materials.

The flute geometry is optimized with a variable helix and variable pitch design, which reduces vibration and harmonics during deep cutting. This design also improves chip formation and evacuation, which is critical in long machining operations.

The higher precision in surface finish achieved by SDF’s end mills ensures smoother operation and reduced leakage in hydraulic systems.

Parameter	SDF Ball End Mill	Competitor Brand A	Competitor Brand B
Material	Micro-grain carbide	Standard carbide	Standard carbide
Revestimiento	TiAlN + nanocrystalline layers	TiN + AlCrN	TiAlN
Helix Angle	38°–45° variable	40° fixed	45° fixed
Pitch Design	Variable pitch	Fixed pitch	Fixed pitch
Surface Finish (Ra)	≤ 1.0 µm	1.2 µm	1.4 µm
Tool Life (Cutting Time, hrs)	15–20 hrs (HRC 48)	10–12 hrs	8–10 hrs
Edge Strength	High (resistant to chipping in interrupted cuts)	Moderate	Low

Typical Customer Application Case:

A European manufacturer of hydraulic components approached SDF with a specific problem during the multi-face machining of a splitter valve body. The existing ball end mill solution was experiencing premature edge wear and frequent tool breakage due to the high hardness of the material and the aggressive axial cutting depth of 3.5 times the tool diameter. The customer required a reliable tool that could maintain consistent performance across 8 different tool paths in a single operation.

SDF’s technical team conducted a comprehensive analysis of the customer’s machining conditions and tool path strategy. They proposed a custom ball end mill with a 42° variable helix and a 5-flute design to improve chip evacuation and reduce vibration. The tool was tested under real production conditions with a cutting speed of 280 m/min and feed per tooth of 0.15 mm/tooth in hardened steel (HRC 47). After three weeks of production use, the customer reported a 23% increase in machining speed and a 35% improvement in tool life, with no edge chipping or breakage observed.

The increased cutting speed reduced cycle time and improved throughput.

Métrica	Before SDF Implementation	After SDF Implementation
Cutting Speed (m/min)	220	280
Feed per Tooth (mm/tooth)	0.12	0.15
Tool Life (hrs)	12	16
Part Quality Pass Rate (%)	88	97

Conclusion and Brand Value Summary:

SDF’s ball end mills are engineered to meet the rigorous demands of hydraulic component manufacturing, especially for complex, multi-face machining operations. With superior coating performance, advanced flute geometry, and a micro-grain carbide base, SDF tools demonstrate excellent wear resistance, thermal stability, and edge toughness.

As a global solution provider, SDF is positioned as a high-performance, cost-effective alternative to traditional international brands. The brand’s R&D capabilities and deep understanding of industrial application requirements enable it to deliver tailored tooling solutions that match or exceed international benchmarks.

Looking ahead, the hydraulic system industry is expected to adopt more multi-axis machining and automation to enhance productivity and reduce cycle times. SDF will continue to lead in innovation, providing next-generation end mills with adaptive geometry and smart coating systems to support these advancements and maintain its role as a trusted partner for precision tooling solutions.