Machined Aluminum Valve
In the project outlined here the precision machining expertise of Kirsan Engineering was retained by our parent company to create a custom aluminum valve. Named the M-20 valve and also known as a rescue re-breathing valve, this part has applications in various industries including military, mining, rail and air transportation. Production was initially handled by a different machine shop and we assumed the process, adopting the tooling and manual fixturing. The previous methods were found to be inadequate, and we launched a full scale process redesign to meet our accuracy and productivity expectations. This valve is a critical component for our business, and is a difficult part to machine. To automate the manufacturing process and obtain repeatable and consistent results we were inspired to design a new product, the unit that would become our S.A.H Spindle Actuated Hydraulics. This patented part is a hydraulically powered fixturing system that eliminates the issues associated with standard hydraulic fixtures. We designed upgraded custom coated tools including PCD (diamond coated), (TIC) titanium carbide, and tin tooling. Additionally, multiple in-machine deburring tools were developed.
Integrating these new components into our advanced machining equipment resulted in a highly accurate and premium quality part with consistent results and reduced cycle times. Our multi-axis Mazak FH-480 horizontal machining center was employed, with its 30HP and 12,000 to 15,000 RPM spindle speeds. The valve is composed of 2014-T6 aluminum, precision machined to reach the dimensions of 2.0" X 1.5" X 1.0". The tightest tolerance of ±.0004 was achieved during manufacturing. The valve was deburred and cleaned, finished with a Type II clear anodizing as per MIL - A - 8625. Accuracy was confirmed throughout production utilizing detailed inspections including 100% external thread inspection, critical characteristics and dimensions inspections.
We employ a First in first out (FIFO) inventory handling techniques to manage production and shipment of the valve. Weekly production volume for the M20 valve is 5,040 units, delivered locally to a Midwest location. To find out more about this M-20 valve production process, our precision machining capabilities and available product lines please contact us directly.
- Equipment Used to Manufacture Part
- Mazak FH-480 Horizontal; 400MM Pallets, (60 - 120) tools, 12,000 to 15,000 RPM. Coated tooling, custom form tools, deburring tools & S.A.H.
- Overall Part Dimensions
- 2.0" X 1.5" X 1.0"
- Tightest Tolerances
- +/- .0004
- Material Used
- 2014-T6 Aluminum Forging
- Material Finish
- Clear Anodize per MIL - A - 8625 Type II
- In process testing/inspection performed
- All Parts - 100% External Threads Checked, Every Pallet - (1) part of (6) Critical, Every Shift - (2) pallets or (12) parts all dimensions
- 5,040 Parts / Week - 252,000 EAU