In the valve manufacturing world, there is no room for error. A one micron defect across a critical sealing surface, or a port that is not square is all that separates the product from an assured reliable long-term operation versus a complete failure. These ultimately uncompromising requirements of precision is what inspires a forge to machining.

But the problem we frequently hear from our valve clients is the fact that they can find a shop to deliver one perfect prototype. They need a partner who will supply tens of thousands all of which need to be identical, all need to be perfect and all need to be on time.

This is where the art of precision meets the science of scale. This is what high-volume CNC machining is all about. This is a sophisticated practice practice that encompasses much more than simply the running of production lots. This is the engineering of the process as a whole so that there is flawless repeatability, to preserve the future of valve manufacturing.

Why “High Volume” is a Failed Engineering Concept

Many consider high volume cnc machining production to be nothing more than simply simple parts. In valve manufacturing quite the opposite is true. The main components of the valve — that is to say — the very finely threaded hydraulic valve body and hydraulic valve block are often very complex. They contain a vast array of intersecting cross holes, very finely machined seats, threaded ports, and common galleries, need to be precisely clean and burr free.

To fabricate these components will require a high volume machine shop not only has the requisite CNC capability, but also an astute understanding of fluid dynamics and energy statistics, as well as geometric dimensioning and tolerancing. The blend of producing a high volume of production machining consists of the ability to recreate the complex geometry, repetitively without variation from one component to another. High volume machining is not machining. It is metrology and logistics in practice.

The Swiss Advantage of Hydraulic Valve Parts

For intricate slender parts such like valve spools, valve stems and specific actuator part types, high-volume screw machining (e.g., Swiss-style CNC lathes) has advantages over other CNC machining methods. The guiding bushing, which supports the bar stock, does not allow any deflection while also enabling machining of more finer features and tight tolerances with a longer part that would be impossible on a conventional lathe. This makes it perfect for producing high volumes of hydraulic valve parts with the exact challenges presented by mobile hydraulics and heavy equipment.

Moving Beyond the Valve Body: The Fittings Ecosystem

A valve is only as good as its connections. The fittings ecosystem – coupling pipe fitting, quick connect hose fittings, and coupling fitting copper components – are just as important to system performance. These fittings, often manufactured in even higher quantities, require the same attention to fit and finish to create a leak-free seal, along with performance attributes to provide integrity under pressure and vibration. A true partner in high volume manufacturing knows that the entire fluid conveyance system must be designed to the same level of rigor.

Relationship with a Hydraulic valve manufacturer

The relationship between a valve designer and their machining partner is a symbiotic one. We don’t get a print and simply start to cut chips. We participate in Value: Design for Manufacturability (DFM) discussions early on. Is it possible to make a radius a little bigger for a stronger tool. Can a tolerance be released with no impact on function to greatly reduce cost? By working together with a hydraulic valve manufacturer we show how to maximize the design for both performance and high volume production.

This collaborative relationship is what makes a good high volume machine shop a collaborative partner in your production plan. It makes your designs not just sound good on paper, but they are wholly executable on the production floor. Regardless if your customer is in the construction industry, agriculture sector, or high volume manufacturing semiconductor space.

Scaling precision is not an option in this economy, it is a necessity. It is how valve companies bring reliable products to the global economy.