Structural Integrity Enhancement and Sustainable Machining Process Optimization for Anti-Lock Braking System Hydraulic Valve Blocks

This paper presents an in-depth study on the structural integrity enhancement and machining process optimization of Anti-lock Braking System (ABS) hydraulic valve blocks, focusing on the transition from the MK60 to the MK100 design. The research combines finite element analysis (FEA), topology optimization, fixture redesign, and coolant technology improvements to achieve significant performance, productivity, and sustainability gains. The MK100 exhibits a mass reduction of 31.6%, an increase in tensile strength by 29.2%, and a fatigue life extension of 35% compared to the MK60. Pressure losses have been reduced by 38.8%, improving braking system responsiveness. On the manufacturing side, fixture redesign increased production capacity from 240 to 480 parts per shift while reducing cycle time from 16 min to 8 min per lot. The transition from a semi-synthetic emulsion coolant (AquaCut EM-X45) to a bio-based oil (BioLube AL-2200) extended coolant replacement intervals from six months to two years, reduced tooling costs, and increased tool life by 25%. These findings demonstrate the feasibility of integrating computational design methods with advanced machining strategies to achieve measurable mechanical and economic benefits in the automotive industry.