To finely machine bores with large diameters in a defined tolerance range, users are often faced with the question: reaming or fine boring? On the one hand it is possible to work significantly faster with multi-cutting edged reaming tools and they are less sensitive to an interrupted cut. On the other hand the reconditioning of reamers with fixed inserts is a complex process.
To simplify this process, to reduce the quantities of tools in circulation and to reduce the logistics effort, as well as to minimise the setting effort, MAPAL has developed the high-performance reaming tool HPR400. Due to special, high-accuracy insert seats, users can replace the inserts on the spot using a torque wrench with this system. Incorrect insert mounting is ruled out, as only one mounting position is possible.
Quantity of tools in circulation and stock reduced
As a result there is no setting effort, or the need to send tools for reconditioning. Users only need to
have the inserts from MAPAL in stock. The quantity of tools required is low, as tool bodies do not need to be reconditioned. With minimal effort and a low number of tools in circulation, the user achieves high-accuracy bores with the HPR400.
The principle of the HPR400 can be combined with other systems and can therefore be designed as a combination tool, for example with pre-machining stages or a clamping system for one-shot solutions.
The reaming tool has an internal coolant supply, the cooling lubricant reaches the insert directly and quickly. The unequal spacing of the insert seats ensures quiet cutting.
Inserts adapted to workpiece material and machining
The HPR400 is available in the diameter range from 50 to 315 mm with an HSK or MAPAL’s own module adaptor. It can be used for almost any workpiece material, as the inserts are adapted correspondingly. MAPAL offers various indexable inserts, made of carbide without or with CVD coating, made of cermet and tipped with PCD or PCBN.
The HPR400 from MAPAL offers maximum accuracy and extremely long tool lives.
Unbeatable combination: HPR 400 and cutting material HC419
Especially for reliable cast iron machining, MAPAL has developed the extremely wear-resistant cutting material HC419 with CVD coating. This cutting material has proven itself with high cutting data and long tool lives, and CVD coatings allow a broad range of alloys to be covered. This is all the more important, as the further development of cast materials for thermal stability and lightweight construction is continuous. Among others, the HPR400 with the cutting material HC419 is already successfully in use at numerous automotive manufacturers, for example for machining brake callipers, swivel bearings and gearbox housings.
Acid test passed in practice
A further application example for the HPR400 is the machining of the main bore in a differential housing. Here the user machines the workpiece material GJS 400 using the tool with a diameter of 150 mm with eight inserts. The requirements are the tolerance to be achieved of IT7 as well as the high-quality surface finish. The HPR400 impresses. With a cutting speed of 160 m/min as well as feed of 1.6 mm, the required tolerance is met and an average roughness of Ra = 1.3-1.45 µm is achieved. And that with a tool life of 2,720 bores. With the tool used previously, a tool life of only 1,000 bores was achieved.
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