Product category:
Drilling, boring and reaming
News Release from: Mapal | Subject: HPR reamers with replaceable heads
Edited by the Manufacturingtalk Editorial
Team on 29 April 2004
Multi-bladed tools hard machine CVT
components
Hard machining is performed in continuously variable transmission components using single and multiple bladed reamers with replaceable heads are used with PCBN cutting edges.
With the combination of mechanics and electronics in car manufacturing, functions have become possible over the last few years which are making driving a vehicle more and more comfortable and as a result much safer One such comfort feature is the continuously variable transmission (CVT) which is already offered by some car manufacturers and which in all probability will be available very soon in all classes of vehicles
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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The internal workings of this transmission are complicated and difficult to manufacture.
Sliding bevel gears and shafts which support each other provide the smooth transmission of force.
For Mapal this offers the opportunity to open up new ways of rational production for the customers through its experience in hard machining with single and multiple bladed tools with PCBN cutting edges.
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Slide actuating tools simultaneously machine and completely finish machine two pre-machined cylinder bores on two separately driven and controlled feed and spindle units.
High performance reamers reduce machining times
High performance reamers' high cutting speeds and, because of the multiple cutting edges, very high feed rates bring extremely good reductions in machining time.
The shafts for these transmission systems are partly designed to be hollow, so that a further shaft can be supported in the hollow shaft.
This means that the diameter of the hollow shaft must be highly accurate.
For bores which lie at the end of the shaft, Mapal HPR reamers with replaceable heads are used.
These multiple bladed reamers have PCBN blades and the HFS connection developed by Mapal.
For interrupted cuts, reamers with blades with angled flutes are used.
With machining values of Vc = 170m/min and f = 0.3 mm, excellent results are achieved for the surface finish (Rz = 2-3 micron), concentricity (2 micron) and cylindrical form.
Without HPR reamers these values are only obtained by using an additional grinding operation.
However, this increases the machining time, and therefore the unit prices, considerably.
Grinding is simply not feasible for the finishing operation on bores, which lie well into the shaft.
The solution in this case is the Mapal single blade reamer with guide pads.
Because of the adjustable blade and the fact that the tool is supported in the bore by guide pads, high quality surface finishes can be obtained.
The internal contour of the bevel gears is also machined with Mapal single blade reamers.
The diameter is several times larger with this but the tolerance for the bore is not.
Even for this task Mapal tools produce the best possible result.
Mapal hard machining tools can be used for almost all applications.
As the example of the stepless gears shows, development in this area is far from stationary and customers from throughout the world will continue to solve their machining tasks in the future with Mapal PCB tools.
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