Product category:
Drilling, boring and reaming
News Release from: Mapal | Subject: HPR high performance reamers
Edited by the Manufacturingtalk Editorial
Team on 30 April 2004
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.
After every Formula 1 motor racing event we hear in the interviews that the winner and his team "have given their best performance ever" The car and its driver were the fastest, stayed on the track the longest and even managed a pit stop in record-breaking time ! The new HPR high performance reamers may do their job less spectacularly and may not arouse as much interest but their performance in high performance cutting is well worth noting and has certain parallels
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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High performance reamers cut machining times
High performance reamers offer dramatic reductions in machining times and at the same time an increase in tool life in the diameter range 1.4 to 50mm.
Form milling cutters offer 30% time saving
Wear-resistant PCBN form milling cutters produce such high surface qualities that the time spent for final manual polishing can be reduced by 30 to 50%.
The cutting data for these fixed tools are characterised by high cutting speeds and, because of the multiple cutting edges, very high feed rates; when combined these bring extremely good reductions in machining time.
By using modern cutting materials and coatings and by controlled, accurate coolant supply directly onto the cutting edge high tool life is achieved.
With all these advantages the system of holder and replaceable head is particularly easy to handle so that stoppage times are very short.
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To put minimal lubrication quantity technology into practice, many institutes and research groups have dealt with specific questions and solutions, but a tool supplier claims to show the way.
New multi-functional tools perform nine operations
Slide actuating tools simultaneously machine and completely finish machine two pre-machined cylinder bores on two separately driven and controlled feed and spindle units.
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.
No setting, no adjusting.
Simple loosen the central screw and the worn head can be removed and replaced.
Even easier and of particular advantage for small diameter heads is the new radial clamping system with which a quarter turn of the clamping element is enough to release the head.
The standard HPR replaceable heads cover a diameter of 1.4 to 50 mm.
The heads are offered with brazed carbide and solid carbide versions in the programme, so that any modern cutting materials, including PCD and PCB, can be used and any coating processes are possible.
Higher, faster, better precision - success stories galore Because of the special configuration options for the HPR replaceable heads, cutting material and blade geometry can be perfectly adapted to the specific needs of the machining task so that where the cutting data is high, the required bore quality is achieved over a long tool life.
Impressive results are obtained, for example, when machining universal joints.
These steel components, which are in widespread use both in the car industry and in general machine manufacturing, are characterised by a fork-shaped design with two bores lying opposite one another.
One particular aspect is that the bores are precisely aligned to accept a cross axis.
Typical materials are quality and high-grade steels (e.g C45, Ck45, 38MnSiSV5).
The machining values for finish machining the bores are cutting speeds of Vc = 120-125m/min and feed rates per tooth of fz = 0.15 - 0.2mm, for which uncoated Cermet is used as a cutting material.
In one example the tool life was increased when machining a four-holed fork in 38nSiVS5 from 40 to 5500 parts compared to fine boring and the surface quality was actually improved! For a very similar part in C45R an increase from 40 to 3600 parts was also possible with the specified requirements met.
And there's more! For a universal joint in Ck45 with two bores od diameter 42H7, a concentricity in the bores of a maximum of 0.05mm was required and the specified surface quality was Rz max.
= 6 micron.
After 54,000 a standard HPR 110 replaceable head had still not reached the end of its life.
The concentricity was 0.035mm maximum.
To coin a phrase: "we are pulling all the levers at once".
And we could list other examples with the HPR replaceable head.
Control levers are devices frequently used for changing direction, converting force and for mechanical control so that right from the beginning high demands are placed on the quality and accuracy of this simple component.
When machining an interconnecting lever for a transmission system in two different designs HPR standard heads HPR 131 are used with diameters of 10 and 12mm.
The components are in 16 MnCr5 and heat treated to a hardness of 450 HV and a tensile strength of 650N/mm2.
With the heads, which have Cermet blades, cutting speeds of Vc = 120m/min and feeds of f = 0.6mm are used.
Compared to the previous method, it was possible to reduce the machining time for both components from 11.5 to 2.5 minutes for the two clamping set ups and at the same time increase production reliability.
In addition the tool life was 4 to 6 times longer.
What more could you want ? Of course HPR replaceable heads are not limited to machining steel components.
Similar successes can be recorded for SG cast iron.
For instance the machining of a bore diameter 26 N6 in a pillow block in GGG 50 was reduced by 11 seconds and the surface finish also improved.
In another example the tool life was again increased and the easier handling was a key reason for the customer to change over from a multi-bladed head system to HPR.
For a machining operation on a bore in a bearing in GGG 40 the tool life with a standard HPR 100 head fitted with coated carbide blades was increased from 4000 to 7000 parts.
When using non-ferrous metals and on hardened parts the advantage of the HPR heads is particularly obvious.
Because the heads can be fitted with PCD or PCB blades, these tools provide significant advantages in speed, bore quality and tool life.
So in the example of machining bores in hardened materials, which were previously coordinate ground, the operation can now be carried out with heads with PCD blades.
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