Product category:
Special purpose and multi-function tooling, broaching, etc.
News Release from: Mapal | Subject: Combination tools with HFS connection
Edited by the Manufacturingtalk Editorial
Team on 10 May 2004
Combined roughing and finishing reduces
cycle time
Now more than ever longer tool life and reductions in machine stoppage time are in the forefront of decision-making - hence the growing importance of combination roughing and finishing tooling.
Now more than ever longer tool life and reductions in machine stoppage time are in the forefront of decision-making This means that it is important to meet the ever greater demands on accuracy with consistent regularity over a number of workpieces, even in materials which are difficult to cut
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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An improvement in accuracy and an increase in tool life, as demonstrated in intensive investigations by Mapal's development department, are directly linked with the cutting depth to be machined.
The smaller this is, the better the surface quality, dimensional stability and tool life.
The best results can be obtained with cutting depths in the area of just a few 1/100 mm.
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To meet this requirement involves spending a great deal of time on pre-machining - in fact this is barely possible since the concentricity between rough and finish machining needs to be extremely precise to allow a consistent machining allowance from such a small dimension.
Previously the solutions to this were by using so-called roughing diameters, i.e a stepped blade with the front stage used for roughing and the rear stage for finishing.
These types of blades are not only very expensive and difficult to manufacture but also to regrind.
In addition the design of the blades for the roughing and finishing operations are then to a large extent the same - or at least they use the same cutting material.
This is often a negative aspect because of different demands on the blades.
The blade for the roughing operation primarily has to be resistant to high temperatures.
The blade for the finishing operation, particularly for the low cutting depth in question, needs a strong edge, Mapal is finding new paths in manufacturing high performance tools by combining the two steps in one tool using the HFS precision connection.
With this the roughing and finishing tools are specifically linked to each other.
One impressive example of the effectiveness of a new type of combination tool is in machining a connecting rod, on the big end.
The roughing stage with tangential blades is connected to a brazed HPR reamer finishing stage.
The particular advantages of this new type of combination tool are: * Time for tool change no longer necessary.
* Quality and life of the tools are increased because of the consistent, low machining allowance for finish machining.
* High cutting values and long tool life because of the excellent design of the roughing and finishing stages.
* Maximum accuracy and low-cost production from appropriate selection of blade type, form and coating for the individual stages.
The machining values are as follows: material C70S6; spindle speed n = 800 rev/min; feed rate Vf = 800mm/min; return travel = 3200mm/min; cutting speed Vr = 120m/min and cutting depth for finishing stage: Ap 0.07mm.
The quality achieved in figures was: 3500 parts; concentricity: 2-4 micron (max.
tolerance 10 micron); cylindrical form: 5 micron (max.
tolerance 10 micron) and surface finish: Rz = 1.7 micron (Rz max.
6.3 micron).
Based on this example it is clear that today, thanks to the HFS system, tool concepts are possible, which only a short while ago would not have been thought possible.
In the future numerous machining tasks will be carried out in which the Mapal HFS connection is applied to combination tools to increase quality and reduce costs.
Postfach 1520 D-73405 Aalen Kontakt Hermann Steidle Telefon +49 / 73 61 / 5 85 - 1 24 Telefax +49 / 73 61 / 5 85 - 1 10 e-mail marketing@de.mapal.com Datum 09.10.2003 Presseinformation Nr.
03-09-23 Seite(n) 3 von 1.
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