Product category:
Special purpose and multi-function tooling, broaching, etc.
News Release from: Mapal | Subject: Tangential roughing tools
Edited by the Manufacturingtalk Editorial
Team on 26 September 2005
Tangential roughing tools cut deeply
Multi-bladed tangential roughing tools fitted with replaceable blades provide stability and a soft cut when rough machining bores having distorted side wall angles.
When rough machining bores in large cast components there are often just a few millimeters cutting depth to deal with, in particular because the cutting depth increases towards the bottom of the bore because of distorted angles The requirements for stability and efficiency from the tools are therefore relatively high
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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The name covers a new family of multi-bladed tangential roughing tools which are fitted with replaceable blades (inserts) which are also newly developed and which have six cutting edges.
Mapal has also consistently applied tangential design for these new roughing tools, and with good reason.
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The tangential mounting position allows highly positive chip geometries, which produces a soft cut and means that the tools run extremely quietly.
In addition the blade geometry for the hexagonal insert has been extensively improved in that an additional support surface is ground which supports the tool on the wall of the bore during machining so that no chatter and vibration occurs.
The blades are designed as perforated inserts and held tangentially on the face side in the tool body.
The blade is fitted at an angle around two axes in the space in order to achieve the required mounting position with regard to clearance angle and support surface.
The precisely manufactured insert seats ensure that all the cutting edges lie on the same cutting track.
In addition the inserts are securely bedded in so that cutting forces which arise are well absorbed.
A further excellent effect produced by tangential design and the soft cut connected with this lies in the low level of power which is required by the machine for cutting.
With the new Mapal TSW tools, as a reverse effect, the number of cutting edges can be clearly increased with the same drive power.
More cutting edges mean higher feed and reduced machining times.
One application example illustrates these advantages: machining the cylinder bore of 80mm diameter for a six-cylinder V engine from CGI with the tool previously used restricts this to three cutting edges.
Attempts to increase the number of cutting edges led to much higher power consumption and to bad bore quality and low tool life because of the heavy vibrations.
The tangential roughing tool from Mapal now machines the cylinder bore with five cutting edges at a cutting speed of 120m/min and a feed rate fz of 0.25 mm.
The machine power remains comparatively low despite the higher number of cutting edges.
The special geometry and mounting position for the insert produces a 30% increase in tool life with this application example and the parallel position of the cylinder bores to each other has been significantly improved.
The new TSW series covers a wide diameter range of 40 to 280mm.
There are two standard sizes of inserts in the programme which are available in various cutting material versions and chip geometry appropriate for the application.
This means that the application range extends from cutting grey cast iron to steel components and aluminium.
The construction of the tangential roughing tools in the standardised series is designed both in a monobloc version and also a modular one consisting of holder and tool head.
The connection of the modular system is designed for the high torques occurring during roughing operations and simultaneously allows exact positioning of the head and the holder in relation to one another.
With the modular design of the Mapal TSW series the new tool system can be used very flexibly.
For example a holder is compatible with several roughing heads and therefore attractive for smaller batches which are frequently repeated.
In addition it is easily possible to adapt working lengths using extensions so that changing demands can met.
Since the bores are rough machined with maximum effectiveness using the new tangential roughing tools, it is not very practical to go back to using single or twin-bladed boring tools for finish machining for example.
The economically practical solutions for finish machining are tangential fine boring tools from the TFB series, another new development, which Mapal presented at EMO 2005.
These adjustable, multi-bladed reaming tools are also designed for high performance cutting with high feed rates with the result these two innovations speed up roughing and finishing large bores many times over.
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