Product category:
Special purpose and multi-function tooling, broaching, etc.
News Release from: Mapal | Subject: Tangential fine boring tools - large bores
Edited by the Manufacturingtalk Editorial
Team on 26 September 2005
Tangential fine boring tools finish
large bores
Tangential fine boring tools for large bores have reaming blades designed as twin-bladed, rhombic replaceable inserts and held in high precision seatings on the front of the tools.
In most areas of industry where large bore diameters are fine machined, cutting specialists do not regard multi-bladed reaming tools as an established method Instead single or twin bladed fine boring tools are normally used, which produce the bore with reliable results at a comfortable rate
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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Cutting rings in this diameter range are also not a real alternative because of their comparatively high setting cost.
Mapal is now taking the offensive against this obvious waste of time and presented a new tool system at EMO 2005 with tangential fine boring tools for specifically machining large bores.
This new development is based on tangential technology, which Mapal applies to reaming tools in this form for the first time.
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The reaming blades are designed as twin-bladed, rhombic replaceable inserts and held in high precision seatings on the front of the tools.
Each insert can be set extremely easily, sensitively and to high precision using Mapal's special wedge adjustment system.
In addition setting the tools is made easier by means of reference tabs on the tool head.
The blade is set by a defined amount beyond the tabs using standard measuring instruments.
Because of the tangential mounting position an extremely quiet and vibration-free cutting operation is obtained from the tools.
This feature, which is already excellent, is then further supported by a support surface on the inserts so that it is hardly right to speak of remaining tools.
As with reamers, with which the radial land guides the tool and the bore surface is then smoothed, this function is also fulfilled with the tangential fine boring tools because of the special Mapal contoured grinding on the blades.
The diameter range for these tools, which are available in standardised series, extends from 60 to 280mm diameter, but using the TFB principle special solutions, have also been used for special solutions up to 335mm in diameter.
The complete diameter range is covered by just one insert size.
The main area of application is in cutting cast iron but components in aluminium or cast steel can also be machined.
Inserts are available in the appropriate cutting materials and blade geometries for the application fields.
With the standard TFB 100 series, the tools are fitted in 'small diameters' from 60 to 100mm in monoblock design and with 6 to 8 inserts.
HSK 63 and HSK 100 plus ISO40 and ISO50 are available as toolholders.
Other connections can of course also be easily used.
Parallel to this from 60mm to 280mm diameter there is also a series which is modular in design.
Tool head and holder are connected with the well-established Mapal modular connection.
Once in use these new reaming tools rapidly prove themselves.
In addition to easy handling for setting the cutting edges, quiet running at high feed rates and the excellent machining results are very impressive.
For example, on a brake component in S.G.
cast iron a surface finish of Rmax 4.5 - 8 micron was machined with cutting values of vf = 560 mm/min and vc = 200 m/min and percentage contact area of 60-80% achieved.
The original requirement was for Rmax = 10 micron and percentage contact of at least 50%.
The results achieved illustrate how these tools bring a new dimension to fine machining.
In the special application already mentioned, with a cylinder diameter of 335mm for a large 16-cylinder diesel engine, as a result of the high cutting values with the tangential fine boring tools, the required production quantity was also possible on the existing machines so that no new investments were necessary.
With this application the engine block in GGG 40 (SG cast iron) is machined with a feed rate of 80mm/min at vc = 100m/min, which reduces the machining process significantly.
In addition to the TFB series for fine machining bores, Mapal has also developed the relevant pre-machining and roughing tools.
The TSW series is also in tangential design so that the advantages of this construction, which are primarily quiet running and stability, are fully utilised.
The application areas for the new tangential tools are numerous.
Starting from the brake manufacturing industry already mentioned to large engines and drive components in vehicles or drive belts in commercial vehicles, the scope can be extended to general machine manufacturing.
Also where bearing points for paper, press or textile machines are to be machined, or even building plant and agricultural vehicles are seen as the application areas.
In principle application areas are wherever any amount of time is wasted with traditional machining tools for machining large bores.
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