Product category:
Special purpose and multi-function tooling, broaching, etc.
News Release from: Mapal | Subject: Tangential roughing and finishing tool
Edited by the Manufacturingtalk Editorial
Team on 02 November 2005
Tangential roughing, fnishing tool cuts
deeper
Tangential roughing and finishing tool completes bore machining operations, such as general access and assembly bores in housings in one pass instead of using two tools.
Developments in manufacturing cast and forged parts over the years have led to production which comes closer to the final contour required So-called 'Near Net Shape' technology suggests a proximity between the rough and the finished contour which is as close as possible so that the "waste" in material is kept as low as possible
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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For the user the advantage is clear: with Near Net Shape technology there are savings both in material and in machining time.
Parallel to this, bore machining on these cast and forged parts has also developed.
Where three machining steps were originally required to remove the excess, now division of rough and finish machining has long been standard practice.
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Mapal has always understood how to translate technical developments into new cutting concepts and always keep a finger on the pulse.
As a result Mapal converts the opportunities which come from the Near Net Shape idea into an innovative tool concept and presented a new product at the EMO 2005 in Hanover from the ISO tool area, with which rough and finish machining bores are carried out simultaneously and savings in machining time of up to 70% achieved.
The new Mapal TSS 100 tangential roughing and finishing tool is intended for bore machining operations, such as bores for water stoppers and general access and assembly bores in housings.
With the new Mapal TSS 100 machining is no longer carried out with two tools one after the other.
Instead a special precision gun boring tool has been developed which carries out the rough and finish machining integrally and in doing so produces better machining results.
The tangential technology allows highly positive blade geometry, with which a soft cut is achieved with less stress on the spindle and fixture.
At the same time the tangential blade mounting produces a high rigidity in the whole system so that the cutting forces are perfectly absorbed when machining greater cutting depths.
To obtain reliable tolerances in the IT8 range with one cut, even under difficult machining conditions such as run-out error on the machine, inconsistent cast parts or varying cutting depths, the tool needs to guide and support itself in the bore.
For this reason Mapal has provided the TSS 100 tool with a special support chamfer on the blade which is tangentially ground to the blade radius.
In addition guide pads help to stabilise the cut.
The accurate fitting of the replaceable blades is also important for a good machining result, to ensure that the blades are on an absolutely identical cutting track.
The Mapal wedge adjustment system provides easy and highly accurate radial adjustment for the finishing blade, thus ensuring the blades are perfectly aligned and excellent performance and tool life.
Mapal TSS 100 tools are supplied for the diameter range 40-80mm and for drilling depths from 1-1.5xD.
In the context of Near Net Shape technology, pre-cast parts are mainly in grey cast iron but also in aluminium but the TSS 100 can also be used for machining steel.
It has been shown that basically cutting depths up to 6mm in grey cast iron (even greater in aluminium) can be cut and the fit tolerance IT8 reliably achieved.
TSS 100 also shows extremely good results with surface finish of Rz <10 micron and roundness of (<20 micron) - with cutting values of 0.6mm feed (with four cutting edges) - and a cutting speed vc of 120-140m/min in grey cast iron.
Mapal has devoted its development targets for 2005 specifically to preventing the waste of resources in production processes.
The new TSS 100 tool also makes an excellent contribution to this with: * A reduction in main times by eliminating a whole operation.
* A reduction in ancillary times by eliminating tool change from rough to finish machining.
* A saving in tool costs as only one tool is needed for both operations.
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