hpr 300 – high performance reamers - mapal · hpr 300 – high performance reamers ... of course...

Reaming

HPR 300 – High Performance ReamersFine machining of large diameters and inexpensive reconditioning

222

MAPAL HPR300

For large diameters and affordable lifecycle costs

When machining bores with large diame-ters, multi-bladed tools offer significant benefits in the machining time compared with finish-boring. The reconditioning of such tools, however, is generally time-consuming and very expensive. HPR 300, the new series from MAPAL, offers a system with which fixed tools can be re-tipped and recoated far more quickly and less expensively. Blades are not brazed or glued. Instead they are clamped securely in the tool body using clamping plates and then ground with μ-precision to MAPAL

quality. This system permits quick and inexpensive reconditioning. HPR 300 can be supplied as standard tool in diameters from mm to 300 mm. The different series are included in the program as straight fluted variants for through bores and blind bores as well as a left hand flu-ted version for through bores. The HSK-A and the alignable MAPAL module con-nection are available as connections. This makes it possible to place reaming heads in the machine spindle directly or as a modular system. Of course HPR300 tools

can also be organised as special solutions, for example as combination tools. This saves additional costs and increases pro-ductivity.

33

0 1 2 3 4 5 6 7 8 9 10

HPR 300

HPR300 – Index

MAPAL HPR300c System overview 4-5

c HPR300 with HSK shank 6-8

c HPR300 with module shank 9-11

c KS flange adapter 12

c HSK adapters 13

c Steep taper adapters 14-16

c Leads and rake angles 17

c HPR300 custom solutions 18-19

MAPAL HPR300 | Introduction

MAPAL HPR300

Reduced costs due to innovative reconditioning

crucial advantage is that the tool body and in particular the shank retains its original, high accuracy. On the replacement of the blades, the tool body is not subjected to any thermal loads whatsoever and com-plex cleaning processes are not required. On conventional reamers, the blades are normally brazed or in some cases even bonded, resulting in damage to the tool body during reconditioning and more fre-quent renewal. On average, brazed tools can be reconditioned a maximum of four

Many cutting edges and low life cycle costs:

– cut costs when machining large diameters– quick and cost-effective reconditioning

times, while the new HPR 300 reamers can be re-tipped at least ten times. In this way HPR300 tools pay for themselves already after the first few reconditionings and save significant costs over the entire service life of a tool.

MAPAL is breaking completely new ground with tool reconditioning in the HPR 300 series. The blades are clamped as blanks in the tool body; they are held in place securely and firmly by clamping plates. Then the diameter and cutting lead geo-metry are ground with high precision. For reconditioning after reaching the end of the tool life, the worn blades can be very easily and quickly replaced with new blade blanks and again ground to the original MAPAL quality with μ precision. A further

Fixed brazed tool

Number of reconditionings / new procurements

Cost

s

4

HPR300

Modular system offers high flexibility

Module adapter

– Steep taper ISO– Steep taper BT– Steep taper ASMEFurther connections on request

Intermediate adapter module on HSK

In standard lengths or adapted individually in length for each application.

Module adapter

– HSK-A adapter– HSK-C adapter

Further connections on request.

HPR300 with module connection

– Individually tailored working length– Tools with only 2 system components (cost-effective procurement)– Must be realigned when the tool is changed

5

The replaceable head holder is optimally aligned for minimum radialrun-out and angle deviations by the adapter with module connection.

Easy handling and maximum changeover accuracy:HPR300 replaceable heads are replaced with HSK in the aligned holder with μ precision at the end of tool life. Then they are simply ready to continue!

The HPR300 system provides maximum flexibility in the selection of blade materials. Carbide, Cermet, ceramic, PCD, PcBN – anything is possible!

The advantage at a glance:

Fast, inexpensive reconditioning

High process reliability

Easy tool handling with no adjustments

Identical performance as brazed tools

Modular system structure

Replaceable head with HSK for ø 40 – 300 mm

For fast, easy replacement in the aligned replaceable head holder

radial alignment angular alignment

MAPAL HPR300 | System overview

6

l1

HSK ød

1

HSK-C40 42,00 - 59,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C50 60,00 - 74,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C63 75,00 - 109,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C80 110,00 - 159,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 160,00 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 180,00 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 220,00 - 300,00 95 12 HU612 HP421 CU134/130 CP134/136 PU620

HPR300Variant Straight fluted for through bores

Shank HSK-C in accordance with DIN 69893-1

HSK-size ø d1 l1 number of

cutting edges

Carbide Coated carbide Cermet Coated Cermet PD PcBN

Dimensions in mm.

on re

ques

t

7

l1

HSK

ød1

HSK-C40 42,00 - 59,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C50 60,00 - 74,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C63 75,00 - 109,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C80 110,00 - 159,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 160,00 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 180,00 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 220,00 - 300,00 95 12 HU612 HP421 CU134/130 CP134/136 PU620

HPR300Variant Left-hand fluted for through bores


HSK-size ø d1 l1 number of

cutting edges


Dimensions in mm.

on re

ques

t

MAPAL HPR300

8

l1

HSK ød1

HSK-C40 42,00 - 59,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C50 60,00 - 74,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C63 75,00 - 109,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C80 110,00 - 159,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 160,00 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 180,00 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620

HSK-C100 220,00 - 300,00 95 12 HU612 HP421 CU134/130 CP134/136 PU620

HPR300Variant Straight fluted for blind bores


HSK-Größe ø d1 l1 number of

cutting edges


Dimensions in mm.

on re

ques

t

9

l1

D

ød1

l1

D ød1

80 60,0 - 69,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620

100 70,0 - 89,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

117 90,0 - 119,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

80 120,0 - 149,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620

100 150,0 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620

117 180,0 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620

140 220,0 - 300,0 95 12 HU612 HP421 CU134/130 CP134/136 PU620

HPR300Variant Straight fluted for through bores

Module connection sizes in accordance with MN5000-14

D ø d1 l1 number of

cutting edges

Carbide Coated carbide Cermet Coated Cermet PCD PcBN

Dimensions in mm.


cutting edges


Dimensions in mm.

on re

ques

ton

requ

est

MAPAL HPR300

10

l1

D ød1

l1

D ød1

80 120,0 - 149,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620

100 150,0 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620

117 180,0 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620

140 220,0 - 300,0 95 12 HU612 HP421 CU134/130 CP134/136 PU620

80 60,0 - 69,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620

100 70,0 - 89,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

117 90,0 - 119,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HPR300Variant Left-hand fluted for through bores



cutting edges


Dimensions in mm.

on re

ques

t


cutting edges


Dimensions in mm.

on re

ques

t

11

l1

D ød1

l1

D ød1

80 120,0 - 149,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620

100 150,0 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620

117 180,0 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620

140 220,0 - 300,0 95 12 HU612 HP421 CU134/130 CP134/136 PU620

80 60,0 - 69,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620

100 70,0 - 89,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

117 90,0 - 119,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620

HPR300Variant Straight fluted for blind bores



cutting edges

carbide Coated carbide Cermet Coated Cermet PCD PcBN

Dimensions in mm.

on re

ques

t


cutting edges

carbide Coated carbide Cermet Coated Cermet PCD PcBN

Dimensions in mm.

on re

uqes

t

MAPAL HPR300

12

D

(Ø 5

5)

l2l1

80 50 55 100 83 1,90 KS-VL-MOD080-HSK-C050-100-21 30327001

80 50 55 150 133 2,65 KS-VL-MOD080-HSK-C050-150-21 30327002

80 50 55 200 183 3,40 KS-VL-MOD080-HSK-C050-200-21 30327004

100 63 70 100 79 3,18 KS-VL-MOD100-HSK-C063-100-21 30327005

100 63 70 150 129 4,36 KS-VL-MOD100-HSK-C063-150-21 30327007

100 63 70 200 179 5,54 KS-VL-MOD100-HSK-C063-200-21 30327008

117 80 87 100 79 4,27 KS-VL-MOD117-HSK-C080-100-21 30327009

117 80 87 150 129 6,65 KS-VL-MOD117-HSK-C080-150-21 30327010

117 80 87 200 179 8,58 KS-VL-MOD117-HSK-C080-200-21 30327012

140 100 110 100 72 7,58 KS-VL-MOD140-HSK-C100-100-21 30327013

140 100 110 150 122 10,61 KS-VL-MOD140-HSK-C100-150-21 30327014

140 100 110 200 172 13,64 KS-VL-MOD140-HSK-C100-200-21 30327015

60 4 M5x16 - 12.9 10003601 K10086-14 10040108 K2865-904 10040109

70 4 M6x20 - 12.9 10003619 K10086-14 10040108 K2865-904 10040109

80 4 M6x20 - 12.9 10003619 K10086-14 10040108 K2865-164 10075074

100 4 M8x25 - 12.9 10003637 K10086-04 10075116 K2865-514 10075100

117 4 M8x25 - 12.9 10003637 K10086-04 10075116 K2865-514 10075100

140 4 M10x30 - 12.9 10003660 K10086-04 10075116 K2865-34 10075099

KS flange adapter with radial and angular alignmentModule connection sizes in accordance with MN5000-14

Long version

Dimensions in mm.

Module

diameter D

Nominal size

HSK-C

Dimensions Weight

kg

Specification Order No.

d1 l1 l2

Usage:

For fitting in the machine spindle or in HSK or SK adapter for mounting HSK tools.

Supply includes:

Standard KS clamping cartridge, thrust pad and threaded pin, stop ring and cylindrical head screws (for fastening the KS flange adapter).

Design:

Through the threaded pins (for alignment) in the machine spindle and in the HSK or SK adapter, exactly adjustable for radial run-out.

Through the thrust pad and threaded pin in the flange adapter, axial run-out exactly adjustable.

Module

diameter

D

Quantity

required

cylindrical head screw

to ISO 4762

Thrust pad Threaded pin

Size Order No. Specification Order No. Specification Order No.

Spare parts for KS flange adapter with radial and angular alignment in accordance with MN 5000-14

Dimensions in mm.

13

�

G1

G

l1

D

50 80 60 M6 M8x1 1,1 OS-AD-HSK-A050-MOD080-060-11 30319386

63 80 60 M6 M8x1 1,5 OS-AD-HSK-A063-MOD080-060-11 30319389

63 100 65 M8 M10x1 2,1 OS-AD-HSK-A063-MOD100-065-11 30319390

63 117 65 M8 M10x1 2,5 OS-AD-HSK-A063-MOD117-065-11 30319391

80 80 60 M6 M8x1 2,1 OS-AD-HSK-A080-MOD080-060-11 30319394

80 100 65 M8 M10x1 2,6 OS-AD-HSK-A080-MOD100-065-11 30319395

80 117 65 M8 M10x1 3,1 OS-AD-HSK-A080-MOD117-065-11 30319396

80 140 75 M10 M10x1 4,2 OS-AD-HSK-A080-MOD140-075-11 30319397

100 80 55 M6 M8x1 3,0 OS-AD-HSK-A100-MOD080-055-11 30319400

100 100 65 M8 M10x1 3,7 OS-AD-HSK-A100-MOD100-065-11 30319401

100 117 65 M8 M10x1 4,0 OS-AD-HSK-A100-MOD117-065-11 30319402

100 140 75 M10 M10x1 5,2 OS-AD-HSK-A100-MOD140-075-11 30319403

60-80 4 M8x1x16 K2865-24 10075355

100-140 4 M10x1x20 K2865-34 10075099

HSK-AdapterShank HSK-A in accordance with DIN 69893-1

Supply includes:

Complete with threaded pins for aligning the radial run-out, does not include coolant tube.

Nominal size

HSK-A

Module

diameter

D

Dimensions Weight

kg


l1 G G1

Module diameter DQuantity

required

Threaded pin

Size Specification Order No.

Dimensions in mm.

Dimensions in mm.

Spare parts

MAPAL High Performance Reamers | HSK adapter

14

G1

l1

GD

40 80 55 M6 M8x1 1,7 OS-AD-CAT040-MOD080-055-11 30320128

40 100 60 M8 M10x1 2,2 OS-AD-CAT040-MOD100-060-11 30320129

45 80 55 M6 M8x1 3,1 OS-AD-CAT045-MOD080-055-11 30320132

45 100 60 M8 M10x1 3,3 OS-AD-CAT045-MOD100-060-11 30320133

45 117 60 M8 M10x1 3,5 OS-AD-CAT045-MOD117-060-11 30320134

50 80 50 M6 M8x1 3,6 OS-AD-CAT050-MOD080-050-11 30320137

50 100 60 M8 M10x1 4,4 OS-AD-CAT050-MOD100-060-11 30320138

50 117 60 M8 M10x1 4,5 OS-AD-CAT050-MOD117-060-11 30320139

50 140 60 M10 M10x1 4,7 OS-AD-CAT050-MOD140-060-11 30320140

MAPAL High Performance Reamers | Steep taper adapters

Steep taper adapters Shank CAT in accordance with ASME B5.50-1994

Nominal size

steep taper

Dimensions G G1 Weight

kg


D l1

Usage:

For use in the machine spindle for mounting KS flange adapters, shrink chucks, hydraulic chucks, chucks for cylindrical shanks or tools with a modular shank in accordance with MAPAL works standard.

Supply includes:

Complete with threaded pins for aligning the radial run-out, does not include pull stud.

Design:

Through the threaded pins the radial run-out of a connection or tool fitted can be adjus-ted exactly in relation to the steep taper.

Dimensions in mm.

15

G1

D

l1

G

�

40 80 65 M6 M8x1 2,0 OS-AD-BT040-MOD080-065-11 30320088

40 100 70 M8 M10x1 2,6 OS-AD-BT040-MOD100-070-11 30320089

45 80 65 M6 M8x1 3,3 OS-AD-BT045-MOD080-065-11 30320092

45 100 75 M8 M10x1 3,5 OS-AD-BT045-MOD100-075-11 30320093

45 117 75 M8 M10x1 4,4 OS-AD-BT045-MOD117-075-11 30320094

50 80 70 M6 M8x1 5,1 OS-AD-BT050-MOD080-070-11 30320097

50 100 70 M8 M10x1 5,3 OS-AD-BT050-MOD100-070-11 30320098

50 117 80 M8 M10x1 6,3 OS-AD-BT050-MOD117-080-11 30320099

50 140 80 M10 M10x1 6,6 OS-AD-BT050-MOD140-080-11 30320100

60-80 4 10075355

100 4 10075099

117 4 10075099

140 4 10075099

Steep taper adaptersShank BT in accordance with JIS B 6339

Nominal size

BT

Module

diameter D

Dimensions Weight

kg


l1 G G1

Dimensions in mm.

Usage:


Supply includes:


Design:


for module diameter

D

Quantity

required

Threaded pin

Order No.

Spare parts

MAPAL High Performance Reamers | Steep taper adapters

16

G1

l1

G

D

40 80 55 M6 M8x1 AD/B 1,7 OS-AD-SK040-MOD080-055-13 10058661









60-80 4 10075355

100-140 4 10075099

40, 45, 50 2 M5x5 10036757

MAPAL High Performance Reamers | HPR replaceable head reamer

Steep taper adaptersShank SK in accordance with DIN 69871 Form AD/B

Nominal size

SK

Module

diameter

D

Dimensions G G1 Form Weight

kg

Specification Order-No.

l1

Dimensions in mm.

Dimensions in mm.

Usage:


Supply includes:


Design:

* Steep taper size SK30 is not available in combined design AD/B!

Normal setting Form AD, if Form B is required, please state with the order.


for module diameter

D

Quantity required

Anzahl

Threaded pin

Order-No.

Spare parts

Dimensions in mm.

for nominal size

SK

Quantity

required

Threaded pin to ISO 4026

Size Order-No.

17

0,55

1

0,4

1,4

1

MA

ME

MC

0,55

MC

MG

45°

30°

75°

6° MG1G*

6° MC1G

0° MA0A

6° MA1G

12° MA1N

6° ML2G

6° MC1G

6° ME1G

25°

30°

ML

45°

0° MW0A

6° MW1G

12° MW1N75°

5°

0,5

0,8

MW


Lead geometries and rake angles

Geometry angle of rake Geometry angle of rakeLead

geometryLead

geometry

MW for higher surface finish qualities MC universalME for left-hand MG for higher surface finish quality MA for material group N

1818

HPR300 Custom solutions

An HPR300 custom tool considerably reduces productive and non-productive times in the machining process when machining a final drive housing on a planetary hub for commercial vehicles. This saved money for the machinery under consideration while increasing productivity and output. The bell-shaped housing made of GGG50 includes various precision bores and chamfer transi-tions. The multi-bladed tool using MAPAL tangential technology is used for pre-machining, and during the same machining step the bore is fine machined using an HPR300 reaming stage. Tangential inserts are also integrated into the tool which produce two cham-fers and an edge break at the same time during this machining sequence. An HPR step reamer is also used for two additional precision fit bores.

Machining Location bore for wheel bearing: ø272 H7 x 20 mm with chamfers and edge breaks Bores for precision fit screws and planetary pins: ø16 H7 and ø32 H7

Saving 65 seconds of productive time 15 seconds of non-productive time 80 seconds saved per part!

19

HPR300 Custom solutions

Stepped tool for gearbox housings

Material ADI1000 |Commercial vehicle industry

Stepped tool for gearbox housings

Material GGG60 |Commercial vehicle industry

Stepped tool with additional HFS con-nection for bearing housing

Material GGG40 |Agricultural sector

Stepped tool for axle carrier

Material cast steel |Commercial vehicle industry


HPR

300-

E-01

-003

-101

2-M

APA

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Ger

man

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of t

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ical

mod

ifica

tion

res

erve

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V1.0.0

MAPAL the major specialist

Reaming and Fine Boring

Gun Boring

Drilling

Milling

Turning

Actuating

Clamping

Setting and measuring

Services

MAPAL Präzisionswerkzeuge Dr. Kress KG

P.O. Box 1520 · D-73405 Aalen · Phone +49 (0) 7361 585-0 · Fax +49 (0) 7361 [email protected] · www.mapal.com

hpr 300 – high performance reamers - mapal · hpr 300 – high performance reamers ... of course...

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