hpr 300 – high performance reamers - mapal · hpr 300 – high performance reamers ... of course...
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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 recondi- tioning
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
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
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
Shank HSK-C in accordance with DIN 69893-1
HSK-Größe ø d1 l1 number of
cutting edges
Carbide Coated carbide Cermet Coated Cermet PD PcBN
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.
D ø d1 l1 number of
cutting edges
Carbide Coated carbide Cermet Coated Cermet PCD PcBN
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
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.
on re
ques
t
D ø d1 l1 number of
cutting edges
Carbide Coated carbide Cermet Coated Cermet PCD PcBN
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
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.
on re
ques
t
D ø d1 l1 number of
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
Specification Order No.
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
Specification Order No.
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
Specification Order No.
l1 G G1
Dimensions in mm.
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.
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
40 100 60 M8 M10x1 AD/B 2,2 OS-AD-SK040-MOD100-060-13 10058662
45 80 55 M6 M8x1 AD/B 3,1 OS-AD-SK045-MOD080-055-13 10058665
45 100 60 M8 M10x1 AD/B 3,3 OS-AD-SK045-MOD100-060-13 10058666
45 117 60 M8 M10x1 AD/B 3,5 OS-AD-SK045-MOD117-060-13 10058667
50 80 50 M6 M8x1 AD/B 3,6 OS-AD-SK050-MOD080-050-13 10058671
50 100 60 M8 M10x1 AD/B 4,4 OS-AD-SK050-MOD100-060-13 10058672
50 117 60 M8 M10x1 AD/B 4,5 OS-AD-SK050-MOD117-060-13 10058673
50 140 60 M10 M10x1 AD/B 4,7 OS-AD-SK050-MOD140-060-13 10058675
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:
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:
* 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.
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.
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
MAPAL High Performance Reamers | HPR replaceable head reamer
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
MAPAL High Performance Reamers | HPR replaceable head reamer
HPR
300-
E-01
-003
-101
2-M
APA
L Pr
inte
d in
Ger
man
y. R
ight
of t
echn
ical
mod
ifica
tion
res
erve
d.
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 585-150info@de.mapal.com · www.mapal.com
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