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- MAPAL FRANCE
- FINE BORING
FINE BORING
FINE BORING
MAPAL is a technology partner providing cost-effective machining solutions across industries like automotive, aerospace, and medical technology. They offer standard tools, custom tool concepts, and process optimization to ensure precision and reliability in manufacturing processes. MAPAL supports clients throughout production phases with networked solutions for peripheral tasks related to machining.
MAPAL specializes in reaming and fine boring, offering a wide range of tools for precise machining of bores. Their tools include single and twin-bladed reamers, fine boring tools with guide pads, and multi-bladed reamers. They emphasize the importance of coatings for tool longevity and offer reconditioning services to maintain tool performance.
MAPAL has introduced innovations like the HPR400 tool for large diameter bores, allowing on-site insert changes to reduce costs and logistics efforts. The EasyAdjust system simplifies tool settings, maintaining precision while reducing effort. The FixReam HSS reamer offers high performance at a lower cost, suitable for small-scale production. New CVD coatings enhance tool life and performance in challenging conditions.
The product range includes single-bladed reamers, twin-bladed reamers, fine boring tools, and high-performance reamers. MAPAL also offers replaceable head reamers and solutions for large diameters, emphasizing precision and cost-effectiveness.
MAPAL provides tools with guide pads and fixed multi-bladed reamers, each suited for specific applications such as unstable machining conditions or high feed rate operations. These tools offer high accuracy and flexibility in cutting material selection.
MAPAL offers application-specific tool solutions tailored to customer requirements, including tools for machining gearbox housings, planetary carriers, and crankshaft bores. The EasyAdjust system is integrated into custom solutions to enhance precision and reduce setup time.
The document details various machining processes, including semi-machining and finish machining of crankshaft bearing bores made from bi-metallic combinations like Alu-GJL. It also discusses replacing conventional turning with external reamers using the EasyAdjust system for improved accuracy.
The document explains the MAPAL principle for tools with guide pads, ensuring high accuracy and performance. It describes the EasyAdjust system designed to reduce setting efforts and highlights the importance of selecting the correct cutting materials for optimal machining results.
The document emphasizes the importance of guide pads in absorbing and dispersing cutting forces, ensuring no displacement forces or bending moments are exerted on the workpiece. It also highlights the use of modern cutting materials like carbide, cermet, PCD, and PcBN for various machining tasks.
The document categorizes indexable inserts into several types based on their lead geometry: AS, AD, AZ, DZ, and EK. Each type is designed for specific machining tasks and materials.
The document highlights the use of modern cutting materials such as carbide, cermet, PCD, and PcBN, suitable for different workpiece materials and machining tasks.
MAPAL offers high-performance reamers with cylindrical shanks, available in tipped and monolithic designs. These reamers are suitable for machining a wide range of materials, including difficult-to-machine workpieces, due to their optimized geometry, cutting material, and coating.
The document describes replaceable head reamers with various head systems, emphasizing their precision and ease of handling. These are available for through and blind bores with a variety of cutting materials.
MAPAL provides custom reamer solutions tailored to specific customer requirements, enhancing cost-effectiveness and productivity. A re-grinding and repair service is also offered to extend the tool life of reamers.
These are highlighted as a cost-effective option for producing precision bores, although their performance is noted to be lower than high-performance reamers.
The programme includes fixed multi-bladed reamers available in three lines: Basic Line, Performance Line, and Expert Line, each tailored for different applications and precision levels.
The document outlines specifications for different reamer designs, including FixReam FXR505G, FixReam FXR505 PcBN, and FixReam FXR503 Short, with details on design, dimensions, and ordering instructions.
Recommendations for cutting data are provided, advising on ordering intermediate sizes and tolerances other than H7 using the configuration description.
The MonoReam series is divided into MonoReam 600, MonoReam 700, and MonoReam 800, each offering different configurations for through bores and blind bores, with various cutting materials and leads.
The document provides a detailed ordering guide, including series selection, diameter, tolerance, lead, and cutting material.
This technical document serves as a comprehensive guide for selecting and ordering high-performance reamers, offering detailed specifications and configurations to meet diverse machining requirements.
The document provides detailed specifications and configurations for HPR and HFS replaceable head reamers and holders, focusing on their adaptable parameters for various machining tasks.
The document highlights the ease of adapting tool diameter to micrometer precision in challenging machining conditions.
The document includes tables listing reamer diameters, lead types, cutting materials, and order numbers for various HPR designs.
The document provides detailed specifications for various types of floating holders used in reaming and fine boring applications, designed for mounting tools with cylindrical shanks and including features such as internal coolant supply and lateral drive areas.
This document provides detailed technical specifications and recommendations for reaming and fine boring processes, focusing on various materials and cutting conditions.
The document categorizes materials based on their strength and hardness, measured in N/mm² and HRC.
The appendix provides cutting speed (vc) and feed (f) recommendations for different materials and cutting depths (ap).
The document references MAPAL machining groups (MMG) for categorizing materials and their respective machining parameters.
Detailed application data is provided for different diameter ranges, specifying cutting speed, feed, and stock removal for each material type.
Catalog excerpts
Your technology partner for cost-effective machining REAMING | FINE BORING
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When there's something more between you and us: That's the MAPAL effect. Aerospace Automotive Machine and plant engineering are looking for a technology expert who thinks the way you think? employ all our resources for the solution of your tasks. Rail transport Medical technology Power generation
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Subsidiaries with production, sales and service in 21 countries Representatives in 25 countries staff worldwide technology leader for the machining of cubic parts Tool and process solutions combined with comprehensive services We see ourselves as a technology partner, supporting you with the development of efficient and resource-saving manufacturing processes using standard tools, individual tool concepts and the optimisation of tool details. Our tools satisfy all the requirements on process reliability, precision and simple handling. How? Using advanced development and design methods as well...
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CONTENTS 01 Introduction Reaming and fine boring competence_ 6 Product overview 10 Selection system 12 Custom solutions 14 02 Tools with guide pads Product overview 24 Selection overview, single and twin-bladed reamers_ 28 Single-bladed reamers 32 Twin-bladed reamers 50 EasyAdjust system 54 Indexable inserts 60 03 Fixed multi-bladed reamers Programme overview 82 Selection overview 86 High-performance reamers with cylindrical shank_ 86 Replaceable head reamer 198 Solutions for large diameters 352 04 Floating holders Product overview 390 Floating holders 396 Self-adjusting floating holders 409 Floating...
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REAMING | FINE BORING | Introduction REAMING AND FINE BORING COMPETENCE MAPAL offers innovative, cost-effective solutions for machining almost all materials. Today, MAPAL is continuing to write the success story related to the fine machining of bores that started with the "first reamer" in 1954. Thanks to decades of experiences as well as continuous further development and optimisation of the tool solutions, along with tailor-made custom solutions, today MAPAL offers a broad standard programme of tools for reaming and fine boring. Reaming and fine boring are the most common methods for fine machining...
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REAMING | FINE BORING | Introduction Latest production equipment The latest 3D design and simulations form the basis for the manufacture of MAPAL tools. The data are transferred via interfaces to the related machining centre that forms part of the state-of-art range of machinery available on site. In this way MAPAL reaming tools are produced to the highest quality requirements with monitoring and control by experienced staff. Precision and effectiveness are guaranteed. Custom solutions Special machining tasks require special tools. For this reason MAPAL offers custom reaming tools individually...
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REAMING | FINE BORING | Introduction HIGHLIGHTS EasyAdjust system Reduced setting effort with the same precision ► more from page 54 MAPAL offers an innovative solution for the simple, precise settings of tools in a very short time with the EasyAdjust system. The EasyAdjust System consists of a precision cassette in which the back taper on the minor cutting edge is already integrated. The setting effort for the back taper is completely eliminated. Due to the exact guidance of the cassette on a precision guide pin, the back taper remains unchanged even during diameter adjustments. The secure mounting...
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REAMING | FINE BORING | Introduction CVD cutting material series Optimally matched to reaming The cutting material types were developed especially for reaming. Although the CVD coatings known to date are wear-resistant thanks to the extremely hard elements in the coating, they are at the same time very brittle and susceptible to fracture. The special process control in the production of the new CVD coating, however, makes the coating far more ductile than in the past while retaining its good wear resistance. The CVD grades are therefore very well suited to reaming ductile cast iron materials...
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REAMING | FINE BORING | Introduction Tools with guide pads High-performance reamers with cylindrical shank 1 Single-bladed reamers One-insert reaming tool with guide pads for direct guiding in the bore 6 FixReam High-performance reamers made of HSS, solid carbide, solid cermet and with PcBN head 2 Twin-bladed reamers Two-cutting edge reaming tool with guide pads makes higher cutting speeds and feeds possible 7 MonoReam Tipped high-performance reamers in fixed, expanding and finely adjustable designs 3 Fine boring tools with EasyAdjust system Reduction of the setting effort for tools with guide...
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Replaceable head reamers 10 HPR100 Fixed design with brazed cutting edges 11 HPR200 Tipped high-performance reamers in fixed, expanding and finely adjustable designs 12 CPR500 Solid carbide design 13 CPR600 Design with brazed cutting edges Solutions for large diameters 14 HPR300 Optimised for economical reconditioning 15 HPR400 Simple insert change on site 16 MultiCut Cutting rings with matching holder range
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REAMING | FINE BORING | Introduction SELECTION SYSTEM Tools with guide pads | Fixed multi-bladed reamers Tools with guide pads First choice for following applications: – Unstable machining conditions – Optimal with floating holder on the lathe – Rib machining and thin-walled parts – Unfavourable length/diameter ratios – Extremely high shape and positional tolerances Fixed multi-bladed reamers First choice for following applications: – Machining with high feed rates – Maximum output in series production – Abrasive and hard workpiece materials – Multiple spindle machining operations – Machining...
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REAMING | FINE BORING | Introduction TOOL PROPERTIES -- Highest accuracies due to exact setting to the µ MAPAL guide pad technology is unrivalled when it comes to the fine machining of bores in any material. The precision of the bore diameter, circularity and cylindrical form as well as the surface finish cannot be produced by other production means, or at least cannot be achieved cost-effectively. -- Indexable insert technology for highest flexibility during cutting material selection -- Intermediate sizes and all tolerances more from page 24 available at short notice TOOL PROPERTIES -- No setting...
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