Reaming. MAPAL MonoReam. Systematic versatility NEW

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Sharyl Amberly Washington
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1 Reaming MAPAL MonoReam Systematic versatility NEW

MAPAL MonoReam With the newly developed multi-bladed reamers in the 600, 700 and 800 series, MAPAL is

The reamers in the MonoReam series are available as fixed, expandable or finely adjustable versions and,

for through bores and blind bores, as well as with different cutting leads and cutting materials.

specific case if general conditions change in production, for example different quantities or bore

With a reduced number of variants a large number of possible applications are covered in fine machining

All tools can be used in common high accuracy chucks such as hydraulic chucks and shrink fit chucks.

2 MAPAL MonoReam With the newly developed multi-bladed reamers in the 600, 700 and 800 series, MAPAL is offering a new, simple, highperformance, standardised reaming system. The reamers in the MonoReam series are available as fixed, expandable or finely adjustable versions and, depending on the application and material, can be ordered as left-hand fluted or straight fluted versions for through bores and blind bores, as well as with different cutting leads and cutting materials. Due to the compatibility between the series, it is possible to change to the optimum system reamer for the specific case if general conditions change in production, for example different quantities or bore tolerances. With a reduced number of variants a large number of possible applications are covered in fine machining with significant rationalisation potential. All tools can be used in common high accuracy chucks such as hydraulic chucks and shrink fit chucks. Advantages: Maximum flexibility thanks to three series with identical dimensions As a result straightforward changing within the MonoReam series Uniform machining results and long tool lives thanks to new adjustment system Straight fluted and left-hand fluted for through bores and blind bores All tools with internal cooling 2

The special three-piece design with screw, pushing ring and adjusting sleeve ensures coaxial errors are compensated and the radial run-out accuracy of the blades after adjustment is within 3 μm.

3 Competence Reaming MonoReam The series at a glance Series 800 Setting to the μm can be realised with the reamers in the MonoReam 800 series. Due to a new type of setting system, which is also used on the finely adjustable MAPAL HPR replaceable head reamers, the blades can be finely adjusted. The special three-piece design with screw, pushing ring and adjusting sleeve ensures coaxial errors are compensated and the radial run-out accuracy of the blades after adjustment is within 3 μm. Very tight bore tolerances can be achieved reliably using the exactly set MonoReam 800 series tools. In the case of expensive cutting materials such as PCD or PcBN, significant cost reductions are possible, as the blades can be readjusted to the μm. As a consequence these high-performance cutting materials are optimally utilised. Series 800 Three-piece design with screw, pushing ring and adjusting sleeve Series 700 The MonoReam tools in the 700 series are used as fixed tools, however this series is optimised for re-grinding to reduce the tool costs. Unlike the MonoReam 800 series, the 700 series is only expanded in diameter by a one-piece expansion screw. The expansion system is therefore suitable for compensation prior to re-grinding and not for setting or readjusting the diameter. Due to the expansion of the diameter it is possible to re-grind all functional surfaces, both on the cutting lead, and also on the tool diameter. As a result, re-ground tools also have the same performance as the original. Series 700 Fixed tool with expansion screw Series 600 The reamers in the MonoReam 600 series are fixed reamers with brazed blades that cannot be adjusted. They are the simplest of the new MonoReam tools and are economical to procure. Like all MonoReam tools, the 600 series is also available as standard in diameters from 7.70 mm to mm and is equipped with four, six or eight blades depending on the diameter. Series 600 Simplest, economical design 3

4 Article overview MonoReam ordering example Series Type of bore Material Coolant supply Flute helix angle Simplest, economical design FIXED Fixed tool with expansion screw EXPANDABLE Three-piece design with screw, pushing ring and adjusting sleeve FINELY ADJUSTABLE P M K N N P M K Tool data Bore diameter ød 1 Overall length l 1 Length l 3 Shank diameter ød 2 Shank length l 2 Blade length l 4 No. of teeth z 7,70-9, ,71-11, ,71-17, ,21-22, ,21-27, ,21-29, ,21-40, Cutting lead Cutting material Feed f z in mm Cutting speed. v c [m/min] Ordering example SERIES DIAMETER MOR ø MonoReam Type of bore: 0 = Through bore 5 = Blind bore Flute helix angle on the blades: 0 = Straight-fluted 1 = Left-hand fluted Reamer and coolant supply: 6: Fixed reamer 7: Expandable reamer 8: Finely adjustable reamer Bore diameter

5 Competence Reaming MonoReam Tool dimensions* MOR610, 710, 810 MOR605, 705, 805 ød2h6 ød1 MOR600, 700, 800 l2 l1 l3 l4 * The dimensions stated are identical for all MonoReam series. P M K1 K2 K3 N Non-alloy steels, cast-steel, alloy steels Stainless, rust and acid-resistant steels Grey cast iron GG20 30 Spheroidal cast iron GGG40 50 Spheroidal/vermicular cast iron GGG60 80 Aluminium, bronze, copper, brass <500 N/mm 2 >500 N/mm 2 R a < 2,0 Ra > 2,0 AlSi Other non-ferrous metals MU2A MY1G MU2A MY1G MU2A MY1G MU2A MY1G MU2A MY1G MU2A MY1G MU2A MY1G MU2A MY1G MU2A MY1G CP136 CP136 CU130 CU130 HP421 HP421 CU130 CU130 HP421 HP421 CP136 CP136 HP421 HP421 HU612 HU612 HU612 HU612 0,12-0,35 0,12-0,35 0,15-0,35 0,15-0,35 0,1-0,3 0,1-0,3 0,25-0,4 0,25-0,4 0,12-0,35 0,12-0,35 0,15-0,4 0,15-0,4 0,15-0,3 0,15-0,3 0,15-0,5 0,15-0,5 0,15-0,5 0,15-0, >250 > FIT CUTTING LEAD CUTTING MATERIAL H7 M Y 1 G - C P Fit: IT or dimensions in μm (example: ) Cutting lead geometry and rake angle: MY1G MU2A Cutting material: HP421 HU612 CP136 CU130 PCD and PcBN on request 5

From practice For machining the hydraulic valve

the MonoReam MOR805 with PCD blades is used.

partially interrupted by an oil channel.

exceed the requirements; it was also possible

6 From practice For machining the hydraulic valve lifter bore in cylinder heads made of AlSiMg, the MonoReam MOR805 with PCD blades is used. The bores are reamed to 12G7 and a surface roughness of R z = 6.3. Other specifications are freedom from burrs and cylindrical form < 8 μm. A special requirement on the tool is the geometry of the bore to be machined. This is a blind bore with a downward cut partially interrupted by an oil channel. This situation makes an optimal coolant supply and chip transport indispensable. The tool life of the previous tool was around 60,000 bores. By using a MonoReam it was possible to meet and exceed the requirements; it was also possible to increase the tool life from 60,000 to 150,000 bores by re-adjusting twice. Tool: Diameter: Machining values: Feed: Tool life: MonoReam MOR805 with 6 PCD blades ø12g7 mm v c = 450 m/min f = 0.4 mm v f = 7,200 mm/min 150,000 bores with two re-adjustments Cooling lubricant: Emulsion 6

7 Competence Reaming MonoReam General technical information Type of bore Internal coolant supply Blind bore For blind bore straight fluted Through bore For through bore straight fluted For through bore with left-hand fluted Cutting materials HU612 Uncoated carbide HP421 Coated carbide CU130 Uncoated Cermet CP136 Coated Cermet On request PCD Polycrystalline diamond PcBN Polycrystalline boron nitride Cutting leads 1 Rake angle 6 Cutting lead MY1G 30 0,6 Rake angle 0 Cutting lead MU2A 45 Other cutting lead geometries and cutting leads with chip breaker on request. 7

8 The great specialist Reaming and Fine Boring Gun Boring Drilling Actuating Milling Turning Clamping Setting and Measuring Customer Services V2.0.0 MAPAL Präzisionswerkzeuge Dr. Kress KG Postfach 1520 D Aalen Telefon +49 (0) Fax +49 (0) MOR-E ZEL Printed in Germany. Right of technical modification reserved.

Reaming and fine boring. EasyAdjust-System Simpler, faster, more cost-effective

Reaming and fine boring. EasyAdjust-System Simpler, faster, more cost-effective Reaming and fine boring EasyAdjust-System Simpler, faster, more cost-effective Never before it had been possible to adjust tools so fast and at such a precision. 2 MAPAL EasyAdjust-System Introduction