The multi-bladed tool systems offer the advantage that the inserts with one (HPR400) or four (HPR400 plus) cutting edges can be exchanged by the customer directly on site and ensure maximum accuracy thanks to high-precision insert seats. The focus of current developments is four new solutions that all pursue one goal: continuing to improve companies’ productivity and sustainably reduce costs.

Reaming and burnishing in one machining step

The combination of reaming and burnishing in one machining step offers benefits, particularly in finishing hydraulic pipes. Previously, an adjustable ISO tool was used here in combination with a burnishing tool. The ISO inserts had to be set and re-set where required, which resulted in great effort expended on setting and monitoring and potentially entailed machine downtime.

In a newly developed tool, MAPAL combines standardised components in a single tool in collaboration with a manufacturer of burnishing tools. Instead of an ISO tool, a HPR400 tool from MAPAL handles the pre-machining. Its inserts do not require setting: The plug & play solution makes them much easier to use. The stock allowance situation can even be adjusted, for instance, to operate with less cutting pressure and thus less energy expenditure. Burnishing takes place right after reaming in one machining step. The combination of two processes in one tool enables significant cost and time savings with maximum process reliability due to lower cycle times.

Innovative one-shot solution for finish machining with high stock allowances

In machining situations with high stock allowances in finish machining, the combination tool with ISO leading stage and HPR400 system is particularly attractive. It enables users to machine bores with up to 6 mm of stock allowance in a single working step. The ISO inserts handle the main machining, while the HPR400 system takes care of the finish machining. This results in very short cycle times for the customer. In addition, there is no need for setting as the inserts on the entire tool do not have to be set.

New HPR400 plus concept for face grooves

The HPR400 plus series was specifically further developed for machining face grooves, with indexable inserts explicitly adapted for bores with special base contours (facing or face groove). The new tool concept with two usable cutting edges improves cost-effectiveness. Despite the face groove, tool and inserts are stable and reliable in machining. Applications can be found in almost all steering knuckles and bearing bores where clearance must be ensured at the bottom of the bore.

HPR400 with PCD inserts for machining stator housings: Innovative solutions for electromobility

The HPR400 system is also suitable for finishing the stator bore in electric motors. As there is now greater demand for motors in higher quantities for mid-segment vehicles, there is a growing need for productive solutions.

In contrast to the blades on a fine boring tool, the HPR400 tools with PCD inserts do not require setting. Due to the higher number of cutting edges, machining speeds are much faster than for a fine boring tool. The technology enables a higher output with lower effort, thus boosting productivity.

Flexible, cost-effective, sustainable and state-of-the-art

With the further developments of HPR400 and HPR400 plus systems for dedicated applications, MAPAL is highlighting its ambition to provide customers from the vehicle construction and fluid power sectors with pioneering solutions for a wide range of challenging machining processes – flexible, cost-effective, sustainable and state-of-the-art.