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Mapal Tool Gathers No Swarf

Mapal Tool Gathers No Swarf

Added to MTDCNC by MAPAL on 20 August 2015

By adopting an innovative reamer suggested by precision cutting tool expert, MAPAL, for use in the manufacture of diesel engine front covers, Shield Group has greatly improved productivity and virtually eliminated downtime caused by previous tool-related problems.  


Accurately finishing 20 mm diameter holes in a 12 mm thick steel plate doesn’t sound like a particularly demanding application but, when machining time must be kept to an absolute minimum and uninterrupted production must be maintained for long periods, the challenges soon become significant. It was for help in addressing these challenges that engineers at Shield Group approached MAPAL.  


At the time, the finishing operations on the holes were being carried out with single-bladed carbide guide-pad reamer. On paper, this appeared to be a good choice but in practice it was found that after only a few holes, the reamers started cutting significantly oversize. Careful investigation revealed the cause of the problem: the reamer was becoming magnetised and was picking up swarf particles from the work piece, during the arduous machining process.


To address this problem, and to allow the precision reaming operations to be carried out at a faster rate, MAPAL suggested switching to one of its HPR series reamers with a unique Cermet cutting head. As Cermet is non-magnetic there could be no problem with swarf pick up, while the superior cutting properties of the tool would allow a significant increase in the machining rate.  


In addition, MAPAL HPR tools have a replaceable cutting head, which means that they are a particularly cost-effective solution. Since the head is attached to the tool using MAPAL’s innovative HFS head-fitting system, accurate runout and interchangeability within microns are guaranteed.   In use, the HPR reamers have fully lived up to expectations. They are allowing Shield Group to finish ream each of the holes in the engine mounting plates in under a second, while delivering an excellent finish on the bore and achieving h7 tolerance.


Tool life before the cutting head needs to be replaced is in excess of 1,000 holes, and the problem of swarf pick up has, as was anticipated, been completely eliminated.   So satisfied is Shield Group with the solution that it is now working with MAPAL to develop solutions to finish ream holes where the diameter is smaller and larger than the original test holes using Cermet tools, in a process where the introduction of robotic machining is planned.

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