MAPAL bores faster for produmax

By devising and implementing a revised boring process, MAPAL was able to cut machining time by 15 minutes per component, while improving accuracy and consistency.

Each of the brake housings has three blind holes of approximately 20 mm diameter and Produmax was producing these by single point boring. This process was, however, more time consuming than the company would have liked. In addition, setting the tool was difficult, and consistently achieving the very high accuracy needed for the diameter of the holes was challenging.

Having carefully analysed the requirements and the process, MAPAL’s engineers suggested that a more satisfactory approach would be to finish the holes using the company’s replaceable-head HPR-series reamers with coated carbide cutting blades.

Since these tools have six blades per head, a high feed rate could be used which would reduce the time needed for the operation. The required setting operations would also be much simpler than with the single-point tool. Further, the use of replaceable head tools meant that tooling costs would be kept to a minimum without sacrificing accuracy or performance, thanks to MAPAL’s HFS adaptors which incorporate a unique high-precision clamping system.

Trials with a HPR150 straight-fluted reamer used in conjunction with coolant quickly revealed that the consistent accuracy of hole size essential in this application could easily be achieved, along with a reduction in machining time of 5 minutes per hole, which totals to 15 minutes per component.

Produmax is now exclusively using the HPR150 tools for these brake housing boring operations, and is delighted with their convenience, performance and economy.