Complex machining processes and stringent quality requirements demand systems that combine effectiveness, precision and ease of use.
Mapal has responded with its HPR400 and HPR400 plus systems, designed for ultra-productive reaming of large diameters.
These multi-bladed tool systems allow customers to exchange inserts directly on site, ensuring maximum accuracy thanks to high-precision insert seats. The HPR400 uses inserts with a single cutting edge, while the HPR400 plus offers four cutting edges for enhanced efficiency. Current developments focus on three new solutions, all aimed at improving productivity and reducing costs sustainably.
One innovation is a one-shot solution for finish machining with high stock allowances. In situations where finish machining involves significant material removal, the combination tool featuring an ISO leading stage and the HPR400 system proves particularly attractive. It enables bores with up to 6mm of stock allowance to be machined in a single step. ISO inserts handle the main machining, while the HPR400 system completes the finish, resulting in very short cycle times. There is also no need for setting, as the inserts across the tool do not require adjustment.
Stability and reliabilityThe HPR400 plus series has been further developed for machining face grooves, with indexable inserts adapted for bores with special base contours such as facing or face grooves. The new concept, featuring two usable cutting edges, improves cost effectiveness while maintaining stability and reliability. This solution is ideal for applications such as steering knuckles and bearing bores, where clearance at the bottom of the bore is essential.
Mapal has also introduced PCD inserts for the HPR400 system to meet the demands of electromobility. The tool is now suitable for finishing stator bores in electric motors, where higher production volumes are required for mid-segment vehicles. Unlike fine boring tools, the HPR400 with PCD inserts eliminates the need for setting and, thanks to its higher number of cutting edges, achieves significantly faster machining speeds. This technology delivers higher output with less effort, boosting productivity.
With these developments, Mapal reinforces its ambition to provide pioneering solutions for vehicle construction and fluid power sectors. The HPR400 and HPR400 plus systems offer flexibility, cost-effectiveness and sustainability, setting new standards for advanced machining processes.