Actuating Tools. MAPAL Competence Actuating Tools and Facing Heads

Transcription

1 Actuating Tools MAPAL Competence Actuating Tools and Facing Heads

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3 The MAPAL ISOTOOL Competence Center in Sinsheim The MAPAL group develops, produces and markets high quality precision tools worldwide for the metal cutting industry. Advice and on site technical service are fundamentally important issues for customer satisfaction on any market. In order to meet the demand for complete tooling programs, MAPAL has also included complex actuating tools and facing heads in its broad range of products since the 1990s. Actuating tools from the MAPAL ISOTOOL GmbH in Sinsheim offer maximum potential for rationalization and optimization in large batch production. Whether on special machines or flexible machining centers, wherever complex contours, different diameters, faces or grooves need to be machined with just one tool, MAPAL will provide the right tooling solution. The experienced and highly specialised MAPAL engineering team will work out the best possible solution with the customer. The elaborate, precisely inter-coordinated mechanics and the large number of different components within an actuating tool require maximum precision and care at each step of production. MAPAL ISOTOOL achieves this high precision by an exclusively manual production process. 3

4 The Combination is the thing... + = The MAPAL actuating tools with guide pads represent all our experiences in metal-cutting. New types of high performance tools emerged from proven technologies. Development, design, production and service to the highest precision provide the basis for products from MAPAL.. In general, MAPAL provides a guarantee for the function of the actuating tools developed and produced. For critical trial tools, however, development is always coordinated and concluded with the customer. In order to complete the installation of the tools at the customer s works as quickly and efficiently as possible, an extensive trials program is conducted for all actuating tools under extreme stress and real application conditions. Installation is then carried out at the customer s works by a MAPAL cutting tool specialist. Over the next few pages MAPAL will introduce a selection of typical complex actuating tools together with the proven series of standard facing heads which are already in use worldwide. 4

5 MAPAL guide pad technology Actuating tool technology Index The Competence Center MAPAL ISOTOOL in Sinsheim 2 Introduction The combination is the thing... Actuating tools for every machining task 6 4 = + MAPAL Technology Function principles Actuating with draw bar 8 Actuating with contact stop concept 9 Actuating with centrifugal force 10 Actuating with coolant pressure 11 Actuating with Tooltronic 12 Actuating principles MAPAL high-tech tools for higher product quality at reduced production costs. Machining examples for special machines 14 for machining centers 17 Actuating tools in practice MAPAL facing heads Survey 21 LAT... 1 single slide 26 LAT... 2 parallel twin slide 28 LAT... C single slide with counter balance slide 30 EAT facing head with eccentric actuating system 32 Adaptation to customer requirements 34 Standard facing heads Test stand for actuating tools. 5

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7 The wide variety of MAPAL actuating tools MAPAL Actuating Tools MAPAL offers high performance concepts for every machining task. The production program includes tools actuated by draw bars for special machines and tools controlled without external feed units for machining centers. These are tools actuated by coolant, spindle speed, centrifugal force or by contact stop. If the tools have a large overhang, guide pads based on MAPAL s tried and tested system are used. LAT and EAT facing heads are included in the standard program. MAPAL Technology MAPAL TOOLTRONIC electronically controlled tools with a high level of function and flexibility are the latest development. General observations on MAPAL facing heads Facing heads are primarily used for facing, grooving and NC contour machining in large batch production on special machines. These slide tools, i.e. the toolholder and the inserts, are actuated by means of an NC controlled cross feed device. This device is located on the spindle drive unit or on the rear side of the feed unit and works centrally through the machine spindle. The economic high performance cutting operations call for a type of facing head specifically suited for each machining task or for a specially designed actuating tool. For machining cast iron and steel the LAT series is mainly used, while the EAT series is used for non-ferrous metals (aluminium). MAPAL offers 2 standard series of facing heads: 1. The LAT series: Facing heads with linear slide actuation for large strokes in the medium spindle speed range. 2. The EAT series: Actuating heads with eccentric round slide actuation for small strokes in the high spindle speed range. 7

8 MAPAL actuating tools Function principle 1 Actuating with draw bars Slide - Mainly used on special machines which are not, or only seldom, refitted. F - Slide generating by means of an actuating bar, either drawing or pushing. - Generating the actuating bar by means of an hydraulic or NC feed unit. Draw bar 8

9 MAPAL actuating tools Function principle 2 Actuating with contact stop Resetting by spring force Workpiece - Slide generating is achieved by using the workpiece surface or a special device as a contact stop. F - Special generating tools can mainly be used on machining centers with torque support. Rotary slide Actuating bar fixed by life center Actuating principles 9

10 MAPAL actuating tools Function principle 3 Actuating with coolant pressure Membrane Oil Slide Slide Coolant pressure Pressure valve Draw bar - Tool feed can be set manually by means of a throttle valve. - Slide actuation is achieved by applying the existing coolant pressure. Normally coolant at 50 bar is required. - Actuating tools can be used on machining centers with the appropriate level of coolant pressure. - Coolant controlled tools are subject to very low maintenance as the coolant pressure is not applied directly on the moving parts but via a membrane onto an oil pad which then lubricates the moving parts. - Advantage: A standard machine can be used without special adjustment. 10

11 MAPAL actuating tools Function principle 4 Actuating with centrifugal force F Z Pistons Axial slide - Slide actuation is achieved by using the centrifugal force produced by two symmetrically aligned pistons when the tool is rotated. The tool is automatically deactivated by spring force after the spindle slows down. Oil F Z F - Special slide generating tools driven by centrifugal force can be used on machining centers with appropriately high spindle speeds. - Advantage: Standard machining center can be used without special adjustment. Actuating principles 11

12 MAPAL actuating tools Function principle 5 Actuating with TOOLTRONIC Motor - Generating the slide is achieved by means of a servomotor in the tool. TOOLTRONIC actuating tools can be used on machining centers or special machines. Machining complex contours is also possible on a machining center. Stator Transmission system - Advantage: TOOLTRONIC provides an additional axis for a machine. Electronics TOOLTRONIC The driving force in precision machining MAPAL TOOLTRONIC has been developed as a self-contained drive system. By inductive and bi-directional data transmission, TOOLTRONIC provides a full, additional NC-axis which is incorporated into the machine control system. This means that the functions of modern CNC control systems, such as interpolation of different axes and adjustment for wear and blade radius, can also be fully utilised when TOOLTRONIC is incorporated. The new, fully-developed electronic system sets new standards in the inductively transferred power of mechatronic tools. Bi-directional data transmission also allows any sensor data to be transferred from TOOLTRONIC to the machine control, opening up new opportunities in machining and control concepts. The type of block tool to be used with TOOLTRONIC depends on the actual machining task. In principle all selfgenerating tools from MAPAL ISOTOOL, which are activated by coolant pressure, centrifugal force, contact stop or draw bar, can be driven and controlled by TOOLTRONIC as an alternative. However, possible applications are not just limited to cutting with a geometrically aligned blade. Combined with TOOLTRONIC, a honing tool with selfgenerating honing pads to provide compensation for wear and dimensional adjustment becomes a block tool. 12

13 Boring head with blade adjustment for cylinder bores Honing tool with selfgenerating honing pads for cylinder bores Actuating principles Valve guide reaming and valve seat turning with EAT head LAT face slide tool with large radial stroke EAT head with boring and facing tool for turning contours Contour machining with MAPAL TOOLTRONIC 13

14 MAPAL actuating tools Actuated by Draw bar Slide boring bar for machining crankshaft bearing holes and thrust walls HSK 40 ø32 ø144 ø8 H7 90 Description : Tool for roughing and finishing of crankshaft journals and with actuating element for facing the thrust walls. Machining values: vc = 120 m/min n = 420 1/min f = 0,16 mm/u Internal machining with EAT facing head on special machines HUB Description: Machining various diameters mm in IT7 quality including machining recesses Machining values: vc = m/min n = min -1 f cylindrical turning = 0.1 mm/rev f recessing = 0.1 mm/rev Material: Gd-AlSi12 (Cu)

15 MAPAL actuating tools Actuated by Draw bar Optional for 4 and 6 engine blocks 1530 Material: Ci26 CuCr e SCI 60 Actuating tools in practice Line boring bar for cylinder bore 745 ø60 ø232 Description: Semi-finishing and finishing including all recesses and water jacket control cuts for truck crankcases. Feature: Nine machining steps combined on one work station. Material: CG26Cr 15

16 MAPAL actuating tools Actuated by Draw bar Boring bar with automatic cutting edge adjustment for wear compensation 212 ø176 ø83 Description: Finish machining of cylinder bores for honing. 4 inserts for semi-finishing; 2 adjustable inserts for finishing. Machining values: vc = 120 m/min n = 460 min -1 f = 0.15 mm/rev Material: CGI Angular turning head for valve seat and valve guide Description: Turning of the main and secondary chamfers of a valve seat. Reaming of the valve passages. Sleeve movement does not depend on the feed movement of the basic tool. Machining values: Valve seat Valve guide vc = 206 m/min vc = 57 m/min n = 2000 min -1 n = 3000 min -1 f = 0.03 mm/rev f = 0.1 mm/rev Material: Misc. sintered metals

17 75 MAPAL actuating tools Actuated by contact stop Special actuating tool with contact stop for facing and recessing 235 ± 0.01 EM ø29 ø120 ø29 ø120 ø EM#2 ø123 EM#1 300 Description: Machining of the balcony depth and the recess on a cylinder bore for a motor. Simultaneous machining of end face and recess acc. to DIN 509 Form F. Machining values: vc = 120 m/min n = 300 min -1 f = 0.08 mm/rev Material: cast iron CG25 Actuating tools in practice Special generating tool for spherical machining 22 Hub Description: Machining the spherical form in differential housings by contacting a life center bearing. Slide is reset by spring force. Machining values: vc = 130 m/min n = min -1 f = 0.05 mm/rev Material: SCI 40 17

18 MAPAL actuating tools Actuated by coolant pressure Line boring bar for machining crankshaft bearing holes on machining centers 725 ø69 H7 ø70 Description: Tool for simultaneous machining of journals on machining centers. Guiding by means of carbide or PCD pads which can be actuated. Machining values: vc = 44 m/min n = 200 min -1 f = 0.08 mm/rev Material: SCI 75 Line boring bar for machining thrust bearings on machining centers Description: Average machining values: Tool for the facing of thrust bearings vc = 95 m/min of cylindrical crankcases on machining n = 320 min -1 centers. Supported in the workpiece by carbide f cylindrical turning = 0.15 mm/rev or PCD pads. Material: SCI 75

19 MAPAL actuating tools Actuated by centrifugal force Centrifugal force tool (CFT) for taper machining Hub Taper 1: ø ± 0.1 Description: Angular slide tool for finishing the taper bore on a passenger car journal. Machining is starting from the small diameter of the bore. Machining values: vc = 230 m/min n = 3500 min -1 f = 0.08 mm/rev Material: SCI 40 Actuating tools in practice Boring bar with elements controlled by centrifugal force for sleeve generating Start position Plunge cutting valve seat (up to 3 chamfers) End position Machining valve guide D = 4...9mm 52 Hub 52 Hub Gas spring ø125 ø125 Gas spring Description: Precision machining of valve seat and valve guide on a cylinder head. After plunge cutting the valve seat, the sleeve is generated with the reamer Machining values: Valve seat Valve guide vc = 120 m/min vc = 120 m/min n = U/min n = U/min f = 0,05 m/min f = 0,15 m/min Material: Misc. sintered metals 19

20 MAPAL inserts Inserts with special geometries for producing recesses and contours Maximum efficiency and economy from the MAPAL actuating tools is primarily achieved by using the right insert. MAPAL offers an extensive range of standard and special inserts covering all the requirements for a variety of cutting materials, coatings and appropriate insert geometries and accuracies. Indexable inserts with PCD or CBN blanks Inserts for tools with guide pads for the precision machining of bores (WP and HX) ISO inserts in all versions and in the high precision MAPAL tolerance grade X Special inserts with multiple cutting edges for recessing operations 20

21 MAPAL facing heads Standard facing heads 21

22 MAPAL standard facing heads LAT Single slide Spindle speed range: low spindle speeds LAT 1 spindle speed limit: n max = 2400 Hub * * slide stroke and change of center of gravity Type of operation: Mainly internal machining, medium to heavy machining with maximum overall rigidity in the slide tool system. LAT Parallel twin slide Spindle speed range: Medium spindle speeds. Important note: The traction force depends on spindle speed, stroke and tool weight. MAPAL ISOTOOL supplies calculations for the dimensions of the cross feed device. Type of operation: In contrast to the standard face turning from outside to inside, LAT 2 facing heads can also be supplied in a semi-standard version for face turning from inside to outside. 22

23 MAPAL standard facing heads LAT...C... Single slide with counter balance Spindle speed range: Medium spindle speeds Important note: Traction depends on spindle speed, stroke and tool weight. MAPAL ISOTOOL supplies calculations for the dimensions of the cross feed device. Type of operation: With the LAT C series the block tools are designed for a specific weight and aligned on the covered counter-balance slide. EAT... Rotary slide STandard facing heads Spindle speed range: high to maximum spindle speeds Advantage: Very low machining forces on draw bar. 23

24 MAPAL standard facing heads Machining tasks: Boring Face turning Boring Grooving Boring with cutting edge lifting Boring, facing, grooving (internal) Contour turning, grooving (external) Facing Contour turning (internal) Grooving (external), centering function optional 24

25 MAPAL standard facing heads The LAT facing heads Here the translatory draw bar movement of the cross feed device is redirected by the mechanical slide drive elements into radial or angular actuating movements. The application data in particular the cutting speed resulting from the machining task, provide appropriate dynamics at high spindle speeds. As the traction depends on the spindle speed and the stroke, the performance of the cross feed device must be suitably dimensioned. MAPAL ISOTOOL provides the appropriate support and the necessary calculations. The EAT actuating heads In conjunction with the relevant mechanical elements, the translatory draw bar movement of the cross feed device is redirected in the EAT actuating head by a cam control system into a rotary movement and produces the necessary swing motion by means of the excentrically supported rotary slide. Compared to the LAT system, EAT actuating heads require significantly less activating forces and drive power in a stable, dynamically balanced situation and are, therefore, particularly suited for HSC machining. STandard facing heads 25

26 alpha Single slide facing head LAT LAT-xxx-1-yy H L1 L2 C L4 L3 Z max A beta D Q max d5 d1 d2 d3 d4 L6 L5 Q max G1 E 40 D1 1 T 1 Z max B Reference code: LAT-xxx-1-yy LAT Linear Actuating Tool (facing head) xxx head diameter = D 1 with one (1) linear slide yy cross stroke = Qmax 26

27 Single slide facing head LAT Reference codes LAT LAT LAT LAT LAT LAT LAT Main dimensions D Q max Z max H ,92 20,26 26,22 38,14 47,67 59,59 75, Connection dimensions D1 d 1 d H7 2 d 3 d 4 d 5 j5 L 1 L 2 L 3 L 4 L 5 L 6 G 1 T 1 alpha beta gamma 66, M10x1 L.H. M10x1 L.H. M12x1,5 L.H. M16x1,5 L.H. M16x1,5 L.H. M20x1,5 L.H. M20x1,5 L.H ,5 29,5 31,5 39,5 55,5 69,5 69, ,08 38,74 43,78 50,86 72,33 88,41 87, M6 (3x) M6 (4x) M6 (6x) M6 (8x) M8 (8x) M10 (8x) M12 (8x) 7, , x Slide dimensions A B C E STandard facing heads 27

28 alpha 1 Parallel double slide facing head LAT LAT-xxx-2-yy H L1 L2 D1 L4 L3 Z max beta 1 D Q max d5 d1 d2 d3 d4 L6 L5 Q max G1 A T 1 Z max B1 B2 Reference code: LAT-xxx-2-yy LAT Linear Actuating Tool (facing head) xxx head diameter = D 2 with 2 opposite linear slide yy cross stroke = Qmax 28

29 Parallel double slide facing head LAT Reference codes LAT LAT LAT LAT LAT LAT Main Connection dimensions dimensions Slide dimensions D Q max Z max H D1 d 1 d H7 2 d 3 d 4 d 5 j5 L 1 L 2 L 3 L 4 L 5 L 6 G 1 T 1 alpha beta A 1 B 1 B ,26 26,22 38,14 47,67 59,59 75, M10x1 L.H. M12x1,5 L.H. M16x1,5 L.H. M16x1,5 L.H. M20x1,5 L.H. M20x1,5 L.H ,5 31,5 39,5 55,5 69,5 69, ,74 43,78 50,86 72,33 88,41 87, M6 (4x) M6 (6x) M6 (8x) M8 (8x) M10 (8x) M12 (8x) 14 14, ,5 STandard facing heads 29

30 alpha Single slide facing head LAT...C... with covered counter balance slide LAT-xxx-C-yy H L1 L2 C L4 L3 Z max beta D Q max d5 d1 d2 d3 d4 L6 L5 G1 A E 40 1 T 1 Q max B Z max D1 Reference code: LAT-xxx-C-yy LAT Linear Actuating Tool (facing head) xxx head diameter = D C with one (1) slide and one (1) covered counter slide yy cross stroke = Qmax 30

31 Single slide facing head LAT...C... with covered counter balance slide Reference codes LAT-100-C-12 LAT-125-C-16 LAT-160-C-24 LAT-200-C-32 LAT-250-C-40 Main dimensions D Q max Z max H ,3 19,07 28,6 38,14 47, D1 d 1 d H7 2 d 3 d 4 d 5 j5 L 1 L 2 L 3 L 4 L 5 L 6 G 1 T 1 alpha beta M10x1 L.H. M12x1,5 L.H. M16x1,5 L.H. M16x1,5 L.H. M20x1,5 L.H ,5 31,5 39,5 55,5 69, ,7 50,93 60,4 81,86 88, M6 (4x) M6 (6x) M6 (8x) M8 (8x) M10 (8x) , Slide dimensions A B C E STandard facing heads 31

32 Rotary slide facing head EAT... with eccentric actuation EAT-xxx-yyy-HSK-Czz Wrench accesss high HSK drive key BH SL KH BL LH Drive key (shown out of position) HSK Interfering contour counterweight L3 ZL G3 KD AD TK1 30 NSA NSA 0 bis 36 QH Cutting edge end position, bar drawn E L2 L1 ZD MBA BD G2 D1 SD SW NSB NSL Counterweight to block tool 7 End position, bar pushed MBD EAT heads in special designs available on request Dimensions for small EAT 100 are designed without internal coolant system Reference code example: EAT HSK-C40 EAT Eccentric Actuating Tool 100 head diameter = D 050 Eccentricity = E (here E = 5.0 mm) HSK-C40 Tool holder 32

33 Rotary slide facing head EAT... with eccentric actuation Reference codes EAT HSK-C32 EAT HSK-C40 EAT HSK-C50 EAT HSK-C63 EAT HSK-C80 EAT HSK-C80 Main dimensions AD KD KH BH E QH ,2 5,0 8,0 12,5 20,0 32,0 3,7 5,9 9,4 14,7 23,5 37,6 Connection dimensions Bushing and bar dimensions with thread LH BD BL SD SL D1 L1 G2 L2 22,4 28,8 36,0 44,8 56,8 72,0 28,8 32,4 39,6 50,4 63,0 81, ,5 13, ,5 22,8 10x1 12x1,5 14x1,5 18x1,5 20x1,5 22x1,5 12, ,5 22, ,5 Connection dimensions, spindle dimensions ZD ZL TK1 G3 L3 MBD MBA M5 M6 M8 M8 M10 M12 7, ,7 14,7 16,6 16, Slide dimensions NSB NSA NSL SW HSK ,5 25, , C32 C40 C50 C63 C80 C80 STandard facing heads 33

34 Adjustments to customer requirements Tooth angle / translation ratio Radial stroke, slide Tooth angle Axial stroke, draw bar Depending on the machining task and the machine requirements, the following variations can be supplied as semistandards without additional charge. 40 tooth angle standard 45 tooth angle 1:1 38 tooth angle 1: tooth angle 1:2 Draw bar designed with bayonet coupling and stop Drawbar designed with stop L8 L8 S L7 L2 Zmax V L9 R L7 L2 Zmax V L9 d6 d6 d9 d7 d4 d8 d7 d4 Reference codes Special design d6 d7 d8 d9 L7 L8 L9 V S R h6 34 LAT LAT LAT LAT LAT LAT LAT LAT LAT LAT LAT LAT LAT LAT-100-C-12 LAT-125-C-16 LAT-160-C-24 LAT-200-C-32 LAT-250-C-40 M24x1, ,2 6 M24x1, ,2 6 M27x1, ,2 6 M33x1, , ,2 10 M45x1, , ,2 10 M56x1, ,2 12 M56x1, ,2 12 M24x1, ,2 6 M27x1, ,2 6 M33x1, , ,2 10 M45x1, , ,2 10 M56x1, ,2 12 M56x1, ,2 12 M24x1, ,2 6 M27x1, ,2 6 M33x1, ,2 10 M45x1, ,2 10 M56x1, ,2 12

35 Adjustments to customer requirements Adaptor flanges for standard spindle heads and for special spindles available on request B Code: D LK d B flange diameter hole circle diameter centering diameter flange thickness d LK-Ø D Tool holder design hole pattern for tool fixing LAT...1 and LAT...C LAT...2 STandard facing heads - flange connection - short, stable block tool - only inserts are changed -HSK - Rapid tool change - can be preset - good tool change accuracy - ABS - Rapid tool change - can be preset - flange connection - tool can also be changed rapidly 35

36 A Review of MAPAL s Competence Reaming and Fine Boring From the wide range of single and twin-bladed reamers with guide pads, together with fine boring tools with guide pads and WP or HX blades, to the HPR High Performance Reamers combined with the MAPAL HFS Head Fitting System for exact concentricity and accurate changeover to give you a general view of our complete knowledge and experience in pre cision machining bores. PCD Tools For pre-machining and finish machining, MAPAL also offers an extensive programme of pre cision tools with fixed PCD (polycrystalline diamond) blades. This includes precision gun boring tools plus circular and end milling tools. The programme of face milling heads from the PowerMill and EcoMill series is characterised by simple, sturdy design and rapid, accurate blade setting. ISO Tools This aspect of MAPAL competence is made up of special tools with ISO elements for gun boring and milling. This includes precision ground blades in the widest variety of cutting materials and coatings. The use of MAPAL's tried and tested adjustment system ensures that the blades are accurately matched to the task. MAPAL offers particular knowledge and ex - perience in tangential technology. Actuating Slide Tools Actuating slide tools offer a high potential for rationalisation and optimisation on special machines and machining centres. In addition to the conventional facing heads, MAPAL also supplies EAT and LAT performance-enhanced actuating systems for generating slide tools. MAPAL TOOLTRONIC tools with their extraordinary range of functions are the latest development. Drilling Yet another area is the product programme for drilling. MAPAL offers the right tool concept for every task, whether for machining aluminium, steel or cast iron, hard machining or dry machining or for use in HSC areas. Specially developed coatings and drills with PCD blades complete the broad-based drilling programme. Clamping MAPAL's modern clamping systems, in conjunction with MAPAL's tried and tested reaming and fine boring tools, guarantee maximum productivity and economy. Whether HSK, ISO or HFS, these high-precision connections and interfaces provide the concentricity and changeover accuracy essential to modern production. Customer Services Project planning, maintenance, management and optimisation the complete CTS service package from MAPAL will accompany you from process design to permanent process optimisation and will ensure optimum and cost-saving use of your tools with the best possible results. AST-E MZ Printed in Germany/Right of technical modifications reserved. MAPAL Präzisionswerkzeuge Dr. Kress KG P.O. Box 1520 D Aalen Phone +49 (0) / Fax +49 (0) / info@de.mapal.com 36