Featuring high accuracy insert seats, customers can replace inserts instantly, using a torque wrench. Incorrect insert mounting is eliminated, as only one mounting position is possible and the inserts can be fitted in any pocket.
With unequal insert seat spacing, a quiet and smooth cutting process is possible, while an internal coolant supply distributes cooling lubricant directly to the cutting edge. The HPR400 system can be combined with other processes and therefore be designed as a combination tool, too.
The HPR400 is available in the range 50 to 315 mm diameter with either a HSK configuration or Mapal’s own module adaptor. Inserts are available in a variety of grades and geometries, which can be adapted accordingly. Indexable carbide inserts with or without CVD coating are offered or, alternately, there is a cermet and tipped line offered with PCD or PcBN.
For cast iron, Mapal has developed the wear-resistant HC419 insert grade with a CVD coating. This supports high cutting data and offers exceptional tool life, while the CVD coating enables a very broad range of alloys to be machined. HPR400 with the HC419 grade is already being successfully implemented by numerous automotive manufacturers, tackling everything from brake callipers and swivel bearings through to gearbox housings.
One automotive customer machining the main bore in a differential housing made of GJS400 material with a tool diameter of 150 mm having eight inserts is obtaining a tolerance level of IT7 with a high quality surface finish. Cutting speed is 160 m/min with a feed of 1.6 mm, with average roughness of Ra= 1.35 micron.
