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<strong>MAPAL</strong> <strong>HPR300</strong> | Introduction<strong>MAPAL</strong> <strong>HPR300</strong>Reduced costs due to innovative reconditioning<strong>MAPAL</strong> is breaking completely new groundwith tool reconditioning in the HPR 300series. The blades are clamped as blanksin the tool body; they are held in placesecurely and firmly by clamping plates.Then the diameter and cutting lead geometryare ground with high precision. Forreconditioning after reaching the end ofthe tool life, the worn blades can be veryeasily and quickly replaced with new bladeblanks and again ground to the original<strong>MAPAL</strong> quality with μ precision. A furthercrucial advantage is that the tool body andin particular the shank retains its original,high accuracy. On the replacement of theblades, the tool body is not subjected toany thermal loads whatsoever and complexcleaning processes are not required.On conventional reamers, the blades arenormally brazed or in some cases evenbonded, resulting in damage to the toolbody during reconditioning and more frequentrenewal. On average, brazed toolscan be reconditioned a maximum of fourtimes, while the new HPR 300 reamers canbe re-tipped at least ten times. In this way<strong>HPR300</strong> tools pay for themselves alreadyafter the first few reconditionings and savesignificant costs over the entire service lifeof a tool.Fixed brazed toolMany cutting edges and low lifecycle costs:– cut costs when machining largediameters– quick and cost-effective reconditioningCostsHPR 3000 1 2 3 4 5 6 7 8 9 10Number of reconditionings / new procurements<strong>HPR300</strong> – Index<strong>MAPAL</strong> <strong>HPR300</strong>c System overview 4-5c <strong>HPR300</strong> with HSK shank 6-8c <strong>HPR300</strong> with module shank 9-11c KS flange adapter 12c HSK adapters 13c Steep taper adapters 14-16c Leads and rake angles 17c <strong>HPR300</strong> custom solutions 18-193
<strong>HPR300</strong>Modular system offers high flexibilityModule adapter– Steep taper ISO– Steep taper BT– Steep taper ASMEFurther connections on requestIntermediate adapter module on HSKIn standard lengths or adapted individually inlength for each application.Module adapter– HSK-A adapter– HSK-C adapterFurther connections on request.<strong>HPR300</strong> with module connection– Individually tailored working length– Tools with only 2 system components(cost-effective procurement)– Must be realigned when the tool is changed4
<strong>MAPAL</strong> <strong>HPR300</strong><strong>HPR300</strong>Variant Left-hand fluted for through boresShank HSK-C in accordance with DIN 69893-1HSKød 1l 1HSK-size ø d 1 l 1 number ofcutting edgesCarbide Coated carbide Cermet Coated Cermet PD PcBNHSK-C40 42,00 - 59,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620HSK-C50 60,00 - 74,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C63 75,00 - 109,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C80 110,00 - 159,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C100 160,00 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C100 180,00 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620HSK-C100 220,00 - 300,00 95 12 HU612 HP421 CU134/130 CP134/136 PU620on requestDimensions in mm.7
<strong>HPR300</strong>Variant Straight fluted for blind boresShank HSK-C in accordance with DIN 69893-1HSKød 1l 1HSK-Größe ø d 1 l 1 number ofcutting edgesCarbide Coated carbide Cermet Coated Cermet PD PcBNHSK-C40 42,00 - 59,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620HSK-C50 60,00 - 74,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C63 75,00 - 109,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C80 110,00 - 159,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C100 160,00 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620HSK-C100 180,00 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620HSK-C100 220,00 - 300,00 95 12 HU612 HP421 CU134/130 CP134/136 PU620on requestDimensions in mm.8
<strong>HPR300</strong>Variant Left-hand fluted for through boresModule connection sizes in accordance with MN5000-14Død 1l 1D ø d 1 l 1 number ofcutting edgesCarbide Coated carbide Cermet Coated Cermet PCD PcBN80 60,0 - 69,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620100 70,0 - 89,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620117 90,0 - 119,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620on requestDimensions in mm.Død 1l 1D ø d 1 l 1 number ofcutting edgesCarbide Coated carbide Cermet Coated Cermet PCD PcBN80 120,0 - 149,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620100 150,0 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620117 180,0 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620140 220,0 - 300,0 95 12 HU612 HP421 CU134/130 CP134/136 PU620on requestDimensions in mm.10
<strong>MAPAL</strong> <strong>HPR300</strong><strong>HPR300</strong>Variant Straight fluted for blind boresModule connection sizes in accordance with MN5000-14l 1Død 1Død 1D ø d 1 l 1 number ofcutting edgescarbide Coated carbide Cermet Coated Cermet PCD PcBN80 60,0 - 69,99 55 6 HU612 HP421 CU134/130 CP134/136 PU620100 70,0 - 89,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620117 90,0 - 119,99 65 8 HU612 HP421 CU134/130 CP134/136 PU620on requestDimensions in mm.l 1D ø d 1 l 1 number ofcutting edgescarbide Coated carbide Cermet Coated Cermet PCD PcBN80 120,0 - 149,99 75 8 HU612 HP421 CU134/130 CP134/136 PU620100 150,0 - 179,99 95 8 HU612 HP421 CU134/130 CP134/136 PU620117 180,0 - 219,99 95 10 HU612 HP421 CU134/130 CP134/136 PU620140 220,0 - 300,0 95 12 HU612 HP421 CU134/130 CP134/136 PU620on reuqestDimensions in mm.11
KS flange adapter with radial and angular alignmentModule connection sizes in accordance with MN5000-14D(Ø 55)Long versionl 2l 1Modulediameter DNominal sizeHSK-CDimensionsd 1 l 1 l 2WeightkgSpecificationOrder No.80 50 55 100 83 1,90 KS-VL-MOD080-HSK-C050-100-21 3032700180 50 55 150 133 2,65 KS-VL-MOD080-HSK-C050-150-21 3032700280 50 55 200 183 3,40 KS-VL-MOD080-HSK-C050-200-21 30327004100 63 70 100 79 3,18 KS-VL-MOD100-HSK-C063-100-21 30327005100 63 70 150 129 4,36 KS-VL-MOD100-HSK-C063-150-21 30327007100 63 70 200 179 5,54 KS-VL-MOD100-HSK-C063-200-21 30327008117 80 87 100 79 4,27 KS-VL-MOD117-HSK-C080-100-21 30327009117 80 87 150 129 6,65 KS-VL-MOD117-HSK-C080-150-21 30327010117 80 87 200 179 8,58 KS-VL-MOD117-HSK-C080-200-21 30327012140 100 110 100 72 7,58 KS-VL-MOD140-HSK-C100-100-21 30327013140 100 110 150 122 10,61 KS-VL-MOD140-HSK-C100-150-21 30327014140 100 110 200 172 13,64 KS-VL-MOD140-HSK-C100-200-21 30327015Dimensions in mm.Spare parts for KS flange adapter with radial and angular alignment in accordance with MN 5000-1412ModulediameterDQuantityrequiredcylindrical head screw Thrust pad Threaded pinto ISO 476260 4 M5x16 - 12.9 10003601 K10086-14 10040108 K2865-904 1004010970 4 M6x20 - 12.9 10003619 K10086-14 10040108 K2865-904 1004010980 4 M6x20 - 12.9 10003619 K10086-14 10040108 K2865-164 10075074100 4 M8x25 - 12.9 10003637 K10086-04 10075116 K2865-514 10075100117 4 M8x25 - 12.9 10003637 K10086-04 10075116 K2865-514 10075100140 4 M10x30 - 12.9 10003660 K10086-04 10075116 K2865-34 10075099Dimensions in mm.Usage:For fitting in the machine spindle or in HSK or SK adapter for mounting HSK tools.Supply includes:Standard KS clamping cartridge, thrust pad and threaded pin, stop ring and cylindricalhead screws (for fastening the KS flange adapter).Design:Through the threaded pins (for alignment) in the machine spindle and in the HSK or SKadapter, exactly adjustable for radial run-out.Through the thrust pad and threaded pin in the flange adapter, axial run-out exactlyadjustable.Size Order No. Specification Order No. Specification Order No.
<strong>MAPAL</strong> High Performance Reamers | HSK adapterHSK-AdapterShank HSK-A in accordance with DIN 69893-1G 1GDl 1Nominal sizeHSK-AModulediameterDDimensionsl 1 G G 1WeightkgSpecificationOrder No.50 80 60 M6 M8x1 1,1 OS-AD-HSK-A050-MOD080-060-11 3031938663 80 60 M6 M8x1 1,5 OS-AD-HSK-A063-MOD080-060-11 3031938963 100 65 M8 M10x1 2,1 OS-AD-HSK-A063-MOD100-065-11 3031939063 117 65 M8 M10x1 2,5 OS-AD-HSK-A063-MOD117-065-11 3031939180 80 60 M6 M8x1 2,1 OS-AD-HSK-A080-MOD080-060-11 3031939480 100 65 M8 M10x1 2,6 OS-AD-HSK-A080-MOD100-065-11 3031939580 117 65 M8 M10x1 3,1 OS-AD-HSK-A080-MOD117-065-11 3031939680 140 75 M10 M10x1 4,2 OS-AD-HSK-A080-MOD140-075-11 30319397100 80 55 M6 M8x1 3,0 OS-AD-HSK-A100-MOD080-055-11 30319400100 100 65 M8 M10x1 3,7 OS-AD-HSK-A100-MOD100-065-11 30319401100 117 65 M8 M10x1 4,0 OS-AD-HSK-A100-MOD117-065-11 30319402100 140 75 M10 M10x1 5,2 OS-AD-HSK-A100-MOD140-075-11 30319403Dimensions in mm.Spare partsModule diameter DQuantityrequired Threaded pinSize Specification Order No.Dimensions in mm.60-80 4 M8x1x16 K2865-24 10075355100-140 4 M10x1x20 K2865-34 10075099Supply includes:Complete with threaded pins for aligning the radial run-out, does not include coolanttube.13
<strong>MAPAL</strong> High Performance Reamers | Steep taper adaptersSteep taper adaptersShank CAT in accordance with ASME B5.50-1994G 1GDl 1Nominal sizesteep taperDimensions G G 1 WeightkgSpecificationOrder No.D l 140 80 55 M6 M8x1 1,7 OS-AD-CAT040-MOD080-055-11 3032012840 100 60 M8 M10x1 2,2 OS-AD-CAT040-MOD100-060-11 3032012945 80 55 M6 M8x1 3,1 OS-AD-CAT045-MOD080-055-11 3032013245 100 60 M8 M10x1 3,3 OS-AD-CAT045-MOD100-060-11 3032013345 117 60 M8 M10x1 3,5 OS-AD-CAT045-MOD117-060-11 3032013450 80 50 M6 M8x1 3,6 OS-AD-CAT050-MOD080-050-11 3032013750 100 60 M8 M10x1 4,4 OS-AD-CAT050-MOD100-060-11 3032013850 117 60 M8 M10x1 4,5 OS-AD-CAT050-MOD117-060-11 3032013950 140 60 M10 M10x1 4,7 OS-AD-CAT050-MOD140-060-11 30320140Dimensions in mm.Usage:For use in the machine spindle for mounting KS flange adapters, shrink chucks, hydraulicchucks, chucks for cylindrical shanks or tools with a modular shank in accordance with<strong>MAPAL</strong> works standard.Supply includes:Complete with threaded pins for aligning the radial run-out, does not include pull stud.Design:Through the threaded pins the radial run-out of a connection or tool fitted can be adjustedexactly in relation to the steep taper.14
<strong>MAPAL</strong> High Performance Reamers | Steep taper adaptersSteep taper adaptersShank BT in accordance with JIS B 6339G 1GDl 1Nominal sizeBTModulediameter DDimensionsWeightkgSpecificationOrder No.l 1 G G 140 80 65 M6 M8x1 2,0 OS-AD-BT040-MOD080-065-11 3032008840 100 70 M8 M10x1 2,6 OS-AD-BT040-MOD100-070-11 3032008945 80 65 M6 M8x1 3,3 OS-AD-BT045-MOD080-065-11 3032009245 100 75 M8 M10x1 3,5 OS-AD-BT045-MOD100-075-11 3032009345 117 75 M8 M10x1 4,4 OS-AD-BT045-MOD117-075-11 3032009450 80 70 M6 M8x1 5,1 OS-AD-BT050-MOD080-070-11 3032009750 100 70 M8 M10x1 5,3 OS-AD-BT050-MOD100-070-11 3032009850 117 80 M8 M10x1 6,3 OS-AD-BT050-MOD117-080-11 3032009950 140 80 M10 M10x1 6,6 OS-AD-BT050-MOD140-080-11 30320100Dimensions in mm.Spare partsfor module diameterDQuantityrequired Threaded pinOrder No.60-80 4 10075355100 4 10075099117 4 10075099140 4 10075099Usage:For use in the machine spindle for mounting KS flange adapters, shrink chucks, hydraulicchucks, chucks for cylindrical shanks or tools with a modular shank in accordance with<strong>MAPAL</strong> works standard.Supply includes:Complete with threaded pins for aligning the radial run-out, does not include pull stud.Design:Through the threaded pins the radial run-out of a connection or tool fitted can be adjustedexactly in relation to the steep taper.15
<strong>MAPAL</strong> High Performance Reamers | HPR replaceable head reamerSteep taper adaptersShank SK in accordance with DIN 69871 Form AD/BG 1GDl 1Nominal sizeSKModulediameterDDimensions G G 1 Form Weightkgl 1SpecificationOrder-No.40 80 55 M6 M8x1 AD/B 1,7 OS-AD-SK040-MOD080-055-13 1005866140 100 60 M8 M10x1 AD/B 2,2 OS-AD-SK040-MOD100-060-13 1005866245 80 55 M6 M8x1 AD/B 3,1 OS-AD-SK045-MOD080-055-13 1005866545 100 60 M8 M10x1 AD/B 3,3 OS-AD-SK045-MOD100-060-13 1005866645 117 60 M8 M10x1 AD/B 3,5 OS-AD-SK045-MOD117-060-13 1005866750 80 50 M6 M8x1 AD/B 3,6 OS-AD-SK050-MOD080-050-13 1005867150 100 60 M8 M10x1 AD/B 4,4 OS-AD-SK050-MOD100-060-13 1005867250 117 60 M8 M10x1 AD/B 4,5 OS-AD-SK050-MOD117-060-13 1005867350 140 60 M10 M10x1 AD/B 4,7 OS-AD-SK050-MOD140-060-13 10058675Dimensions in mm.Spare partsfor nominal sizeSKQuantityrequiredThreaded pin to ISO 4026SizeOrder-No.for module diameterDQuantity requiredAnzahl Threaded pinOrder-No.40, 45, 50 2 M5x5 10036757Dimensions in mm.60-80 4 10075355100-140 4 10075099Dimensions in mm.Usage:For use in the machine spindle for mounting KS flange adapters, shrink chucks, hydraulicchucks, chucks for cylindrical shanks or tools with a modular shank in accordance with<strong>MAPAL</strong> works standard.Supply includes:Complete with threaded pins for aligning the radial run-out, does not include pull stud.Design:* Steep taper size SK30 is not available in combined design AD/B!Normal setting Form AD, if Form B is required, please state with the order.Through the threaded pins the radial run-out of a connection or tool fitted can be adjustedexactly in relation to the steep taper.16
<strong>MAPAL</strong> High Performance Reamers | HPR replaceable head reamerLead geometries and rake anglesLeadGeometry angle of rake Geometry angle of rakegeometryLeadgeometryMG130°6° MG1G*MWMCMEMGMAfor higher surface finish qualitiesuniversalfor left-handfor higher surface finish qualityfor material group N0,550,80° MW0AMC0,445°6° MC1G0° MA0A0,5MW5°75°6° MW1G12° MW1NMA75°6° MA1G12° MA1N1,4ME30°6° ME1G0,55MC45°6° MC1G1ML25°6° ML2G17
<strong>HPR300</strong> Custom solutionsAn <strong>HPR300</strong> custom tool considerably reduces productive andnon-productive times in the machining process when machininga final drive housing on a planetary hub for commercial vehicles.This saved money for the machinery under consideration whileincreasing productivity and output. The bell-shaped housing madeof GGG50 includes various precision bores and chamfer transitions.The multi-bladed tool using <strong>MAPAL</strong> tangential technology isused for pre-machining, and during the same machining step thebore is fine machined using an <strong>HPR300</strong> reaming stage. Tangentialinserts are also integrated into the tool which produce two chamfersand an edge break at the same time during this machiningsequence. An HPR step reamer is also used for two additionalprecision fit bores.MachiningSavingLocation bore for wheel bearing:ø272 H7 x 20 mm with chamfers and edgebreaksBores for precision fit screws andplanetary pins: ø16 H7 and ø32 H765 seconds of productive time15 seconds of non-productive time80 seconds saved per part!18
<strong>MAPAL</strong> High Performance Reamers | HPR replaceable head reamer<strong>HPR300</strong> Custom solutionsStepped tool forgearbox housingsMaterial GGG60 |Commercial vehicleindustryStepped tool forgearbox housingsMaterial ADI1000 |Commercial vehicleindustryStepped tool withadditional HFS connectionfor bearinghousingMaterial GGG40 |Agricultural sectorStepped tool for axlecarrierMaterial cast steel |Commercial vehicleindustry19
<strong>MAPAL</strong> the major specialistReaming and Fine BoringGun Boring<strong>Dr</strong>illingMillingTurningActuatingClampingSetting and measuringServicesV1.0.0<strong>MAPAL</strong> Präzisionswerkzeuge <strong>Dr</strong>. <strong>Kress</strong> <strong>KG</strong>P.O. Box 1520 · D-73405 Aalen · Phone +49 (0) 7361 585-0 · Fax +49 (0) 7361 585-150info@de.mapal.com · www.mapal.com<strong>HPR300</strong>-E-01-003-1012-<strong>MAPAL</strong> Printed in Germany. Right of technical modification reserved.
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