MAPAL has introduced the EA-Performance-System, a fine boring solution designed to simplify tool setting while maintaining precision in the 10 to 19 mm diameter range.
The system enables diameter adjustment with a single adjustment screw, reducing setting effort for operators. MAPAL said the system is designed to deliver high dimensional accuracy and surface quality.
Fine boring tools traditionally use two adjustment elements to set the diameter and cutting-edge taper. This setting process requires operator expertise. MAPAL previously introduced its EasyAdjust-System for diameter ranges from 20 mm, using one adjustment screw for diameter adjustment and a back taper integrated into the cartridge system.
With the EA-Performance-System, MAPAL has extended the one-screw setting principle to the 10 to 19 mm diameter range through a new design configuration. The company said the system is also designed for use across a broad range of materials.
Technical design for demanding applications
The design implementation of stable insert fixation with integrated back taper in this diameter range places high demands on system design, manufacturing precision and stability. It requires the insert seat and clamping mechanism to be precisely coordinated. MAPAL has achieved this by adapting the design of the connection between the insert and the clamping system.
At the heart of the innovation is a newly developed indexable insert with defined contact geometry, which, in combination with a matching clamping jaw, achieves positive-locking and reproducible positioning of the insert. The clamping mechanism between the indexable insert and clamping jaw transfers the setting movement precisely and ensures stable fixation under process load.
New benchmark for easy, precise fine boring
In order to meet the highest precision requirements in small diameter ranges, the new EA-Performance-System from MAPAL for the first time enables micrometre-precise setting with easy handling and maximum process reliability. Minimised correction effort, low reject rates and stable machining processes ensure high efficiency in applications like high-precision fit and bearing bores, for example in transmission housings, cylinders, crankshafts and camshafts.
The system is already being used by select customers, where the stable setting behaviour and reproducible machining results have been confirmed in ongoing production.