HOLLFELDER
CUTTING TOOLSGA200-VARIO

Boring system for diameters
44 mm - 130 mm… precise… flexible… innovative

The new boring system

Features:– μm-precise diameter adjustment for fineboring thanks to insert holder with
Hollfelder-Guhring tapered screw adjustment– suitable for roughing with ISO standard inserts as well– large adjustment range– internal coolant supply is directed straight to the cutting edge
– different insert holders for fine- and rough boring– unequal cutting edge spacing ª 170°
– adaptable to suit all kind of spindles and lengths– rigid connection between basic adapter and interchangeable insert holder

lf ex2ytilibisteem

for diameters from 44 to 130 mm

Advantages of the overall concept:– roughing and finish machining with only one tool head thanks toprogressive cutting process– close tolerances can be maintained– one basic adapter for different diameters– no retraction marks thanks to unequal cutting edge spacing– wide range of insert geometries and coatings available according tonoisicprecustomer specifications

3

The new boring system GA200-VARIO
from Hollfelder-Guhring
Suitable insert holders and inserts are available for roughing as well as forfine machining.
Depending upon the basic adapter the adjustment range is 11-24 mm in Øi.e. basic adapter 1 =>D = 44 - 55 mm		 basic adapter 5 =>D = 106 -130 mm

The basic adapters are adaptable/extendable thanks to theHSK-connections.

4

impresses with high flexibility andenormous accuracy
HOLLFELDER-GÜHRING CUTTING TOOLSThe tapered screw adjustment of the fine boring cartridges provide the possibility toμm-accurately adjust all insert diameters. The capability of this high-performance
tooling system can be applied for a variety of machining tasks and is optimallysuited for all different kinds of materials as well as for HSC machining.
Features of the fine boring holder:- highly accurate, guide-like insert pocket- precision ground cutting insert- tapered screw for μm-accurate diameter adjustment- simple handling ª only two parts ª clamping set and adjustment element
The advantages:- extreme operational smoothness and durable insert pockets- superior axial run-out and concentricity accuracy- extremely long tool life
- excellent surface quality- simple adjustment in μm-range

Further information regarding this adjustment system as well as instructions can be foundon page 14.

5

Boring systemfor diameters from 44-130 mm
GAGA

GA

H2
ØD

H3

ØD

ØD

H1

LA°

L1

15

L1

L

B

CL1
L

Basic adapter
Diameter DTotal length LShankAB

CGA basic adapter

Part no.

max. RPM*

44-55 mm

HSK 40-C

55 mm

55,5 mm55,5 mm

GK 040 02 007 804

302824373

5.800

55-69 mm

HSK 50-C

60 mm

60,5 mm60,5 mm

GK 050 12 025 805

302824377

4.600

69-86 mm

HSK 63-C

60 mm

60,5 mm60,5 mm

GK 063 12 207 806

302824383

3.700

86-106 mm

HSK 63-C

60 mm

60,5 mm60,5 mm

GK 080 12 102 806

302824385

3.000

106-130 mm

HSK 63-C

73 mm

73,5 mm73,5 mm

GK 102 22 144 806

302824389

2.450

Fine boring holder
Diameter DLength L1

H1 – Holder for finishing

Part no.

44-55 mm

27 mm

GD 4090 0002R

302824375

55-69 mm

27 mm

GD 4090 1001R

302824379

69-86 mm

27 mm

GD 4090 1002R

302824382

86-106 mm

27 mm

GD 4090 1003R

302824387

106-130 mm

35 mm

GD 4090 2001R

302824391

Diameter D

Length L1

H3 – Holder for roughing 180°

Part no.

44-55 mm27,5 mm

GD 09T3 0029R

302824702

Holder for roughing

55-69 mm27,5 mm

GD 09T3 1184R

302824703

69-86 mm27,5 mm

GD 09T3 1185R

302824704

86-106 mm

27,5 mm

GD 09T3 1186R

302824705

106-130 mm

35,5 mm

GD 09T3 2251R

302824706

Diameter D

Length L1

H3 – Holder for roughing 150°

Part no.

44-55 mm27,5 mm

GD 09T3 0028R

302824374

alternative

55-69 mm27,5 mmGD 09T3 1181R

302824378

69-86 mm27,5 mm

GD 09T3 1182R

302824381

86-106 mm

27,5 mm

GD 09T3 1183R

302824386

106-130 mm

35,5 mm

GD 09T3 2250R

302824390* balancing quality must be checked

Ordering example:
Quantity Description
1 piece Basic adapter
2 pieces Holder for roughing 150°

Number
GK 063 12 207 806
GD 09T3 1182R

Part no.
302824383
302824381

1 piece2 pieces

GK 063 12 207 806
GD 4090 1002R

302824383
302824382

6Basic adapter
Holder for finishingReductions, basic adaptersand extensionsReductions HSK-A / HSK-C
Part no. 4355
HSK-A

HSK-C

l1

d340,063

7063

d14050,063

80635050,100901005063,10010010063SKHSK-C

d3d1

CodeSW

l1

Basic adapters SK / HSK-C
SK to DIN 69871 form AD

Part no. 4512
Coded1

d1

d2

l1

SW

l140,040

4040

4040,050

40405040,063

7040

6350,040

4050

4050,050

4050

5050,063

405063Extensions HSK-A / HSK-C
Part no. 4549

d3d1

Code80,040

SWl1

HSK-A / HSK-Cl1

d1 / d380

4080,050

80

50100,05010050

100,063100

63140,063140

63

Extensions HSK-C
Part no. 4351
HSK-C
l1

d1 / d3

50,04050

4060,050

60

50

80,06380

63d3d1

CodeSWl1

Further information can be found in the Guhring catalogue GM300.

7

Indexable inserts precision groundfor GA200-Vario boring systemsInsert W 4090-…. …. L
4,511°

2,54,515°

with wiper geometry

80°

RAL°

Code
40,90040,90140,90240,903

9

Drawing no.
W 4090-0225 1000 LW 4090-0425 1000 L
W 4090-0225 1620 L
W 4090-0425 1620 L

with wiper geometry
CodeDrawing no.
40,900W 4090-0225 1011 L
40,901
W 4090-0425 1011 L
40,902
W 4090-0225 1611 L
40,903W 4090-0425 1611 Lright inserts on request

R AL°
0,2 100,4 100,2 160,4 16

Part no.
20194
uncoated
K10

Part no.
20460
coated
G12Part no.
20462
coated
G16Part no.
20200
uncoated
K10

Part no.
20465
coated
G12Part no.
20467
coated
G16

•
•
•
•

R AL°
0,2 100,4 100,2 160,4 16

•
•
•
•

•••
•

••
•
•

Insert W 4093-…. …. L PCD- / PCBN-tipped
15°11°

with wiper geometry

R80°

1,84,54,53

Code
40,93040,93140,93240,933

Drawing no.
W 4093-0018 0000 LW 4093-0218 0000 L
W 4093-0418 0000 L
W 4093-0818 0000 L

with wiper geometry
Code
Drawing no.
40,930W 4093-0018 0011 L40,931
W 4093-0218 0011 L
40,932
W 4093-0418 0011 L• ex stock • on request
8R AL°
0,05 00,200,400,80

R AL°
0,05 00,200,40right inserts on request
Part no.
20212
PCD••••Part no.
20214
PCD•••Part no.
20213
CBN•
••••
•
••
•
•
•

Solid carbide ISO indexable inserts
precision groundwith standard chipbreaker 10°, form CR

9,53

AL
7°°
80

9,673,97CodeISO code
R AL°
93,020 CCHX 09T302 L 116 0,2 1093,040 CCHX 09T304 L 116 0,4 1093,080 CCHX 09T308 L 118 0,8 10CodeISO code
R AL°
93,020 CCHX 09T302 L 116 0,2 1093,040 CCHX 09T304 L 116 0,4 1093,080 CCHX 09T308 L 118 0,8 10Part no.
6678
uncoatedK10Part no.
6698
TiN
K10

Part no.
6680TiAlN SuperA
K10

Part no.
6686
ProtonK10Part no.
6682
uncoated
P40

Part no.
6684
TiN
P40

Part no.
6676
TiAlN SuperA
P40

Part no.
6688
ProtonP40

Part no.
6278
uncoated
K10

Part no.
6298
TiN
K10

Part no.
6662
ProtonK10Part no.
6282
uncoated
P40

Part no.
6284
TiN
P40

Part no.
6664
Proton
P40

•
•
•

•
•
•

•
•
•

•
•
•

•
•
•

•
•
•

•
•
•

•
•
•

with standard chipbreaker 18°, form C
R

9,53

AL7°°
80

9,67

3,97

Code
ISO code
R AL°
93,020 CCHX 09T302 L 216 0,2 1893,040 CCHX 09T304 L 216 0,4 1893,080 CCHX 09T308 L 218 0,8 18CodeISO code
R AL°93,020 CCHX 09T302 L 216 0,2 1893,040 CCHX 09T304 L 216 0,4 1893,080 CCHX 09T308 L 218 0,8 18

•
•
•

•
•
•

•
•
•

•
•
•

•
•
•

•
•
•

Part no.
6280
uncoatedP10

•
•
•

9

Concept:pre- and finish machining in one stepTechnology and advantages
The different roughing holders H2 & H3 were each designed 0.5 mm longer (L1) than the corresponding
fine boring holders H1.
Therefore, for example, it is possible to fit two different holders to a basic adapter.
In the following, the diameter range 44 mm – 55 mm is shown as an example:

1x GD 09T3 0029R ª H2 – holder for roughing
55,527,5i.e. Ø 49,5 mm

Ø D1 Ø D2i.e. Ø 50 mm

Ø44-Ø55 mm

GK 040 02 007 804

2755

D1 – finishing
D2 – roughing

1x GD 4090 0002R ª H1 – holder for finish machining
The roughing insert D2 is adjusted 0.5 mm smaller in diameter than the finishing insert D1.
This is set to the final required measurement.
During machining, the roughing insert leads the finishing insert by 0.5 mm due to the longer holder.

ª progressive cutting process Zeff = 1
Advantages:
Roughing and finish machining with one basic adapter in one cut• the roughing operation can possibly be omitted
For the production of holes with high geometric requirements• very high surface quality• Maintaining straightness is possible even during interrupted machining processes.

10Concept:
unequal cutting edge spacing 170°
Technology and advantages
Thanks to the 170° insert spacing the tool can travel up to 0.7 mm in the y-direction following theconclusion of the finishing operation. Hereby, a clearance of approximately 0.06 mm between hole andinsert is created!
The tool can now be drawn from the hole without the surface being damaged by scoring marks caused
during retraction!
ª higher feed rate through Zeff = 2
1. Fine machining of hole with two effective inserts.
The inserts are turned towards each other by 170°.
2. Orientated spindle stop
Off-set for retraction

170°

AY-direction

5°

3. Tool travels in y-direction ª Tool free!

A50:1
Created clearance betweenhole and insert

Bore in component /work piece diameter
Cutting tool path

4. Tool retraction in rapid traverse ª no score marks!

11

Presetting device for GA200-Vario andA setting device was specificly developed for the pre-setting of GA200-Vario tools.

Presetting device
Part no.
302952490

The scope of delivery includes a digital dial gauge. It can be moved horizontally with a rail guide.
The large and clear digital display allows easy reading of the measuring value.
By using different setting adapters any tool size can be adjusted with the same setting device.

Ø 100

Ø 80 h7

L1

Setting adapter (intermediate flange + adapter flange)

12Shankfor diameter D

Length L1

Part no.

HSK 40-C

44-45 mm

68 mm

302954841

HSK 50-C

55-69 mm

63 mm

302954842

HSK 63-C

69-130 mm

63 mm

302954843

required accessories

In addition, the following measuring masters are required. All diameters are covered.
Setting screw with nut
Base body

Ø D2

Ø D1

LL

Measuring diameter D3 and D4 only with Guhring no. 302952508

Measuring master
Measuring diameter D1, D2, D3, D4

Length L

Part no.

HSK 40-CShank

44 mm, 50 mm

55 mm

302952506

HSK 50-C55 mm, 62 mm

60 mm

302952507

HSK 63-C

69 mm, 80 mm, 90 mm, 100 mm

60 mm

302952508

HSK 63-C

106 mm, 120 mm

73 mm

302952509

The following setting key enables the customer to re-adjust the fine boring tool during the machining process
without having to remove it from the machine.
Setting key for the adjustment of insert type W4090
Setting key (incl. SW 1.5 bit)

SW 1,518

Part no.

20000,0 =302896089

107 (100-108)

Ordering example:
Quantity Description
1 piece Adjustment tool
1 piece Setting adapter HSK 50-C
1 piece Measuring master HSK 50-C

Part no.
302952490
302954842
302952507

13

Adjustment instruction

Adjustment of holder H1 for fine boring• The top of the tapered screw (V) must be even flush with			 the top of the holder body (picture 1)• Install a new insert into the pocket seat and slightly tighten			 the clamp set (S)• Tighten the clamping screw (KS) with torque wrench			 to 1 Nm max (picture 2)• Adjust both holders using screw (VS) to within Ø 0.20 - 0,25 mm			 of required nominal diameter• Tighten the clamping screw KS to required torque specification
KS M4x16 (12.9)

KS M6x25 (12.9)

5.1 Nm

17.6 Nm

Torque value

VS1KSVS2• The roughing tool holder (H2, H3) has to be adjusted according to the requested dimension.
Changing fine boring inserts
Disassembly/Assembly:• Loosen the clamping set S (1 to 2 turns) and remove the worn insert• Clean the insert pocket• Unscrew the tapered screw (V) 1 to 2 full rotations• Insertion of new insert• Press insert into the pocket, hold and pre-tension clamping set S to 250 - 350 Ncm
Assembly:• Fine boring inserts need be adjusted within approximately 0,05 mm to the nominal dimension• Tighten the clamp set (S) to required torque value
The use of a torque wrench is highly recommended:
E5001 adjustable 100-600 Ncm E5400-15 fixed 345 Ncm for Tx15
• Adjust the insert to the required machining diameter via tapered screw.
It is not necessary to re-tighten the clamping set!
Tightening torques for clamping sets
Tool body series

Clamping set STorque Ncm

Torx size

Taper screw VH 4090E 1040345

Tx 15

E 2997

Assembly tools
SW 3 resp. 5 for KS
SW 3 resp. 5 for VS
SW 1,5for V

14Part no. 4921 Code 3,000 resp. 5,000
Part no. 4921 Code 3,000 resp. 5,000
Part no. 4921 Code 1,500

Application example

Finish machining of Pin bore on connecting rod
Workpiece

connecting rod

Material

36MnVS4Tool

GA200-Vario fine boring tool Ø 66.00 mm

Number of teeth

2Insertacc. to customer specification

Cutting grade

HM with PROTON coating TiAlN

Cutting speed

vc = 250 m/min

Number of revolutionsn = 1.205 rev./min

Feed rate

169 mm/min

Feed rate per tooth0.07 mm

Cutting depth

0.3 mm (0.6 in diameter)

Coolant

yes, internal

15

CUTTING TOOLSHOLLFELDER-GÜHRING CUTTING TOOLS
Wertachstraße 27 • D - 90451 Nürnberg • Germany
Telefon + 49 (0) 911 / 64 19 22-0 • Fax + 49 (0) 911 / 64 19 22-10
E-Mail: info@hollfelder-guehring.de • Internet: www.hollfelder-guehring.de

148 820/1502-II-22 • Printed in Germany • 2015
Products, technical data and price subject to change

HOLLFELDER