MAPAL VersaCut en

Turning
MAPAL VersaCut
Universal, stable hard grooving
and hard turning
22
MAPAL VersaCut | Introduction
Introduction 3
PcBN hard grooving with System overview 4
maximum stability
Designation code 5
The new exible grooving system VersaCut from MAPAL provides
the optimum prerequisites for the special requirements of hard
machining. The PcBN-tipped inserts are extremely stably clamped.
Here a solid clamping jaw presses the insert into a prismatic Inserts 6-12
mounting. The clamping plate itself is embedded in the tool
holder to ensure unimpeded chip ow and to protect the clamp-
ing plate against wear. The inserts are very stable due to the
short projection length and can be changed very quickly. Through Holders 13
the special insert design, damage to the holder caused by insert
fracture is practically excluded.
Technical notes 14
The system includes inserts of varying widths and forms for
recessing and grooving as well as thread machining. Inserts with
PCD tipping or special designs are also possible as an option.
All inserts have the same prismatic shape and size, so that Handling 15
only a single holder size is required for grooving depths of up
to 5 mm and grooving widths from 1.2 to 6 mm. The holder is
available with varies shanks for example: Rectangular shaft,
HSK-T or other modular systems, as well as in numerous custom
versions. As a result the new MAPAL VersaCut hard grooving
range combines stability and a great variety of applications in
one system.
3
The VersaCut system
Optimal chip removal

Embedded clamping plate
Holder with clearance
Leading edge on insert
Optional coolant outlet
High level of flexibility, one tool

holder for all insert variants
No damage to grooving holder Maximum stability during hard

in case of insert fracture grooving using PcBN
High clamping force
Stabile, embedded jaw
Prism mounting
Application areas
Standardised inserts for grooving, groove turning and thread cutting
Groove turning Groove turning Recessing Retaining Thread Parting off

(radius insert) washers/rings
Page 6-7 Page 8 Page 9-10 Page 11 Page 12 Page 12
4
MAPAL VersaCut | Specication
Specication MAPAL VersaCut
Groove cutting
VCI - EN L - -W400 T300 - R010 T51 - FU824
Maximum Cutting
Type Design Corner radius
grooving depth material
VCI VersaCut L Left hand design Stated in 1/100 mm Stated in 1/100 mm

Insert R Right hand design For radius inserts 0.5xD
Application and design Cutting width or diameter Edge design
EN General recessing insert Example: T51 Continuous cut

SR Grooving insert for locking rings W400 Width 4.0 mm S59 Interrupted cut
SS Grooving insert for locking washers D400 Diameter 4.0 mm
SD Groove turning insert (only on radius inserts)
GD Thread turning insert P60 P60 Thread prole 60
AS Parting off insert
Grooving holder
VCH - L - S1616 - A - 0
Type Tool holder shape
VCH VersaCut A 0
Holder B 90
X Variable angle
e.g. X75 for 75
Design Shank design and size Coolant supply
L Left hand design S Rectangular shank b x h 0 without IK

R Right hand design HSK HSK-T40 1 with IK
HSK-T63
5
MAPAL VersaCut | Turning
VersaCut VCI-SD_
Groove turning L R
E
R
Fig. Left hand design
W
R
E
Edge design T51 for continuous cut
W T RE Design Specication Order No.
2 0,02 4 0,2 left VCI-SDL-W200T400-R020T51-FU824 30316777

2 0,02 4 0,2 right VCI-SDR-W200T400-R020T51-FU824 30316783
2,5 0,02 4 0,2 left VCI-SDL-W250T400-R020T51-FU824 30316778
2,5 0,02 4 0,2 right VCI-SDR-W250T400-R020T51-FU824 30316784
Dimensions in mm.
Edge design S59 for interrupted cut
2 0,02 4 0,2 left VCI-SDL-W200T400-R020S59-FU824 30316803

2 0,02 4 0,2 right VCI-SDR-W200T400-R020S59-FU824 30316809
2,5 0,02 4 0,2 left VCI-SDL-W250T400-R020S59-FU824 30316804
2,5 0,02 4 0,2 right VCI-SDR-W250T400-R020S59-FU824 30316810
Dimensions in mm.
6
VersaCut VCI-SD_
Groove turning L R
E
R
W
R
E

Dimensions in mm.

Dimensions in mm.
7
VersaCut VCI-SD_
Groove turning (radius insert)
R Fig. Left hand design
W
R
W T R Design Specication Order No.
3 0,02 5 1,5 left VCI-SDL-D300T500-R150T51-FU824 30316833

3 0,02 5 1,5 right VCI-SDR-D300T500-R150T51-FU824 30316828
3,5 0,02 5 1,75 left VCI-SDL-D350T500-R175T51-FU824 30316834
3,5 0,02 5 1,75 right VCI-SDR-D350T500-R175T51-FU824 30316829
4 0,02 5 2 left VCI-SDL-D400T500-R200T51-FU824 30316835
4 0,02 5 2 right VCI-SDR-D400T500-R200T51-FU824 30316830
Dimensions in mm.
3 0,02 5 1,5 left VCI-SDL-D300T500-R150S59-FU824 30316843

3 0,02 5 1,5 right VCI-SDR-D300T500-R150S59-FU824 30316838
3,5 0,02 5 1,75 left VCI-SDL-D350T500-R175S59-FU824 30316844
3,5 0,02 5 1,75 right VCI-SDR-D350T500-R175S59-FU824 30316839
4 0,02 5 2 left VCI-SDL-D400T500-R200S59-FU824 30316845
4 0,02 5 2 right VCI-SDR-D400T500-R200S59-FU824 30316840
Dimensions in mm.
8
VersaCut VCI-EN_
Recessing insert
E
R
W
R
E
1,5 0,02 3,5 0,2 left VCI-ENL-W200T400-R020S59-FU824 30316736

1,5 0,02 3,5 0,2 right VCI-ENR-W150T350-R020T51-FU824 30316831
2 0,02 4 0,2 left VCI-ENL-W200T400-R020T51-FU824 30316694
2 0,02 4 0,2 right VCI-ENR-W200T400-R020T51-FU824 30316703
2,5 0,02 4 0,2 left VCI-ENL-W250T400-R020T51-FU824 30316696
2,5 0,02 4 0,2 right VCI-ENR-W250T400-R020T51-FU824 30316704
Dimensions in mm.

1,5 0,02 3,5 0,2 right VCI-ENR-W150T350-R020S59-FU824 30316832
2 0,02 4 0,2 left VCI-ENL-W200T400-R020S59-FU824 30316736
2 0,02 4 0,2 right VCI-ENR-W200T400-R020S59-FU824 30316743
2,5 0,02 4 0,2 left VCI-ENL-W250T400-R020S59-FU824 30316737
2,5 0,02 4 0,2 right VCI-ENR-W250T400-R020S59-FU824 30316745
Dimensions in mm.
9
VersaCut VCI-EN_
Recessing insert
E
R
W
R
E
1,5 0,02 3,5 0,4 left VCI-ENL-W150T350-R040T51-FU824 30316857

1,5 0,02 3,5 0,4 right VCI-ENR-W150T350-R040T51-FU824 30316858
Dimensions in mm.

1,5 0,02 3,5 0,4 right VCI-ENR-W150T350-R040S59-FU824 30316860
Dimensions in mm.
10
VersaCut VCI-SR_
Slots for retaining rings
T
E
R
W
R
E

DIN 471
For shaft
WNB W T RE Design Specication Order No.
diameter
18 - 26 1,3 H13 1,4 0,02 1,8 0,12 links

left VCI-SRL-W140T180-R012T51-FU824 30316679
18 - 26 1,3 H13 1,4 0,02 1,8 0,12 rechts
right VCI-SRR-W140T180-R012T51-FU824 30316673
28 - 35 1,6 H13 1,70 0,02 3 0,15 links
28 - 35 1,6 H13 1,70 0,02 3 0,15 rechts
36 - 48 1,85 H13 1,95 0,02 3 0,18 links
36 - 48 1,85 H13 1,95 0,02 3 0,18 rechts
50 - 63 2,15 H13 2,25 0,02 3 0,2 links
50 - 63 2,15 H13 2,25 0,02 3 0,2 rechts
Dimensions in mm.
VersaCut VCI-SS_
Slots for retaining washers
T
E
R
R
E

DIN 6799
For shaft
WNB W T RE Design Specication Order No.
diameter
10 - 14 1,15 +0,08 1,19 0,02 3 0,11 links

left VCI-SSL-W119T300-R011T51-FU824 30316688
10 - 14 1,15 +0,08 1,19 0,02 3 0,11 rechts
right VCI-SSR-W119T300-R011T51-FU824 30316683
11 - 15 1,25 +0,08 1,29 0,02 3 0,12 links
11 - 15 1,25 +0,08 1,29 0,02 3 0,12 rechts
13 - 18 1,35 +0,08 1,39 0,02 4 0,13 links
13 - 18 1,35 +0,08 1,39 0,02 4 0,13 rechts
16 - 24 1,55 +0,08 1,59 0,02 4 0,15 links
16 - 24 1,55 +0,08 1,59 0,02 4 0,15 rechts
20 - 31 1,8 +0,08 1,84 0,02 4 0,18 links
20 - 31 1,8 +0,08 1,84 0,02 4 0,18 rechts
Dimensions in mm.
11
VersaCut VCI-AS_
Parting off
T
E
R
W
R
E
1,5 0,02 4,8 0,2 left VCI-ASL-W150T480-R020T51-FU824 30418274

1,5 0,02 4,8 0,2 right VCI-ASR-W150T480-R020T51-FU824 30419166
2 0,02 4,8 0,2 left VCI-ASL-W200T480-R020T51-FU824 30418276
2 0,02 4,8 0,2 right VCI-ASR-W200T480-R020T51-FU824 30419167
3 0,02 5 0,2 left VCI-ASL-W300T500-R020T51-FU824 30418277
3 0,02 5 0,2 right VCI-ASR-W300T500-R020T51-FU824 30419168
Dimensions in mm.
T
VersaCut VCI-GD_
R
Metric 60 ISO thread
60
R
M4 / M5 0,9 0,1 left VCI-GDL-P60T090-R010T51-FU824 30364781

M4 / M5 0,9 0,1 right VCI-GDR-P60T090-R010T51-FU824 30316841
M6 0,9 0,14 left VCI-GDL-P60T090-R014T51-FU824 30364783
M6 0,9 0,14 right VCI-GDR-P60T090-R014T51-FU824 30316842
M8 1 0,18 left VCI-GDL-P60T100-R018T51-FU824 30335855
M8 1 0,18 right VCI-GDR-P60T100-R018T51-FU824 30316846
Dimensions in mm.
12
VersaCut standard tool holder

Rectangular shank
l1
l2
l3
l4
Coolant Tool holder

Shank design Size l1 l2 l3 l4 Design Specication Order No.
supply shape
Rectangular shank 20 x 20 150 49 20 27 without IK 0 left VCH-L-S2020-A-0 30365899

Rectangular shank 20 x 20 150 49 20 27 without IK 0 right VCH-R-S2020-A-0 30376199
Rectangular shank 20 x 20 150 49 20 27 with IK 0 left VCH-L-S2020-A-1 30320282
Rectangular shank 20 x 20 150 49 20 27 with IK 0 right VCH-R-S2020-A-1 30317676
Rectangular shank 25 x 25 150 49 25 32 without IK 0 left VCH-L-S2525-A-0 30365901
Rectangular shank 25 x 25 150 49 25 32 without IK 0 right VCH-R-S2525-A-0 30376202
Rectangular shank 25 x 25 150 49 25 32 with IK 0 left VCH-L-S2525-A-1 30320283
Rectangular shank 25 x 25 150 49 25 32 with IK 0 right VCH-R-S2525-A-1 30317677
Dimensions in mm.
VersaCut standard tool holder

HSK
l2
l1
Coolant Tool holder

Shank design Size l1 l2 Design Specication Order No.
supply shape
HSK 40-T 70 30 without IK 0 left VCH-L-HSK-T040-A-0 30427900

HSK 40-T 70 30 without IK 0 right VCH-R-HSK-T040-A-0 30428073
HSK 40-T 70 30 with IK 0 left VCH-L-HSK-T040-A-1 30428071
HSK 40-T 70 30 with IK 0 right VCH-L-HSK-T040-A-1 30428072
HSK 63-T 100 40 without IK 0 left VCH-L-HSK-T063-A-0 30365905
HSK 63-T 100 40 without IK 0 right VCH-R-HSK-T063-A-0 30376187
HSK 63-T 100 40 with IK 0 left VCH-L-HSK-T063-A-1 30320284
HSK 63-T 100 40 with IK 0 right VCH-R-HSK-T063-A-1 30316478
Dimensions in mm. Further shanks upon request.
13
MAPAL VersaCut | Technical notes
Cutting edge design and PcBN grades
Cutting edge design

Cutting conditions
Continuous cut
Slightly to heavily interrupted

cut and in case of large uctuations
in the stock removal.
The selection of suitable cutting edge A chamfered cutting edge is the

l1
chamfered T51
designs is the most important vari- preferred design for continuous to
1
able, along with the PcBN grade used slightly interrupted cuts. Depending
and the cutting parameters selected, on the form, the chamfer prevents
for improving the machining result crater wear and burr formation.
with the insert. Longer tool lives,
better surface quality or increased
dimensional accuracy on the part
are in many cases dependent on the Rounding of the chamfered cut-
chamfer geometry selected. l1
chamfered and
ting edge gives the insert additional
1 rounded S59
stability. The S design is particularly
suitable for high loads during a con-
R
tinuous cut and interrupted cut.
PcBN grades
PcBN grade with low portions of CBN.

FU824 The universal grade for machining hardened parts also with an interrupted
cut at medium cutting speeds.
14
MAPAL VersaCut | Handling
Handling
Simple, quick insert change
Step 1: Step 2:
Release clamping Remove cutting
element
Release the clamp-
ing screw until the Pull cutting ele-
cutting element can ment out of the
be pulled out of the prism connection.
prism connection to
the front.
Step 3: Step 4:
Clean mounting Fit cutting
element
Blow out prism
insert seat using Push new insert
compressed air. into prism connec-
tion against the
stop surface. Then
tighten clamping
screw.
Cutting data recommendation VersaCut
Cutting vc f ap Cutting
Material Application
conditions [m/min] [mm/rev] [mm] edge design
Case hardened steel, heat-treated steel,
100-140-180 0,03-0,08-0,15 T51

Recessing,
tool steel, ball bearing steel
groove turning
Hardened steel 47-65HRC
80-100-120 0,02-0,03-0,05 S59
Retaining ring 100-140-180 0,03-0,05-0,08 T51

H
Retaining washer 100-140-180 0,03-0,05-0,08 T51
Thread 50-70-90 0,02-0,04-0,06 T51
Parting off 100-120-160 0,03-0,05-0,07 T51
15
MAPAL the major specialist
Reaming and ne boring

Boring V1.0.1
Drilling
Milling
Turning
Actuating
Clamping
Setting and measuring
Services
VCU-E-01-020-0412-HD Printed in Germany. Right of technical modifications reserved.
MAPAL Przisionswerkzeuge Dr. Kress KG

P.O. Box 1520 D-73405 Aalen Phone +49 (0) 7361 585-0 Fax +49 (0) 7361 585-150
info@de.mapal.com www.mapal.com

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Turning

PcBN hard grooving with System overview 4

Optimal chip removal

High level of flexibility, one tool

No damage to grooving holder Maximum stability during hard

Groove turning Groove turning Recessing Retaining Thread Parting off

Specication MAPAL VersaCut

VCI VersaCut L Left hand design Stated in 1/100 mm Stated in 1/100 mm

Application and design Cutting width or diameter Edge design

EN General recessing insert Example: T51 Continuous cut

Type Tool holder shape

Design Shank design and size Coolant supply

L Left hand design S Rectangular shank b x h 0 without IK

Edge design T51 for continuous cut

W T RE Design Specication Order No.

2 0,02 4 0,2 left VCI-SDL-W200T400-R020T51-FU824 30316777

Edge design S59 for interrupted cut

W T RE Design Specication Order No.

2 0,02 4 0,2 left VCI-SDL-W200T400-R020S59-FU824 30316803

Edge design T51 for continuous cut

W T RE Design Specication Order No.

2 0,02 4 0,4 left VCI-SDL-W200T400-R040T51-FU824 30316789

Edge design S59 for interrupted cut

W T RE Design Specication Order No.

2 0,02 4 0,4 left VCI-SDL-W200T400-R040S59-FU824 30316816

R Fig. Left hand design

Edge design T51 for continuous cut

W T R Design Specication Order No.

3 0,02 5 1,5 left VCI-SDL-D300T500-R150T51-FU824 30316833

Edge design S59 for interrupted cut

W T RE Design Specication Order No.

3 0,02 5 1,5 left VCI-SDL-D300T500-R150S59-FU824 30316843

Edge design T51 for continuous cut

W T RE Design Specication Order No.

1,5 0,02 3,5 0,2 left VCI-ENL-W200T400-R020S59-FU824 30316736

Edge design S59 for interrupted cut

W T RE Design Specication Order No.

1,5 0,02 3,5 0,2 left VCI-ENL-W150T350-R020S59-FU824 30316837

Edge design T51 for continuous cut

W T RE Design Specication Order No.

1,5 0,02 3,5 0,4 left VCI-ENL-W150T350-R040T51-FU824 30316857

Edge design S59 for interrupted cut

W T RE Design Specication Order No.

1,5 0,02 3,5 0,4 left VCI-ENL-W150T350-R040S59-FU824 30316859

Edge design T51 for continuous cut

18 - 26 1,3 H13 1,4 0,02 1,8 0,12 links

Edge design T51 for continuous cut

10 - 14 1,15 +0,08 1,19 0,02 3 0,11 links

Edge design T51 for continuous cut

W T RE Design Specication Order No.

1,5 0,02 4,8 0,2 left VCI-ASL-W150T480-R020T51-FU824 30418274

Edge design T51 for continuous cut

W T RE Design Specication Order No.

M4 / M5 0,9 0,1 left VCI-GDL-P60T090-R010T51-FU824 30364781

VersaCut standard tool holder

Fig. Left hand design

Coolant Tool holder

Rectangular shank 20 x 20 150 49 20 27 without IK 0 left VCH-L-S2020-A-0 30365899

VersaCut standard tool holder

Coolant Tool holder

HSK 40-T 70 30 without IK 0 left VCH-L-HSK-T040-A-0 30427900

Cutting edge design and PcBN grades

Cutting edge design