INNOVATIONS 2019 Your technology partner for machining - Mapal
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Your technology partner for machining INNOVATIONS 2019
When something exceptional develops between us:
That´s the MAPAL effect.
We
You
don't want to do everything
differently. But many things
Opening
up oppor-
tunities
always find new ways to
get more for you out of
your processes.
better.
Innovations
and product range additions 2019
The MAPAL catalogues contain the complete MAPAL portfolio – for the sectors
reaming | fine boring, drilling from solid | boring | countersinking, milling,
turning, clamping, actuating, setting | measuring | dispensing and services.
The catalogues can be downloaded from and ordered at mapal.com
Contents
Process solutions Milling
Electromobility – Innovative machining concepts OptiMill-SPM – Reliable processes when milling from solid 19
for all components 04 Radial ISO indexable inserts –
Reliable machining of unstable structural parts Portfolio for milling rounded off 20
susceptible to vibration 06 OptiMill milling cutters and power chucks –
Cost-effective machining of all connecting rod types 08 Optimum combination for high-performance milling 22
TTD-Tritan – Machining of heat exchangers FaceMill-Diamond – Greater flexibility for face milling 24
taken to the next level 10
Aerospace – Drills ensure greater process reliability 12 Clamping
Vibration damping – Significantly improved surface finishes 25
Reaming and fine boring
Miniaturised clamping chucks –
MonoReam – Optimised cooling for reaming 14 Maximum productivity in a confined space 26
FixReam – Improved series and new model 15
Chip breaker for the machining of aluminium Dispensing
with low silicone content 16 UNIBASE-S – Reduce time and logistics 27
Drilling Services
MEGA-Speed-Drill-Steel – Highest productivity Process analysis identifies potentials 28
and longest tool life 17
Tool Management 4.0 – Successful applications 30
Tritan-Drill – Drilling with three cutting edges
for all materials and applications 18
4 INNOVATIONS 2019 | Process solutions
1 2
Electromobility –
Innovative machining concepts for all components
Even today, MAPAL already offers a wide range ried out on machines with HSK A63 spindle. back-flushing system ensures a far more ef-
of innovative machining solutions for the ma- For the main bore, however, a machine with fective removal of the chips, thus preventing
nufacturing of the individual parts and com- HSK A100 spindle had to be used. That is due chips from scratching the machined surface.
ponents of electrified motor vehicles. on the one hand to the high cutting torques
of up to 500 Nm, and on the other hand to 2. Chatter-free machining of highly
1. High precision for large diameters the maximum permissible tool weight and til- complex thin-walled battery housings
using ultralight tools ting moment. Cost-effective manufacturing MAPAL offers the necessary tools with the op-
The high-precision machining of the main with short cycle times calls for a solution in timum strategy for the different variants of
bore in stator housing presents a challenge for which the complete machining can be carried the battery housing. PCD as cutting materi-
tool and machine. All other steps in the pro- out on one machine with small connections, al and the MQL technology are used for ma-
duction of the stator housing could be car- as these machines are characterised by their ximum cost-effectiveness. Different milling
high spindle speeds, lower investment and technologies are employed to reduce the cut-
operating costs and lower energy consumpti- ting forces, depending on the required stock
on. In order to meet these demands, MAPAL removal, machining application and compo-
has developed a fine boring tool of ultra- nent. For certain contours, for example, the
light design. The low weight of around use of milling cutter for high-volume machi-
10 kg meets the precondition for use ning can be expedient. The SPM milling cutter
on machines with smaller spindles. In from MAPAL is ideally suited to this applica-
addition to the weight, MAPAL tion. Thanks to its high positive cutting edge
has also optimised the coo- geometry and the optimised chip flutes, the
ling channels, a special cutting force is reduced by up to 15% com-
INNOVATIONS 2019 | Process solutions 5
3
pared with conventional milling cutters. If, for are manufactured. The demands on form and
example, deep pockets are to be machined, position tolerances here lie in the range of a AT A GLANCE
MAPAL employs special PCD milling cutters few µm. A particular challenge here, for ex-
-- Concepts and processes for all the
whose cutting edges are arranged with both ample, is the machining of the “screw”. A de-
positive and negative axis angle. In combina- fined rectangularity of less than 0.04 mm and components to be machined
tion with the trochoidal milling strategy, the a surface roughness (Rz) in the single-digit µm -- For example, stator housing, battery housing
cutting force is kept very low even in this ma- range have to be assured. Despite these de- and auxiliary units
chining operation – despite the material re- mands, the thin walls and the depth of the
moval rate over the entire depth of the pocket. part, finishing has to be carried out in a sing-
le pass. MAPAL has developed an SPM milling ADVANTAGES
3. Spiral forms with tolerances in the cutter with finishing geometry and highly po-
µm range sitive rake angle for this application. It ensu- -- Complete machining from a single source
Not only the drive and the energy storage sys- res low-vibration cutting and has an additio- -- Maximum precision – assured through
tem are affected by the electrification of the nal chamfer on the diameter. It can perform decades of experience
vehicles, but also a number of auxiliary units. the machining of base, wall and chamfer on -- New tool concepts thanks to innovative
One example of this is the electric refrigerant the front face in a single step. As a result, the production methods
compressor. The heart of an electric refrige- close tolerances for rectangularity and surface
rant compressor is two nested aluminium spi- finish can be reliably achieved.
rals – scroll stator and scroll rotor. The effici-
ency of the electric refrigerant compressor de-
pends essentially on how precisely these parts
6 INNOVATIONS 2019 | Process solutions
Reliable machining of unstable structural parts
susceptible to vibration
Thin-walled parts are used in a wide variety of many machining steps, this would require of the tool body. Vibrations can be reduced
applications. These components are often ma- a huge number of tools. The expedient mer- here by an appropriate design and choice of
nufactured close to the net shape, but never- ging of these steps using combination tools material. Furthermore, an intelligent arrange-
theless require a great many machining ope- in order to reduce the non-productive times ment of the cutting edges in form and positi-
rations. The particular challenge for these ma- and the number of tool slots is therefore the on helps to keep the cutting forces low. And
chining processes is that due to their design, ideal solution – also from the point of view of finally the machining process itself offers pos-
these parts are very unstable and susceptib- the customer. sibilities for reliable machining of parts su-
le to vibration. That creates special demands sceptible to vibration. Reorganisation and the
upon the design of the process and the tools. Thanks to its vast understanding of the pro- choice of alternative sub-processes create a
cesses for the machining of unstable structu- change in the distribution of forces that can
For the customer it is important that these ral parts, MAPAL is able to offer cost-effecti- increase the process reliability. For example,
parts are preferably machined in a single clam- ve and reliable processes. Three aspects are of the use of a circular milling operation instead
ping system. In order to meet this demand and particular importance here. Firstly the adjust- of a solid drilling operation can help to stabi-
to make as many of the surfaces to be machi- ment of the cutting rate is a factor for redu- lise the process.
ned as accessible to the tools as possible, cer- cing or avoiding rising vibration. Both vibra-
tain allowances have to be made in the clam- tion of the tool – which would result in short
ping system. As a consequence, the workpi- tool lives and poor machining results – and vi-
ece is not optimally supported and tends to bration of the workpiece have to be prevented.
vibrate. Thin webs, voids and interruptions to The latter would result in a recoiling of the
be machined and widely fluctuating stock re- part against the cutting edge and could cause
movals from the cast blank also call for spe- damage to the tool. The second important ad-
cial tool solutions. For large parts with a great justment in the tool design is the evaluation
INNOVATIONS 2019 | Process solutions 7
Adapted tool solutions
1
make vibration controllable
3
AT A GLANCE
1. Solid drill with diamond-coated
-- Process and tool design for the indexable inserts 3. Plunge miller cutting above centre
machining of unstable parts susceptible n ISO indexable inserts with three cutting n Optimised front geometry and chip flute
to vibration edges for maximum cost-effectiveness design
n Combined machining of chamfers using n Modified clamping tool with vibration
-- Combination tools
PCD cutting edges reduces the machining dampers
-- Modified designs of tools and clamping n Load-reduced cutting edge arrangement
time
systems
ADVANTAGES 2 4
-- Cost-effective and stable processes
-- Reduced non-productive times
-- Increased process reliability thanks to
optimum force distribution 2. Circular milling cutter for face and
circumferential milling
n Process-adapted tool design: special helix 4. (Set of) disc milling cutters
angle with Z=3 reduces the circular miller for Slot face milling
cutting forces while Z=6 maximises the n Simultaneous finishing of ribs and chambers
cutting data of the face milling operation n Balanced cutting with cut distribution to
n Particularly wear-susceptible machining prevent jamming of the chips and to ensure
performed using ISO indexable inserts a smooth milling process
8 INNOVATIONS 2019 | Process solutions
Process solution for machining
all types of connecting rods
Connecting rods are highly stressed engine When machining the connecting rod, the others, the new CVD coating from MAPAL is
parts. To take account of downsizing and the small connecting pin bore in particular is a used, which combines the previously opposing
reduction of CO2 emissions, connecting rods challenge. Depending on the geometry, there high ductility and high wear resistance para-
are also becoming increasingly lighter. This is are completely different drilling situations. For meters and thus allows machining with sig-
achieved on the one hand through the use of example, for stepped connecting rods or tra- nificantly higher cutting speeds than before.
high-strength and innovative materials, and pezoidal connecting rods, flat, deep and coni-
on the other hand through modern produc- cal spherical surfaces or for existing forging The tool body of the new tools is made of an
tion processes. This also changes the shape of noses. MAPAL has developed a modular tool optimised material with significantly less vib-
the connecting rods and the variety of shapes concept for drilling from solid with indexable ration. A central coolant supply in the holder
increases. MAPAL offers the complete pro- inserts especially for this type of machining. ensures an optimum supply of coolant directly
cess for machining different types of connec- Radially integrated, sintered indexable inserts at the cutting edges. This means a significant
ting rods – whether on the transfer line or the each with four cutting edges are used here. increase in process reliability and stability du-
machining centre as well as for wet or MQL ring the machining of bores.
machining. The placement of the indexable inserts and the
chip flutes are adapted to the special require- As a complete provider, MAPAL not only of-
ments of the different drilling situations. The fers the optimum tools, but also chucks per-
cutting materials are also adapted. Amongst fectly tailored to the respective type of machi-
INNOVATIONS 2019 | Process solutions 9
ning, including hydraulic power chucks or the
HTC with slim contour for locations that are AT A GLANCE ADVANTAGES
difficult to access, such as the oil bore. With
-- Complete process from a single source -- Perfectly matched tool and tool clamping
the mechatronic actuating tool TOOLTRONIC,
MAPAL also offers the appropriate solution -- Machining of all connecting rod types concept
for complex geometries, for example bores -- Process for wet and MQL machining -- Solutions for even complex geometries
that are not circular or shaped bores with an -- Cost-effective and reliable machining process
oil groove. MAPAL thus offers customers the
complete process with minimum tool chan-
ges, which is specially geared to the prevailing
conditions in each case.
10 INNOVATIONS 2019 | Process solutions
TTD-Tritan –
Machining of heat exchangers taken to the next level
Many versions of heat exchanger are used in Triple edge drill is the method of choice cy. The TTD-Tritan is perfectly centered via its
different industries where they allow, for ex- pronounced drill tip, ensures very good circu-
ample, waste heat to be used for other pro- The triple-edge TTD-Tritan replaceable head larity and in many cases makes a piloting su-
cesses. In the case of shell & tube heat ex- drill improves the machining of the tube pla- perfluous. In addition, the cost-intensive car-
changers that are generally made of metal and tes with respect to cost-effectiveness, pre- bide is limited to the tool head for the repla-
are classified as recuperators, one medium cision and performance. On the TTD-Tritan, ceable head system, which leads to low tool
passes through the tube bundle and a second tool head and tool holder are joined by Hirth costs even with large diameters.
medium flows through the shell. A heat ex- serrations. This connection is easy to opera- The replaceable head system also has a posi-
change takes place without mixing the media. te and particularly stable, so that all the drill tive influence on stock-keeping, as the wear
Depending on the size, the tube plate at the reaches the performance level of the solid parts are essentially limited to the drill heads.
end has a large number of bores. In order to carbide equivalent. In addition it guarantees That in turn reduces the capital tied up in the
ensure that the medium does not escape at the best torque transmission with simultane- warehouse.
this component transition, high demands on ous high changing and radial run-out accura-
positioning accuracy and dimensional accura- MAPAL offers a wide range of diameters in
cy are made on the bores. all common lengths to allow various types of
tube plate to be machined. Smaller diameters
are produced with the solid carbide design of
the Tritan-Drill.INNOVATIONS 2019 | Process solutions 11
AT A GLANCE
-- The right drill concept for front and inter-
mediate plates
-- Triple-edge replaceable head drill for the
The BONUS
machining of heat exchangers
QTD indexable insert drill
-- Easily operated, sturdy connection
with new pyramid tip for
-- Pronounced drill tip for very good circularity
stack machining
In addition to the two front tube
ADVANTAGES plates, slightly thinner intermediate
plates with the same bore pattern are also installed in shell & tube
-- Significant increase in feed rate and tool life heat exchangers. These intermediate plates are stacked above one
-- Tritan geometry for good bore results another for machining, spot welded together, drilled and then separa-
-- Replaceable head system for high cost- ted again. With the QTD indexable insert drill with innovative, paten-
effectiveness and easy handling ted pyramid tip, MAPAL has the optimum solution for even this appli-
-- Complete machining in one machining step cation in its portfolio. The newly developed indexable insert with py-
ramid tip has a very small chisel edge and a tip angle of 120°. Further-
more, the indexable insert is self-centering and ensures a controlled
bore entrance. The intermediate plates can thus be reliably drilled in a
single machining step.12 INNOVATIONS 2019 | Process solutions
Aerospace –
Drills ensure greater process reliability
The number of aircraft built per year is rising Conventional robots frequently do not have ted optimally to the material and the bound-
continuously. Final assembly of the aircraft, the optimum rigidity. This results on the one ary conditions, depending on the machining
however, is still far from being a fully automa- hand from the constantly changing positions situation.
ted production line process. As a rule, an air- of the main axes and the use of multi-stage
craft is fully assembled in one place. But here planetary gear units, and on the other hand The “MicroReamer” micro-cutting stage pa-
again, the degree of automation is increasing from the high weight of the end-effectors tented by MAPAL has the ability to cut at the
with more and more robots being used. Here used that necessitate laborious control com- side and to bring the diameters of all the lay-
robots with end-effectors for drilling and ri- pensation before commissioning. The tool ers to tolerances in the IT8 range. The burr at
veting mounted on shuttles are moved from therefore has the task of carrying out the dril- the bore outlet that has to be less than 0.1
assembly position to assembly position along ling process reliably and over a long tool life mm can also be reliably achieved with this mi-
the aircraft fuselage and position themselves under these difficult boundary conditions. cro-cutting stage.
automatically.
In addition to this lack of rigidity, the very Also of great influence is the differential tip
heterogeneous material combinations used angle, i.e. the combination of a small tip angle
in modern aircraft construction also repre- in the middle of the tool and a large tip angle
sent a major challenge for the tool develop- at the outside diameter. The small tip angle
ment. Multi-layer machining is state-of-the- in the middle ensures immediate self-cente-
art with combinations of aluminium, titanium ring, a good radial run-out of the tool on en-
and CFRP materials often being used. MAPAL tering the material and hence a high diame-
has defined various tool features especially ter precision. The large tip angle at the outer
for the aerospace industry that can be adap- diameter guarantees a small outlet burr whenThe industry is also reac-
INNOVATIONS 2019 | Process solutions 13
ting with the development of
more rigid robot systems that
in combination with the op-
timised tool solutions further
enhance the process reliabi-
lity and flexibility of aircraft
assembly.
Picture: Broetje-Automation GmbH
aluminium or titanium are on the bore exit of
the component. In cases where CFRP forms AT A GLANCE
the external material layer, the differential
-- Tool solutions for drilling processes with
tip angle prevents delamination at the bore
exit. The prevention of any burr formation and robots
delamination is of great importance for the -- Wide range of material combinations can be
compact fitting of the aircraft parts and hence controlled
for optimum strength that prevents localised
overloading of the structure.
ADVANTAGES
In combination with innovative diamond coa-
tings that prevent the formation of built-up -- High process reliability
edges, high-performance drills from MAPAL -- Optimum tool design for every application
ensure reliable processes and cost-effective -- Many years of experience guarantee the best
results when machining using robots. machining results14 INNOVATIONS 2019 | Reaming and fine boring
MonoReam –
Optimised cooling for reaming
Multi-bladed reamers are the tool of choice Thanks to special cooling lubricant outlets on
when high cutting rates and short machi- the multi-bladed reamers, the coolant can AT A GLANCE
ning times are called for. In view of the limi- now be delivered to exactly where it is nee-
ded. In this way optimal chip removal and -- MonoReam multi-bladed reamers with
tations of conventional production methods,
it has not been possible to date with steel tool ideal cooling, as well as efficient lubrication optimised cooling
bodies to direct the coolant exactly to all the of the cutting edges and the arc land cham- -- Special cooling lubricant outlets thanks to
functional areas of the tool. Compromises al- fer are ensured. In turn, this aspect results in additive manufacturing
ways had to be accepted in the design of the less abrasive wear on the arc land chamfer, -- Suitable for MQL
coolant channel bores. Thanks to additive ma- better chip removal as well as optimised ma- -- Straight and left-hand fluted, short and long
nufacturing, MAPAL has now succeeded in re- chining results. design
designing the coolant supply and the form of -- Suitable for through bores and blind bores
the coolant outlet and to gear the system per- All reamers in the three MonoReam series are
fectly for reaming operations. available with the new additively manufactu-
red tool heads and therefore optimised coo- ADVANTAGES
ling and lubrication – even on the usage of
MQL. The MonoReam reamers are available as -- Efficient cooling and lubrication of blade and
fixed (600), expanding (700) and adjustable arc land chamfer
(800) variants. The three series are -- Improved chip removal
interchangeable. -- Better machining resultsINNOVATIONS 2019 | Reaming and fine boring 15
FixReam –
Improved series and new model
The FixReam high-performance solid carbide chined with one and the same reamer. That is
reamers (FXR) cover a wide range of applica- made possible by the innovative design. It is AT A GLANCE
tions. Depending on the diameter, the high- therefore suitable also for use with short and
medium production runs. Stocking costs are -- Optimised series – new substrates, new
performance reamers have between four and
eight cutting edges with internal cooling and reduced thanks to the universal range of ap- coatings, new arc land chamfer
achieve correspondingly high feed rates. plications. In addition, the short form of the -- New and universal model for through bores
reamer preserves carbide metal resources and and blind holes in steel and cast iron
MAPAL has optimised the whole range. New improves the stability of the tool. machining
carbide substrates geared specifically to the
machining operation in combination with new
coatings result in longer tool lives. A new arc ADVANTAGES
land chamfer allows the reamers to enter the
bore more precisely – as a result, circularities -- Tool life, circularity and cylindrical form
and cylindrical forms are further improved. improved
-- Reduced stock costs thanks to universal
In addition to the optimised series, MAPAL is FixReam short
also presenting a further model of the high- -- Carbide metal resources are conserved
performance reamer. The new “FixReam short”
for the machining of steel and cast iron allows
both through bores and blind holes to be ma-16 INNOVATIONS 2019 | Reaming and fine boring
New chip breaker for the machining
of aluminium with low silicone content
The machining of parts made from alumini- MAPAL has now developed a new chip brea-
um with low silicone content (silicone content ker to ensure defined chip breaking during bo- AT A GLANCE
less than three percent) results in long chips. ring and reaming with PCD in aluminium com-
ponents with low silicone content. Its special -- Special topology of the chip breaker
These have a negative effect on the process in
a number of ways. On the one hand there is topology developed in time-consuming 3D si- -- Developed using 3D simulation
a risk of the chips wrapping around the tool mulations ensures defined chip breaking and -- Defined chip breaking and chip shape
and hence negatively influencing the surface hence short chips. Even with low feed rates
finish and the dimensional accuracy of the and low stock removal, defined chip breaking
bore. On the other hand, long chips cannot be and a defined chip shape are ensured. This ADVANTAGES
reliably removed from the part, the clamping guarantees highest performance and process
fixture and the machine automatically during reliability. -- Highest performance
series production. This can lead to machine -- Process reliability
standstill and laborious reworking. The newly developed chip breaker can be in- -- for universal application
tegrated into the PCD cutting edge or PCD in- -- No damage to the surface due to scratching
dexable insert, irrespective of the particular -- No damage to the cutting edge due to long
application, and can therefore be universally chips
used. -- Universally applicable for every PCD cutting
edgeINNOVATIONS 2019 | Drilling 17
MEGA-Speed-Drill-Steel –
Highest productivity and longest tool
With the MEGA-Speed-Drill-Steel, MAPAL is
presenting a new drill for high-speed machi- AT A GLANCE
ning that is specially geared to the drilling of
-- High-speed drill for drilling in steel
steel.
-- Available in the diameter range 3-20 mm
Compared with conventional two cutting edge -- Drilling depth 5xD
drills, the new MEGA-Speed-Drill-Steel allows
up to 20 percent higher feeds and up to dou-
ble the cutting speeds. Three guide chamfers ADVANTAGES
ensure maximum smooth running and pro-
cess reliability. Thanks to the precision ground -- Cutting edge extremely sturdy and strong
flute profile, friction between chips and tool -- Long tool lives
is reduced and the chips are removed quickly -- Highest productivity
and reliably. Thanks to its special crowned
form, the main cutting edge is extremely stur-
dy and strong. The combination of these fea-
tures ensures long tool lives and maximum
productivity.18 INNOVATIONS 2019 | Drilling
Tritan-Drill-Alu Tritan-Drill-Iron Tritan-Drill-Uni-Plus Tritan-Step-Drill-Steel
Tritan-Drill – Drilling with three cutting edges
for all materials and applications
Tritan drills from MAPAL have established The Tritan-Step-Drill-Steel was developed for
themselves across the board due to their great stepped bores in tapping bores. The two cut- AT A GLANCE
economic advantages. Four new designs com- ting edge drills used to date tend to oscillate up
and down along the chisel edge due to the flat- -- Tritan-Drill-Uni-Plus for universal application:
plete the range of products.
ness of the chisel edge in the middle, resulting Available as standard with shank form HA in
The tool geometry of the Tritan-Drill-Uni-Plus in poor boring results. The new Tritan-Step- the diameter range 4-20 mm and in the
for the machining of steels, stainless steel al- Drill-Steel with three cutting edges has an in- lengths 5xD and 8xD
loys and cast iron materials has been further novative point thinning and precision ground -- Tritan-Drill-Alu and Tritan-Drill-Iron as
developed. Smooth flute profiles improve chip chip flutes for closely rolled and broken chips. application-specific special solutions for the
removal and a wear-resistant coating increases The chips are reliably removed through the re- respective material groups
the tool life by up to three times. latively small chip flute. The crowned cutting -- Tritan-Drill-Step-Drill for stepped bores in
edge with pulling cut from the centre to the tapping bores
The Tritan-Drill-Alu and the Tritan-Drill-Iron sturdy corner of the cutting edge makes the
are now available for drilling in aluminium and drill extremely sturdy. In combination with a
cast iron materials. The Tritan-Drill-Alu has a wear-resistant coating, the machining results ADVANTAGES
tailored, polished flute profile. Large chip flu- are outstanding: Compared with double edge
tes and a special, sharp cutting edge preparati- stepped drills, the Tritan drills allow double the -- Very high cost-effectiveness and performance
on ensure optimum chip formation and reliab- feed rates to be achieved – with a simultaneous thanks to high feed rates and long tool lives
le chip removal. The Tritan-Drill-Iron impresses increase in the tool life. -- Broad range of standard versions guarantees
with its corner radius design that offers greater high availability
stability and wear resistance of the corner of
the cutting edge and a special wear-resistant
coating.INNOVATIONS 2019 | Milling 19
Picture: F. Zimmermann GmbH
OptiMill-SPM –
Reliable processes when milling from solid
Aluminium structural parts, such as wing The new finishing geometry prevents the
parts and frame ribs, are generally milled from pulling inwards of the tool during the finishing AT A GLANCE
solid material – with up to 95 percent materi- of deep pockets even with high wrapping.
-- Maximum contact depth
al removal. Fault-free machining with respect
to dimensional accuracy and surface finish is The tools in the OptiMill-SPM series are cha- -- Polished chip flutes
crucial here. And the part structure that be- racterised by their conical neck. In this way -- Highly positive rake angle and conical form
comes more and more delicate with increa- high rigidity is guaranteed over the entire ma- -- PCD and ISO indexable inserts available
sing material removal and decreasing wall chining process. The highly positive cutting
thickness represents an additional challenge. geometry and the optimised chip flutes ensure
The reduction of the cutting forces produced a significantly reduced cutting force. ADVANTAGES
therefore has a major effect on the quality of
the part. Above all thin walls and free-stan- -- Optimum chip removal
ding sections can be displaced by excessively -- Reduced cutting forces and high surface
high cutting forces. finish quality
-- Reliable machining of delicate components
MAPAL has now developed new tools with po-
lished indexable inserts for the roughing and
finishing of these parts. The new tools com-
plement the MAPAL SPM range for the machi-
ning of structural parts. For roughing, a spe-
cial cutting edge profile has been developed
that significantly reduces the cutting forces
and the heat introduction into the component.20 INNOVATIONS 2019 | Milling
Radial ISO indexable inserts –
Portfolio for milling rounded off
MAPAL is rounding off its portfolio of stan- four different PVD cutting materials, based their very smooth running and low noise. In
dard milling tools with a milling cutter range on newly developed carbide substrates and addition, very long tool lives are achieved
of compacted radial ISO indexable inserts. coatings, are available for the milling cutters. due to the possibilities for exact adjustment
Until now the focus was mainly on a milling to the respective material and the respecti-
cutter range with ground tangential ISO in- Depending on the requirement, the most ve application.
dexable inserts. These are used in particu- economically efficient version is used. For ex-
lar for special applications, very large stock ample, between eight and 16 cutting edges
removal, unstable conditions or disc milling per radial ISO indexable insert can be selec-
cutters. ted for face milling and between two, four
and eight cutting edges for shoulder milling.
MAPAL has incorporated the comprehensive The new tools are convincing in use due to
know-how gathered in these special applica-
tions into the new series of milling cutters
with radial ISO indexable inserts. The new
powerful face, shoulder, slot and shell end
face milling cutters are designed for roug-
hing and for medium machining of cast iron,
steel and stainless steel. They have optimally
designed tool bodies with the ideal number
of teeth for the respective application. Posi-
tive and negative indexable inserts made ofINNOVATIONS 2019 | Milling 21
AT A GLANCE
-- Milling cutter range with compacted radial
ISO indexable inserts 1. Face milling cutter with close spac-
ing and 16 cutting edges for maxi-
-- Plane, shoulder, slot and shell end face milling
mum cost-effectiveness
cutters
2. Shoulder milling cutter with cylin-
-- For roughing and medium machining of cast drical shank and positive basic form
iron, steel and stainless steel – ideally suited for steep angle
-- Positive and negative indexable inserts made plunging
2 3
from four different PVD cutting materials 3. Shoulder milling cutter with eight 1
cutting edges
4. Shell end face milling cutter for
steady machining operations –
ADVANTAGES ideal for shoulder milling with large
cutting depths 6 4
-- Comprehensive complete range for cost-
5. Shell end face milling cutter with
effective and efficient machining cylindrical shank and up to four 5
-- Very smooth running cutting edges
-- Low noise 6. Shoulder milling cutter with cylin-
drical shank and up to four cutting 7
-- Maximum tool lives
edges
7. Face milling cutter with positive
basic form – ideal for machining
operations susceptible to vibration22 INNOVATIONS 2019 | Milling
OptiMill-Trochoid-Uni OptiMill-Trochoid-PM OptiMill-Alu-HPC-Pocket OptiMill-Uni-Wave
OptiMill milling cutters and power chucks –
Optimum combination for high-performance milling
MAPAL is extending its range of solid carbi- For this, the OptiMill-Uni-HPC-Pocket that MAPAL has not only expanded
de milling cutters and presenting new models is successfully used for numerous machining its range of high-performance
from the OptiMill ranges ‘Wave’, ‘Trochoid’ operations was specially adapted to the ma- solid carbide milling cutters,
and ‘Alu-HPC-Pocket’. chining of aluminium – including adding a but with the new power chuck
new coating. is now offering at the same time
The trochoidal milling cutters from the MAPAL the optimum holder for the new
OptiMill-Trochoid range now have additio- With the OptiMill-Uni-Wave, full slot mil- milling cutters.
nal specially formed chip breakers. These en- ling with a groove depth of up to 3xD is pos-
sure short chips and their reliable discharge sible. The solid carbide milling cutter that can The new power chuck impresses with strong
from the process. The solid carbide tools im- be used for a wide range of materials can be clamping, simple handling and very good ra-
press with very high cost-effectiveness thanks operated with high feeds. Thanks to the inno- dial run-out. The location bore is manufactu-
to high cutting rates with cutting depths up vative knurled roughing geometry, short and red in the single-digit µm range. A patented
to ap = 5xD. closely rolled chips are produced during ma- spring element in the location bore ensures a
chining that can be reliably discharged from defined form closure between tool and chuck.
Time-consuming ramping processes or pilot the process. The milling cutter is now available The tool can be reliably clamped in the chuck
bores are frequently the order of the day as standard in new sizes and lengths. by hand without the use of a torque wrench.
when milling pockets. In order to eliminate The chuck exhibits its full strengths during
these steps during the machining of alumini- high-speed milling operations.
um, MAPAL is now offering the OptiMill-Alu-
HPC-Pocket solid carbide milling cutter.INNOVATIONS 2019 | Milling 23
AT A GLANCE ADVANTAGES
-- Combination of power chuck and high- -- Easy handling
performance milling cutter -- Maximum cost-effectiveness and precision
-- The right tool for every milling application -- Coordinated complete system from a single
with new features, for further materials and source
in new sizes
-- Groove milling, trochoidal milling and pocket
milling24 INNOVATIONS 2019 | Milling
FaceMill-Diamond –
Greater flexibility for face milling
The FaceMill-Diamond PCD face milling cut- The most apparent change in the new Face-
ter has been successfully in use worldwide Mill-Diamond results from the demand for AT A GLANCE
for many years. It demonstrates its particu- greater flexibility and independence of the
machine interface. The face milling cutter is -- Large number of fixed brazed PCD cutting
lar strength, however, during HPC applications
or when machining unstable parts – and that now designed as a modular cutter head va- edges
with cutting depths up to 10 mm. The mono- riant. The milling cutter can now be flexib- -- Proven geometry variants available for
lithic design with brazed PCD cutting edges ly used particularly for small series with dif- different surface finish demands
allows large numbers of teeth, thus enabling ferent machine parks or even for large series (< 10 µm / > 10 µm)
high feeds and higher material removal rates. that are produced on another machine and -- Cutting depths of up to ap = 10 mm possible
Machining with the FaceMill-Diamond results then relocated.
in very good surface finishes and a long tool
life. ADVANTAGES
The FaceMill-Diamond has now been over- -- Improved chip removal and longer tool lives
hauled with the goal of making the proven thanks to cooling directly at the cutting edge
solution even better. For optimum cooling -- Cutter head variant for flexible use with
and lubrication of the PCD cutting edges, the different machine interfaces
coolant outlets are positioned directly at the
cutting edges in the new model. This ensures
an improved chip removal and offers signifi-
cant benefits, particularly in applications with
MQL or blowing air.INNOVATIONS 2019 | Clamping 25
WITHOUT vibration damper WITH vibration damper
Vibration damping –
Significantly improved surface finishes
Vibration often occurs during machining. This The result: A system for vibration damping
leads to dynamic instability of the system. In- tailored to the rigidity of all common machine AT A GLANCE
adequate surface finishes, insufficient accura- types. It can be used for machining different
materials with different tools. -- System for vibration suppression directly in
cy, high machining noises, shortened tool lives
and, in extreme cases, broken tools and cut- the tool shank for tools with long projection
ting edges can be the result. The self-contained system of auxiliary mass length
and several steel spring packages counteracts -- Tailored to the rigidity of all common
In order to minimise these vibrations and their the deflection of the tool body and minimi- machine types
consequences, MAPAL has now developed an ses it. Compared with tools without absorber -- Available with internal coolant supply for
innovative system for vibration damping in the system, the vibration amplitudes can be up to clamping diameters 16, 22 and 27 mm with a
tool shank, as particularly tools for boring and 1,000 times lower. Despite the long projection length of 200 and 300 mm for SK40, SK50,
milling with very long projection length tend length, quiet, stable running is achieved. This HSK-A63 and HSK-A100 connections
to vibrate due to an inadequate dynamic rigi- makes it possible to work at higher cutting
dity of the overall system. When designing the speeds and significantly increases the materi-
new system, the developers took into account al removal rate. In addition, significantly bet- ADVANTAGES
all factors arising from the interaction of the ter surface finishes are achieved thanks to vi-
machine tool, the tool and type of clamping bration damping. -- Smooth, steady running despite long
as well as the component. projection length
-- Higher cutting speeds, higher material
removal rates
-- Better surface finishes26 INNOVATIONS 2019 | Clamping
MAPAL equips the chucks for the miniature sector with decentralised
coolant outlets that direct the cooling lubricant exactly to the cut-
ting edge.
Miniaturised clamping chucks –
Maximum productivity in a confined space
Thanks to additive manufacturing, MAPAL has mogeneous acceleration and deceleration of New possibilities –
succeeded in producing hydraulic chucks in the whole tool system of chuck and tool for not only for tool clamping
miniature format with HSK E25 connection, less loading of the spindle.
for example for the direct clamping of tools The new small hydraulic chucks also offer new
with a diameter of 3 mm. These meet all the The innovative manufacturing method has possibilities for the clamping of workpieces.
demands on chucks for the miniature sector also enabled the chucks for the miniature sec- For example, for the clamping of artificial hip
with respect to radial run-out accuracy, ba- tor to be equipped with decentralised coolant joint balls. Specially formed clamping cham-
lancing value, cooling lubricant supply and outlets. These outlets are designed using pa- bers inside the chuck and a special outside
handling. rameters such as coolant pressure, setting di- geometry ensure that the balls are very pre-
mension and spindle speed so that they deliver cisely and at the same time gently clamped.
In order to guarantee perfect radial run-out the cooling lubricant precisely to the cutting Particularly in medical technology, topics such
accuracy, innovative clamping chamber sys- edge. In the best case, a metered total-loss lu- as reproducible precision are taking on enor-
tems are integrated into the new chucks that brication system is achieved that eliminates mous importance – and this is ensured during
fit tightly against the shank of the tool. They the need for subsequent cleaning of the parts. machining thanks to the new chucks.
are fitted with dirt grooves as protection
against micro-soiling. The demanded balan- The new miniature chucks from MAPAL allow
cing value is ensured thanks to the internal quick and simple clamping of the tool. Neit-
balancing geometries and supporting structu- her training courses nor high setup costs or
res that also aid the optimisation of weight expensive peripherals are required for imple-
and strength. The miniature chucks allow ho- mentation of the chucks.INNOVATIONS 2019 | Clamping 27
Thanks to additive manufacturing, the hydraulic clamping tech-
nology can also be used for chucks with HSK E25 connection
and lean contour.
AT A GLANCE
-- Hydraulic chucks in the miniature sector
-- From HSK E25 connection
-- Tool and workpiece clamping
ADVANTAGES
-- Direct clamping of small-diameter tools
-- Highest precision
Thanks to the use of a clamping arbor with hydrau-
-- Decentralised coolant outlets lic clamping technology, workpieces such as here
-- Easy handling the example of an artificial hip joint ball can be
clamped extremely precisely.28 INNOVATIONS 2019 | Dispensing
UNIBASE-S –
Reduce time and logistics
MAPAL offers a variety of UNIBASE dispen- chucks. This saves the employee a trip to the
sing systems for optimum storage and ma- central warehouse and ensures manufactu- AT A GLANCE
nagement of tools, components and acces- ring-related article procurement.
-- Stock-controlled dispensing system
sories. They can be individually linked thanks
to the modular principle. These systems are Article removal is quick and uncomplicated -- 80 tool slots, individual dispensing
often situated in a central location in the in just a few steps. To do this, the employee -- Central locking
production hall. In order to store and ma- logs on directly to the device via the integra-
nage frequently required consumables in ted touchscreen. After the desired article has
a decentralised and space-saving manner, been selected via the pre-installed software, ADVANTAGES
MAPAL has developed the new, cost-effective the search function of the software supports
UNIBASE-S single automatic dispenser. It can this and an LED illumination identifies the -- Just-in-time article procurement
be linked to an existing UNIBASE system or compartment with the corresponding artic- -- Cost-effective
used as a stand-alone solution. le. The dispensing drum is rotated manually -- Very compact – installation directly on the
so that it is at the removal position and the workbench
Thanks to its compact dimensions, the article can be removed. The system automa-
UNIBASE-S stock-controlled dispensing sys- tically registers the withdrawal – in this way,
tem can be installed directly on the work- the current status is always used.
bench. The 80 tools slots provide ideal sto-
rage for e.g. indexable inserts, tools orINNOVATIONS 2019 | Services 29
Process analysis
identifies potentials
Customers use the re.tooling service when between control panel and numerical control chine and verifies the reduced program run-
they set up manufacturing for a new compo- unit. No intervention is made in the machine times, improved component qualities and re-
nent, or when converting the existing machine controller, so that the warranty for the machi- duced tool costs in renewed process audits at
park for the manufacturing of a new compo- ne and its controller is not affected. regular intervals.
nent. Or when optimisation is necessary du-
ring running production. In such cases, MAPAL After the data collection, the MAPAL experts
offers the comprehensive analysis of all the analyse all the productive and non-producti- AT A GLANCE
process-relevant data and NC programs using ve times, paying attention for example to the
software options that represent a new module spindle speeds, feed rates and current power -- New module for the re.tooling service
in the re.tooling service, and so identify pre- consumption. The use of every single tool and -- Process optimisation during running
viously unused potentials. This is possible for the corresponding CNC programs is examined, manufacturing
the machining of one part, of several parts or the movements are visualised and correspon- -- Identification of optimisation measures
also for identical machining operations on se- ding optimisation potentials are identified. It
veral machines. The result: Customers achieve becomes apparent, for example, when a tool
a higher part production – without increasing runs for a period of time without power con- ADVANTAGES
tool or machine wear. sumption. In this case the approach path of-
fers savings potential. The analysis also reveals -- Higher process reliability
All the relevant information on process, com- inconsistent machining operations that could -- Higher part productivity thanks to reduced
ponent, materials, machine and parts produ- endanger the process reliability. program runtimes
ced is collected directly at the manufacturing -- Higher component quality
line – with a focus on the individually defined Depending on the customer’s demands, -- Lower tool costs
goals. The software collects the data during MAPAL then takes over the CNC optimisati-
the running process from the communication on, transfers the improved process to the ma-30 INNOVATIONS 2019 | Services
Tool Management 4.0 –
successful applications
For around one year now, MAPAL has been of- Examples:
fering its “Tool Management 4.0”. This uses the
open-cloud platform from c-Com GmbH. The Cost per part reporting for Regrinding handling for roll milling cutters
processes are digitised and displayed transpa- engine production For another MAPAL customer, a TIER1 supplier
rently using the c-Com SaaS solution (Soft- For example, MAPAL has changed over the to the automotive industry, the focus is on re-
ware as a Service). In addition to the bene- whole tool management to the new platform grinding as the first step in the changeover to
fits of classic tool management, such as 100% for the works of a car manufacturer with the Tool Management 4.0. MAPAL has been res-
tool availability, resource conservation and re- capacity for the manufacturing of 500,000 ponsible for the tool management there since
duced inventory costs, Tool Management 4.0 engines per year. The existing tool manage- 2012. Even then, the tool costs were reduced
opens up completely new potentials for the ment is conducted exclusively via the plat- by around 15 percent.
customer. Where individual lists with limited form. The most important indicators at tool
access were used in the past, the data are now level, such as consumption, stocks and over- The supplier has some 60 different roll milling
available to every authorised person with Tool all the cost-per-part can be displayed trans- cutters from various suppliers in use for more
Management 4.0. It no longer has to be main- parently and read out automatically. than 70 machining operations. The logistics
tained in different systems. Data discontinuity surrounding the regrinding of the roll milling
is prevented. The individual projects are now cutters that was not part of the tool manage-
being gradually changed over to Tool Manage- ment has been handled to date in the form of
ment 4.0, depending on the agreement with vast Excel files that are constantly sent back
the customer. The first projects are already in and forth by e-mail between the company’s
successful operation. logistics department and the respective sup-
plier. The consequences of this method were
stocks that were too high or too low, regularINNOVATIONS 2019 | Services 31 difficulties with the suppliers due to a shor- with a data matrix code (DMC) and the data indexable inserts that are used for hard mil- tage of tools and resulting stoppages in pro- stored in the cloud. The current stock and sta- ling are being serialised. With a clear bene- duction – along with the high administrati- tus, how often the tools have already been re- fit for the customer: The status of every sin- ve costs for clarifying misunderstandings. The ground and the remaining tool life can now be gle special indexable insert is known at all manufacturers of the roll milling cutters have checked at any time. In this way, the tool costs times so that optimum use can be made of indeed saved the number of regrinding proces- for the roll milling cutters were reduced by 20 the regrinding potential of the PcBN cutting ses of each individual tool in a database, but percent within a very short period of time – material. this data was not available to the customer. thanks purely to the transparent overview. With the changeover to Tool Management 4.0, A similar project that MAPAL is carrying out MAPAL has now also taken responsibility for for an automotive industry supplier also invol- this aspect. First these tools were personalised ves the regrinding handling. In this case, PcBN
MILLING
TURNING
SERVICES
CLAMPING
ACTUATING
REAMING | FINE BORING
SETTING | MEASURING | DISPENSING
DRILLING | BORING | COUNTERSINKING
Discover tool and service solutions now that give you a lead:
www.mapal.com
Order-No. 10161413 | V1.0.0
NEU19-EN-NE-01-080-0818-VVA Printed in Austria. Technical data subject to change without notice. © MAPAL Dr. Kress KG | Reprinting, in whole or in part, only with the approval of the publisher.You can also read
