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- Offer Profile
- MAPAL is today the major
specialist worldwide for individual machining solutions with the highest
precision and cost-effectiveness. We concentrate on the complete bore
machining and on demanding milling and turning operations using PCD and PcBN
tools. In close co-operation with our customers, perfect results are
produced from innovative first class technology, comprehensive services and
unique application know-how. The basis for these results is our engineering
knowledge, the high level of qualification of our employees and the leading
manufacturing quality within the corporate group. Our commitment to our
German sites is marked by our drive for consistent quality and perfection.
In close proximity to the customer, our subsidiaries ensure with their high
level of commitment that our products and our know-how are available on
markets all over the world.
MAPAL Metalworking and Plastic Cutting Tools
Large bores with high material removal rate
- Machining large bores with high material removal rate
In a large housing made of grey cast iron, five bores
with different diameters from 200 to 600 mm are to be
machined. The cored bores have a radial stock removal of 15
to 20 mm and are 120 mm deep. Double edge spindle tools have
been used for this machining task up to now.
Due to the high stock removal, two or three spindle tool
pre-machining operations are necessary. To be able to
machine different diameters, either different tools are
required or the tools must adjusted, a time-consuming task.
These tools are difficult to handle due to their weight and
due to the mostly modular construction. The handling effort
is to be avoided and the long machining time is to be
reduced using a new machining solution.
The MAPAL solution is a helix milling cutter that is
equipped with tangential indexable inserts with four cutting
edges. Due to the arrangement of the inserts and the
positive, soft cut of the MAPAL tangential technology, it is
possible to pre-machine these bores in one step. An
optimised cut distribution ensures the wear is specifically
distributed between the various inserts and as a result
minimised. The helix milling cutter selected for this part
has a diameter of 140 mm and is able to machine all five
bores one after the other. The number of pre-machining tools
required is therefore reduced from ten to just one tool.
The usage of the versatile helix milling cutter
significantly reduces the investment in tools. However, the
special saving effect comes from the new machining time.
Whereas with the old machining method a total of 2.5 hours
were needed to machine the five diameters, now this task is
performed in only one hour. The productivity and capacity of
the machine have increased accordingly. As the power
consumption during helix milling is also lower than for the
previous method, the spindle is protected and therefore
consumes less energy.
- Lower investment costs due to
saving of nine tools
- Reduction in the machining time from 2.5 hours to 1 hour
- Increase in the productivity and capacity
- Lower energy consumption
Special process on the machining of a hub carrier
- Special process with combination tools makes it
possible to machine a hub carrier made of grey cast iron
The requirements on machining the hub carrier were clear. The customer
requested a complete machining process with tools and the related
documentation. The machine concept was fixed – a three-spindle custom
The particular challenge during the machining of the hub carrier was that
the customer had defined very challenging requirements in relation to cycle
time and costs per workpiece. In addition, the complete machining process
was to function on an existing custom machine with three spindles and the
quality requirements were very high.
To achieve these objectives, the MAPAL tool experts relied entirely on
combination tools for the machining. Various operations were combined in one
tool. It was necessary to match the machining values and as a result also
the NC program accordingly.
This optimised tool design made possible the complete machining of the
workpiece using only eight tools. As a result it was possible to save
considerable non-productive time, as the tool change takes a long time. The
special know-how from the entire MAPAL product range flowed into the
individual tools. From tangential technology to boring and milling, all the
way to drilling and circular milling using solid carbide tools, a large
number of technologies were used to reliably achieve the specified
After a short time it was possible to achieve both challenging requirements,
the cycle time and the costs per workpiece, to the total satisfaction of the
customer. This effect resulted in further collaboration and in MAPAL taking
over tool management.
Machining of a valve seat and valve guide
- Modern precision tool provides more
production capacity with lower costs at the same time on the
machining of a valve seat and valve guide
The machining of the valve seat and valve guide is one
of the primary cost drivers during the machining of cylinder
heads. Exact angles at the sealing chamfers on the valve
seat rings and close tolerances on the concentricity between
valve seat and valve guide must be met. In addition to the
high geometric requirements, the increasing requirements on
the high-temperature stability of the valve seat rings mean
that in general very hard and difficult to machine sintered
materials are used.
The tool concept that meets these requirements while
reducing costs at the same time must make use of the most
suitable cutting material and have corresponding precision.
Cutting material and insert geometry are responsible for the
tool life and make a significant contribution to the costs
per workpiece. However, the overall design of the tool is
The solution for these tasks is a MAPAL tool with indexable blades and guide
pads. It guarantees a qualitatively flawless result due to the high
precision of the inserts, the insert seats and the connection in relation to
the valve guide. The HX inserts for machining the chamfers on the valve seat
ring are of a hexagonal shape and have six cutting edges. Due to a clever
arrangement, these inserts can even be used several times for the different
chamfers. The precision insert seat in which the HX inserts are mounted
makes it possible to change the inserts without any setting process, as all
the angles match exactly.
Conversely, all the tools previously used for this machining task require to
some extent time-consuming setting work on an insert change. Also it was
normally necessary to set the radial run-out on the replacement of the valve
guide reamers mounted in the base tool. In the new MAPAL concept the tool
for machining the valve guide is now connected using the proven HFS
connection. The tool is changed with a radial run-out accuracy of < 5 µm by
simply screwing in or unscrewing. This very stable connection also makes it
possible to increase the feed rate.
The comparison of the conventional system with the MAPAL solution
produces a very clear result. The much higher feed rate and the related
cycle time reduction result in a significant improvement in the production
capacity, or even in less investment in machinery for new projects. As no
setting work is required and it is only necessary to change inserts and
tools, there are also significant savings in the area of the non-productive
times. However the most important effect on the costs per workpiece is the
inserts for machining the valve seat rings. Due to the stable mounting, the
right PcBN grade and the ideal cutting edge geometry, the tool lives are
increased by five to ten times compared to other systems.
- Cycle time
reduction due to much higher feed rate
- Setting no longer necessary
- Five to ten times higher tool lives
Machining large diameters of a brake drum
- MAPAL combination tool for machining of large diameters
with the example of a GGG50 brake drum
The customer gave clear specifications for the machining of the GGG50 brake
drum with its diameter of 268 mm H7. The process existing to date with a
single-bladed spindle tool had to be optimised and shortened. In addition
there was the demand for reliable achievement of coaxialities of 0.05 mm and
surface tolerances of Rz 6.3 µm during the process.
During the machining of large diameters, the achievement of the demanded
tolerances by finish-boring is always problematic due to the wear
compensation of the blade that is frequently necessary. Furthermore,
finish-boring drastically increases the cycle time. The challenge is
therefore to develop a tool concept which satisfies both of the customer's
demands – reliable achievement of the required precision during the process
and short machining times.
In order to meet the customer's demands, the MAPAL specialists developed a
tool which combines three machining processes.
The use of an HPR 300 tool which combines reaming for the finish-machining
with the ISO tangential technology for the premachining allows the demanded
quality specifications for the large diameter to be reliably achieved during
the process. The multiple blades of these two stages allow higher cutting
values to be used and the machining time is significantly reduced. The tool
is easy to use, as both the reaming and the tangential blades do not have to
be adjusted. The additional integration of an HPR mounting tool for the
machining of two further diameters (16 and 32 mm) into this tool also saves
This process optimisation using a MAPAL combination tool allowed the
machining time to be reduced by 1500 hours/year, the quality demands on the
process to be reliably achieved and two tools to be saved.
of the machining time by 1500 hours/year
- Reduction of the machining costs: 2 tools are saved
- Reduction of the non-productive times: Saving of 2 tool changes
- All the customer's demands made on the process reliably achieved
Milling fibre-reinforced plastics
- High requirements on milling fibre-reinforced plastics
The machining of CFRPs (carbon fibre reinforced plastics) places high
requirements on the tools used, their geometries and coatings. Due to the
abrasiveness of carbon fibres in relation to the cutting material, standard
tools very rapidly become blunt and the end of tool life is reached after
only a few parts. To be able to cut carbon fibres that are laid in a matrix
form, increased performance at the cutting edge is required. This statement
applies above all if the carbon fibre content is more than 60 %. On milling
the peripheral contour on a 21 mm thick structural part for a sports car,
the customer had a clear requirement to double the tool life from the
previous 10 parts to 20.
The challenge is to keep the milling tool sharp and therefore to prevent
delamination at the part edges produced. In this way expensive, manual
re-work is saved. At the same time, the issue is to reduce the machining
time and to realise long tool lives.
The eight cutting edge, diamond coated solid carbide end milling cutter
OptiMill-Composite-Speed has a high performance geometry with a serration.
This serration makes possible improved chip removal and therefore an
extremely high volume of chips in one machining step. As a result the
machining is undertaken using only one tool in one step and the roughing
step necessary previously is saved. With twice the feed and three times the
material removal rate the tool life is increased fourfold and the quality
requirements in relation to surface roughness reliably achieved. As a result
the customer's expectation in relation to tool life were exceeded by a
further 20 parts.
- Four times the tool life reduces the tool costs
- Doubled feed halves the machining time
- Only 1 machining step
Tunnel bores in gearbox housings
- Machining large tunnel bores in gearbox housings with
several diameters and close tolerances
The tunnel bores are stepped and often have 6 to 8 different diameters in
the range from 160 to 290 mm. The bores are required to have high
concentricity in relation to each other with ø tolerances from IT7 to IT9 at
the same time. Furthermore, this housing is to be machined on a standard
Tools for machining these large diameters are very heavy, particularly if
several steps are to be machined at once. As standard machines are mostly
only able to change a tool weight of max. 20 kg, the machining is normally
distributed over several tools. This situation signifies long machining
times that comprise the individual productive times and the non-productive
times, which depend on the number of tools. In addition, the usage of
several tools makes compliance with the concentricity requirements extremely
Using a specially designed lightweight tool it is possible to combine all
the diameters to be machined on one tool and to keep within the total weight
allowed for tool changes on standard machines. The individual sections are
equipped with inserts and guide pads. The pads support the tool during the
machining and contribute to the quiet running of the tool despite the long
The result of this unique machining solution is a significant time saving
with a simultaneous improvement in quality. Depending on the housing and the
number of features to be machined, the machining time is reduced by up to 80
%. The increase in productivity and the related cost savings are
correspondingly high. The requirements for the concentricities and surface
finishes are significantly bettered. This aspect provides process
reliability and part quality.
- Reduction of the machining time by up
to 80 %
- Increase in productivity
- Significant increase in the machining quality
- High process reliability
Fine machining of steel material like C70
- The chip under control with MAPAL HPR high performance
Machine downtimes in automated processes during mass production are a
nightmare for the managerial staff. A possible reason for the occurrence of
this situation is that the chips produced are not transported away quickly
and reliably. However this aspect is important so that parts can be loaded
reliably by robots without interruption. In this specific case, it is
connecting rods that are manufactured. The connecting rods made of C70 steel
are produced on highly automated systems in 20 shifts per week. Long chips
regularly jam the automatic loading by the robots and prevent the correct
clamping of the parts in multiple holders. The task was to optimise the chip
formation in the existing process to machine the "small eye" with Ø 33N7 to
ensure a stable process.
During the fine machining of steel materials such as C70, the challenge is
to reliably break the very thin and therefore highly flexible chips into
small chips that are easy to transport. This aspect is crucial for a
continuous process. At the same time there must not be any shortfalls in the
productivity and output. The high cutting speeds, feeds and the long tool
lives of modern high performance tools must also be maintained.
To address these requirements, MAPAL specialists have developed a modified
design of an HPR reamer. Due to the specific design of the blade geometry,
the chip is reliably broken. This action is provided by a special lead with
chip breaker. The high cutting and feed rates of vc = 140 m/min and vf =
1500 mm/min are retained and short chips that are easy to transport away are
produced. Through an additional optimisation of the cutting material, the
tool life was increased to 10,000 parts.
Due to this process optimisation with a MAPAL HPR tool, it was possible to
eliminate the machine downtime. As a result, and due to the long tool life,
the productivity was significantly increased. The process runs reliably and
stably - the nightmare of downtimes is a thing of the past!
and reliable process
- 30% reduction in machine downtime
- 40% longer tool life
- Lower machining costs
- All customer needs reliably achieved
Reaming & Fine boring
- From the wide range of MAPAL single and twin-bladed
reamers as well as fine boring tools with guide pads and WP or HX blades,
through the HPR replaceable head reamers in combination with the MAPAL HFS®
clamping system for exact radial run-out accuracy and changeover accuracy,
to monoblock reamers made of carbide, cermet or HSS - you have a complete
overview of our know-how for the fine machining of bores.
- MAPAL offers a comprehensive programme for roughing and
semi-finish machining of bores. Precision boring tools and circular milling
tools with PCD tips guarantee reliable pre-machining and finish machining of
non-ferrous metals. Custom tools with ISO indexable inserts and tangential
technology make cost-effective pre-machining and fine machining possible
even at large diameters.
- MAPAL, the major specialist, also offers a wide range of
standardised, ex-stock tools for drilling into the solid - from the solid
carbide drill to the replaceable head system. Developed for universal use in
different materials and for the requirements of special applications.
- Actuating tools offer high rationalisation and
optimisation potential for custom machines and machining centres. Along with
the conventional facing heads EAT and LAT, MAPAL also offers high
performance drive units for actuating tools. The MAPAL TOOLTRONIC® tools
feature extraordinary functionality.
- MAPAL has built up comprehensive know-how in the milling
area. A comprehensive PCD tool programme is available for non-ferrous
metals. The MAPAL PCD end milling cutters in the HP-EndMill product range
are designed for high performance machining in a very wide range of
applications. MAPAL also has the right solution for every application
involving face milling. The machining of several, axially offset recesses,
which often also have different shapes, is undertaken perfectly with PCD
circular milling tools from MAPAL. A range of solid carbide end milling
cutters is also available. Milling tools with ISO indexable inserts and PcBN
inserts complete the milling programme.
- The latest area of MAPAL expertise is turning, with a
clear focus on hard turning. Building on many years of experience with the
super hard cutting materials PcBN and PCD in the areas of gun boring,
milling and reaming, MAPAL has also acquired a detailed understanding of the
turning process. Today the programme includes a wide selection of PCD and
PcBN indexable inserts for hard turning with a large selection of cutting
materials and cutting edge design. In the MAPAL SolidGrip programme for hard
turning, competences in the area of insert clamping and cutting materials
are bundled to form a very stable and rigid tool system.
- The modern clamping systems from MAPAL in conjunction
with the proven MAPAL reaming and fine boring tools guarantee maximum
productivity and cost-effectiveness. Whether HSK, SK or HFS® - the highly
precise connections bring the required radial run-out accuracy and
changeover accuracy to modern machining. The HSK technology is also used on
lathes and turning-milling centres. Sensitive adaptors ensure high precision
Setting & Measuring
- Fine machining of bores means production to a tolerance
of IT6 to IT7, i.e. production to within a few µm. Production on modern high
performance machines requires tools that guarantee these tolerances over a
long service life, tolerances that can always be achieved with every tool.
An important parameter for optimal and constant tool lives is exact,
consistent setting. MAPAL setting fixtures make this possible and provide
the certainty of setting to consistent µm accuracy, despite their ease of
Tools with indexable blades and guide pads
Tools with indexable blades and guide pads
- The MAPAL technology of tools with guide pads is
unrivalled regarding the fine machining of bores in any workpiece material.
The accuracy of the bore diameter, the roundness and cylinder form as well
as the surface finishing can not be achieved with other tooling at least not
equally economical. Based on the wide range of standardized designs with
well approved cutting systems, MAPAL is offering specifically to the
machining task designed special tools. With combination tools complex
workpiece contours are machined efficient and economical in one process
Fixed multibladed reamers
- With fixed multibladed reamers drastically reduced
machining times are possible. The multiple number of blades allow higher
feed rates what is determining the machining times. Due to specifically
developed systems and modern manufacturing techniques MAPAL offers also on
this sector highest accuracy and precision.
The product range offers a variaty which covers every machining task what so
ever. Starting from Monoblock designs to head changing systems the program
is unique. Additional to the standard program the special tools set the
benchmark for highest productivity.
MAPAL has built up comprehensive know-how in the area of PCD tools and is
today one of the most important manufacturers in this sector. The programme
consists of precision gun boring tools, circular and end milling tools as
well as a very successful range of face milling solutions. State-of-the-art
and highly precise clamping systems in combination with exact grinding
quality open up many possibilities for these fixed PCD tools, not only in
the HSC area.
ISO tools from MAPAL - the leading technology
- Many parts from the automotive and commercial vehicle
industry, mechanical engineering and systems engineering or the energy and
aerospace industry require accuracies in the machining process in the range
from IT 9 to IT 7. It must be possible to optimally machine high stock
removal, large bore diameters and varying structures while taking into
account the tolerance parameters, the stability of the part and the
performance of the machine. ISO tool solutions are predestined for these
requirements and cover the complete range of workpiece materials, in
particular cast parts.
Solid carbide tools
- The high performance solid carbide tools provide the
ideal prerequisites for economic use in all areas of technology. Ongoing
development and constant willingness to find special solutions to problems
guarantee reliable tool designs both in the HSC area and for dry machining
and machining with minimal lubrication.
The high level of competence and decades of experience held by the
specialists in solid carbide tools in the MAPAL Group, together with their
proximity to customers and their inventiveness, guarantee that the right
tool concept is always available for economic and reliable production.
- Actuating tools from MAPAL offer maximum potential for
rationalization and optimization on special machines and machining centres.
The product programme consists of both conventional facing heads EAT and LAT
as well as high-performance drive units for actuating tools. The MAPAL
TOOLTRONIC® provides an additional axis for the machine.
Tools for modern lightweight materials
- Fibre-reinforced plastics, titanium, nickel-based alloys,
CFRP-metal multilayer composites, aramide, honeycomb, plastics
PcBN hard machining tools
- MAPAL became involved with the development and use of
PcBN tools with geometrically defined blades at an early stage.
For this reason MAPAL has developed new tool solutions for all application
areas by the practical interlinking and adaptation of efficient and
effective system elements in house. Whether for turning, milling or reaming,
MAPAL offers an economical and reliable tool solution in any application
area which can call on the full capabilities of PcBN as a cutting material.
Clamping chucks & adaptors
- MAPAL’s modern clamping systems, in conjunction with
MAPAL’s tried and tested reaming and fine boring tools, guarantee maximum
productivity and economy. Whether HSK, ISO or HFS®, these high-precision
connections and interfaces provide the concentricity and changeover accuracy
essential to modern production.
Setting and measuring devices
- MAPAL is a recognised specialist for fine boring using
adjustable tools. The exact adjustment and measurement of these tools is a
prerequisite for high part quality.
- In focus – new tools and processes for important
sectors of industry
The specialists and developers at MAPAL have been particularly intensively
engaged in these topics in recent months.
- Tap the potential savings during the machining of car
If every second counts, major specialists are required. Specialists who are
familiar with the machining processes down into the detail and who from this
detailed knowledge develop innovations for real progress in machining. For
this purpose we offer our experience from many individual solutions for
specific tasks in the automotive industry. And a willingness to take new and
perhaps also unusual paths in the dialogue with the customer.
Modern lightweight materials
- More and more applications are making use of
Where reducing weight while maintaining stability is a key issue, modern
materials are conquering ever more applications. Products of lightweight
design, particularly those made of fibre composite materials and
multimaterial systems (CFRP-metal multilayer composites), are becoming
increasing common in the key industry of vehicle manufacture, as they spread
from their origins in the aerospace industry. Here lightweight design is
also playing a crucial role in the introduction of electric mobility.
Lightweight materials are in the meantime established in wind energy
converters and are increasingly common in machine tools, industrial robots
and the consumer sector. In intensive collaboration with customers, for
example from the aerospace sector, MAPAL has created a comprehensive range
of tools for the reliable machining of modern materials.
- Increasing productivity during the machining of large
Increasing global passenger and freight traffic by road/rail, by sea and
in the air, as well as the generation of energy by alternative means, for
example, wind power and hydropower, are resulting in increasing demand for
large parts. The high costs of these parts require, on the one hand, a high
level of accuracy, reliability and quality from the machining process. On
the other hand, it is imperative to increase the efficiency of processes and
productivity, also during the manufacture of large parts. Here new types of
tool concepts can sustainably increase efficiency during the machining of
large parts with the objective of reducing the machining times, combined
with increased process reliability and quality.
Energy-efficient tool concepts
- Our contribution to energy efficiency
MAPAL specialists optimise the process management:
- Higher speeds
- Modern Technology
Minimum quantity lubrication
- Topics such as energy efficiency and conservation of
resources are becoming increasingly important. In the machining sector these
issues are affecting above all the machine tool and the cooling lubricant.
There is particularly high potential for savings on conversion from wet
machining with cooling lubricant to minimum quantity lubrication (MQL). By
avoiding the usage of cooling lubricant the operating costs for the
individual machines can be significantly reduced – by 30 to 50 %.