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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.
Product Portfolio
  • MAPAL Metalworking and Plastic Cutting Tools

      • Large bores with high material removal rate

      • Machining large bores with high material removal rate

        Machining task
        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.

        Challenge
        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.

        Our 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.

        MAPAL Effect
        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

        Machining task

        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 machine.

        Challenge
        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.

        Our solution
        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 objectives.

        MAPAL Effect
        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

        Machining task
        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.

        Challenge
        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 also important.

        Our solution
        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.

        MAPAL Effect
        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

        Machining task
        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.

        Challenge
        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.

        Our solution
        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 tool changes.

        MAPAL Effect
        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.
        • Reduction 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

        Machining task
        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.

        Challenge
        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.

        Our solution
        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

        Machining task
        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 machine.

        Challenge
        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 difficult.

        Our solution
        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 projection length.

        MAPAL Effect
        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 reamers

        Machining task
        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.

        Challenge
        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.

        Our solution
        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.

        MAPAL Effect
        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!
        • Stable and reliable process
        • 30% reduction in machine downtime
        • 40% longer tool life
        • Lower machining costs
        • All customer needs reliably achieved
    • Applications

        • 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.
        • Boring

        • 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.
        • Drilling

        • 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

        • 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.
        • Milling

        • 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.
        • Turning

        • 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.
        • Clamping

        • 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 machining.
        • 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 use.
      • 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 step.
          • 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.
          • PCD tools
             

          • 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
             

          • 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.
        • MAPAL Technology

        • 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.
            • Automotive industry

            • Tap the potential savings during the machining of car components

              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 lightweight materials

              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.
            • Large parts

            • Increasing productivity during the machining of large parts

              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:
              • Less non-productive time
              • 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 %.