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MAPAL

Stand: N182
_Aerospace
Machines & Precision Tools
_Rail
_Space & Satellite
Product Design & Engineering
_Automotive
_Defence & Security
_Energy
_Marine & Yacht
Composites Engineering
Innovation & Sustainability Trail
https://www.mapal.com

About us

MAPAL are a manufacturer and supplier of high-quality precision cutting tools. We offer a wide range of tooling from standard carbide drills, reamers, end mills and holders. Our bespoke packages, tool management and technology services offer specialised expertise and support in Automotive, Aerospace, Medical, Die & Mould, Fluid Technology and Titanium Machining sectors.

Products

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Spotfacing tool with microstop cage

To protect aircraft from lightning strikes, all parts must be electrically connected to each other. This means removing the paint in the bore area during assembly. MAPAL has developed an innovative spotfacing tool with a patent-pending microstop cage that removes the paint efficiently and is particularly user-friendly in a plug-and-play solution. The new tool replaces the previously used brushes and offers numerous advantages. It stops the surface from getting scratched and being penetrated too deeply, minimises operator errors and is easy to maintain. The tool rotates within the cage and only protrudes out as far as the material to be removed, ensuring precise machining. The innovative tool is extremely versatile and is also suitable for countersinking, chamfering and deburring. The spotfacing tools are available in two sizes for standard coating thicknesses. The two sizes come in different colours – another advantage ensuring faultless application. An extraction system can also be fitted to the tool to comply with environmental regulations and to avoid harmful chromate dust.

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OptiMill®-Tro-Inox & OptiMill®-Uni-HPC-Pocket

The OptiMill-Tro-Inox trochoidal milling cutter has been specially designed for applications with problematic chip removal. Especially for small pockets, pocket corners or difficult component contours, a central cooling channel ensures reliable chip removal thanks to its high cooling and flushing capacity. The solid carbide milling cutter is available in diameters ranging from 6 to 20 mm. The OptiMill-Uni-HPC-Pocket in 3xD has been developed to optimise time-consuming ramping processes when machining pockets. With a patented plunge face, the milling cutter can be plunged at angles of up to 45°. The arrangement of the chip breakers ensures straightforward chip removal. The OptiMill-Uni-HPC-Pocket in 3xD is available in diameters ranging from 5 to 20 mm.

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UNIQ® DReaM Chuck, 4.5°

To meet customer requirements and continue to support the switch from shrink chucks to hydraulic expansion technology, the range of UNIQ DReaM Chuck, 4.5° for reaming and drilling applications and for use with finishing cutters has been upgraded to now include new lengths and interfaces. With the UNIQ DReaM Chucks, MAPAL is the first supplier in the world to offer hydraulic chucks with the original heat shrink contour according to DIN 69882-8 in 160 mm for HSK-A63 and HSK-A100. This means that hydraulic chucks can also be used in deep grooves with critical tool restrictions.

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OptiMill-Composite-Speed-Plus

A new dimension of process reliability! The OptiMill-Composite-Speed-Plus features a new diamond coating developed by MAPAL with even distribution and higher coating thickness. The bigger core diameter increases fracture strength by 50 percent. The improved groove profile ensures efficient, reliable removal of dust and process heat even when machining large volumes. The cutting wedge has been specially optimised to meet the requirements of brittle workpiece material. The special cuttingedge serration causes double compression so that fibre fraying on the workpiece edges of the upper and lower sides are reliably separated. This allows the OptiMill-Composite-Speed-Plus to attain a new dimension in process reliability. Compared to the OptiMill-Composite-Speed, 20 percent longer tool life is achieved.

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Machining solutions for e-mobility

For the vehicle industry, mobility is changing with the goal of a CO2-neutral future. This means developing alternative drive concepts. One approach is to move away from the combustion engine and towards the electric drive. But this change will not happen overnight. The components of the conventional drive are being further developed and the use of vehicles with hybrid systems is increasing. Nevertheless – sooner or later, fully electrified vehicles will be the main users of roads. As a supplier of cutting tools for the automotive industry, MAPAL incorporated this topic into the company's strategic orientation at an early stage. And transferred its expertise in machining the conventional power train to the components to be machined in electrically powered vehicles.

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Die & Mould

Die and mould makers expect high process and product expertise from their cutting tools manufacturer. This is because the tool life of the moulds to be created and the precision of the moulded parts are extremely important for competitiveness in mass production. Therefore, they require their tools to offer the highest levels of precision, a long tool life, and – above all – process reliability. It is precisely these aspects that make MAPAL successful in sectors such as the automotive industry, machine engineering and the aerospace industry. Now the precision tool manufacturer is also offering efficient and economical solutions for the complete machining process in the die & mould sector. Versatile and precise high-performance tools and special tool holders with narrow contours and a precise radial run-out minimise polishing effort and reworking thanks to a constant surface finish in the milling process.

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Titanium Machining

AEROSPACE Titanium and titanium alloys are predestined for use in aerospace. High demands are placed on workpiece material strength and corrosion resistance in relation to their specific weight. This results in a wide range of applications extending from small mechanically processed structural parts to load-bearing parts in the fuselage or blades in the engine. AUTOMOTIVE Lower weight means lower fuel consumption resulting in fewer emissions. Therefore, many different applications for titanium materials can be found in automotive engineering. Starting with engine components, through to transmission parts and suspension elements as well as exhausts. The automotive manufacturers’ objective is to make vehicles lighter and therefore more environmentally friendly. MEDICAL TECHNOLOGY Titanium is practically the perfect workpiece material for medical technology as it can be implemented extensively due to its bio-compatibility (i.e. its stability in biological surrounding – anti-allergenic), low thermal conductivity and anti-magnetic behaviour.

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Tools for the Aerospace Industry

LIGHTWEIGHT DESIGN COMPETENCE Lightweight materials are finding more and more applications Modern lightweight materials offer many different advantages. They make it possible to work in a more energy-efficient manner, save materials and, at the same time, to increase performance and productivity, particularly in mechanical and plant engineering. Parts can be made significantly lighter by making use of lightweight materials. They are used by the automobile and aircraft industry, among others, to create more efficient designs for their vehicles. In spite of their lightness and the fact that less materials are required in their production, these modern materials make it possible to manufacture parts that are stable and safe. Therefore, lightweight design meets the demand for increased safety as well as that for reduced fuel-consumption. In close collaboration with our customers, such as those in the aerospace sector, MAPAL has created a comprehensive range of tools for reliably machining modern materials. The range of tools includes both tools for part manufacturing and those for final assembly. Part manufacturing In part manufacturing, the machining of parts is stationary, i.e. parts are cut in a machine in several clamping positions. While small to medium cubic parts can be machined on a machining centre, large parts require special gantry machines. Final assembly Even today, handheld machines are still used in the final assembly of aircraft, due to their size. For example, in final assembly lines (FAL), rivet holes are made in the outer skin of the aircraft’s fuselage. The tools are equipped with special guiding elements.

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OptiMill®-Alu-Wave

High-volume machining at over 20 l/min. The new solid carbide roughing cutter Opti-Mill-Alu-Wave for aluminium materials takes full advantage of the performance of the fastest machines on the market, achieving a material removal rate of up to 21 litres per minute. The cord roughing cutter has large, flat shafts for optimal chip formation. Polished chip flutes facilitate chip removal. The three-side cutter is fitted with central cooling and a modified face geometry, which enables ramp angles up to 30 degrees. The OptiMill-Alu-Wave is not only ideal for aerospace structural parts but also for applications in the automotive field and general machine engineering. Diameter ranges from 12 to 25 mm with projection lengths short, medium and long are available. Further variations are configurable, so close-contour roughing is also supported.

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UNIQ - New generation of clamping chucks

The newly-developed hydraulic clamping system enables high machining parameters through excellent stability and accuracy. It minimises self-excited vibration so that clamped tools are not exposed to micro-vibration. This in turn leads to a reduced spindle load of up to 15 percent, enables a significantly longer tool life and guarantees optimal surface quality. In addition, the brilliant surface which MAPAL creates using a specially developed polishing process ensures that the chucks are more resistant to dirt and corrosion. Users can safely clamp the tool in the holder with little force requirement. This is ensured by “foolproof handling”, i.e. simple and self-explanatory handling of the chucks. This saves a considerable amount of time compared to other clamping mechanisms, especially with the UNIQ DReaM Chuck 4.5°. ✔ Maximum stability at optimal use of resources ✔ Low actuation torque ✔ High long-term temperature resistance ✔ Optimum surface quality ✔ Dirt and corrosion-resistant ✔ Self-explanatory, simple handling --- HYDRO CLAMPING CHUCK - UNIQ MILL CHUCK Reliable. Dynamic. Agile. 💡 High thermal stability of 80 °C even with very long milling cycles (over 240 minutes). 💡 For high-performance milling operations up to max. 33,000 revolutions per minute. 💡 Maximum process reliability and tool life due to award-winning industrial design. Hydro clamping chuck - UNIQ DReaM Chuck 4,5° Visionary. Flexible. Economical. 💡 Hydraulic chuck with the original dimensions of a shrink chuck (DIN contour with 4.5°). 💡 Application-oriented system design. 💡 Maximum process reliability and tool life due to award-winning industrial design.

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Drilling, Boring and Countersinking

In the area of drilling using solid carbide tools, MAPAL is one of the world's largest providers. The programme of solid carbide drills covers solutions for the reliable and cost-effective machining of almost every workpiece material and is completed by modern replaceable head systems for the highest cost-effectiveness. Starting from the focus on the manufacture of custom tools for customer-specific machining solutions, MAPAL has developed a comprehensive standard programme for drilling, boring and countersinking. DRILLING As a technology partner, MAPAL offers a comprehensive standard programme of solid carbide drills and has a replaceable head system for all machining operations. Irrespective of which workpiece materials, whether non-ferrous metals, steels, modern lightweight materials or difficult to machine materials, MAPAL offers the right drill! BORING MAPAL offers tangential tools TSW, ModulBore and customer-specific PCD tools for boring. For tools with ISO indexable inserts, MAPAL offers a completely new, cost-effective programme of indexable inserts available ex-stock for the optimal machining solution. COUNERSINKING Every machining process has latent potential for boosting productivity. Also supposedly secondary machining operations such as countersinking offer significant potential for improvement, as is demonstrated by MAPAL with the extremely unequal spaced countersinks. These operate with significantly reduced axial and radial forces, achieve better surfaces, longer tool lives, and ensure optimal screw and rivet joints

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NeoMill®-Alu-QBig

Fast material removal rates with low cutting forces and high-quality surface finishes. The new indexable insert cutters NeoMill-Alu-QBig are a highly economical solution for larger diameters. They offer maximum efficiency with a material removal rate of up to 18 litres per minute. Thanks to ultra-strong bolts and a fine-balancing system, this tool boasts a spindle speed of up to 35,000 rpm. The combination of low cutting forces and high-precision indexable inserts enables high-quality surface finishes. Internal cooling and very large chip spaces ensure optimal heat dissipation and chip removal. Depending on the application, the milling cutter is available with uncoated inserts, PVD-coated indexable inserts and CVD-diamond indexable inserts. The tool bodies are available in a diameter range of 32 to 80 mm for hollow shank taper (HSK) or shank taper (SK) as well as mounting tool variants.

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MEGA-Speed-Drill Series

Maximum speeds, faster drilling The MEGA-Speed-Drill series sets new standards in high-speed machining and ensures maximum efficiency. The optimum interplay of cutting speed, feed rate and innovative drill geometry achieves an outstanding metal removal rate. At the same time, the specially customised cutting geometry significantly reduces the cutting forces. The MEGA-Speed-Drill utilises the full potential of machines with high speed and low spindle power. Highly polished flutes and stable guide chamfers enable up to 30 % higher feed rates than conventional drills. The result: more precise, faster and more efficient drilling processes that take your productivity to a new level.

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Tailored Services from MAPAL

Tailored to the customers' manufacturing needs In the metal-machining industry, the focus is on process costs. Anybody who wants to control them must understand all processes. Here it is good if businesses can rely on a technology partner who offers comprehensive support from planning to the series production process. With its focus on the manufacture of custom tools, MAPAL has always focussed on holistic advice and support for machining tasks and processes. Specifically tailored services offer fundamental support in all phases and all areas of production whether it be - Setting up a new production facility, Process optimisation, Introduction of new technologies, Re-tooling existing machines for new parts, Optimising tool inventory, Expanding the know-how of the employees. ENGINEERING As an engineering partner, MAPAL accompanies its customers from the planning to the optimisation of the production. They can select from service modules as required, or make use of service packages specially tailored to their needs. In both cases, MAPAL experts with many years of experience place their high level of innovation and their holistic perspective of processes at the customers' disposal. The technology centre with its state-of-the-art equipment is able to exactly simulate every production process, allowing the specialists to find new, and even better solutions for our customers. LOGISTICS Too many tools in the store signify unnecessary costs. Not enough will result in production stoppage. There is therefore a significant potential for savings both in the tool inventory and the tool management process. MAPAL logistics experts help to tap all the available financial scope. Transparent and available information on tool inventory is the first milestone in this respect. MAINTENECNCE ✔ Reconditioning of individual tools ✔ Complete maintenance contracts for specific tools and devices ✔ Repairs of tool bodies that are damaged due to chipping or erosion, or a damaged insert seat

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High-volume machining of aluminium materials

MAPAL is taking full advantage of the performance of the quickest machines available on the market with the new solid carbide roughing cutter OptiMill-Alu-Wave for aluminium materials, achieving a material removal rate of up to 21 litres per minute. At the same time, it is of course also possible to use the high-volume milling cutter on less powerful machines. The tool manufacturer is thus taking into account the fact that aeroplane parts are often manufactured on machines with spindle outputs between 40 and 80 kW, for which there was previously no suitable milling cutter in the portfolio. The OptiMill-Alu-Wave is not only ideal for aerospace structural parts but is also suitable for applications in the automotive field and general machining. For the product launch from the EMO trade fair onwards, diameter ranges from 12 to 25 mm with projection lengths of 3xD, 4xD and 5xD are available. A configurator makes further variants possible, which also supports close-contour roughing. The new indexable insert milling cutters NeoMill-Alu-QBig are a highly economical solution for larger diameters. In order to achieve as large a material removal rate as possible of up to 18 litres per minute, the new aluminium volume milling cutter is designed for use at spindle speeds of up to 35,000 rpm (with a diameter of 50 mm). For a tight fit despite high centrifugal forces, screws with increased tensile strength are used to hold the indexable inserts firmly in the prismatic seat. In addition, countersinks on the indexable insert ensure weight savings. MAPAL has fitted the tool body with a fine balancing system. Four threaded bores enable precise adjustment in order to protect the machine spindle at high speeds and achieve the highest possible surface finishes. With the solid carbide milling cutter OptiMill-Alu-Wave and the NeoMill-Alu-QBig indexable insert milling cutter, MAPAL showcases a complete range of products from 12 to 63 mm for high-volume machining of aluminium materials.

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MEGA-Deep-Drill-Steel

With the MEGA-Deep-Drill-Steel, MAPAL showcases the new standard for deep drilling which has been specially designed for machining steel and cast iron. The solid carbide deep drills are optimally protected with an innovative coating with HiPIMS technology in the cutting edge area. The head coating also ensures frictionless chip removal and is therefore the prerequisite for the reliable production of deep bores. The remaining length of the MEGA-Deep-Drill-Steel remains uncoated. “In our opinion, there is nothing smoother than a polished solid carbide surface”, Michael Villwock, Product Manager for Solid Carbide Tools, reaffirms the approach. Spherical cutting edges provide a high level of stability and thus ensure a long tool life and high level of productivity. The point angles were selected so that the deep drills always start the cut with the chisel in the pilot bore. The standard range available from stock includes length ratios of 15xD to 40xD and the diameter range from 3 mm to 16 mm, with the long designs up to 9 mm. Adapted pilot drills are available for difficult drilling conditions. With the MEGA-Deep-Drill-Steel, deep drilling is possible without pecking cycles at very high feed rates. The tools are suitable both for use with internal cooling and for minimum quantity lubrication, which has a positive effect on the tool life in steel machining. Field tests have shown that the new deep drills from MAPAL meet the highest requirements for tool life and performance even with demanding materials. Compared to its predecessors, up to 50 percent higher feed rates can be achieved.

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Milling Competence

In the area of milling, MAPAL tool experts have developed numerous machining solutions in recent years. The focus has been on tools adapted to the related customer requirements. Along with these individual tool solutions, however, the usage of high-performance standard tools plays a major role in many applications. Therefore a comprehensive standard programme has evolved from these custom tools. ✔ For all applications ✔ For every material ✔ Custom solutions ✔ High-performance coatings ✔ Latest Manufacturing Equipment ✔ Reconditioning in original quality

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Turning Competence - Rational, exact and efficient

Building on extensive experience with the extremely hard cutting materials PcBN and PCD from the area of boring, milling and reaming, MAPAL has also obtained a profound understanding of the turning process. A clear focus is on hard turning. The range from MAPAL includes special tool solutions for scroll-free turning for complete machining of sealing faces, bearing surfaces and bearing seats on the lathe. This saves time-consuming re-clamping of the workpieces on grinding machines. To utilise optimally costly PcBN round inserts, MAPAL has developed a system with indexable round inserts that makes simply defined rotation of the insert in the machine possible. In this way the insert can be utilised optimally. Maximum stability during hard grooving with PcBN is ensured by the grooving system VersaCut. It offers the optimal prerequisites for the special requirements of hard machining. Today MAPAL offers a broad selection of PCD and PcBN-tipped indexable inserts for hard turning with an extensive selection of cutting materials and cutting edge design. Product Highlights: 💡 PcBN round inserts with indexing 💡 Scroll-free turning 💡 VersaCut grooving and turning system 💡 PcBN indexable inserts 💡 PCD indexable inserts

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OptiMill®-Tro-Titan

Five-edge trochoidal milling cutter for milling titanium. MAPAL's five-edge trochoidal milling cutter OptiMill-Tro-Titan, which offers maximum material removal rate while providing an excellent surface finish at the same time. Unequal spacing and gradient prevent vibration, which result in quiet cutting behaviour. The modern multilayer coating counteracts adhesive wear and takes the cutter to a new level of performance. It is designed for trochoidal milling in part-contact cutting, trimming and for cutting depth up to 3xD. 🔎 Modern cutting material 🔎 Special geometry 🔎 Unequal spacing and gradient 🔎 Polished chip flute ✔ Tough carbide for highly dynamic loads ✔ Multilayer coating for ideal thermal stability ✔ Micro-prepared cutting edge stabilises the process ✔ Optimum relationship between chip and relief angle to minimise heat ✔ Smooth running ✔ Top surface qualities thanks to fewer vibrations ✔ Effective chip transport ✔ Reduced friction

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