Your technology partner for machining INNOVATIONS 2015

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1 Your technology partner for machining INNOVATIONS 2015

2 When something exceptional develops between us: That's the MAPAL effect.

3 You do not want to do everything differently. But many things better. Opening up opportunities We find new ways to obtain more for you.

4 4 INNOVATIONS 2015 Drilling WORLD FIRST Insert drill QTD for small diameters For the conventionally produced QTS holders, the existing standard product range with 1.5xD, 3xD and 8xD has been extended to include holders for the drilling depth 12xD. The insert drill QTD had previously been available from 13 mm diameter. Responsible for this is i.a. in the cooling duct in the basic tool body. The smaller the basic tool body, the more the normal central coolant supply system impairs the performance of the tool. The central coolant supply weakens the core of the drill and makes it unstable. Furthermore, the cooling ducts have to be made increasingly smaller. This results in a decreasing flow rate of the coolant to the cutting edge. Steel basic tool bodies with spiral cooling ducts that are common in solid carbide tools are not yet common in small diameters. Laser sintering enables optimum cooling duct design Laser sintering enables basic bodies in the diameter range from 9 to 12 mm with spiral cooling ducts to be produced by 3D printing. Compared with the central coolant supply with diversions, this design achieves a 100% increased coolant flow rate, particularly thanks to the deviation from the circular cooling duct profile. The insert drill QTD for small diameter ranges has been registered for patent and is available as standard. The standard insert range with the types 1-4 offers optimum cutting edges of steel, stainless steel, cast iron and aluminium. - Laser sintered drills from ø 9 to 12 mm - 100% increase in coolant flow rate through spiral cooling ducts - Holders in 1.5, 3, 8 and 12xD - Inserts type 1-4 for steel, stainless steel, cast iron and aluminium

5 Drilling INNOVATIONS Reliable stepped bore in one machining step MAPAL has developed a step drill specially for the screw bores in the connecting rod with which the mass production of these parts can be made far more effective. The new step drill produces the screw bore in just one machining step. A special geometry, coating and edge preparation in combination with the four guide chamfers ensure optimum process reliability with very high performance and tool life. With a newly developed chip guiding stage (patent pending), a short spiral ship is produced at the countersink diameter that is freely discharged and cannot wrap around drill or chuck. In order to ensure process reliability and consistently good results in mass production, the drill was made from a special ductile carbide material in combination with a sturdy geometry and is ideally suited to the production of large quantities of connecting rods. - "One-shot" solution - Chip guiding stage for optimum chip removal - Specially for screw bores in connecting rods - High process reliability - IT7 tolerance

6 6 INNOVATIONS 2015 Boring Reliable boring of large bore depths with spring-loaded guide pads With the spring-loaded guide pads, MAPAL has developed a tool concept (patent pending) that makes the machining of bores with medium to large diameters and long projection lengths far more productive and significantly more reliable. Until now there were two fundamental difficulties with these boring operations. The long projection length of the tools in conjunction with a large tool head leads to vibrations. For this reason, single- or twin-bladed spindle tools with low dead weight are generally used, but they can only be operated at low cutting speeds. A second point lies in the inhomogeneous material structures of the raw part which hence require different stock removals. Spring-loaded guide pads allow smooth machining and high cutting data The new machining solution increases the process reliability and accelerates the machining. The modular tool concept combines the tangential with the guide pad technology. The tool head can be fitted with up to eight indexable inserts. A combination of conventional, fixed brazed and spring-loaded guide pads ensures the stability and reliability of the machining operation. The spring-loaded guide pads are positioned such that the resulting spring force (shown in the diagram as a blue arrow) ensures that the fixed guide pads lie perfectly against the material of the bore and support the tool (green arrows). This guarantees smooth machining even with fluctuating stock removals or wear of the inserts. Very good bore qualities are achieved even with high cutting data. - Smooth running and high cutting speeds - Time savings and increased process reliability - High stability

7 Boring INNOVATIONS % faster with spiral-fluted PCD step drill A proven means of making production processes more effective is to combine several machining operations in one tool. At the same time, however, this creates a very high volume of chips that have to be reliably controlled and efficiently discharged. The new spiral-fluted PCD step drill from MAPAL ensures optimum chip transport so that extreme reductions in machining time for drilling and boring processes in aluminium parts are possible. Where previously three tools were necessary for piloting, deep hole drilling and boring, these three operations can now be performed with just one tool in a single shot. Optimum chip removal and reduced heat input into the part Several features are crucial for the exceptional performance of the new PCD step drill, and these have to be perfectly matched. The spiral-fluted chip spaces, in particular, contribute to a very good chip transport out of the bore and ensure that there is no congestion of chips even at the transition from the solid drilling to the boring step. The right flute geometry and pitch is crucial for this, and the chip flutes are also polished over the whole length of the drill to minimise the friction of the chips. The PCD blades embedded perfectly into the spiral of the solid drilling and boring step result in a good cutting behaviour of the drill. This reduces the heat input into the part compared with conventional drills with straight flutes. And finally the correct position of the coolant outlets for MQL machining is crucial for the performance of the drill so that the aerosol reaches the points where lubrication is necessary. This reduces the risk, for example, of build-up edges and naturally also helps to prolong the tool life of the drill. Producing spark plug bores 75% faster One application example is the spark plug bore in a cylinder head of AlSi6Cu4. The bore is produced on a machining centre with minimum quantity lubrication, making the controlled removal of the chips from the bore particularly important. At a spindle speed of n = 5,600 rpm and a feed rate of v f = 2,500 mm/min, the cycle time is reduced by 75%. That corresponds to a time saving of 42 seconds for a cylinder head for a 4-cylinder engine, offering a significant boost in profitability and productivity. - Spiral-fluted high-performance drill with optimally embedded PCD - 75% reduced machining time thanks to one-shot solution - Increased profitability and productivity

8 8 INNOVATIONS 2015 Countersinking WORLD FIRST Countersinking revolutionised smooth, fast, precise Countersinks are standard products. They are produced in large quantities and are used in practically every machining process, because as the saying goes: No bore without a countersink. The design of countersinks, however, has barely changed over the past decades, if at all. Equipped with three blades, the tools have an equal pitch between the cutting edges. Large axial forces cause vibrations of the tool and result in a poor surface finish. Furthermore, the tools do not achieve long tool lives. acting perpendicularly to the tool axis are also reduced. Such optimised operating conditions create far less vibrations at the tool, allowing higher accuracies and better surface finishes to be achieved. The precision of the countersink leads to an immediately improved contact of bolted and riveted joints, eliminating settling of the joint under load after assembly. The reduced load on the machine also extends the tool life of the tools. Thanks to the smooth and stable running, the tools can also be operated with higher cutting data, resulting in considerable savings in time. The new countersinks (patent pending) raise countersinking operations to a new technological level. The unequal spacing (patent pending) reduces forces by more than 50% But why shouldn t a secondary machining process also be optimised? MAPAL developed a completely new generation of countersinks with significantly reduced axial forces. The cutting edges of the new countersinks have an unequal pitch. With this pitch, the axial force is reduced by more than 50 % compared with conventional countersinks. The forces - Higher precision - Better surface finish - 50% reduced axial forces compared with conventional countersinks - Less vibration at the tool - Time savings thanks to higher cutting speeds - No settling with bolted and riveted joints

9 Reaming INNOVATIONS External reaming redefined with the EasyAdjust-System MAPAL relies on the proven guide pad technology when it comes to external reaming. Long, thin parts are thus precisely reamed on single or multi-spindle automatic lathes. The guide pads absorb the cutting forces so that no displacement forces are exerted on tool and part. Precisely adjustable indexable blades allow optimal diameter tolerances, roundness and cylindrical forms to be produced. Thanks to ongoing further developments, significant increases in productivity are now also achieved. Easy handling with the EasyAdjust-System Optimum adjustment of the blades is a challenge during external reaming, as the blades are inside the tool and are difficult to access. The EasyAdjust-System offers the optimum solution here. An innovative cassette with integrated back taper completely eliminates the need for adjustment for the back taper of the minor cutting edge. The integration of the EasyAdjust-System into the external reamers thus makes the technology even more effective. cost- Adaptive floating holder corrects axial offset When using reamers on lathes, axial errors frequently occur between the adapter and the bore to be machined. MAPAL therefore recommends the use of floating holders which correct the axial offset. A floating holder of- fers a significantly improved process reliability particularly if the offset changes continuously due to the thermal expansion of the machine or due to different positions on cycling the revolver. The new adaptive floating holders are ideally adapted to the application in deflection direction, floating stroke and deflection force. Reaming operations with stationary tools thus achieve a far higher productivity. - Reduced setting time thanks to innovative cassette - Cost-effectiveness, handling and process reliability increased - Longer tool lives and higher part quality

10 10 INNOVATIONS 2015 Reaming WORLD FIRST Weight-optimised external reamers thanks to laser-sintered tools External reamers function better, the lighter they are particularly when machining shafts with small diameters. However, a conventionally manufactured steel tool for the machining of a diameter of 8.5 mm already weighs 400 grammes. This weight and the resulting inertia considerably limit the maximum possible cutting speeds % Weight optimisation of the tools immediately brings noticeable increases in productivity. MAPAL is one of the first companies in the industry to use the additive production process of laser sintering to optimise the weight of the external reamers. Thanks to a specially developed rib structure inside the tool (patent pending) it is now possible to produce the above-mentioned reamer with a weight of 172 grammes, i.e. to more than halve the weight. Machining with the laser-sintered external reamers can now be carried out faster and with higher precision. - Higher speeds - Shorter machining times - Significant increase in productivity

11 Reaming Reiben INNOVATIONS NEUHEITEN HPR with easy on-the-spot insert changing Compared with boring tools, bores with large diameters can be machined far faster using multi-bladed tools. The reconditioning of such tools, however, is costly and time-intensive. With a new HPR series, MAPAL has developed a system that eliminates these disadvantages. The inserts are replaced by the customer directly on the spot. Care does not have to be taken that the new inserts are installed in a particular seat. Subsequent setting is not required. And logistic costs are cut. The number of tools in circulation is reduced and the costs per part are significantly lowered. The customer thus achieves high-precision bores with minimum expense. The tools that are available above 100 mm diameter can be cost-effectively fitted with various indexable inserts of carbide, Cermet and the latest cutting materials PCD and PcBN. - Independent insert changing by the user on the spot - Insert installation independent of the seat position - Reduction of the cost per part - Reduced coating costs - Reduction in the number of tools in circulation - For all cutting materials - Tolerance H7 - From ø 100 mm Can also be used in combination with the adjustable TFB system and the EasyAdjust-System. Here: Special tool for the machining of a bearing flange of GGG40. Combination H5 with H7/H8 bore.

12 12 INNOVATIONS 2015 Reaming Up to 300% longer tool life during reaming thanks to new coating Practically no tool is used without coating for the high-performance machining of cast iron materials. Apart from the geometry of the blades, it is the properties of the coating, in particular, that are of crucial importance for the performance, which is why they are adapted to the specific loads and wear mechanisms of the application. Although the cutting depths are relatively small during reaming, the loads directly at the cutting edge are concentrated on a comparatively small area. The optimum coating for reaming must be very thin for sharp cutting edges and must have a very good adhesion to the substrate. A further important factor is a good balance between hardness and ductility. New HC418 cutting material grade ideally geared to reaming MAPAL has developed a coating specially formulated for reaming with the new HC418 cutting material grade. Although the CVD coatings known to date are wear-resistant thanks to their extremely hard coating constituents, they are at the same time very brittle and susceptible to fracture. The special process control in the production of the new CVD coating, however, makes it far more ductile than to date while retaining its good wear resistance. The new HC418 is therefore very well suited to the reaming of ductile cast iron materials (GGG, GJS, GJV) and in difficult machining situations with interrupted cut or unstable conditions. In preliminary field tests, increases in tool life of between 50 and 300% were achieved with the new HC418 grade on material GJV450. HC416 HC418 Properties Very hard / brittle Hard / not brittle GJL GJV, GJS Difficult conditions Tool life in field test (GJV450) Plus % - Coating ideally formulated for reaming - High wear resistance with simultaneously good ductility - Longer tool lives in cast materials and under difficult conditions

13 Boring, Milling INNOVATIONS Cost-effective roughing and semi-finish machining with innovative tangential indexable inserts MAPAL has developed a new generation of tangential indexable inserts for roughing and semi-finishing operations. The sintered CTMQ inserts with four cutting edges are particularly cost-effective in applications with larger admissible tolerances, as is generally the case for roughing. Tailored in the first step to the machining of steel and cast iron, the indexable inserts have innovative coatings developed on MAPAL s in-house coating line. The tangential indexable inserts are classified in the tolerance class M, but achieve far better results for both the inside diameter and the plate thickness. The right quality for every application The new CTMQ tangential indexable inserts are an optimum complement to the highprecision CTHQ inserts. These ground precision inserts of tolerance class H are intended for finish-machining and for exacting semi-finishing. The MAPAL portfolio of tangential indexable inserts thus offers the right insert for every demand with respect to precision and costs, and hence a cost-effective and reliable machining solution. CTHQ CTMQ Finish Semi-finish Roughing - Sintered tangential indexable insert with four cutting edges - Ideal for roughing and semi-finishing - The ideal complement to precisionground inserts

14 14 INNOVATIONS 2015 Milling High-volume milling cutter for aluminium machining In the aerospace industry, aluminium structural parts such as frame elements or wing parts are generally milled from solid material. Often more than 90% of the raw part is cut away. New machine generations with sufficient drive power and the necessary spindle speeds allow for an efficient high-performance machining of aluminium parts. MAPAL has developed a new range of aluminium roughing milling cutters. The OptiMill- SPM (Structural Part Machining) high-performance milling cutters have a cutting edge length that corresponds to approx. 60% of the diameter. This represents the maximum contact depth for the high-performance milling of aluminium. Thanks to the high positive cutting edge geometry and the optimised chip spaces, the cutting force of PCD milling cutters is reduced by up to 15%. Even when milling on standard machines, this reduction in cutting force results in more efficient machining parameters, and hence in improved performance. Bending of the tool during the machining process is prevented by the form of the milling cutter (bottleneck). A further benefit of this conical design is the clearance that is created between the wall of the part and the milling cutter shank. Particularly with deep pockets, this prevents scratching of the part wall caused by chips. The OptiMill-SPM tools are available in the diameter range from 6 to 50 mm, both as solid carbide and as PCD variants in the standard range. The product portfolio also includes variants with the CFS replaceable head system. - High material removal rate > 8 l/min with 32 mm diameter with HSK - Soft, low-vibration cutting thanks to highly positive rake angle and increased axis angle: Higher quality, lower power consumption - High stability thanks to optimally embedded PCD blades: No notching effects or protrusions - Unhindered chip flow: No corners or sharp edges in the chip flute

15 Turning INNOVATIONS WORLD FIRST 3 Indexable PcBN round inserts for hard turning Sustainability, profitability and efficiency are the keywords in modern-day production. Maximum use has to be made of expensive cutting materials such as PcBN without the processes losing reliability and stability. MAPAL has developed a new system with indexable round inserts of PcBN for hard turning. The indexing (1) is optimally matched to the applied cutting depth by different defined pitches. Slightly loosening the sturdy clamp is sufficient to allow the insert to be turned to the next defined working position. The spring bolt (3) then engages exactly in the indexing hole. Changing times are thus shortened and efficiency is increased without losing performance or stability compared with monolithic tool holders. The choice between spindles (2) for roughing and finishing (stock removal) and plates for combined longitudinal turning/facing allows the optimum spindle system to be selected for every application, while the basic tool holder remains the same. - Defined turning of the indexable inserts - Changing on the machine possible - Indexable inserts for steel and cast iron - Different step increments - Maximum utilisation of the cutting material - Indexable inserts for smooth and interrupted cuts

16 16 INNOVATIONS 2015 Clamping New programme hydraulic chucks In order to ensure the exact radial run-out of rotating tools it is often necessary to compensate existing errors in the overall system, consisting of spindle, chuck and tool. For this MAPAL is now presenting its new alignable chuck based on the proven hydraulic expansion technology with which the errors of the overall system can be set to zero. The hydraulic chuck is set using an alignment set with three adjustment elements. This produces high stability and functionality but with simple handling at the same time. The alignment system is sealed by a fixed ring so that it requires minimum maintenance and is dirt resistant. Alignment is made by wedges in the clamping chuck, this preventing any jamming of the tool. The self-locking of the T-nuts ensures that once set, the angle is maintained over a long period of operation. The hydraulic chuck is ideally suited to workpiece clamping on tool grinding machines and for machining operations with high demands on tolerances and surface finish. - Compensation of spindle errors - Easy handling with hydraulic expansion technology - Higher quality and longer tool life - No tool jamming - Dirt resistant and low maintenance

17 Clamping INNOVATIONS Hydraulic expanding arbors - reliable clamping systems for large diameters The need for precision machining is increasing continuously, as the demands on high-quality surfaces and tolerances rise sharply. And so the demands on the chuck as the connecting element between tool and machine also increase. A new system has been developed to improve the radial and axial run-out of milling cutter arbors. It is based on the hydraulic expansion technology and is therefore simple to use and offers good stability and damping. The MAPAL hydraulic expanding arbors are ideally suited to workpiece clamping and are suitable at the same time for finishing and grinding operations. Tools with fitting tolerances of H6 can be precisely, permanently and reliably clamped. High surface finish qualities thanks to the damping of the hydraulic expansion system, optimum radial run-out and the constant balancing behaviour are the key hallmarks of this system. Exact radial run-out and high repetition accuracy Easy and reliable handling in no time Fitting tolerances of H6 can be precisely, permanently and reliably clamped Good stability and damping

18 18 INNOVATIONS 2015 Dispensing Individual dispensing system for defined tool removal The automatic UNIBASE-M tool dispensing system has been expanded to include an important option. It now offers even greater security with respect to stock differences and wrong dispensing. With the implementation of a dispensing limit it is now possible to selectively dispense single items. The main focus in the development of this system was on functionality and ease of operation, but also on cost-effectiveness and the highest possible flexibility. Whereas other systems operate with individual controllers per drawer, MAPAL has developed a common controller for all the drawers. It is thus possible to easily and cost-effectively implement drawer dividers in different heights. This applies also to individual tool dispensing. The control is central here again, and enables a functional and cost-effective system to be offered. This new option gives a further significant boost to the performance of the UNIBASE-M system. - Dispensing limitation for selective dispensing of individual parts and stock control - Flexible modular system - Drawers with different heights available, also for retrofitting - Moderate additional expense with benefits in cost-effectiveness

19 Setting INNOVATIONS UNISET-P with tactile measuring sensor In order to achieve optimum surface finishes during face milling it is essential that all the blades run perfectly axially. While optical systems reach their limits when it comes to exact setting, high-precision setting of the axial run-out is a matter of course with the tactile measuring sensor in the UNI- SET-P. Originally developed for quick and convenient optical measurement of drilling and milling tools, the axial run-out of milling heads can now also be set with µ precision. Should the measuring sensor not be required, it can be removed quickly and easily. This option makes the UNISET-P even more versatile and offers the greatest possible benefits. - Vertical measuring sensor for tactile setting of the axial run-out of milling cutters - Tactile setting of height and length of all tools possible - Modular system for mounting on the cross-member

20 Discover tool and service solutions now that give you a lead: Reaming and fine boring Boring Drilling Milling Turning Clamping Actuating Setting and measuring Services Order-No V1.0.0 InnovationS-EN WD Printed in Germany. Right of technical information reserved. MAPAL Präzisionswerkzeuge Dr. Kress KG Reprints, even of excerpts, require the consent of the publisher.

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