MAPAL Dr. Kress KG will be represented at this year's EMO in Hanover with a completely newly designed 360 m² stand. Under the motto "Production with MAPAL effect: Fast, reliable, efficient", MAPAL is presenting leading technological tool solutions for modern production processes in Hall 4, Stand D13. Apart from machining solutions tailored to the customer's needs, MAPAL also offers a broad spectrum of innovative products for reaming, boring, milling, turning and clamping together with the corresponding services. A complete product portfolio is thus available for the machining of cubic parts. The range is being expanded with a large number of new products, some of which are described briefly below.
50% time saving when setting reamers and fine boring tools
The tools with guide pads from MAPAL are the ultimate solution when it comes to precision bores with the highest demands on the bore quality. These demands are satisfied by the MAPAL system with micrometre-precision, delicate setting mechanisms for diameter and taper. And that is exactly where the latest development, Easy Adjust System, comes in. The optimum back taper on the minor cutting edge is already integrated into an innovative cassette. These adjustment operations can therefore be eliminated with no loss of quality. Tools with Easy Adjust System are only adjusted in diameter, this significantly increasing the process reliability at insert change. Due to the exact guidance of the cassette on a precision pin, the back taper remains unchanged even at diameter adjustments. The time for adjustment per insert is halved by the new development!
Reliable solutions for all trendsetting part developments
The finish of the cylinder bore surfaces in engine blocks has great importance with respect to the fuel consumption. Constant further developments are therefore being initiated here. This challenge is being resolved on the one hand by the trend to a thinner walled design and a lighter, more compact construction of the engine blocks. Furthermore, the cylinder bore surfaces are coated using innovative methods in order to reduce the friction, and hence the fuel consumption. An innovative coating method here is the twin-wire arc-sprayed coating (TWAS) process. The new technology changes the whole machining process of the cylinder bore surfaces. The surfaces have to be pre-machined in order to achieve an optimum coating adhesion. After application, the coating is finish-machined in order to minimise the time required for the subsequent honing operation. Through continuous testing and development work, MAPAL has created reliable tool solutions for pre-machining and finish-machining of TWAS and plasma coatings for use both on transfer lines and in machining centres.
New indexable insert drills for short machining times and simple handling
The new MAPAL drill with changing system significantly reduces the costs per bore by comparison with a solid carbide drill. Characteristic attributes of the standard tool are a stable interface for a large number of insert changes, a long service life of the tool holder and a simple, error-free mounting of the insert. The different inserts have been optimised for long tool lives to suit the geometry and the cutting material and adapted to the materials to be machined. The new drill is available in the diameter range from 12 to 32 mm and with tool holder lengths up to 8xD.
Flexible production on lathes with HSK-T revolvers
The reduction of the machine downtimes is a major starting point for further developments in the tool technology; crucial for fast tool changes are clamping tools with optimised interfaces. On lathes, it is not unusual for the chip-to-chip times to add up to between 10 and 15 minutes, as alignment operations and control cuts were often necessary with the interfaces used to date. This is where the HSK-T technology comes in, allowing a tool change in less than 30 seconds. The new HSK-T revolver enables the level of utilisation of the machine, and hence the productivity to be significantly increased.
Precision drill chuck for tools for machining miniature parts
The micromachining currently being demanded in particular by the medical, communication technology, jewellery and watch industries is also presenting the tool clamping technology with challenges. Tool diameters from 0.1 mm have to be securely clamped with very high precision. It was for precisely these applications that the Micro-DrillChuck was developed that in the shank versions HSK, SK and cylindrical shank achieves spindle speeds of up to 60,000 rpm, run-out accuracies better than 0.01 mm and a homogeneous force distribution.
50% time saving when setting reamers and fine boring tools
The tools with guide pads from MAPAL are the ultimate solution when it comes to precision bores with the highest demands on the bore quality. These demands are satisfied by the MAPAL system with micrometre-precision, delicate setting mechanisms for diameter and taper. And that is exactly where the latest development, Easy Adjust System, comes in. The optimum back taper on the minor cutting edge is already integrated into an innovative cassette. These adjustment operations can therefore be eliminated with no loss of quality. Tools with Easy Adjust System are only adjusted in diameter, this significantly increasing the process reliability at insert change. Due to the exact guidance of the cassette on a precision pin, the back taper remains unchanged even at diameter adjustments. The time for adjustment per insert is halved by the new development!
Reliable solutions for all trendsetting part developments
The finish of the cylinder bore surfaces in engine blocks has great importance with respect to the fuel consumption. Constant further developments are therefore being initiated here. This challenge is being resolved on the one hand by the trend to a thinner walled design and a lighter, more compact construction of the engine blocks. Furthermore, the cylinder bore surfaces are coated using innovative methods in order to reduce the friction, and hence the fuel consumption. An innovative coating method here is the twin-wire arc-sprayed coating (TWAS) process. The new technology changes the whole machining process of the cylinder bore surfaces. The surfaces have to be pre-machined in order to achieve an optimum coating adhesion. After application, the coating is finish-machined in order to minimise the time required for the subsequent honing operation. Through continuous testing and development work, MAPAL has created reliable tool solutions for pre-machining and finish-machining of TWAS and plasma coatings for use both on transfer lines and in machining centres.
New indexable insert drills for short machining times and simple handling
The new MAPAL drill with changing system significantly reduces the costs per bore by comparison with a solid carbide drill. Characteristic attributes of the standard tool are a stable interface for a large number of insert changes, a long service life of the tool holder and a simple, error-free mounting of the insert. The different inserts have been optimised for long tool lives to suit the geometry and the cutting material and adapted to the materials to be machined. The new drill is available in the diameter range from 12 to 32 mm and with tool holder lengths up to 8xD.
Flexible production on lathes with HSK-T revolvers
The reduction of the machine downtimes is a major starting point for further developments in the tool technology; crucial for fast tool changes are clamping tools with optimised interfaces. On lathes, it is not unusual for the chip-to-chip times to add up to between 10 and 15 minutes, as alignment operations and control cuts were often necessary with the interfaces used to date. This is where the HSK-T technology comes in, allowing a tool change in less than 30 seconds. The new HSK-T revolver enables the level of utilisation of the machine, and hence the productivity to be significantly increased.
Precision drill chuck for tools for machining miniature parts
The micromachining currently being demanded in particular by the medical, communication technology, jewellery and watch industries is also presenting the tool clamping technology with challenges. Tool diameters from 0.1 mm have to be securely clamped with very high precision. It was for precisely these applications that the Micro-DrillChuck was developed that in the shank versions HSK, SK and cylindrical shank achieves spindle speeds of up to 60,000 rpm, run-out accuracies better than 0.01 mm and a homogeneous force distribution.
