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Page 1 | MAPAL Impulse
400 visitors to
the 3rd MAPALdialogue
Trochoidal milling
fitness program for themilling machine
Optimisation in
dialysis machinemanufacture
MQL technology:Resource-saving and energy-efficient
Information, Ideas, Internals No. 51 | June 2013
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Page 2 | MAPAL Impulse
Building on a good market
position with new innovations.
EDITORIAL
Dear reader, dear business associate,
After a very positive business year 2012
during which we were able to record
growth of around 10 %, we are cau-
tiously looking forward to 2013 with
optimism despite the widely reported
increasing sense of crisis. What is the
reason for our generally positive mood?
On the one hand MAPAL is out infront with the market leaders in many
product areas, in particular fine machi-
ning, on the other hand we have a very
broad base with our comprehensive
product range and can better compen-
sate for fluctuations in some sectors.
With our international production and
sales network in 21 countries we can
also offer a high degree of customer
proximity and can react flexibly to
varying market requirements. Last but
not least, as a family business we areindependent of external investors and
possible short-term shifts in strategy;
we are therefore dependable as a long-
term partner for our customers. All of
these factors, combined with the high
level of skill and ability of our em-
ployees, are essential prerequisites for
maintaining and further expanding our
good market position with continuous
innovations.
MAPAL technology has therefore been
the center of attention at many inter-
national trade fairs and congresses. The
possibilities offered by MAPAL system
solutions and indeed also by our high
performance standard products for
drilling, milling, reaming and turning
are of great benefit for the customer.
Recently our development engineers
developed a new tool for trochoidal
milling; this tool is of unrivalled per-
formance. The result is shorter machi-
ning times, better tool utilisation, as
well as noticeably lower tool wear. Incombination with the new hydraulic
chuck, High TorqueChuck, which can
withstand temperatures up to 170 C,
milling becomes highly efficient in all
aspects.
With MQL technology we offer a fully
mature product range for the machi-
ning process with minimum quantity
lubrication; this technology is taking
on an increased sense of importance
given the current situation of ever in-creasing energy prices. Many customers
use this technology, on the one hand to
save around 30 % of the energy costs
and to reduce the coolant consumption
to a minimum, however on the other
hand also to reduce the impact on the
environment and to create better wor-
king conditions for staff.
During all MAPAL development work
the maxims of cost-effectiveness,
energy-efficiency and conservation of
resources are in the foreground to give
our customers a technological lead and
to make possible sustainable produc-
tion.
Have a good read
Yours, Dr. Dieter Kress
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Page 3 | MAPAL Impulse
CONTENTS
MAPAL at CIMT in Beijing and Turning
Days in Villingen-Schwenningen
MAPAL addressed the increasing
demand for energy-efficient, resource-saving precision tools and machining
methods during its successful ap-
pearance at CIMT in Beijing. It was
possible to make many new customer
contacts. Along with the product in-
novations, the ReTooling service, that
is the re-tooling of existing machines
for new parts, was a hot topic for
our specialists. With a good 175,000
visitors, CIMT is the largest show for
metal machining in China.
MAPAL also attended the trade fair
Turning Days in Villingen-Schwen-
ningen and was able to successfully
demonstrate its competence in the
area of tools for lathes and clampingtools. HSK-T, Versacut hard turning as
well as MAPAL conversions for lathes
to HSK-T were the focus of interest of
the numerous visitors to the fair.
MAPAL has a new
Head of Marketing
and Corporate Com-
munications
Since February 2013
Andreas Enzenbach (47)has been responsib-le for internationalproduct marketing as
well as internal and external communication.Enzenbach has many years of experience ininternational capital goods marketing in the
mechanical engineering and systems enginee-ring sectors and is a specialist for communica-
tion strategies.
Armin Kasper new
Regional Sales Di-
rector for China andTaiwan
Since April 2013
Armin Kasper has beenthe MAPAL GroupsRegional Sales Director
responsible for theimportant growth
regions of China and Taiwan. As a long-serving
sales manager from MAPAL WWS, a specialistfor PCD tools and key account manager, Kasper
has extensive expert knowledge and experiencein international sales. He will therefore be ableto provide very significant support to our sales
company MAPAL China on the sale of our tools.
News
MAPAL at international trade fairs
News from the MAPAL Group
NEWSTICKER
MAPAL Group News from the MAPAL Group Page 3
MAPAL dialogue: successful customer days Page 8
Product Highlights Solid carbide TTD offer: yes, I will. Page 6
Hybrid Tools Page 7
Trochoidal milling Page 10
PCD tools with lasered cutting edges Page 12
MAPAL setting fixture UNISET Page 16
Reports from practicet Fresenius Medical Care: custom-made tool solutions Page 18 MAPAL Poland: LFP water pump housing Page 20
MAPAL and Ford: optimal processes Page 22
Imprint Page 24
175,000 visitors to CIMT in Beijing. Turning and clamping areas in the spotlight:
Turning Days in Villingen-Schwenningen.
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Producing greater added value with lower energy usage by increasing
the energy efficiency of production processes.
News topics from the MAPAL Group
3D view of the newly planned company
headquarters MAPAL C&S in the Czech Republic.
New building for MAPAL C&S
The construction work on the new
headquarters of MAPAL C&S s.r.o in
the Czech city of Mlada Boleslav, near
Prague, started in May. Our current
building is too small for further deve-
lopment, says Petr Pokorny, General
Manager of the subsidiary in the
Czech Republic. The production faci-
lities of the automotive manufacturer
SKODA are also nearby. The new buil-
ding for MAPAL C&S includes a two-
floor administration area and a 1,000
square metre production building. The
result is a significant increase in capa-
city for the manufacture of PCD tools
and re-grinding solid carbide tools.
MAPAL is investing around 1.2 milli-on euros in this project, which is to be
completed by the end of the year.
In touch with the latest trends with
MAPAL
Improved drilling processes for solid
carbide drills, MAPAL tangential tech-
nology and universal high-pressure
chucks were the key topics at the 8th
Amberg tool seminar. In recent years
the seminar in Oberpfalz has become
established as an important specialist
forum for industrial users. Around
120 participants from all sectors of
the metal machining industry along
with graduates and scientists listened
to the presentations given by MA-
PAL speakers and saw for themselves
the practical implementation of the
information presented during demons-
trations. Intensive use was also madeof the opportunity to chat personally
to our experts.
Tool applications are continuously chan-ging. An edge in terms of knowledge willsecure competitive advantages. Seminars,workshops, forums or conferences offerinformation first hand. The experts fromMAPAL regularly attend a large numberof seminar events. In exciting presenta-tions they convey new know-how anddepict the latest trends and develop-ments in tool technology.
You will find an overview of the up-coming seminars and events in whichMAPAL will take part on our homepage atwww.mapal.com/aktuel-les/fachvortrae-ge. The list is continuously updated.
Conversions for lathes offer higheraccuracy with increased productivity
In 2008 HSK-T was standardised
specially for the usage of upright
tools on lathes. It features high chan-
geover and repetition accuracy, high
fitting accuracy, high rigidity, as well
as exact radial positioning accuracy.
The greatest advantage of HSK-T
compared to existing systems is
the very quick, straightforward tool
change. While with the standardisedconnections used in the past, 10 to
15 minutes were often necessary for
the tool change, with HSK-T the time
required is reduced to less than 30
seconds.
Paired with very high change-over
accuracy, there is a significant reduc-
tion in the machine downtimes and
as a result a significant increase in
productivity for the user. Along with
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complete conversion, it is also possible
to partially convert existing revolvers.
On stations with frequent tool chan-
ges, conversion to HSK-T is particu-
larly advantageous, as the investment
is manageable and pays for itself in
a short time. MAPAL offers conversi-
ons from all common connections on
lathes to HSK-T, across machines and
independent of manufacturer, as well
as a wide range of turning holders.
News
New building at MAPAL C&S in the Czech Republic
Increasing productivity with HSK-T
Technology report 2 on the topic of energy efficiency
TECHNOLOGY
REP RT
2nd MAPAL technology report
Which factors affect the energy con-
sumption of the machining process and
how can energy be saved? This is the
issue covered in the 2nd MAPAL tech-
nology report. Prof. Dr.-Ing. Eckehard
Kalhfer, the Chair for Machining at
the university in Aalen, and Dr. Jochen
Kress, member of the senior manage-
ment, have analysed the energy con-
sumption of machine tools and indivi-
dual process steps. Their report shows
how, with only little investment, for
instance the usage of energy-efficient
tools and optimal machining proces-
ses, to some extent significant energy
savings and therefore cost savings can
be achieved. The technology report is
included with this issue of Impulse.
Would you like to continue to read re-
gularly our scientific publications? Then
make use of our free subscription. You
will find the registration form on our
homepage at www.mapal.com/aktuelles/
technologiereport/anmeldung.-.
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Clever changing with the replaceablehead drill TTD from MAPAL
Replaceable head tool systems are
now indispensable in modern produc-
tion. Increasing raw material prices,
lean inventories and the consideration
of life cycle costs against the pure
purchase price favour the usage of
replaceable head systems. MAPAL
has introduced on the market highly
productive systems for all application
areas; systems that are in no way
inferior to monolithic tools quite
the opposite. With a focus on highly
precise, very stable connections it has
been possible to limit the usage of
expensive carbide to the tool head,
and to make the machining stable andprecise overall.
In the area of drilling from the solid
MAPAL relies on the replaceable head
drill TTD. At the center is the torque
transfer connection TTS (Torque
Transfer Schnittstelle) which permits
optimal torque transfer and at the
same time high changeover and radial
run-out accuracies. In this way the re-
placeable head drill TTD achieves the
performance of a solid carbide drillwith lower costs.
Success stories from the different sec-
tors and workpiece materials under-
line the performance of the replace-
able head drill TTD. For example in
gearbox housings made
of GJL-200 the 28 mm
fixing bores are drilled
using a replaceable head
drill TTD from MAPAL.
It is possible to opti-
mally meet the require-ments of the customer in
relation to the dimensional accuracy
of the diameter. However the TTD also
realises significant saving potential by
doubling the feed rate in comparison
to the solid carbide drill used previ-
ously. With 1,430 mm/min and 140
m/min cutting speed, 200 bores can be
reliably machined using a replaceable
drill head.
In an application from steel machi-
ning, clamps for folding machines
made of ST52 are drilled using the
replaceable head drill TTD.
83 bores with a diameter of 20 mm
and a length of 106 mm are required
per part. By using the MAPAL tool
it was possible to reduce the machi-
ning time from 39.7 to 18.1 seconds this corresponds to reduction in the
machining time of 54 %. Together
with an increase in the tool life of 77
%, the TTD reduces the costs per bore
by 60 % referred to the customers
annual production volume! There are
also examples of the successful usage
of the replaceable head drill TTD in
modern workpiece material combina-
tions. For example the machining of
bores for the connection of a ships
CFRP drive shaft to a steel hub. Usinga combination tool from MAPAL
with a TTD solid drilling stage and a
countersink step with PCD-tipped ISO
indexable inserts it was possible to
reduce the machining time by more
than 80 %.
Increasing raw material prices, lean inventories and the consideration
of life cycle costs favour replaceable head systems.
Highlights from the product areas
Simply scan the QR code or go towww.mapal.com/aktion
*Valid on ordering a TTD replaceable head with tool holder.You will find the full terms and conditions of the offer at www.mapal.com/aktion
Test the MAPAL replaceablehead drill TTD and exploit theperformance of a solid carbidedrill with lower costs.
TO CHANGE
without risk. Producequickly and effi ciently
using the replaceable headdrill TTD.**
YES
,IWILL
YES, I WILLThe current MAPAL replaceable head drill TTD cam-paign will continue until the end of June. You willfind more information on this topic on our homepagewww.mapal.com
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Page 7 | MAPAL Impulse
Pre-machining and fine machining
intelligently combined
Custom-made combination tools
open up high potential for increasing
productivity and process reliability. In
the specific case of a MAPAL custo-
mer, it was necessary to pre-machine
and fine machine particularly cost-
effectively two connection bores with
diameters of 31 mm and 36 mm on an
AlSiMg1 swivel bearing for a car. This
requirement sets two challenges for
the tool design. Firstly, the low silicon
content of the aluminium alloy requi-
res an innovative tool concept that
ensures optimal chip breaking of the
otherwise long continuous chips. On
the other hand, to meet the cycle timerequirements, particularly productive
pre-machining and fine machining
are required as both diameters require
high stock removal.
To solve this task, MAPAL developed
two combination tools that combine
both the pre-machining and fine ma-
chining on one tool body.
The pre-machining was designed on
both tools as a solid drilling sta-
ge with replaceable ISO indexable
inserts. The appropriate cutting edge
geometry, as well as twisted and also
polished chip spaces with a helix ang-
le of 15 ensure reliable chip breaking
and chip removal. Due to the large
core cross-section of the solid drilling
stage, the tools are stable and par-
ticularly smooth in operation. After
the solid drilling stage, the stages for
fine machining follow with the brazed
PCD cutting edges. During process
design, the machining operations
were optimally distributed over the
two tools.
First tool one (see figure) is used todrill the large diameter using the
indexable inserts. Then the next
stage machines a spot face on the
end of the bore using the related
chamfers. Using tool two, the
small diameter is drilled in the
solid and then fine machined and
chamfered using the following
stages. Then the chamfer on the
bore outlet is made using this
tool by circulating. The same tool
then moves to the larger diameter,
fine machines the bore and also pro-
duces the chamfer of the exit of this
bore by circulating.
MAPAL specialists have achieved
maximum productivity and cost-
effectiveness in this machining task
both in the process design and the
tool design. The two combination
tools complete all the machining
tasks for which at least four tools
would normally be required. Also
the MAPAL hybrid tools combine the
different machining systems in such
a manner that excellent performance,
simple handling and cost-effective
reconditioning are achieved.
News
Yes, I will to change without risk
Intelligent combination of machining systems
Pre-machining and fine machi-
ning intelligently combined
MAPAL hybrid tools combine different tool tech-
nologies
1
2
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Erfolgreiche Kundentage bei MAPAL
Minimum quantity lubrication was the
topic of the customer days at MAPAL
this year. Around 400 participants
came to Aalen, above all series pro-
duction manufacturers and suppliers
to the automotive industry; they came
to obtain information on this envi-
ronment-friendly and energy-saving
form of material machining. By means
of the minimum quantity technology,
up to 80 % less coolant and up to 40
% less electrical power is consumed in
comparison to conventional processes.
At the end of the two-day event the
participants were impressed by the
diverse mix of broadly based presen-
tations, practical tool demonstrations,
a large exhibition of MQL compo-
nents, as well as the tours through theMAPAL production buildings.
Dr. Dieter Kress was pleased by the
unexpectedly large number of visitors
who travelled from all over Germa-
ny, Austria, Poland and Switzerland:
With minimum quantity lubrication
we have selected the right topic, he
concluded. Minimum quantity lubri-
cation (MQL) is in principle nothing
new. The first bores were dry ma-
chined some 20 years ago. However,
the keen interest shows that MQL is
a very complex system. One, as Dr.
Jochen Kress added, in which there
has been significant progress in re-
cent years: We are now at the point
that we can also use MQL technolo-
gy on broad front. The increasing
industrial interest in energy-efficient
production is giving MQL technology
additional lift: It is a comparatively
simple way to save energy, says Dr.
Jochen Kress.
And businesses will increasingly
exploit energy-saving potential in
the future to lower their costs for
energy and resources such as waterand material, stated also Prof. Dr.
Ing. Eckehard Kalhfer. The Chair
for Machining at the university in
Aalen has investigated the effect
of MQL on energy efficiency. The
basic annual consumption of an
operational machine tool is around
66,000 kWh. On the usage of central
cooling lubricant systems, states
Prof. Kalhfer, the energy demand
innovative technologies in use
MAPAL Di LOG
400 visitors on 10 and 11 April 2013
P R E S E N T A T I O N S | D E M O N S T R A T I O N S | I N - H O U S E
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is high compared to the energy
demand of the machining process
itself. Using various model invoices
he demonstrated that the electri-
city consumption can by reduced
by up to 40 % by using minimum
quantity lubrication. In this way it
is possible to save a lot of money,
the scientist stated.
However MQL technology requi-
res careful usage, says Dr. Jochen
Kress. All components, that is the
tool, machine, fixture and above
all the process must mesh opti-
mally. Two acknowledged MAPAL
specialists, Christian Schmidt and
Joachim Vaas, provided informati-
on on the special features of MQLtools and correct process design
in relation to lubrication, trans-
port of chips and cooling. Suitable
chucks were presented by Michael
Neumann: MAPAL has developed a
modular system for clamping tools.
We accompany the customer
during the entire process design,
from planning, through pilot trials, to
production, Dr. Jochen Kress descri-
bes the product and service portfolio.
MAPAL has a large array of machine-
ry for tests and optimisation and has
extensive experience with all materi-
als. Even demanding processes such
as connecting rod machining can be
implemented using MQL.
Peter Vogl, Director of Design & Tech-
nology at GROB Werke GmbH & Co.
KG in Mindelheim and Werner Roth,
Head of Application Engineering at
Maschinenfabrik Heller, Nuertingen
reported on how machine tools suita-
ble for MQL should be designed. The
manufacturers of machining centers,
custom machines and transfer lines
have already realised numerous MQLprojects together with MAPAL.
Currently around one in five of the
machines supplied by the business
have MQL technology says Roth. Vogl
spoke a slightly increasing tendency
in large-scale series production manu-
facturing. The machines are designed
such that lubricant can be supplied
X H I B I T I O N | E X P E R I E N C E | E X C H A N G E O F V I E W S
Continued on next page.
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through the tool as well as by means
of single-channel or dual-channel
systems.
Dr. Dirk Sellmer, Head of the Re-
search and Development department
at MAPAL gave an overview of the
different MQL feed units. Whether you
select a single or dual-channel variant
is essentially a question of philosophy
the expert stated. The same applies
to the choice of the right lubricant, a
topic that is also the subject of fre-
quent discussion. Fatty alcohols and
ester oils are not equally suitable as
lubricants in his opinion. It depends
on the application. Aerosols are not
flammable, however chip dust in com-
bination with wall oil could cause anexplosion. Modern extraction systems
prevent this situation from occurring.
Marcus Krauss, Sales Manager at Kel-
ler Lufttechnik, Kirchheim unter Teck,
is observing a trend toward small,
decentral systems. The advantages:
They need little space, can be used
flexibly and can be controlled direct-
ly via the machine tool. Ford, for
example, uses an individual separator
to blow the return air back into the
room.
The report from a user of MQL
technology was equally exciting
and informative for many partici-
pants to the MAPAL customer days.
At Punch Powerglide, Strasbourg,
around 300,000 gearboxes for cars are
manufactured per year, for this reason
around two years ago it was decided
to change to minimum quantity lubri-
cation for the production of converter
housings. Good environment manage-
ment and cost savings were the key
reasons explained planning manager
Roland Muller. Initially we had a
few problems with tool breakages and
noise, but it was possible to address
these issues quickly. It was possible
to reduce the cycle time using MQL,
the surrounding area is clean and
attitudes are positive. Mullers conclu-
sion: I am convinced we did the right
thing.
P R E S E N T A T I O N S | D E M O N S T R A T I O N S | I N - H O U S E
innovative technologies in use
MAPAL Di LOG
The development of MQL system components is sufficiently advan-
ced that this technology can now be used on a broad front.
CONTINUEDFROMPAGE5.
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Andreas Bro (Gebr. HellerMaschinenfabrik GmbH, Nuertingen):
There has been a lot of
information provided in a very
short time.
Olaf Kiener (Julius Schle DruckgussGmbH, Schwaebisch Gmuend):
It was a perfect event that
has exceeded my expecta-
tions.
Wolfgang Mller (Opel, Kaiserslautern):
A very good mix of theory and practice. It
was a great event because a large number of
external manufacturers were also present.
Michael Zinz (Deutz AG, Ulm):
The presentations were informative, the
works tour and the exhibition very interes-
ting. We are satisfied all round.
X H I B I T I O N | E X P E R I E N C E | E X C H A N G E O F V I E W S
Thank you for the feedback on this event you will also find a summary of the customer days online atwww.mapal.com/aktuelles/kundentage-mapal-dialog/
Your MAPAL Impulse editorial team
Alexander Koch (Schunk GmbH Et Co. KG,Lauffen am Neckar):
The dialogue was very well organised, inte-
resting and varied. I have learnt a lot aboutMQL technology.
Interviews
with visitors
Fit for manufacturing processes
with minimum quantity lubrication
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Fitness program for the CNC milling machine
With trochoidal milling significant
improvements in tool costs, clamping
systems, machining times and the load
on the machine components can be
achieved in many applications compa-
red to conventional milling.
A comparison of the cutting data
determined during a MAPAL milling
trial already shows what is possi-
ble with this process, which is also
known as wave milling: while during
the conventional dry milling of case
hardened steel (16MnCr5) a cutting
speed of around 200 m/min at a feed
of 0.05 mm/tooth was achieved, it was
possible to tackle the same task with a
cutting speed of 600 m/min at double
the feed rate using the new trochoidalcarbide milling cutter from MAPAL.
Even on machining V2A steel it was
possible to achieve a significant incre-
ase in speed by changing the milling
technology: at a feed of 0.05 mm/
tooth, a cutting speed of 250 m/min
was achieved instead of the 60 to 100
m/min otherwise possible.
This performance increase is made
possible by a combination of high
performance milling cutters speciallydeveloped by MAPAL for this process,
the HighTorque Chuck (HTC) and the
actual process. The advantage during
movement is essentially the reduced
tool contact. While during conventio-
nal milling of a slot the wrap angle is
180 (full cut), with trochoidal milling
it can be selected as a function of the
cutting depth and limited to maxi-
mum 70. This situation is made pos-
sible by a milling cutter with a smaller
diameter that moves trochoidally at a
high spindle speed; each trochoid is
deeper into the cut.
Due to the smaller wrap angle, less
heat is produced. The machining
forces are also lower such that even
spindles with low power and torque
are suitable for the machining process.
In addition, the chip load is lower
with trochoidal milling. As the milling
cutter does not completely fill the
slot or pocket, chip congestion and
renewed cutting of chips is as good
as excluded. This aspect is of impor-
tance particularly for slots that are
deep in relation to their width. During
conventional milling, low feeds and
cutting depths are used here due to
the problems described. A maximummilling depth of 1.5 x D is normal.
Not so with trochoidal milling: by
avoiding the full cut, cutting depths
of up to 2 x D are achievable even
without specially developed milling
cutters.
For the user, this situation sig-
nifies shorter machining times,
better tool utilisation and
noticeably lower tool wear.
Due to the rapidly increasingcarbide prices, the latter in
particular is attracting the
attention of metal machi-
nists who can profit twice
over on changing to trocho-
idal milling: from the longer
tool lives and from the
lower procurement costs for
the milling cutter resulting
from the smaller diameters.
If trochoidal milling is used in
machining centers, additional cost
savings are possible. Because widely
varying slot widths or pocket sizes
can be produced with only one tool,
the tool needs to be changed less
frequently and there is space left in
the tool magazine. Trochoidal milling
also offers advantages in relation to
design. Due to the lower radial forces,
significantly more delicate parts and
parts significantly with thinner walls
can be realised and greater accuracies
achieved. At the same time the load
on the spindle bearings is eased and
the tool life is increased.
The OptiMill product family from
MAPAL includesmilling
cut-
Trochoidal milling also for machining centers
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Customer benefits
Shorter machining time and better tool utilisation
Higher cutting volumes and feeds
ters suitable for dry trochoidal milling
with DIN shank lengths 2 x D. For
applications with even higher requi-
rements, MAPAL has now developed
and added to the product range an
entirely new milling cutter with a
cutting length of 3 x D and a diameter
from 6 to 20 mm. Specially designed
unequal spacing (EU spacing) of the
five cutting edges combined with an
innovative geometrical design of the
cutting wedge reduces the excitation
of vibration here. Balancing (balan-
cing quality 2.5) undertaken during
the manufacturing process further
reduces the risk of vibration. As such
the patent-applied milling cutter
can even be used at extremely high
spindle speeds without problems. Sothat with the greater cutting depths
now possible, jamming does not occur
due to the long chips produced in
the process, the tool designers have
also integrated a chip breaker that
cuts the chips in half. This feature
safeguards the trouble-free removal
of the chips from the machine com-
partment. A special tool adapter is not
required for trochoidal milling using
the MAPAL milling cutters. However,
if the potential of trochoidal milling
and the new milling cutter is to be
fully exploited, it is recommended to
use the new MAPAL HTC chuck. The
chuck combines the very good dam-
ping properties of hydraulic chucking
technology with the high holding
forces of shrinking technology. The
HTC reliably transmits high torques.Even heating to 170 does not affect
the HTC chuck, as milling trials have
confirmed. As a rule, cooling is there-
fore not necessary.
Smaller or more delicate parts, higher
accuracies and the continuing pres-
sure to further reduce tool, operating
and maintenance costs are making the
call for more efficient milling proces-
ses louder. Thanks to the availability
of more powerful tools such as the
new MAPAL trochoidal milling cutters
and the increasing usage of powerful
CNC controllers and CAM software,
there is now nothing to hinder the
broad usage of the trochoidal milling
process. The time is right for trochoi-
dal milling!
MAPAL OptiMill milling
cutter in use.
Figure on right: Trochoidal
milling cutter clamped in
the MAPAL High-Torque
Chuck.
Your contact person for further information:
Andreas Rinn | [email protected]
ae
fz
Feed motion
r1
Machining area per
trochoid.
Chip per cutting
edge.
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Page 14 | MAPAL Impulse
Innovative manufacturing technology for external machining tools:
PCD tools with lasered cutting edges
Productivity and quality significantly increased
The competence center for PCD tools
in the MAPAL Group, MAPAL WWS
GmbH in Pforzheim, is the largest
and most technologically advanced
production facility for PCD tools
in the world. In collaboration with
LASERPLUSS AG, also part of the
MAPAL Group, (see box on the right),
another significant development has
been achieved on the production side:
by using RayCutter 5-axis CNC laser
machines for laser finishing PCD
cutting edges, it has been possible to
significantly increase the stability and
with it the productivity and quali-
ty of complex external machining
tools. The engineers in Pforzheim are
impressed with the new technolo-
gy and are expanding the capacity.The RayCutters have been used in
production for around three years. The
development of the new machining
method for external machining tools
started in 2011, and the process was
very successfully introduced in 2012.
By the middle of 2013, five RayCut-
ters were in use in the production of
PCD tool cutting edges.
Machining of a hose connection tho-
roughly revised
In one application, production of
a complex external contour on a
hose connection made of AlSi7 was
thoroughly optimised by MAPAL. The
part is manufactured on a four-spindle
machining center in high quantities,
absolute process reliability and the
high quality of the surfaces machined
in relation to dimensional accuracy
and surface finish must therefore
be ensured. The complete external
contour must also be produced in
one machining cycle. The customer
was dissatisfied with the part quality
produced by the previous process. The
machined area had a poor surface fi-
nish with clearly visible chatter marks.
Also, the dimensional accuracy varied
between the four spindles, an aspect
that made it more difficult to meet the
tolerances.
The tool used originally comprised
screw-mounted inserts and was corre-
spondingly unstable. It was necessary
to adjust the delicate inserts individu-
ally and there was a tendency for the
adjustment to change during machi-
ning. This situation often resultedin only one of the two cutting edges
actually cutting. At a spindle speed of
5,000 min-1it was only possible to use
a feed per tooth 0.1 mm.
Lasered cutting edges maintain the
stability of the tool
The specialists from MAPAL designed
a PCD external machining tool of
monoblock design to make the machi-
ning more stable and to improve thesmooth running. The design permits
high accuracies in length, shape and
diameter. However, the special high-
light is the machining of the cutting
edges. Unlike in the past, these cutting
edges are lasered instead of wire
eroded. This innovative technology
has significant positive effects on ma-
chining quality and productivity with
this complex form of external ma-
chining. To be able to wire erode the
cutting edge contours in monoblock
tools in the conventional manner, the
tool body must be relieved. As a result
the area behind the cutting edge beco-
mes very unstable. As a consequence,
the tool tends to vibrate; the cutting
data must be drastically reduced in
some cases. If the cutting edges are
finish lasered using the new process,
the cutting edge pocket remains stable
and vibration is prevented. It is only
necessary to take into account any
tool restrictions. The improved tool
stability therefore makes possible
significant increases in the machi-
ning quality and productivity as well
as an effective two cutting edge and
multi-cutting edge capability. Christi-
an Molch, General Manager at MAPALWWS, says
on this
issue:
This laser
technology
developed
by MAPAL
and LA-
SERPLUSS
is excel-
lently sui-
ted to theproduction
of com-
plex, very
delicate
geometries
on external
machining
tools. The
process
operates
withoutLASER-TECH
N
O
LO
G
Y
Picture from the
cutting edge
preparation on th
RayCutter.
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Page 15 | MAPAL Impulse
physical contact and is practically
unlimited in relation to geometry. As
a result MAPAL is also technologically
leading in the area of complex PCD
external machining tools.
Cycle time reduced by 23 %
The potential of the new tool gene-
ration has been confirmed in series
production at the customer. After
machining, the part has a very good,
chatter-free surface finish as well as
good geometrical accuracy, and that
with significantly increased machi-
ning values (n = 8,500 min-1, fz =
0.16 mm). The customer has several
positive effects due to the usage of
the MAPAL PCD external machining
tool. It saves handling costs, as com-
plicated and time-consuming setting
is not required. The monoblock tool is
also 50 % cheaper to procure than the
competitor tool. However, the achie-
vement of the highest diameter and
length tolerances as well as the best
surface finishes with high cutting data
is decisive. As a result it is possible to
reduce the cycle time by 23 %.
Very deep axial recesses
In a further example, very deep axial
recesses are produced on a machining
center.
Originally the machining was under-
taken using recess tools with clam-ped carbide inserts. The responsible
member of the MAPAL sales team and
the specialists in Pforzheim developed
recess tools with lasered cutting edges
for pre-machining and fine machining
during this task. The pre-machining is
undertaken into the solid using a two-
cutting edge tool with impressive
cutting data:
n = 6,000 min-1, fz= 0.05 mm and
300 mm/min feed rate. The tool for
the fine machining is of single-cuttingedge design and machines the work-
piece with a spindle speed of 8,000
min-1, 0.1 mm feed per tooth and a
feed rate of 800 mm/min.
Your contact person for further information:
Michael Hils | [email protected]
LASERPLUSS AG in Kirschweiler bei Idar-Ober-
stein has specialised in the manufacture of laser
systems for precision applications for cutting me-
tals and hard materials, for marking and engra-
ving all materials, and for welding plastics. The
company founded in 1997 with Dipl.-Ing. Werner
Schulz as its head has been part of the MAPAL
Group since 2009.
Figure top: Cost-effective external machining with PCD tools from MAPAL.
Figure bottom: Machined joint contour on a sample part.
The RayCutter 5-axis
CNC laser machine from
LASERPLUSS AG.
Customer benefits
High process reliability
Deep axial recesses possible
Significantly higher cutting data
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Setting fixture UNISET-V vision developed for complete solutions
Measuring and setting complete machining tools
Planning new projects is time-consu-
ming and expensive. More and more
customers therefore make use of the
comprehensive range of services offe-
red by MAPAL related to part design
and the delivery of the related compo-
nents. As along with technologically
leading and highly productive tools,
MAPAL offers extensive know-how on
machining. This aspect relates to both
custom services as well as to high
precision peripheral equipment for
adjusting and measuring the tools.
Process reliability and part quality due
to exact measuring
During the design of tools for com-
plete machining, fine machining toolsplay a crucial role. As the tools are
often used for the last manufacturing
step, all tolerance requirements on
the part in relation to surface finish,
dimensional, contour and positional
accuracy must be reliably met. As a
specialist for fine machining, MAPAL
relies on fine boring tools with guide
pads that can be adjusted to the m.
Very tight tolerances can be achieved
with these tools. Due to the setting
features on the tools it is possible toaddress flexibly any special aspects
related to the workpiece material or
the machine. The exact measurement
and adjustment of these tools is a
prerequisite for high process reliability
and part quality. These tasks are suc-
cessfully undertaken using a precise
measuring and setting fixture that is
integrated into the process chain.
Highest measuring accuracy with
UNISET-V vision
For cost-effective series production it
is particularly important that tools can
be measured and set to the highest
precision both quickly and efficiently
to ensure constant availability at the
machining center and to avoid down-
times. The example of a complete ma-
chining process on clutch and gearbox
housing makes this aspect clear. The
optimal machining of the often thin-
walled, large aluminium cast parts
requires comprehensive know-how
during tool design. In particular there
are high requirements on the shape,
position, surface finish and diameter
of the shaft bearing bores. The soluti-on a complex, multi-stage combinati-
on tool that, along with high accuracy,
significantly reduces the machining
times. Along with fixed brazed PCD
boring tools, these tools use adjustab-
le inserts and guide pads, as well as
face cutter heads with adjustable PCD
milling cartridges for finish machining
of the sealing faces. For setting the
tools to the um, MAPAL has developed
a CNC-controlled setting fixture in
the form of the UNISET-V series thatis perfectly matched to the require-
ments placed on these tools due to
the combination of tactile and optical
measuring methods.
Tactile measuring method for setting
fine boring tool with guide pads
The vertical setting fixture UNISET-
V vision is equipped with electronic
measuring sensors that make it possib-
le to exactly set fine boring tools with
guide pads to within 1 m. Depending
on the position of the guide pads and
insert, either protrusion measure-
ment or swinging lever measurement
is used. As soon as the measuring
sequence for a tool has been defined
and saved once using the teach-in
programming, from then on the mea-
surement of the tool is undertaken au-
tomatically via the CNC controller. In
this way it is possible to significantly
reduce the non-productive times in
the measuring room, particularly in
case of complex, multi-stage tools for
shaft bearing bores.
State-of-the art camera system forthe optical measurement
PCD face cutter heads in the Eco-
Mill series are sophisticated, efficient
tools. A prerequisite for their reliable
usage and long tool lives are inserts
1.1
2.1
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Page 17 | MAPAL Impulse
Customer benefits
Universal setting and measuring device for
manufacturer-independent tool concepts
Fully automatic measuring sequences using CNC controller
Highest accuracy due to solid mechanical construction
that move within defined tolerances.
For finish machining PCD face cutter
heads are used; here the exact and
effective setting of the axial run-out
on all cutting edges is necessary.
Using the UNISET-V vision each PCD
cassette on the face cutter head is
moved to and measured using the
optical camera system. If necessary,
the axial run-out can then be simply
and quickly corrected at the adjus-
ting element on the milling cutter. Inparallel the setting process is moni-
tored optically on the touchscreen
monitor for the UNISET-V vision. Also
all other tools used for the complete
machining process are measured using
the optical measuring device. All rele-
vant measuring data, for example tool
lengths or diameters, can be assigned
to the tool using the UNISET-V vision.
The measured data are either saved
directly on the tool using a Baluff
chip, or applied directly to the tool
body in the form of a printed label.
With both processes, it is ensured that
no time-consuming corrections are
necessary on the usage of the tools on
the machining center.
A single setting fixture for all require-
ments
The different measuring methods for
a very wide range of tool systems, the
high precision due to the solid basic
mechanical set-up and the CNC elec-
tronics make the UNISET-V vision an
all-rounder in the tool setting room.
In particular in the case of tools for
complete machining the UNISET-V
vision ensures real productivity ad-
vantages are obtained due to its high
degree of flexibility and ease of use, it
is therefore an indispensable element
of the complete process chain.
Your contact person for further information:
Michael Hils | [email protected]
The UNISET-V vision makes itpossible to set and measure all tooconcepts used for the completemachining of clutch and gearboxhousings.
Verticalsetting fixtureUNISET-Vvision.
1.1 | During the protrusion measurement forsetting fine boring tools with guide pads, themeasuring sensors are first moved to the positionof the guide pads and the measuring range set
to zero. Then the adjustable inserts are moved toand the measuring range is again set to zero atthe highest point. Due to the low contact pres-sure on the insert and the reduced measuringforce, delicate PCD-tipped inserts can also bemeasured reliably and without risk of damage.
1.2 | The operator now sets the defined nominaldimensions such as the overhang on the insert inrelation to the guide pad and the diameter.
2.1 | Optical measurement of a PCD face cutterhead in the EcoMill series.
2.2 | Setting the axial run-out at the adjustingelement on the milling cutter.
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Page 18 | MAPAL Impulse
Identifying and utilising optimisation potential in machining
productivity increase due to custom tool solutions
Machining for dialysis equipment significantly optimised
Unmanned machine tool operation
safeguarded, machining time halved,
tool life increased by 20 times, surface
quality visibly improved - these are
only some of the impressive results of
the latest process optimisation in ma-
chining at Fresenius Medical Care on
its site in Schweinfurt. Since 1979 the
company has developed and manufac-
tured dialysis machines for the inter-
national market with great success in
this industrial city in Lower Fran-
conia. Every year more than 40,000
systems leave the factory that main-
tains its position in relation to the
international competition by means of
efficiency and clear work processes.
The strategy of Fresenius Medical Care
is to be better than the competition inrelation to the quality of the dialysis
products and production costs.
To implement these goals the world-
leading manufacturer of dialysis
equipment has relied on know-how
and tools from MAPAL for machining
since 2000. In close co-operation
we have managed to further stream-
line production processes, to reduce
tool costs and to improve quality
repeatedly in recent months, reportsLudwig Schmittlein, who is respon-
sible for milling technical support in
machining at Fresenius Medical Care
Deutschland GmbH.
Process optimisation makes possible
unmanned production
As such, a multiblock made of po-
lypropylene can now also be manu-
factured unmanned and therefore
around the clock as a result of a tool
change. Prior to the change the blind
bores necessary on this assembly
were realised in three steps: Due to
the large diameter of 42 mm, first the
bore was pre-drilled using a standard
drill, the bore was then drilled out and
subsequently machined to the cor-
rect dimension using a milling cutter.
This method has the disadvantage
that long chips were produced during
boring that, on the one hand, soiled
the machine tool, and on the other
hand took a lot of space in the chip
bin. These two aspects together pre-
vented unmanned operation at night,
Benedikt Hetterich, head of the milling
area and quality assurance in machi-
ning at Fresenius, describes the initialsituation.
As the machine configuration did not
permit milling from the solid, based
on experience in other applications
MAPAL engineers suggested a solution
with a carbide replaceable head
drill TTD with 180 geometry
and a PCD-tipped milling cut-
ter with which the blind bore
is circular milled in a helix
after drilling. We have beenworking very successfully with
this solution for approx. one
year, Ludwig Schmittlein is
pleased to state. The chips are
space-savingly small, boring
out is not required at all and
the milling cutter can operate
with much higher feed such
that we can operate unmanned
and also faster than before.
Another earlier optimisation project
also made a significant contribution
to increasing through-put at Freseni-
us: The filter block, also manufac-
tured from a block of polypropylene,
for the therapy system 4008 from
Fresenius needs a 91 mm deep blind
bore. However, the walls of the bore
are not straight, but taper at 1 degree
downwards, at the transition from the
flat base of the bore to the side wall
the bore has a radius; there is also a
straight section to the opening. As for
the multifunction block, until recently
standard drills were used for pilot dril-
ling and boring out. The 1-angle was
then cut with 0.2 mm cutting depth
and a radius milling cutter controlled
by a CAD program. Just this one pro-cess took 30 minutes and transition
marks and scoring could occur on the
surface. Using the alternative develo-
ped by the MAPAL specialists in close
co-operation with us, we only need 16
minutes for the complete machining
Drilling from the solid and circular milling
with optimised chip breaking make possibleunmanned production.
SOFT
M
ILLIN
G
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Page 19 | MAPAL Impulse
Customer benefits
Unmanned production possible
Tool costs reduced
Machining timed reduced
Das fertig gefrste Werkstck.
Your contact person for further information:
Michael Neumann | [email protected]
of the part, reports Ludwig Schmitt-
lein with pride.
The chamber opening on the filter
block is now drilled in one step using
a replaceable head drill TTD with
a special design. The drill has the
MEGA-180 geometry that makes it
possible a flat bottom in bores in one
machining step. The contour is then
milled using a customer-specific car-
bide form cutter with one material re-
moval rate. As a result with the new
tools we have achieved short chips, a
good surface finish and flowing tran-
sitions also in this application, adds
Benedikt Hetterich. Fresenius also
benefits from longer tool lives,
as his colleague emphasises: Whilewe could produce approx. 600 parts
with a corner radius milling cutter,
we have now passed the 1,500 mark
and still do not need to change the
replaceable head.
Fresenius was able to achieve an even
more significant increase in tool lives
by means of tool optimisation in the
case of a part made of polypropylene
with 30 % glass fibre content: Prior to
the change a recess was produced with
the aid of a conventional solid carbide
circular milling cutter. Although
the tool was economical to procure,
it had to be replaced after only 600
parts due to wear, Benedikt Hetterich
looks back. For the last two years we
have used instead a circular milling
cutter with PCD cutting material that
cost almost three times as much, but
that lasts for at least 16,000 parts! At
an annual production rate of 36,000
pieces this means savings of almost
6,000 euros a year in tool costs alone.But that is not enough. In a partner-
ship-based co-operation with the tool
specialists at MAPAL, the responsible
staff at Fresenius have been able to
achieve other improvements in many
areas. We are therefore very happy
with the support provided by MAPAL
and the quality of the tools, Benedikt
Hetterich and Ludwig Schmittlein
agree.
Dialysis machine
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Page 20 | MAPAL Impulse
Complete machining with minimum number of tools and mini-
mum number of different indexable inserts.
Complete machining of water pump housings
MAPAL has been represented in Po-
land with a dedicated subsidiary since
2002. The team around General Mana-
ger Aleksander Zielonka comprises 27
staff in sales and service. Comprehen-
sive local support to customers with
technologically leading tool solutions
is the premise of MAPAL Narzedzia
Precyzyjne Spka z.O.O.. Here the
focus is on partnership-based collabo-
ration with customers and machinery
manufacturers. An example of this
aspect is a project realised at the end
of 2012.
Leszczyn ska Fabryka Pomp (LFP) was
founded in 1868. The privatisation of
the organisation and a new strategic
direction placed the focus on deve-lopment activities. Today LFP is the
leading manufacturer of pumps and
pump systems in Poland and one of
the most modern manufacturers of
cast parts in the world.
SW (Schwbische Werkzeugmaschi-
nen GmbH), as an important MAPAL
technology partner, opened the door
to LFP. In the past some small tool
deliveries were made; deliveries that
demonstrated the professional supportand the quality of the tools.
Fewer tools for higher productivity
In 2012 SW was tasked by LFP to
deliver the machine and the fix-
ture for machining new water pump
housings made of EN-GJL250. In turn
the machinery manufacturer suggested
MAPAL Poland as a suitable tool and
technology partner for meeting the
customers requirements: complete
machining with a minimum number
of tools and a minimum number of
different indexable inserts.
Robert Adamczak, Director of Techno-
logy and Innovation at LFP, descri-
bes the collaboration as very good
and trouble-free: The water pump
housings are machined on an SW
BA600-2 machining center using
MAPAL tool technology. Our require-
ments for a reduced number of tools
as well as a lower cycle time compa-
red to the competition have been met
perfectly by the MAPAL solution. We
also achieved our objectives signifi-
cantly more quickly and straightfor-
wardly during the implementationphase.
Latest tool technology in use
The tool technology for the pump
housing was the result of collaborati-
on between Robert Adamczak and Pi-
otr Nowacki (project manager) at LFP,
Lukasz Barteczka, project engineer in
Czech sales at SW, and the MAPAL
team, comprising regional sales mana-
ger Piotr Jadrzyk, salesperson MarcinWawrzonkowski and Martin Rottenbil-
ler, who co-ordinated the activities in
the headquarters in Aalen. The project
features the following highlights: the
main bore on the water pump housing
is pre-machined using two multi-stage
ISO boring tools based on tangential
technology. In similar projects at LFP
three tools were used for this purpose.
In addition to this saving in tools, the
machining using the MAPAL tools
is also significantly faster. With a
cutting speed of 120 m/min and a feed
per tooth of 0.2 mm the pre-machi-
ning takes significantly less time than
predicted. For the main bore a circula-
rity of 0.05 mm and a concentricity of
0.025 mm are required. For this reason
the fine machining is undertaken
using a multi-stage fine boring tool
with guide pads at a spindle speed
of 540 min-1and a feed of 0.15 mm/
rev. In this way it, is possible to meet
the quality requirements reliably and
machine all steps in the main bore
simultaneously. With the ISO boring
bars used in the past at LFP, there
were often problems with the
concentricity of the individual
steps in relation to each other.
External recess is interpolated.
The interpolation turning
method is used to machine
an external recess. Lower tool
costs with high workpiece qua-
lity at the same time were the
key arguments for this machi-
ning technology. The machine
from SW used is very suitable
for interpolation turning dueto its dynamic performance
and rigidity.
Stockkeeping optimised
MAPAL was also able to meet
the requirement from LFP to
minimise and standardise the
inserts used: The same in-
dexable inserts are used for all
workpiece variants such thatCOM
PLETEM
ACHINING
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Page 21 | MAPAL Impulse
Customer benefits
Leading tool technology
Custom services
Partnership-based collaboration
the stockkeeping is limited to only a
few types. Different tool bodies are
available for varying bore dimensi-
ons on the variants. A call warehouse
in the process of establishment at
MAPAL in Poznan for the necessary
indexable inserts is intended to realise
even more optimisation potential.
Project realisation in record time
Due to the smooth collaboration
between the partners involved, the
machining was accepted after just one
week, a task that normally takes up to
two months. It was therefore possible
to start production earlier than plan-
ned. Reason enough for LFP to invol-
ve MAPAL again in future projects,
as Piotr Nowacki, chief technologist
at LFP, confirms: Our decision to use
MAPAL technology was definitely
correct. We are convinced that this
collaboration will bring many tech-
nical and commercial advantages for
efficient production also in future
projects.
Partnership-based collaboration (f.l.t.r.): PiotrNowacki (LFP chief technologist), ukasz Barteczka(project engineer at SW) and Piotr Jdrzyk (respon-sible salesperson at MAPAL Poland).
Pre-machining of main bore usinga combination tool with ISOindexable inserts.
The fine machining is undertakenusing a multi-stage tool withguide pads.
Your local contact in Poland:
Alexander Zielonka | [email protected] turning is used to produce an external recess.
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Machining of the Sigma engine in Taubat successful due to
modern tool technology and close collaboration
Worldwide collaboration for optimal processes MAPAL and Ford
The Ford Motor Companys Taubatproduction site was founded in 1974and is considered in Brazil to be apioneer in the production of engi-nes, gearboxes and other automotiveparts. Ford Taubat produces 430,000engines and 500,000 gearboxes per
year. The latest production processesare used to machine and assemblethe cast parts. In January this yearFord Taubat was able to achieve twomajor milestones: the total produc-tion of engines passed five million,the production of gearboxes the fourmillion mark.
Ford launched a new series of Sigmaengines in December 2009. This inno-
vative engine generation was develo-ped as a global platform. Ford descri-bes the Sigma engine as light, durable,economical, low noise and lowemission; the engine is manufacturedin Germany, England, Romania andBrazil. 600 million US Dollars wereinvested in Taubat to manufacturethe new engine. As a consequence itwas possible to double the productioncapacity for engines.
Collaboration at global level
Ford approached MAPAL with the taskof designing the machining processfor the Sigma engine, the first engineon which the engine block, cylinderhead and gearbox housing are madeof aluminium. To optimally addressthe requirements on the machiningprocess and to ensure the usage of the
same technology on all productionsites, several MAPAL sites aroundthe world worked together. MAPALEngland was responsible for the engi-neering and the overall co-ordinationof the project. The tools were deve-loped in Aalen and in the Germancompetence centers, and then broken-in and tested in the test center. Forthe production in Brazil, Joo PauloSouza is always on site in Taubatand, together with the team aroundTechnical Manager Rogerio Rodrigues,is responsible for a smooth runningprocess. Duilio Dalla Rosa was respon-sible for breaking-in at the machinerymanufacturer; today he supports theSigma Camaari Industrial Complex in
Camaari. Ford Taubat had alreadyestablished a partnership with MAPALdo Brazil in 2008; this partnership in-
volved the delivery of technologicallyleading tools as well as optimisationservices in production at Ford.
Based on the example of the Sig-ma engine it is clear that significantpotential can still be tapped on site tomake production more cost-effectiveand more reliable. Some highlights
from the Sigma project in Taubat arepresented in the following.
Costs halved during the machining of
the cylinder bores
During the machining of the cast cy-linder bores it was possible to reducethe machining costs by more than50 % due to a continuous process
of improvement and optimisation.Originally a six-cutting edge tool withPcBN blades was used for the ma-chining. The end of the tool life wasreached after 250 parts per cuttingedge. During optimisation the spe-cialists from MAPAL do Brazil wereable to reduce the number of cuttingedges on the tool and at the same timeto triple the tool life. The cycle timeremains unchanged with the currentmachining values (n = 2,400 min-1and vc= 583 m/min, vf= 1,296 mm/min).
More teeth bring higher milling speed
and improved tool life
The sealing faces between theengine block and cylinder blockare machined using an EcoFeedface milling cutter with a diame-ter of 250 mm and 36 teeth. TheEcoFeed face milling cutters areequipped with disposable millingcartridges and therefore involvesignificantly less logistics effortduring handling. The EcoFeedachieves perfect surface finishesdue to exact positioning of the
milling cartridges in the tool bodyand the sensitive wedge adjust-ment of the inserts.
In surface machining at Ford
Taubat it was possible to signifi-cantly improve the performance ofthe EcoFeed by means of optimi-sation on site. While originally it
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Page 23 | MAPAL Impulse
Customer benefits
International project management
Detailed local know-how for optimised processes
Cost reduction by more than 50 %
Your local contact in Brazil:
Sidney Pimenta Paiva | [email protected]
The team at MAPAL do Brazil from left to right:
Technical Manager Rogerio Rodrigues, Duilio
Dalla Rosa, General Manager Sidney Pimenta
Paiva and Mairon Cezar from the engineering
team as well as Joo Paulo Souza, the engineer
responsible in the Taubat works.
Tool for machining valve seat and valve guide.
Significantly increased cost-effectiveness during the machining
of face surfaces on engine block and cylinder head the Eco-
Feed. Engine production at Ford Taubat.
8,500
25,000
3,700
15,000
Engine block machining:
Cylinder head machining:
Before:
New:
Before:
New:
3-times the tool life
was possible to machine 8,500 engine
blocks and 3,700 cylinder heads, the
tool lives are now even more impres-
sive: one EcoFeed face milling cutter
machines 25,000 engine blocks and
15,000 cylinder heads with a cutting
speed of 3,000 m/min and feed rate of
11,000 mm/min.
Successful teamwork
The successful collaboration with Ford
shows how MAPAL is available to as-
sist customers worldwide with know-
how, commitment and a team of spe-
cialists. These days when projects are
often transnational, it is essential to
be able to offer the same product and
engineering know-how in all markets.
With subsidiaries in 21 countries, a
continuous exchange of knowledge at
all levels and the focus on a close re-
lationship with the customer based on
trust, MAPAL is predestined to become
a dependable partner.
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Responsible for the content:
Andreas Enzenbach
Editorial team: A Enzenbach O Munz
Publisher:
MAPAL Przisionswerkzeuge Dr. Kress KG
P.O. Box 1520 D-73405 Aalen
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