New product highlights in the MAPAL tool range · number of services to support ongoing production....

| MAPAL Impulse

Bearbeitung Lenkungs-Spurstangenanbindung, ABS Sensorbohrung und der Information, ideas, internals

New product highlightsin the MAPAL tool range

Nr. 47 | January 2012

Custom PCD milling cut-ter machines slots 1 mm wide in one machining step

PerformanceMill: tangen-tial milling cutter with ISO indexable inserts

Thermally stable bridge tools made of carbon fibre rein-forced plastic

| MAPAL Impulse Page 3 | MAPAL Impulse

News from the MAPAL Group– Many impressed visitors at the EMO in Hanover– MAPAL and BECK receive AEO certificate– 20th Aalen Jazz Festival stages performance at MAPAL with Tingvall Trio

The three important elements during tool selection:

highly productive and cost-effective manufacturing processes –

optimisation – re.tooling

EDITORIAL

A B S O L U T P R Ä Z I S I O N

presented new solutions, tools and services distributed over an area of 500 square metres. The centre point of the presentations was highly produc-tive manufacturing solutions, along with numerous new products in the areas of reaming, drilling and milling. Among others a new type of machi-ning method for the manufacture of wind turbine gearboxes using an ac-tuating tool with a TOOLTRONIC unit was exhibited. “Our already very high expectations were actually exceeded, as such the events at the show set a very positive sign for clear progress in the coming months”, said Dr. Dieter Kress.

MAPAL receives AEO certificateThe Main Customs Office in Ulm has awarded the AEO-F certificate to MAPAL. With this certificate the com-pany is considered by the customs au-thorities to be particularly dependable and trustworthy, and in future will be able to manage the cross-border trade of its goods in international commerce more easily and more efficiently. The AEO certificate was introduced by the EU as part of the development of worldwide standards for the protection of the international delivery chain against risks due to criminal activities, in particular terrorist attacks. With the status AEO-F (full) MAPAL has now been awarded the highest level of the internationally recognised quality mark. The advantages of the AEO-F certificate are faster and easier cus-toms formalities and more transparent transport routes. „With this certificate we have optimal prerequisites for supplying our customers as quickly as

possible“, says Matthias Vossler, head of the MAPAL Logistics department. August Beck in Winterlingen has also successfully passed the AEO-F assess-ment procedure and is registered with the customs authorities as an „autho-rized economic operator“.

Aalen Jazz Festival: The Tingvall Trio plays in Aalen for the 1st timeOn 03.11. MAPAL opened its doors to herald the traditional Jazz Festival. The Tingvall Trio prepared the way for a successful concert weekend. Numerous jazz fans came together in the canteen. Martin Tingvall (piano), Jürgen Spiegel (drums) and Omar Rodriguez (bass) are consummate musicians who love and breathe jazz, and who personify this great music on stage. The two-hour concert was full of entertaining jazz that got under the skin – an evening jazz fans will not forget so quickly.

MAPAL Group Review of the EMO 2011 Page 2 AEO certificate presented to MAPAL Page 3 20th Aalen Jazz Festival Page 3 MAPAL Group MAPAL in Asia Page 4

Title topic MAPAL Competence milling | PerformanceMill Page 6

Product highlight LAT large | Bridge tools in CFRP design | ModulBore Page 8

Report from practice Turntable manufacture at Burghardt+Weber Page 10 CFRP manufacture in Liba factory Page 12 Re.tooling – machining steering rack tube at Mando Page 14

CONTENT

Certainty due to the right pro-cessAs a really comprehensive exhibition for precision tools and machine tools, the EMO 2011 in Hanover has shown just how many precision tools are available. It is difficult to maintain an overview. And above all to make the correct selection.

The time required to make the selec-tion increases with the complexity of the task. The tool with the highest performance for a single, specific task is found comparatively quickly. The search becomes more difficult in the case of components for a high-ly productive machining process. In this case, and if existing machining operations are to be re-designed, it is worthwhile involving the manufactu-rers of precision tools in the selection process. For this purpose MAPAL of-fers a comprehensive range of services based on its extensive knowledge and many years of experience.

MAPAL supports tool selection with three service modules. The Tool Expert Team (TET) develops highly producti-ve and cost-effective manufacturing processes including tool design. The optimisation specialists (TOS) revise

and improve existing machining processes in collaboration with the customer. The third and latest ser-vice module is re.tooling. This ser-vice supports customers during the manufacture of a new part on an existing machine. For this purpose MAPAL designs the entire machining process and, along with the tools, also supplies the fixtures and the CNC programming.

In addition, MAPAL also offers a large number of services to support ongoing production. These services range from re.conditioning, the regrinding and reconditioning of the tools, through TLS, the comprehensive tool logistics, to tool management with billing based on costs per workpiece. Also MAPAL supports the training of customer em-ployees with tailored training courses. So that an overview is maintained not only during the tool selection, but also during daily production.

We are viewing the new year 2012 with confidence and also looking forward to continued excellent colla-boration.

With best wishes

Dr. Dieter Kress

The EMO 2011 in Hanover – machining solutions that inspireThe world‘s largest trade show for machine tools and precision tools, the EMO, took place in Hanover this year. Six days, 2,037 exhibitors from 41 countries and 140,000 trade visitors from all over the world once again honoured the EMO this year. The new trademark concept of the MAPAL Group with the two booths for MAPAL and tool-traders-partner was very successful. The MAPAL Group

Michael Jung (on the left in the photograph) and Jörg Soravia from the Main Customs Office in Ulm presented the AEO-F certificate to Dr. Dieter Kress. On the right in the photograph the presentation of the certificate to Johannes Spengler and Jürgen Lochmann (BECK) by Walter Senn and Michael Jung from the Main Customs Office in Ulm.


PAKISTANPAKISTAN

VIETNAM

CHILE

In the coming years the largest impulse for market growth in the machine tool and precision tool industry will come from the Asian region. The speed and extent of the establishment of high-end modern production facilities are very impressive. The analyses of market potential for the Asian countries fore-cast growth for all these countries in the machine tool manufacturing area and automotive industry in the coming years.

In the wake of this enormous econo-mic upturn, on the one hand Asian businesses have progressed very significantly and, on the other hand, many organisations from the western world have established production fa-cilities there. MAPAL entered this now so important region over 30 years ago. In 1978 a contact was concluded with a representative in Japan. In the meantime the MAPAL Group is now represented with a dedica-ted subsidiary in Japan, as well as in a further seven countries in this region. With a further five representatives, East Asia, South-East Asia and South Asia are covered by an extensive network. The motivation for MAPAL was and is the proxi-mity to the customer and the direct dialogue with the customer. A network was established that ensures perfect customer support and that meets stan-dards comparable to those to be found on other sites in the MAPAL Group. This aspect applies to the engineering, the service and the quality of the products manufactured there. These standards are ensured by over 600 dedicated specialists in the MAPAL

subsidiaries and a further 200 well-trained staff at the representatives in this region. They also receive sup-port from the competence centres in Germany. An example of this issue is the recently agreed expansion of the manufacture of PCD tools in South Korea. With the support of MAPAL WWS, high quality PCD tools are manufactured there using the same production and QA processes as in the competence centre. The high quality standards for MAPAL precision tools also apply to the other product groups such as fine boring tools, ISO-tipped tools and solid carbide tools, whether in China, India, Taiwan or Japan.

High quality, high performance pre-cision tools are, however, only part of the MAPAL success story in Asia. Engineering and services related to the tools and the machining process are a

further key element. Like the overall worldwide MAPAL network, the sub-sidiaries in Asia are also able to offer and implement complete machining solutions.

A recent example of the comprehensi-ve design of original equipment comes from China. Together with the Chinese subsidiary of a European machine-ry manufacturer, the end customer,

Dongfeng Peugeot Citroen Automobile (DPCA), has realised a project for a transfer line for engine manufacture that was entirely implemented in China for the first time. MAPAL China Ltd. was appointed general supplier and in this role was able to prepa-re and implement the complete tool concept and the machining strategy. To be able to meet the tight deadlines specified for the manufacture of the tools, various production sites in Asia and Germany were used.

MALAYSIA

ASIAASIA

THAILAND

PHILIPPINES

A strong network due to local competence


Perfect local customer support ensured also in Asia

„By linking the extensive experience in process design available in the MAPAL Group with the strong teams in the local subsidiaries we are always able to supply our Asian customers with the right solutions“, states Stefan Kühnle, Regional Manager Asia. For instance our subsidiaries in Japan and India are very closely meshed with the machinery manufacturers based there and independently undertake design work that is also destined for custo-mers in other countries such as the USA, China, Thailand or Malaysia. An example of this aspect is a production

line that was built in India for Proton in Malaysia. The planning and design of the tools was undertaken entire-ly in India. After the delivery of the tools, which were manufactured in India and in the MAPAL competence centres, the local service team in Malaysia was able to seamlessly take over and further support the project, with initial assistance from Germany. These are only two cases of many that demonstrate how MAPAL addres-ses and successfully implements the wishes and requirements of globalised organisations.

Customer benefits

– The right machining strategies– Support to all customer production sites at high level – Local presence in eleven countries in the region

SÜDKOREASÜDKOREASÜDKOREA

MAPAL in Asia: China | MAPAL China Ltd. I Shanghai

Phone: +86 / 21 / 54 22 31 77 [email protected]

Indonesia | PT. Trieka Karya Cemerlang Jakarta Utara Phone: +62 / 21 / 65 83 73 68 [email protected]

Japan | MAPAL KK I Saitama Phone: +81 / 48 / 9 49 14 00 info(at)jp.mapal.com

Malaysia | MAPAL Malaysia Sdn. Bhd. Selangor Darul Ehsan Phone: +60 / 03 / 89 61 91 96 [email protected]

Pakistan | TECHNODYN I Pawalpindi Phone: +92 / 51 / 2 52 95 37 [email protected]

Philippines | MESCO Inc. I Pasig City Phone: +63 / 2 / 6 31 17 75 [email protected]

Singapore | MAPAL Sales Office South East Asia I Singapore Phone: +65 / 96 /86 98 05 [email protected]

South Korea | MAPAL HITECO Co. Ltd. Jungwang-Dong Phone: +82 / 31 / 3 19 08 60 [email protected]

Taiwan | MAPAL Precision Tool Systems Co. Ltd. Tainan Phone: +8 86 / 6 / 2 25 22 16 [email protected]

Thailand | MAPAL (THAILAND) Co. Ltd. Bangkok Phone: +66 / 2 / 72 92 51 23 [email protected]

Vietnam | Cap Do Industrial Equipment Co. Ltd. Tan Binh Dist Phone: +84 / 8 / 38 10 84 27 [email protected]

Your contact person for further information:

Stefan Kühnle | [email protected]

Dr. Jochen Kress:

„Asia is a growth region. Due to the strong, local units and competent local staff we can optimally support our custo-mers as they exploit the markets.“

The team at MAPAL China Limited, based in Shanghai, in a team photo during a visit by Dr. Jochen Kress and Armin Kasper.

MAPAL Hiteco, KoreaMAPAL China MAPAL KK, Japan MAPAL Taiwan MAPAL ThailandMAPAL Malaysia


A B S O L U T P R Ä Z I S I O N MAPAL PerformanceMill –the high performance milling range for all application areas

End milling cuttersPerformance-EndMill

Face milling cuttersPerformance-FaceMill

Shoulder milling cuttersPerformance-CornerMill

Disc milling cuttersPerformance-DiscMill

Helix milling cuttersPerformance-HelixMill

Shell end face milling cuttersPerformance-ShellMill

Planfräser Walzenstirnfräser

HP-EndMill

CPMill

Performance-DiscMill

Performance-HelixMill

ISO-Tangential

ISO-Radial

PowerMill

Performance-FaceMill

Performance-CornerMillEcoMill

WalzenstirnfräserISO-Tangential

Performance-ShellMill

1 2 3 4 5 6

OptiMill

HP-FaceMill

The current MAPAL programme includes a broad range of precision tools. As a specialist for the machining of cubic parts, the emphasis is as before on bore machining.However, in recent years MAPAL has developed numerous innovative solutions for milling, in particular for custom tools. These many years of experience and the accumulated know-how are now combined into a comprehensive programme of high performance milling cutters. In future MAPAL will bundle all its competence in milling machining under the name PerformanceMill.

Newly developed milling cutters with ISO indexable inserts are part of the standard programme as are the successful OptiMill® solid carbide end milling cutters, the new replaceable milling cutters CPMill and the PCD-tipped face milling cutters with their red anodised aluminium tool bodies. The Perfor-manceMill milling programme forms a complete range with common performance features – high-est cost effectiveness with maximum performance!

New milling cutters with ISO indexable inserts

The positive experience in the area of high performance custom ISO tools has been implemented in a standard programme for a very wide range of applications. The tangential milling cutters are a special highlight. Reduced cutting forces due to the positive cutting edge geometries lower the drive power required from the machine and as a result increase the efficien-cy. In addition, the soft cutting behaviour results in longer tool lives. The PerformanceMill milling cutters with ISO indexable inserts are designed with high accuracy insert seats and include, along with face and shoulder cutter heads, also shell end face and disc milling cutters as well as the particularly innovative helix milling cutters for shell end face and bore machining. Perfectly matched cutting edge geometries and high performance coatings are basic features of the tangential indexable inserts, which are available in two or four cutting edge designs.

Solid carbide end milling cutters

The MAPAL solid carbide milling cutter program-me contains both monolithic end milling cutters and also a replaceable head system. Under the name OptiMill® the standard programme inclu-des universal end milling cutter types and also types specially designed for specific applica-tions for machining steel, cast iron, aluminium, stainless and composite materials, as well as hard milling. The new MAPAL CPMill milling cutters meet all the requirements on a modern, successful replaceable head system. Along with the milling heads with optimal cutting materials and cutting edge geometries, a high perfor-mance connection is crucial here. The new CFS connection from MAPAL guarantees high radial run-out accuracy and straightforward handling. As a result the replaceable milling cutters CPMill provide the prerequisites for the best possible performance, precision and tool life.

PCD milling cutters

The PCD milling programme for machining non-ferrous metals includes the end milling cutters HP-EndMill with brazed PCD blades and the face milling head systems Power, Eco, and FaceMill. These PCD milling cutters are designed for high performance machining in a very wide range of applications. The end milling cutter programme includes five different milling cutter types with which all common diameters are covered. Whe-ther for milling deep pockets, or machining high ribs, the right milling cutter is available for every machining task. The PCD face milling cutter programme is designed for high removal rates, defined surface roughness or special require-ments on the flatness of the part.

Irrespective of the requirements placed on the tools during the milling,the MAPAL PerformanceMill programme provides the solution.

MAPAL PerformanceMill


Customer benefits

– High flexibility and process reliability– Machining of diameters and contours with one tool- Modular system for roughing and finishing– Dimensional stability due to usage of CFRP for bridge tools

LAT-large and ModulBore for flexibility in new applicationsA B S O L U T P R Ä Z I S I O N

New product highlights in the MAPAL tool programme

MAPAL, as the major specialist for complete machining, is continuously further developing its broad range of precision tools to be able to offer the ideal solution for specific machining tasks. The product highlights listed in the following are primarily intended for application areas in which high flexibility is required due to small to medium lot sizes and a high level of part variation.

Your contact persons for further information:

Christian Schmidt | [email protected] Rettenmaier | [email protected]

Face turning unit LAT-large brings flexibility for large bores

The main requirements on modern tool concepts for machining large bores, for instance in housings for wind turbine gearboxes, are high flexibility and process reliability. Circular or helix milling cutters are very high performance tools for the pre-machining, however these solutions are mostly unsuitable for the final ma-chining. The required tolerances cannot be achieved and it is often necessary to machine contours, recesses or chamfers in addition to the diameter. The new face turning units LAT-large have been especially developed for these applica-tions. The facing slides are powered by a TOOLTRONIC® unit with integrated electric motor that is supplied with energy and data by the machine. The low maintenance, mechatronically controlla-ble facing heads are programmed for the required contour via the NC controller.

LAT-large units are in use at a manufac-turer of wind turbine gearboxes. With a stroke of 75 or 100 mm the diameter range from 230 to 750 mm is covered with only three facing heads. The large facing heads are loaded into the machine tool from a portal loader. Four connection points are used to fix the facing head to the machine. The machining spindle is driven via an HSK 100 connection. For these types of applications, conven-tional actuating tools can be replaced with mechatronic tools that offer a new dimension in flexibility and make possible new machining tasks.

MAPAL ModulBore for ø 6 – 1000 mm

With the new boring programme „Mo-dulBore“, MAPAL is offering a complete system for pre-machining and finishing bores in the diameter range from ø 6 – 1000 mm. Due to its modular const-ruction, the system can be very flexibly configured to the related machining task.

Twin bladed boring tools are available for roughing. These tools are very stable and have high performance due to a face side serration on which the insert holders are mounted. The usage of ISO indexa-ble inserts with positive basic geometry, helical chip spaces as well as internal coolant supply ensure a broad range of applications, a high level of work safety and straightforward handling.The programme includes ModulBore fine boring heads from as small as ø 6 mm. They feature high precision and robust construction, are easy to handle and also

have internal coolant supply. There is no „stick-slip“ effect on the fine adjust-ment of the heads in either adjusting direction; adjustment is therefore very accurate. Worthy of special mention are the ModulBore Plus boring bars and fine boring heads, as well as the ModulBo-re fine boring cartridges. These system components are available with 2 µm fine adjustment; the adjusting system is easy to operate and reliable due to its simple construction.

The ModulBore system components ideally supplement the range of MAPAL custom ISO tools available. The roughing tool components and above all the finely adjustable elements can be integrated into interesting new tool combinations.

ModulBore-Carbon for con-stant accuracy with large diameters

During the fine machining of large bores from approximately 500 mm, steel or aluminium bridge tools reach their limits if the highest accuracies are required with fluctuating temperatures. If the ambient temperature changes or the tool heats up during the machining, there are dimensional fluctuations due to the ther-mal expansion of the material. It is ne-cessary to re-adjust the tool and to make an additional control cut in the part. To avoid this manufacturing effort, MAPAL has developed ModulBore bridge tools with CFRP tool bodies. The coefficient of thermal expansion of CFRP is practically zero and the tool therefore produces with consistent high accuracy even in fluctuating temperatures. The low weight

of the lightweight design is advantage-ous during handling, operation during adjustment is also easy and reliable due to the usage of the ModulBore fine adjustment system. The CFRP design is suitable for bridge tools in the diameter range from 500 – 3,500 mm. The tools can be designed for internal and external machining, as double-bladed tools, with leading stage and finely adjustable stage, as well as single-bladed tools with balan-cing weight.

1 2 3

1 2 3


Burkhardt + Weber relies on MAPAL tools for customer projects and for

in-house manufacture


Highest accuracies for bearing bores in machine turntables

Customer benefits

– Optimal tool concept for pre-machining and fine machining – Bores reliably machined with a length of more than 1.5 m – Optimal support by guide pads for highest quality

Burkhardt + Weber Fertigungssysteme GmbH in Reutlingen is part of the Ita-lian Gruppo Riello Sistemi. Within the corporate group it is the competence centre for precision machining centres and custom machines, primarily for machining large parts. The range of applications stretches from large die-sel engines, industrial gearboxes and wind turbine gearboxes, pumps, parts for printing presses, to precision com-ponents for machine tools. The parts are typically made of steel and cast iron, but also of Inconel or duplex steels. The machines are individually configured and adapted to the ma-chining task for the customers from a very wide range of sectors. Along with the machine, the planning also often involves the necessary fixtures and the tool package for an optimally matched process.

MAPAL tools for projects and in-house manufacture

The quality requirements on the machines are very high at Burkhardt + Weber. Core components such as spindle, tool magazine, pallet chan-ger and machine table are produced in-house in manufacturing areas with a high level of vertical integration. As for its customer projects, for years Burkhardt + Weber has successfully worked together with MAPAL on new tool solutions for in-house manufac-turing. A demanding machining task in which MAPAL tools have estab-lished a commanding position is the

machining of the bearing bore for the shaft for the turntable drive. Along with very close tolerances on the diameter, above all the straightness and the position accuracy of the very long bores are crucial for the optimal function of the worm gear.

Tool solution for turntable housing from a single source

For the fine machining of the bearing bore in turntable housings, Burk-hardt + Weber has relied on MAPAL tools with guide pads for many years. During the production planning for the Burkhardt + Weber MCX 1200, a single-source tool solution was sought for machining the bearing bore that is crucial for the precision of the turntable with ø115H6. Also absolutely reliable machining of the very large and expensive housings is imperati-ve. Re-working or even scrap is not acceptable. The machining length in this turntable housing made of GGG60 requires a tool length of over 1.5 metres, and the total of three bore sections for the shaft bearing must have a concentricity of < 20 µm. The machining is made even more difficult as the bore is interrupted and the tools exit from one section of the bore and have to enter in the next section. As a solution for this demanding task MAPAL developed a tool concept in which the pre-machining and fine machining are optimally matched to each other. The complete machining task was spread over three tools.

Initially a „short“ pilot tool with 500 mm projection length with vc = 80 m/min and vf = 90 mm/min is used for pre-machining.The first stage of the tool is desig-ned with four face side tangential roughing blades. The following two semi-finishing stages machine the pilot diameter for the subsequent ma-chining tasks. During the first of these subsequent tasks the entire length of the bore is initially bored out using a roughing tool. The cutting depth of ap = 10 mm is divided over 2 + 2 tangential inserts, one of the insert pairs is adjustable to be able to adjust the protrusion in relation to the guide pads. The modular tool has guide pads on the tool body for optimal support also during roughing. The roughing head is connected to the tool body via an HSK connection. In this way the

f.l.t.r.: Dieter Eißler (head of technology at Burkhardt + Weber), Harald Friedl (TVT/tool design at Burkhardt + Weber) as well as Sven Frank (MAPAL regional sales manager).

head can be replaced, for example in case of wear. Then the bore is fine machined to ø115H6 using a tool with guide pads; the tool has two blades per diameter is equipped with a pre-machining and fine machining stage. The cutting data are vc = 60 m/min and vf = 30 mm/min. The roughing and fine machining tools each have a projection length of 1550 mm and are moved into the machine compart-ment and fitted in the spindle using a tool pallet. As described, both tools are equipped with MAPAL guide pad technology and as a result achieve values for straightness, cylindrical form and diameter tolerance that cannot be achieved with any other tool with a similar level of process

reliability. The required tolerances are achieved without problems and the personnel responsible at Burkhardt + Weber are very satisfied with the results of the open and objective-orientated collaboration with the

MAPAL specialists.


Oliver Spiller | [email protected] housing with bearing bore shown. 1.5 m long boring bars for roughing and fine machining with guide pad technology.



Ideal collaboration on the machining of CFRP partsCustomer benefits

– Reliable machining of CFRP– PCD tools for high cutting data and tool lives– Combination tool performs 8 machining tasks in one step– Highly accurate cutting edges also with delicate geometries

Liba and MAPAL – two specialists for carbon parts

Liba Maschinenfabrik GmbH in Naila / Franconia is third-generation family business and was founded by Karl Liebrandt in 1945. With approx. 350 staff the organisation develops and manufactures high-tech systems for the production of warp knitted fabrics and non-woven fabrics; here the close collaboration with the customer for the realisation of individual solu-tions is an important factor of the company‘s success. The core product is tricot machines that, in combinati-on with systems for the manufacture of multiaxial non-woven structures, can manufacture a very wide range of semi-finished textile products. At an early stage Liba specialised in the production of systems for special textiles for industrial applications. Among other areas, the specialists at Liba have many years of experience with glass and carbon fibre lamina-tes. Due to the special technology employed in the machines manufac-tured by Liba, non-woven structures can be individually configured and in this way adapted to the properties subsequently required of the part. The application areas are correspondingly varied, while the focus is increasingly on lightweight materials for automoti-ve manufacture and alternative forms of energy generation.

Dimensionally stable CFRP parts improve process reliability

Liba utilises its know-how in the area of CFRP not just for its customers, but

also during the further development of in-house machine technology. As such the so-called warp knitting tool car-rier, one of the core components of a tricot machine, is manufactured from carbon profiles. Up to 8000 needles are mounted on these bars; the spa-cing between the needles must be very accurate for reliable production and the high quality of the required warp knitted fabric. The machines must produce reliably around the clock. As a result the dimensional stability of CFRP with fluctuating temperatures is particularly important so that the textiles are woven with constant pre-cision. In addition, the dynamic forces are reduced by the low weight of the carbon profile.

Machining of carbon profiles

The more than 6 m long carbon profi-les are machined at Liba on a special machine tool manufactured by EiMa Maschinenbau GmbH. MAPAL is a va-lued milling and drilling tool partner for improving the process reliability and productivity of the machi-ning process together with the responsible members of staff at Liba. Mounting slots, various bores and threads are to be machined on thecarbon profiles. Here the typical problems during the machining of CFRP are to be avoided, such as delami-

nation, frayed edges or burnt resin. MAPAL brought its special know-how on solid carbide and PCD tools to the projects and solutions were developed that provide fast, reliable machining.

Eight at once with custom PCD milling cutter

For the bores Liba uses the MEGA-Drill-Composite drill from MAPAL with the UD configuration, that is for unidirectional fibre composite materi-als. The drills are used for instance for tapping bores or fixing bores. MAPAL PCD end milling cutters equipped with cooling ducts are used for trimming. Compressed air is blown through the ducts to keep the chip spaces clear at high spindle speeds of approx. 13,000 1/min. Compared to solid carbide milling cutters, higher gutting data can be used with PCD tools, which si-

gnifies increased output with the long profiles. Various PCD disc milling cutters are a real highlight for the machining of CFRP profiles. Worthy of special mention here is a custom milling cutter that mills eight moun-ting slots in one machining step and is faster and more accurate during this process than would be possible using a single tool.The slots are only 1 mm wide and have a tolerance of 0.02 mm on the spacing. The machining stages are of six edge design and are arranged offseton a spiral. In this way high cutting data are possible without causing the part to vibrate. During the manufacture of the tool the manufacturing know-how of MAPAL is particularly important for the exact implementation

of the total of 48 cutting edges. The spacing and diameter of the cutting edges in relation to each other are subject to tight tolerances and the special cutting edge geometry for CFRP ensures completely burr-free slots. The staff at Liba Maschinenfab-rik GmbH are very satisfied with both the process reliability and the quality and performance of the MAPAL tools.

In the picture from left to right: Markus Pfingst (machine operator at Liba), Ralf Hampl (head of production planning and control at Liba), Ro-land Ernst (production), Reinhold Zornek (techni-cal consultant at MAPAL) Jürgen Burger (machine operator at Liba).


Jens Ilg | [email protected]

Custom PCD milling cutters machine eight slots only 1 mm wide in one machining step.

Tools made of solid carbide and PCD for machining CFRP.

A tricot machine of type Copcentra Twin. Machine for CFRP machining.

t


Customer benefits

– Complete implementation by experienced specialists– Saving in resources, costs and time– Dependable local support

MAPAL re.tooling service: complete process

planning for new workpieces up to commissioning


A perfect team: GROB high performance machines and MAPAL re.tooling

were undertaken by MAPAL staff on the machines at GROB in Mindel-heim. Due to changes in the alumini-um casting at short notice, a further machining step had to be added and various MAPAL solid carbide tools re-vised. „MAPAL has proven itself with its flexibility and speed of reaction“, says the project manager at GROB, Hong Lou.

After preliminary acceptance and demonstration of the process capabili-ty, a further 200 pre-series production parts were manufactured. The specia-lists from MAPAL were also on site during this period to be able to react immediately if necessary. Shortly af-terwards the machines were shipped to the end customer in China. With the final acceptance MAPAL and GROB again jointly confirmed the capabili-

ty of the machine, fixture, tools and process. Hand-over to the customer then followed.With MAPAL re.tooling our customers receive a complete, reliable process from a single source. New projects are realised using the latest technologies in the shortest time with transparent costs.


Frank Stäbler | [email protected]

For many years GROB and MAPAL have collaborated closely and success-fully in the project business. Custo-mers with the highest requirements and demands in manufacturing rely on high performance machinery from GROB and MAPAL tool technology.

For three years GROB has marketed a series of standard machines. Alongside the G350, the G550 series for larger workpieces now completes the product range of the Mindelheim-based ma-chine tool manufacturer. The horizon-tal 5-axis centres impress with their stability, flexibility and performance. For a new project GROB has sold four G350 series machining centres to an automotive supplier. The machines are used for the production of aluminium steering rack tubes in China. The order placed by the automotive supplier on GROB was not just for the sale of the machines. The project also inclu-ded the complete process planning including the design of all tools, the clamping fixture and the NC program, including commissioning in China.

For this project GROB decided for the MAPAL re.tooling service, that is GROB decided to give the entire res-ponsibility for the machining process to MAPAL. GROB was convinced by the many years of experience with the planning of complete tool packages,

the innovative MAPAL tool techno-logy and the know-how related to efficient processes. A further decision criterion for „outsourcing“ the respon-sibility for the process to MAPAL was the very critical schedule due to the high level of utilisation of in-house resources.

MAPAL tools have already been used successfully worldwide for machi-ning aluminium steering rack tubes for a number of years. MAPAL has extensive experience here and offers a cost-effective solution for every re-quirement. Special MAPAL PCD tools have become established in the series production manufacture of these parts.

MAPAL re.tooling in practice

The new project started with the de-finition of the process and machining strategy, a cycle time study, as well as a draft clamping concept to enable the entire part to be manufactured on a 5-axis machining centre in one clam-ping system. The most cost-effective

machining sequence and the optimal tools for this strategy as well as a detailed collision analysis are crucial factors here.This work was immediately followed by the manufacture of the tools and the clamping fixture. In parallel MA-PAL prepared the NC program for the machine controller.

The project manager Timo Killinger from MAPAL reports: „Due to the close collaboration with fixture and tool design as well as the NC pro-grammer, it was possible to prepare a high performance overall process in a very short time“.

Both the installationof the process as wellas the fine tuning of the NC program

f.r.t.l.: Hong Lou (project manager at GROB), Roman Kutzner (MAPAL regional sales mana-ger) and Timo Killinger (project manager at MAPAL re.tooling).

Innovative and cost-effective MAPAL tool technology.

Everything from a single source – MAPAL takes over complete project responsibility.

GROB G350 – machining centre for the highest requirements.

»Yes, you are right. It is not just the individual tool that counts, but the overall solution. Parti-cularly if we are saving tool costs and machi-ning time. And that over the entire period of use.

For me this is the MAPAL effect.«

Machining solutions that inspire.

Machining large bores with high materi-al removal rate

With MAPAL helix milling cutters, large bores can be machined with high material removal rates in one machining step.

The result: subsequent tools are not re-quired and the machining time is reduced by 50 - 80 %.

Machining solutions that inspire.

Find out more about the MAPAL effect: www.mapal.com/effektQ

R-Co

de

Perfekt für Sie gemacht.


IMP4

7-E-

01-0

80-0

212-

WD

Prin

ted

in G

erm

any.

Righ

t of

tec

hnic

al m

odifi

catio

n re

serv

ed.

Machining large bores with high materi-


Perfekt für Sie gemacht.Perfekt für Sie gemacht.

Responsible for the content: Hermann Steidle

Editorial team: H. Steidle, A. Duda, O. Munz, M. Schwenninger, M. Winter

Design: I. Rettenmaier

Publisher:MAPAL Präzisionswerkzeuge Dr. Kress KGP.O. Box 1520 D-73405 AalenPhone +49 7361 585-0 Fax 07361 [email protected] www.mapal.com

IMPR

ESSU

M

New product highlights in the MAPAL tool range · number of services to support ongoing production....

Documents

Transcript of New product highlights in the MAPAL tool range · number of services to support ongoing production....