mapal competence – pcd tools

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MAPAL Competence –PCD Tools

A Review of MAPAL’s Competence

Reaming and Fine BoringFrom the wide range of single and twin-bladed reamers with guide pads, together with fineboring tools with guide pads and WP or HX blades, to the HPR High Performance Reamerscombined with the MAPAL HFS® Head Fitting System for exact concentricity and accuratechangeover – to give you a general view of our complete knowledge and experience in precision machining bores.

PCD ToolsFor pre-machining and finish machining, MAPAL also offers an extensive programme of precision tools with fixed PCD (polycrystalline diamond) blades. This includes precision gunboring tools plus circular and end milling tools. The programme of face milling heads from the PowerMill and EcoMill series is characterised by simple, sturdy design and rapid, accurateblade setting.

ISO ToolsThis aspect of MAPAL competence is made up of special tools with ISO elements for gunboring and milling. This includes precision ground blades in the widest variety of cuttingmaterials and coatings. The use of MAPAL's tried and tested adjustment system ensures thatthe blades are accurately matched to the task. MAPAL offers particular knowledge and ex-perience in tangential technology.

Generating Slide ToolsGenerating slide tools offer a high potential for rationalisation and optimisation on specialmachines and machining centres. In addition to the conventional facing heads, MAPAL alsosupplies EAT and LAT performance-enhanced actuating systems for generating slide tools.MAPAL TOOLTRONIC® tools with their extraordinary range of functions are the latest develop-ment.

DrillingYet another area is the product programme for drilling. MAPAL offers the right tool conceptfor every task, whether for machining aluminium, steel or cast iron, hard machining or drymachining or for use in HSC areas. Specially developed coatings and PCD blades complete the broad-based drilling programme.

Clamping SystemsMAPAL's modern clamping systems, in conjunction with MAPAL's tried and tested reamingand fine boring tools, guarantee maximum productivity and economy. Whether HSK, ISO orHFS®, these high-precision connections and interfaces provide the concentricity and change-over accuracy essential to modern production.

Customer ServicesProject planning, maintenance, management and optimisation – the complete CTS® servicepackage from MAPAL will accompany you from process design to permanent process optimi-sation and will ensure optimum and cost-saving use of your tools with the best possibleresults. PK

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MAPALMAPAL WWS Werner Stief GmbH

Heilbronner Straße 25 • D-75179 PforzheimTel. +49 (72 31) 96 63-0 • Fax +49 (72 31) 96 [email protected] • www.mapal.com

MAPAL Präzisionswerkzeuge Dr. Kress KG

P.O. Box 1520 • D-73405 AalenTel. +49 (73 61) 5 85-0 • Fax +49 (73 61) 5 85-1 [email protected] • www.mapal.com

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ABS housing

Anti-locking brake systems for carsare now an integral part of the automobile industry. Electronicallycontrolled braking systems preventthe wheel from locking.

ABS housings are safety related components which are subject to acpk analysis. The increasing demandsfor tolerances, burr-free results andan extremely low Si content in thematerial make cutting operations achallenge. In particular extremelyhigh stipulations are made formachining bores in engines andpumps. Decisive factors for success-ful production are surface finish,accuracy, concentricity and inter -relating positions. For bores in pumpsmaximum tolerances of IT 7 with asurface finish of Ra 0.2 µm apply.

Solid carbide tools for pre-machiningtogether with tools with fixed PCDblades and fine boring tools withguide pads are typical tools for thesecomponents.

PCD is a fascinating cutting material,which has ever since its development,more than 30 years ago, won an extre-mely high importance for the machi-ning of aluminium, also increasingly ofCFRP and other modern materials.MAPAL WWS was part of thedevelopment right from the verybeginning and can call itself a pioneerof the introduction of PCD inmechanical machining.Decisive was the introduction of theeroding process for the machining ofPCD blades. It was with that possible toeconomically machine this extremelyhard cutting material with highest pre-cision.

In combination with the HSKconnection the manufacturing andutilisation of rotating tools becamepossible with high complexity for themachining of aluminium and non-ferrous metals. The results are excellenttool lives and with that the basis forthe rational manufacturing, even ofcomplex components.

Brilliant – tools with PCD (polycrystalline diamond)have captured the world!

The handling of the tools generallyproduced in monoblock constructionform is very simple. Care must be takenthereby of the precision of the machinespindle and the tool clamping.

MAPAL has built up a world-widenetwork of companies for technicalconsultation for the designing andutilisation of PCD tools, as well as theservicing, tipping and optimisation.With this a highly qualified and promptservice is guaranteed for these tools –also world-wide. This guarantees thehuge success story for PCD tools willbe continued.

Dr. Dieter Kress

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MAPAL WWS Competence –Precision gun boring 18

Who’s counting the applications opportunities? 20From experience – guidelines and cutting values in practice 22Machining examples 24

MAPAL WWS Competence –Circular milling and end milling 28

We manufacture to size 30HP-EndMill – standard programme 32From experience – guidelines and cutting values in practice 38Machining examples 40

MAPAL WWS Competence –Face milling 44

The perfect standard tools 46The perfect solution for every machining task 48PowerMill and EcoMill series 50Face milling heads – standard programme 54Machining examples 66

After Sales and Customer Services 70

Fast Repair – repairs and service 72Milling Head Management –a dependable performance level right from the start 74Pick-up-Service – direct from the customer 76

PCD tools made to measure 78

Quality from quotation to production 80Enquiry form for drilling and gun boring operations 82Enquiry form for milling operations 83

Our experience is second to none 84

Machining examples 86

Our CompetencePCD diamond as a high-tech product 4Taking the lead – ideas, products and services 6Precision – the perfect geometry for every tool 8Competence centre – MAPAL WWS in Pforzheim 10PCD tools – worldwide competence and global network 12PCD tools – from precision gun-boring to circular milling 14

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When the first polycristalline diamond(PCD) was introduced at the beginningof the 1980s it brought a revolution inthe development of cutting materialbut also a revolution in tool manu-facturing.How did this come about?At approximately 1,500°C and at apressure of approximately 60 kbar anexceptional quality of synthetic dia-mond, together with a carbide substrate, was subjected to a sinteringprogramme. An extremely complicatedchemical process then followed.Cobalt, a chemical component of car-bide, acted as a catalyst and caused anintensive structural change in the indi-vidual diamond particles. This inten-

sive structural change a sensation,providing a cutting material with thehardness and wear resistance of dia-mond, the hardest material on earth.The carbide substrate gave the cuttingmaterial the necessary strength andunder day-to-day machiningconditions offered the best possibleconditions for brazing the blades ontosuitable carriers. At the beginning theblade size for these so-called PCDblanks was limited but sizes are nowavailable up to a diameter of 75 mm.

A cutting material of this hardness wasa tough nut to machine, in the truestsense of the word. The familiar grind-ing methods were not suitable so new

PCD –Diamond as a high-tech product

ones were developed and refined to perfection. Wire erosion and laser technology are now state of the art. The originally limitations to cuttingforms and geometries no longer exist.

In just 30 years PCD has developed intothe super cutting material for machin-ing non-ferrous metals and non-metal-lic component materials and it would be impossible to imagine modern pro-duction technology without it.

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Just as with conventional cuttingmaterials, such as carbide, there areconsiderable variations in quality inthe cutting edge. Various machiningtasks and the variable abrasiveness ofthe material require variations in cut-ting materials. The results of our manyyears of experience in diamond bladeshave been an amazing range of modifi-cations using different PCD grades.Different grain sizes in the microstruc-ture of the diamonds can be variedwith a selection of coating thicknesses

combined with a number of blanksizes. Irrespective of the machiningtask for which you require a PCD blade,this allows us, to select the right dia-mond quality.

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ideas, products and servicesConstantly increasing demands onmodern cutting operations require amodern, highly flexible approach fromthe tool manufacturer. Our compe-tence in dealing with PCD cuttingmaterial is reflected in day-to-day tooldesign.The ongoing objective is to combineseveral machining tasks with one tool.For the user this means that unproduc-tive ancillary time for tool change isdispensed with.Not infrequently tool concepts occuras a result of this motivation which areunique in design. We are becomingmore competent in this way thinking

and acting as a result of high produc-tion reliability when manufacturingthe tools. However, constant develop-ments in machining PCD are not suffi-cient in themselves. Any parameterswhich are required for tool manufac-turing need to be constantly drivenforward. Examples are modern brazingmethods and filigree balancingsystems. The high potential perform-ance by our products, enhanced by theenormous technical competence of ourapplication specialists, are guaranteesfor success in solving the tasks whichare faced.

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Precision –the perfect geometry for every toolThis principle is a thread runningthrough all areas of the organisationlike the symmetry line through thetechnical drawing of a tool. With thesame precision as that required in thedetailed design of every blade, theimplementation of these details iseffected in all the production areas.Manual work stations are thus in har-mony even in the most modern opera-tions with fully automatic productionunits. An intelligent computer systemfor controlling production routines and

constant quality assurance – all build-ing blocks which fit perfectly together.The highest priority for all the workstations is precision and quality. Com-plete documentation of all the pro-cesses and inspection procedures toaccompany the process are the basisfor the constantly high quality level of all tools. The result of all theseendeavours is rational and reliableproduction at the customers’ works.

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The precision on the tool cannot betried out but simply produced. It istherefore essential that even duringthe preliminary sequences, such aswhen separating PCD sections from theblank or brazing, work is carried outextremely carefully. Only tools whichhave been perfectly produced rightfrom their basic assembly on the toolcarrier can achieve a tolerance range ofa few microns with high precisionoperations such as electrical dischargemachining or PCD grinding.

Competence Centre –MAPAL WWS in Pforzheim/Germany

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Consistent quality at all sites isensured by MAPAL WWS which hasbeen the competence centre for theMAPAL Group for all fixed, brazed PCDtools since 1994. This means that thecustomer can rely on the same highMAPAL quality throughout the worldin engineering, product programmeand customer service.

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With a workforce of more than 500people worldwide, the PCD tool prod-uct group is one of the most importantof the MAPAL divisions. A sales andservice network with branches in morethan 40 countries on every continentguarantees the best possible consulta-tion and customer care at theirproduction sites.

One important element of this networkis engineering on site, with whichMAPAL can react swiftly and flexibly tocustomer requirements. By constanttraining and further training for per-sonnel and worldwide exchange of

experience, MAPAL ensures the samehigh technical standards are providedeverywhere. That means the customerreceives the best solution for him,whether in Europe, America or Asia.

The production of MAPAL PCD tools innumerous countries also guaranteesflexibility, rational delivery times andhigh tool availability. The network forproduction and repair of PCD tools isconstantly being expanded.

The MAPAL Group in figures• More than 3,300 employees• 26 subsidiaries• 17 production sites• 30 service and consultation offices

EuropeGermany MAPAL Dr. Kress KG in Aalen

MAPAL WWS GmbH in PforzheimMAPAL ISOTOOL GmbH in SinsheimMILLER GmbH in AltenstadtRudolf Strom GmbH in Vaihingen/Enz

England MAPAL Ltd. in RugbyFrance MAPAL France

in Le Chambon FeugerollesItaly MAPAL Italia S.R.L. in Gessate/MIPoland MAPAL Narzędzia Precyzyjne

Spółka z.o.o. in PoznańCzech Republic MAPAL CZ s.r.o. in Dlouhá Lhota

AmericaUSA MAPAL Inc. in Port Huron/MIMexico MAPAL FRHENOSA

in San Pedro Garza GarciaBrazil MAPAL do BRASIL Ferramentas de

Precisão Ltda. in IbiritéMAPAL Qualifer Ltda. in Belo Horizonte

AustraliaAustralia Valcor Australia Sales Pty. Ltd. in Ballarat

AsiaChina MAPAL China Ltd. in ShanghaiKorea MAPAL HTT Co. Ltd. in Kyunggi-Do

MAPAL TET Office Asia in UlsanJapan MAPAL KK in TokyoIndia MAPAL INDIA Private Ltd. in BangaloreMalaysia MAPAL Malaysia Sdn. Bhd.Singapore MAPAL Asia TET Office in SingaporeTaiwan MAPAL Precision Tool Systems Co. Ltd.

in TainanThailand MAPAL (Thailand) Co. Ltd.

Worldwide – MAPAL Group sites

PCD tools –worldwide competence and global network

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Germany – MAPAL WWS GmbH in Pforzheim

England – MAPAL Ltd. in Rugby

France – MAPAL France in Le Chambon Feugerolles

Italy – MAPAL Italia S.R.L. in Gessate/MI

Production sites for fixed,brazed PCD tools

Service centresCzech Republic MAPAL CZ s.r.o. in Dlouhá LhotaMexico MAPAL FRHENOSA in San Pedro Garza GarciaJapan MAPAL KK in Tokyo

USA – MAPAL Inc. in Port Huron/MI

Brazil – MAPAL do BRASIL Ferramentas de PrecisãoLtda. in Ibirité

China – MAPAL China Ltd. in Shanghai

Korea – MAPAL HTT Co. Ltd. in Kyunggi-DoO

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India – MAPAL INDIA Private Ltd. in Bangalore Taiwan – MAPAL Precision Tool Systems Co. Ltd. in Tainan

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PCD tools –from precision gun boring to circular milling

Gun boring – the challengeThe bore defines the func-tion. In almost all cases thequality of a product dependson the precision of the boreswithin it. Both static anddynamic tasks and functionsare effected by the bores.For tools for manufacturingbores of this kind the nameMAPAL WWS is a mark ofquality and economics. Thealmost unlimited designoptions for the PCD blade forthe relevant tools presentunimaginable opportunities.Several machining tasks canbe easily combined with onetool. The saving of tools andelimination of unproductiveancillary times improve theproduction economics at thecustomers’ works.The manufacture of a step-ped bore for which all thechamfers and radii have tobe machined is solved withone tool. The concentricityof the individual steps isguaranteed. Even machining

axial grooves or spot facingmounting faces can be eco-nomically resolved with oneboring tool. As no radial for-ces affect the component,requirements for flatness orangular precision can be metmany times more easily thanwith conventional turning orcircular operations. Machin-ing of a complex externalcontour, for example on adome, is another applicationfor efficient drilling opera-tions. By designing the toolin the form of a bell, the com-plete machining operationcan be carried out in theaxial direction. Even the large

allowance which is fre-quently present with appli-cations of this sort, can besafely dealt with. Cuttingdepths of more than 4 mmper side are not infrequentlyachieved. Irrespective of theproduct – whether this is anefficient combustion enginefor a sports car or a set ofmixer taps for the bathroom– the bore defines the func-tion.

Circular milling – the formis decisiveAs always it is an advantageto carry out certain opera-tions by circular milling.When machining hydraulic

parts control edges have tobe produced in the relevantpiston bore. Often severalgrooves are required whichare axially offset to oneanother. Sometimes all theseslots have different forms.These are decisive factors forusing PCD tools. Frequentlythis allows several opera-tions to be combined withone tool. The complete formis then produced in onecircular movement on themachine.This is only possible becauseof the harmonic cuttingbehaviour of the PCD blade.Cutting forces are limited toa minimum and the tenden-cy to produce chatter doesnot arise. Radial grooves onexternal contours can beeconomically produced bycircular milling. For this thetool is designed as a bellwith the blades located onthe internal contour of the

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tool. With a radial deflectionof a few millimeters thegroove can be produced witha very slight circular move-ment.Because the PCD does notproduce burring the manu-facture of threads is increas-ingly significant. Cross holeswhich occur in thread flanksset extremely high demandsfor follow-on machining onthe parts. By using PCDthread milling cutters sub-sequent machining is totallyunnecessary.

End mills – pure perform-anceEnd mills with PCD bladesare currently still attractinglittle attention for use onmodern machining equip-ments. The large range ofstandard end mills in solidcarbide is probably theexplanation for this. How-ever, it is in this particulararea that there are numer-ous arguments for using PCDend mills. Costly eroding toproduce forms, such as thoseproduced from graphite orlarge dimensioned integral

components for aircraftproduction, require long toollife and reliability from themilling cutters used.Particularly highly abrasivematerials cause wear to beproduced unchecked on mil-ling blades for solid carbidemilling cutters. The result isthat distortions in geometryoccur on forms or the requir-ed corner radii are not pro-duced. It is in these casesthat the enormous potentialof PCD end mills can be

demonstrated. The recognis-ed advantage of long toollife for PCD cutting materialcan be directly applied.Time-consuming reworkingon formed parts or prepara-tion of sister tools is no lon-ger required. The specificallyadapted standard program-me of PCD end mills is de-signed directly for theseapplication areas.

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PCD tools – production reliability for pre-machining and finish machining

Face milling – the classictoolSimple but sturdy construc-tion combined with the facil-ity to change and adjustmilling cartridges at extreme-ly low cost makes this pro-duct a classic among PCDtools. Numerous applicationprovide daily proof of thereliability of the milling headsystem. Logically developed,adapted to the needs ofmodern cutting, the range ofuses stretch from conven-tional milling operations tohigh speed cutting. The intel-ligent directing of the cool-ant through the tool alsoallows successful use ofminimal lubrication. Because

of the high diversity ofgeometry in the standardrange of milling cutters, theuser is always able to use theprefect blade for differentcomponent materials. Themilling cartridges, which canbe set axially to high preci-sion, along with the appro-priate tool holder, achievesurface finishes and tool lifewhich speak for themselves.

Reaming and fine boring –precision to perfectionIn addition to PCD precisiongun boring tools with fixedblades the product program-me for reaming and fineboring includes precision

tools with replaceable, dia-mond-tipped blades andguide pads and PCD-tippedmulti-bladed reamers. Fortools with guide pads, inaddition to PCD blades forlong tool life and particular-ly good surface finish, dia-mond guide pads are alsoused for their extremelygood sliding properties andwear-resistance.

Because of MAPAL’s long-established principle, thesetools, which can also beused in the HSC area, areparticularly impressive inhigh precision areas.

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But it is not only in alumin-ium machining that MAPALtools are tipped with PCD asa cutting material for ream-ing and fine boring. Inno-vative tool solutions for useon cast iron materials allowfollow-on operations previ-ously required to be dis-pensed with, such as grind-ing and honing.MAPAL tools for reamingand fine boring have becomethe byword for absoluteprecision and reliability inmodern production through-out the world.

Gun boring and milling –with ISO InsertsA further product area isspecial tools with diamondtipped ISO Inserts. Variousmounting and adjustmentoptions for the blades en-sure exact concentricity andtherefore maximum tool life.The extensive experienceand numerous innovativeideas provided by the MAPALspecialists produce extreme-ly successful tool concepts.

With HPR high precisionreamers MAPAL offers a pro-gramme of fixed PCD tippedmulti-bladed reamers forfine machining bores.Because the coolant is sup-plied directly onto the blade,the HPR reamers are alsowell suited for use withminimal lubrication. In con-junction with the HFS® HeadFitting System, concentricityand changeover accuraciesare achieved to extremelyhigh precision and providethe prerequisite for newdimensions in modern highperformance cutting.

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Gun boring tools produced to high precision guaran-tee reliable application for every machining task.Various tool designs – with two, four or six blades –ensure perfect dimensional stability and highaccuracies of form in the bores to be produced. High tool rigidity is achieved, particularly where tooldimensions are small, by using carbide as the carriermaterial.

• Who’s counting the application opportunities?

• From experience – guidelines and cutting values in practice

• Machining examples

Competence – Precision gun boring

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produced are all factorswhich are perfectly met bythese tools. The quality ofthe precision ground PCDblade is the absolute maxi-mum. 100,000 bores are notunusual. Maximum care inproduction guarantees totalefficiency both from thenew tool and even when thishas been reconditioned.

The extensive experienceprovided by MAPAL WWSspecialists is clearly demon-strated in gun boring tools inthe quality of the toolswhich are produced. Thedesign of the tools, which isperfectly adapted for theapplication in question,increases productivity andproduction reliability in use.The high requirements forbalance and the guaranteedconcentricity of the blades

MAPAL WWS Competence – Precision gun boringWho’s counting the applications opportunities?

Getting to grips with thechipLaser eroded chip breakersallows optimum clearancefrom the working area ofmaterial which has beenremoved. This means thatstoppages in ongoingproduction caused by chipjams are avoided.

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Modular – the solutionTo achieve therequired concen-tricity on thespindle, modulartool holder sys-tems are used.Axial and radialadjustment facili-ties allow therequired concen-tricity to beobtained, in par-ticular onmachines withISO spindles.

The blade –precision indetailProduction toler-ances of ≤ 3 µmfor tool diameters,multiple bladesand back taperallow demands onthe blade to beanticipated. Theresult is reflectedin every bore.

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Al < 4%Si 300 – 1.200 0,1 – 0,4 0,1 – 4,0

Al 4–8%Si 200 – 1.000 0,1 – 0,4 0,1 – 4,0

Al 9–13%Si 100 – 800 0,08 – 0,2 0,1 – 4,0

Al > 13% Si 100 – 800 0,05 – 0,2 0,1 – 3,0

Magnesium alloys 200 – 1.000 0,1 – 0,4 0,1 – 4,0

Copper alloys 100 – 500 0,05 – 0,2 0,1 – 4,0

Brass alloys 200 – 1.000 0,05 – 0,15 0,1 – 4,0

Graphite 250 – 1.500 0,01 – 0,1 0,1 – 2,0

Gfk – Cfk 200 – 1.800 0,03 – 0,25 0,1 – 3,0

Material Cutting speed Feed/blade Cutting depthvc (m/min) fz (mm) (mm)

From experience –guidelines and cutting values in practice

PCD gun boring tools are individual toolsolutions which are specially designed fora specific application. To present recom-mendations for cutting values whichcover all possibilities in a table would beunrealistic. Too many factors have a directeffect on the machining result. Differentwall thicknesses, cross bores or interrup-

tions can affect the system. The valuesshown in the diagram should therefore beregarded as guidelines. MAPAL WWSspecialists would be pleased to offer youtheir knowledge and experience to findthe solution to special requirements.

The highest priority forrough boring with PCD toolsis the multiple cutting func-tion of the tool. The run-outerror measured for the toolon the machine spindleshould not exceed 5 µm. Forcritical bores or fits thisshould only be a maximumof 3 µm. To monitor thiscriterion concentricity checkpoints are located on thetool right next to the blades.Here the user can have adirect influence on the tool’sconcentricity. The accuracy

of the cutting track for theblades can be improved bymeans of axial and radialadjustment screws, forexample on modular toolholders, or simply by turningthe tool in the hydraulicexpanding chuck.

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Examples from practice – for use in practice

Bore too large

Cause?• Tool diameter may be too

large• Cutting speed too high• Feed too high• Run-out error too high• Cutting lead uneven• Coolant unsuitable

Bore too small

Cause?• Tool worn• Cutting speed too low• Feed too low• Ductile material –

contracts after machining• Allowance insufficient

Bore tapered

Cause?• Run-out error too high• Cutting lead not correct• Pre-machining not correct

Bad surface in bore

Cause?• Coolant unsuitable• Build-up on cutting edge• Tool blunt – possible

fracturing on blade• Chip removal bad• Residual imbalance too

great

Bore has chatter marks

Cause?• Build-up on cutting edge• Tool blunt• Coolant unsuitable• Run-out error too high• Residual imbalance too

great• Clamping set-up not

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Bore has feed grooves

Cause?• Tool blunt, possible

fracturing on blade• Build-up on cutting edge• Coolant unsuitable

Bore is convex

Cause?• Workpiece not correctly

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Valve housingMaterial: • Aluminium (AlMgSi1)Tool: • MAPAL WWS

stepped gun boring toolCutting material: • PCDRequirement: • Gun boring without interim

machining operation• Bore quality:

D 32.5D10 mmD 34.2F8 mmD 38.0A11 mm

Allowance: • 13.5 mm per sideResult: • Surface quality Rz = 0.34 µmMachining values: • Spindle speed n = 4,500 rpm

• Feed per tooth fz = 0.08 mm

Material: • Aluminium (AlMgSi0.5)Tool: • MAPAL WWS

stepped gun boring toolCutting material: • PCDRequirement: • Burr-free cross bores

• Bore quality:D 4.6M7 mmD 10.0H9 mmD 13.15H8 mmwith all chamfers

Allowance: • 0.4 mm per sideResult: • Tool life more than

100,000 boresMachining values: • Spindle speed n = 5,000 rpm


MAPAL WWS Competence - Precision gun boringMachining examples

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Material: • Aluminium (GDAlSi9Cu3)Tool: • MAPAL WWS

stepped gun boring toolCutting material: • PCDRequirement: • Gun boring with spot facing

• Finish machining in precast bore– without pre-machining!

• Stepped face machining from D 30 to 93 mm with integral holetolerance D 76H8 mm

• Interrupted cut• Different allowances• Double spindle used

Result: • Tool life more than 20,000 boresMachining values: • Spindle speed n = 1,100 rpm


Cylinder head

Pump housing

Material: • Aluminium (AlSi7MgCu0.5)Tool: • MAPAL WWS gun boring toolCutting material: • PCDRequirement: • Machining hydraulic lifter bore

• D 12G7 mm; because of statisticalproduction control, however,limited to IT6 quality

• Problem: blind bore with severalinterruptions

Result: • Tool life approx. 75,000 boresMachining values: • Spindle speed n = 12,000 rpm


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Pump housing

Housing Material: • Aluminium (AlSi12Cu1 Fe)Tool: • MAPAL WWS

stepped gun boring toolCutting material: • PCDRequirement: • Bell machining

incl. face surface• D 32.0±0.075 mm / 27.99–0.05 mm• Length of fit approx. 70 mm

Result: • Tool life more than 30,000bores

Machining values: • Spindle speed n = 6,000 rpm• Feed per tooth fz = 0.038 mm

MAPAL WWS Competence - Precision gun boringMachining examples

Special feature: • Tool with integral PCD soliddrill for machining threadedcore bores on face side. Thisallows a tool to be saved.

Material: • Aluminium (GDAlSi9Cu3)Tool: • MAPAL WWS

stepped gun boring toolCutting material: • PCDRequirement: • Finish machining pump chamber

• Interrupted cut throughout• Bore diameter D 47H8 mm• Double spindle used• Surface quality Rz max = 10 µm

Result: • Surface quality Rz max = 1–2 µm• Tool life more than 20,000 bores


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Material: • Aluminium (AlMgSi0.5)Tool: • MAPAL WWS

stepped gun boring toolCutting material: • PCDRequirement: • Bell machining with variable

allowance• Double spindle used• D 17.35±0.05 mm• D 22.6±0.25 mm• Twice R1±0.08 mm• Surface quality Ra = 1.6 µm

Result: • Surface quality Ra = 0.7 µmMachining values: • Spindle speed n = 6,500 rpm


Clutch housing

Adaptor

Material: • Aluminium (GD AlSi9Cu3)Tool: • MAPAL WWS

stepped gun boring toolCutting material: • PCDRequirement: • D 11.8R7 mm

• D 70.62±0.025 mm• D 80.034±0.019 mm• D 146.885±0.035 mm• D 147.7±0.1 mm• Maximum tool weight 8 kg• Surface quality Ra = 0.8 µm

Result: • Tool weight 5.8 kg incl. tool holder• Require surface finish achieved

Special feature: • Tool body in titanium• Combination tool – 4 machining

operations combined with one tool

29

These tools represent high performance cutting.Extremely high precision when eroding the blades,best balancing quality on the tool and the excellentcutting properties of diamond – the combinationreaches new dimensions in milling. Precision andlong tool life – the bywords for this product family.

• We manufacture to size

• HP-EndMill – standard programme

• From experience – guidelines and cutting values in practice


Symbols for quick reference to find the right end mill:

Type

Single and multi-bladed

Blade over centre

Full radius; blade over centre

Spiral blade arrangement

Coolant

External coolant

Internal coolant

Tool holder

Cylindrical shank

HSK-A

ISO/BT

Competence – Circular milling and endmilling

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when the chip moves over thecutting surface are advantageswhich are directly reflected inthe milling performance of thetool in question. The machine’spower consumption is notice-ably lowered and the processitself becomes more stable.This also has a very positiveeffect on the life of the tool.

Optimum contouraccuracyIntricate grooves,transition radii orchamfers – almostany contours can be produced on thePCD blade withoutdistortion. It is alsonot unusual forseveral features tobe on one tool.

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MAPAL WWS Competence –Circular milling and end millingWe manufacture to size

Bell machiningThe economic solutionfor machining externalcontours. The toolmakes a small circularmovement around thecomponent.

Milling with PCD blades – aneven more economic solutionJust as with milling thisproduces all the advantages ofthe diamond blade – withoutcompromising the machiningresult. The extreme hardness ofthe diamond combined withthe toughness of the carbideoffers the best combination foreffectively milling. These prop-erties are further enhanced as aresult of the highly polishedchip surface. Low forces whencutting off the chip and thereduced coefficient of friction

31

For MAPAL WWS it is qualityand not the quantity whichtakes centre stage. The stan-dard programme HP-EndMillis divided into five sections.Milling cutters designedspecifically for an applicationcan also be supplied in theshortest possible time.

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Optimum geometryThe spirally arrangedchip space geometryand the division ofcut on the bladeallows extremely high rates of stockremoval when roughmilling.

The standard end millprogrammeIt is the intention with thisproduct series to restrict it tothe most important elements.Tables which are hard tofollow sometimes stretchingover several pages of the cat-alogue, confuse and causeuncertainty in selecting theappropriate tool.

32

4,0 4,0 60 12 10 45 0,1x45° 0° 7-50041-10

5,0 5,0 60 13 10 45 0,1x45° 0° 7-50051-10

L2L3

L4

L1

d 1 h

10

d 2 h

6

Dimensions in mm.

Milling cutter Shank Overall Chip groove Blade Shank Cutting Axial angle Orderdiameter diameter length length length length lead No.d1 h10 d2 h6 L1 L2 L3 L4

Design:Milling cutter diameter: 4,0 – 5,0 mmNo. of blades: 1 (cutting over centre)Shank form: HA (DIN 6536)Axial angle: neutralCoolant supply: external (standard),

internal (on request)

The smallest PCD milling cutters ø 4 and 5 mm, designed for intricate milling tasks,e.g. in precision mechanics or for manu-facturing printed circuit boards.

MAPAL WWSHP-EndMillType 50

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6,0 6,0 60 12 10 45 0,1x45° 0°/2° 7-51061-__*

6,0 6,0 60 17 15 40 0,1x45° 0°/2° 7-51062-__*

6,0 6,0 80 22 20 55 0,1x45° 0°/2° 7-51063-__*

8,0 8,0 80 12 10 60 0,1x45° 0°/4° 7-51081-__*

8,0 8,0 80 18 15 60 0,1x45° 0°/4° 7-51082-__*

8,0 8,0 80 22 20 50 0,1x45° 0°/4° 7-51083-__*

10,0 10,0 80 12 10 50 0,1x45° 0°/4° 7-51101-__*

10,0 10,0 80 18 15 50 0,1x45° 0°/4° 7-51102-__*

10,0 10,0 80 22 20 50 0,1x45° 0°/4° 7-51103-__*

12,0 12,0 100 15 10 70 0,1x45° 0°/4° 7-51121-__*

12,0 12,0 100 20 15 70 0,1x45° 0°/4° 7-51122-__*

12,0 12,0 100 24 20 70 0,1x45° 0°/4° 7-51123-__*

L2L3

L4

L1

d 1 h

10

d 2 h

6

Dimensions in mm.

Axial angle positiveAxial angle negativeAxial angle neutral

Axial angle neutral –10

Axial angle negative –20

Axial angle positive –30

Blade form Through blade

*Order number plus required blade form (see table below and order example).

Milling cutter Shank Overall Chip groove Blade Shank Cutting Axial angle Orderdiameter diameter length length length length lead No.d1 h10 d2 h6 L1 L2 L3 L4

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This series from ø 6 to 12 mm with variouscutting edge lengths is the universal geniusin the end mill programme. All tools have ablade up to the centre, which means thatdrilling can also be used. The applicationrange extends from contour milling work onGfk and Cfk components to slot milling workand deburring on cast aluminium parts.

Design:Milling cutter diameter: 6,0 – 12,0 mmNo. of blades: 2 (cutting over centre)Shank form: HA (DIN 6535)Axial angle: neutral, negative or positiveCoolant supply: internal (standard),

external (on request)

Order example for HP-EndMillwhere d1 = 6,0 mm, blade length L3 = 10 mm,axial angle neutral, through blade.Order No.: 7–51061–10

MAPAL WWSHP-EndMill

Type 51

34

4,0 4,0 60 12 10 45 2,0 0° 1 7-52041-10

6,0 6,0 80 12 10 65 3,0 0° 1 7-52061-10

8,0 8,0 80 12 10 60 4,0 0° 2 7-52081-10

10,0 10,0 80 12 10 50 5,0 0° 2 7-52101-10

L2L3

L4

L1

d 1 h

10

R

d 2 h

6

Dimensions in mm.

Milling cutter Shank Overall Chip groove Blade Shank Radius Axial angle No. of Orderdiameter diameter length length length length blades No.d1 h10 d2 h6 L1 L2 L3 L4 R Z

Design:Milling cutter diameter: 4,0 – 10,0 mmNo. of blades: 1 or 2 (cutting over centre, with full radius)Shank form: HA (DIN 6535)Axial angle: neutralCoolant supply: internal (standard), external (on request)

Not just of interest to form designers. Theseball-head end mills are characterised by thehigh accuracy of form of the full radius. Thetools with numbers of teeth from Z 1 to Z 2,according to diameter range, are notable fortheir quiet running – not just in the HSC area.


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L2L3

d 1 h

10

L4

L1

d 2 h

6

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6,0 8,0 55 10 5 40 R 0,2 2° 2 7-53065-30

8,0 8,0 60 12 5 40 R 0,2 4° 2 7-53085-30

10,0 10,0 75 12 5 55 R 0,2 4° 2 7-53105-30

12,0 12,0 85 12 10 60 R 0,2 6° 2 7-53121-30

14,0 16,0 85 12 10 60 R 0,2 6° 3 7-53141-30

16,0 16,0 85 12 10 60 R 0,2 6° 3 7-53161-30

20,0 20,0 100 12 10 50 R 0,2 6° 3 7-53201-30

L2L3

L4L1

d 1 h

10

d 2 h

6

Dimensions in mm.

Milling cutter Shank Overall Chip groove Blade Shank Cutting Axial angle No. of Orderdiameter diameter length length length length lead blades No.d1 h10 d2 h6 L1 L2 L3 L4 Z

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Design:Milling cutter diameter: 6,0 – 20,0 mmNo. of blades: 2 or 3Shank form: HA (DIN 6535)Axial angle: positiveCoolant supply: internal

The high performance product group in thestandard range. Specially designed for highsettings and tooth feeds. In principle thesetools are designed with internal coolant.Machining of closed pockets is carried outwith these milling cutters by plunge millinginto the workpiece. This is readily achievedwithout reducing the feed rate even wherethere is no central blade.

MAPAL WWSHP-EndMill

Type 53

HP-EndMill type 53 – Z 3

HP-EndMill type 53 – Z 2

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16,0 16,0 100 50 30 50 0,1x45° 15° 3 7-57083-00

20,0 20,0 100 50 30 50 0,1x45° 15° 3 7-57103-00

25,0 25,0 110 50 30 50 0,1x45° 15° 3 7-57123-00

L2

L3

d 1 h

10

L4

L1

d 2 h

6

can also be accessed with this type ofmilling cutter by plunge milling. A highperformance end mill programme withwhich long tool life can be expected.

Dimensions in mm.

Milling cutter Shank Overall Chip groove Blade Shank Cutting Axial angle No. of Orderdiameter diameter length length length length lead blades No.d1 h10 d2 h6 L1 L2 L3 L4 Z

Design:Milling cutter diameter: 16,0 – 25,0 mmNo. of blades: 3Shank form: HA (DIN 6535)Axial angle: positiveCoolant supply: internal

High removal rates in cutting are easilyproduced with this type of end mill. Thespirally arranged rows of blades are bestsuited to high volume cutting, for examplefor integral components. The availabledrive power can then be perfectly appliedfor cutting large volumes. Closed pockets


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L2

L3

d 1 h

10

A

L2

L3

d 1 h

10

A

37

32,0 100 50 30 HSK-A 63 0,1x45° 15° 3 7-57163-04

40,0 100 60 40 HSK-A 63 0,1x45° 15° 3 7-57204-04

50,0 100 60 40 HSK-A 63 0,1x45° 15° 4 7-57254-04

63,0 100 60 40 HSK-A 63 0,1x45° 15° 4 7-57314-04

32,0 100 50 30 SK 40 0,1x45° 15° 3 7-57163-01

40,0 100 60 40 SK 40 0,1x45° 15° 3 7-57204-01

50,0 100 60 40 SK 40 0,1x45° 15° 4 7-57254-01

63,0 100 60 40 SK 40 0,1x45° 15° 4 7-57314-01

32,0 100 50 30 BT 40 0,1x45° 15° 3 7-57163-02

40,0 100 60 40 BT 40 0,1x45° 15° 3 7-57204-02

50,0 100 60 40 BT 40 0,1x45° 15° 4 7-57254-02

63,0 100 60 40 BT 40 0,1x45° 15° 4 7-57314-02

Dimensions in mm.

Milling cutter Dimension Chip groove Blade Shank Cutting Axial angle No. of Orderdiameter A length length form lead blades No.d1 h10 ±0,02 L2 L3 Z

Design:Milling cutter diameter: 32,0 – 63,0 mmNo. of blades: 3 or 4Shank form: HSK–A 63, ISO 40

(DIN 69871 AD/B), BT 40Axial angle: positiveCoolant supply: internal

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MAPAL WWSHP-EndMill

Type 57

HP-EndMill type 57 – ISO 40

HP-EndMill type 57 – HSK–A 63

38

task. Small milling cutter diameters withlarge feeds would be debatable, just asroughing with a tool diameter of 20 mmin conjunction with a low cutting depth.MAPAL WWS specialists are happy to beof assistance with their knowledge andexperience in solving special requirements.

The PCD HP-EndMill is characterised bythe high multiple cutting performance ofthe individual cutting edges. Productiontolerances of ≤ 5 µm for radial and axialrunning ensure the actual multiple cut-ting performance. Thermal expandingchucks or mechanical pneumatic chucksare the best means of clamping thesetools. One further important point for use, particularly under HSC conditions, is balance. Optimum conditions areachieved if the milling cutter and the tool holder are balanced together.

For end milling with high chip volume thecutting values are adjusted to the poten-tial performance of the machine. Becauseof the significantly lower cutting forceswith PCD milling cutters compared to sol-id carbide tools, settings or teeth feedrates can be increased to reach the limitsof the machine’s performance. Selectionof the appropriate setting should ofcourse be made at a sensible level for the

Al < 4%Si 500 – 5,000 0.05 – 0.2 0.1 – 5.0

Al 4–8%Si 500 – 4,000 0.05 – 0.2 0.1 – 5.0

Al 9–13%Si 400 – 3,800 0.05 – 0.2 0.1 – 5.0

Al > 13% Si 250 – 3,000 0.03 – 0.15 0.1 – 3.0

Magnesium alloys 300 – 6,000 0.05 – 0.3 0.1 – 4.0

Copper alloys 300 – 6,000 0.05 – 0.4 0.1 – 3.0

Brass alloys 300 – 5,000 0.05 – 0.25 0.1 – 4.0

Graphite 250 – 2,500 0.05 – 0.2 0.1 – 3.0

Gfk – Cfk 250 – 4,000 0.08 – 1.0 0.1 – 5.0

Material Cutting speed Feed/blade Cutting depthvc (m/min) fz (mm) (mm)

From experience – guidelines and cutting values in practice

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Q = ae · ap · vf1000

vf = fz · Z · n

D · π · n1000vc =

vfZ · n

fZ

fz = =

f = fz · Z

n =vc · 1000

D · π

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Calculation fz eff for peripheral milling with small ae (up to approx. 0.25 · D)

fz eff = fz D/ae

ae effective cutting width (mm)ap cutting depth (mm)D tool diameter (mm)π 3.14159…Z number of teeth

Machining factor Mathematical symbol used Unit Formula

Spindle speed n (min-1)

Cutting speed vc (m/min)

Feed per blade fz (mm)

Feed per revolution fu (mm)

Feed rate vf (mm/min)

Chip-to-chip volume Q (cm3/min)

Examples from practice – for use in practice

40

Material: • Aluminium (AlSi17CuMg)Tool: • MAPAL WWS milling tool Z 3

(spiral blade arrangement)• D 67.4• with internal coolant

(coolant pressure 70 bar)• Tool holder HSK 80

Cutting material: • PCDRequirement: • Pre-machining bearing race for crank

shaft bearing• Pre-machining into the solid (bearing

race is not pre-cast)Result: • Tool life 650 m

• Machining into the solid possibleMachining values: • Spindle speed n = 2,600 rpm


Cylinder crankcase

MAPAL WWS Competence – Circular milling and end millingMachining examples

Material: • Aluminium (GDAlSi12Cu1)Tool: • MAPAL WWS combination

tool• Milling operation Z 4• Tool operates as bell

Cutting material: • PCDRequirement: • Machining complete external

contour with all radii andchamfers

• Double spindle usedResult: • Required accuracy of form

fully achievedMachining values: • Spindle speed n = 8,000 rpm


Steering box

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M_PKD_S_28-43.QX 14.02.2008 15:22 Uhr Seite 40

41

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Material: • Aluminiumforged and heat-treated (AlSi1)

Tool: • MAPAL WWS combination tool Z 4• with internal coolant

Cutting material: • PCDRequirement: • Groove located in an axial slot

• Groove width 2.8 mm with R 0.4 at base and chamfer at entry

• Circular form 0.02 mm (statistically checked)

Result: • cpk value achieved > 2.2Machining values: • Spindle speed n = 12,000 rpm

• Feed per tooth fz = 0.1 mmSpecial features: • For safety reasons the tool is

designed as a bell with a closedring in front of the blades

Material: • Polypropylene (PPH 2250)Tool: • MAPAL WWS ball nosed

milling cutter Z 1• Combination tool with internal

coolant• D 120 mm with R 109.70.1 mm

Cutting material: • PCDRequirement: • Complete contour produced in

a single cutResult: • Required accuracy of form

easily achieved• Reduction in machining time

by 30 %Machining values: • Spindle speed n = 2,000 rpm

• Feed rate vf = 400 mm/minSpecial features: • Machining into the solid

• Aluminium disc as swarfprotection plate

Plastic housing for medical technology

Flange

42

Material: • Aluminium (GDAlSi9)Tool: • MAPAL WWS circular milling

tool Z 4• with internal coolant

Cutting material: • PCDRequirement: • Machining holding slots

• Spaces between grooves ± 0.03 mm

Result: • Machining of all holding slotspossible in a single cut


Special features: • Machining grooves (5 at atime) carried out in half shell

• Tool deflection prevented bymeans of a solid carbide corein the tool

Cylinder headCam shaft bearing bore

Material: • Aluminium (EN AC-AlSi12CuFe)Tool: • MAPAL WWS milling tool Z 5

• Combination tool with internalcoolant

• ISO 40 toolholderCutting material: • PCDRequirement: • Required surface finish

• Ra = 0.8 µm (face surface)Result: • Surface finish requirement

easily metMachining values: • Spindle speed n = 8,000 rpm

• Feed per tooth fz = 0.08 mmSpecial features: • 2 machining operations with one

tool on a PCD plate• Groove with D 55H12 mm• Face milling on face of bore

Gear housing for gate drive system

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MAPAL WWS Competence – Circular milling and end millingMachining examples

43

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Material: • Aluminiumforged and heat-treated (AlSi1)

Tool: • MAPAL WWS thread milling toolZ 2

• with internal coolantCutting material: • PCDRequirement: • Threaded bore with cross boresResult: • Burr–free in cross bore when

using PCD thread milling toolMachining values: • Spindle speed n = 12,000 rpm

• Feed per tooth fz = 0.1 mmSpecial features: • With a solid carbide thread mil-

ling tool a burr is created in thecross bores. This previouslyrequired a 100 % inspection andthe parts to be re-machined.

Flange

Material: • Aluminium wrought alloy (AlSi1)Tool: • MAPAL WWS

HP–EndMill Z 3• D 20 mm• Blade length 20 mm

Cutting material: • PCDRequirement: • Reduction in machining time

• Machining previously with solidcarbide tool

Result: • Increase in cutting results with endmill HP–EndMill by 30 %

Machining values: • Spindle speed n = 18,000 rpm• Feed per tooth fz = 0.18 mm• Effective cutting width ae = 20 mm• Cutting depth ap = 10 mm

Special features: • Machining from the solid• 90 % of blank part becomes swarf

Integral component

45

Cutting depth max. 2 mm

High feed rates

Finish machining on unstable parts

Replaceable milling cartridges

EcoMill seriesEcoFeed EcoSpeed EcoFix

Cutting depth max. 4 mm

High feed rates

Finish machining on unstable parts

Milling cartridges can be reground

Special milling cartridges possible

PowerMill seriesPowerFeed PowerSpeed PowerFix

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Programme summary and help for selection

High stock removal rates, defined surface uniformityor special requirements for the flat surface of thecomponent – irrespective of what requirements areset for face milling on the tool. MAPAL WWS facemilling heads offer the solution.

• Maximum precision as standard

• The optimum solution for every machining operation

• PowerMill and EcoMill series

• Face milling heads – standard programme

• Milling cutter arbors


Competence – Face milling

46

A low cost 24-hour regrind-ing service with the Power-Mill series or use of replace-able milling cartridges withthe EcoMill series offer achoice of two versions.

With the PowerMill andEcoMill series, this productfamily, which is designed tosuit every imaginable require-ment for face milling opera-tions, is impressive in anumerous areas. The com-ponents, which are reducedto a sensible minimum, to-gether with the simple butstudy construction, ensureuncomplicated and extreme-ly fast tool setting. Differentnumbers of teeth allow thebest possible tool to beselected so that maximumeconomy can be achievedwith the milling process.

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MAPAL WWS Competence – Face millingThe perfect standard tools

47

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Controlled chip clearancefrom the effective workingarea and brushing processesafter the milling operationare probably the most fre-quently used applications ofvariations from the standardprogramme. MAPAL WWSsupplies tool designs whichalso allow these problems tobe easily solved.

To complement the standardPowerMill and EcoMillseries, MAPAL WWS alsoconstantly provide specialsolutions for face millingtools which are designed fora specific application.

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The perfect solution for every machining task

49

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Special design milling cartridgesIn addition to milling heads with special dimen-sions, milling cartridges which vary from thestandard are repeatedly supplied for individualmachining tasks. These are designed by MAPALWWS for use in the PowerMill series.

for his machining operationbut his machine is restrictedby the maximum possibletool diameter. As a specialsolution MAPAL WWS offerslaterally flattened millingheads for this – so-calledbeam milling cutters. Withspindle orientation themachine can then be ‘out-witted’.

Complete machining opera-tions, with which faces andspacing can be produced in asingle milling pass, are notunusual. For these applica-tions the classic milling headsystem is then used as a discmilling cutter version.Face milling operationswithin housings or millingoperations in which theeffective working point is ata distance from the spindlenose often lead to vibrations.Here the PowerFix seriesvariation with special vibra-tion damping elements with-in the milling cutter bodyare particularly good. Byusing this tool solution theoperation often becomeseconomic for the first time,even under HSC conditions.

It is not unusual for the userto have the problem that amilling cutter is needed witha large blade cutting track

50

The PowerMill series, the classicamongst all the milling heads, hasbeen constantly adapted to meet thegrowing demands of cutting operations.The main difference to the EcoMillseries lies in the milling cartridge. With the PowerMill series the millingcartridges are designed with largerPCD blades. In addition to the greatercutting depth up to a maximum of 4 mm, this also allows regrinding.Because of accurate production to fitthe aluminium body, the high precisionmilling cartridge guarantees perfectcircular movement of the blades.

Locking screwAdditional lockingscrews allow reliable usein HSC operations.

Swarf protection platesReplaceable swarf protection platesincorporated into the milling head ensurethe aluminium body has a long life.

PCD PT blade PCD wide face milling blade PCD facing blade PCD corner blade

Regrindable milling cartridgesMaximum cutting depth 4 mm.

under ISO 1940/1) is achieved bymeans of lateral balancing screws. Aparticularly innovative feature is thecoolant screw which, in addition toholding the head on the milling arbor,also enables coolant to be passed fromthe centre.

Easy setting for the milling cartridge isachieved with an adjustment screwwhich together with the additionallocking screw ensures perfect seatingfor the blade in the tool body. Thismeans there are no problems whenused under HSC conditions. The enor-mously high balancing quality (G2.5

PowerFix Face milling headPowerFeed Face milling headPowerSpeed Face milling head

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MAPAL WWS Face milling heads in the PowerMillSeries – PowerSpeed, PowerFeed and PowerFix

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PCD corner blade PCD facing blade PCD wide face milling blade PCD PT blade

Replaceable milling cartridgesMaximum cutting depth 2 mm.

SettingSensitive wedge adjustmentallows the blades to be setwith maximum precision foraxial running.

EcoSpeed Face milling head EcoFeed Face milling head EcoFix Face milling head

the aluminium tool body. Centrifugalforces which occur during machiningare compensated for by a precisiondovetail guide. The new arrangementof the milling blades with integralswarf protection plate clearly increasesthe life of the milling cutter body. Per-fect surface finish is achieved with thismilling cutter as a result of the sensi-

tive and effective wedge adjustment onthe blades in the Z direction. Initiallydesigned for finishing operations, thismilling head is notable for extremelyquiet running which it easily achievesdespite the high feed rates.

The EcoMill series, with the EcoSpeed,EcoFeed and EcoFix systems, representa new dimension in face milling forHSC operations. The series includesnumerous innovations. By usingreplaceable milling cartridges thereduction in logistics costs from handling is also impressive, likewisethe positioning of the milling blade in

MAPAL WWS Face milling heads in the EcoMillSeries – EcoSpeed, EcoFeed and EcoFix

52

Face milling heads PowerMill and EcoMill – easy handling for high precision results

• Locate the face milling head in the setting fixture• Fit the milling cartridge on the basic body using

holding screws • Pre-adjust the milling cartridge with adjusting

screws

• Tighten holding screws with 14 Nm

• Finely adjust the milling cartridgewith adjusting screw

With the PowerMill series fine adjustment is carried out after the millingcartridge has been finally fitted and the appropriate torque applied. The adjust-ment screws which have been specially developed for this series allow the bladesto be perfectly adjusted. The design of the milling cartridge allows an adjustmentrange of at least 1 mm.

PowerMill series – fine adjustment with adjusting screw

The efficiency of a Milling Head Sys-tem is not just demonstrated by theclassic assessment factors. Cuttingresults, tool life or surface finishachieved and even tool planning are ofprime importance. A further importantfactor for a successful system, how-ever, is handling. A minimum of ex-tremely simple hand movements mustbe achieved to prepare the millinghead at the tool setting stage for useon the machine. It is not unusual, par-ticularly in large cutting organisations,

to also recondition the face millingheads at the end of their life within thecustomer’s own tool managementsystem. A decisive factor here is thathigh precision blade setting can becarried out with the least possibleamount of work. It is only in this waythat reliable batch production can beobtained even with reground millingcartridges.

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Based on this technology, a new type of wedge adjustment was developed for theEcoMill series. Here the adjusting element has a wedge-shaped surface which liesdirectly against the milling cartridge. By turning the right-hand and left-handthreaded spindle the axial running can be effortlessly set within the required high-precision range. Combined with the easy handling, the accuracy to beachieved surpasses all the previous results.

• Position face milling head in setting fixture• Fit milling cartridge with holding screw onto basic

body• Adjust milling cartridge roughly with adjusting

screw

• Tighten holding screw at 8 Nm • Finely adjust milling cartridge with adjustingwedge

EcoMill series – with wedge adjustment

A decisive factor for this is the preci-sion with which the milling tool bodyand also the milling cartridges arethemselves manufactured. Costly set-ting devices, time-consuming settingprocedures and expensive settingequipment are not required. One set-ting fixture, whose construction isdesigned for the primary requirement,plus a precision indicator, is quitesufficient.

High precision fine adjustmentThe basis for perfect finish machiningof a milled surface is the exact axialsetting of all the blades to maximumprecision. This factor was given partic-ular attention when designing thePowerMill and EcoMill series. Whilewith conventional face milling cutters,whose technology is often based onclamped blades, these have to be posi-tioned in 3 planes in relation to eachother, here setting in one direction isquite sufficient.

54

max 4

d 1*

d 2d 1*

125/140

63 3 48 22 Steel 25.000 0,85 7-01063-01

63 5 48 22 Steel 25.000 0,80 7-21063-01

80 5 50 27 Aluminium 25.000 0,75 7-01080-01

80 6 50 27 Aluminium 25.000 0,75 7-11080-01

80 7 50 27 Aluminium 25.000 0,80 7-21080-01

100 6 50 32 Aluminium 21.650 1,08 7-01100-01

100 8 50 32 Aluminium 21.650 1,20 7-21100-01

125 8 63 40 Aluminium 18.550 2,20 7-01125-01

125 10 63 40 Aluminium 18.550 2,20 7-21125-01

125 12 63 40 Aluminium 18.550 2,25 7-41125-01

140 10 63 40 Aluminium 18.550 2,40 7-01140-01

160 10 63 40 Aluminium 14.990 2,75 7-01160-01

160 12 63 40 Aluminium 14.990 2,80 7-21160-01

180 10 63 40 Aluminium 13.500 3,40 7-01180-01

200 12 63 60 Aluminium 12.200 4,15 7-01200-01

250 15 63 60 Aluminium 9.760 6,70 7-01250-01

315 18 80 60 Aluminium 7.750 13,35 7-01315-01

400 24 80 60 Aluminium 6.100 21,40 7-01400-01

500 30 80 60 Aluminium 4.880 34,50 7-01500-01

Spin

dle

spee

d n

max

(rpm

)

Milling head diameter d1

Dimensions given in mm.*d1 depends on type of milling cartridge, see page 57.Supplied as follows: Face milling head with all accessory parts.Milling cartridges and milling cutter arbor not included.For milling cartridges see page 57. For accessories and spare parts see page 63.For milling cutter arbors see page 64 and 65.L.H. version available on request.

Spindle speed n max for PowerSpeed Face milling head

Milling head No. of Setting Tool holder Material Spindle speed Weight incl. Order No.diameter blades dimension diameter basic body n max milling cartridges basic body

d1* Z EM (±0,05) d2 (rpm) kg R.H.

Design:Milling cutter diameter: 63 – 500 mmNo. of blades: 3 – 30Coolant supply: internal

MAPAL WWSFace milling head – PowerSpeed

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55

max 4

d 1*

d 2d 1*

63 8 48 22 Steel 25.000 0,80 7-04063-01

80 8 50 27 Aluminium 20.000 0,75 7-04080-01

100 10 50 32 Aluminium 18.000 1,20 7-04100-01

125 13 63 40 Aluminium 16.000 2,20 7-04125-01

160 18 63 40 Aluminium 13.000 2,15 7-04160-01

180 20 63 40 Aluminium 11.500 2,60 7-04180-01

200 24 63 60 Aluminium 10.000 4,40 7-04200-01

250 30 63 60 Aluminium 8.000 7,00 7-04250-01

315 38 80 60 Aluminium 7.000 14,10 7-04315-01

400 50 80 60 Aluminium 6.100 22,10 7-04400-01

Spin

dle

spee

d n

max

(rpm

)


Spindle speed n max for PowerFeed Face milling head

Dimensions given in mm.*d1 depends on type of milling cartridge, see page 57.Supplied as follows: Face milling head with all accessory parts.Milling cartridges and milling cutter arbor not included.For milling cartridges see page 57.For accessories and spare parts see page 63.For milling cutter arbors see page 64 and 65.Special version with greater number of teeth available on request.L.H. version available on request.

63 8 6 Steel

80 8 max. 10 Aluminium or steel



160 18 max. 28 Aluminium

Millling head No. of teeth Material –diameter Standard version Special basic body

d1 Z Z


d1* Z EM (±0,05) d2 (rpm) kg R.H.

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Design:Milling cutter diameter: 63 – 400 mmNo. of blades: 8 – 50 (standard)Coolant supply: internal

MAPAL WWSFace milling head – PowerFeed

d 1*

max 4

d 1*

56

Drehzahlen n max für Planfräskopf PowerFix

Dimensions given in mm.*d1 depends on type of milling cartridge, see page 57.Supplied as follows: Face milling head with all accessory parts.Milling cartridges not included.For milling cartridges see page 57. For accessories and spare parts see page 63.Special version with greater no. of teeth available on request.L.H. version available on request.

Spin

dle

spee

d n

max

(rpm

)


Spindle speed n max for PowerFix Face milling head

50 4 max. 6 Steel

63 5 max. 8 Steel

80 5 max. 10 Steel

100 6 max. 15 Steel

Milling head No. of teeth Material –diameter Standard version Special basic body

d1 Z Z

50 4 100 HSK-A 63 Steel 25.000 1,55 kg 7-44050-01

63 5 100 HSK-A 63 Steel 24.360 2,0 kg 7-54063-01

80 5 100 HSK-A 63 Steel 22.000 2,65 kg 7-54080-01

100 6 100 HSK-A 63 Steel 19.000 3,7 kg 7-64100-01

50 4 100 SK 40 Steel 25.000 1,75 kg 7-45050-01

63 5 100 SK 40 Steel 24.360 2,2 kg 7-55063-01

PowerFix Face milling head – HSK-A 63

Design:Milling cutter diameter: 50 – 100 mmNo. of blades: 4 – 6 (standard)Shank form: HSK-A 63, ISO 40

(DIN 69871 AD/B)Coolant supply: internal

Milling head No. of Setting Shank form Material Spindle speed Weight incl. Order No.diameter blades dimension basic body n max milling cartridges basic body

d1* Z EM (±0,05) (rpm) kg R.H.

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MAPAL WWSFace milling head – PowerFix

57

02 PowerMill 1 6°

2 3°

3 0°

1 ≤ 5 µm ≤ 5 µm

2 ≤ 10 µm

3 ≤ 20 µm

4 > 20 µm

max

475°

d1d1 + 1 mm

R

αβ

d1

β

α

d1 - 2 mmd1

7 - 02 6 1 1 - 0 2m

ax 4

90°

d1 + 1 mmd1 = Nominal ø

2 PCD

5 carbide

1)PT blade: Only top rake No. 3 (0°) can be selected

Type No. 9 PT bladeType No. 8 Wide face milling blade Type No. 7 Facing bladeType No. 6 Corner blade

Milling cartridges

No. Cutting material

0 R.H.

1 L.H.

No. Running direction

e) Running direction f) Cutting material

d) Blade form

No. Type No. 6 (corner blade) Type No. 8 Type No. 9 Type No. 7 (facing blade) (wide face milling blade) (PT blade)

Required Rz value Required Rz value(on part) Radius (on part)

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No. Top rake

6 Corner blade

7 Facing blade

8 Wide face milling blade

9 PT blade1)

No. TypeNo. Series

a) Series b) Type c) Top rake

Milling Cartridges forMAPAL WWS Face milling heads

from the PowerMill series• Max. cutting depth: 4 mm

• Suitable for regrinding

d) Blade forme) Running directionf) Cutting material

c) Top rakeb) Typea) Series

58

d 1*

d 2

max 2

d 1*

63/80

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Dimensions given in mm.*d1 depends on type of milling cartridge, see page 61.Supplied as follows: Face milling head with all accessory parts.Milling cartridges and milling cutter arbor not included.For milling cartridges see page 61.For accessories and spare parts see page 63.For milling cutter arbors see page 64 and 65.Milling head diameter d1

Spin

dle

spee

d n

max

(rpm

)

Spindle speed n max for EcoSpeed Face milling head

Design:Milling cutter diameter: 63 – 400 mmNo. of blades: 5 – 28Coolant supply: internal

MAPAL WWSFace milling head – EcoSpeed

63 5 48 22 Aluminium 33.000 0,40 7-05063-01

80 6 50 27 Aluminium 33.000 0,70 7-05080-01

100 8 50 32 Aluminium 29.500 1,10 7-05100-01

125 10 63 40 Aluminium 25.500 2,20 7-05125-01

160 12 63 40 Aluminium 22.200 2,80 7-05160-01

200 16 63 60 Aluminium 18.100 4,20 7-05200-01

250 20 63 60 Aluminium 14.500 6,70 7-05250-01

315 24 80 60 Aluminium 11.500 12,90 7-05315-01

400 28 80 60 Aluminium 9.000 21,30 7-05400-01


d1* Z EM (±0,05) d2 (rpm) kg R.H.

59

d 1*

d 2

max 2

d 1*

63/80Milling head diameter d1

Spin

dle

spee

d n

max

(rpm

)

Spindle speed n max for EcoFeed Face milling head

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63 8 48 22 Aluminium 33.000 0,42 7-06063-01

80 10 50 27 Aluminium 33.000 0,75 7-06080-01

100 14 50 32 Aluminium 29.500 1,20 7-06100-01

125 18 63 40 Aluminium 25.500 2,20 7-06125-01

160 24 63 40 Aluminium 22.200 2,80 7-06160-01

200 28 63 60 Aluminium 18.100 4,30 7-06200-01

250 36 63 60 Aluminium 14.500 6,80 7-06250-01

315 46 80 60 Aluminium 11.500 13,00 7-06315-01

400 58 80 60 Aluminium 9.000 21,60 7-06400-01


d1* Z EM (±0,05) d2 (rpm) kg R.H.

Design:Milling cutter diameter: 63 – 400 mmNo. of blades: 8 – 58 (standard)Coolant supply: internal

MAPAL WWS Face milling head – EcoFeed

Dimensions given in mm.*d1 depends on type of milling cartridge, see page 61.Supplied as follows: Face milling head with all accessory parts.Milling cartridges and milling cutter arbor not included.For milling cartridges see page 61. For accessories and spare parts see page 63.For milling cutter arbors see page 64 and 65.Special version with greater number of teeth available on request.

d 1*

max 2

d 1*

60

Dimensions given in mm.*d1 depends on type of milling cartridge, see page 61.Supplied as follows: Face milling head with all accessory parts.Milling cartridges not included. For milling cartridges see page 61.For accessories and spare parts see page 63.Special version with greater number of teeth available on request.

Spin

dle

spee

d n

max

(rpm

)


Spindle speed n max for EcoFix Face milling head

Milling head No. of Setting Shank form Material Spindle speed Weight incl. Order No.diameter blades dimension basic body n max milling cartridges basic body

d1* Z EM (±0,05) (rpm) kg R.H.

50 6 100 HSK-A 63 Steel 27.000 1,50 7-08050-04

63 8 100 HSK-A 63 Steel 27.000 1,85 7-08063-04

80 10 100 HSK-A 63 Steel 25.000 2,50 7-08080-04

100 14 100 HSK-A 63 Steel 20.000 3,55 7-08100-04

50 6 100 SK 40 Steel 27.000 1,65 7-08050-05

63 8 100 SK 40 Steel 27.000 2,05 7-08063-05

Design:Milling cutter diameter: 50 – 100 mmNo. of blades: 6 – 14

(standard)Shank form: HSK-A 63, ISO 40

(DIN 69871 AD/B)Coolant supply: internal

EcoFix Face milling head – HSK-A 63

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MAPAL WWSFace milling head – EcoFix

61

07 EcoMill 1 6°

2 3°

3 0°

1 ≤ 5 µm ≤ 5 µm

2 ≤ 10 µm

3 ≤ 20 µm

4 > 20 µm

max

275°

d1d1 + 1 mm

R

αβ

d1

β

α

d1 - 2 mmd1

7 - 07 7 1 2 - 0 2m

ax 2

90°

d1 + 1 mmd1 = Nominal ø

2 PCD

5 carbide

c) Top rakeb) Typea) Series

d) Blade forme) Running directionf) Cutting material

No. Cutting material

1)PT blade: Only top rake No. 3 (0°) can be selected

Type No. 6 Corner blade Type No. 7 Facing blade Type No. 8 Wide face milling blade Type No. 9 PT blade

Milling cartridges

No. Running direction

0 R.H.

f) Cutting materiale) Running direction

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No. Type No. 6 (corner blade) Type No. 8 Type No. 9 Type No. 7 (facing blade) (wide face milling blade) (PT blade)

Required Rz value Required Rz value(on part) Radius (on part)

d) Blade form

No. Top rake

6 Corner blade

7 Facing blade

8 Wide face milling blade

9 PT blade1)

No. TypeNo. Series

a) Series b) Type c) Top rake

Milling Cartridges forMAPAL WWS Face milling heads

from the EcoMill series• Max. cutting depth: 2 mm• Unsuitable for regrinding

A (±0,02)L2

L3

d 1 (j

s 8)

d 1 (j

s 8)

62

40 10 100 HSK-A 63 20 10 4° 1,43 7-58201-04-__*

50 12 100 HSK-A 63 20 10 4° 1,71 7-58251-04-__*

63 14 100 HSK-A 63 20 10 4° 1,98 7-58311-04-__*

80 16 100 HSK-A 63 20 10 4° 2,39 7-58401-04-__*

100 18 100 HSK-A 63 20 10 4° 3,01 7-58501-04-__*

125 22 100 HSK-A 63 20 10 4° 4,21 7-58621-04-__*

80 16 100 HSK-A 100 20 10 4° 4,68 7-58401-08-__*

100 18 100 HSK-A 100 20 10 4° 5,36 7-58501-08-__*

125 22 100 HSK-A 100 20 10 4° 6,34 7-58621-08-__*

40 10 100 SK 40 20 10 4° 1,63 7-58201-01-__*

50 12 100 SK 40 20 10 4° 1,96 7-58251-01-__*

63 14 100 SK 40 20 10 4° 2,2 7-58311-01-__*

80 16 100 SK 40 20 10 4° 2,6 7-58401-01-__*

100 18 100 SK 40 20 10 4° 3,2 7-58501-01-__*

125 22 100 SK 40 20 10 4° 4,5 7-58621-01-__*

40 10 100 BT 40 20 10 4° 1,6 7-58201-02-__*

50 12 100 BT 40 20 10 4° 2,0 7-58251-02-__*

63 14 100 BT 40 20 10 4° 2,2 7-58311-02-__*

80 16 100 BT 40 20 10 4° 2,6 7-58401-02-__*

100 18 100 BT 40 20 10 4° 3,2 7-58501-02-__*

125 22 100 BT 40 20 10 4° 4,5 7-58621-02-__*

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Milling cutter No. of Dimension Shank form Chip groove Blade Cutting Weight Orderdiameter blades A length length lead kg No.d1 (js 8) Z (±0,02) L2 L3

MAPAL WWS Face milling cutter – HP-FaceMill

Design:Milling cutter diameter: 40 – 125 mmNo. of blades: 10 – 22Shank form: HSK-A 63 and 100, ISO 40

(DIN 69871 AD/B), BT 40Axial angle: positiveCoolant supply: internalCutting lead: chamfer or radius

Dimensions given in mm. Special dimensions available on request.

This product family is particularly intend-ed for face milling operations with highallowances. Cutting depths are possible upto 10 mm. In addition because of the largenumber of teeth exceedingly good feedrates are achieved. This is of particularadvantage for machines with low spindle

speeds. Vibrations which occur duringmachining, which are also caused by thecomponent, are absorbed by the massivetool body and not passed on to the surfacebeing machined.

Selection of cutting lead and geometry:Blade geometry Chamfer Radius Surface quality

0,1x45° R 0,2 R 0,4 R 0,6 Rz ≤ 10 µm Rz > 10 µmChamfer C 1 – – – 2 3

Radius R – 2 4 6 2 3

Order examples: 7-58201-04-C12 or 7-58201-04-R43

Cutting lead chamfer

Chamfer size 0,1 x 45°Surface quality Rz ≤ 10 µm

Cutting lead radius

Radius 0,4 mmSurface quality Rz > 10 µm

*Order no. and required blade geometry (see table below and order examples).

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Dimensions in mm.1) 80 to 500 (PowerSpeed and PowerFeed), 160 to 400 (EcoSpeed and EcoFeed)2) for special milling heads3) for PowerSpeed only4) on external hole circle only

Designation for Face milling heads for milling Dimensions Weight OrderPowerSpeed PowerFix EcoSpeed EcoFix head diameter No.PowerFeed EcoFeed d1

Coolant screw 50 23,6 g 7-03008-00

Coolant screw 63 82,3 g 7-03008-01

Coolant screw 80 176,2 g 7-03008-02

Coolant screw 100 263 g 7-03008-03

Coolant screw 125 and 140 595 g 7-03008-04

Coolant cover 160 and 180 0,2 kg 7-03009-01

Coolant cover 200 0,5 kg 7-03009-02





Holding screw 160 to 500 M6x20 4,3 g 7-03001-04

Insert nut 1) M6x8 2,3 g 7-03009-11

Insert nut 63 to 400 M5x10 1,9 g 7-03009-12

Shim adjuster 50 to 500 0,25 0,5 g 7-03004-00





Balancing screw 80 to 160 M6x10 1,4 g 7-03007-01

Balancing screw 200 to 500 M10x10 2,7 g 7-03007-02

Balancing screw 2) M8x10 2,2 g 7-03007-03

For milling cartridgesHolding screw 63 to 400 M5x11 (Torx) 1,3 g 7-03002-03

Threaded spindle 63 to 400 M5x0,5LH/RHx17 1,9 g 7-03002-04

Adjustment wedge 63 to 400 1,6 g 7-03002-05

Holding screw 50 to 500 M6x12 5 g 7-03001-01

Holding screw 50 to 60 M6x12 (flat head) 3,9 g 7-03001-03

Adjusting screw 50 to 500 M5x8 2,5 g 7-03002-01

Locking screw 3) 50 to 500 M6x12 1,6 g 7-03003-03

For swarf protection plateSwarf protection plate (R.H.) 63 to 500 1,4 g 7-03005-01

Swarf protection plate (L.H.) 63 to 500 1,4 g 7-03005-02

Torx screw 63 to 500 M3x7 0,3 g 7-03006-01

For milling cutter arborHolding screw 160 M12x40 46 g 7-03001-05

Holding screw 200 to 500 M16x50 104 g 7-03001-06

Holding screw4) 315 to 500 M20x55 150 g 7-03001-07

Accessories and spare parts forMAPAL WWS Face milling heads

64

63 22 50 50 19 1,1 MN5050-58-K 10066802

63 27 60 60 21 1,3 MN5051-58-K 10066803

63 32 78 60 24 1,4 MN5052-58-K 10066804

63* 40 89 60 27 1,9 MN5053-58-K 10066805

63* 60** 140 70 27 4,2 MN5055-58-K 10067153

80 22 50 50 19 2,3 MN5050-59-K 10066806

80 27 60 50 21 2,5 MN5051-59-K 10066808

80 32 78 60 24 2,6 MN5052-59-K 10066810

80* 40 89 60 27 3,6 MN5053-59-K 10066811

100 22 50 50 19 2,5 MN5050-60-K 10066812

100 27 60 50 21 2,7 MN5051-60-K 10066813

100 32 78 50 24 2,8 MN5052-60-K 10066814

100* 40 89 60 27 3,8 MN5053-60-K 10066815

100* 60 140 70 40 5,5 MN5055-60-K 10066817

22 MT1013-01 10005640 M4x10 10003583

27 MT1215-01 10005165 M4x16 10003586

32 MT1422-01 10004063 M5x16 10003601

40 MT1623-01 10004064 M5x16 10003601

60 MT2625-01 10010103 M12x25 10003675

A

L1

d d 1

Dimensions in mm.Supplied as follows: with key blocks screwed on, coolant screw not included (coolant screw is included with supply of face milling head).Design: permissible concentricity variation of hollow taper shank to arbor d = 0.01 mm.With 6 balancing bores on periphery.Note: Sizes marked with * have an additional 4 threaded holes for cutting heads with tool holding to DIN 2079.**d 60 mm with nominal size HSK-A 63:– max. milling head diameter D 250 mm– no balancing holes on periphery.

Arbor Key block Holding screw ISO 4762diameter for key block

d Code Order No. Dimensions Order No.

Spare parts

Nominal size Dimensions Weight Code Order No.

HSK-A d d1 A L1 kg

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Milling cutter arborsto DIN 69882-3Location shank HSK-Ato DIN 69893-1

65

40 22 50 35 19 1,05 MN1180-52 10066837

40 27 50 35 21 1,1 MN1181-52 10066838

40 32 78 50 24 1,65 MN1182-52 10066839

40* 40 89 50 27 1,85 MN1183-52 10066840

40* 60** 140 70 27 4,3 MN1185-52 10011328

A

L1

d d 1

22 MT1013-01 10005640 M4x10 10003583

27 MT1215-01 10005165 M4x16 10003586

32 MT1422-01 10004063 M5x16 10003601

40 MT1623-01 10004064 M5x16 10003601

60 MT2625-01 10010103 M12x25 10003675

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Dimensions in mm.Supplied as follows: with key blocks screwed on,

coolant screw not included (coolant screw is included with supply of face milling head).

Design: permissible concentricity variation of ISO shank to arbor d = 0.01 mm.

Note: Sizes marked with * have an additional 4 threaded holes for cutting heads with

tool holding to DIN 2079.**d 60 mm: max. milling head diameter D 250 mm.

Arbor Key block Holding screw ISO 4762diameter for key block

d Code Order No. Dimensions Order No.

Spare parts

Nominal size Dimensions Weight Code Order No.

ISO d d1 A L1 kg

Milling cutter arborsISO location shank to DIN 69871 AD/B

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Material: • Aluminium (GD AlSi8Cu3)Tool: • MAPAL WWS face milling head

PowerSpeed Z 8 • with integral deburring brushes• D 125 mm

Cutting material: • PCDRequirement: • Milling of combustion chamber

side over a total width of 380 mm

• Max. possible tool diameter onmachine = D 125 mm

Result: • Flatness = < 10 µm• Surface quality Rz = 4 µm

Machining values: • Spindle speed n = 6,500 rpm• Feed per tooth vf = 6,240 mm

Special feature: • Machine surface in severaltracks by laterally offsettingface milling cutter.

• Transitions which are producedare smoothed with integralbrushes

• Brushes activated by increasingcoolant pressure

Cylinder head


PowerFeed Z 6 (special design)• D 370 mm

Cutting material: • PCDRequirement: • Face mill on machining centre

• Machine the whole surface in one cut

Result: • Flatness = 9 µm• Straightness = 8 to 10 µm• Surface quality

Rz = 1.6 µm / Rmax = 2.2 µmMachining values: • Spindle speed n = 3,000 rpm

• Feed vf = 1,800 mm/minSpecial feature: • Design of a flattened face milling

head (beam milling cutter) for use on machining centres

Valve body

MAPAL WWS Competence – Face millingMachining examples

67

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Material: • Aluminium (GK AlSi7Mg)Tool: • MAPAL WWS face milling head

PowerSpeed Z 10• D 160 mm

Cutting material: • PCDRequirement: • Machining of reverse side of

lining on a machining centre• Double spindle to be used

Result: • Tool life approx. 1.5 million parts• Cutting lead with R 6

Machining values: • Spindle speed n = 4,000 rpm• Feed vf = 3,200 mm/min.

Material: • Aluminium (GD AlSi9)Tool: • MAPAL WWS face milling head

PowerFeed Z 8• D 63 mm

Cutting material: • PCDRequirement: • Milling over whole component

• Milling path per componentapprox. 5 m

Result: • Tool life approx. 15,000 parts• Milling path approx. 75,000 m


Special feature: • Dimension A for face milling headand milling cutter arbor = 208 mm

Timing housing

Disc brake housing

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Material: • Aluminium (GD AlSi9Cu3)Tool: • MAPAL WWS facing head

PowerSpeed Z 8+8• D 250 mm

Cutting material: • PCDRequirement: • Milling of a bearing slot with

a width of 50.35 ± 0.02 mm• Machining of component on

both edgesMachining values: • Spindle speed n = 8,000 rpm

• Feed per tooth fz = 0.08 mmSpecial feature: • Double sided face milling head

with Z 8+8 allows completemachining in one pass

Console

Material: • Cast iron (GG 25)Tool: • MAPAL WWS facing head

EcoFeed Z 10• D 80 mm

Cutting material: • PCBRequirement: • Surface quality for lateral seal

surfaces Ra = 0.8 µmResult: • Surface quality

• Ra = 0.32 – 0.53 µm• Tool life 2,000 parts


Special feature: • As much as 13 times longer toollife compared to conventionalface milling head

Hydraulic housing

MAPAL WWS Competence – Face millingMachining examples

69



Cutting material: • PCDRequirement: • Face milling and control cut in

clutch bell in one operationResult: • Surface quality Ra = 6 µm on

face surface• Tool life more than 30,000 m

on face surfaceMachining values: • Spindle speed n = 8,500 rpm

• Feed per tooth fz = 0.07 mmSpecial feature: • A spiral milling tool has been

incorporated into the locationarbor for the face milling headfor the control cut.

Cylinder head cover

Clutch housing

Material: • Aluminium (GD AlSi7Cu3)Tool: • MAPAL WWS facing head


Cutting material: • PCDRequirement: • Dry machining

• Surface quality Rz = max. 15 µm

Result: • Surface quality Rz = 3.8 µm

• Tool life more than 50,000 partsMachining values: • Spindle speed n = 3,000 rpm

• Feed per tooth fz = 0.1 mmSpecial feature: • Tool fitted with 12 facing blades

and 3 wide finishing blades

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In the modern cutting environment there are numer-ous elements which need to be observed. Questionson the best possible process or tool layout and thevarious processing options to maintain batchproduction – all aspects to which special attentionneeds to be given. MAPAL’s tremendous breadth ofexperience can be applied to every request in thebest possible way.

• Fast Repair – Reconditioning and service

• Milling Head Management – a dependable performance level right from the start

• Pick-up-Service – Direct to the customer

After Sales andCustomer Services

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Original tool PCD blade Repair holder

Fast and trouble-free

Reconditioning and service

Effective production calculationsthroughout the whole of the life of thecomponent require maximum reliabili-ty in calculation data. It is thereforehelpful for the planning department ifreconditioning costs which occur formachining tools are already known inadvance or have even been specified.The removal of work on the logisticsfor processing repairs also gives theuser the opportunity to concentrate onhis own activities. It is exactly theseaspects which produced the motiva-

tion for a modern repair managementsystem. The preparation of basic toolholders combined with the multipleapplication properties offered by PCDblades provided the breakthrough forthe Fast Repair System. Constantavailability of ready-to-use specialtools increases production reliability,raises productivity and as a resultensures that each batch producerremains competitive in the market.

Fast Repair –

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The application of the repair systemfollows on from the end of the optimi-sation process in batch production.Subject to the tools which alreadyexist, the need for repair carriers iscalculated on the basis of productionfigures and other parameters. Thesetool carriers are issued accordingly atthe first regeneration stage and arethen constantly available. For subse-quent reconditioning work the PCDblade from the original tool is changedover onto the new carrier and re-fittedin parallel. This means there are doublethe number of tools in circulation. Theexcess is kept in a consignment stockwhich can be set up on site and is thenavailable to the customer. This resultsin ongoing availability for all specialtools, which also safeguards the conti-nuity of the batch production againstunforeseen events (e.g. crash).

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performance level right from the startMilling Head Management – A guaranteed

Milling with a face milling head isfrequently the first operation inmachining a component. For thisreason the operation needs to beapproached with extreme caution.Varying allowances, caused by thedifferent loads of blanks, sometimesnot yet surface treated, have a directeffect on the face milling tool.

The milling result achieved, however,represents the basis for further boremachining. Production reliability withthis process is the basis for trouble-free complete machining of thecomponent. The user must be able todepend on this tool, particularly afterregeneration.

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MAPAL WWS

Cleanness, care and precision are themain factors at the forefront of recon-ditioning milling heads. Once disman-tled the tools are basically cleaned,worn parts changed and the systemthen reconstructed from scratch. Wornparts are passed on for the repair pro-cedure and the tool is refitted withregenerated blades from stock. Afterassembly with the appropriate millingcutter holder, the milling cartridges areset to the original setting dimension.The customer is then given back a toolwhich is immediately ready to use.

Length adjustments are not required.The tool will easily achieve the sametool life as before.

If a milling head managementagreement is undertaken, we willguarantee this work is carried outwithin 48 hours.

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Consignment stock administration for MAPAL WWS milling heads

Contractstarts

Customer

Consignment stock Delivery

Milling headsreturned

Consignment withdrawal recorded

InvoiceAccounts record

Milling headsprocessed

Milling heads prepared for repair

Milling headsprepared

Millingheads in use

Withdrawalnotified inwritten

Contractends

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Pick-up-Service – Direct to the customer

An effective order processing system,both for new orders and for recondi-tioning, requires all the working prac-tices to run perfectly. As a result thedespatch method should also not beoverlooked. Prompt deliveries of theproducts at firmly agreed times makehandling easier for the user. This can beachieved by introducing a Pick-up sys-tem. The tools are collected or returneddirectly from the customer by ourtechnical service engineers.

A special advantage is produced forlarge organisations if difficultdespatch routes and unnecessarilylong stoppage time can be avoided.This eliminates long-winded process-ing of deliveries by parcel services andguarantees “Just in Time” despatch.

More information on the countries andregions in which the Pick-up-Service isavailable can be obtained from yourMAPAL representative or from one ofthe MAPAL branches.

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We see it as perfectly natural toprepare our products for transport inthe best possible way. For this reasonwe place great value on using suitablepacking methods. Large size tools, suchas milling heads, are despatched inspecial wooden cases whose stabilityensures the tools are perfectlycontained. Individual special tools arepacked in polystyrene foam in highquality boxes. This absorbs any impactswhich occur during transport and thetool does not suffer any damage.

High quality packaging –for safe transport

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When designing a suitable tool for the machiningoperation MAPAL accepts a high degree of responsi-bility for the production process. MAPAL specialistsare constantly aware of this. Consequently the bestpossible machining solution is always sought. Newmachining concepts are frequently the result ofthese efforts. The experience they have gained ispassed directly to the customer.

• PCD special tools – quality from quotation to production

• Enquiry form for drilling and gun boring operations

• Enquiry form for milling operations

PCD tools made to measure

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PCD special tools need to fit the appli-cation in question like a made-to-measure suit. Our team of techniciansand engineers in the technical salesdepartment specialises in meeting thishigh demand for quality. Ongoingtraining and further training, both intheory and in our trials laboratory,ensure this level of knowledge is main-tained. As competent tool specialistsyour contacts in the internal servicedepartment are available for anyqueries on PCD tools. Once yourenquiry has been received, the bestpossible tool layout will be worked out.With the price proposal you will receivea technical drawing on which the toollayout will be shown.

PCD tools made to measure –quality from quotation to production

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The processing of an enquiry follows a tried and tested procedure. After thetask has been examined, possible criti-cal restrictions – such as cross bores or interrupted cuts – are given specialconsideration. Our tool technologydepartment is frequently activelyinvolved in the decision-makingprocess. Recurring operations ontypical parts, such as cylinder heads,brake or steering components, arelisted in an electronic tool catalogueand constantly updated. This tooldesign system at MAPAL WWS is con-sistently applied from quotation todesign. This means the customer canbe certain that the machining proposalis based on the very latest tool tech-nology. As a result he can take directadvantage of the innovation capacityof our organisation.

In designing complete machiningoperations MAPAL WWS specialists areavailable as competent contact part-ners – even on site if required. Thehighest priority in tool layout is alwaysto achieve maximum productivitybecause “profit from cutting opera-tions depends on the blade”.

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Please send to:Address see last page.

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Component Machine ToolDescription Manufacturer/type/machining centre/transfer line Type rotating

stationary

Material Type vertical Tool No.

horizontal

multi-spindle/ No.

ø tolerance (mm) Variable spindle speed Yes Diameter/tolerance (mm)

No

Drilling depth (mm) Variable feed Yes Working length (mm)

No

through hole Max. spindle speed (min-1) Cutting over centre Yes

blind bore No

Cross bore Yes Power (kW) Coolant internal

No external

Interruptions Yes Spindle accuracy (µm) Shank (HSK, ABS/Weldon, etc.)

No Size/form

Stepped bore Yes Spindle adaptor

No

Pre-machining Yes Guide bush Yes Adjustable adaptor Yes radial

No No No angular

Cutting depth/allowance (mm/ø) Coolant Yes Other adaptors/holders

No

Quality to be achieved Coolant supply externally

through spindle

Surface quality Type oil

emulsion

Roundness (µm) Emulsion mineral oil %

mixture %

Straightness (µm) Coolant pressure (bar)

Cylindricity (µm) Coolant quantity (l/min)

Concentricity (µm)

Machining time (min)

Other notes (Drawing No., workpiece/tool)

Enquiry formfor drilling and gun boring operations

Company Customer number (if available)

Contact partner Department

Address

E-Mail Tel./Fax

Technical consultant Enquiry No. Date

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Component Machine ToolDescription Manufacturer/type/machining centre/transfer line Type

Material Type vertical Tool No.

horizontal

multi-spindle/ No.

Cutting depth/allowance (mm) Variable spindle speed Yes Diameter/tolerance (mm)

No

Face milling Variable feed Yes Blade length (mm)

Circular milling No

Climb milling Max. spindle speed (min-1) Cutting over centre Yes

Conventional milling No

Quality to be achieved Power (kW) Coolant internal

external

Surface quality Spindle accuracy (µm) Shank (HSK, ABS/Weldon, etc.)

Size/form

Flatness (µm) Spindle location

Coolant Yes Other adaptors/holders

No

Coolant supply external

through spindle

Type oil

emulsion

Coolant pressure (bar)

Other notes (Drawing No., workpiece/tool)

Company Customer number (if available)

Contact partner Department

Address

E-Mail Tel./Fax

Technical consultant Enquiry No. Date

Enquiry formfor milling operations

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Our experience is second to none

For the complete machining of cubic componentsthe MAPAL Group holds a leading position amongsttool suppliers. As a result of the variety of productsfrom the different areas of competence, theoptimum tool layout is produced for reliable produc-tion. The range of products extends from efficientstandard tools to complex special tools – both forpre-machining and for finish machining operations.

To plan the whole production process and design andacquire all the tools needed for the operation, a teamof cutting specialists – the Tool Expert Team (TET) isavailable at MAPAL which has successfully productmanaged complete machining operations for com-ponents for many years.

Machining examples

• Valve body• Cylinder head• Transmission housing• Steering box• Main brake cylinder housing• ABS housing

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To machine valve bodies for automatictransmission systems up to 50 tools areused. The position of the bores, the clampingpoints and the relatively small size of thepart compared to other workpieces makemachining a challenge. However, absoluteprecision bores are the prerequisite for thepart to function perfectly. The valve bodybores on the face side, with up to four steps,and possibly an additional contour, pass forexample through ribs just a few millimetersin depth. Sometimes these features have tobe produced in solid material.

MAPAL supplies high precision tools for allmachining steps, whether for face machin-ing, for pre-machining and gun boring, or forthe final finish machining.

Valve bodyCompetence in practice

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Cylinder head

Nowadays cylinder heads are producedalmost entirely from aluminium. For thisreason PCD as a cutting material plays adecisive role in machining these parts.Overall PCD is gaining importance in theautomotive industry as a result of theincreasing number of light metalcomponents.

In addition to the parent bores and sparkplug bores, plus the high precision cam shaftbearing bore, particular requirements aremade in the cylinder head on valve seat andvalve guide machining. Here concentricity,roundness, accuracy of form and surfacequality play the decisive role in trouble-freevalve function – a vital requirement forachieving optimum engine performance.

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Transmission housingWhether tools with fixed blades for pre-machining and finish machining or fine bor-ing tools with high precision adjustment, therange of products offers solutions for everytask. The principal production tasks on trans-mission housings include selector shaftbores and bearing bores which are subject tostatistical production requirements in form,position, surface finish and bore diameter. These bores are partly interrupted by ventila-tion or oil slots – something which places aspecific demand on the tool. With MAPALprecision tools these machining tasks arereliably and precisely solved within therequired tolerances.

Competence in practice

MAPAL has supplied precision tools for thewide diversity of types of clutch and trans-mission housings for more than 30 years andas a result holds a special position in theindustry through the knowledge and experi-ence it has gained.

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The various versions of steering gear boxescan extend to lengths of up to 350 mm andare therefore a special challenge to the toolmanufacturer. In particular it is important toensure the required quality of the recipro-cating piston bore with regard to surfacefinish, concentricity and straightness withreliable production results. Large chip spacesand intensive cooling make sure the numer-ous chips which are produced are removed.One special feature when finish machiningthe reciprocating piston is in the simultane-ous machining of various diameters with dif-ferent defined and specified surface finishwhich lie within a specific range. This meansthat a surface which is too good does notalways corresponds with the productionconcept.

MAPAL also demonstrates high flexibilityand wide experience in project planning forthese complex components.

Steering boxes

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Machining is mainly carried out in 2 clamp-ing positions on multi-spindle machiningcentres with high performance MAPAL WWStools. For flange machining with turningalong the external spigot diameter, high per-formance, multi-bladed PCD bell tools areused. The piston bore is gun bored with PCDstepped tools and finish machined to a highsurface quality with PCD reamers with guidepads. Multi-bladed PCD fine boring tools arebeing increasingly used to achieve higherfeed rates. The lateral connection bores arepre-machined and finish machines in onestep with PCD combination tools.

In the brake system area, main brake cylinders inaluminium alloys are important componentswhich are subject to strict safety conditions. When machining the main brake cylinder housing,quality and production reliability therefore havemaximum priority.

Main brake cylinder housingCompetence in practice

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ABS housing

Anti-locking brake systems for carsare now an integral part of theautomobile industry. Electronicallycontrolled braking systems preventthe wheel from locking.

ABS housings are safety relatedcomponents which are subject to acpk analysis. The increasing demandsfor tolerances, burr-free results andan extremely low Si content in thematerial make cutting operations achallenge. In particular extremelyhigh stipulations are made formachining bores in engines andpumps. Decisive factors for success-ful production are surface finish,accuracy, concentricity and inter-relating positions. For bores in pumpsmaximum tolerances of IT 7 with asurface finish of Ra 0.2 µm apply.

Solid carbide tools for pre-machiningtogether with tools with fixed PCDblades and fine boring tools withguide pads are typical tools for thesecomponents.

It was the cutting material PCD whichbrought the MAPAL and WWS compa-nies together. As a specialist in preci-sion machining, MAPAL saw the enor-mous opportunities of the new cuttingmaterial on the one hand but also theextremely high demands on productiontechnology and on the capabilities ofthe workforce when manufacturingtools with PCD (polycrystallinediamond) blades which cannot not beadjusted. An organisation operating inthe jewellery town of Pforzheim in Ger-many seemed to be the right partnerfor the challenge.Werner Stief had first had contact withthis completely new cutting material asfar back as 1978. As he had already hada great deal of experience in machiningdiamonds, PCD aroused his curiosityand he recognised the extent of thetask. When WWS was first establishedin 1980 it could scarcely have beenimagined how PCD tool manufacturingwould develop. This artificially madecutting material came onto the marketat exactly the right time. The amountof aluminium components – particular-ly in the automobile industry – wasincreasing to a disproportionate extentat that time and provided the rightenvironment for using PCD blades. Thefurther development of the machiningtechnology for this cutting materialwas mainly improved and optimised asa result of WWS’s activities.

Brilliant –two partners who complement each other perfectly

The pioneering work by WWS was toenable the eroding method to be usedfor manufacturing PCD blades.MAPAL’s takeover of WWS in 1994provided the initial spark for furtherturbulent development. The increasingacceptance of the HSK connection sys-tem was also helpful and extremelyimportant in the years that followed.The changeover accuracy of within 3 µm which resulted from this has sig-nificant effects on concentricity andthe use of multiple blades and as aconsequence on the life of PCD tools.These are just some of the reasonswhich have contributed to the hugesuccess story of PCD tools.

Dr. Dieter Kress Werner Stief

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MAPALMAPAL WWS Werner Stief GmbH

Heilbronner Straße 25 • D-75179 PforzheimTel. +49 (72 31) 96 63-0 • Fax +49 (72 31) 96 [email protected] • www.mapal.com

MAPAL Präzisionswerkzeuge Dr. Kress KG

P.O. Box 1520 • D-73405 AalenTel. +49 (73 61) 5 85-0 • Fax +49 (73 61) 5 85-1 [email protected] • www.mapal.com

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MAPAL Competence –PCD Tools

A Review of MAPAL’s Competence

Reaming and Fine BoringFrom the wide range of single and twin-bladed reamers with guide pads, together with fineboring tools with guide pads and WP or HX blades, to the HPR High Performance Reamerscombined with the MAPAL HFS® Head Fitting System for exact concentricity and accuratechangeover – to give you a general view of our complete knowledge and experience in pre cision machining bores.

PCD ToolsFor pre-machining and finish machining, MAPAL also offers an extensive programme of pre cision tools with fixed PCD (polycrystalline diamond) blades. This includes precision gunboring tools plus circular and end milling tools. The programme of face milling heads from the PowerMill and EcoMill series is characterised by simple, sturdy design and rapid, accurateblade setting.

ISO ToolsThis aspect of MAPAL competence is made up of special tools with ISO elements for gunboring and milling. This includes precision ground blades in the widest variety of cuttingmaterials and coatings. The use of MAPAL's tried and tested adjustment system ensures thatthe blades are accurately matched to the task. MAPAL offers particular knowledge and ex -perience in tangential technology.

Generating Slide ToolsGenerating slide tools offer a high potential for rationalisation and optimisation on specialmachines and machining centres. In addition to the conventional facing heads, MAPAL alsosupplies EAT and LAT performance-enhanced actuating systems for generating slide tools.MAPAL TOOLTRONIC® tools with their extraordinary range of functions are the latest develop-ment.

DrillingYet another area is the product programme for drilling. MAPAL offers the right tool conceptfor every task, whether for machining aluminium, steel or cast iron, hard machining or drymachining or for use in HSC areas. Specially developed coatings and PCD blades complete the broad-based drilling programme.

Clamping SystemsMAPAL's modern clamping systems, in conjunction with MAPAL's tried and tested reamingand fine boring tools, guarantee maximum productivity and economy. Whether HSK, ISO orHFS®, these high-precision connections and interfaces provide the concentricity and change-over accuracy essential to modern production.

Customer ServicesProject planning, maintenance, management and optimisation – the complete CTS® servicepackage from MAPAL will accompany you from process design to permanent process optimi-sation and will ensure optimum and cost-saving use of your tools with the best possibleresults.

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mapal competence – pcd tools

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