mapal - impulse_51

8/14/2019 Mapal - Impulse_51

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Page 1 | MAPAL Impulse

400 visitors to

the 3rd MAPALdialogue

Trochoidal milling

fitness program for themilling machine

Optimisation in

dialysis machinemanufacture

MQL technology:Resource-saving and energy-efficient

Information, Ideas, Internals No. 51 | June 2013


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Building on a good market

position with new innovations.

EDITORIAL

Dear reader, dear business associate,

After a very positive business year 2012

during which we were able to record

growth of around 10 %, we are cau-

tiously looking forward to 2013 with

optimism despite the widely reported

increasing sense of crisis. What is the

reason for our generally positive mood?

On the one hand MAPAL is out infront with the market leaders in many

product areas, in particular fine machi-

ning, on the other hand we have a very

broad base with our comprehensive

product range and can better compen-

sate for fluctuations in some sectors.

With our international production and

sales network in 21 countries we can

also offer a high degree of customer

proximity and can react flexibly to

varying market requirements. Last but

not least, as a family business we areindependent of external investors and

possible short-term shifts in strategy;

we are therefore dependable as a long-

term partner for our customers. All of

these factors, combined with the high

level of skill and ability of our em-

ployees, are essential prerequisites for

maintaining and further expanding our

good market position with continuous

innovations.

MAPAL technology has therefore been

the center of attention at many inter-

national trade fairs and congresses. The

possibilities offered by MAPAL system

solutions and indeed also by our high

performance standard products for

drilling, milling, reaming and turning

are of great benefit for the customer.

Recently our development engineers

developed a new tool for trochoidal

milling; this tool is of unrivalled per-

formance. The result is shorter machi-

ning times, better tool utilisation, as

well as noticeably lower tool wear. Incombination with the new hydraulic

chuck, High TorqueChuck, which can

withstand temperatures up to 170 C,

milling becomes highly efficient in all

aspects.

With MQL technology we offer a fully

mature product range for the machi-

ning process with minimum quantity

lubrication; this technology is taking

on an increased sense of importance

given the current situation of ever in-creasing energy prices. Many customers

use this technology, on the one hand to

save around 30 % of the energy costs

and to reduce the coolant consumption

to a minimum, however on the other

hand also to reduce the impact on the

environment and to create better wor-

king conditions for staff.

During all MAPAL development work

the maxims of cost-effectiveness,

energy-efficiency and conservation of

resources are in the foreground to give

our customers a technological lead and

to make possible sustainable produc-

tion.

Have a good read

Yours, Dr. Dieter Kress


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CONTENTS

MAPAL at CIMT in Beijing and Turning

Days in Villingen-Schwenningen

MAPAL addressed the increasing

demand for energy-efficient, resource-saving precision tools and machining

methods during its successful ap-

pearance at CIMT in Beijing. It was

possible to make many new customer

contacts. Along with the product in-

novations, the ReTooling service, that

is the re-tooling of existing machines

for new parts, was a hot topic for

our specialists. With a good 175,000

visitors, CIMT is the largest show for

metal machining in China.

MAPAL also attended the trade fair

Turning Days in Villingen-Schwen-

ningen and was able to successfully

demonstrate its competence in the

area of tools for lathes and clampingtools. HSK-T, Versacut hard turning as

well as MAPAL conversions for lathes

to HSK-T were the focus of interest of

the numerous visitors to the fair.

MAPAL has a new

Head of Marketing

and Corporate Com-

munications

Since February 2013

Andreas Enzenbach (47)has been responsib-le for internationalproduct marketing as

well as internal and external communication.Enzenbach has many years of experience ininternational capital goods marketing in the

mechanical engineering and systems enginee-ring sectors and is a specialist for communica-

tion strategies.

Armin Kasper new

Regional Sales Di-

rector for China andTaiwan

Since April 2013

Armin Kasper has beenthe MAPAL GroupsRegional Sales Director

responsible for theimportant growth

regions of China and Taiwan. As a long-serving

sales manager from MAPAL WWS, a specialistfor PCD tools and key account manager, Kasper

has extensive expert knowledge and experiencein international sales. He will therefore be ableto provide very significant support to our sales

company MAPAL China on the sale of our tools.

News

MAPAL at international trade fairs

News from the MAPAL Group

NEWSTICKER

MAPAL Group News from the MAPAL Group Page 3

MAPAL dialogue: successful customer days Page 8

Product Highlights Solid carbide TTD offer: yes, I will. Page 6

Hybrid Tools Page 7

Trochoidal milling Page 10

PCD tools with lasered cutting edges Page 12

MAPAL setting fixture UNISET Page 16

Reports from practicet Fresenius Medical Care: custom-made tool solutions Page 18 MAPAL Poland: LFP water pump housing Page 20

MAPAL and Ford: optimal processes Page 22

Imprint Page 24

175,000 visitors to CIMT in Beijing. Turning and clamping areas in the spotlight:

Turning Days in Villingen-Schwenningen.


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Producing greater added value with lower energy usage by increasing

the energy efficiency of production processes.

News topics from the MAPAL Group

3D view of the newly planned company

headquarters MAPAL C&S in the Czech Republic.

New building for MAPAL C&S

The construction work on the new

headquarters of MAPAL C&S s.r.o in

the Czech city of Mlada Boleslav, near

Prague, started in May. Our current

building is too small for further deve-

lopment, says Petr Pokorny, General

Manager of the subsidiary in the

Czech Republic. The production faci-

lities of the automotive manufacturer

SKODA are also nearby. The new buil-

ding for MAPAL C&S includes a two-

floor administration area and a 1,000

square metre production building. The

result is a significant increase in capa-

city for the manufacture of PCD tools

and re-grinding solid carbide tools.

MAPAL is investing around 1.2 milli-on euros in this project, which is to be

completed by the end of the year.

In touch with the latest trends with

MAPAL

Improved drilling processes for solid

carbide drills, MAPAL tangential tech-

nology and universal high-pressure

chucks were the key topics at the 8th

Amberg tool seminar. In recent years

the seminar in Oberpfalz has become

established as an important specialist

forum for industrial users. Around

120 participants from all sectors of

the metal machining industry along

with graduates and scientists listened

to the presentations given by MA-

PAL speakers and saw for themselves

the practical implementation of the

information presented during demons-

trations. Intensive use was also madeof the opportunity to chat personally

to our experts.

Tool applications are continuously chan-ging. An edge in terms of knowledge willsecure competitive advantages. Seminars,workshops, forums or conferences offerinformation first hand. The experts fromMAPAL regularly attend a large numberof seminar events. In exciting presenta-tions they convey new know-how anddepict the latest trends and develop-ments in tool technology.

You will find an overview of the up-coming seminars and events in whichMAPAL will take part on our homepage atwww.mapal.com/aktuel-les/fachvortrae-ge. The list is continuously updated.

Conversions for lathes offer higheraccuracy with increased productivity

In 2008 HSK-T was standardised

specially for the usage of upright

tools on lathes. It features high chan-

geover and repetition accuracy, high

fitting accuracy, high rigidity, as well

as exact radial positioning accuracy.

The greatest advantage of HSK-T

compared to existing systems is

the very quick, straightforward tool

change. While with the standardisedconnections used in the past, 10 to

15 minutes were often necessary for

the tool change, with HSK-T the time

required is reduced to less than 30

seconds.

Paired with very high change-over

accuracy, there is a significant reduc-

tion in the machine downtimes and

as a result a significant increase in

productivity for the user. Along with


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complete conversion, it is also possible

to partially convert existing revolvers.

On stations with frequent tool chan-

ges, conversion to HSK-T is particu-

larly advantageous, as the investment

is manageable and pays for itself in

a short time. MAPAL offers conversi-

ons from all common connections on

lathes to HSK-T, across machines and

independent of manufacturer, as well

as a wide range of turning holders.

News

New building at MAPAL C&S in the Czech Republic

Increasing productivity with HSK-T

Technology report 2 on the topic of energy efficiency

TECHNOLOGY

REP RT

2nd MAPAL technology report

Which factors affect the energy con-

sumption of the machining process and

how can energy be saved? This is the

issue covered in the 2nd MAPAL tech-

nology report. Prof. Dr.-Ing. Eckehard

Kalhfer, the Chair for Machining at

the university in Aalen, and Dr. Jochen

Kress, member of the senior manage-

ment, have analysed the energy con-

sumption of machine tools and indivi-

dual process steps. Their report shows

how, with only little investment, for

instance the usage of energy-efficient

tools and optimal machining proces-

ses, to some extent significant energy

savings and therefore cost savings can

be achieved. The technology report is

included with this issue of Impulse.

Would you like to continue to read re-

gularly our scientific publications? Then

make use of our free subscription. You

will find the registration form on our

homepage at www.mapal.com/aktuelles/

technologiereport/anmeldung.-.


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Clever changing with the replaceablehead drill TTD from MAPAL

Replaceable head tool systems are

now indispensable in modern produc-

tion. Increasing raw material prices,

lean inventories and the consideration

of life cycle costs against the pure

purchase price favour the usage of

replaceable head systems. MAPAL

has introduced on the market highly

productive systems for all application

areas; systems that are in no way

inferior to monolithic tools quite

the opposite. With a focus on highly

precise, very stable connections it has

been possible to limit the usage of

expensive carbide to the tool head,

and to make the machining stable andprecise overall.

In the area of drilling from the solid

MAPAL relies on the replaceable head

drill TTD. At the center is the torque

transfer connection TTS (Torque

Transfer Schnittstelle) which permits

optimal torque transfer and at the

same time high changeover and radial

run-out accuracies. In this way the re-

placeable head drill TTD achieves the

performance of a solid carbide drillwith lower costs.

Success stories from the different sec-

tors and workpiece materials under-

line the performance of the replace-

able head drill TTD. For example in

gearbox housings made

of GJL-200 the 28 mm

fixing bores are drilled

using a replaceable head

drill TTD from MAPAL.

It is possible to opti-

mally meet the require-ments of the customer in

relation to the dimensional accuracy

of the diameter. However the TTD also

realises significant saving potential by

doubling the feed rate in comparison

to the solid carbide drill used previ-

ously. With 1,430 mm/min and 140

m/min cutting speed, 200 bores can be

reliably machined using a replaceable

drill head.

In an application from steel machi-

ning, clamps for folding machines

made of ST52 are drilled using the

replaceable head drill TTD.

83 bores with a diameter of 20 mm

and a length of 106 mm are required

per part. By using the MAPAL tool

it was possible to reduce the machi-

ning time from 39.7 to 18.1 seconds this corresponds to reduction in the

machining time of 54 %. Together

with an increase in the tool life of 77

%, the TTD reduces the costs per bore

by 60 % referred to the customers

annual production volume! There are

also examples of the successful usage

of the replaceable head drill TTD in

modern workpiece material combina-

tions. For example the machining of

bores for the connection of a ships

CFRP drive shaft to a steel hub. Usinga combination tool from MAPAL

with a TTD solid drilling stage and a

countersink step with PCD-tipped ISO

indexable inserts it was possible to

reduce the machining time by more

than 80 %.

Increasing raw material prices, lean inventories and the consideration

of life cycle costs favour replaceable head systems.

Highlights from the product areas

Simply scan the QR code or go towww.mapal.com/aktion

*Valid on ordering a TTD replaceable head with tool holder.You will find the full terms and conditions of the offer at www.mapal.com/aktion

Test the MAPAL replaceablehead drill TTD and exploit theperformance of a solid carbidedrill with lower costs.

TO CHANGE

without risk. Producequickly and effi ciently

using the replaceable headdrill TTD.**

YES

,IWILL

YES, I WILLThe current MAPAL replaceable head drill TTD cam-paign will continue until the end of June. You willfind more information on this topic on our homepagewww.mapal.com


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Pre-machining and fine machining

intelligently combined

Custom-made combination tools

open up high potential for increasing

productivity and process reliability. In

the specific case of a MAPAL custo-

mer, it was necessary to pre-machine

and fine machine particularly cost-

effectively two connection bores with

diameters of 31 mm and 36 mm on an

AlSiMg1 swivel bearing for a car. This

requirement sets two challenges for

the tool design. Firstly, the low silicon

content of the aluminium alloy requi-

res an innovative tool concept that

ensures optimal chip breaking of the

otherwise long continuous chips. On

the other hand, to meet the cycle timerequirements, particularly productive

pre-machining and fine machining

are required as both diameters require

high stock removal.

To solve this task, MAPAL developed

two combination tools that combine

both the pre-machining and fine ma-

chining on one tool body.

The pre-machining was designed on

both tools as a solid drilling sta-

ge with replaceable ISO indexable

inserts. The appropriate cutting edge

geometry, as well as twisted and also

polished chip spaces with a helix ang-

le of 15 ensure reliable chip breaking

and chip removal. Due to the large

core cross-section of the solid drilling

stage, the tools are stable and par-

ticularly smooth in operation. After

the solid drilling stage, the stages for

fine machining follow with the brazed

PCD cutting edges. During process

design, the machining operations

were optimally distributed over the

two tools.

First tool one (see figure) is used todrill the large diameter using the

indexable inserts. Then the next

stage machines a spot face on the

end of the bore using the related

chamfers. Using tool two, the

small diameter is drilled in the

solid and then fine machined and

chamfered using the following

stages. Then the chamfer on the

bore outlet is made using this

tool by circulating. The same tool

then moves to the larger diameter,

fine machines the bore and also pro-

duces the chamfer of the exit of this

bore by circulating.

MAPAL specialists have achieved

maximum productivity and cost-

effectiveness in this machining task

both in the process design and the

tool design. The two combination

tools complete all the machining

tasks for which at least four tools

would normally be required. Also

the MAPAL hybrid tools combine the

different machining systems in such

a manner that excellent performance,

simple handling and cost-effective

reconditioning are achieved.

News

Yes, I will to change without risk

Intelligent combination of machining systems

Pre-machining and fine machi-

ning intelligently combined

MAPAL hybrid tools combine different tool tech-

nologies

1

2


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Erfolgreiche Kundentage bei MAPAL

Minimum quantity lubrication was the

topic of the customer days at MAPAL

this year. Around 400 participants

came to Aalen, above all series pro-

duction manufacturers and suppliers

to the automotive industry; they came

to obtain information on this envi-

ronment-friendly and energy-saving

form of material machining. By means

of the minimum quantity technology,

up to 80 % less coolant and up to 40

% less electrical power is consumed in

comparison to conventional processes.

At the end of the two-day event the

participants were impressed by the

diverse mix of broadly based presen-

tations, practical tool demonstrations,

a large exhibition of MQL compo-

nents, as well as the tours through theMAPAL production buildings.

Dr. Dieter Kress was pleased by the

unexpectedly large number of visitors

who travelled from all over Germa-

ny, Austria, Poland and Switzerland:

With minimum quantity lubrication

we have selected the right topic, he

concluded. Minimum quantity lubri-

cation (MQL) is in principle nothing

new. The first bores were dry ma-

chined some 20 years ago. However,

the keen interest shows that MQL is

a very complex system. One, as Dr.

Jochen Kress added, in which there

has been significant progress in re-

cent years: We are now at the point

that we can also use MQL technolo-

gy on broad front. The increasing

industrial interest in energy-efficient

production is giving MQL technology

additional lift: It is a comparatively

simple way to save energy, says Dr.

Jochen Kress.

And businesses will increasingly

exploit energy-saving potential in

the future to lower their costs for

energy and resources such as waterand material, stated also Prof. Dr.

Ing. Eckehard Kalhfer. The Chair

for Machining at the university in

Aalen has investigated the effect

of MQL on energy efficiency. The

basic annual consumption of an

operational machine tool is around

66,000 kWh. On the usage of central

cooling lubricant systems, states

Prof. Kalhfer, the energy demand

innovative technologies in use

MAPAL Di LOG

400 visitors on 10 and 11 April 2013

P R E S E N T A T I O N S | D E M O N S T R A T I O N S | I N - H O U S E


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is high compared to the energy

demand of the machining process

itself. Using various model invoices

he demonstrated that the electri-

city consumption can by reduced

by up to 40 % by using minimum

quantity lubrication. In this way it

is possible to save a lot of money,

the scientist stated.

However MQL technology requi-

res careful usage, says Dr. Jochen

Kress. All components, that is the

tool, machine, fixture and above

all the process must mesh opti-

mally. Two acknowledged MAPAL

specialists, Christian Schmidt and

Joachim Vaas, provided informati-

on on the special features of MQLtools and correct process design

in relation to lubrication, trans-

port of chips and cooling. Suitable

chucks were presented by Michael

Neumann: MAPAL has developed a

modular system for clamping tools.

We accompany the customer

during the entire process design,

from planning, through pilot trials, to

production, Dr. Jochen Kress descri-

bes the product and service portfolio.

MAPAL has a large array of machine-

ry for tests and optimisation and has

extensive experience with all materi-

als. Even demanding processes such

as connecting rod machining can be

implemented using MQL.

Peter Vogl, Director of Design & Tech-

nology at GROB Werke GmbH & Co.

KG in Mindelheim and Werner Roth,

Head of Application Engineering at

Maschinenfabrik Heller, Nuertingen

reported on how machine tools suita-

ble for MQL should be designed. The

manufacturers of machining centers,

custom machines and transfer lines

have already realised numerous MQLprojects together with MAPAL.

Currently around one in five of the

machines supplied by the business

have MQL technology says Roth. Vogl

spoke a slightly increasing tendency

in large-scale series production manu-

facturing. The machines are designed

such that lubricant can be supplied

X H I B I T I O N | E X P E R I E N C E | E X C H A N G E O F V I E W S

Continued on next page.


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Page 10 | MAPAL ImpulsePage 10 | MAPAL Impulse

through the tool as well as by means

of single-channel or dual-channel

systems.

Dr. Dirk Sellmer, Head of the Re-

search and Development department

at MAPAL gave an overview of the

different MQL feed units. Whether you

select a single or dual-channel variant

is essentially a question of philosophy

the expert stated. The same applies

to the choice of the right lubricant, a

topic that is also the subject of fre-

quent discussion. Fatty alcohols and

ester oils are not equally suitable as

lubricants in his opinion. It depends

on the application. Aerosols are not

flammable, however chip dust in com-

bination with wall oil could cause anexplosion. Modern extraction systems

prevent this situation from occurring.

Marcus Krauss, Sales Manager at Kel-

ler Lufttechnik, Kirchheim unter Teck,

is observing a trend toward small,

decentral systems. The advantages:

They need little space, can be used

flexibly and can be controlled direct-

ly via the machine tool. Ford, for

example, uses an individual separator

to blow the return air back into the

room.

The report from a user of MQL

technology was equally exciting

and informative for many partici-

pants to the MAPAL customer days.

At Punch Powerglide, Strasbourg,

around 300,000 gearboxes for cars are

manufactured per year, for this reason

around two years ago it was decided

to change to minimum quantity lubri-

cation for the production of converter

housings. Good environment manage-

ment and cost savings were the key

reasons explained planning manager

Roland Muller. Initially we had a

few problems with tool breakages and

noise, but it was possible to address

these issues quickly. It was possible

to reduce the cycle time using MQL,

the surrounding area is clean and

attitudes are positive. Mullers conclu-

sion: I am convinced we did the right

thing.

P R E S E N T A T I O N S | D E M O N S T R A T I O N S | I N - H O U S E

innovative technologies in use

MAPAL Di LOG

The development of MQL system components is sufficiently advan-

ced that this technology can now be used on a broad front.

CONTINUEDFROMPAGE5.


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Page 11 | MAPAL ImpulsePage 11 | MAPAL Impulse

Andreas Bro (Gebr. HellerMaschinenfabrik GmbH, Nuertingen):

There has been a lot of

information provided in a very

short time.

Olaf Kiener (Julius Schle DruckgussGmbH, Schwaebisch Gmuend):

It was a perfect event that

has exceeded my expecta-

tions.

Wolfgang Mller (Opel, Kaiserslautern):

A very good mix of theory and practice. It

was a great event because a large number of

external manufacturers were also present.

Michael Zinz (Deutz AG, Ulm):

The presentations were informative, the

works tour and the exhibition very interes-

ting. We are satisfied all round.

X H I B I T I O N | E X P E R I E N C E | E X C H A N G E O F V I E W S

Thank you for the feedback on this event you will also find a summary of the customer days online atwww.mapal.com/aktuelles/kundentage-mapal-dialog/

Your MAPAL Impulse editorial team

Alexander Koch (Schunk GmbH Et Co. KG,Lauffen am Neckar):

The dialogue was very well organised, inte-

resting and varied. I have learnt a lot aboutMQL technology.

Interviews

with visitors

Fit for manufacturing processes

with minimum quantity lubrication


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Fitness program for the CNC milling machine

With trochoidal milling significant

improvements in tool costs, clamping

systems, machining times and the load

on the machine components can be

achieved in many applications compa-

red to conventional milling.

A comparison of the cutting data

determined during a MAPAL milling

trial already shows what is possi-

ble with this process, which is also

known as wave milling: while during

the conventional dry milling of case

hardened steel (16MnCr5) a cutting

speed of around 200 m/min at a feed

of 0.05 mm/tooth was achieved, it was

possible to tackle the same task with a

cutting speed of 600 m/min at double

the feed rate using the new trochoidalcarbide milling cutter from MAPAL.

Even on machining V2A steel it was

possible to achieve a significant incre-

ase in speed by changing the milling

technology: at a feed of 0.05 mm/

tooth, a cutting speed of 250 m/min

was achieved instead of the 60 to 100

m/min otherwise possible.

This performance increase is made

possible by a combination of high

performance milling cutters speciallydeveloped by MAPAL for this process,

the HighTorque Chuck (HTC) and the

actual process. The advantage during

movement is essentially the reduced

tool contact. While during conventio-

nal milling of a slot the wrap angle is

180 (full cut), with trochoidal milling

it can be selected as a function of the

cutting depth and limited to maxi-

mum 70. This situation is made pos-

sible by a milling cutter with a smaller

diameter that moves trochoidally at a

high spindle speed; each trochoid is

deeper into the cut.

Due to the smaller wrap angle, less

heat is produced. The machining

forces are also lower such that even

spindles with low power and torque

are suitable for the machining process.

In addition, the chip load is lower

with trochoidal milling. As the milling

cutter does not completely fill the

slot or pocket, chip congestion and

renewed cutting of chips is as good

as excluded. This aspect is of impor-

tance particularly for slots that are

deep in relation to their width. During

conventional milling, low feeds and

cutting depths are used here due to

the problems described. A maximummilling depth of 1.5 x D is normal.

Not so with trochoidal milling: by

avoiding the full cut, cutting depths

of up to 2 x D are achievable even

without specially developed milling

cutters.

For the user, this situation sig-

nifies shorter machining times,

better tool utilisation and

noticeably lower tool wear.

Due to the rapidly increasingcarbide prices, the latter in

particular is attracting the

attention of metal machi-

nists who can profit twice

over on changing to trocho-

idal milling: from the longer

tool lives and from the

lower procurement costs for

the milling cutter resulting

from the smaller diameters.

If trochoidal milling is used in

machining centers, additional cost

savings are possible. Because widely

varying slot widths or pocket sizes

can be produced with only one tool,

the tool needs to be changed less

frequently and there is space left in

the tool magazine. Trochoidal milling

also offers advantages in relation to

design. Due to the lower radial forces,

significantly more delicate parts and

parts significantly with thinner walls

can be realised and greater accuracies

achieved. At the same time the load

on the spindle bearings is eased and

the tool life is increased.

The OptiMill product family from

MAPAL includesmilling

cut-

Trochoidal milling also for machining centers


13/24

Page 13 | MAPAL Impulse13 | MAPAL Impulse

Customer benefits

Shorter machining time and better tool utilisation

Higher cutting volumes and feeds

ters suitable for dry trochoidal milling

with DIN shank lengths 2 x D. For

applications with even higher requi-

rements, MAPAL has now developed

and added to the product range an

entirely new milling cutter with a

cutting length of 3 x D and a diameter

from 6 to 20 mm. Specially designed

unequal spacing (EU spacing) of the

five cutting edges combined with an

innovative geometrical design of the

cutting wedge reduces the excitation

of vibration here. Balancing (balan-

cing quality 2.5) undertaken during

the manufacturing process further

reduces the risk of vibration. As such

the patent-applied milling cutter

can even be used at extremely high

spindle speeds without problems. Sothat with the greater cutting depths

now possible, jamming does not occur

due to the long chips produced in

the process, the tool designers have

also integrated a chip breaker that

cuts the chips in half. This feature

safeguards the trouble-free removal

of the chips from the machine com-

partment. A special tool adapter is not

required for trochoidal milling using

the MAPAL milling cutters. However,

if the potential of trochoidal milling

and the new milling cutter is to be

fully exploited, it is recommended to

use the new MAPAL HTC chuck. The

chuck combines the very good dam-

ping properties of hydraulic chucking

technology with the high holding

forces of shrinking technology. The

HTC reliably transmits high torques.Even heating to 170 does not affect

the HTC chuck, as milling trials have

confirmed. As a rule, cooling is there-

fore not necessary.

Smaller or more delicate parts, higher

accuracies and the continuing pres-

sure to further reduce tool, operating

and maintenance costs are making the

call for more efficient milling proces-

ses louder. Thanks to the availability

of more powerful tools such as the

new MAPAL trochoidal milling cutters

and the increasing usage of powerful

CNC controllers and CAM software,

there is now nothing to hinder the

broad usage of the trochoidal milling

process. The time is right for trochoi-

dal milling!

MAPAL OptiMill milling

cutter in use.

Figure on right: Trochoidal

milling cutter clamped in

the MAPAL High-Torque

Chuck.

Your contact person for further information:

Andreas Rinn | [email protected]

ae

fz

Feed motion

r1

Machining area per

trochoid.

Chip per cutting

edge.


14/24


Innovative manufacturing technology for external machining tools:

PCD tools with lasered cutting edges

Productivity and quality significantly increased

The competence center for PCD tools

in the MAPAL Group, MAPAL WWS

GmbH in Pforzheim, is the largest

and most technologically advanced

production facility for PCD tools

in the world. In collaboration with

LASERPLUSS AG, also part of the

MAPAL Group, (see box on the right),

another significant development has

been achieved on the production side:

by using RayCutter 5-axis CNC laser

machines for laser finishing PCD

cutting edges, it has been possible to

significantly increase the stability and

with it the productivity and quali-

ty of complex external machining

tools. The engineers in Pforzheim are

impressed with the new technolo-

gy and are expanding the capacity.The RayCutters have been used in

production for around three years. The

development of the new machining

method for external machining tools

started in 2011, and the process was

very successfully introduced in 2012.

By the middle of 2013, five RayCut-

ters were in use in the production of

PCD tool cutting edges.

Machining of a hose connection tho-

roughly revised

In one application, production of

a complex external contour on a

hose connection made of AlSi7 was

thoroughly optimised by MAPAL. The

part is manufactured on a four-spindle

machining center in high quantities,

absolute process reliability and the

high quality of the surfaces machined

in relation to dimensional accuracy

and surface finish must therefore

be ensured. The complete external

contour must also be produced in

one machining cycle. The customer

was dissatisfied with the part quality

produced by the previous process. The

machined area had a poor surface fi-

nish with clearly visible chatter marks.

Also, the dimensional accuracy varied

between the four spindles, an aspect

that made it more difficult to meet the

tolerances.

The tool used originally comprised

screw-mounted inserts and was corre-

spondingly unstable. It was necessary

to adjust the delicate inserts individu-

ally and there was a tendency for the

adjustment to change during machi-

ning. This situation often resultedin only one of the two cutting edges

actually cutting. At a spindle speed of

5,000 min-1it was only possible to use

a feed per tooth 0.1 mm.

Lasered cutting edges maintain the

stability of the tool

The specialists from MAPAL designed

a PCD external machining tool of

monoblock design to make the machi-

ning more stable and to improve thesmooth running. The design permits

high accuracies in length, shape and

diameter. However, the special high-

light is the machining of the cutting

edges. Unlike in the past, these cutting

edges are lasered instead of wire

eroded. This innovative technology

has significant positive effects on ma-

chining quality and productivity with

this complex form of external ma-

chining. To be able to wire erode the

cutting edge contours in monoblock

tools in the conventional manner, the

tool body must be relieved. As a result

the area behind the cutting edge beco-

mes very unstable. As a consequence,

the tool tends to vibrate; the cutting

data must be drastically reduced in

some cases. If the cutting edges are

finish lasered using the new process,

the cutting edge pocket remains stable

and vibration is prevented. It is only

necessary to take into account any

tool restrictions. The improved tool

stability therefore makes possible

significant increases in the machi-

ning quality and productivity as well

as an effective two cutting edge and

multi-cutting edge capability. Christi-

an Molch, General Manager at MAPALWWS, says

on this

issue:

This laser

technology

developed

by MAPAL

and LA-

SERPLUSS

is excel-

lently sui-

ted to theproduction

of com-

plex, very

delicate

geometries

on external

machining

tools. The

process

operates

withoutLASER-TECH

N

O

LO

G

Y

Picture from the

cutting edge

preparation on th

RayCutter.


15/24


physical contact and is practically

unlimited in relation to geometry. As

a result MAPAL is also technologically

leading in the area of complex PCD

external machining tools.

Cycle time reduced by 23 %

The potential of the new tool gene-

ration has been confirmed in series

production at the customer. After

machining, the part has a very good,

chatter-free surface finish as well as

good geometrical accuracy, and that

with significantly increased machi-

ning values (n = 8,500 min-1, fz =

0.16 mm). The customer has several

positive effects due to the usage of

the MAPAL PCD external machining

tool. It saves handling costs, as com-

plicated and time-consuming setting

is not required. The monoblock tool is

also 50 % cheaper to procure than the

competitor tool. However, the achie-

vement of the highest diameter and

length tolerances as well as the best

surface finishes with high cutting data

is decisive. As a result it is possible to

reduce the cycle time by 23 %.

Very deep axial recesses

In a further example, very deep axial

recesses are produced on a machining

center.

Originally the machining was under-

taken using recess tools with clam-ped carbide inserts. The responsible

member of the MAPAL sales team and

the specialists in Pforzheim developed

recess tools with lasered cutting edges

for pre-machining and fine machining

during this task. The pre-machining is

undertaken into the solid using a two-

cutting edge tool with impressive

cutting data:

n = 6,000 min-1, fz= 0.05 mm and

300 mm/min feed rate. The tool for

the fine machining is of single-cuttingedge design and machines the work-

piece with a spindle speed of 8,000

min-1, 0.1 mm feed per tooth and a

feed rate of 800 mm/min.


Michael Hils | [email protected]

LASERPLUSS AG in Kirschweiler bei Idar-Ober-

stein has specialised in the manufacture of laser

systems for precision applications for cutting me-

tals and hard materials, for marking and engra-

ving all materials, and for welding plastics. The

company founded in 1997 with Dipl.-Ing. Werner

Schulz as its head has been part of the MAPAL

Group since 2009.

Figure top: Cost-effective external machining with PCD tools from MAPAL.

Figure bottom: Machined joint contour on a sample part.

The RayCutter 5-axis

CNC laser machine from

LASERPLUSS AG.

Customer benefits

High process reliability

Deep axial recesses possible

Significantly higher cutting data


16/24


Setting fixture UNISET-V vision developed for complete solutions

Measuring and setting complete machining tools

Planning new projects is time-consu-

ming and expensive. More and more

customers therefore make use of the

comprehensive range of services offe-

red by MAPAL related to part design

and the delivery of the related compo-

nents. As along with technologically

leading and highly productive tools,

MAPAL offers extensive know-how on

machining. This aspect relates to both

custom services as well as to high

precision peripheral equipment for

adjusting and measuring the tools.

Process reliability and part quality due

to exact measuring

During the design of tools for com-

plete machining, fine machining toolsplay a crucial role. As the tools are

often used for the last manufacturing

step, all tolerance requirements on

the part in relation to surface finish,

dimensional, contour and positional

accuracy must be reliably met. As a

specialist for fine machining, MAPAL

relies on fine boring tools with guide

pads that can be adjusted to the m.

Very tight tolerances can be achieved

with these tools. Due to the setting

features on the tools it is possible toaddress flexibly any special aspects

related to the workpiece material or

the machine. The exact measurement

and adjustment of these tools is a

prerequisite for high process reliability

and part quality. These tasks are suc-

cessfully undertaken using a precise

measuring and setting fixture that is

integrated into the process chain.

Highest measuring accuracy with

UNISET-V vision

For cost-effective series production it

is particularly important that tools can

be measured and set to the highest

precision both quickly and efficiently

to ensure constant availability at the

machining center and to avoid down-

times. The example of a complete ma-

chining process on clutch and gearbox

housing makes this aspect clear. The

optimal machining of the often thin-

walled, large aluminium cast parts

requires comprehensive know-how

during tool design. In particular there

are high requirements on the shape,

position, surface finish and diameter

of the shaft bearing bores. The soluti-on a complex, multi-stage combinati-

on tool that, along with high accuracy,

significantly reduces the machining

times. Along with fixed brazed PCD

boring tools, these tools use adjustab-

le inserts and guide pads, as well as

face cutter heads with adjustable PCD

milling cartridges for finish machining

of the sealing faces. For setting the

tools to the um, MAPAL has developed

a CNC-controlled setting fixture in

the form of the UNISET-V series thatis perfectly matched to the require-

ments placed on these tools due to

the combination of tactile and optical

measuring methods.

Tactile measuring method for setting

fine boring tool with guide pads

The vertical setting fixture UNISET-

V vision is equipped with electronic

measuring sensors that make it possib-

le to exactly set fine boring tools with

guide pads to within 1 m. Depending

on the position of the guide pads and

insert, either protrusion measure-

ment or swinging lever measurement

is used. As soon as the measuring

sequence for a tool has been defined

and saved once using the teach-in

programming, from then on the mea-

surement of the tool is undertaken au-

tomatically via the CNC controller. In

this way it is possible to significantly

reduce the non-productive times in

the measuring room, particularly in

case of complex, multi-stage tools for

shaft bearing bores.

State-of-the art camera system forthe optical measurement

PCD face cutter heads in the Eco-

Mill series are sophisticated, efficient

tools. A prerequisite for their reliable

usage and long tool lives are inserts

1.1

2.1


17/24


Customer benefits

Universal setting and measuring device for

manufacturer-independent tool concepts

Fully automatic measuring sequences using CNC controller

Highest accuracy due to solid mechanical construction

that move within defined tolerances.

For finish machining PCD face cutter

heads are used; here the exact and

effective setting of the axial run-out

on all cutting edges is necessary.

Using the UNISET-V vision each PCD

cassette on the face cutter head is

moved to and measured using the

optical camera system. If necessary,

the axial run-out can then be simply

and quickly corrected at the adjus-

ting element on the milling cutter. Inparallel the setting process is moni-

tored optically on the touchscreen

monitor for the UNISET-V vision. Also

all other tools used for the complete

machining process are measured using

the optical measuring device. All rele-

vant measuring data, for example tool

lengths or diameters, can be assigned

to the tool using the UNISET-V vision.

The measured data are either saved

directly on the tool using a Baluff

chip, or applied directly to the tool

body in the form of a printed label.

With both processes, it is ensured that

no time-consuming corrections are

necessary on the usage of the tools on

the machining center.

A single setting fixture for all require-

ments

The different measuring methods for

a very wide range of tool systems, the

high precision due to the solid basic

mechanical set-up and the CNC elec-

tronics make the UNISET-V vision an

all-rounder in the tool setting room.

In particular in the case of tools for

complete machining the UNISET-V

vision ensures real productivity ad-

vantages are obtained due to its high

degree of flexibility and ease of use, it

is therefore an indispensable element

of the complete process chain.


Michael Hils | [email protected]

The UNISET-V vision makes itpossible to set and measure all tooconcepts used for the completemachining of clutch and gearboxhousings.

Verticalsetting fixtureUNISET-Vvision.

1.1 | During the protrusion measurement forsetting fine boring tools with guide pads, themeasuring sensors are first moved to the positionof the guide pads and the measuring range set

to zero. Then the adjustable inserts are moved toand the measuring range is again set to zero atthe highest point. Due to the low contact pres-sure on the insert and the reduced measuringforce, delicate PCD-tipped inserts can also bemeasured reliably and without risk of damage.

1.2 | The operator now sets the defined nominaldimensions such as the overhang on the insert inrelation to the guide pad and the diameter.

2.1 | Optical measurement of a PCD face cutterhead in the EcoMill series.

2.2 | Setting the axial run-out at the adjustingelement on the milling cutter.


18/24


Identifying and utilising optimisation potential in machining

productivity increase due to custom tool solutions

Machining for dialysis equipment significantly optimised

Unmanned machine tool operation

safeguarded, machining time halved,

tool life increased by 20 times, surface

quality visibly improved - these are

only some of the impressive results of

the latest process optimisation in ma-

chining at Fresenius Medical Care on

its site in Schweinfurt. Since 1979 the

company has developed and manufac-

tured dialysis machines for the inter-

national market with great success in

this industrial city in Lower Fran-

conia. Every year more than 40,000

systems leave the factory that main-

tains its position in relation to the

international competition by means of

efficiency and clear work processes.

The strategy of Fresenius Medical Care

is to be better than the competition inrelation to the quality of the dialysis

products and production costs.

To implement these goals the world-

leading manufacturer of dialysis

equipment has relied on know-how

and tools from MAPAL for machining

since 2000. In close co-operation

we have managed to further stream-

line production processes, to reduce

tool costs and to improve quality

repeatedly in recent months, reportsLudwig Schmittlein, who is respon-

sible for milling technical support in

machining at Fresenius Medical Care

Deutschland GmbH.

Process optimisation makes possible

unmanned production

As such, a multiblock made of po-

lypropylene can now also be manu-

factured unmanned and therefore

around the clock as a result of a tool

change. Prior to the change the blind

bores necessary on this assembly

were realised in three steps: Due to

the large diameter of 42 mm, first the

bore was pre-drilled using a standard

drill, the bore was then drilled out and

subsequently machined to the cor-

rect dimension using a milling cutter.

This method has the disadvantage

that long chips were produced during

boring that, on the one hand, soiled

the machine tool, and on the other

hand took a lot of space in the chip

bin. These two aspects together pre-

vented unmanned operation at night,

Benedikt Hetterich, head of the milling

area and quality assurance in machi-

ning at Fresenius, describes the initialsituation.

As the machine configuration did not

permit milling from the solid, based

on experience in other applications

MAPAL engineers suggested a solution

with a carbide replaceable head

drill TTD with 180 geometry

and a PCD-tipped milling cut-

ter with which the blind bore

is circular milled in a helix

after drilling. We have beenworking very successfully with

this solution for approx. one

year, Ludwig Schmittlein is

pleased to state. The chips are

space-savingly small, boring

out is not required at all and

the milling cutter can operate

with much higher feed such

that we can operate unmanned

and also faster than before.

Another earlier optimisation project

also made a significant contribution

to increasing through-put at Freseni-

us: The filter block, also manufac-

tured from a block of polypropylene,

for the therapy system 4008 from

Fresenius needs a 91 mm deep blind

bore. However, the walls of the bore

are not straight, but taper at 1 degree

downwards, at the transition from the

flat base of the bore to the side wall

the bore has a radius; there is also a

straight section to the opening. As for

the multifunction block, until recently

standard drills were used for pilot dril-

ling and boring out. The 1-angle was

then cut with 0.2 mm cutting depth

and a radius milling cutter controlled

by a CAD program. Just this one pro-cess took 30 minutes and transition

marks and scoring could occur on the

surface. Using the alternative develo-

ped by the MAPAL specialists in close

co-operation with us, we only need 16

minutes for the complete machining

Drilling from the solid and circular milling

with optimised chip breaking make possibleunmanned production.

SOFT

M

ILLIN

G


19/24


Customer benefits

Unmanned production possible

Tool costs reduced

Machining timed reduced

Das fertig gefrste Werkstck.


Michael Neumann | [email protected]

of the part, reports Ludwig Schmitt-

lein with pride.

The chamber opening on the filter

block is now drilled in one step using

a replaceable head drill TTD with

a special design. The drill has the

MEGA-180 geometry that makes it

possible a flat bottom in bores in one

machining step. The contour is then

milled using a customer-specific car-

bide form cutter with one material re-

moval rate. As a result with the new

tools we have achieved short chips, a

good surface finish and flowing tran-

sitions also in this application, adds

Benedikt Hetterich. Fresenius also

benefits from longer tool lives,

as his colleague emphasises: Whilewe could produce approx. 600 parts

with a corner radius milling cutter,

we have now passed the 1,500 mark

and still do not need to change the

replaceable head.

Fresenius was able to achieve an even

more significant increase in tool lives

by means of tool optimisation in the

case of a part made of polypropylene

with 30 % glass fibre content: Prior to

the change a recess was produced with

the aid of a conventional solid carbide

circular milling cutter. Although

the tool was economical to procure,

it had to be replaced after only 600

parts due to wear, Benedikt Hetterich

looks back. For the last two years we

have used instead a circular milling

cutter with PCD cutting material that

cost almost three times as much, but

that lasts for at least 16,000 parts! At

an annual production rate of 36,000

pieces this means savings of almost

6,000 euros a year in tool costs alone.But that is not enough. In a partner-

ship-based co-operation with the tool

specialists at MAPAL, the responsible

staff at Fresenius have been able to

achieve other improvements in many

areas. We are therefore very happy

with the support provided by MAPAL

and the quality of the tools, Benedikt

Hetterich and Ludwig Schmittlein

agree.

Dialysis machine


20/24


Complete machining with minimum number of tools and mini-

mum number of different indexable inserts.

Complete machining of water pump housings

MAPAL has been represented in Po-

land with a dedicated subsidiary since

2002. The team around General Mana-

ger Aleksander Zielonka comprises 27

staff in sales and service. Comprehen-

sive local support to customers with

technologically leading tool solutions

is the premise of MAPAL Narzedzia

Precyzyjne Spka z.O.O.. Here the

focus is on partnership-based collabo-

ration with customers and machinery

manufacturers. An example of this

aspect is a project realised at the end

of 2012.

Leszczyn ska Fabryka Pomp (LFP) was

founded in 1868. The privatisation of

the organisation and a new strategic

direction placed the focus on deve-lopment activities. Today LFP is the

leading manufacturer of pumps and

pump systems in Poland and one of

the most modern manufacturers of

cast parts in the world.

SW (Schwbische Werkzeugmaschi-

nen GmbH), as an important MAPAL

technology partner, opened the door

to LFP. In the past some small tool

deliveries were made; deliveries that

demonstrated the professional supportand the quality of the tools.

Fewer tools for higher productivity

In 2012 SW was tasked by LFP to

deliver the machine and the fix-

ture for machining new water pump

housings made of EN-GJL250. In turn

the machinery manufacturer suggested

MAPAL Poland as a suitable tool and

technology partner for meeting the

customers requirements: complete

machining with a minimum number

of tools and a minimum number of

different indexable inserts.

Robert Adamczak, Director of Techno-

logy and Innovation at LFP, descri-

bes the collaboration as very good

and trouble-free: The water pump

housings are machined on an SW

BA600-2 machining center using

MAPAL tool technology. Our require-

ments for a reduced number of tools

as well as a lower cycle time compa-

red to the competition have been met

perfectly by the MAPAL solution. We

also achieved our objectives signifi-

cantly more quickly and straightfor-

wardly during the implementationphase.

Latest tool technology in use

The tool technology for the pump

housing was the result of collaborati-

on between Robert Adamczak and Pi-

otr Nowacki (project manager) at LFP,

Lukasz Barteczka, project engineer in

Czech sales at SW, and the MAPAL

team, comprising regional sales mana-

ger Piotr Jadrzyk, salesperson MarcinWawrzonkowski and Martin Rottenbil-

ler, who co-ordinated the activities in

the headquarters in Aalen. The project

features the following highlights: the

main bore on the water pump housing

is pre-machined using two multi-stage

ISO boring tools based on tangential

technology. In similar projects at LFP

three tools were used for this purpose.

In addition to this saving in tools, the

machining using the MAPAL tools

is also significantly faster. With a

cutting speed of 120 m/min and a feed

per tooth of 0.2 mm the pre-machi-

ning takes significantly less time than

predicted. For the main bore a circula-

rity of 0.05 mm and a concentricity of

0.025 mm are required. For this reason

the fine machining is undertaken

using a multi-stage fine boring tool

with guide pads at a spindle speed

of 540 min-1and a feed of 0.15 mm/

rev. In this way it, is possible to meet

the quality requirements reliably and

machine all steps in the main bore

simultaneously. With the ISO boring

bars used in the past at LFP, there

were often problems with the

concentricity of the individual

steps in relation to each other.

External recess is interpolated.

The interpolation turning

method is used to machine

an external recess. Lower tool

costs with high workpiece qua-

lity at the same time were the

key arguments for this machi-

ning technology. The machine

from SW used is very suitable

for interpolation turning dueto its dynamic performance

and rigidity.

Stockkeeping optimised

MAPAL was also able to meet

the requirement from LFP to

minimise and standardise the

inserts used: The same in-

dexable inserts are used for all

workpiece variants such thatCOM

PLETEM

ACHINING


21/24


Customer benefits

Leading tool technology

Custom services

Partnership-based collaboration

the stockkeeping is limited to only a

few types. Different tool bodies are

available for varying bore dimensi-

ons on the variants. A call warehouse

in the process of establishment at

MAPAL in Poznan for the necessary

indexable inserts is intended to realise

even more optimisation potential.

Project realisation in record time

Due to the smooth collaboration

between the partners involved, the

machining was accepted after just one

week, a task that normally takes up to

two months. It was therefore possible

to start production earlier than plan-

ned. Reason enough for LFP to invol-

ve MAPAL again in future projects,

as Piotr Nowacki, chief technologist

at LFP, confirms: Our decision to use

MAPAL technology was definitely

correct. We are convinced that this

collaboration will bring many tech-

nical and commercial advantages for

efficient production also in future

projects.

Partnership-based collaboration (f.l.t.r.): PiotrNowacki (LFP chief technologist), ukasz Barteczka(project engineer at SW) and Piotr Jdrzyk (respon-sible salesperson at MAPAL Poland).

Pre-machining of main bore usinga combination tool with ISOindexable inserts.

The fine machining is undertakenusing a multi-stage tool withguide pads.

Your local contact in Poland:

Alexander Zielonka | [email protected] turning is used to produce an external recess.


22/24


Machining of the Sigma engine in Taubat successful due to

modern tool technology and close collaboration

Worldwide collaboration for optimal processes MAPAL and Ford

The Ford Motor Companys Taubatproduction site was founded in 1974and is considered in Brazil to be apioneer in the production of engi-nes, gearboxes and other automotiveparts. Ford Taubat produces 430,000engines and 500,000 gearboxes per

year. The latest production processesare used to machine and assemblethe cast parts. In January this yearFord Taubat was able to achieve twomajor milestones: the total produc-tion of engines passed five million,the production of gearboxes the fourmillion mark.

Ford launched a new series of Sigmaengines in December 2009. This inno-

vative engine generation was develo-ped as a global platform. Ford descri-bes the Sigma engine as light, durable,economical, low noise and lowemission; the engine is manufacturedin Germany, England, Romania andBrazil. 600 million US Dollars wereinvested in Taubat to manufacturethe new engine. As a consequence itwas possible to double the productioncapacity for engines.

Collaboration at global level

Ford approached MAPAL with the taskof designing the machining processfor the Sigma engine, the first engineon which the engine block, cylinderhead and gearbox housing are madeof aluminium. To optimally addressthe requirements on the machiningprocess and to ensure the usage of the

same technology on all productionsites, several MAPAL sites aroundthe world worked together. MAPALEngland was responsible for the engi-neering and the overall co-ordinationof the project. The tools were deve-loped in Aalen and in the Germancompetence centers, and then broken-in and tested in the test center. Forthe production in Brazil, Joo PauloSouza is always on site in Taubatand, together with the team aroundTechnical Manager Rogerio Rodrigues,is responsible for a smooth runningprocess. Duilio Dalla Rosa was respon-sible for breaking-in at the machinerymanufacturer; today he supports theSigma Camaari Industrial Complex in

Camaari. Ford Taubat had alreadyestablished a partnership with MAPALdo Brazil in 2008; this partnership in-

volved the delivery of technologicallyleading tools as well as optimisationservices in production at Ford.

Based on the example of the Sig-ma engine it is clear that significantpotential can still be tapped on site tomake production more cost-effectiveand more reliable. Some highlights

from the Sigma project in Taubat arepresented in the following.

Costs halved during the machining of

the cylinder bores

During the machining of the cast cy-linder bores it was possible to reducethe machining costs by more than50 % due to a continuous process

of improvement and optimisation.Originally a six-cutting edge tool withPcBN blades was used for the ma-chining. The end of the tool life wasreached after 250 parts per cuttingedge. During optimisation the spe-cialists from MAPAL do Brazil wereable to reduce the number of cuttingedges on the tool and at the same timeto triple the tool life. The cycle timeremains unchanged with the currentmachining values (n = 2,400 min-1and vc= 583 m/min, vf= 1,296 mm/min).

More teeth bring higher milling speed

and improved tool life

The sealing faces between theengine block and cylinder blockare machined using an EcoFeedface milling cutter with a diame-ter of 250 mm and 36 teeth. TheEcoFeed face milling cutters areequipped with disposable millingcartridges and therefore involvesignificantly less logistics effortduring handling. The EcoFeedachieves perfect surface finishesdue to exact positioning of the

milling cartridges in the tool bodyand the sensitive wedge adjust-ment of the inserts.

In surface machining at Ford

Taubat it was possible to signifi-cantly improve the performance ofthe EcoFeed by means of optimi-sation on site. While originally it


23/24


Customer benefits

International project management

Detailed local know-how for optimised processes

Cost reduction by more than 50 %

Your local contact in Brazil:

Sidney Pimenta Paiva | [email protected]

The team at MAPAL do Brazil from left to right:

Technical Manager Rogerio Rodrigues, Duilio

Dalla Rosa, General Manager Sidney Pimenta

Paiva and Mairon Cezar from the engineering

team as well as Joo Paulo Souza, the engineer

responsible in the Taubat works.

Tool for machining valve seat and valve guide.

Significantly increased cost-effectiveness during the machining

of face surfaces on engine block and cylinder head the Eco-

Feed. Engine production at Ford Taubat.

8,500

25,000

3,700

15,000

Engine block machining:

Cylinder head machining:

Before:

New:

Before:

New:

3-times the tool life

was possible to machine 8,500 engine

blocks and 3,700 cylinder heads, the

tool lives are now even more impres-

sive: one EcoFeed face milling cutter

machines 25,000 engine blocks and

15,000 cylinder heads with a cutting

speed of 3,000 m/min and feed rate of

11,000 mm/min.

Successful teamwork

The successful collaboration with Ford

shows how MAPAL is available to as-

sist customers worldwide with know-

how, commitment and a team of spe-

cialists. These days when projects are

often transnational, it is essential to

be able to offer the same product and

engineering know-how in all markets.

With subsidiaries in 21 countries, a

continuous exchange of knowledge at

all levels and the focus on a close re-

lationship with the customer based on

trust, MAPAL is predestined to become

a dependable partner.


24/24

Responsible for the content:

Andreas Enzenbach

Editorial team: A Enzenbach O Munz

Publisher:

MAPAL Przisionswerkzeuge Dr. Kress KG

P.O. Box 1520 D-73405 Aalen

IMPRINT

mapal - impulse_51

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