The Company.

MAPAL Präzisionswerkzeuge Dr. Kress KG – a medium-sized family company –has been for decades one of the leading suppliers of precision tools for the metalmachining industry. As a supplier MAPAL provides support for its customers fromproject planning for individual processes to Tool Management.

The MAPAL Group headquarters

With the establishment of MAPAL byDr. Georg Kress in 1950 in Aalen, thefoundation stone was laid for the com-pany which now operates worldwide.The meteoric success of the companybegan with the successful introductionof single blade reamers with guidepads (the MAPAL principle).Based on this tradition the headquar-ters in Aalen is now the main produc-tion site for reamers and fine boringtools with guide pads. With morethan 1.200 employees, multi-bladedreamers, clamping systems and settingdevices are also produced in Aalen.In addition to the general manage-ment, the central functions are alsolocated in the headquarters as coor-dination points for the whole MAPAL

Group. Along with the developmentand marketing centre, the new cus-tomer services centre is also part of theMAPAL Group central functions. In theproduction area MAPAL Aalen suppliesthe manufacturing daughter com-panies with tool bodies and numerousadditional parts. The headquartersis also the venue for the wide varietyof MAPAL’s general and advanced trai-ning events. This includes technicalseminars and technical orientation aswell as offer training sessions, both forcustomers and for employees from allMAPAL’s daughter companies andagents.

MAPAL Präzsisionswerkzeuge Dr. Kress KG

P.O. Box 1520 | D-73405 Aalen | Phone +49 (7361) 585-0 | Fax +49 (7361) 585-150info@de.mapal.com | www.mapal.com

MAPAL ISOTOOL GmbH in SinsheimMAPALWWS GmbH in Pforzheim MILLER GmbH in Altenstadt

WTE Präzisionstechnik GmbH in KemptenAugust Beck GmbH & Co. KG in Winterlingen Rudolf Strom GmbH in Vaihingen/Enz

The WWS company was set up inPforzheim in 1980 and has been partof the MAPAL Group since 1994.Today MAPAL WWS GmbH is theleading manufacturer of tools withPCD blades. Combination tools forboring operations and circular inter-polation milling are among theirhighlights.

With the foundation of MAPALISOTOOL GmbH in Sinsheim in 1997MAPAL extended its range of productswith generating slide tools and slidetools, together with special tools withISO elements.

MILLER GmbH, founded in 1991 hasbeen part of the MAPAL Group since2003. MILLER produces precision toolsfor drilling, milling and counterboringin solid carbide and in Cermet.

The MAPAL Group in Germany

In addition to its headquarters in Aalen, there are six othercompetence Centres of within the MAPAL Group in Germany:

August Beck GmbH & Co. KG wasfounded as a mechanical workshop in1906 in Winterlingen. A comprehen-sive standard programme of reamingand countersinking tools forms thebasis of August Beck GmbH & Co. KG.

WTE Präzisionstechnik GmbH is adeveloper and manufacturer of highaccuracy chucks for tool clampingtechnology. Core competencies:precision drill chuck systems, hydraulicchucking sector and shrinking techno-logy.

Rudolf Strom GmbH in Vaihingen/Enzhas been part of the MAPAL Groupsince 1999 and produces special toolswith ISO elements for a wide variety ofapplications.

MAPAL Sites in Germany

Quality, close customer contact and early identification of the developments and demands of the market are MAPAL'sprimary objectives. More than 3.000 people employed by the MAPAL Group work out perfect solutions every day forcustomers' machining tasks.

Because of the ongoing general and advanced training of personnel and the constant exchange of experience,MAPAL ensures high technical standards worldwide and guarantees MAPAL's legendary quality.

MAPAL worldwide

India |MAPAL INDIA Private Ltd. in BangaloreItaly |MAPAL Italia S.R.L. in Gessate/MIJapan |MAPAL KK in TokyoKorea |MAPAL HTT Co. Ltd. in Kyunggi-DoMalaysia |MAPAL Malaysia Sdn. Bhd.in Selangor Darul EhsanMexico |MAPAL FRHENOSA S.A. de C.V.in MonterreyPoland |MAPAL Narzedzia Precyzyjne Spólka z o.o.in PosenSingapore | MAPAL Sales Office South East AsiaSouth Africa |MAPAL SPECTRA Carbide ToolingTechnology in Port ElizabethTaiwan |MAPAL Precision Tool System Co. Ltd.in TainanThailand |MAPAL THAILAND Co. Ltd. in BangkokCzech Republic |MAPAL CZ s.r.o. in Dlouhá LhotaUSA |MAPAL Inc. in Port Huron MI

MAPAL Group sites

Australia | Valcor Australia Sales Pty. Ltd.in Ballarat, VictoriaBrasil |MAPAL do Brasil –Ferramentas de preçisão Ltda. in Belo HorizonteChina |MAPAL China Production und Trading Ltd.in ShanghaiGermanyMAPAL Dr. Kress KG in AalenMAPALWWS GmbH in PforzheimMAPAL ISOTOOL GmbH in SinsheimMILLER GmbH in AltenstadtRudolf Strom GmbH in Vaihingen/EnzAugust Beck GmbH & Co. KG in WinterlingenWTE Präzisionstechnik GmbH in KemptenFranceMAPAL France S.A.S. in Le Chambon FeugerollesMAPAL France - Bureau Villepinte in ParisMAPAL France – Bureau ToulouseGreat Britain |MAPAL Ltd. in Rugby

MAPAL – always close to the customer, everywhere.

MAPAL

Reliably innovative

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„How can one define a company, anextremely lively organism,which hasdeveloped further an further formorethan 50 years andwithwhich somanypeople - customers throughout theworld, employees and suppliers - are soclosely linked, in a brochurewith just afewpages?Wehave dared to do so becauseweknow that in our Company it comesdown to just a few importantprinciples.

Wewant to be close to our customers,be and remain in dialoguewith them,think and act for them.Find and forma teamwhichwill feelpermanently committed to this idea.

At all levels of the company“

Dr. Dieter KressChairman & Managing Director

„Quality, reliability and innovativestrength are also factorswhich playa decisive role in the company - dayafter day.

Using brief comments throughoutwehope to illuminate the various aspectsof our company and clarifywhat isimportant to us.

Nowand in the future.”

Dr. Jochen KressMember of the senior management

Perfect dialogueBranches and products

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Workpieces and processes in the automotive industry –New machining solutions for that extra productivity andcost-effectiveness

If every second counts, major specialists are required. Specialists who arefamiliar with the machining processes down into the detail and who from thisdetailed knowledge develop innovations for real progress in machining. Forthis purpose we offer our experience from many individual solutions for speci-fic tasks in the automotive industry. And a willingness to take new andperhaps also unusual paths in the dialogue with the customer.

“The customers expect us to provide themwith a comprehensive,reliable and innovative programme fromour range of competences –at all the principal production sites in theworld. This is whatwe do.This is howMAPAL is set up.“Dr. Dieter Kress

Reliable machining of modern lightweight materials

Where reducing weight while maintaining stability is a key issue, modernmaterials are conquering ever more applications. Products of lightweightdesign, particularly those made of fibre composite materials and multimaterialsystems (CFRP-metal multilayer composites), are becoming increasingcommon in the key industry of vehicle manufacture, as they spread from theirorigins in the aerospace industry. Lightweight materials are in the meantimeestablished in wind energy converters and are increasingly common in machi-ne tools, industrial robots and the consumer sector. In intensive collaborationwith customers, for example from the aerospace sector, MAPAL has created acomprehensive range of tools for the reliable machining of modern materials.

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Increasing global passenger and freight traffic by road/rail, by sea and in the air,as well as the generation of energy by alternative means, for example, windpower and hydropower, are resulting in increasing demand for large parts. Thehigh costs of these parts require, on the one hand, a high level of accuracy, relia-bility and quality from the machining process. On the other hand, it is imperativethe efficiency of processes and productivity are increased, also during the manu-facture of large parts. Here new types of tool concepts can sustainably increaseefficiency during the machining of large parts with the objective of reducing themachining times, combined with increased process reliability and quality.

Short machining times, high process reliability andhigh process quality when machining large parts

As a competent tool partner, MAPAL offers a comprehensive services sector. Costsavings start in the planning stage for MAPAL customers. As a result of innovativeand reliable tool concepts, the specialists fromMAPAL show the way for cost-effective production of a part and savings with complex post-machining proce-dures Tool Management by MAPAL provides the right tool in the right quantity, atthe right time, at the right place and at the right price. Profitable production isguaranteed.

Custom-made services for a furtherincrease in efficiency

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Nowadays, customers expect suppliersto be a technology partner with know-how in all areas of the machining pro-cess. Due to advancing globalisation ofcustomers and the standardisation ofmachines, the importance of the pro-cess is increasing.

The metalworking industry has chan-ged. Where previously the focus duringnegotiations was on keywords likequality, technology, employee qualifi-cation and delivery time, today it is thetopics of cost transparency, life-cyclecosts, cost per part etc. that matter.There are several reasons for this deve-lopment. Customers are increasinglylooking for technology partners withwhich they can work together in allareas of the process.

With our roots in custom tool produ-ction, we are a problem solver andorientated closely with the customer.Advice and support for machining tasksand processes along with the relatedknow-how on the machining of work-pieces are therefore also attributedever increasing importance. Accordin-gly, today MAPAL has a very high levelof workpiece competence. In addition,MAPAL covers the complete range oftasks for machining cubic parts inclu-

ding process analysis and planning,tool technology and logistics servicesand retooling tool machines for newparts (re.tooling).

Due to advancing globalisation of customers and the standardisation of machines,the importance of the process is increasing

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Reaming andfine boring tools

For 60 years, using reamers and fineboring tools with guide pads, MAPALhas set the highest quality standardsfor cutting with geometrically definedcutting edges. The MAPAL principleguarantees the dimensional stabilityand form of the bore within just a fewmicrons, reliably and economically.While the guide pads are specificallydesigned for their task (guiding thetool in the bore), the blades, which areprecisely matched to the machiningtask in cutting material and cuttinglead, deal with cutting the material.Whether cast iron, steel or othermaterials, MAPAL tools always achieveremarkable results.

Also in the area of multi-bladed, fixedreamers MAPAL offers a versatile rangeof high performance tools that addressthe requirements of many customersfor high quality with easy tool hand-ling.

The portfolio ranges from ø 0.6 - 300mm and stretches frommicroreamersthrough monoblock designs to theinnovative replaceable head systems,the high performance reamers in theHPR series.

Due to the HFS® replaceable headsystem and the accuracies that canbe achieved with it, this modern,modular tool system offers maximumperformance and flexibility, as well asadvantageous combinations of diffe-rent cutting systems on custom tools,and as a result totally new forms ofefficient production.

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PCD tools

In the area of tools with PCD bladesMAPAL has emerged as one of the prin-cipal manufacturers in the last tenyears. The programme for this productline includes precision gun boringtools, circular interpolation millingtools and end mills, and a successfulface milling head system with replace-able milling cartridges.

Modern and high-precision clampingsystems combined with precisiongrinding quality for maximum dimen-sional stability and concentricity openup numerous options for fixed andbrazed MAPAL PCD tools, not onlyin HSC operations.

ISO tools

Tools with ISO elements represent efficient and reliablesolutions with all materials for pre-machining and finemachining when boring and milling. ISO indexable insertsand tool holders are used in a radial and preferably tangenti-al form for the boring tools. The milling program includesface and shoulder cutter heads, face end and disc millingcutters as well as helix milling cutters for the cost-effectiveand flexible machining of large bores. A wide range of sele-cted substrates, geometries and coatings with suitable inde-xable inserts ensures that the optimal cutting edge can beused for every application.

Actuating tools

Actuating tools are available for maximum rationalisationand optimisation potential, particularly in mass production.Different mechanical actuating principles combined withfacing heads allow for complex contours, various diameters,flat surfaces or recesses to be machined with just one tool.As a result of the mechatronic TOOLTRONIC® tool systemthat is directly connected to the controller as a drive modu-le, the machine has an additional axis available. TOOLTRO-NIC® opens even more possibilities for flexible and cost-effective machining.

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Clamping systems

MAPAL offers a complete system ofclamping devices for use on machiningcentres, special machines and transferunits, right through to multi-taskingmachines. The programme of precisionchucks is rounded off by a wide rangeof extensions and reducing elementsplus adaptors and flange adaptors.MAPAL´s programme of clampingsystems offers the perfect solution forevery application and a connectionwhich provides the tool with the con-centricity and repeatable accuracy itrequires in use. Numerous options andperspectives for modern productiontechnology open up.

Solid carbide tools

To provide a complete range of compe-tences in bore machining, MAPAL alsooffers a product line of excellent spe-cial and standard tools in solid carbide.This range from simple drills to thelatest high performance drill. Toolswhich achieve reaming quality in asingle pass are a particular highlightin this product line.Coatings developed especially forboring and the use of super cuttingmaterials PCD and PCBN are furtherfeatures which increase the perfor-mance of MAPAL solid carbide tools.

Setting devices

The precision of surface, form and di-mension which can be achieved withMAPAL tools with guide pads are at thetop end of what is feasible with geo-metrically defined blades. To manu-facture to micro-precision reliably andrepeatedly with every new blade andevery new tool, MAPAL offers specialtool setting devices which make set-ting easy. Mechanical and electronicversions are included in the supplyprogramme.

Customer services

MAPAL provides perfect engineeringfor the entire machining process.Fromthe pilot phase through design, plan-ning and procurement of components,to start-up, MAPAL provides appropri-ate, cost-effective services. The custo-mer receive support during the manu-facturing process and optimisation iscontinuous.

MAPAL service guarantees optimumresults for your special applications –and at reduced costs. Many years ofintensive and customer-orientatedcollaboration make MAPAL a specialistalso in the service area.

Realizing the impossibleInnovation

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“We believe that real innovations provide the thrust for the develop-ment of a company. But for innovationswemust create freedom in ouremployees’ thinking and acting. It is only freedomwhichwill lead tonewways that drive technology forwards.And: Innovationsmust be presented to the customerswith force,courage and pace. Only thenwill they bring the company success.“

Dr. Jochen Kress

MAPAL was and is decisively involvedin the development of new technolo-gies. At the MAPAL development cen-tre experienced specialists deal inten-sively with subjects such as minimalquantity lubrication, high speed andhigh performance cutting (HSC andHPC) and the machining of specialmaterials. Today hardened steels,sintered materials, CGI or ADI playan important role in this. MAPAL cus-tomers profit from this technologicaladvance with tools which offer greatereconomies and quality.

Minimal quantity lubrication TOOLTRONIC®

Innovations are a feature of all MAPALproducts. Many of these innovationsrelate to the solution of tasks withwhich our customers confront uson a daily basis. Often unusual waysare adopted for this and almost un-achievable targets reached. In prin-ciple, the objective is to find new toolideas which achieve savings potentialof more than 30%. A modern rangeof machines in MAPAL's developmentcentre allows trials to be carried out asclosely as possible to how the opera-tions will run subsequently at the cus-tomer's works.

By working doggedly on new tasks,but also by making large and smallsteps with current problems, MAPALinnovations repeatedly lead to newpaths and new opportunities in cuttingoperations. Examples such as machi-ning cast iron with PCD, hard machi-ning with multi-bladed tools or thedevelopment of the HFS® Head FittingSystem demonstrate expertise, a rich-ness of ideas and creative potential.

Hard machining

Replaceable Head Systems:left: Replaceable milling cutter CPMillright: HFS® Head Fitting Systems withradial clamping

Face milling heads with PCDand PCBN replaceable cartridges

Absolutely precisePrecision

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The precision which can be achievedon the part relates directly to the pre-cision of the tool. With the diversityand number of MAPAL's special toolsconsistent and thorough quality assur-ance represents an indispensable andfundamental principle for the products'success. The use of modern machiningmethods combined with decades ofexperience guarantees that the toolsachieve the highest precision.

“Precision isMAPAL's promise to themarket and consequently an ongo-ing and self-evident obligation on our Company. Our customers can relyon this. And they know it.“ Dr. Dieter Kress

The high precision of MAPAL toolsreflects directly on the customers' pro-duction. For finish machining MAPALoffers interesting tool concepts withwhich previously necessary semifinish-ing operations and even additionaloperations, such as grinding or honing,can be dispensed with entirely. The re-duction in production costs and thesimultaneous increase or assuranceof machining results under batch pro-duction conditions is the aim of everyMAPAL tool we offer.

The requirements for circular andcylindrical form and surface finishwhen producing valve bodies forautomatic transmission systems areless than 4 µm, with additional SPClimitations. MAPAL tools achieve thisquality thanks to their precision andthe MAPAL principle. In a furtherexample a critical surface requirementis achieved when machining a steeringbox with a particular cutting lead. Theresult lies with a dominant waviness ofWDc at < 0,2 µm. This means thatthere is no need for costly additionalmachining on the bore.

Absolutely dependableReliability

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“If one is constantly in dialoguewith customers – aswe are – reliabilityin all areas and at all levels of the company is an essentialmaxim forpeople’s dealings. How can one otherwise face the customer?“Dr. Dieter Kress

The provision of process-orientated,comprehensive and customer-focusedsolutions defines the way MAPAL ope-rates. This includes much more thanmanufacturing efficient tools, preci-sion blades or accurate clamping devi-ces. Reliable customer services cove-ring all products are ultimately theguarantee of their sound and profitablefunction. Service is an evermore im-portant factor in MAPAL's understand-ing and the capacity which is reservedfor this is suitably large. MAPAL is opento finding innovative ways when offer-ing customer services. Considerableexperience in the machining of cubicparts provides the necessary back-ground.

The demands set by the customer withregard to process reliability has a Cpkvalue of 1,67. Production reliabilityincreases as the Cpk value increases.3 to 4 times the values, for example, isachieved when machining the camshaft bearing bore in cylinder heads.Diameter tolerances and concentricityresults for the individual journals inrelation to each other are accuratelymaintained, both for the cam shaft andthe crank shaft bearing bore, by meansof the guide pads in MAPAL tools.

Reliable partners and reliable toolingbring about the appropriately highprocess reliability for today's require-ments. This means that when they arefitted onto the spindle, the tools im-mediately produce the right quality,the blade cuts for a long and preciselydetermined time and the preparationand tool supply is properly organised.MAPAL has the right products to offerfor all these factors and as a resultprovides reliable production.

Dialogue with technologySharpening the senses

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“Dialoguewith technology – constant, uninhibited and free. For thisweneed towin over our younger employees. This is the onlywaywewillfind the new ideas, pioneering solutions, real innovationswhich themanufacturing economyneeds.“ Dr. Dieter Kress

The people at MAPAL navigate theconflicting fields of defining tasksand applying possible solutions bycontinuous dialogue. This dialogueis with other people but also withtechnology itself.Chip form, wear or the surface of thepart – they all provide informationabout possible improvements. And thistechnical dialogue is conducted inter-nationally. All personnel at MAPALsites in Europe, America and Asiawork responsibly together with and fortechnology within their area of work;by doing so they contribute to thesuccess of the MAPAL Group and to thesuccessful use of tools by customers –worldwide.

A prerequisite for qualified personnelis good general and advanced training.Today, because developments aremoving even faster, it is important torecognise this for the old and theyoung. It is in acknowledgement ofthis that MAPAL guides and challengesits employees and offers general andadvanced training in the various areasof work.There is also dialogue and associationwith universities and research insti-tutes. By commissioned work orworking together on combinedprojects, fundamental trends areinvestigated and solutions workedout together.

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“We are constantly in dialoguewith technology – at all levels of thecompany, hour by hour, day by day. Thismeans that opportunities areexploredwhich present themselves in awide variety of technical fields– to the customers' advantage and for constantly optimised andefficient production processes.“ Dr. Dieter Kress

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