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Reaming and Fine boring competence

Reaming | Fine Boring – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

MAPAL offers innovative, cost-effective solutions for machining almost all materials. Today, MAPAL is continuing to write the success story related to the fine machining of bores that started with the “first reamer” in 1954. Thanks to decades of experiences as well as continuous further development and optimisation of the tool solutions, along with tailor-made custom solutions, today MAPAL offers a broad standard programme of tools for reaming and fine boring.

Reaming and fine boring are the most common methods for fine machining bores and impress with the most precise results. The manufacture of the tools is based on the same precision as MAPAL tools provide in practice. MAPAL offers a suitable solution to suit the complexity of the machining operation and the requirements on precision and surface finish: single and twinbladed reamer reamers, fine boring tools with guide pads and WP or HX indexable inserts stand for the highest precision.

The programme also includes multi-bladed reamers: replaceable head reamers combined with high-accuracy clamping systems, monoblock reamers made of carbide, cermet or HSS as well as systems for machining large diameters.

Drilling, boring and countersinking competence

Drilling | Boring | Countersinking – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

Starting from the focus on the manufacture of custom tools for customer-specific machining solutions, MAPAL has developed a comprehensive standard programme for drilling, boring and countersinking.

In the area of drilling using solid carbide tools, MAPAL is one of the world’s largest providers. The programme of solid carbide drills covers solutions for the reliable and cost-effective machining of almost every workpiece material and is completed by modern replaceable head systems for the highest cost-effectiveness.

Tools with ISO indexable inserts are taking a leading role in the area of boring. Building on its know-how related to fine machining, MAPAL has developed a comprehensive standard programme for this machining.

Milling competence

Milling – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

In the area of milling, MAPAL tool experts have developed numerous machining solutions in recent years. The focus has been on tools adapted to the related customer requirements. Along with these individual tool solutions, however, the usage of high-performance standard tools plays a major role in many applications. Therefore a comprehensive standard programme has evolved from these custom tools.

MAPAL’s many years of experience, accumulated know-how and high level of process understanding in the area of milling are reflected in the standard programme. Process reliability, efficiency and the highest productivity for customers are therefore guaranteed.

Milling cutters from MAPAL arrive at the customer after extensive research and development work, design and simulation using the latest software, production and finally inspection on the latest manufacturing equipment. In conjunction with the most efficient cutting materials, MAPAL therefore offers the optimal milling tool for almost all applications and workpiece materials.

Turning competence

Turning – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

Building on extensive experience with the extremely hard cutting materials PcBN and PCD from the area of boring, milling and reaming, MAPAL has also obtained a profound understanding of the turning process. A clear focus here is on hard turning.

The range from MAPAL includes special tool solutions for scroll-free turning for complete machining of sealing faces, bearing surfaces and bearing seats on the lathe. This saves time-consuming re-clamping of the workpieces on grinding machines.

To utilise optimally costly PcBN round inserts, MAPAL has developed a system with indexable round inserts that makes simply defined rotation of the insert in the machine possible. In this way the insert can be utilised optimally. Maximum stability during hard grooving with PcBN is ensured by the grooving system VersaCut. It offers the optimal prerequisites for the special requirements of hard machining.

Today MAPAL offers a broad selection of PCD and PcBN-tipped indexable inserts for hard turning with an extensive selection of cutting materials and cutting edge design. In addition, the MAPAL portfolio includes a broad HSK-T program with turning holders for the connections HSK-T40, 63 and 100. A complete machine-specific range of conversion systems makes it possible to integrate the advantages of the HSK-T connection also in an existing environment.

Clamping competence – The optimal clamping tool for every application

Clamping – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

On using tools, their connection to the machine spindle, and therefore the clamping technology, plays a central role that is often undervalued.

On fine machining parts, very good results can be achieved with the highest radial run-out accuracies. The effect is very significant even on drilling or milling, as lower radial variations have a positive effect on tool lives.

Manufactured with the latest technology, the clamping technology programme from MAPAL offers the perfect solution for every application and a connection that ensures the tool has the necessary performance, radial run-out and changeover accuracy in use. From the manual HSK clamping units with the MAPAL KS clamping cartridge, through clamping tools with flange module, hydraulic and shrinking technology to adapters, the MAPAL standard programme covers a wide variety of systems and technologies. MAPAL offers a comprehensive range of standard programme also for machining with minimum quantity lubrication MQL.

Actuating competence

Actuating – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

Actuating tools stand for maximum rationalisation and optimisation potential in machining. For this reason, and to address the requirements for complete tool ranges, innovative actuating tools, boring bars and facing heads have formed part of the MAPAL portfolio since the 1990s. Whether for special machines or for complete machining on flexible machining centres – if the issue is to machine complex contours, non-cylindrical bores, face surfaces or recesses on cubic parts, MAPAL offers the optimal tool.

The product range includes mechanical actuating tools, which on the machine side are driven by drawbars/push rods or U axis systems, as well as NC-controlled tools, and the particularly flexible mechatronic tool system TOOLTRONIC, for machines without an additional feed unit.

The experienced, highly specialised MAPAL engineering team prepares the optimal solution for a machining task in close collaboration with the customer. Complex, exactly calibrated mechanisms and the numerous different parts inside an actuating tool require the highest accuracy and care during every production step.

To safeguard the high precision of the tools, they are only assembled manually at MAPAL. To commission the tools as quickly and efficiently as possible at the customer, complex actuating tools are comprehensively tested in advance under extreme loads and real application conditions. Commissioning at the customer is then undertaken by a MAPAL machining specialist.

Setting, Measuring, Dispensing

Setting | Measuring | Dispensing – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

MAPAL is the recognised specialist for fine boring using adjustable tools. The exact setting and measurement of these tools is a prerequisite for high part quality. The lack of suitable equipment for setting tools with guide pads led MAPAL to become involved in the development and manufacture of mechanical and electronic setting fixtures over 30 years ago. MAPAL always places very high value on meeting the tightest of tolerances of < 2 μm and on the extraordinary precision and longevity of the devices.

The high precision of the MAPAL setting fixtures is due to the combination of an exact basic mechanical set-up and a tactile measuring method. Among other aspects, measuring errors due to vibration or oscillations are completely eliminated by the solid mechanical construction with a granite slab and the vibration-damped adjustable feet. Errors due to temperature fluctuations are excluded by the usage of high-quality materials.

Services

Services – Catalog

Supplementary Volume 2018 – Catalog

Supplementary Volume 2019 — Catalog

In the metal-machining industry, the focus is on process costs. Anybody who wants to control them must understand all processes. Here it is good if businesses can rely on a technology partner who offers comprehensive support from planning to the series production process.

MAPAL’s roots lie in the manufacture of custom tools. For this reason we have always focussed on holistic advice and support for machining tasks and processes.

We support you in all phases and all areas of production with our services. Irrespective of whether you are setting up a new production facility, optimising your processes, introducing new technologies, re-tooling your machines for new parts, optimising your tool inventory, or want to expand the know-how of your employees.

Trusted Partnership

MAPAL join hands with WALTER and HOUGHTON to have a strong presence in Australia to cater for all machining needs.

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