1 Neuheiten_2013_V07_DE_EN.indd :26

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1 INNOVATIONS

2 2 When something exceptional develops between us: That s the MAPAL effect.

3 Innovations and product range additions 2014 Just in time for the EMO, we are offering our customers a wide range of new developments as well as further developments of products and solutions already introduced. The maxims of cost-effectiveness, energyefficiency and conservation of resources are at the forefront of all our developments in order to give our customers a technological lead and allow sustainable production. The close cooperation between our technical consultants worldwide who listen to and identify the needs of the markets with the central Research & Development department plays a crucial role here. This symbiosis of market needs and understanding for the customer with the high technical know-how of the whole machining process ensures that we recognise the demands and technological trends of the different industries in good time and can react accordingly. In the field of fine boring tools, for example, we have achieved a pioneering development with the EasyAdjust System that is currently unrivalled for profitability and simplicity of handling on the market. Apart from significantly reduced setting times, the EasyAdjust System also offers an HX blade with six cutting edges that results in lower cutting material costs with unchanged high precision. adjusting are of great benefit to the customer. Because these possibilities always mean a significant technological step forward. The possibilities offered by the MAPAL system solutions, but also by our high performance standard products for drilling, milling, reaming and turning as well as services related to measuring and Dr. Dieter Kress Dr. Jochen Kress 3

4 » REAMING AND FINE BORING EasyAdjust-System Drastically reduces setting times WORLD FIRST Martin Häfele MAPAL has achieved a breakthrough in the field of fine boring tools with insert that significantly increases the costeffectiveness of the tools. Innovative cassette with integrated back taper The heart of the EasyAdjust-System is an innovative cassette that stably holds the inserts with their six or four cutting edges without any play. The back taper of the minor cutting edge is already integrated into this cassette. The setting time for the back taper is completely eliminated. Due to the exact guidance of the cassette on a precision guide pin, the back taper remains unchanged even during diameter adjustments. Matching cassettes and clamping jaws are available for different back tapers that can be selected and employed, depending on the application. The secure mounting of the insert is ensured by a stable, force-closure system of clamping groove and clamping jaw. Significant economic benefits In practice the EasyAdjust-System significant improves the cost-effectiveness: The HX insert with six useful cutting edges can be inserted quickly and precisely with different back tapers. As only the diameter now has to be set, process reliability after insert change is enhanced an effect that becomes all the more significant, when more inserts are installed in a tool. And the time for adjustment per blade is reduced to a fraction by the new development. With the new development, MAPAL has succeeded in maintaining the high precision of the MAPAL fine boring tools while at the same time increasing cost-effectiveness by simplifying the handling. Setting time drastically reduced Cost-effectiveness, ease of handling and process reliability increased Precision remains high HX insert with six usable cutting edges 4

5 » DRILLING Microsection of a thermally sprayed coating. Motors with thermally sprayed coatings Reliably machined Siegfried Wendel Siegfried.Wendel@de.mapal.com In aluminium cylinder crankcases, lining of the cylinder bore surfaces with cast or shrink-fit grey iron bushes is today state-of-the-art. In order to be able to build aluminium engine blocks with even thinner walls and lighter weight in future, the cast bushes are replaced by thermally sprayed ferrous metal coatings. On the one hand these can be applied far thinner, and on the other the friction between piston ring and cylinder bore surface is also reduced. Conditioning of the cylinder bore surface with PCD contour blades For this new technology, MAPAL has developed new tools for the pre-machining and conditioning of the cylinder bore surface before thermal spraying in order to ensure optimum coating adhesion. PCD contour blades are used to create a defined structure on the cylinder bore surface with which the sprayed coating can optimally interlock and adhere itself. The structuring needs to have small undercuts and at the same time be designed to prevent blistering or inhomogeneity in the sprayed coating. Fine machining tool with HX inserts as preparation for precision honing After the spraying of the coating, the cylinder bore surfaces are dressed using fine machining tools with HX inserts. The geometry of the bore surface is thus prepared for the final precision honing. Tools with PcBN blades are used here, as the very hard sprayed coatings place a very high load on the cutting edges. As with other applications in hard machining, the know-how in the choice of the right PcBN grade and the edge preparation are crucial for success. The fine machining tool is furthermore equipped with coolant-controlled actuator mechanisms and cutting compensation. Tool solutions for current developments Structuring of the bore surface Fine machining before precision honing 5

6 » DRILLING Tritan-Drill Operates with up to twice the feed rate in challenging drilling situations Andreas Rinn Specially designed for challenging drilling situations Innovative lead geometry for very good chip removal and low cutting pressure Ideal for through-drilling or on entry into cross bores Ideal for inclined bore entries Up to twice the feed rate The Tritan Drill was presented as the problem-solver for difficult drilling situations in Since then the three-edge drill has been employed successfully and reliably in numerous applications where conventional drills reached their limits. MAPAL has now achieved a significant optimisation of the lead geometry. Innovative lead geometry for very good chip removal and low cutting pressure The Tritan-Drill has unique generous point thinnings machined into the chip space which discharge the chips with minimum friction into the chip flutes. Cutting pressure and edge temperature are very low, and practically no build-up edges occur even during dry drilling of aluminium. The aggressive, self-centring chisel edge bites into the material on the first contact with the workpiece and holds the drill reliably in position. Ideal for through-drilling or on entry into cross bores The Tritan-Drill demonstrates its strengths particularly in situations where other drills fail: While two-edge drills drift during through-boring and create a significant burr, the Tritan Drill remains stable, the bore outlet sharp-edged and with minimum burr. The Tritan-Drill is perfectly suited also to precise positional drilling with large projection lengths. And best of all, the Tritan Drill achieves up to twice the feed rate 6

7 » DRILLING STD indexable insert drill ø mm / up to 8xD Dietmar Apprich Dietmar.Apprich@de.mapal.com Broad range of diameters from mm Sturdy system Easy handling Error-free indexable insert replacement Optimum chip formation and chip discharge thanks to ideally matched geometries between indexable insert and holder MAPAL is presenting a new high-performance drill for the middle to upper diameter range the STD indexable insert drill. It impresses with a very good chip formation and reliable chip removal thanks to an optimised chip flute. Sturdy mounting, simple clamping system The indexable insert is held in a particularly sturdy and precise prism mounting so that high cutting values and bore qualities can be achieved. The clamping system for the indexable insert is both particularly simple and extremely effective. It consists of a spring-loaded screw that is inserted transversely through the indexable insert, clamping the insert securely in the prism mounting. Indexable inserts for steel, stainless steel and aluminium The standard range offers indexable inserts with optimally adapted blade geometries and coatings for the machining of steel, stainless steel and aluminium. Very good tool lives with high process reliability are achieved and ultimately a very cost-effective drilling process. 7

8 » DRILLING CFK hand drills IT8 in one shot Jens Ilg special MAPAL drills, so that the machining results in higher profitability of the assembly process by eliminating one work step. IT8 quality in one shot possible No delamination and fibre protrusion with CFRP No burr formation with titanium Hand tools are still frequently used in the final assembly of the various fuselage sections of passenger aircraft for the drilling of rivet holes or bolt holes. The reason for this is the lack of accessibility of the parts. At the same time, high demands are made on the bores. In particular, the process has to be absolutely reliable, as the parts are very expensive and scrap or reworking is not acceptable. MAPAL has developed tools for this special application that set new standards when it comes to the machining of, for example, CFRP/titanium stacks. Not only the typical problems such as delamination, protruding fibres with CFRP or burr formation in titanium are reliably avoided. Tolerances in the range of IT8 can be achieved in one shot with the 8

9 » DRILLING MEGA-Speed-Drill Iron Inox Steel Three times faster and more reliable Andreas Rinn Guiding chamfer 1 Guiding chamfer 3 Guiding chamfer 2 incl. side relief Significantly higher cutting speeds Polished chip flute guarantees optimal chip removal Powerful in cast iron, steel and stainless steel The MEGA-Speed-Drill has a completely new cutting edge geometry with unequal spacing and three guiding chamfers. This prevents vibration and reduces friction. The highly polished chip flutes guarantee optimal chip flow. These features in combination with the new lead geometries and cutting materials geared specially to the drilling of cast iron, steel and stainless steels allow the MEGA-Speed drill to produce bores with 30 % higher feed rates than has been possible to date with conventional drills. With this extension of the MEGA-Speed Drill range, the machining of steel, cast iron and stainless steels can be performed with higher performance in the diameter ranges from 3 to 20 mm and drilling depths 3xD, 5xD and 8xD with the standard range. 9

10 » DRILLING Replaceable drill head TTD Type 04 Faster drilling, faster changes 10 Dietmar Apprich Thanks to the innovative drill geometry, the MEGA-Speed Drill has outstanding properties with respect to centring, stability and chip removal. This geometry therefore now forms the basis for the new drill head geometry Type 04 of the TTD replaceable head drill for applications in steel and cast materials. special facet geometry. In addition, very smooth running is enhanced by the special 3-chamfer geometry. The combination of these properties enables long tool lives and drilling results to be achieved at the highest level. For steel and cast materials with high machining demands Broad diameter range Longer tool lives due to smooth running in the bore thanks to 3-chamfer geometry Increased performance due to significantly reduced feed forces of up to 50 % Feed forces can therefore be reduced by up to 50 % compared with similar replaceable drill heads. This allows for significant performance increases and short machining times. The TTD Type 04 is designed for steel and cast materials and achieves very good machining results even for problematic and difficult machining tasks. This is achieved because the drill features an optimal centring capability and the chips are optimally discharged into the chip spaces of the TTS holder as a result of the 3-chamfer geometry of the TTD Type 04 10

11 » MILLING OptiMill -Composite-Speed Machines CFRP parts on robots Hans-Peter Wengert Low cutting forces reduce vibrations in the whole system Delamination-free trimming of CFRP parts on robots The machining on robots reduces machine costs The further spreading of complex CFRP parts in industry depends greatly on how these parts can be machined costeffectively. Various research projects are already investigating which machining method is the best solution here. In one joint project focussing on the possibilities of producing and machining CFRP parts with robots, MAPAL is responsible for the machining tools. MAPAL milling tools meet demands of robot production Due to their large number of interacting axes, robots cannot be compared with machining centres with respect to stability, precision and vibration behaviour during machining. These boundary conditions therefore have to be taken into consideration during the development of the tools. For these machining applications, MAPAL offers special milling tools that work with very low cutting forces and therefore transmit minimum vibrations to the whole system. They are particularly suitable, for example, for the trimming of CFRP parts using robots. 11

12 » MILLING EcoFeed-Blue The new face milling cutter with replaceable milling inserts Christian Molch A clean solution for high-speed aluminium machining Part cleaning represents a significant cost factor in series production. This applies in particular to geometrically complex castings, such as cylinder head and valve housings. This is where the new EcoFeed-Blue face milling cutter comes into its own. In order to come as close as possible to the goal of a dirt-free finished part, an innovative PCD milling insert has been developed. The special chip guidance geometry keeps the chips reliably away from the workpiece surface. Optimised for dry machining Thanks to the new milling inserts, a significantly improved visual surface quality is achieved with ductile and long-chipping materials, as the risk of scores is reduced. This has advantages particularly during dry machining and with minimum quality lubrication. The integrated coolant outlets in the milling inserts ensure optimum cooling and lubrication of the blades, particularly with minimum quality lubrication. The significantly reduced work of subsequent cleaning of the parts is particularly important for machining processes without the use of cooling lubricants. Economic basic design The construction of the new EcoFeed-Blue is similar to that of the proven EcoFeed principle. Here the inserts are in the form of milling inserts and are securely fixed by a highly precise dovetail guide. No additional elements are necessary for the clamping of the milling inserts. The exact positioning of the inserts in the aluminium tool body is retained over the entire tool life. Replacement of the milling inserts is extremely easy. Adjustment is very user-friendly with radially accessible, wedge-shaped adjusting elements. The axial run-out can therefore be set with μ precision. The new EcoFeed-Blue milling inserts are available as shoulder, face or wide face milling inserts and can be installed in the existing EcoMill tool bodies. Reconditioning in OEM quality MAPAL offers milling head management as a special service. This service guarantees the customer correct reconditioning of the milling heads at the end of the tool life and the dependable availability of the tools. Significantly improved surface quality as the chips are discharged to the outside High process reliability as less chips and dirt in the finished part No abrasion of the milling tool body High cutting speeds and feed rates Reduced noise level due to shorter blade projection at the face (0.5 mm) 12

13 » MILLING OptiMill -Silent Highly efficient and extremely quiet Andreas Rinn Ideal for thin-walled parts Vibration-free thanks to special cutting edge spacing Extremely quiet even at high cutting speeds Also suitable for trochoidal milling Particularly for milling applications, the avoidance of vibrations and the associated high noise level is an important starting point for further developments. The OptiMill -Silent sets new standards here. Vibration-free thanks to special cutting edge spacing The new OptiMill -Silent solid carbide milling cutter has been specifically developed with the goal of milling vibrationfree, and hence of achieving very good results with regard to quality and tool life even with the highest cutting rates. All the parameters of the milling cutter were therefore optimally matched. The special cutting edge spacing and the path of the chip flutes, in particular, contribute to ensuring that practically no vibrations occur even with thin-walled parts. Ideal for high cutting values The outstanding characteristics of the OptiMill -Silent come to bear in particular with high cutting values. The new milling cutter has proved to be very effective even for trochoidal milling. With this milling strategy, low radial cutting depths are used so that milling can be carried out with twice the normal cutting speeds and infeeds. 13

14 » MILLING OptiMill For trochoidal milling Andreas Rinn In many applications, trochoidal milling allows significant improvements to be achieved in tool costs, clamping systems, machining times and the load on the machine components compared with conventional milling, particularly with high-strength materials. For this milling technology, MAPAL is extending its OptiMill product family. Trochoidal milling in combination with the new OptiMill allows cutting edge lengths of 3xD that could not be achieved with conventional tools to date. 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. Balancing (balancing quality 2.5) undertaken during the manufacturing process further reduces the risk of vibration. Through this the patent pending milling cutter can even be used at extremely high spindle speeds without problems. So that with the greater cutting depths now possible, jamming does not occur due to the long chips produced in the process, as 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 compartment. 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 damping 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. Cutting length 3xD with special chip breaker geometry Vibration damping due to unequal spacing Balanced to G2.5 Low machining forces 14

15 » CLAMPING HighTorque Chuck HTC Reliable clamping force even at temperatures up to 170 C Jochen Schmidt Jochen.Schmidt@de.mapal.com High torque transmission Optimum damping properties High thermal stability up to 170 C at the tool shank With HSK, SK or BT shank Suitable for MQL Many metalworking companies are making efforts to exploit the savings potentials in machining production through a more efficient use of energy and material. High-speed machining, high-volume machining and minimum quantity lubrication are therefore the trend. In order to achieve optimum results, particularly when high precision and process reliability are called for, it is not only the right machine/tool combination that has to be chosen, but also the optimum clamping system as the crucial interface. Here the market offers a wide range of different clamping systems. The MAPAL HTC combines the advantages of the different clamping systems in one chuck. Also by high process temperatures th HTC guarantees the damping properties and simple handling of a hydraulic chuck, as well as the frictional force transmission with good run-out accuracies. The HTC is thus a universal chuck for a broad spectrum of machining operations. Thanks to shorter set-up times and its suitability for resource-conserving machining processes, it increases the efficiency of machining operations. 15

16 » MECHATRONIC SYSTEMS World first UNISET-P The completely new setting fixture with optimum ergonomics Stephan Köstler With the new UNISET-P, ergonomics was at the focus of the development. The greatest benefit compared with conventional setting fixtures is the very good accessibility to the tool during adjustment, and hence unprecedented ergonomics. The portal construction creates the space necessary to allow optimum access to the setting systems on the tools. Measuring camera and back-light source are integrated into the pillars of the portal, and are therefore not in the way during adjustment as with the conventional bracket constructions. Furthermore, the portal construction ensures maximum precision and is both mechanically and thermally extremely stable. The UNISET-P has a particularly compact design, but nevertheless practically all tools up to a diameter of 500 mm and a length of 600 mm can be perfectly measured and set. Various measuring methods It offers as standard additional light and transmitted light measurement, for example for the axial adjustment of face milling cutters. As an option the UNISET- P offers an additional cross-member in the portal that can be coupled to the drive of the measuring lens. An additional measuring sensor or measuring lens can be attached to the cross-member in order to be able to carry out axial measurements or even a rotational centre measurement. Innovative software offers numerous advantages The integrated software was developed strictly on the basis of user-friendliness. Optimum ergonomic accessibility Compact and versatile Large measuring range up to Ø 500 and length 600 mm Optional tactile measurement in axial direction It is thus possible, for example, to create fully automated program runs within seconds thanks to the integrated control geometries. Tools are automatically detected and approached. The new software even allows the contour of a rotating tool to be determined. Thanks to the wide variety of options and modular expansion possibilities, the UNISET-P can now be tailored even better to the specific wishes of the customer. WORLD FIRST 16

17 » MECHATRONIC SYSTEMS UNIBASE-M Automatic tool dispensing systems Michael Hils The new UNIBASE-M automatic tool dispensing system stands for optimum storage and management of tools, components and accessories and offers numerous innovative and user-friendly features. UNIBASE-M is designed as a modular system for the management and dispensing of tools, which ensures quick, efficient and controlled tool availability. Starting from a basic module with computer unit it can be individually configured to suit the application. Storage is either centralised or decentralised directly at the machine. Completely new is the intuitive software with extended functions which ensures quick, efficient and controlled tool availability. For example, a control logic gives the user an indicated of the selected drawer. Machine standstills due to a lack of tools, huge tool stocks due to excessive goods orders or double orders, as well as time and cost-intensive ordering processes can be reduced or completely eliminated with UNIBASE-M. UNIBASE-M can be easily integrated into external ERP systems on and in existing operating facilities. Automatic tool dispensing Intuitive software Variable drawer division Simple order handling Avoidance of down times 17

18 » MECHATRONIC SYSTEMS TOOLTRONIC Fit for the future Michael Hils Increased user-friendliness and simpler commissioning were the goals of the general modification of the TOOLTRONIC mechatronic tool system. In addition to extensive electronic improvements, the range of applications was significantly expanded. Commissioning greatly simplified With a new and lean version of the onmachine controller, the stator box, it is now possible to call up and evaluate the current status and detailed information of the interchangeable tool axis (U axis) via a modern touchscreen display. This is possible not only during operation, but also during commissioning. The direct and simple access to the U axis without additional tools such as a mobile PC greatly simplifies the set-up for the machine manufacturer. Should errors exist, they can be very quickly analysed and corrected using the call-up possibilities and information from the stator box. Various application tools complete the further development and offer significant added value. User-friendly and space-saving A lack of space in the switch cabinet is often a problem when it comes to the integration of mechatronic tool systems or U axis systems, particularly if these systems have to be retrofitted in standard machining centres without design modifications. Until now, several individual components such as stator box and computer module had to be installed for the integration of the TOOLTRONIC unit into a machining centre. This needed a considerable amount of space and generally resulted in a separate switch cabinet solution outside of the machining centre. The new stator box now contains all the individual components in one module, reducing the space requirements by 90 %. PREVIOUS SWITCH CABINET SOLUTION New TOOLTRONIC stator box reduces space requirements by 90 %. Reduction in the switch cabinet components Compact electronic units Simplified commissioning and machine integration 18

19 Further development of the actuator unit new LAT Series The high-precision EAT range (Eccentric Actuating Tool) designed for high speeds and modified strokes has now been expanded to include a new LAT Series (Linear Actuating Tool). The new LAT Series closes the gap for applications requiring high speeds and long strokes (over 100 mm). This is achieved using an integrated unbalance correction. In conjunction with a direct measuring system on the tool side, all the demands with respect to application and costeffectiveness can now be met. New TOOLTRONIC LAT Series (Linear Actuating Tool) Monitoring of mechanical actuating tools with TOOLTRONIC -S For difficult machining operations, such as recesses and facing operations on parts during industrial-scale production, mechanical actuating tools are often an inexpensive solution for meeting irregular demands. MAPAL offers innovative tools for this which can carry out actuating functions on machining centres without an additional feed unit. These are coolant-controlled, spindle speed-regulated centrifugal force tools or actuating tools with contact stop. One limitation with these systems, however, is that there is no feedback as to whether the slide is extended or retracted when entering the workpiece. In the event of faults or damage, the workpiece, mount or in the worst case expensive machine components can be destroyed. With TOOLTRONIC -S, the end position control system for monitoring mechanical actuating tools, MAPAL can now offer a simple solution to this problem. Irrespective of the method of actuations, TOOLTRONIC -S polls the end positions via sensors in the tool and feeds the information back to the machine controller. The process reliability is significantly enhanced when using mechanical actuating tools. New LAT Series for high speeds and long strokes More process reliability thanks to TOOLTRONIC -S Coolant-controlled actuating tool with TOOLTRONIC -S 19

20 NEUHEIT-E WD Printed in Germany. Right of technical modifications reserved.