MAPAL a large number of interested customers live at EMOPlus in Aalen more on pages 4 and 5

Transcription

1 41 December 2009 INFORMATION IDEAS INTERNAL MAPAL a large number of interested customers live at EMOPlus in Aalen more on pages 4 and 5 Coupled tools with guide pads Face machining with MAPAL facing heads Premachining of cylinder bore using tangential tools

2 Page 2 MAPAL Impulse EMOPlus EDITORIAL EMOPlus We held three technology days, which could also be called an in-house exhibition, under this certainly challenging title in Aalen in November 09. EMOPlus says on the one hand that the entire range that was on show at the EMO 2009 in Milan was again presented in Aalen; but with the "Plus" that makes the technology days something special. The most important innovations could be seen and evaluated "in action", that is in practical use in the MAPAL trials and development department. The demonstrations were accompanied by talks from experts on the background to the new developments and with more detailed information. Various complete machining processes on interesting workpieces were particularly well received by the many visitors. During this process MAPAL was able to demonstrate its singular knowledge of complete machining, including planning, process definition and manufacture of complex production tasks. The in-depth discussion of the results in smaller groups gave all the participants important tips that are particularly valuable at the moment as we all search for ways out of the crisis. The plus to the EMO indeed proved to be a plus for our customers and visitors to the MAPAL EMO. The way out of the crisis is above all with innovations, that means with efficient new developments. This issue of MAPAL Impulse is intended to give you some interesting tips on this aspect. Yours, Dr. Dieter Kress MAPAL Brazil receives the Top Supplier Award 2009 from Ford The Top Supplier Award is an award from Ford to the suppliers that meet the criteria innovation, cost reduction, dependability of supply and top quality to Ford's fullest satisfaction. MAPAL Brazil received the award in the Industrial Material category. After the evaluation of all the analyses, in the end only 9 out of 1,000 suppliers received awards. The awards were presented in a ceremony on 10 November in Sao Paulo by Marcus de Oliveira, President of Ford Mercosur, as well as the Vice President Global Purchase Ford Motor Co., Thomas Brown. MAPAL was awarded the prize for its trend-setting work in relation to process optimisation. In parallel with the current Z-Tech project, MAPAL is also heavily involved in the production processes for the new Sigma engine generation. The Top Supplier Award is very important for MAPAL. It symbolises the successes achieved in recent years. The main focus here was on establishing first class service as well as seamless logistics. A working group was in the end formed at MAPAL to be able to concentrate fully on the requirements from Ford. Sidney Paiva, General Manager MAPAL Brazil: This award will be an incentive for us to continue to drive forward the optimisations. Sidney Paiva, General Manager MAPAL Brazil receives the coveted Top Supplier Award.

3 MAPAL Impulse Page 3 News from the MAPAL Group Coveted Top Supplier Award for MAPAL Brazil Terrific prelude to the 18th Aalen Jazz Festival "The Hang Allstars in the MAPAL canteen terrific prelude to the 18th Aalen Jazz Festival. On Sunday, 5 November 09, the MAPAL canteen became a Mecca for jazz fans in the region. The stream of visitors started very early. The stage was big, the lighting in the entire room set the right atmosphere. The mood was full of expectation. Then unusually punctually the six musicians from the "The Hang Allstars" threaded their way through the crowd to make their appearance and then Herbert Kullmann described it as follows in the Aalen news: "The audience was promised a very special live musical event at the opening of the 18th Aalen Jazz Festival. What this meant was demonstrated by the jazz musicians in the packed MAPAL canteen with their first few notes, and also unashamedly with the volume: harmonious sound, great rhythm, sometimes drumming, sometimes more rock n' roll or sometimes even with a hint of the blues "The Hang Allstars", Dave (Oscar winner) and Don Grusin, Lee Ritenour, Wolfgang Schmid, Will Kennedy and Nils Wülker, combine funk and fusion in their music with astounding virtuosity, flavoured with a dash of contemporary world music, and also the excellent addition of acoustic jazz particularly during the second set. An unusual, exciting and energetic performance, a genial smooth and funky sound that captivated the public " No jazz enthusiast will forget this evening at MAPAL. Contents editor: Hermann Steidle Editing team: H. Steidle, M. Berger, O. Munz, M. Winter, T. Zimmermann Design: I. Rettenmaier Published by: MAPAL Präzisionswerkzeuge Dr. Kress KG P.O. Box 1520 D Aalen Phone +49 (0) Fax +49 (0) info@de.mapal.com

4 Page 4 MAPAL Impulse MAPAL in-house exhibition "EMOPlus" impresses more than 250 visitors. MAPAL stan Soon after this year's EMO in Milan, MAPAL held an in-house exhibition "EMOPlus". The key element of this in-house exhibition was that in Aalen it was not only possible to see the new tools already exhibited in Milan, the new tools were also able to demonstrate their capabilities in practice. For this purpose, a total of fourteen new developments were in action on various machines in the trials area. These tools included the new large reamers in the HPR300 series, various solid carbide drill designs with new cutting edge geometries, the helix milling, innovations in milling and drilling CFRP materials, as well as the demonstration of contour machining to the µm using the MAPAL TOOLTRONIC. The visitors welcomed the opportunity to talk in detail to the MAPAL product specialists in attendance about existing and also new machining tasks, and the related solutions using the new MAPAL tools. Many visitors were surprised as just how comprehensive the MAPAL range has now become. It includes not only guided fine boring tools, but the complete range of tools and services for machining cubic parts, and is not just limited to the machining of aluminium & steel, but can also be used for machining new materials such as titanium and GFRP/CFRP. Particularly apparent was MAPAL's ability to offer to some extent completely new solutions to problems for machining cubic parts that make it possible for the customer to make significant savings in machining time and costs. Interesting talks on important and much discussed current problems covered the following topics: Lowering costs and increasing precision new opportunities with fixed reamers Lathes saved new machining concept with TOOLTRONIC for turbocharger production Making tool costs transparent and reducing them using TOOL MANAGEMENT Cost-effective machining of large bores circular milling cutters and helix milling cutters with tangential inserts increase performance and costeffectiveness 200 m/min cutting speed on drilling in steel new face geometries increase productivity Drilling and milling CFRP and GFRP new geometries and cutting materials for reliable, precise machining Dr. Jochen Kress was positive about the results of the three-day EMOPlus: "For us the in-house exhibition was a complete success, like the EMO in Milan. This is clear from the number of visitors, however it is also even clearer from the discussions held. There were suggestions for the day-to-day work of practically every customer and the customers therefore obtained a tangible benefit from their visit to MAPAL. This issue can also be seen from the many enquiries as a consequence of the in-house exhibition."

5 MAPAL Impulse Page 5 EMO in Milan EMOPlus in Aalen d at the EMO in Milan. A large number of impressed customers live at the EMOPlus in Aalen MAPAL fine boring tools, new opportunities due to the "MAPAL principle" HPR 300 for large diameters IN ACTION: HPR 300 New tool concepts for reaming IN ACTION: MonoReam I multi-tooth reamer - New solid carbide tools for drilling IN ACTION: Titan Drill I Mega Drill 180 I Mega Speed Drill Replaceable head drill TTD IN ACTION: TTD for machining stainless steel - ISO tools with MAPAL tangential technology IN ACTION: Helix milling Solid carbide end milling cutter range IN ACTION: Routers for micromachining I High-performance milling cutters for fibre-reinforced workpiece materials Hard machining for cost-effective machining with PCBN IN ACTION: PCBN round insert with new indexing PCD tools, reliable during roughing and fine machining Tools for machining CFRP / GFRP IN ACTION: CFRP drilling MAPAL TOOLTRONIC New linear actuating tool for more stroke IN ACTION: Con-rod machining using TOOLTRONIC Complete machining with MAPAL based on the example of the turbocharger New HPH chucks for highest possible torque transmission UNISET-V vision. New setting fixture for simple, quick and convenient operation LIVE DEMONSTRATION MAPAL Toolbase tool dispensing systems LIVE DEMONSTRATION RayDesk, the compact precision solution for individual marking and engraving LIVE DEMONSTRATION Interested audience at the talks in-depth specialist conversations live demonstrations the customers were very satisfied.

6 Page 6 MAPAL Impulse The latest member of the MAPAL Group LASERPLUSS the name is the range LASERPLUSS AG in Kirschweiler near Idar-Oberstein, Germany has specialised in the manufacture of laser systems for precision applications involving the marking and engraving of all materials, welding plastics and cutting metals and hard materials. The company founded in 1997 with Dipl. Ing. Werner Schulz at its head now has a powerful partner in the form of the MAPAL Group. Innovation and precision are also important corporate principles at MAPAL and therefore form the foundation for successful collaboration and for the further development of LASERPLUSS AG. Lasers for machining materials Laser machining refers to machining using light. If light is incident on a material, the energy from the light is absorbed. The reaction of the material can range from simple heating, through melting, to vaporisation, or to the breaking of atomic bonds. Good results from laser machining require the controlled application of the laser light to suit the related material; timing, positioning and the amount of energy applied are important. The employees at LASERPLUSS AG have the necessary skills to select and optimise the various laser sources for the best use. Special know-how flows into the configuration of the laser source to suit the planned application. The latest laser technology is always used in systems from LASERPLUSS. The product range comprises three series. The RayMarker and its smaller brother the RayDesk are optimised for marking and engraving. The RayCutter is the basis for precision machining down to the µ range. Modern, energy-efficient fibre lasers are used with increasing frequency in the RayMarker series for marking, engraving or welding. The degree of control and accuracy of these lasers is also crucial for obtaining optimal results here. On the other hand solid-state lasers trimmed for absolute precision are used in the RayCutter series for precision machining. Perfect cutting with the RayCutter Applications with high requirements on the accuracy are often to be found on components for micro-technology. For example, the RayCutter is used to build components for micro-robots that can grip and position nanotubes under a microscope. These robots required extremely small motors and gearboxes, as well as minuscule grippers. Miniature gear wheels or micro-grippers made from ceramic materials are machined using the RayCutter. Very high dynamic accuracy with the RayCutter Along with the bundled energy, speed and precision are further attributes of the laser. Due to control that is exactly synchronised in relation to time and position, as well as a specially optimised mechanical configuration, the RayCutter achieves new dimensions in precision laser machining. As no mechanical forces act on the laser beam like they do on a cutting edge during mechanical machining, the basic configuration of the cutting system from LASERPLUSS is fundamentally different to that of a machine tool. To always be able to position quickly and precisely, very fast, light axes are attached to a robust granite gantry. As a result the RayCutter as an overall system can achieve machining and contour accuracies below the 2 µm limit. Appropriate measurement technology ensures reproducibility, and software developed in-house permits quick programming and a high degree of flexibility. A major application area that will be important in the future is the manufacture of cutting edges on tools for mechanical machining, such as indexable inserts/blades or milling cutters. Here ultra hard cutting materials such as CVD diamond are increasingly used that can no longer be machined using conventional methods. The laser has clear advantages in this area. The tools are brought "into shape" without the application of force, without physical contact and without thermal damage. A major plus for the user. The RayCutter provides conditions that are indeed ideal. The applications range from cutting, through final machining of the outer contour, to lasing 3D structures that are important for the chip discharge and tribological effects.

7 MAPAL Impulse Page 7 Customer benefit Fast, wear-free operation without physical contact Individual production sequence possible Saving in additional materials Perfectly marked with the RayMarker The RayMarker and the compact RayDesk are used wherever precise, clean and durable markings or engravings need to be applied. The special advantages of laser marking are in the fast, wear-free processing without physical contact and the saving in additional materials. With marking speeds of up to 5,000 mm, the RayMarker is a market leader. An easy to understand, graphical user interface for the software and the ability to import data from all common drawing and computer programs make working with the RayMarker and RayDesk as easy as using a printer. The good access in the working area makes it possible to add a large number of extras for handling workpieces. Devices from the NC-controlled rotary indexing table for simultaneous loading during the marking process using palletising systems and transport units, to robot loading permit integration in fully automated production lines. The engineering for the marking system is as individual as the production process. Applications from a very wide range of areas of industry are now reliably undertaken using the 100 RayMarkers that have been manufactured up to now. The marking and engraving of high value materials in the jewellery sector, the marking of special surfaces on glass, porcelain, plastics or metals, often on surfaces of widely varying form, are frequent tasks. In the case of an example from Left: Werner Schulz demonstrating the µm accuracy of the RayCutter. Right: RayDesk the compact precision solution for individual marking and engraving. medical technology, the RayMarker is used as for welding plastics along with exact marking. The component is a newly developed blood diagnostics system that comprises two chip card-sized pieces of plastic that must be welded together. The weld seam is along curved paths in the top plate. Figures left: CVD cutting edge after grinding... and after precision lasing on the RayCutter Right: RayCutter and RayMarker, optimally configured for the related application.. Your contact for Laser systems: Werner Schulz wschulz@laserplussag.de Jan Marc Heinemann jmheinemann@laserplussag.de

8 Page 8 MAPAL Impulse MAPAL HPR300 provides process improvements during the machining of stub axle assemblies Reduced costs due to innovative reconditioning Saving time and costs with innovations MAPAL has implemented this motto, for example, with the HPR300 reamers for large bores. Kessler + Co, a manufacturer of heavy-duty planetary axles, transfer gearboxes and wheel drives, has been able to obtain significant process improvements and lower costs compared to the previous production solution by using this tool. Annually, Kessler + Co. produces around 45,000 heavy-duty planetary axles and gearboxes that are used in heavy goods vehicles. The bearing bores for needle or plain bearings on the stub axle assemblies have diameters of around 72 mm with fits of IT6-7; Kessler ensures that the number of different diameters is kept as low as possible using a modular system. Looking for process improvements Initially the bores were machined using a single insert boring tool, however with highly unsatisfactory results. If it was necessary to change an insert, it was necessary to set the tool using a measuring cut and only low tool life was achieved, and even during this short time process reliability was poor. Unmanned shifts without rework were therefore inconceivable on the nine machines in the production area. The managers at Kessler looked for new tools to improve the process, to save costs and at the same time to increase process reliability with minimum effort for the machine operator. As a result of the partnership-based collaboration between Kessler +Co. and MAPAL, a solution was found that meets all the requirements in the form of the HPR300 series of reamers. Plug & Play with multi-bladed reamers The HPR family was specially developed for the efficient machining of precision bores. It not only achieves the required accuracy, but also fulfils the increasing frequently expressed desire for Plug & Play that is there must not be any setting effort for the user. The HPR reamers are exactly ground to the required tolerance and can be used in the machine without setting effort. In case of wear they are easy to replace using precision connections. A new development in this HPR family, which in the end was used at Kessler + Co., is the HPR300 reamer for diameters in the range mm. The special feature: The blades are not brazed in place as usual, but clamped in the tool body as blanks. This method is particularly advantageous on the reconditioning of worn tools. It is significantly easier, quicker and cheaper. At Kessler + Co. the HPR300 reamer outclassed other providers in extensive comparative tests. The crucial aspects were the quality of the bore, the tool life and the process reliability. The HPR300 was able to win due to the best tool lives and higher cutting speeds at the same time. It was also possible to significantly lower the costs per bore with the new tools. Due to the longer tool lives and the process reliability, unmanned shifts with pallet changing systems became possible in the overall process. Finally, it was also possible to reduce the number of tools in circulation, as the new HPR300 reamers are quickly reconditioned by MAPAL. Successful results Even during the initial trials on a ø72h7 bore in a stub axle assembly, the HPR300 reamer was able to match the best competitors. Together with the machining specialists at MAPAL, the cutting material and the cutting edge geometry were optimised such that the tool life increased from 240 to 750 bores. The cutting data are vc = 90 m/min and vf = 800 mm/min and produce shorter machining times. The long tool life without any setting effort has also significantly reduced the load on the machine operators. The high process reliability also makes possible unmanned shifts without rework. Longer service life and reduced reconditioning costs Once the end of the tool life is reached, the tools go back to MAPAL to the reconditioning service. Here the second HPR300-reamer process improvement becomes apparent. The worn blades can be very easily and quickly replaced with new blade blanks and ground to the original quality again. A crucial advantage is that the tool body and in particular the shank retains its original, high accuracy. On the replacement of the blades, the tool body is not subjected to any thermal loads whatsoever and complex cleaning processes are no longer required.

9 MAPAL Impulse Page 9 Customer benefit Enormously improved tool lives from 240 to 750 bores Plug and Produce very easy tool handling without adjustment Increased process reliability makes possible unmanned shifts An average brazed tool can be reconditioned three to four times, while the new HPR300 reamers can be re-tipped a minimum of fifteen times. Compared to brazed multi-bladed reamers, the initial investment in the HPR300 tool is somewhat higher. However this additional cost is paid back by the longer service life of the tool body after only the first reconditioning cycles. Calculated over the entire service life of a tool, the user can make considerable cost savings in this way. f.l.t.r.: Michael Neumann (MAPAL product manager), Klaus Weiss (supervisor Kessler & Co.), Hubert Fuchs (foreman craftsman Kessler & Co.) as well as Marc Wagner (MAPAL sales representative). MAPAL HPR300 reamer with clamped blades for low-cost reconditioning. 6 bores are efficiently machined per clamping system using HPR300 reamers. Your contact for HPR300 reamers: Michael Neumann michael.neumann@de.mapal.com

10 Page 10 MAPAL Impulse The machining of faces on various earthing rods and arrester rods at OBO in Menden using facing heads from MAPAL Machining the faces on rods With 30,000 products, OBO BETTERMANN GmbH & Co. has progressed from a metal machining business to a complete provider of advanced building installation technology. The business founded in 1911 with more than 30 enterprises and international production facilities, as well as 2,000 employees, ensures that products all over the world conduct electrical power, carry data and control energy. Face machining with MAPAL tools The product range at OBO includes earthing systems. A good earthing system forms the basis for a good lightning protection system. The lightning current safely conducted by the arrestor and diverter is fed to earth. Additional tasks are the equipotential bonding between the diverters and the control of the potential in the accessible areas. Various earth rods represent the simplest solution for retrofitting a lightning protection system and are mainly installed vertically, reaching deep into the ground. During the production of the earthing rods that form part of the earthing systems, both end faces must be machined. For machining the faces OBO uses a flexible face machining system manufactured by SEMA. The machinery manufacturer SEMA Maschinenbau has developed and successfully introduced onto the market several standard machines for face machining and rotary transfer systems. The system used for the face machining is equipped with a revolver with six tool stations on a 3-axis unit. The revolver is fitted with MAPAL tools to rough turn, to face, to countersink, to circular mill or to mill the faces on the earth rods. The range of tools stretches from a turning tool with ISO inserts, solid carbide drills and milling cutters, to solid carbide spiral counterboring tools. The system also has two face turning units with two facing heads from MAPAL on a two-axis unit. The facing heads with double slide and knurling function are used to machine various outer contours on earthing rods and arrestor rods. Large number of variants on one machining system Twelve different earthing rods and arrestor rods are machined on the face machining system. Many features of the products vary significantly. For instance the diameter varies between 16 mm and 20 mm. In addition, among other aspects different materials are machined, such as ST50-2, AlMgSi0,5 and AlMgSiF27. However the main difference is in the different shapes of the outer contours. These range from a spherical shape to a pointed shape. In addition, it is also possible to fit a standard drill or a tap drill to the facing head using a central connection. By using the facing heads it is therefore possible to machine a large number of different shapes on one machine. The high degree of flexibility due to the MAPAL facing heads is a key aspect in this case. Complete machining of an earthing rod made from St50-2 At the start of the face machining, a 12.3-mm diameter bore is drilled in earthing rods made from St50-2 with the aid of the MEGA-Drill-Steel from MAPAL. The machining is performed with internal cooling, at a spindle speed of n = 3,000 rpm and a feed of f = 0.25 mm. Then a MAPAL turning tool with four inserts machines the end of the earthing rod (see Fig. 1). A Cermet indexable insert roughly turns the outside of the earthing rod. Two carbide indexable inserts fitted at 45 machine two chamfers on the end of the rod and the fourth insert performs the facing. The rough turning is performed at a spindle speed of n = 2,600 rpm and a feed of f = 0.3 mm. The milling and facing are then performed at a lower spindle speed of 1,100 rpm and a lower feed of f = 0.1 mm. Face machining with MAPAL turning tool

11 MAPAL Impulse Page 11 Customer benefit Complete machining on one face machining system Different diameters, contours and total lengths can be machined Large variety of parts covered A solid carbide ball head milling cutter with a diameter of 11.8 mm is used for circular milling a radius of 6 mm in the pre-drilled bore. The circular milling is performed at a spindle speed of 2,000 rpm and a feed of f = 0.08 mm. The other end, the point (see Fig. 2) is produced with the aid of two facing heads. The contour of the point is pre-turned in the first work step, then the longitudinal surface is then machined and, in the final work step with the first facing head, the contour is finished by turning. The cutting data are as follows: Point pre-turning: vf = 120 m/min f = 0.2 mm Spigot longitudinal surface: vf = 75 to 100 m/min f = 0.17 to 0.2 mm Point finishing by turning: vf = 35 m/min f = 0.08 mm Fig. 2: Outer contour of the point on the earthing rod MAPAL facing head with knurling function. Face machining system from SEMA. f.l.t.r.: Christof Gawron (supervisor turning shop OBO), Torsten Schönhaus (department manager METAL OBO), Johann Knauer (technical consultant MAPAL), Stefan Prumbaum (head of wire machining OBO) and Andreas Seydl (sales SEMA Maschinenbau). Then the second facing head knurls the earthing rod with grooves parallel to its axis. The knurling is performed at a feed rate of vf = 35 m/min and a feed of f = 0.4 mm. OBO decided on the usage of facing heads from MAPAL due to the high degree of flexibility. As a result the customer can manufacture different shapes on the ends of rods using one and the same system. This advantage saves the cost of investing in new machines. Fig. 1: Contour of the face machining with turning tool on revolver. Possible shapes and contours that can be machined using the two MAPAL facing heads. Your contact for actuating tools: MAPAL facing heads Dietmar Rettenmaier dietmar.rettenmaier@de.mapal.com

12 Page 12 MAPAL Impulse Best concentricity even on double-sided machining Coupled tools with guide pads absolute precision in gearbox housings During new development work in vehicle and car manufacture, marked by the overall objectives of the conservation of resources, reduced CO 2 emissions and ultimately increased energy efficiency, the gearbox has a central role in the power train. The gearbox must be optimally matched to the power output and torque from the engine to guarantee vehicle performance and comfort, and to reduce the fuel consumption with high overall efficiencies. The performance and quality of complex gearboxes depends on the exact interaction of components that must be very precisely manufactured. The gearbox housing forms the basic component, so to speak, in which the various parts are housed and mounted. The diameters of the bearing seats must be manufactured to within tight tolerances; the position tolerances, such as the positioning accuracy and the concentricity of the axes in relation to each other, must also be exactly right. These requirements are met optimally using MAPAL tools with guide pads, independent of the housing part geometry and the related machining sequence. MAPAL guide pad technology is predestined for fine machining of high accuracy bores, for instance in gearbox housings. By supporting the tool in the bore using the pads, accuracies in the diameter, circularity and cylindrical form can be achieved more reliably than with hardly any other tool system. In addition, even the highest of requirements in relation to the concentricity of stepped bores are not a problem, indeed these are one of the showpiece disciplines of MAPAL tools with guide pads. Even if the machining of bearing bores must be undertaken from two sides due to the shape of the gearbox housing, MAPAL offers solutions with which the highest qualities can be guaranteed. The special feature of these custom tools is that two multi-stage tools can be inserted from opposing sides of the gearbox housing and coupled together using a central guide pin. The guide pin is also fitted with highly accurately ground guide pads and engages in a plain bearing on the second part of the tool. As a result the tools almost melt together to form a single unit and the axes of the bores machined are exactly concentric. 1. side 2. side The mutual support between the tools eliminates inaccuracies on the two sides that would otherwise be seen in the machining result due to fluctuating stock removal or position errors on the fixture and clamping system. In an example of this technology, various diameters in the range ø mm are machined using two coupled fine machining tools. The required concentricity is up to 20 µm depending on the diameter. First the counter-rotating tools are inserted in the gearbox housing and coupled. Then the stepped bores and chamfers on the two sides are machined in sequence and finally the tools removed from the housing. The machining is performed on a custom machine that has been integrated into an interlinked machining centre line. Along with the required concentricity, the tolerances on the diameters and surface finishes are also reliably Geometry: ø74,6 ±0,01 / ø147 H7 ø89 ±0,1 / ø157 H8 / ø174 H9 / ø179 H7 2 x chamfers 2 x chamfers / 1 x face Spindle speed: n = 1500 rpm n = 1500 rpm Feed rate: vf = 300 mm/min vf = 150 mm/min Cutting speed: vc = 690 m/min vc = 840 m/min at largest diameter) Cutting material: PCD PCD Productive time: t h = 15,4 sec. t h = 6,8 sec.

13 MAPAL Impulse Page 13 Customer benefit Optimal support and accuracy Reliable concentricity at very high accuracy Various diameters and chamfers in one machining step achieved. The surface finish on the finely machined bores in the aluminium housings is Ra = 0.4 µm and is met effortlessly using PCD inserts on a large number of housings. The tool lives of the inserts depend on the diameter and length of the bores, as well as on the cutting conditions. For instance at large bore diameters that, in some cases, also involve interrupted cuts approx. 30,000 bores can be machined, while at the smaller diameters more than 60,000 bores are achieved. Absolute precision and process know-how for modern drive concepts The example described clearly shows that very good machining results can be achieved with guide pads even under difficult conditions due to innovative tool technology. As a result of its many years of experience and know-how in the area of the complete The tools are supported via the guide pin and plain bearing. machining of gearbox housings, MAPAL has sound expertise in the design of complete production processes. As a consequence individual, cost-effective solutions for the various applications are produced. The tools support each other and in this way achieve the highest possible accuracies. Your contact for tools with guide pads: Alfred Haas alfred.haas@de.mapal.com

14 Page 14 MAPAL Impulse Premachining of cylinder bores in compressor housings using modular MAPAL tangential roughing tools MAPAL TSW tools reduce the process costs Progressive technology in an around the compressor under this motto Bock develops innovative technical solutions that set standards for the compressor and the entire refrigeration system in relation to energy efficiency, safety and reliability. Bock Kältemaschinen GmbH based in Frickenhausen, Germany is a medium-sized family business that has more than 330 employees worldwide. The product range encompasses compressors and units for stationary and mobile cooling and airconditioning in commercial and industrial environments. Bock products are used in all areas of cooling, e. g. in supermarkets, cold stores, in the chemical industry and also in mobile applications such as the airconditioning in buses, trains and ships. Every year more than 50,000 units leave the factory buildings in Frickenhausen. The continuous further development of the product range as well as the continuous optimisation of the production process are an important element of corporate success at Bock. For example, the optimisation of the processes for the mechanical production of the cast compressor housings is continuously under review. In particular, the managers at Bock were looking for an alternative method for the complex pre-machining of cylinder bores. The bores cast in GG25 were to be machined more easily and more cost-effectively. The close collaboration with the responsible MAPAL sales representative as well as MAPAL's extensive experience in the area of ISO gun boring tools with tangential technology resulted in Bock converting the existing tool concept on two Heller machining centres. Difficult machining conditions require innovative tool solution Prior to the design of the new tool, the actual situation was intensively analysed in relation to the housing blank to be machined. Difficult cutting conditions due to a core offset on the cast bores (ø 64.5 mm), fluctuations in stock removal, as well as interrupted cuts at the bore outlet had to be taken into account during the planning phase. In addition, housing blanks for a total of seven compressor series each with up to seven variants need to be machined. There are differences only in the number of bores (four, six or eight cylinders) and the three capacity-dependent final dimensions for the cylinder bores (ø 70 mm, 75 mm and 80 mm). Depending on the compressor type produced, the stock removal for the pre-machining can therefore be up to 15 mm on the diameter. The tool system used up to now, a double edge, modular boring tool was at its limits. To reduce the axial and radial inaccuracies on the blades, the tool had to be set using adjustable insert seats. Continued on page 16 ø 69,5

15 MAPAL Impulse Page 15 Customer benefit Flexible tool concept reduces machining time and reduces process costs Easy tool handling increases process reliability Cast blanks made from GG25 prepared for machining. ø 69,5 ø 74,5 ø 79,5 The MAPAL TSW tool of modular design makes it possible to machine three different diameters with an additional chamfer. ø 79,5 ø 74,5 Your contact for ISO tools: Peter Holzbrecher

16 Page 16 MAPAL Impulse Customer benefit Twice the tool life and two tool changes saved MAPAL TSW tools reduce the process costs Continued from page 14/15 Despite this increased handling effort, it was not unusual for the tool life to come to a premature end due to insert fracture as a result of vibration due to fluctuating machining tolerances. Time-consuming re-work and interruptions to production were the consequence. Due to the high stock removal, the pre-machining of the ø 74.5 mm and ø 79.5 mm had to be divided between two tools. Flexibility and performance of the MAPAL TSW tools impress By converting the production process to MAPAL tangential roughing tools, it was possible to impressively optimise the pre-machining of the compressor housing. The three different machining diameters are now machined using only one modular tool system. This tool system comprises three replaceable, multi-bladed roughing heads and a tool holder. High accuracy fixed blade seats make setting unnecessary. The positive, tangential position of the indexable blades with six cutting edges in conjunction with the supporting arc shaped land produces soft cutting behaviour that is gentle on the machine, even with Machining data based on the example of ø 79.5 mm interrupted cuts. An additional 45 chamfer needed on the bore entrance is realised using replaceable cartridges. For roughing the ø 74.5 mm and ø 79.5 mm the tool heads were designed with cut distribution (4 + 4 blades). The high stock removal is possible without any problems due to, on the one hand, the soft cutting behaviour of the tools and, on the other hand, the machining centres with geared spindles. Process costs reduced, tool life doubled Finally, those involved at Bock and MAPAL were able to take stock of the notable results of the optimisation. For all machining diameters it was possible to Sven Frank (MAPAL regional sales manager), Alfred Kloos (tool setter at Bock), Bernd Gollmer (work preparation Bock), Markus Schubert (head of mechanical production). increase the tool life by more than 100 %. Per bore diameter only one roughing tool is required, a tool change is not required. Higher feeds due to the doubling of the number of teeth shorten the machining times. Indexable insert fractures are a thing of the past. The high machining quality of the TSW tools in relation to surface finish and position accuracy have a particularly positive effect on the subsequent fine machining. The easy tool handling significantly shortens the nonproductive times and increases the process reliability. In total, it was possible to reduce the process costs per tool by approx. 7 %. The procurement of the new MAPAL TSW tools has paid for itself in just six months. IMP41-e WD Pritned in Germany. Right of technical modifiactions reserved. Competition MAPAL TSW Tools required 2 1 No. of teeth 2 (per tool) Cutting speed v c 400 m/min 200 m/min Feed f 0,23 mm 1,2 mm Spindle speed n 1602 rpm 801 rpm Stock removal a p 3,7 mm (per tool) 7,5 mm Machining time t 16,2 s 8,12 s Tool life (cutting time) 40 min. 100 min. Bock refrigeration compressor with 6 cylinders of type HG7, ready to install.