resource-saving and energy-efficient - mapal: … · 2013-06-26 · milling machine optimisation in...

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400 visitors to the 3rd MAPAL dialogue

Trochoidal milling – fitness program for the milling machine

Optimisation in dialysis machine manufacture

MQL technology:Resource-saving and energy-efficient

Information, Ideas, Internals No. 51 | June 2013

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Building on a good market

position with new innovations.

EDITORIAL

A B S O L U T P R Ä Z I S I O N

Dear reader, dear business associate,

After a very positive business year 2012 during which we were able to record growth of around 10 %, we are cau-tiously looking forward to 2013 with optimism despite the widely reported increasing sense of crisis. What is the reason for our generally positive mood? On the one hand MAPAL is out in front with the market leaders in many product areas, in particular fine machi-ning, on the other hand we have a very broad base with our comprehensive product range and can better compen-sate for fluctuations in some sectors. With our international production and sales network in 21 countries we can also offer a high degree of customer proximity and can react flexibly to varying market requirements. Last but not least, as a family business we are independent of external investors and possible short-term shifts in strategy; we are therefore dependable as a long-term partner for our customers. All of these factors, combined with the high level of skill and ability of our em-

ployees, are essential prerequisites for maintaining and further expanding our good market position with continuous innovations.

MAPAL technology has therefore been the center of attention at many inter-national trade fairs and congresses. The possibilities offered by MAPAL system solutions and indeed also by our high performance standard products for drilling, milling, reaming and turning are of great benefit for the customer. Recently our development engineers developed a new tool for trochoidal milling; this tool is of unrivalled per-formance. The result is shorter machi-ning times, better tool utilisation, as well as noticeably lower tool wear. In combination with the new hydraulic chuck, High TorqueChuck, which can withstand temperatures up to 170° C, milling becomes highly efficient in all aspects.

With MQL technology we offer a fully mature product range for the machi-ning process with minimum quantity lubrication; this technology is taking on an increased sense of importance given the current situation of ever in-creasing energy prices. Many customers use this technology, on the one hand to save around 30 % of the energy costs and to reduce the coolant consumption to a minimum, however on the other hand also to reduce the impact on the

environment and to create better wor-king conditions for staff.

During all MAPAL development work the maxims of cost-effectiveness, energy-efficiency and conservation of resources are in the foreground to give our customers a technological lead and to make possible sustainable produc-tion.

Have a good read

Yours, Dr. Dieter Kress

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CONTENTS

MAPAL at CIMT in Beijing and Turning Days in Villingen-Schwenningen

MAPAL addressed the increasing demand for energy-efficient, resource-saving precision tools and machining methods during its successful ap-pearance at CIMT in Beijing. It was possible to make many new customer contacts. Along with the product in-novations, the ReTooling service, that is the re-tooling of existing machines for new parts, was a hot topic for our specialists. With a good 175,000 visitors, CIMT is the largest show for metal machining in China.

MAPAL also attended the trade fair Turning Days in Villingen-Schwen-ningen and was able to successfully demonstrate its competence in the area of tools for lathes and clamping tools. HSK-T, Versacut hard turning as well as MAPAL conversions for lathes to HSK-T were the focus of interest of the numerous visitors to the fair.

MAPAL has a new Head of Marketing and Corporate Com-munications

Since February 2013 Andreas Enzenbach (47) has been responsib-le for international product marketing as

well as internal and external communication. Enzenbach has many years of experience in international capital goods marketing in the mechanical engineering and systems enginee-ring sectors and is a specialist for communica-tion strategies.

Armin Kasper new Regional Sales Di-rector for China and TaiwanSince April 2013 Armin Kasper has been the MAPAL Group‘s Regional Sales Director responsible for the important growth

regions of China and Taiwan. As a long-serving sales manager from MAPAL WWS, a specialist for PCD tools and key account manager, Kasper has extensive expert knowledge and experience in international sales. He will therefore be able to provide very significant support to our sales company MAPAL China on the sale of our tools.

News

– MAPAL at international trade fairs– News from the MAPAL Group

NEWSTICKER

MAPAL Group News from the MAPAL Group Page 3 MAPAL dialogue: successful customer days Page 8

Product Highlights Solid carbide TTD offer: yes, I will. Page 6 Hybrid Tools Page 7 Trochoidal milling Page 10 PCD tools with lasered cutting edges Page 12 MAPAL setting fixture UNISET® Page 16

Reports from practicet Fresenius Medical Care: custom-made tool solutions Page 18 MAPAL Poland: LFP water pump housing Page 20 MAPAL and Ford: optimal processes Page 22

Imprint Page 24

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

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Producing greater added value with lower energy usage by increasing

the energy effi ciency of production processes.

News topics from the MAPAL Group

3D view of the newly planned companyheadquarters MAPAL C&S in the Czech Republic.

New building for MAPAL C&S

The construction work on the new headquarters of MAPAL C&S s.r.o in the Czech city of Mlada Boleslav, near Prague, started in May. „Our current building is too small for further deve-lopment“, says Petr Pokorny, General Manager of the subsidiary in the Czech Republic. The production faci-lities of the automotive manufacturer SKODA are also nearby. The new buil-ding for MAPAL C&S includes a two-fl oor administration area and a 1,000 square metre production building. The result is a signifi cant increase in capa-city for the manufacture of PCD tools and re-grinding solid carbide tools. MAPAL is investing around 1.2 milli-on euros in this project, which is to be completed by the end of the year.

In touch with the latest trends with MAPAL

Improved drilling processes for solid carbide drills, MAPAL tangential tech-nology and universal high-pressure chucks were the key topics at the 8th Amberg tool seminar. In recent years the seminar in Oberpfalz has become established as an important specialist forum for industrial users. Around 120 participants from all sectors of the metal machining industry along with graduates and scientists listened to the presentations given by MA-PAL speakers and saw for themselves the practical implementation of the information presented during demons-trations. Intensive use was also made of the opportunity to chat personally to our experts.

Tool applications are continuously chan-ging. An edge in terms of knowledge will secure competitive advantages. Seminars, workshops, forums or conferences off er information fi rst hand. The experts from MAPAL regularly attend a large number of seminar events. In exciting presenta-tions they convey new know-how and depict the latest trends and develop-ments in tool technology.

You will fi nd an overview of the up-coming seminars and events in which MAPAL will take part on our homepage at www.mapal.com/aktuel-les/fachvortrae-ge. The list is continuously updated.

Conversions for lathes off er higher accuracy with increased productivity

In 2008 HSK-T was standardised specially for the usage of upright tools on lathes. It features high chan-geover and repetition accuracy, high fi tting accuracy, high rigidity, as well as exact radial positioning accuracy.The greatest advantage of HSK-T compared to existing systems is the very quick, straightforward tool change. While with the standardised connections used in the past, 10 to 15 minutes were often necessary for the tool change, with HSK-T the time required is reduced to less than 30 seconds. Paired with very high change-over accuracy, there is a signifi cant reduc-tion in the machine downtimes and as a result a signifi cant increase in productivity for the user. Along with

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complete conversion, it is also possible to partially convert existing revolvers. On stations with frequent tool chan-ges, conversion to HSK-T is particu-larly advantageous, as the investment is manageable and pays for itself in a short time. MAPAL offers conversi-ons from all common connections on lathes to HSK-T, across machines and independent of manufacturer, as well as a wide range of turning holders.

News

– New building at MAPAL C&S in the Czech Republic – Increasing productivity with HSK-T – Technology report 2 on the topic of energy effi ciency

TECHNOLOGY

REP RT

2nd MAPAL technology report

Which factors affect the energy con-sumption of the machining process and how can energy be saved? This is the issue covered in the 2nd MAPAL tech-nology report. Prof. Dr.-Ing. Eckehard Kalhöfer, the Chair for Machining at the university in Aalen, and Dr. Jochen Kress, member of the senior manage-ment, have analysed the energy con-sumption of machine tools and indivi-dual process steps. Their report shows how, with only little investment, for

instance the usage of energy-effi cient tools and optimal machining proces-ses, to some extent signifi cant energy savings and therefore cost savings can be achieved. The technology report is included with this issue of Impulse. Would you like to continue to read re-gularly our scientifi c publications? Then make use of our free subscription. You will fi nd the registration form on our homepage at www.mapal.com/aktuelles/technologiereport/anmeldung.-.

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Clever changing with the replaceable head drill TTD from MAPAL

Replaceable head tool systems are now indispensable in modern produc-tion. Increasing raw material prices, lean inventories and the consideration of life cycle costs against the pure purchase price favour the usage of replaceable head systems. MAPAL has introduced on the market highly productive systems for all application areas; systems that are in no way inferior to monolithic tools – quite the opposite. With a focus on highly precise, very stable connections it has been possible to limit the usage of expensive carbide to the tool head, and to make the machining stable and precise overall.

In the area of drilling from the solid MAPAL relies on the replaceable head drill TTD. At the center is the torque transfer connection TTS (Torque Transfer Schnittstelle) which permits optimal torque transfer and at the same time high changeover and radial run-out accuracies. In this way the re-placeable head drill TTD achieves the performance of a solid carbide drill with lower costs.

Success stories from the different sec-tors and workpiece materials under-line the performance of the replace-able head drill TTD. For example in gearbox housings made of GJL-200 the ø 28 mm fi xing bores are drilled using a replaceable head drill TTD from MAPAL. It is possible to opti-mally meet the require-ments of the customer in

relation to the dimensional accuracy of the diameter. However the TTD also realises signifi cant saving potential by doubling the feed rate in comparison to the solid carbide drill used previ-ously. With 1,430 mm/min and 140 m/min cutting speed, 200 bores can be reliably machined using a replaceable drill head.In an application from steel machi-ning, clamps for folding machines made of ST52 are drilled using the replaceable head drill TTD.

83 bores with a diameter of 20 mm and a length of 106 mm are required per part. By using the MAPAL tool it was possible to reduce the machi-ning time from 39.7 to 18.1 seconds – this corresponds to reduction in the machining time of 54 %. Together with an increase in the tool life of 77 %, the TTD reduces the costs per bore by 60 % referred to the customer‘s annual production volume! There are also examples of the successful usage of the replaceable head drill TTD in modern workpiece material combina-tions. For example the machining of bores for the connection of a ships‘ CFRP drive shaft to a steel hub. Using a combination tool from MAPAL with a TTD solid drilling stage and a countersink step with PCD-tipped ISO indexable inserts it was possible to reduce the machining time by more than 80 %.

Increasing raw material prices, lean inventories and the consideration

of life cycle costs favour replaceable head systems.

Highlights from the product areas

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

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

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

…TO CHANGE… …without risk. Produce quickly and effi ciently using the replaceable head drill TTD.**

YE

S, I

WIL

L…

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

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Pre-machining and fine machining intelligently combined

Custom-made combination tools open up high potential for increasing productivity and process reliability. In the specific case of a MAPAL custo-mer, it was necessary to pre-machine and fine machine particularly cost-effectively two connection bores with diameters of 31 mm and 36 mm on an AlSiMg1 swivel bearing for a car. This requirement sets two challenges for the tool design. Firstly, the low silicon content of the aluminium alloy requi-res an innovative tool concept that ensures optimal chip breaking of the otherwise long continuous chips. On the other hand, to meet the cycle time requirements, particularly productive pre-machining and fine machining are required as both diameters require high stock removal.

To solve this task, MAPAL developed two combination tools that combine both the pre-machining and fine ma-chining on one tool body.

The pre-machining was designed on both tools as a solid drilling sta-ge with replaceable ISO indexable inserts. The appropriate cutting edge geometry, as well as twisted and also polished chip spaces with a helix ang-le of 15° ensure reliable chip breaking and chip removal. Due to the large core cross-section of the solid drilling stage, the tools are stable and par-ticularly smooth in operation. After the solid drilling stage, the stages for fine machining follow with the brazed PCD cutting edges. During process design, the machining operations were optimally distributed over the two tools.

First tool one (see figure) is used to drill the large diameter using the indexable inserts. Then the next stage machines a spot face on the end of the bore using the related chamfers. Using tool two, the small diameter is drilled in the solid and then fine machined and chamfered using the following stages. Then the chamfer on the bore outlet is made using this

tool by circulating. The same tool then moves to the larger diameter, fine machines the bore and also pro-duces the chamfer of the exit of this bore by circulating.

MAPAL specialists have achieved maximum productivity and cost-effectiveness in this machining task both in the process design and the tool design. The two combination tools complete all the machining tasks for which at least four tools would normally be required. Also the MAPAL hybrid tools combine the different machining systems in such a manner that excellent performance, simple handling and cost-effective reconditioning are achieved.

Highlights from the product areas

News

– Yes, I will – to change without risk – Intelligent combination of machining systems

Pre-machining and fine machi-

ning intelligently combined

MAPAL hybrid tools combine different tool tech-nologies

1

2

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Erfolgreiche Kundentage bei MAPAL

Minimum quantity lubrication was the topic of the customer days at MAPAL this year. Around 400 participants came to Aalen, above all series pro-duction manufacturers and suppliers to the automotive industry; they came to obtain information on this envi-ronment-friendly and energy-saving form of material machining. By means of the minimum quantity technology, up to 80 % less coolant and up to 40 % less electrical power is consumed in comparison to conventional processes. At the end of the two-day event the participants were impressed by the diverse mix of broadly based presen-tations, practical tool demonstrations, a large exhibition of MQL compo-nents, as well as the tours through the MAPAL production buildings.

Dr. Dieter Kress was pleased by the unexpectedly large number of visitors who travelled from all over Germa-ny, Austria, Poland and Switzerland: „With minimum quantity lubrication we have selected the right topic“, he concluded. Minimum quantity lubri-cation (MQL) is in principle nothing

new. The fi rst bores were dry ma-chined some 20 years ago. However, the keen interest shows that MQL is a very complex system. One, as Dr. Jochen Kress added, in which there has been signifi cant progress in re-cent years: „We are now at the point that we can also use MQL technolo-gy on broad front.“ The increasing industrial interest in energy-effi cient production is giving MQL technology additional lift: „It is a comparatively simple way to save energy“, says Dr. Jochen Kress.

And businesses will increasingly exploit energy-saving potential in the future to lower their costs for energy and resources such as water and material, stated also Prof. Dr. Ing. Eckehard Kalhöfer. The Chair for Machining at the university in Aalen has investigated the effect of MQL on energy effi ciency. The basic annual consumption of an operational machine tool is around 66,000 kWh. On the usage of central cooling lubricant systems, states Prof. Kalhöfer, the energy demand

… innovative technologies in use

MAPAL Di LOG

400 visitors on 10 and 11 April 2013

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

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Erfolgreiche Kundentage bei MAPAL

is high compared to the energy demand of the machining process itself. Using various model invoices he demonstrated that the electri-city consumption can by reduced by up to 40 % by using minimum quantity lubrication. „In this way it is possible to save a lot of money“, the scientist stated.

However MQL technology requi-res careful usage, says Dr. Jochen Kress. All components, that is the tool, machine, fi xture and above all the process must mesh opti-mally. Two acknowledged MAPAL specialists, Christian Schmidt and Joachim Vaas, provided informati-on on the special features of MQL tools and correct process design in relation to lubrication, trans-port of chips and cooling. Suitable chucks were presented by Michael Neumann: MAPAL has developed a modular system for clamping tools.

„We accompany the customer during the entire process design,

from planning, through pilot trials, to production“, Dr. Jochen Kress descri-bes the product and service portfolio. MAPAL has a large array of machine-ry for tests and optimisation and has extensive experience with all materi-als. Even demanding processes such as connecting rod machining can be implemented using MQL.Peter Vogl, Director of Design & Tech-nology at GROB Werke GmbH & Co. KG in Mindelheim and Werner Roth, Head of Application Engineering at Maschinenfabrik Heller, Nuertingen reported on how machine tools suita-ble for MQL should be designed. The manufacturers of machining centers, custom machines and transfer lines have already realised numerous MQL projects together with MAPAL.

Currently around one in fi ve of the machines supplied by the business have MQL technology says Roth. Vogl spoke a slightly increasing tendency in large-scale series production manu-facturing. The machines are designed such that lubricant can be supplied


Continued on next page.

| MAPAL ImpulsePage 10 | MAPAL Impulse

through the tool as well as by means of single-channel or dual-channel systems.

Dr. Dirk Sellmer, Head of the Re-search and Development department at MAPAL gave an overview of the different MQL feed units. Whether you select a single or dual-channel variant is essentially a question of philosophy the expert stated. The same applies to the choice of the right lubricant, a topic that is also the subject of fre-quent discussion. Fatty alcohols and ester oils are not equally suitable as lubricants in his opinion. „It depends on the application“. Aerosols are not flammable, however chip dust in com-bination with wall oil could cause an explosion. Modern extraction systems prevent this situation from occurring.Marcus Krauss, Sales Manager at Kel-ler Lufttechnik, Kirchheim unter Teck, is observing a trend toward small, decentral systems. The advantages: „They need little space, can be used flexibly and can be controlled direct-ly via the machine tool.“ Ford, for

example, uses an individual separator to blow the return air back into the room.

The report from a user of MQL technology was equally exciting and informative for many partici-pants to the MAPAL customer days. At Punch Powerglide, Strasbourg, around 300,000 gearboxes for cars are manufactured per year, for this reason around two years ago it was decided to change to minimum quantity lubri-

cation for the production of converter housings. Good environment manage-ment and cost savings were the key reasons explained planning manager Roland Muller. „Initially we had a few problems with tool breakages and noise, but it was possible to address these issues quickly.“ It was possible to reduce the cycle time using MQL, the surrounding area is clean and attitudes are positive. Muller‘s conclu-sion: „I am convinced we did the right thing.“


… innovative technologies in use

MAPAL Di LOG

The development of MQL system components is sufficiently advan-

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

Continued from page 5.

| MAPAL ImpulsePage 11 | MAPAL Impulse

Andreas Broß (Gebr. HellerMaschinenfabrik GmbH, Nuertingen):

„There has been a lot of information provided in a very short time.“

Olaf Kiener (Julius Schüle Druckguss GmbH, Schwaebisch Gmuend):

“It was a perfect event that has exceeded my expecta-tions.“

Wolfgang Müller (Opel, Kaiserslautern):

„A very good mix of theory and practice. It was a great event because a large number of external manufacturers were also present.“

Michael Zinz (Deutz AG, Ulm):

„The presentations were informative, the works tour and the exhibition very interes-ting. We are satisfi ed all round.“


Thank you for the feedback on this event –you will also fi nd a summary of the customer days online at www.mapal.com/aktuelles/kundentage-mapal-dialog/

Your MAPAL Impulse editorial team

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

„The dialogue was very well organised, inte-resting and varied. I have learnt a lot about MQL technology.“

Interviews with visitors

„Fit for manufacturing processeswith minimum quantity lubrication“

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Fitness program for the CNC milling machine

With trochoidal milling signifi cant improvements in tool costs, clamping systems, machining times and the load on the machine components can be achieved in many applications compa-red to conventional milling.

A comparison of the cutting data determined during a MAPAL milling trial already shows what is possi-ble with this process, which is also known as wave milling: while during the conventional dry milling of case hardened steel (16MnCr5) a cutting speed of around 200 m/min at a feed of 0.05 mm/tooth was achieved, it was possible to tackle the same task with a cutting speed of 600 m/min at double the feed rate using the new trochoidal carbide milling cutter from MAPAL. Even on machining V2A steel it was possible to achieve a signifi cant incre-ase in speed by changing the milling technology: at a feed of 0.05 mm/tooth, a cutting speed of 250 m/min was achieved instead of the 60 to 100 m/min otherwise possible.

This performance increase is made possible by a combination of high performance milling cutters specially developed by MAPAL for this process, the HighTorque Chuck (HTC) and the actual process. The advantage during movement is essentially the reduced tool contact. While during conventio-nal milling of a slot the wrap angle is 180° (full cut), with trochoidal milling it can be selected as a function of the cutting depth and limited to maxi-mum 70°. This situation is made pos-sible by a milling cutter with a smaller diameter that moves trochoidally at a

high spindle speed; each trochoid is deeper into the cut.

Due to the smaller wrap angle, less heat is produced. The machining forces are also lower such that even spindles with low power and torque are suitable for the machining process. In addition, the chip load is lower with trochoidal milling. As the milling cutter does not completely fi ll the slot or pocket, chip congestion and renewed cutting of chips is as good as excluded. This aspect is of impor-tance particularly for slots that are deep in relation to their width. During conventional milling, low feeds and cutting depths are used here due to the problems described. A maximum milling depth of 1.5 x D is normal. Not so with trochoidal milling: by avoiding the full cut, cutting depths of up to 2 x D are achievable even without specially developed milling cutters.

For the user, this situation sig-nifi es shorter machining times, better tool utilisation and noticeably lower tool wear. Due to the rapidly increasing carbide prices, the latter in particular is attracting the attention of metal machi-nists who can profi t twice over on changing to trocho-idal milling: from the longer tool lives and from the lower procurement costs for the milling cutter resulting from the smaller diameters.

If trochoidal milling is used in machining centers, additional cost savings are possible. Because widely varying slot widths or pocket sizes can be produced with only one tool, the tool needs to be changed less frequently and there is space left in the tool magazine. Trochoidal milling also offers advantages in relation to design. Due to the lower radial forces, signifi cantly more delicate parts and parts signifi cantly with thinner walls can be realised and greater accuracies achieved. At the same time the load on the spindle bearings is eased and the tool life is increased.

The OptiMill® product family from MAPAL includes milling cut-

Trochoidal milling – also for machining centers

| MAPAL Impulse 13 | MAPAL Impulse

Customer benefi ts

– Shorter machining time and better tool utilisation– Higher cutting volumes and feeds

ters suitable for dry trochoidal milling with DIN shank lengths 2 x D. For applications with even higher requi-rements, MAPAL has now developed and added to the product range an entirely new milling cutter with a cutting length of 3 x D and a diameter from 6 to 20 mm. Specially designed unequal spacing (EU spacing) of the fi ve cutting edges combined with an innovative geometrical design of the cutting wedge reduces the excitation of vibration here. Balancing (balan-cing quality 2.5) undertaken during the manufacturing process further reduces the risk of vibration. As such the patent-applied milling cutter can even be used at extremely high spindle speeds without problems. So that with the greater cutting depths

now possible, jamming does not occur due to the long chips produced in the process, the tool designers have also integrated a chip breaker that cuts the chips in half. This feature safeguards the trouble-free removal of the chips from the machine com-partment. A special tool adapter is not required for trochoidal milling using the MAPAL milling cutters. However, if the potential of trochoidal milling and the new milling cutter is to be fully exploited, it is recommended to use the new MAPAL HTC chuck. The chuck combines the very good dam-ping properties of hydraulic chucking technology with the high holding forces of shrinking technology. The HTC reliably transmits high torques. Even heating to 170° does not affect

the HTC chuck, as milling trials have confi rmed. As a rule, cooling is there-fore not necessary.

Smaller or more delicate parts, higher accuracies and the continuing pres-sure to further reduce tool, operating and maintenance costs are making the call for more effi cient milling proces-ses louder. Thanks to the availability of more powerful tools such as the new MAPAL trochoidal milling cutters and the increasing usage of powerful CNC controllers and CAM software, there is now nothing to hinder the broad usage of the trochoidal milling process. The time is right for trochoi-dal milling!

MAPAL OptiMill® milling cutter in use.

Figure on right: Trochoidal milling cutter clamped in the MAPAL High-Torque Chuck.

Your contact person for further information:

Andreas Rinn | [email protected]

ae

fz

Feed motion

r1

Machining area per trochoid.

Chip per cutting edge.

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Innovative manufacturing technology for external machining tools:

PCD tools with lasered cutting edges

Productivity and quality significantly increased


The competence center for PCD tools in the MAPAL Group, MAPAL WWS GmbH in Pforzheim, is the largest and most technologically advanced production facility for PCD tools in the world. In collaboration with LASERPLUSS AG, also part of the MAPAL Group, (see box on the right), another significant development has been achieved on the production side: by using RayCutter® 5-axis CNC laser machines for laser finishing PCD cutting edges, it has been possible to significantly increase the stability and with it the productivity and quali-ty of complex external machining tools. The engineers in Pforzheim are impressed with the new technolo-gy and are expanding the capacity. The RayCutters® have been used in production for around three years. The development of the new machining method for external machining tools started in 2011, and the process was very successfully introduced in 2012. By the middle of 2013, five RayCut-ters® were in use in the production of PCD tool cutting edges.

Machining of a hose connection tho-roughly revised

In one application, production of a complex external contour on a hose connection made of AlSi7 was thoroughly optimised by MAPAL. The part is manufactured on a four-spindle machining center in high quantities, absolute process reliability and the high quality of the surfaces machined in relation to dimensional accuracy and surface finish must therefore

be ensured. The complete external contour must also be produced in one machining cycle. The customer was dissatisfied with the part quality produced by the previous process. The machined area had a poor surface fi-nish with clearly visible chatter marks. Also, the dimensional accuracy varied between the four spindles, an aspect that made it more difficult to meet the tolerances.

The tool used originally comprised screw-mounted inserts and was corre-spondingly unstable. It was necessary to adjust the delicate inserts individu-ally and there was a tendency for the adjustment to change during machi-ning. This situation often resulted in only one of the two cutting edges actually cutting. At a spindle speed of 5,000 min-1 it was only possible to use a feed per tooth 0.1 mm.

Lasered cutting edges maintain the stability of the tool

The specialists from MAPAL designed a PCD external machining tool of monoblock design to make the machi-ning more stable and to improve the smooth running. The design permits high accuracies in length, shape and diameter. However, the special high-light is the machining of the cutting edges. Unlike in the past, these cutting edges are lasered instead of wire eroded. This innovative technology has significant positive effects on ma-chining quality and productivity with this complex form of external ma-chining. To be able to wire erode the

cutting edge contours in monoblock tools in the conventional manner, the tool body must be relieved. As a result the area behind the cutting edge beco-mes very unstable. As a consequence, the tool tends to vibrate; the cutting data must be drastically reduced in some cases. If the cutting edges are finish lasered using the new process, the cutting edge pocket remains stable and vibration is prevented. It is only necessary to take into account any tool restrictions. The improved tool stability therefore makes possible significant increases in the machi-ning quality and productivity as well as an effective two cutting edge and multi-cutting edge capability. Christi-an Molch, General Manager at MAPAL WWS, says on this issue: „This laser technology developed by MAPAL and LA-SERPLUSS is excel-lently sui-ted to the production of com-plex, very delicate geometries on external machining tools. The process operates without LA

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Picture from the cutting edge preparation on the RayCutter®.

| MAPAL Impulse

Productivity and quality signifi cantly increased

physical contact and is practically unlimited in relation to geometry. As a result MAPAL is also technologically leading in the area of complex PCD external machining tools.“

Cycle time reduced by 23 %

The potential of the new tool gene-ration has been confi rmed in series production at the customer. After machining, the part has a very good, chatter-free surface fi nish as well as good geometrical accuracy, and that with signifi cantly increased machi-ning values (n = 8,500 min-1, fz = 0.16 mm). The customer has several positive effects due to the usage of the MAPAL PCD external machining

tool. It saves handling costs, as com-plicated and time-consuming setting is not required. The monoblock tool is also 50 % cheaper to procure than the competitor tool. However, the achie-vement of the highest diameter and length tolerances as well as the best surface fi nishes with high cutting data is decisive. As a result it is possible to reduce the cycle time by 23 %.

Very deep axial recesses

In a further example, very deep axial recesses are produced on a machining center.

Originally the machining was under-taken using recess tools with clam-ped carbide inserts. The responsible member of the MAPAL sales team and the specialists in Pforzheim developed recess tools with lasered cutting edges for pre-machining and fi ne machining during this task. The pre-machining is undertaken into the solid using a two-cutting edge tool – with impressive cutting data:n = 6,000 min-1, fz = 0.05 mm and 300 mm/min feed rate. The tool for the fi ne machining is of single-cutting edge design and machines the work-piece with a spindle speed of 8,000 min-1, 0.1 mm feed per tooth and a feed rate of 800 mm/min.


Michael Hils | [email protected]

Cycle time reduced by 23 %

The potential of the new tool gene-ration has been confi rmed in series production at the customer. After machining, the part has a very good,

INFOLASERPLUSS AG in Kirschweiler bei Idar-Ober-stein has specialised in the manufacture of laser systems for precision applications for cutting me-tals and hard materials, for marking and engra-ving all materials, and for welding plastics. The company founded in 1997 with Dipl.-Ing. Werner Schulz as its head has been part of the MAPAL Group since 2009.

Figure top: Cost-eff ective external machining with PCD tools from MAPAL.Figure bottom: Machined joint contour on a sample part.

The RayCutter® 5-axis CNC laser machine from LASERPLUSS AG.

Customer benefi ts

– High process reliability– Deep axial recesses possible– Signifi cantly higher cutting data

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Setting fixture UNISET-V vision – developed for complete solutions

Measuring and setting complete machining tools

Planning new projects is time-consu-ming and expensive. More and more customers therefore make use of the comprehensive range of services offe-red by MAPAL related to part design and the delivery of the related compo-nents. As along with technologically leading and highly productive tools, MAPAL offers extensive know-how on machining. This aspect relates to both custom services as well as to high precision peripheral equipment for adjusting and measuring the tools.

Process reliability and part quality due to exact measuring

During the design of tools for com-plete machining, fine machining tools play a crucial role. As the tools are often used for the last manufacturing step, all tolerance requirements on the part in relation to surface finish, dimensional, contour and positional accuracy must be reliably met. As a specialist for fine machining, MAPAL relies on fine boring tools with guide pads that can be adjusted to the µm. Very tight tolerances can be achieved with these tools. Due to the setting features on the tools it is possible to address flexibly any special aspects related to the workpiece material or the machine. The exact measurement and adjustment of these tools is a prerequisite for high process reliability and part quality. These tasks are suc-cessfully undertaken using a precise measuring and setting fixture that is integrated into the process chain.

Highest measuring accuracy with UNISET-V vision

For cost-effective series production it is particularly important that tools can be measured and set to the highest precision both quickly and efficiently to ensure constant availability at the machining center and to avoid down-times. The example of a complete ma-chining process on clutch and gearbox housing makes this aspect clear. The optimal machining of the often thin-walled, large aluminium cast parts requires comprehensive know-how during tool design. In particular there are high requirements on the shape, position, surface finish and diameter of the shaft bearing bores. The soluti-on a complex, multi-stage combinati-on tool that, along with high accuracy, significantly reduces the machining times. Along with fixed brazed PCD boring tools, these tools use adjustab-le inserts and guide pads, as well as face cutter heads with adjustable PCD milling cartridges for finish machining of the sealing faces. For setting the tools to the um, MAPAL has developed a CNC-controlled setting fixture in the form of the UNISET-V series that is perfectly matched to the require-ments placed on these tools due to the combination of tactile and optical measuring methods.

Tactile measuring method for setting fine boring tool with guide pads

The vertical setting fixture UNISET-V vision is equipped with electronic

measuring sensors that make it possib-le to exactly set fine boring tools with guide pads to within 1 µm. Depending on the position of the guide pads and insert, either protrusion measure-ment or swinging lever measurement is used. As soon as the measuring sequence for a tool has been defined and saved once using the teach-in programming, from then on the mea-surement of the tool is undertaken au-tomatically via the CNC controller. In this way it is possible to significantly reduce the non-productive times in the measuring room, particularly in case of complex, multi-stage tools for shaft bearing bores. State-of-the art camera system for the optical measurement

PCD face cutter heads in the Eco-Mill series are sophisticated, efficient tools. A prerequisite for their reliable usage and long tool lives are inserts

1.1

2.1

| MAPAL Impulse

Customer benefi ts

– Universal setting and measuring device for manufacturer-independent tool concepts– Fully automatic measuring sequences using CNC controller– Highest accuracy due to solid mechanical construction

that move within defi ned tolerances. For fi nish machining PCD face cutter heads are used; here the exact and effective setting of the axial run-out on all cutting edges is necessary. Using the UNISET-V vision each PCD cassette on the face cutter head is moved to and measured using the optical camera system. If necessary, the axial run-out can then be simply and quickly corrected at the adjus-ting element on the milling cutter. In parallel the setting process is moni-tored optically on the touchscreen monitor for the UNISET-V vision. Also all other tools used for the complete machining process are measured using the optical measuring device. All rele-

vant measuring data, for example tool lengths or diameters, can be assigned to the tool using the UNISET-V vision. The measured data are either saved directly on the tool using a Baluff chip, or applied directly to the tool body in the form of a printed label. With both processes, it is ensured that no time-consuming corrections are necessary on the usage of the tools on the machining center.

A single setting fi xture for all require-ments

The different measuring methods for a very wide range of tool systems, the high precision due to the solid basic

mechanical set-up and the CNC elec-tronics make the UNISET-V vision an all-rounder in the tool setting room. In particular in the case of tools for complete machining the UNISET-V vision ensures real productivity ad-vantages are obtained due to its high degree of fl exibility and ease of use, it is therefore an indispensable element of the complete process chain.


Michael Hils | [email protected]

The UNISET-V vision makes it possible to set and measure all tool concepts used for the complete machining of clutch and gearbox housings.

1.2

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Vertical setting fi xture UNISET-V vision.

1.1 | During the protrusion measurement for setting fi ne boring tools with guide pads, the measuring sensors are fi rst moved to the position of the guide pads and the measuring range set to zero. Then the adjustable inserts are moved to and the measuring range is again set to zero at the highest point. Due to the low contact pres-sure on the insert and the reduced measuring force, delicate PCD-tipped inserts can also be measured reliably and without risk of damage.

1.2 | The operator now sets the defi ned nominal dimensions such as the overhang on the insert in relation to the guide pad and the diameter.

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

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

| MAPAL Impulse

Identifying and utilising optimisation potential in machining –

productivity increase due to custom tool solutions


Machining for dialysis equipment signifi cantly optimised

Unmanned machine tool operation safeguarded, machining time halved, tool life increased by 20 times, surface quality visibly improved - these are only some of the impressive results of the latest process optimisation in ma-chining at Fresenius Medical Care on its site in Schweinfurt. Since 1979 the company has developed and manufac-tured dialysis machines for the inter-national market with great success in this industrial city in Lower Fran-conia. Every year more than 40,000 systems leave the factory that main-tains its position in relation to the international competition by means of effi ciency and clear work processes. The strategy of Fresenius Medical Care is to be better than the competition in relation to the quality of the dialysis products and production costs.

To implement these goals the world-leading manufacturer of dialysis equipment has relied on know-how and tools from MAPAL for machining since 2000. „In close co-operation we have managed to further stream-line production processes, to reduce tool costs and to improve quality repeatedly in recent months“, reports Ludwig Schmittlein, who is respon-sible for milling technical support in machining at Fresenius Medical Care Deutschland GmbH.

Process optimisation makes possible unmanned production

As such, a ‚multiblock‘ made of po-lypropylene can now also be manu-factured unmanned and therefore

around the clock as a result of a tool change. Prior to the change the blind bores necessary on this assembly were realised in three steps: Due to the large diameter of 42 mm, fi rst the bore was pre-drilled using a standard drill, the bore was then drilled out and subsequently machined to the cor-rect dimension using a milling cutter. „This method has the disadvantage that long chips were produced during boring that, on the one hand, soiled the machine tool, and on the other hand took a lot of space in the chip bin. These two aspects together pre-vented unmanned operation at night“, Benedikt Hetterich, head of the milling area and quality assurance in machi-ning at Fresenius, describes the initial situation.

As the machine confi guration did not permit milling from the solid, based on experience in other applications MAPAL engineers suggested a solution with a carbide replaceable head drill TTD with 180° geometry and a PCD-tipped milling cut-ter with which the blind bore is circular milled in a helix after drilling. „We have been working very successfully with this solution for approx. one year“, Ludwig Schmittlein is pleased to state. „The chips are space-savingly small, boring out is not required at all and the milling cutter can operate with much higher feed such that we can operate unmanned and also faster than before.“

Another earlier optimisation project also made a signifi cant contribution to increasing through-put at Freseni-us: The „fi lter block“, also manufac-tured from a block of polypropylene, for the therapy system 4008 from Fresenius needs a 91 mm deep blind bore. However, the walls of the bore are not straight, but taper at 1 degree downwards, at the transition from the fl at base of the bore to the side wall the bore has a radius; there is also a straight section to the opening. As for the multifunction block, until recently standard drills were used for pilot dril-ling and boring out. The 1°-angle was then cut with 0.2 mm cutting depth and a radius milling cutter controlled by a CAD program. Just this one pro-cess took 30 minutes and transition marks and scoring could occur on the surface. „Using the alternative develo-ped by the MAPAL specialists in close co-operation with us, we only need 16 minutes for the complete machining

Drilling from the solid and circular milling with optimised chip breaking make possible unmanned production.

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| MAPAL Impulse

Customer benefi ts

– Unmanned production possible– Tool costs reduced– Machining timed reduced

Das fertig gefräste Werkstück.


Michael Neumann | [email protected]

of the part“, reports Ludwig Schmitt-lein with pride. The chamber opening on the fi lter block is now drilled in one step using a replaceable head drill TTD with a special design. The drill has the MEGA-180° geometry that makes it possible a fl at bottom in bores in one machining step. The contour is then milled using a customer-specifi c car-bide form cutter with one material re-moval rate. „As a result with the new tools we have achieved short chips, a good surface fi nish and fl owing tran-sitions also in this application“, adds Benedikt Hetterich. Fresenius also benefi ts from longer tool lives,as his colleague emphasises: „While we could produce approx. 600 parts with a corner radius milling cutter, we have now passed the 1,500 mark and still do not need to change the replaceable head.“

Fresenius was able to achieve an even more signifi cant increase in tool lives by means of tool optimisation in the case of a part made of polypropylene with 30 % glass fi bre content: Prior to the change a recess was produced with the aid of a conventional solid carbide circular milling cutter. „Although the tool was economical to procure, it had to be replaced after only 600 parts due to wear“, Benedikt Hetterich looks back. „For the last two years we have used instead a circular milling cutter with PCD cutting material that cost almost three times as much, but that lasts for at least 16,000 parts!“ At an annual production rate of 36,000 pieces this means savings of almost 6,000 euros a year in tool costs alone. But that is not enough. In a partner-ship-based co-operation with the tool specialists at MAPAL, the responsible staff at Fresenius have been able to achieve other improvements in many

areas. „We are therefore very happy with the support provided by MAPAL and the quality of the tools“, Benedikt Hetterich and Ludwig Schmittlein agree.

Dialysis machine

| MAPAL Impulse

Complete machining with minimum number of tools and mini-

mum number of different indexable inserts.


Complete machining of water pump housings

MAPAL has been represented in Po-land with a dedicated subsidiary since 2002. The team around General Mana-ger Aleksander Zielonka comprises 27 staff in sales and service. Comprehen-sive local support to customers with technologically leading tool solutions is the premise of MAPAL Narzedzia Precyzyjne Spółka z.O.O.. Here the focus is on partnership-based collabo-ration with customers and machinery manufacturers. An example of this aspect is a project realised at the end of 2012.

Leszczyn ska Fabryka Pomp (LFP) was founded in 1868. The privatisation of the organisation and a new strategic direction placed the focus on deve-lopment activities. Today LFP is the leading manufacturer of pumps and pump systems in Poland and one of the most modern manufacturers of cast parts in the world.

SW (Schwäbische Werkzeugmaschi-nen GmbH), as an important MAPAL technology partner, opened the door to LFP. In the past some small tool deliveries were made; deliveries that demonstrated the professional support and the quality of the tools.

Fewer tools for higher productivity

In 2012 SW was tasked by LFP to deliver the machine and the fix-ture for machining new water pump housings made of EN-GJL250. In turn the machinery manufacturer suggested MAPAL Poland as a suitable tool and technology partner for meeting the

customer‘s requirements: complete machining with a minimum number of tools and a minimum number of different indexable inserts.

Robert Adamczak, Director of Techno-logy and Innovation at LFP, descri-bes the collaboration as very good and trouble-free: „The water pump housings are machined on an SW BA600-2 machining center using MAPAL tool technology. Our require-ments for a reduced number of tools as well as a lower cycle time compa-red to the competition have been met perfectly by the MAPAL solution. We also achieved our objectives signifi-cantly more quickly and straightfor-wardly during the implementation phase.“

Latest tool technology in use

The tool technology for the pump housing was the result of collaborati-on between Robert Adamczak and Pi-otr Nowacki (project manager) at LFP, Lukasz Barteczka, project engineer in Czech sales at SW, and the MAPAL team, comprising regional sales mana-ger Piotr Jadrzyk, salesperson Marcin Wawrzonkowski and Martin Rottenbil-ler, who co-ordinated the activities in the headquarters in Aalen. The project features the following highlights: the main bore on the water pump housing is pre-machined using two multi-stage ISO boring tools based on tangential technology. In similar projects at LFP three tools were used for this purpose. In addition to this saving in tools, the machining using the MAPAL tools

is also significantly faster. With a cutting speed of 120 m/min and a feed per tooth of 0.2 mm the pre-machi-ning takes significantly less time than predicted. For the main bore a circula-rity of 0.05 mm and a concentricity of 0.025 mm are required. For this reason the fine machining is undertaken using a multi-stage fine boring tool with guide pads at a spindle speed of 540 min-1 and a feed of 0.15 mm/rev. In this way it, is possible to meet the quality requirements reliably and machine all steps in the main bore simultaneously. With the ISO boring bars used in the past at LFP, there were often problems with the concentricity of the individual steps in relation to each other.

External recess is interpolated.

The interpolation turning method is used to machine an external recess. Lower tool costs with high workpiece qua-lity at the same time were the key arguments for this machi-ning technology. The machine from SW used is very suitable for interpolation turning due to its dynamic performance and rigidity. Stockkeeping optimised

MAPAL was also able to meet the requirement from LFP to minimise and standardise the inserts used: The same in-dexable inserts are used for all workpiece variants such that C

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| MAPAL Impulse

Customer benefi ts

– Leading tool technology – Custom services – Partnership-based collaboration

the stockkeeping is limited to only a few types. Different tool bodies are available for varying bore dimensi-ons on the variants. A call warehouse in the process of establishment at MAPAL in Poznan for the necessary indexable inserts is intended to realise even more optimisation potential.

Project realisation in record time

Due to the smooth collaboration between the partners involved, the machining was accepted after just one

week, a task that normally takes up to two months. It was therefore possible to start production earlier than plan-ned. Reason enough for LFP to invol-ve MAPAL again in future projects, as Piotr Nowacki, chief technologist at LFP, confi rms: „Our decision to use MAPAL technology was defi nitely correct. We are convinced that this

collaboration will bring many tech-nical and commercial advantages for effi cient production also in future projects.“

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

Pre-machining of main bore using a combination tool with ISO indexable inserts.

The fi ne machining is undertaken using a multi-stage tool with guide pads.

Your local contact in Poland:

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

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| MAPAL Impulse


Machining of the Sigma engine in Taubaté successful due to

modern tool technology and close collaboration

Worldwide collaboration for optimal processes – MAPAL and Ford

The Ford Motor Company‘s Taubaté production site was founded in 1974 and is considered in Brazil to be a pioneer in the production of engi-nes, gearboxes and other automotive parts. Ford Taubaté produces 430,000 engines and 500,000 gearboxes per year. The latest production processes are used to machine and assemble the cast parts. In January this year Ford Taubaté was able to achieve two major milestones: the total produc-tion of engines passed fi ve million, the production of gearboxes the four million mark.

Ford launched a new series of Sigma engines in December 2009. This inno-vative engine generation was develo-ped as a global platform. Ford descri-bes the Sigma engine as light, durable, economical, low noise and low emission; the engine is manufactured in Germany, England, Romania and Brazil. 600 million US Dollars were invested in Taubaté to manufacture the new engine. As a consequence it was possible to double the production capacity for engines.

Collaboration at global level

Ford approached MAPAL with the task of designing the machining process for the Sigma engine, the fi rst engine on which the engine block, cylinder head and gearbox housing are made of aluminium. To optimally address the requirements on the machining process and to ensure the usage of the

same technology on all production sites, several MAPAL sites around the world worked together. MAPAL England was responsible for the engi-neering and the overall co-ordination of the project. The tools were deve-loped in Aalen and in the German competence centers, and then broken-in and tested in the test center. For the production in Brazil, João Paulo Souza is always on site in Taubaté and, together with the team around Technical Manager Rogerio Rodrigues, is responsible for a smooth running process. Duilio Dalla Rosa was respon-sible for breaking-in at the machinery manufacturer; today he supports the Sigma Camaçari Industrial Complex in Camaçari. Ford Taubaté had already established a partnership with MAPAL do Brazil in 2008; this partnership in-volved the delivery of technologically leading tools as well as optimisation services in production at Ford.

Based on the example of the Sig-ma engine it is clear that signifi cant potential can still be tapped on site to make production more cost-effective and more reliable. Some highlights from the Sigma project in Taubaté are presented in the following.

Costs halved during the machining of the cylinder bores

During the machining of the cast cy-linder bores it was possible to reduce the machining costs by more than 50 % due to a continuous process

of improvement and optimisation. Originally a six-cutting edge tool with PcBN blades was used for the ma-chining. The end of the tool life was reached after 250 parts per cutting edge. During optimisation the spe-cialists from MAPAL do Brazil were able to reduce the number of cutting edges on the tool and at the same time to triple the tool life. The cycle time remains unchanged with the current machining values (n = 2,400 min-1 and vc = 583 m/min, vf = 1,296 mm/min).

More teeth bring higher milling speed and improved tool life

The sealing faces between the engine block and cylinder block are machined using an EcoFeed face milling cutter with a diame-ter of 250 mm and 36 teeth. The EcoFeed face milling cutters are equipped with disposable milling cartridges and therefore involve signifi cantly less logistics effort during handling. The EcoFeed achieves perfect surface fi nishes due to exact positioning of the milling cartridges in the tool body and the sensitive wedge adjust-ment of the inserts. In surface machining at Ford

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

| MAPAL Impulse

Customer benefi ts

– International project management– Detailed local know-how for optimised processes– Cost reduction by more than 50 %

Your local contact in Brazil:

Sidney Pimenta Paiva | [email protected]

The team at MAPAL do Brazil from left to right: Technical Manager Rogerio Rodrigues, Duilio Dalla Rosa, General Manager Sidney Pimenta Paiva and Mairon Cezar from the engineering team as well as João Paulo Souza, the engineer responsible in the Taubaté works.

Tool for machining valve seat and valve guide.Signifi cantly increased cost-eff ectiveness during the machining of face surfaces on engine block and cylinder head – the Eco-Feed. Engine production at Ford Taubaté.

8,500

25,000

3,700

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Engine block machining:

Cylinder head machining:

Before:

New:

Before:

New:

3-times the tool life

was possible to machine 8,500 engine blocks and 3,700 cylinder heads, the tool lives are now even more impres-sive: one EcoFeed face milling cutter machines 25,000 engine blocks and 15,000 cylinder heads with a cutting speed of 3,000 m/min and feed rate of 11,000 mm/min.

Successful teamwork

The successful collaboration with Ford shows how MAPAL is available to as-sist customers worldwide with know-how, commitment and a team of spe-cialists. These days when projects are often transnational, it is essential to be able to offer the same product and

engineering know-how in all markets. With subsidiaries in 21 countries, a continuous exchange of knowledge at all levels and the focus on a close re-lationship with the customer based on trust, MAPAL is predestined to become a dependable partner.

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Responsible for the content: Andreas Enzenbach

Editorial team: A. Enzenbach , O. Munz,S. Raab, K. Rehor, S. Schmick

Design: I. Rettenmaier

Publisher:MAPAL Präzisionswerkzeuge Dr. Kress KGP.O. Box 1520 D-73405 AalenPhone +49 07361 585-0 Fax +49 7361 [email protected] www.mapal.com

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