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When something exceptional develops between us:Thats the MAPAL eect.

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Just in time for the EMO, we are oe-

ring our customers a wide range of newdevelopments as well as further develop-ments of products and solutions alreadyintroduced.

The maxims of cost-eectiveness, energy-e ciency and conservation of resourcesare at the forefront of all our develop-ments in order to give our customers atechnological lead and allow sustainableproduction. The close cooperation bet-ween our technical consultants world-wide who listen to and identify the needs

of the markets with the central Research& Development department plays acrucial role here. This symbiosis of marketneeds and understanding for the custo-mer with the high technical know-how ofthe whole machining process ensures that

we recognise the demands and technolo-

gical trends of the dierent industries ingood time and can react accordingly.

In the field of fine boring tools, forexample, we have achieved a pioneeringdevelopment with the EasyAdjust Systemthat is currently unrivalled for profita-bility and simplicity of handling on themarket. Apart from significantly reducedsetting times, the EasyAdjust System alsooers an HX blade with six cutting edgesthat results in lower cutting materialcosts with unchanged high precision.

The possibilities oered by the MAPALsystem solutions, but also by our highperformance standard products fordrilling, milling, reaming and turning aswell as services related to measuring and Dr. Dieter Kress Dr. Jochen Kress

adjusting are of great benefit to the

customer. Because these possibilitiesalways mean a significant technologicalstep forward.

Innovations and product range additions

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EasyAdjust-SystemDrastically reduces setting times

REAMING AND FINE BORING

MAPAL has achieved a breakthrough inthe field of fine boring tools with insertthat significantly increases the cost-eectiveness of the tools.

Innovative cassette with integratedback taper

The heart of the EasyAdjust-System isan innovative cassette that stably holdsthe inserts with their six or four cuttingedges without any play. The back taper ofthe minor cutting edge is already integra-ted into this cassette. The setting time forthe back taper is completely eliminated.Due to the exact guidance of the cassette

on a precision guide pin, the back taperremains unchanged even during diameteradjustments. Matching cassettes andclamping jaws are available for dierentback tapers that can be selected andemployed, depending on the application.

The secure mounting of the insert is en-

sured by a stable, force-closure system ofclamping groove and clamping jaw.

Significant economic benefits

In practice the EasyAdjust-System signifi-cant improves the cost-eectiveness: TheHX insert with six useful cutting edgescan be inserted quickly and precisely withdierent back tapers. As only the diame-ter now has to be set, process reliabilityafter insert change is enhanced aneect that becomes all the more signifi-

cant, when more inserts are installed ina tool. And the time for adjustment perblade is reduced to a fraction by the newdevelopment.

Your contact person

for further information:

Martin Hfele

[email protected]

AT A GLANCE:

Setting time drastically reducedCost-eectiveness, ease of handlingand process reliability increased

Precision remains highHX insert with six usablecutting edges

With the new development, MAPAL

has succeeded in maintaining the highprecision of the MAPAL fine boringtools while at the same time increasingcost-eectiveness by simplifying thehandling.

WORLD FIRST

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DRILLING

Motors with thermally sprayed coatingsReliably machined

In aluminium cylinder crankcases, liningof the cylinder bore surfaces with castor shrink-fit grey iron bushes is todaystate-of-the-art. In order to be able to

build aluminium engine blocks with eventhinner walls and lighter weight in future,the cast bushes are replaced by thermallysprayed ferrous metal coatings.On the one hand these can be appliedfar thinner, and on the other the frictionbetween piston ring and cylinder boresurface is also reduced.

Conditioning of the cylinder boresurface with PCD contour blades

For this new technology, MAPAL has de-veloped new tools for the pre-machiningand conditioning of the cylinder boresurface before thermal spraying in orderto ensure optimum coating adhesion.PCD contour blades are used to create

a defined structure on the cylinder bore

surface with which the sprayed coatingcan optimally interlock and adhere itself.The structuring needs to have small un-dercuts and at the same time be designedto prevent blistering or inhomogeneity inthe sprayed coating.

Fine machining tool with HX inserts aspreparation for precision honing

After the spraying of the coating, thecylinder bore surfaces are dressed usingfine machining tools with HX inserts. The

geometry of the bore surface is thus pre-pared for the final precision honing. Toolswith PcBN blades are used here, as thevery hard sprayed coatings place a veryhigh load on the cutting edges. As withother applications in hard machining,the know-how in the choice of the right

Your contact person


Siegfried Wendel

[email protected]

AT A GLANCE:

Tool solutions for currentdevelopments

Structuring of the bore surfaceFine machining before precisionhoning

PcBN grade and the edge preparation

are crucial for success. The fine machi-ning tool is furthermore equipped withcoolant-controlled actuator mechanismsand cutting compensation.

Microsection of a thermallysprayed coating.

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DRILLING

Tritan-DrillOperates with up to twice

the feed rate in challengingdrilling situations

The Tritan Drill was presented as the

problem-solver for di cult drilling situa-tions in 2010. Since then the three-edgedrill has been employed successfully andreliably in numerous applications whereconventional drills reached their limits.MAPAL has now achieved a significantoptimisation of the lead geometry.

Innovative lead geometry for very goodchip removal and low cutting pressure

The Tritan-Drill has unique generous pointthinnings machined into the chip space

which discharge the chips with minimumfriction into the chip flutes. Cutting pres-sure and edge temperature are very low,and practically no build-up edges occureven during dry drilling of aluminium. Theaggressive, self-centring chisel edge bitesinto the material on the first contact withthe workpiece and holds the drill reliably

in position.

Ideal for through-drilling or on entryinto cross bores

The Tritan-Drill demonstrates itsstrengths particularly in situations whereother drills fail: While two-edge drillsdrift during through-boring and create asignificant burr, the Tritan Drill remainsstable, the bore outlet sharp-edged andwith minimum burr. The Tritan-Drill isperfectly suited also to precise positionaldrilling with large projection lengths.

And best of all, the Tritan Drill achievesup to twice the feed rate

Your contact person


Andreas Rinn

[email protected]

AT A GLANCE:

Specially designed for challenging

drilling situations Innovative lead geometry for very goodchip removal and low cutting pressure

Ideal for through-drilling or on entryinto cross bores

Ideal for inclined bore entries

Up to twice the feed rate

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STD indexable insert drill 13 - 32 mm / up to 8xD

MAPAL is presenting a new high-per-

formance drill for the middle to upperdiameter range the STD indexableinsert drill. It impresses with a verygood chip formation and reliable chipremoval thanks to an optimised chipflute.

Sturdy mounting, simple clampingsystem

The indexable insert is held in a particu-larly sturdy and precise prism mountingso that high cutting values and bore

qualities can be achieved. The clampingsystem for the indexable insert is bothparticularly simple and extremely eec-tive. It consists of a spring-loaded screwthat is inserted transversely through theindexable insert, clamping the insertsecurely in the prism mounting.

Indexable inserts for steel, stainlesssteel and aluminium

The standard range oers indexable

inserts with optimally adapted blade geo-metries and coatings for the machining

Your contact person


Dietmar Apprich

[email protected]

AT A GLANCE:

Broad range of diameters from

13 - 32 mm

Sturdy system

Easy handling

Error-free indexable insert replacement

Optimum chip formation and chip

discharge thanks to ideally matched

geometries between indexable insert

and holder

of steel, stainless steel and aluminium.

Very good tool lives with high processreliability are achieved and ultimately avery cost-eective drilling process.

DRILLING

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CFK hand drillsIT8 in one shot

DRILLING

Your contact person


Jens Ilg

[email protected]

Hand tools are still frequently used inthe final assembly of the variousfuselage sections of passenger aircraftfor the drilling of rivet holes or bolt holes.

The reason for this is the lack of accessi-bility of the parts.

At the same time, high demands aremade on the bores. In particular, theprocess has to be absolutely reliable, asthe parts are very expensive and scrapor reworking is not acceptable.

MAPAL has developed tools for thisspecial application that set new stan-dards when it comes to the machining

of, for example, CFRP/titanium stacks.Not only the typical problems such asdelamination, protruding fibres with CFRPor burr formation in titanium are reliablyavoided. Tolerances in the range of IT8can be achieved in one shot with the

special MAPAL drills, so that the machi-

ning results in higher profitability of theassembly process by eliminating one workstep.

AT A GLANCE:

IT8 quality in one shot possible

No delamination and fibre protrusion

with CFRP

No burr formation with titanium

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DRILLING

MEGA-Speed-Drill Iron | Inox | SteelThree times faster and more reliable

AT A GLANCE:

Significantly higher cutting speeds

Polished chip flute guarantees optimalchip removal

Powerful in cast iron, steel andstainless steel

Guiding

chamfer 1

Guiding chamfer 2

incl. side relief

Guiding

chamfer 3

The MEGA-Speed-Drill has a completelynew cutting edge geometry with unequalspacing and three guiding chamfers. Thisprevents vibration and reduces friction.

The highly polished chip flutes guaranteeoptimal chip flow.

These features in combination with thenew lead geometries and cutting materi-als geared specially to the drilling of castiron, steel and stainless steels allow theMEGA-Speed drill to produce bores with

30 % higher feed rates than has beenpossible to date with conventional drills.

With this extension of the MEGA-Speed

Drill range, the machining of steel, castiron and stainless steels can be perfor-med with higher performance in thediameter ranges from 3 to 20 mm anddrilling depths 3xD, 5xD and 8xD with thestandard range.

Your contact person


Andreas Rinn

[email protected]

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10

Replaceable drill head TTD Type 04Faster drilling, faster changes

Your contact person


Dietmar Apprich

[email protected]

special facet geometry. In addition, very

smooth running is enhanced by the spe-cial 3-chamfer geometry. The combinati-on of these properties enables long toollives and drilling results to be achieved atthe highest level.

AT A GLANCE:

For steel and cast materials with high

machining demands

Broad diameter range

Longer tool lives due to smoothrunning in the bore thanks to3-chamfer geometry

Increased performance due tosignificantly reduced feed forces ofup to 50 %

DRILLING

Thanks to the innovative drill geometry,

the MEGA-Speed Drill has outstandingproperties with respect to centring,stability and chip removal. This geometrytherefore now forms the basis for thenew drill head geometry Type 04 of theTTD replaceable head drill for applicationsin steel and cast materials.

Feed forces can therefore be reducedby up to 50 % compared with similarreplaceable drill heads. This allows forsignificant performance increases andshort machining times.

The TTD Type 04 is designed for steel andcast materials and achieves very goodmachining results even for problematicand di cult machining tasks. This isachieved because the drill features anoptimal centring capability and the chipsare optimally discharged into the chipspaces of the TTS holder as a result of the

3-chamfer geometry of

the TTD Type 04

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MILLING

Your contact person


Hans-Peter Wengert

[email protected]

OptiMill-Composite-SpeedMachines CFRP parts on robots

The further spreading of complex CFRPparts in industry depends greatly onhow these parts can be machined cost-eectively. Various research projects arealready investigating which machiningmethod is the best solution here. In one

joint project focussing on the possibilitiesof producing and machining CFRP partswith robots, MAPAL is responsible for themachining tools.

MAPAL milling tools meet demands ofrobot production

Due to their large number of interactingaxes, robots cannot be compared withmachining centres with respect to sta-bility, precision and vibration behaviour

AT A GLANCE:

Low cutting forces reduce vibrations

in the whole systemDelamination-free trimming of

CFRP parts on robots

The machining on robots reduces

machine costs

during machining. These boundary con-

ditions therefore have to be taken intoconsideration during the development ofthe tools.

For these machining applications, MAPALoers special milling tools that work withvery low cutting forces and thereforetransmit minimum vibrations to thewhole system. They are particularlysuitable, for example, for the trimmingof CFRP parts using robots.

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12/2012

EcoFeed-BlueThe new face milling cutter

with replaceable milling inserts

MILLING

A clean solution for high-speedaluminium machining

Part cleaning represents a significant

cost factor in series production. Thisapplies in particular to geometricallycomplex castings, such as cylinder headand valve housings. This is where thenew EcoFeed-Blue face milling cuttercomes into its own. In order to come asclose as possible to the goal of a dirt-freefinished part, an innovative PCD millinginsert has been developed. The specialchip guidance geometry keeps the chipsreliably away from the workpiece surface.

Optimised for dry machiningThanks to the new milling inserts, a signi-ficantly improved visual surface quality isachieved with ductile and long-chippingmaterials, as the risk of scores is reduced.

This has advantages particularly during

dry machining and with minimum qualitylubrication. The integrated coolant out-lets in the milling inserts ensure optimumcooling and lubrication of the blades,particularly with minimum quality lubri-cation. The significantly reduced work ofsubsequent cleaning of the parts is parti-cularly important for machining processeswithout the use of cooling lubricants.

Economic basic design

The construction of the new

EcoFeed-Blue is similar to that of theproven EcoFeed principle. Here the insertsare in the form of milling inserts andare securely fixed by a highly precisedovetail guide. No additional elementsare necessary for the clamping of themilling inserts. The exact positioning ofthe inserts in the aluminium tool body isretained over the entire tool life. Repla-cement of the milling inserts is extremelyeasy. Adjustment is very user-friendlywith radially accessible, wedge-shaped

adjusting elements. The axial run-out cantherefore be set with precision. The newEcoFeed-Blue milling inserts are availableas shoulder, face or wide face millinginserts and can be installed in the exis-ting EcoMill tool bodies.

Your contact person


Christian Molch

[email protected]

AT A GLANCE:

Significantly improved surfacequality as the chips are dischargedto the outside

High process reliability as less chipsand dirt in the finished part

No abrasion of the milling tool

bodyHigh cutting speeds and feed ratesReduced noise level due to shorterblade projection at the face(0.5 mm)

Reconditioning in OEM quality

MAPAL oers milling head managementas a special service. This service guaran-tees the customer correct reconditioningof the milling heads at the end of thetool life and the dependable availabilityof the tools.

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13/2013

Particularly for milling applications, the

avoidance of vibrations and the associa-ted high noise level is an importantstarting point for further developments.The OptiMill-Silent sets new standardshere.

Vibration-free thanks to specialcutting edge spacing

The new OptiMill-Silent solid carbidemilling cutter has been specifically deve-loped with the goal of milling vibration-free, and hence of achieving very good

results with regard to quality and toollife even with the highest cutting rates.All the parameters of the milling cutterwere therefore optimally matched. Thespecial cutting edge spacing and the pathof the chip flutes, in particular, contributeto ensuring that practically no vibrationsoccur even with thin-walled parts.

Your contact person


Andreas Rinn

[email protected]

AT A GLANCE:

Ideal for thin-walled parts

Vibration-free thanks to special

cutting edge spacing

Extremely quiet even at high cutting

speeds

Also suitable for trochoidal milling

Ideal for high cutting values

The outstanding characteristics of theOptiMill-Silent come to bear in particu-lar with high cutting values. The new mil-ling cutter has proved to be very eectiveeven for trochoidal milling.

With this milling strategy, low radialcutting depths are used so that millingcan be carried out with twice the normalcutting speeds and infeeds.

OptiMill-SilentHighly e cient and extremely quiet

MILLING

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MILLING

OptiMillFor trochoidal milling

In many applications, trochoidal millingallows significant improvements to beachieved in tool costs, clamping systems,machining times and the load on the

machine components compared withconventional milling, particularly withhigh-strength materials.

For this milling technology, MAPAL isextending its OptiMill product family.Trochoidal milling in combination withthe new OptiMill allows cutting edgelengths of 3xD that could not be achievedwith conventional tools to date. Speciallydesigned unequal spacing (EU spacing)of the five cutting edges combined with

an innovative geometrical design of thecutting wedge reduces the excitation ofvibration. Balancing (balancing quality2.5) undertaken during the manufactu-ring process further reduces the riskof vibration. Through this the patent

pending milling cutter can even be used

at extremely high spindle speeds withoutproblems. So that with the greater cut-ting depths now possible, jamming doesnot occur due to the long chips producedin the process, as the tool designers havealso integrated a chip breaker that cutsthe chips in half. This feature safeguardsthe trouble-free removal of the chipsfrom the machine compartment. A specialtool adapter is not required for trochoidalmilling using the MAPAL milling cutters.However, if the potential of trochoidalmilling and the new milling cutter is to

be fully exploited, it is recommended touse the new MAPAL HTC chuck. The chuckcombines the very good damping pro-perties of hydraulic chucking technologywith the high holding forces of shrinkingtechnology. The HTC reliably transmitshigh torques. Even heating to 170 does

Your contact person


Andreas Rinn

[email protected]

AT A GLANCE:

Cutting length 3xD with specialchip breaker geometry

Vibration damping due to unequalspacing

Balanced to G2.5Low machining forces

not aect the HTC chuck, as milling trials

have confirmed.

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15/2015

CLAMPING

HighTorque Chuck HTCReliable clamping force even

at temperatures up to 170C

Many metalworking companies are

making eorts to exploit the savingspotentials in machining productionthrough a more e cient use of energyand material. High-speed machining,high-volume machining and minimumquantity lubrication are therefore thetrend.

In order to achieve optimum results, par-ticularly when high precision and processreliability are called for, it is not onlythe right machine/tool combination thathas to be chosen, but also the optimum

clamping system as the crucial interface.Here the market oers a wide range ofdierent clamping systems. The MAPALHTC combines the advantages of thedierent clamping systems in one chuck.Also by high process temperatures th HTCguarantees the damping properties and

Your contact person


Jochen Schmidt

[email protected]

AT A GLANCE:

High torque transmissionOptimum damping properties

High thermal stability up to 170C

at the tool shank

With HSK, SK or BT shank

Suitable for MQL

simple handling of a hydraulic chuck, as

well as the frictional force transmissionwith good run-out accuracies.The HTC is thus a universal chuck for abroad spectrum of machining operations.Thanks to shorter set-up times and itssuitability for resource-conservingmachining processes, it increases thee ciency of machining operations.

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World first UNISET-P

The completely newsetting fixture with

optimum ergonomics

MECHATRONIC SYSTEMS

With the new UNISET-P, ergonomics wasat the focus of the development. The gre-atest benefit compared with conventionalsetting fixtures is the very good accessi-

bility to the tool during adjustment, andhence unprecedented ergonomics. Theportal construction creates the spacenecessary to allow optimum access tothe setting systems on the tools. Measu-ring camera and back-light source areintegrated into the pillars of the portal,and are therefore not in the way duringadjustment as with the conventionalbracket constructions. Furthermore, theportal construction ensures maximumprecision and is both mechanically and

thermally extremely stable. The UNISET-Phas a particularly compact design, butnevertheless practically all tools up to adiameter of 500 mm and a length of 600mm can be perfectly measured and set.

Various measuring methods

It oers as standard additional lightand transmitted light measurement, forexample for the axial adjustment of facemilling cutters. As an option the UNISET-P oers an additional cross-member inthe portal that can be coupled to thedrive of the measuring lens. An additio-nal measuring sensor or measuring lenscan be attached to the cross-memberin order to be able to carry out axialmeasurements or even a rotational centremeasurement.

Innovative software oers numerousadvantages

The integrated software was developedstrictly on the basis of user-friendliness.

Your contact person


Stephan Kstler

[email protected]

AT A GLANCE:

Optimum ergonomic accessibilityCompact and versatile

Large measuring range up to 500 and length 600 mm

Optional tactile measurement inaxial direction

It is thus possible, for example, to create

fully automated program runs withinseconds thanks to the integrated controlgeometries. Tools are automatically de-tected and approached. The new softwareeven allows the contour of a rotating toolto be determined.

Thanks to the wide variety of optionsand modular expansion possibilities, theUNISET-P can now be tailored even betterto the specific wishes of the customer.

WORLD FIRST

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MECHATRONIC SYSTEMS

UNIBASE-MAutomatic tool dispensing systems

The new UNIBASE-M automatic tooldispensing system stands for optimumstorage and management of tools,components and accessories and oers

numerous innovative and user-friendlyfeatures.

UNIBASE-M is designed as a modular sys-tem for the management and dispensing

of tools, which ensures quick, e cient

and controlled tool availability. Startingfrom a basic module with computer unitit can be individually configured to suitthe application. Storage is either cen-tralised or decentralised directly at themachine.

Completely new is the intuitive softwarewith extended functions which ensuresquick, e cient and controlled tool avai-lability. For example, a control logic givesthe user an indicated of the selecteddrawer. Machine standstills due to a

lack of tools, huge tool stocks due toexcessive goods orders or double orders,as well as time and cost-intensiveordering processes can be reduced orcompletely eliminated with UNIBASE-M.

Your contact person


Michael Hils

[email protected]

AT A GLANCE:

Automatic tool dispensing Intuitive softwareVariable drawer divisionSimple order handlingAvoidance of down times

UNIBASE-M can be easily integrated into

external ERP systems on and in existingoperating facilities.

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18/2018

TOOLTRONIC

Fit for the future

MECHATRONIC SYSTEMS

Increased user-friendliness and simplercommissioning were the goals of thegeneral modification of the TOOLTRONICmechatronic tool system. In addition to

extensive electronic improvements, therange of applications was significantlyexpanded.

Commissioning greatly simplified

With a new and lean version of the on-machine controller, the stator box, it isnow possible to call up and evaluate thecurrent status and detailed informationof the interchangeable tool axis (U axis)via a modern touchscreen display. This is

possible not only during operation, butalso during commissioning. The direct andsimple access to the U axis without ad-ditional tools such as a mobile PC greatlysimplifies the set-up for the machinemanufacturer. Should errors exist,

they can be very quickly analysed and

corrected using the call-up possibilitiesand information from the stator box.Various application tools complete thefurther development and oer significantadded value.

User-friendly and space-saving

A lack of space in the switch cabinet isoften a problem when it comes to theintegration of mechatronic tool systemsor U axis systems, particularly if thesesystems have to be retrofitted in stan-

dard machining centres without designmodifications.

Until now, several individual componentssuch as stator box and computer modulehad to be installed for the integrationof the TOOLTRONIC unit into a machi-ning centre. This needed a considerableamount of space and generally resultedin a separate switch cabinet solutionoutside of the machining centre. The newstator box now contains all the individual

components in one module, reducing thespace requirements by 90 %.

Your contact person


Michael Hils

[email protected]

New TOOLTRONIC stator box reduces space

requirements by 90 %.

AT A GLANCE:

Reduction in the switch cabinetcomponentsCompact electronic unitsSimplified commissioning andmachine integration

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19/2019

Further development of the actuator

unit new LAT Series

The high-precision EAT range (EccentricActuating Tool) designed for high speedsand modified strokes has now beenexpanded to include a new LAT Series(Linear Actuating Tool).

The new LAT Series closes the gap for ap-plications requiring high speeds and longstrokes (over 100 mm). This is achievedusing an integrated unbalance correction.

In conjunction with a direct measuringsystem on the tool side, all the demandswith respect to application and cost-eectiveness can now be met.

Monitoring of mechanical actuating

tools with TOOLTRONIC-SFor di cult machining operations, suchas recesses and facing operations onparts during industrial-scale production,mechanical actuating tools are often aninexpensive solution for meeting irregulardemands. MAPAL oers innovative toolsfor this which can carry out actuatingfunctions on machining centres with-out an additional feed unit. These arecoolant-controlled, spindle speed-regu-lated centrifugal force tools or actuating

tools with contact stop. One limitationwith these systems, however, is that thereis no feedback as to whether the slideis extended or retracted when enteringthe workpiece. In the event of faults ordamage, the workpiece, mount or in theworst case expensive machine compo-nents can be destroyed.

With TOOLTRONIC-S, the end positioncontrol system for monitoring mecha-nical actuating tools, MAPAL can now

oer a simple solution to this problem.Irrespective of the method of actuations,TOOLTRONIC-S polls the end positionsvia sensors in the tool and feeds the in-formation back to the machine controller.The process reliability is significantly en-

hanced when using mechanical actuating

tools.

New TOOLTRONIC LAT Series

(Linear Actuating Tool)

AT A GLANCE:

New LAT Series for high speeds andlong strokes

More process reliability thanks toTOOLTRONIC-S

Coolant-controlled actuating tool with

TOOLTRONIC-S

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