MAPAL Dr. Kress

With the MEGA-Deep-Drill-Steel, MAPAL showcases the new standard for deep drilling at the EMO, which has been specially designed for machining steel and cast iron.

The solid carbide deep drills are optimally protected with an innovative coating with HiPIMS technology in the cutting edge area. The head coating also ensures frictionless chip removal and is therefore the prerequisite for the reliable production of deep bores. The remaining length of the MEGA-Deep-Drill-Steel remains uncoated. “In our opinion, there is nothing smoother than a polished solid carbide surface”, Michael Villwock, Product Manager for Solid Carbide Tools, reaffirms the approach.

Spherical cutting edges provide a high level of stability and thus ensure a long tool life and high level of productivity. The point angles were selected so that the deep drills always start the cut with the chisel in the pilot bore. The standard range available from stock includes length ratios of 15xD to 40xD and the diameter range from 3 mm to 16 mm, with the long designs up to 9 mm. Adapted pilot drills are available for difficult drilling conditions.

With the MEGA-Deep-Drill-Steel, deep drilling is possible without pecking cycles at very high feed rates. The tools are suitable both for use with internal cooling and for minimum quantity lubrication, which has a positive effect on the tool life in steel machining. Field tests have shown that the new deep drills from MAPAL meet the highest requirements for tool life and performance even with demanding materials. Compared to its predecessors, up to 50 percent higher feed rates can be achieved.

MAPAL is launching a series of new cylindrical shank reamers with brazed cutting edges. Within the range of monolithic solid carbide tools for reaming, they are adding a particularly sustainable variant to the existing product series.

What’s special about the FixReam 700 reamers is their frequent usability, which is achieved by replacing the cutting edges and regrinding. A tool can be reground up to twice before new cutting edges have to be brazed in. After that, it is possible to regrind the tool twice again, replace the cutting edges again and then regrind the tool twice more. One reamer therefore has nine tool lives. During servicing, the manufacturer expands the tool a little with an expansion screw and can thus regrind all functional surfaces, i.e. lead and diameter. Tool costs can be reduced by up to 15 percent compared to a tool without an expansion function.

MAPAL has developed and patented new geometries especially for these reamers. As a result, users achieve up to 30 percent better roundness and cylindrical form as well as improved chip removal compared to other cylindrical shank reamers. The FixReam 700 reamers are available in two variants for through bores and blind bores. They are available in two lengths as short or long versions, as is customary in the market. The tools can be configured in a diameter range from 9.9 to 32.2 mm.

As of the EMO trade fair, the FixReam 700 tools are available with uncoated, wear-resistant cermet cutting edges for machining steel and cast iron materials with high stock availability. Other variants with coated carbide and cermet cutting edges will follow in 2024.

MAPAL is launching two new products for high-volume milling of aluminium for the EMO 2023, thus expanding its portfolio for the aerospace industry. The two milling cutter series in solid carbide and with indexable inserts are particularly suitable for use on high-performance machines.

With its new solid carbide roughing cutter OptiMill-Alu-Wave for aluminium materials, MAPAL is taking full advantage of the performance of the quickest machines available on the market, thus achieving a material removal rate of up to 21 litres per minute. At the same time, it is of course also possible to use the high-volume milling cutter on less powerful machines. The tool manufacturer is thus taking into account the fact that aeroplane parts are often manufactured on machines with spindle outputs between 40 and 80 kW, for which there was previously no suitable milling cutter in the portfolio.

The template for the new aluminium milling cutter was the cord roughing cutter OptiMill-Uni-Wave, which is successfully used in steel machining. For optimum chip formation when machinig aluminium, the roughing cutter has large, flat waves. Polished chip flutes facilitate chip removal. The cutter with three cutting edges is fitted with central cooling and a modified face geometry, which enables ramp angles up to 30 degrees. In order to prevent imbalance in high speed ranges, the developers have dispensed with pull-out protection and recommend the hydraulic clamping technology of MAPAL. For applications in the limit range, there is the option to use the Safe-LockTM pull-out protection from Haimer.

The OptiMill-Alu-Wave is not only ideal for aerospace structural parts but is also suitable for applications in the automotive field and general machining. For the product launch from the EMO trade fair onwards, diameter ranges from 12 to 25 mm with projection lengths of 3xD, 4xD and 5xD are available. A configurator makes further variants possible, which also supports close-contour roughing.

MAPAL is launching two new products for high-volume milling of aluminium for the EMO 2023, thus expanding its portfolio for the aerospace industry. The two milling cutter series in solid carbide and with indexable inserts are particularly suitable for use on high-performance machines.

The new indexable insert milling cutters NeoMill-Alu-QBig are a highly economical solution for larger diameters. In order to achieve as large a material removal rate as possible of up to 18 litres per minute, the new aluminium volume milling cutter is designed for use at spindle speeds of up to 35,000 rpm (with a diameter of 50 mm). For a tight fit despite high centrifugal forces, screws with increased tensile strength are used to hold the indexable inserts firmly in the prismatic seat. In addition, countersinks on the indexable insert ensure weight savings. MAPAL has fitted the tool body with a fine balancing system. Four threaded bores enable precise adjustment in order to protect the machine spindle at high speeds and achieve the highest possible surface finishes.

In addition, focus was placed during development on low cutting forces and highly precise indexable inserts. High chip volumes with very high achievable surface finishes of R_a 0.8 µm and R_z 4.0 µm for rough and fine machining can thus be achieved with the tool. For the main application, machining wrought aluminium alloys, MAPAL uses uncoated cutting edges with a highly positive rake angle and polished chip guiding stage for low frictional resistance. This reduces the amount of heat generated. For this purpose, PVD-coated indexable inserts for machining Al-Li alloys and CVD-diamond-coated indexable inserts for the automotive industry and general machining are available in the portfolio. The maximum stock removal is 12.5 mm. Internal cooling and very large chip spaces ensure optimum heat dissipation and chip removal. MAPAL produces the tool bodies in a diameter range of 32 to 63 mm for hollow shank taper or shank taper as well as mounting tool variants.

With the solid carbide milling cutter OptiMill-Alu-Wave and the NeoMill-Alu-QBig indexable insert milling cutter, MAPAL showcases a complete range of products from 12 to 63 mm for high-volume machining of aluminium materials at EMO 2023.

MAPAL is launching two new products for high-volume milling of aluminium for the EMO 2023, thus expanding its portfolio for the aerospace industry. The two milling cutter series in solid carbide and with indexable inserts are particularly suitable for use on high-performance machines.

The new indexable insert milling cutters NeoMill-Alu-QBig are a highly economical solution for larger diameters. In order to achieve as large a material removal rate as possible of up to 18 litres per minute, the new aluminium volume milling cutter is designed for use at spindle speeds of up to 35,000 rpm (with a diameter of 50 mm). For a tight fit despite high centrifugal forces, screws with increased tensile strength are used to hold the indexable inserts firmly in the prismatic seat. In addition, countersinks on the indexable insert ensure weight savings. MAPAL has fitted the tool body with a fine balancing system. Four threaded bores enable precise adjustment in order to protect the machine spindle at high speeds and achieve the highest possible surface finishes.

In addition, focus was placed during development on low cutting forces and highly precise indexable inserts. High chip volumes with very high achievable surface finishes of R_a 0.8 µm and R_z 4.0 µm for rough and fine machining can thus be achieved with the tool. For the main application, machining wrought aluminium alloys, MAPAL uses uncoated cutting edges with a highly positive rake angle and polished chip guiding stage for low frictional resistance. This reduces the amount of heat generated. For this purpose, PVD-coated indexable inserts for machining Al-Li alloys and CVD-diamond-coated indexable inserts for the automotive industry and general machining are available in the portfolio. The maximum stock removal is 12.5 mm. Internal cooling and very large chip spaces ensure optimum heat dissipation and chip removal. MAPAL produces the tool bodies in a diameter range of 32 to 63 mm for hollow shank taper or shank taper as well as mounting tool variants.

With the solid carbide milling cutter OptiMill-Alu-Wave and the NeoMill-Alu-QBig indexable insert milling cutter, MAPAL showcases a complete range of products from 12 to 63 mm for high-volume machining of aluminium materials at EMO 2023.