• O sistema mecatrónico de ferramentas TOOLTRONIC como acionamento universal para uma maior versatilidade e flexibilidade de fabrico.
  • Ferramentas de cavilha da MAPAL
  • As ferramentas de acionamento da MAPAL são produzidas na unidade de Eppingen.
  • Os diferentes tipos de acionamento e saída são combinados de acordo com os requisitos e a aplicação.

Competência atuação

Ferramentas acionadas são sinônimo do mais alto potencial de racionalização e otimização na usinagem. Por este motivo e para cumprir a exigência de programas de ferramentas completos, é que desde o início dos anos 1990 o portfólio da MAPAL também inclui ferramentas acionadas, barras de mandrilagem e cabeçotes de facear inovadores. Seja para máquinas especiais ou para usinagem completa em centros de usinagem flexíveis – quando se trara de usinar contornos complexos, perfurações não cilíndricas, superfícies planas ou canais em componentes cúbicos – a MAPAL oferece a solução de ferramenta ideal.

A gama de produtos
  • engloba ferramentas acionadas mecânicas, com acionamento pela máquina por meio de barras de traçãopressão ou sistemas de eixo U,
  • bem como ferramentas com comando NC como o sistema mecatrônico de ferramentas TOOLTRONIC, especialmente flexível, para máquinas sem unidade de avanço adicional.
​​​A experiente e altamente especializada equipe de engenharia da MAPAL desenvolve, em estreita colaboração com o cliente, a solução ideal para a respectiva tarefa da usinagem. A mecânica refinada, concebida sob medida, e o grande número de peças diferentes no interior de uma ferramenta acionada, exigem altíssima precisão e cuidado em cada etapa de produção. E para assegurar a precisão das ferramentas, na MAPAL elas são monta das exclusivamente de modo manual. Para colocar a ferramenta em funcionamento no cliente, da forma mais rápida e eficiente possível, ferramentas acionadas complexas são previamente testadas de modo abrangente e sob condições de operação reais sob carga extrema. A colocação em funcionamento junto ao cliente é então realizada por um especialista em usinagem da MAPAL.




 

Applications for acutation tools

  • A contour that is being processed with an actuating tool is marked in red.

    Complex contours

    Machining turning geometries on cubic parts

  • The picture shows a group of tools for the complete machining of a turbocharger.

    Complete machining on machining centres

    MAPAL tool solutions from the actuating range allow for the machining of complete workpieces on machining centres. A change to  lathes is not necessary.

  • Certain actuating tools from MAPAL have the ability to compensate cutting edge wear.

    Cutting edge wear compensation

    A fine adjustment for automatic wear compensation offers highest accuracies and an optimum utilization of the cutting edges.

Product overview

Types of input and output

Different types of input and output are combined depending on the requirements of the application.

Depending on the type of machine of the customer, there are different types of input available.
For the output there are also different types available - for moving and controlling or for compensating and lifting.

Mechatronic tool system TOOLTRONIC

The mechatronic tool system TOOLTRONIC from MAPAL.

TOOLTRONIC – the universal input for more manufacturing versatility and flexibility on machining centres and special machines. 
TOOLTRONIC for machining centres is a full interchangeable tool axis that permits a broad spectrum of applications.

Facing heads

Facing heads from MAPAL for facing, grooving and contour machining.

Facing heads are used for face turning, recessing and machining contours predominantly in large-scale series production on special machines. 
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The operation of this slide tool and the actuation of the tool holder and inserts is via an NC-controlled crossfeed device that is on the spindle drive or on the rear of the feed unit.

Line boring bars

Line boring bars from MAPAL are used especially for machining bearing bars.

Line boring bars are tools for the special machining of bearing journals in housings. During this process the tool is guided by at least one guide bearing in the fixture (workpiece clamping). 
Several inserts in the tool permit the simultaneous machining of several journals. An optional drawbar/push rod makes possible additional face machining at the related journal and/or cutting edge lifting to compensate for cutting edge wear.

Line boring bars are used for machining crankshaft and camshaft bores. They are considered the most accurate way of manufacturing these bores in the crankcase.

Special applications

  • Wobble tools from MAPAL for machining internal and external profiles.

    Wobble tools

    Machining of internal and external profiles

    MAPAL wobble tools make possible the cost-effective manufacture of internal and external profiles that is also gentle on the machine. 
    ​​​​​​​
    A wobble movement is generated by the rotation of the wobble bar. Due to this wobble, only the point on these tools is used and therefore the load is also only on the point. The feed force required is significantly lower than during the conventional broaching and shaping process and therefore reduces the load on the machine tool's feed unit.

  • Interpolation tools from MAPAL are used to machine turning processes on machining centres.

    Interpolation turning

    Turning processes on machining centres

    Interpolation turning is a machining process that can be used to realise turning processes on machining centres. It is used, for example, for recesses on cubic workpieces that are otherwise produced using circular milling. However, many other geometries typical for turning, for example the taper form, can also be produced using interpolation turning on machining centres.

    An important prerequisite for the use of this process is that the machine has a main spindle that can be operated as a position-controlled axis.

Services for actuating tools

Regular maintenance by qualified MAPAL employees increases the effectiveness and longevity of the actuating tools significantly.

Engineering - Design - Commissioning - Maintenance

In the actuating tool sector, MAPAL offers comprehensive advice on the entire product portfolio. During initial conversations the requirements on the machining process are recorded by the salesperson. In order to offer a tailored product, the broad standard product range is complemented by customer-specific modifications to standardised components.

Tailored service contracts allow a reliable planning of maintenance appointments and reduce the service costs. The MAPAL service team checks the tools at a defined maintenance interval.

An independent service display extends the service life of MAPAL actuating tools.

Self-sufficient service indicator simplifies preventive maintenance

MAPAL has developed a particularly simple system that helps users with the question of the timing and frequency of service work on rotating tools.
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An integrated service chip with LED, partly also possible as an upgrade, signals an upcoming maintenance service by „blinking“. The service interval is based on the operating hours of the tool.