MAPAL Empower your aluminium machining

Empower Your Aluminium Machining

Engineering is the key

With decades of experience in the design, production and application of tools for aluminium machining, MAPAL is the leading technology partner for the machining of aluminium components. In order to be able to offer customers optimum machining processes, MAPAL provides market, material and engineering expertise in addition to a comprehensive product and application portfolio. The full potential of a machining process can only be realised through the interaction of all influencing factors and cooperation in a spirit of partnership - this is what MAPAL stands for.
MAPAL Empower your aluminium machining

Focus on the customer

MAPAL customer in focus

Industries and components

Challenges of aluminium machining

  • MAPAL ALu machining FLEXIBILITY WITHOUT COMPROMISE

    Flexibility without compromise

    Solid carbide milling cutters with innovative face geometry and large chip flutes enable universal milling, ramping and drilling with one tool.

  • HIGHLY PRECISE AND DEFINED SURFACES AND SHAPES

    Highly precise and defined surfaces and shapes

    Face milling systems with carbide and PCD as well as radius and form milling cutters guarantee precise surfaces and contours, even on free-form surfaces.

  • MAPAL challenges in aluminium machining

    Complicated process requirements

    Vibration-damped milling holders and customised tool systems ensure reliable machining results under complicated requirements.

  • MAPAL challenges in aluminium machining

    High volume milling

    Milling systems with a highly positive rake angle and large, polished chip spaces maximise the material removal rate and enable high metal removal rates with low cutting forces and high surface quality.

  • MAPAL challenges in aluminium machining

    Defined chip breaking and control

    Inserts with chip breaking geometries, highly positive cutting edges and indexable drilling inserts provide short, controlled chips.

  • MAPAL challenges in aluminium machining

    Reduced burr formation when machining bores

    Milling instead of drilling and drills with countersink minimise burrs and enable machining in a single step.

  • MAPAL challenges in aluminium machining

    Highest productivity in serial production

    Multi-cutting edged solid car-bide tools, replaceable drilling heads and combination tools increase productivity in serial production.

  • MAPAL challenges in aluminium machining

    Process reliability when drilling deep bores

    Matched pilot and deep drilling tools of solid carbide as well as PCD tools ensure process reliable machining of deep bores. 

Products and applications

Milling with solid carbide
  • MAPAL Schaftfräser OptiMill-Alu-HPC

    OptiMill-Alu-HPC

    Shoulder milling cutter

    • High-performance milling cutter for efficient machining of aluminium
    • ø range: 3,00 - 20,00 mm

    Go to the product

  • MAPAL end milling cutter OptMill-Alu-HPC-Pocket

    OptiMill-Alu-HPC-Pocket

    Shoulder milling cutter

    • Unique face geometry with integrated drill point for pocket milling
    • ø range: 5.00 - 20.00 mm

    To the shop

  • OptiMill-Alu-Wave

    Shoulder milling cutter

    • Roughing cutter for high-volume machining
    • ø range: 12.00 - 25.00 mm

    To the shop

  • MAPAL end milling cutter OptiMill-SPM-Finish

    OptiMill-SPM-Finish

    Shoulder milling cutter

    • Finishing of deep pockets and filigree component structures
    • ø range: 12.00 - 25.00 mm

  • MAPAL OptiMill-3D-BN-Alu milling cutter

    OptiMill-3D-BN-Alu

    Ball nose end mill

    • For machining high-strength aluminium alloys
    • ø range: 1.00 - 20.00 mm

    To the shop

  • MAPAL OptiMill-3D-CR-Alu milling cutter

    OptiMill-3D-CR-Alu

    Corner radius milling cutter

    • For machining high-strength aluminium alloys
    • ø range: 2.00 - 20.00 mm

    To the shop

Milling with PCD
  • OptiMill-Diamond

    Shoulder milling cutter

    • Optimised geometry for more stability and improved cooling directly at the cutting edge
    • ø range: 4.00 - 63.00 mm

  • MAPAL end milling cutter OptiMill-Diamond-SPM

    OptiMill-Diamond-SPM

    Shoulder milling cutter

    • For high-volume machining
    • ø range: 6.00 - 50.00 mm

  • MAPAL PCD face milling cutter FaceMill-Diamond

    FaceMill-Diamond

    PCD face milling cutter

    • Increased productivity thanks to maximum feed rates and metal removal rates
    • ø range: 40.00 - 125.00 mm

  • FaceMill-Diamond-ES

    PCD face milling cutter

    • Suitable for many different machining operations with very good surface finishes
    • ø range: 32.00 - 90.00 mm

  • MAPAL face milling cutters with PCD

    NeoMill-Diamond System Power

    PCD face milling heads

    • All-rounder for roughing and finishing
    • ø range: 50.00 - 400.00 mm

  • MAPAL face milling cutters with PCD

    NeoMill-Diamond System Eco

    PCD face milling heads

    • Designed for finishing operations with high surface qualities
    • ø range: 50.00 - 400.00 mm

Milling with indexable inserts
  • NeoMill-Alu-QBig

    Shoulder milling cutter

    • Large metal removal rates with low cutting forces and high surface qualities
    • ø range: 32.00 - 80.00 mm

  • NeoMill-T-Finish

    Finish face milling cutter

    • Finishing with maximum accuracy and without setting
    • ø range: 50.00 - 315.00 mm

Drilling
  • Tritan-Drill-Alu

    Solid carbide twist drill

    • Especially for high-feed machining of aluminium
    • ø range: 4.00 - 20.00 mm

    To the shop

  • MAPAL drilling MEGA-Drill-Alu

    MEGA-Drill-Alu

    Solid carbide twist drill

    • High-precision solid drill bit for the best drilling quality
    • ø range: 2.80 - 20.00 mm

    To the shop

  • MEGA-180°-Drill-Alu MAPAL drill

    MEGA-180°-Drill-Alu

    Solid carbide twist drill

    • For optimum roundness and surfaces in drill holes
    • ø range: 3.00 - 20.00 mm

    To the shop

  • MEGA-Deep-Drill-Alu MAPAL drill

    MEGA-Deep-Drill-Alu

    Solid carbide twist drill

    • Excellent for deep drilling applications in aluminium
    • ø range: 3.00 - 12.00 mm

    To the shop

  • Vollbohren mit MAPAL Wechselkopfsystem

    QTD indexable insert drill

    Solid drilling with replaceable head system

    • Economical system with indexable inserts
    • ø range: 8.00 - 50.00 mm

  • Vollbohren mit MAPAL Wechselkopfsystem

    TTD replaceable head drill

    Solid drilling with replaceable head system

    • Double-edged replaceable head drill with five different drill heads
    • ø range: 12.00 - 45.00 mm

Reaming
  • MAPAL Reaming Fixream

    FixReam 500

    Reamer

    • Versatile range of applications
    • ø range: 3.00 - 14.00 mm

       

    To the shop

  • MAPAL reaming Fixream500plus

    FixReam 500 Plus

    Reamer

    • Cost-efficient high-performance reamer for precise blind and through holes
    • ø range: 3.00 - 14.00 mm

  • FixReam 700

    Reamer

    • Reconditioning enables significant reduction in cost per part
    • ø range: 9,900 - 32,000 mm

  • MN reamers

    Single bladed reamers

    • Tools for maximum precision

Clamping
  • UNIQ DReaM Chuck, 4.5°

    Hydraulic chucks with a new design 

    • For reaming and drilling applications as well as for finishing during milling operations
    • This is achieved through an optimal interplay of geometric and functional properties
    • Outstanding surfaces as well as improved handling
    • Increasing productivity during the machining of contour-critical parts

    To the shop

  • UNIQ Mill Chuck, HA

    Hydraulic chucks with a new design 

    • Hydraulic chuck for highly dynamic milling applications
    • This is achieved through an optimal interplay of geometric and functional properties
    • Excellent results when using tools with HA shanks
    • Process reliability – even on high-quality parts 

    To the shop

  • HighTorque Chuck HTC

    Hydraulic chuck 

    • High level of torque transmission
    • Ideal damping properties
    • Excellent rigidity of the entire system
    • Radial run-out accuracy < 3 μm
    • 3° slim design for use in contour-critical applications 


       

    To the shop

  • MAPAL HydroChuck MHC

    HydroChuck MHC

    Hydraulic chuck 

    • Excellent vibration dampening
    • High degree of radial run-out accuracy
    • Ultra-short and compact design for high rigidity





       

    To the shop

  • ThermoChuck MTC

    Shrink chuck 

    • Long tool life through the use of high-temperature tool steel 
    • High torque transmission and radial rigidity
    • Precision balanced as standard
    • MQL-suitable
    • With and without axial tool length adjustment 

       

    To the shop

  • MAPAL slip-on reamer arbor

    Milling cutter arbor – MDA / MCA

    Milling cutter arbor 

    • Vibration-cancelling design (MDA) with vibration dampening system
    • Adapted to the rigidity of all common machine types
    • Smooth, stable running despite long projections delivers better surface finish
    • Milling cutter arbor (MCA) with large face connection for roughing and pre-finishing operations in large diameter ranges

  • MAPAL HSK adapter

    Adapter

    Extensions, reducers and adapters 

    • Wide range of options for modular tool systems
    • Hydraulic extensions and tool extensions for thermal expanding chucks
    • HSK reducers and extensions
    • KS steep taper adapter



       

    To the shop

  • MAPAL MQL chuck

    Clamping chuck for MQL

    Broad standard programme of MQL clamping tools

    • Shrink and hydraulic chucks
    • 1 and 2-channel system
    • High energy efficiency





       

    To the shop

    Examples from practice

    • Increased productivity thanks to maximum feed rates and metal removal rates

      Highly precise and defined surfaces and shapes

      The FaceMill-Diamond milling cutter revolutionises the machining of aluminium with a high silicon content by offering unparalleled precision and maximum tool life.

    • Significantly better surfaces thanks to vibration damping

      Complicated process requirements

      Innovative solutions for vibration damping during machining improve machining quality and significantly extend tool life.

    • Economical processing with robots

      Complicated process requirements

      The precise machining of large-format aluminium battery trays places high demands on process reliability and dimensional accuracy - crucial for the performance of modern electric vehicles.

    • Minimising vibrations with long tool overhang

      Complicated process requirements

      The secure clamping and exact positioning of shell cutters remains a challenge, especially with high torques and cutting forces - crucial for precise and stable machining processes.

    • Structural parts in record time

      Complicated process requirements

      The challenge in the precise machining of aluminium components lies in the combination of high material removal rates and tight dimensional tolerances - crucial for efficiency and quality in production.

    • Aluminium machining in new dimensions

      High volume milling

      The precise machining of large-format aluminium components requires maximum stability and process reliability - essential for demanding applications in the aerospace industry.

    • Spotlight on cost-per-part in machining stator housings

      Highest productivity in serial production

      The machining of complex aluminium workpieces requires maximum precision and adaptability - the key to efficiency and top quality in series production.

    • Minimum quantity lubrication with MAPAL

      Highest productivity in serial production

      The challenge of environmentally friendly aluminium machining lies in the reduction of lubricants - minimum quantity lubrication enables sustainable production with consistent precision and efficiency.

    • The best deep bores with PCD

      Process reliability when drilling deep bores

      The challenge of deep drilling in aluminium lies in avoiding dimensional deviations and stresses - crucial for ensuring precise and error-free holes in demanding components.

    • Dry processing of laminated composites in aircraft construction

      Reduced burr formation when machining bores

      Dry machining of laminated composites places enormous demands on precision and tool life - crucial for minimising material wear and achieving the highest surface quality.

    • Milling instead of drilling

      Reduced burr formation when machining bores

      Switching from drilling to milling when machining aluminium components has the potential to drastically reduce process times and increase precision at the same time - an innovative solution for more efficient production.

    • With strategy to the battery frame

      Reduced burr formation when machining bores

      The machining of thin-walled aluminium battery frames poses a particular challenge, as deformations and dimensional deviations must be avoided at all costs - crucial for accuracy of fit and stability in e-mobility.

    MAPAL Services

    Mapal Services - Engineering, Logistic, Maintenance, Training

    With the engineering service module, MAPAL guarantees fast, precise and safe manufacturing. Further savings potential can be tapped in the area of logistics and maintenance. And in the area of training, MAPAL ensures that the specialist know-how it has gathered is transparently and completely available to the customer – this gives customers a decisive lead over their competitors.

    All of the services offered by MAPAL focus on optimal processes and comprehensive support on the way to Industry 4.0. The goal is to always significantly assist the customer in achieving smooth, productive and economical manufacturing.

    Advantages:

    • Solutions for complete workpieces including tools, devices, NC programs and commissioning
    • Complete process design and implementation from a single source
    • Fast and flexible on-site support worldwide
    • Efficient and cost-optimised tool technology
    • Optimum coordination of tool, workpiece, equipment and machine
    • Highest product quality, process reliability and cost-effectiveness right from the start
    • Fast throughput from planning to implementation with maximum planning security