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

    To the shop

  • 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 NeoMill-Diamond-Eco

    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

    Fresas de corte en esquina

    • Grandes volúmenes de eliminación de virutas con bajas fuerzas de corte y alta calidad de la superficie
    • Rango de ø: 32.00 - 80.00 mm

  • NeoMill-T-Finish

    Fresa plana para acabado

    • Acabado con máxima precisión y sin ajuste
    • Rango de ø: 50,00 - 315,00 mm

Taladrado
  • Tritan-Drill-Alu

    Broca helicoidal de metal duro

    • Especial para el mecanizado de alto avance de aluminio
    • Rango de ø: 4.00 - 20.00 mm

    Ir a la tienda

  • MAPAL drilling MEGA-Drill-Alu

    MEGA-Drill-Alu

    Broca helicoidal de metal duro

    • Broca sólida de alta precisión para la mejor calidad de taladrado
    • Rango de ø: 2.80 - 20.00 mm

    Ir a la tienda

  • MEGA-180°-Drill-Alu MAPAL drill

    MEGA-180°-Drill-Alu

    Broca helicoidal de metal duro

    • Para redondeces y superficies óptimas al taladrar
    • Rango de ø: 3.00 - 20.00 mm

    Ir a la tienda

  • MEGA-Deep-Drill-Alu MAPAL drill

    MEGA-Deep-Drill-Alu

    Broca helicoidal de metal duro

    • Excelente para aplicaciones de taladrado profundo en aluminio
    • Rango de ø: 3.00 - 12.00 mm

    Ir a la tienda

  • Vollbohren mit MAPAL Wechselkopfsystem

    Brocas de plaquitas de corte QTD

    Taladrado en macizo con sistema de cabezal intercambiable

    • Sistema rentable con plaquitas de corte intercambiables
    • Rango de ø: 8.00 - 50.00 mm

  • Vollbohren mit MAPAL Wechselkopfsystem

    Brocas de cabezal intercambiable TTD

    Taladrado en macizo con sistema de cabezal intercambiable

    • Broca de cabezal intercambiable de doble filo con cinco cabezales de taladrado distintos
    • Rango de ø: 12.00 - 45.00 mm

Escariado
  • MAPAL Reaming Fixream

    FixReam 500

    Escariador

    • Amplio ámbito de aplicación
    • Rango de ø: 3.00 - 14.00 mm
       

    Ir a la tienda

  • MAPAL reaming Fixream500plus

    FixReam 500 Plus

    Escariador

    • Escariadores asequibles de alto rendimiento para agujeros ciegos y agujeros pasantes precisos
    • Rango de ø: 3.00 - 14.00 mm

  • FixReam 700

    Escariador

    • El reacondicionamiento permite reducir considerablemente el costo por pieza
    • Rango de ø: 9.900 - 32.000 mm

  • Escariadores MN

    Escariadores de un filo

    • Herramientas para una máxima precisión

Sujeción
  • UNIQ DReaM Chuck, 4.5°

    Nuevo diseño del adaptador hidráulico

    • Para escariado y taladrado, así como acabado durante el fresado
    • Combinación óptima de propiedades geométricas y funcionales
    • Superficies extraordinarias con manejo mejorado simultáneo
    • Flexibilidad y productividad máximas durante el mecanizado de componentes de perfiles complicados

    Ir a la tienda

  • UNIQ Mill Chuck, HA

    Nuevo diseño del adaptador hidráulico

    • Adaptador hidráulico para fresados muy dinámicos
    • Combinación óptima de propiedades geométricas y funcionales
    • Resultados magníficos al usarse herramientas con mango HA
    • Máxima seguridad de proceso, incluso si los componentes son de alta calidad

    Ir a la tienda

  • HighTorque Chuck HTC

    Mandril de expansión hidráulica

    • Alta transmisión del par
    • Características de amortiguación idóneas
    • Resistencia extraordinaria del sistema completo
    • Precisión de concentricidad < 3 µm
    • Diseño estrecho de 3° para usarse en perfiles complicados

       

    Ir a la tienda

  • MAPAL HydroChuck MHC

    HydroChuck MHC

    Adaptador hidráulico

    • Extraordinaria amortiguación de las vibraciones
    • Alta precisión de concentricidad
    • Diseño supercorto y compacto de gran rigidez



     

    Ir a la tienda

  • ThermoChuck MTC

    Portaherramientas térmico 

    • Larga vida útil gracias a la utilización de acero para herramientas altamente resistente al calor
    • Elevada transmisión del par y rigidez radial
    • Equilibrado estándar de precisión
    • Adecuados para MQL
    • Con y sin ajuste longitudinal axial de la herramienta
       

    Ir a la tienda

  • MAPAL slip-on reamer arbor

    Portafresa – MDA / MCA

    Portafresa 

    • Diseño con amortiguación de vibraciones (MDA) con sistema antivibraciones
    • Adaptado a la rigidez de todos los tipos de máquina comunes
    • Marcha suave y estable a pesar de una proyección larga para mejorar la calidad de superficie
    • Portafresa (MCA) con cara plana de apoyo axial mejorada para desbastado y semiacabado con gran rango de diámetro

  • MAPAL HSK adapter

    Adaptador

    Alargaderas, reducciones y adaptadores

    • Gran variedad de opciones para sistemas modulares de herramienta
    • Alargaderas de hidroexpansión y contracción
    • Reducciones y prolongaciones HSK
    • Adaptadores de cono de gran inclinación KS

    Ir a la tienda

  • MAPAL MQL chuck

    Mandril de sujeción para MQL

    Amplio programa estándar de sistemas de sujeción MQL

    • Mandril de contracción e adaptador hidráulico
    • Sistema de 1 y 2 canales
    • Alta eficiencia energética





       

    Ir a la tienda

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

Increase your efficiency in aluminum machining - request a callback now!