Titanium machining takes off

In medical technology, this workpiece material is used for implants because of its strength and compatibility with human tissue. There are high demands placed on dimensional accuracy and high-quality surface finishes to ensure a long service life of hip protheses and titanium implants.

Automotive manufacturers use it to create powerful sports cars. Application involves semi-machining and finish machining of chassis components. The blades of large gas turbines, made of titanium, absorb enormous forces.

The aircraft industry is producing more and more highly stressed parts made of titanium. MAPAL is making drilling and milling of the ductile, high-strength workpiece material more productive, thereby reducing costs.

Tool program for titanium machining

MAPAL overview product portfolio for titanium machining

Milling cutters with replaceable cutting edges

NeoMill-4-HiFeed90
High-feed milling cutter
High-feed milling cutter with four-edge radial indexable insert
Universal tool system to ensure maximum productivity
Ø area: 16.00 – 200.00 mm
NeoMill-Titan-2-Corner
Shoulder milling cutter
Shoulder milling cutter with double-edge radial indexable inserts
Positive basic shape for parts susceptible to vibrations
Cutting depths of up to 10 mm
Ø area: 40.00 – 100.00 mm
NeoMill-Titan-2-Shell
Shell end face milling cutter
Shell end face milling cutter with double-edge radial indexable inserts
Ideal for deep shoulder milling and trimming with high cutting depths of up to 57 mm
Ø area: 32.00 – 80.00 mm

Milling with fixed cutting edges

OptiMill-Titan-HPC
Shoulder milling cutter
Four-edge shoulder milling cutter for roughing and finishing titanium
Special cutting edge finish for optimal surfaces and edges
Highest degree of tool stability through maximum core dimension and core rise at the shank
Different corner radii available
Ø area: 6.00 – 25.00 mm
OptiMill-Tro-Titan
Trochoidal milling cutters
Five-edge trochoidal milling cutter
Maximum material removal rate while providing an excellent surface finish at the same time
Optimised unequal spacing
Finely balanced cutting tool for protecting the machine spindle and a longer tool life
Cutting depth up to 3xD
Ø area: 6.00 – 25.00 mm

Drilling from solid

MEGA-Speed-Drill-Titan
Solid carbide drill
Double-edge high-speed drill
Four margin lands for precise surface accuracy and cylindricity
Convex cutting edge with corner chamfer for high stability
Novel knurled profile to protect the margin lands
Maximum heat and wear resistance
Ø area: 3.00 – 20.00 mm

Reaming and fine boring

FixReam-FXR
High-performance reamers with a cylindrical shank
High-performance reamer made from solid carbide
Straight-fluted for through and blind bores
Left-hand fluted for through bores
Ideal for implementing short cycle times
Variety of cutting materials and coatings available
Ø area: 2.80 – 20.20 mm
HPR replaceable head reamer
Replaceable head reamers with HFS connection
High-precision replaceable head system in a fixed design with brazed cutting edges
Precise radial run-out and changeover accuracy of <3 μm
Highest degree of economic efficiency due to modular system
Suitable for minimum quantity lubrication (MQL)
Ø area: 7.00 – 65.00 mm

Boring

Boring in titanium
Boring tools with tangential technology
Component-specific custom tools for highest productivity, economic processes and stable machining concepts
CTHQ and FTHQ tangential indexable inserts
Special arc shaped land for optimal machining results at a length-to-diameter ratio >3.5xD
ø area: from 22.00 mm

Clamping

UNIQ Mill Chuck
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
UNIQ DReaM Chuck
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
HydroChuck MHC
Hydraulic chuck
Excellent vibration dampening
High degree of radial run-out accuracy
With axial tool length adjustment
Mill Chuck, System HB
Side lock chuck
Easy to handle thanks to use of a differential screw
Maximum cost-effectiveness and precision
Axial tool positioning can be defined using spring system
Decentralised coolant outlets for maximum process reliability
MFS milling head holder
Tool adapter for screw-in milling cutter
Simple and fast clamping of screw-in milling cutters
Exact interaction of taper and face connection
Greatest possible stability and rigidity
Universally deployable for roughing and finishing operations
HFS replaceable head holders
Tool adapter for HPR replaceable head reamer
Precise radial run-out and changeover accuracy of <3 μm
Taper and face connection provide the greatest possible stability and rigidity
Safe and easy handling
Suitable for minimum quantity lubrication (MQL)
Milling cutter arbor
Milling cutter arbor
Milling cutter arbor (MCA) with enlarged face connection
Ideally suited for roughing and pre-finishing operations in large diameter ranges
High flexibility through different lengths
Adapter
Alignment adapter module
For high-precision alignment of all flange modules
Compensation of radial run-out and angular errors of the machine spindle
Better surface quality and longer tool life
Hollow shank taper adapter and steep taper adapter available

Competence in titanium machining

Aerospace

Aerospace

Titanium and titanium alloys are predestined for use in aerospace. High demands are placed on workpiece material strength and corrosion resistance in relation to their specific weight. This results in a wide range of applications extending from small mechanically processed structural parts to load-bearing parts in the fuselage or blades in the engine.

Machining example torsion link

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Fine boring tool
- Arrangement of the cutting edges
- Perfect concentricity of the bores
- Optimal surface roughness
- Perfect bore geometry
- Stable machining thanks to guide pads
- High accuracy of repetition and easy tool setting
2 / 5

NeoMill-Titan-2-Shell
- Maximum machining rates
- Optimum chip removal
- Very quiet running
- Variable cooling concept
- Cutting edges with various corner radii can be deployed
- Variety of cutting materials available
3 / 5

MEGA-Speed-Drill-Titan
- 140° point angle
- Little development of built-up edge due to extremely smooth coating
- Four margin lands (best roundness values)
- Convex cutting edge
- Internal coolant supply
- Newly designed chip flute (optimal chip removal)
- Efficient coolant flow (avoids friction and heat at the cutting edge)
4 / 5

OptiMill-Titan-HPC
- Special edge preparation (stable cutting edge)
- Optimal pitch (stable cut, smooth running)
- Core rise for more stability
5 / 5

FixReam
- Solid carbide or brazed design
- Bore quality: H7
- DLC coating for optimal performance
- Configurable diameter
- Design for through or blind bores
- Suitable for minimum quantity lubrication (MQL)

Machining example hingeline

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Deburring tools made from solid carbide

With these custom tools in a special spherical shape, the bore entrance and exit of the main bore as well as the fixing bore are deburred through circilar milling.
2 / 6

NeoMill-Titan-2-Corner
- High machining rates
- Very quiet running
- Cutting edges with various corner radii can be deployed
- Variety of cutting materials available
3 / 6

MEGA-Speed-Drill-Titan
- Extends tool life by 30% compared to previous solutions
- Drilling specialist for high cutting speeds and feed rates
- Short cycle times
4 / 6

TTD replaceable head drill, custom drill, boring bar
- TTD replaceable head drill for piloting the first lug
- Custom drill with additional guide element at the neck for medium machining of lugs from both sides
- Bearing-guided boring bar for precise finishing of the main bore from one side
5 / 6

OptiMill-Titan-HPC
- Increases tool life by 35%
- Perfect solution for roughing, medium machining and finishing
- Excellent price-performance ratio
- Fits Mill Chuck, System HB
- Optimal pitch (stable cut, smooth running)
- Core rise for more stability
6 / 6

OptiMill-Tro-Titan
- Extends tool life by 10% compared to previous solutions
- High removal rates possible
- Unequal spacing of the cutting edges
- Special coating to avoid deposits
- Specially designed chip flute for optimum chip removal

Machining example valve housing

1 / 7

Solid carbide drill
- For difficult drilling applications
- Innovative lead geometry for good chip removal and low cutting pressure
- Significantly more performance, up to twice the feed rate compared to previous solutions
2 / 7

Boring tool with interchangeable blades
- Three-stage boring tool for medium machining
- No setting of cutting edges necessary
- Economical tool concept for roughing bores
- High machining rates possible
- Indexable inserts with excellent thermal stability
3 / 7

Boring tool made of solid carbide with four edges
- Long tool life thanks to special coating
- Coating protects the cutting edges against high temperatures and excessive wear and tear
- The internal coolant supply and chip channel geometries ensure efficient chip removal
4 / 7

HPR replaceable head reamer with six edges
- Perfect concentricity of the bores
- High feed rate possible and therefore less machining time
- Adjustable adapter enables precise tool settings and eliminates spindle errors
- Complete finishing in a single step
5 / 7

Solid carbide drill with three edges
- Special triple-edge geometry
- Perfect positioning of the drill
- Highly suitable for inclined bore entrances or cross bores
6 / 7

Boring tool made of solid carbide with four edges
- Special geometry
- Stable machining
- Optimal guide into the bore
- Four cutting edges ensure the right geometry of the bore prior to finishing
7 / 7

HPR reamer with six edges
- Can be repaired by desoldering/soldering the blades
- Perfect roundness of the bore due to the matching multi-cutting edge geometry
- Internal cooling ensures effective chip transport

Automotive

Automotive

Lower weight means lower fuel consumption resulting in fewer emissions. Therefore, many different applications for titanium materials can be found in automotive engineering. Starting with engine components, through to transmission parts and suspension elements as well as exhausts. The automotive manufacturers’ objective is to make vehicles lighter and therefore more environmentally friendly.

Machining example control arm

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MEGA-Speed-Drill-Titan
- Extends tool life by 30% compared to previous solutions
- Drilling specialist for high cutting speeds and feed rates
- Short cycle times
2 / 4

OptiMill-Titan-HPC
- Four-edge roughing milling cutter
- Polished chip flute
- Heat-resistant high-performance coating
- Unequal cutting edge (smooth cut)
3 / 4

HPR replaceable head reamer
- Radial run-out and changeover accuracy less than 3 μm
- Easy to handle
- Maximum precision and productivity
- Internal coolant supply to directly cool the cutting edges
- Particularly economical (replaceable head)
4 / 4

NeoMill-Titan-2-Shell
- Maximum machining rates
- Optimum chip removal
- Very quiet running
- Variable cooling concept
- Cutting edges with various corner radii can be deployed
- Variety of cutting materials available

Medical technology

Medical technology

Titanium is practically the perfect workpiece material for medical technology as it can be implemented extensively due to its bio-compatibility (i.e. its stability in biological surrounding – anti-allergenic), low thermal conductivity and anti-magnetic behaviour.

Machining example hip joint

1 / 1

OptiMill-Tro-Titan
- Heat-resistant high-performance coating
- Specially designed chip flute for optimum chip removal
- Heat reduction in the cutting zone

Machining example bone plates

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OptiMill-Tro-Titan
- Heat-resistant high-performance coating
- Specially designed chip flute for optimum chip removal
- Heat reduction in the cutting zone
2 / 2

MEGA-Speed-Drill-Titan
- Extends tool life by 30% compared to previous solutions
- Drilling specialist for high cutting speeds and feed rates
- Short cycle times

Contact

Dr. Piotr Tyczynski Global Head of Segment Management Aerospace & Composites piotr.tyczynski@mapal.com Phone: +48 607 767 066

Titanium machining takes off

Tool program for titanium machining

NeoMill-4-HiFeed90

NeoMill-Titan-2-Corner

NeoMill-Titan-2-Shell

OptiMill-Titan-HPC

OptiMill-Tro-Titan

MEGA-Speed-Drill-Titan

FixReam-FXR

HPR replaceable head reamer

Boring in titanium

UNIQ Mill Chuck

UNIQ DReaM Chuck

HydroChuck MHC

Mill Chuck, System HB

MFS milling head holder

HFS replaceable head holders

Milling cutter arbor

Adapter

Competence in titanium machining

Contact