Empower Your Aluminium Machining

Focus on the customer

Customer requirements

According to MAPAL's philosophy, the perfect solution is only the one that is precisely tailored to the needs and requirements of the customer without unnecessary over-engineering. MAPAL sees itself as a solution provider and technology partner and, in contrast to a pure tool supplier, not only considers the technical aspects but also puts itself in the customer's shoes. This customer focus is behind each solution approach and enables MAPAL to offer customers tailor-made tool concepts for their requirements.

Engineering

MAPAL's many years of experience and countless solutions developed for machining aluminium have resulted in a broad product and application portfolio. Both for the bore machining and milling of aluminium. This extensive product portfolio and the high level of manufacturing expertise form the basis for the optimum machining process for aluminum components. But the tools alone are not enough. Only customer-specific engineering turns a broad product and application portfolio into a perfect solution. This is where MAPAL's absolute strength lies. Many years of experience and the development of ever new solutions for the production of aluminum components make the tool manufacturer a first-class solution provider in this field.

Customised solution

Comprehensive market knowledge in the automotive, aerospace, fluid power and die & mould focus segments enables a deep understanding of the specific components and their manufacturing processes. In combination with in-depth materials expertise, this knowledge enables us to develop customised solutions from a diverse product portfolio - similar to a modular system.
This integrative approach, which combines market requirements, part geometries, machines, processes and economic aspects, allows MAPAL to offer customers customised tool concepts based on the ‘Basic-Performance-Expert’ solution approach.

Industries and components

Automotive

• Combined brake housing

  Process reliability with exact chip  control

  
  Combined brake housings made from extruded aluminium with low silicon content require short chips and reliable chip breaking. A new chip breaker creates a defined chip form and maximum process reliability, even for low feed rates and stock removals.

• Gigacasting / Megacasting

  Stable machining of large, thin-walled components

  Thin-walled components with deep machining contours require solutions with vibration damping. These ensure quiet running and improved surface quality and are gentle on the machines, even when long projection lengths are involved.

• Scroll compressor

  Spiral shapes with tolerances in the μm range

  
  Not only the drive and energy storage systems are affected by the electrification of vehicles, but also some auxiliary units. An example of this is the scroll compressor.

• Battery housing

  Machining complex, thin-walled  housings vibration-free

  MAPAL offers the appropriate tools with the optimal machining strategy for the various housing variants for batteries and power electronics. The powerful tool portfolio includes PCD and solid carbide tools.

• Electric motor housings

  High-precision with large diameters

  
  Different electric motor housings are used in vehicles with electric drives. You can differentiate between three basic types of construction. MAPAL offers innovative tool solutions for machining tasks with the housing types.

• Cylinder head

  Precise cylinder head machining for minimised emissions

  The aluminium cylinder head requires extremely precise machining to ensure the supply of fuel and air and to minimise emissions through precise valve control.

Aerospace and Composites

• Hydraulic pump housing

  Process-secure machining of complex hydraulic pumps in aerospace

  In the aerospace sector, complex hydraulic pumps pose significant challenges for manufacturing. Difficult process conditions, thin-walled parts, deep bores with cross holes, and low-silicon aluminum make precise chip breaking and control exceptionally challenging.

Fluid power

• Pneumatic valve housing

  Precision solutions for pneumatic valve housings

  Customised combination tools for the precise and burr-free machining of pneumatic valve housings. High process reliability and perfect surface quality ensure maximum efficiency in large-scale production.

• Pneumatic cylinder housing

  Efficient machining of pneumatic cylinder housings

  MAPAL offers specialised tools for the precise machining of pneumatic cylinder housings. High process reliability and burr-free surfaces guarantee quality and efficiency in the series production of heavy mechanical components.

Die & Mould

• Bottle mould

  Highly productive machining of pre-series and prototype moulds

  Solid carbide and PCD tools for fast and precise machining of aluminium moulds, ideal for pre-series and prototype production with short machining times.
   

Challenges of aluminium machining

Products and applications

Examples from practice

MAPAL Services

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

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