• El sistema mecatrónico de herramientas TOOLTRONIC como accionamiento universal para una mayor versatilidad y flexibilidad en la fabricación.
  • Herramientas para espigas de MAPAL
  • Las herramientas MAPAL se fabrican en la planta de Eppingen.
  • Los distintos tipos de accionamiento y salida se combinan en función de los requisitos y la aplicación.

Competencia de herramientas accionadas

Las herramientas accionadas ofrecen el máximo potencial de racionalización y optimización en el arranque de virutas. Por lo tanto y para atender la demanda de programas completos de herramientas, desde principios de los años 1990 la gama de productos de MAPAL incluye también herramientas accionadas, barras de mandrinar y cabezales de careado innovadores. Ya sea para máquinas especiales o para el mecanizado completo en centros de mecanizado flexibles: cuando se trata de mecanizar contornos complejos, agujeros no cilíndricos, superficies planas o ranuras en componentes cúbicos, MAPAL tiene la solución por medio de la herramienta óptima.

El programa de producto
  • comprende herramientas accionadas mecánicas que se accionan dentro de la máquina por medio de barras de tracción o sistemas de eje-U, así como herramientas controladas por NC, ​​​​​​​
  • como el sistema de herramientas mecatrónico TOOLTRONIC, especialmente flexible, para máquinas sin unidad de avance adicional.

El experimentado equipo de ingeniería de ramientas accionadas mecánicas que se accionan dentro de la máquina por medio de barras de tracción o sistemas de eje-U, así como herramientas controladas por NC, como el sistema de herramientas mecatrónico TOOLTRONIC, especialmente flexible, para máquinas sin unidad de avance adicional. El experimentado equipo de ingeniería de 
MAPAL, altamente especializado, elabora en estrecha colaboración con el cliente la solución óptima para su tarea de arranque de virutas. La esmerada mecánica, adaptada con precisión, y la gran variedad de componentes diferentes en el interior de una herramienta accionada requieren la máxima precisión y cuidado en cada fase de producción. Para asegurar la alta precisión de las herramientas, éstas se montan en MAPAL solo manualmente. Para ejecutar la puesta en servicio de las herramientas en el cliente lo más rápida y eficientemente posible, las herramientas accionadas complejas se prueban previamente con cargas extremas y en condiciones de uso reales. Un especialista en arranque de virutas de MAPAL efectúa la puesta en servicio en el cliente.

 

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.