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

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  • 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

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  • 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

    Nuevo diseño de mandril de expansión hidráulica 

    • Para escariado y taladrado, así como alisado 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

  • UNIQ Mill Chuck

    Nuevo diseño de mandril de expansión hidráulica 

    • Mandril de expansión hidráulica para fresados muy dinámicos
    • Combinación óptima de propiedades geométricas y funcionales
    • Resultados magníficos al usarse herramientas con mango HA
    • Máxima estabilidad en el proceso, incluso si los componentes son de gran calidad

  • HighTorque Chuck HTC

    Mandril de expansión hidráulica 

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

  • MAPAL HydroChuck MHC

    HydroChuck MHC

    Mandril de expansión hidráulica 

    • Extraordinario amortiguador de vibración
    • Alta precisión de concentricidad
    • Modelo supercorto y compacto de gran rigidez

  • ThermoChuck MTC

    Sistema de sujeción por contracción térmica 

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

  • MAPAL slip-on reamer arbor

    Portafresa – MDA / MCA

    Portafresa 

    • Modelo 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 superficial
    • Portafresa (MCA) con cara plana de apoyo axial mejorada para desbastado y semiacabado con gran rango de diámetro 

  • MAPAL HSK adapter

    Adaptador

    Prolongaciones, reducciones y adaptador 

    • Gran variedad de opciones para sistemas modulares de herramienta
    • Prolongaciones de sujeción hidráulica y térmica
    • Reducciones y prolongaciones HSK
    • Adaptador de cono de gran inclinación

  • 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.

    Servicios de MAPAL

    Con el módulo de servicios de​​​​​​​ ingeniería, MAPAL garantiza una fabricación rápida, precisa y segura. En el ámbito de​​​​​​​ logística y​​​​​​​ mantenimiento se pueden descubrir más potenciales de ahorro. Y en el ámbito de la​​​​​​​ formación, MAPAL se asegura de que el conocimiento especializado reunido está disponible de forma íntegra y transparente para el cliente, lo cual le permite avanzar de forma decisiva frente a la competencia.

    En todas las​​​​​​​ ofertas de servicios de MAPAL, todos los procesos y la asistencia amplia están orientados a la industria 4.0, siempre con el objetivo de contribuir de forma importante a la fabricación fluida, productiva y económica por parte del cliente.

    Ventajas:

    • Soluciones completas para piezas de trabajo, incluyendo herramientas, dispositivos, programa CN y puesta en servicio
    • Diseño del proceso completo e implementación de un solo proveedor
    • Asistencia en sitio rápida y flexible en todo el mundo
    • Tecnología de herramientas eficiente y con optimización de costes
    • Adaptación óptima entre la herramienta, la pieza de trabajo, el dispositivo y la máquina
    • Máxima calidad de producción, seguridad del proceso y rentabilidad desde el principio
    • Ejecución rápida desde la planificación hasta la implementación con la máxima seguridad de planificación