01.01.2020
Complete Supplier in Tool and Mould Making
Not only does MAPAL deliver tools and clamping technology to our customers but also complete processes and the way into the digitalized production
Companies that make dies and moulds expect high process and product expertise from their cutting tools manufacturer. They require their tools to o®er the highest levels of precision, a long tool life, and – above all – process reliability. It is precisely these aspects that make MAPAL successful in sectors such as the automotive industry, machine engineering and the aerospave industry. So it shouldn’t come as a surprise that the precision tool manufacturer is now also taking o® in the field of die and mould making.
Structural changes to the market in fields such as the automotive industry are prompting many suppliers to strategically reposition themselves. “That’s why we have begun to develop in sectors other than our largest source of trade – the automotive industry – years ago. We have established ourselves in the aerospace sector within just a few years”, explains Dr Jochen Kress, President of the MAPAL Group. MAPAL is now planning to do something similar in the die and mould sector.
MAPAL has always offered tools that are also used in die and mould. “However, we hadn’t yet developed the market penetration or comprehensive portfolio we needed”, says Dr Jochen Kress. MAPAL has therefore gradually built up both its portfolio and relevant expertise, most recently by integrating the company voha-tosec into the MAPAL Group. In taking over
the company from Lindlar, MAPAL not only gained sound, deep knowledge of the market, but also products that complement the existing portfolio. New tools were developed in close cooperation.
the company from Lindlar, MAPAL not only gained sound, deep knowledge of the market, but also products that complement the existing portfolio. New tools were developed in close cooperation.
New milling cutters made from solid carbide
MAPAL has introduced a new, powerful range of solid carbide milling cutters specifically developed for die and mould under the product name OptiMill-3D. “In addition to extremely heat-resistant coatings and special carbide substrates, these tools are characterised by their dimensions and geometries, which are specially adapted to mould”, explains Carsten Klein, who is responsible for the die and mould making market segment.
The range includes tools with special face geometry for milling hardened components, a shoulder radius milling cutter for finishing 3D shapes up to a hardness of 66 HRC and new circular radius milling cutters for use in deep cavities or for complex free-form surfaces.
Greater cost-effectiveness with ISO tools
A new range of milling cutters with ISO indexable inserts was also presented at EMO. The programme includes round insert milling cutters, high-feed and 90° shoulder milling cutters, ball and toric end milling cutters and finishing milling cutters. As such, the range of ISO indexable inserts covers the workpiece materials cast iron, steel, stainless steel, non-ferrous metal
and hardened workpiece materials up to 65 HRC. Different cutting materials and coatings are used depending on requirements and the material to be machined.
and hardened workpiece materials up to 65 HRC. Different cutting materials and coatings are used depending on requirements and the material to be machined.
Nearly 100 % coverage – and not just for tools
“Today, we are able to cover almost 100 percent of the needs of companies that make die and moulds,” says Carsten Klein. This includes not only the milling cutters mentioned above, but also the complete range for drilling and reaming. However, when it comes to many milling tasks in die and mould making, the focus is not just on tool technology. Another decisive factor is the programming of the machine, which is a complex matter. MAPAL supports customers in this task and works closely with the relevant software manufacturers to do so.
As a full-service supplier, MAPAL’s oerings extend beyond the tool and its programming: MAPAL wants to be a technology partner for its customers. For this reason, the company also supplies the appropriate clamping technology – among other things. The portfolio for this area includes everything needed for clamping. “Our 3-degree chuck in particular has proven itself
in die and mould making”, says Kress. This innovative high-performance chuck boasts a special feature: the HighTorque Chuck (HTC) with a slender contour combines the advantages of hydraulic expansion technology (such as the highest possible accuracy) with the three-degree back taper known from shrink chucks.
in die and mould making”, says Kress. This innovative high-performance chuck boasts a special feature: the HighTorque Chuck (HTC) with a slender contour combines the advantages of hydraulic expansion technology (such as the highest possible accuracy) with the three-degree back taper known from shrink chucks.
Individually adapted chucks
Individually adapted chucks are made possible by additive manufacturing. This process enables the soldered connection between the sleeve and tool body previously necessary to be dispensed with. This was a limiting factor not only in terms of chuck geometry, but also in terms of thermal stability and torque transmission. Thanks to its geometrical freedom, the hydraulic expansion clamping technology can also be used in the case of parts with large tool restrictions or for deep cavities in places that are di¨cult to access, which previously required the use of shrink chucks. “We individually adapt our chucks to each customer’s machining”, explains Carsten Klein. This means that it is often possible to use standard tools instead of costly specialised tools.
Zusätzlich zu Werkzeugen, Programmierung und Spannmitteln gehört die komplette Peripherie zum Einstellen und Messen von Werkzeugen sowie Ausgabesysteme zur Lagerung und Verwaltung von Komponenten zum Portfolio von MAPAL. „Darüber hinaus unterstützen wir unsere Kunden mit umfassenden Dienstleistungen“, sagt Klein. Ein Beispiel für eine solche Dienstleistung ist das Toolmanagement 4.0, das auf Basis der Open-Cloud-Plattform c-Com angeboten wird. „Damit muss sich der Kunde um nichts mehr bezüglich der Werkzeuge kümmern – wir übernehmen die Lagerung, die Bevorratung, den Einkauf sowie die Wiederaufbereitung der Werkzeuge“, präzisiert Klein. Und das bei 100-prozentiger Transparenz für den Kunden.
„Letztendlich entscheidet der Markt, wie gut wir im Werkzeug- und Formenbau Fuß fassen werden“, gibt Dr. Kress zu bedenken. MAPAL erhoffe sich allerdings gute Chancen: „Wir können nicht nur als Komplettanbieter punkten, wir stehen unseren Kunden auch mit unserer jahrzehntelang gesammelten Erfahrung zur Seite.“ Ein Aspekt, der MAPAL von jeher wichtig war: Vor Ort zu sein, Probleme zu lösen und hohe Erwartungen zu erfüllen.
Vorerst liegt die Konzentration auf den Werkzeug- und Formenbauern in Deutschland. „Wir wollen noch mehr Erfahrungen in der Branche sammeln“, sagt Dr. Jochen Kress, „und diese dann einfließen lassen, wenn wir weltweit unser Engagement verstärken.“
