02.12.2025

Economical drilling done smart

MAPAL fulfils requirements for the tool and mouldmaking industry

The secret to the success of the machining company Zerspanungstechnik Mangner GmbH in Bad Laasphe, Germany, is targeted investment in optimisation. Drilling has been made more efficient thanks to a large tool package from MAPAL. The package is made up of 110 TTD replaceable head drills along with a big stock of solid carbide heads.

#CaseStudies #Die&Mould #Drilling #Industries
The project managers Uwe Rein, Dominik Geßner and Mike Mangner with the tools.
  • The project managers Uwe Rein, Dominik Geßner and Mike Mangner with the tools.
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    Migrated manufacturing in the area of drilling at the company Zerspanungstechnik Mangner GmbH entirely to MAPAL’s TTD replaceable head drill system (from left): Uwe Rein (Regional Sales Manager, MAPAL), Dominik Geßner (Production Manager, Mangner) and Mike Mangner (Managing Director, Mangner). ©MAPAL 

  • The picture shows a Hermle machining center.
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    Mangner mainly uses Hermle machining centers for production. Programming is carried out directly at the machines. ©MAPAL 

  • The picture shows two different drill heads from MAPAL.
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    The Hirth serration of the TTD drill from MAPAL ensures the drill heads sit very securely. This enables optimal torque transfer as well as high changeover and radial run-out accuracies. ©MAPAL 

  • The picture shows the four people involved in the project: Dominik Geßner, Uwe Rein, Mario Schäfer and Mike Mangner.
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    Examining the drill head of a TTD tool (from left): Dominik Geßner (Production Manager, Mangner), Uwe Rein (Regional Sales Manager, MAPAL), Mario Schäfer, (Assistant Production Manager, Mangner) and Mike Mangner (Managing Director, Mangner). ©MAPAL 

  • Mangner-MAPAL_Bild-04_800x533.jpg
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    The large tool package from MAPAL for Mangner includes a total of 110 TTD replaceable head drills with diameters from 12 to 45 mm and lengths of up to 12xD. ©MAPAL 

  • The picture shows a component placed on a Euro pallet.
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    Mangner primarily uses TTD exchangeable-head drills for piloting deep holes and for complete drilling of so-called cooling risers. ©Mangner 

  • View of the Mangner GmbH site in Bad Laasphe
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    Mangner GmbH, a specialist in machining technology, primarily serves customers in tool and mold making as a traditional contract manufacturer, focusing on die casting, sand casting, and model construction. ©Mangner 
When Mike Mangner started his company in a small rented hall in 2013, tools still had to be changed by hand. The young company developed quickly. Just one year later, the company bought its current and set up the first Hermle machines. As a traditional contract manufacturer, most of Mangner’s customers come from the tool and mouldmaking industry. The company offers them services like pressure die casting, sand casting and modelmaking. Most of the work is destined for the automotive industry. Besides this, parts are also produced for general machine engineering. Mangner’s customers come from all over Germany, but above all from their region.
The project managers Uwe Rein, Dominik Geßner and Mike Mangner with the tools.
Migrated manufacturing in the area of drilling at the company Zerspanungstechnik Mangner GmbH entirely to MAPAL’s TTD replaceable head drill system (from left): Uwe Rein (Regional Sales Manager, MAPAL), Dominik Geßner (Production Manager, Mangner) and Mike Mangner (Managing Director, Mangner).   ©MAPAL
In the meanwhile, 15 machining centres can be found on their shop floor, above all from Hermle. From the smallest 5-axis machine to the machining centre for components as large as 1 x 1 m, they cover a wide spectrum of components. There are about two machines for every operator. Programming takes place directly at their workplaces. Mike Mangner’s optimisation philosophy involves having many identical machines in operation. A next step in the standardisation process involves making available as many of the same tools as possible for these machines. ‘With this concept, we are in a strong position and can employ our operators flexibly’, Mike Mangner explains.

Hirth serration from MAPAL enables high torque

Dominik Geßner switched to Mangner as a production manager two years ago, bringing along his experience and contacts. MAPAL and their Regional Sales Manager Uwe Rein was among them. Geßner advocated the use of TTD replaceable head drills, which he had come to know and appreciate over the years.
The picture shows a Hermle machining center.
Mangner mainly uses Hermle machining centers for production. Programming is carried out directly at the machines.   ©MAPAL

The TTD replaceable head drill is the primary application for the TTS (Torque Transfer System) interface. The interface owes its stability to the radially arranged Hirth serration with 12 or 18 teeth, depending on the diameter of the adapted solid-carbide drill head being used. Due to the serration’s form closure, variable geometries of the replaceable head are possible. In addition, optimal torque transfer and high radial run-out and change-over accuracy are ensured.

The replaceable drill head is secured by a threaded pin affixed to the side of the tool holder. This allows the drill bit to be changed directly in the machine. The positioning aid integrated in the serration ensures that the chip flutes and coolant transfer from the tool holder to the replaceable drill head match. With its cutting-edge geometry, the drill head has a quality and performance level similar to solid carbide drills.
 

The picture shows two different drill heads from MAPAL.
The Hirth serration of the TTD drill from MAPAL ensures the drill heads sit very securely. This enables optimal torque transfer as well as high changeover and radial run-out accuracies.   ©MAPAL

Machining time reduced

‘The true advantage of these drills comes into play in hardened materials, which it can machine reliably’, Geßner reports. ‘We achieve a long tool life here, which reduces our throughput of drill bits.’ At Mangner, bores used to take place prior to hardening. By eliminating the need for an additional clamping step, set-up time has been reduced. This increases efficiency in manufacturing, thereby providing the company with added value.

The previously used tool system had a particular weak point: if a solid-carbide drill head broke off, the drill bit holder was usually also damaged. In Geßner’s experience, this has never happened with MAPAL. After breakage, work could always continue with a new drill head, limiting any resulting damage. ‘I primarily considered changing the tool system from a cost perspective’, says Mike Mangner, explaining why he chose MAPAL.
 

The picture shows the four people involved in the project: Dominik Geßner, Uwe Rein, Mario Schäfer and Mike Mangner.
Examining the drill head of a TTD tool (from left): Dominik Geßner (Production Manager, Mangner), Uwe Rein (Regional Sales Manager, MAPAL), Mario Schäfer, (Assistant Production Manager, Mangner) and Mike Mangner (Managing Director, Mangner).   ©MAPAL

Steigerung von Wirtschaftlichkeit und Nachhaltigkeit

Mangner nutzt die Bohrer vor allem zum Pilotieren von Tiefbohrungen und zum Komplettbohren von Kühlungen, so genannten Kühlsteigern. Der normale Anschliff der Schneiden beträgt 140°, MAPAL bietet aber auch Varianten für spezielle Anwendungen an. So können mit einer 180°-Spitze Senklochbohrungen ausgeführt werden, die sonst nur mit einem Fräser möglich sind. Kugelbohrer ermöglichen Radien am Ende. Bei pfleglicher Behandlung können die Bohrköpfe bis zu drei Mal bei MAPAL nachgeschliffen werden, wie Dominik Geßner berichtet. „Das ist sehr nachhaltig und senkt damit auch den Durchschnittspreis des Werkzeugs.“

Das von MAPAL gelieferte Werkzeugpaket enthielt Durchmesser von 12 bis 45 mm, wobei die Werkzeuglängen 3xD, 5xD, 8xD und 12xD betragen. „Einen gewissen Durchmesserbereich decken wir mit den Wechselkopf-Bohrern in zehntel Abstufungen ab“, so Geßner. „Mit Bohrern, die komplett aus Vollhartmetall bestehen, wären die Werkzeuge unbezahlbar.“ Die vielen Größen spiegeln die unterschiedlichen Anforderungen in der Fertigung wider. Serien mit bis zu 100 Teilen laufen hier eher selten. Typische Losgrößen bewegen sich zwischen 1 und 10 Stück. Das Material ist oft Warmarbeitsstahl 1.2343, aber auch Spezialwerkstoffe, unterschiedliche gehärtete Stähle und Aluminium werden bearbeitet. 
 

Mangner-MAPAL_Bild-04_800x533.jpg
Das große Werkzeugpaket von MAPAL für Mangner enthielt insgesamt 110 Wechselkopf-Bohrer TTD im Durchmesserbereich von 12 bis 45 mm mit Längen bis zu 12xD.   ©MAPAL
Nach dem erfolgreichen Einsatz der TTD-Bohrer dürfte die Zusammenarbeit zwischen Mangner und MAPAL weiter ausgebaut werden. Reibahlen sind bereits im Einsatz. Auch mit Fräsern wird versuchsweise schon geschlichtet. Uwe Rein kann sich vorstellen, dass das Hochvorschubfräsen der nächste Schritt sein könnte.
Blick auf den Standort der Mangner GmbH in Bad Laasphe
Die Zerspanungstechnik Mangner GmbH bedient als klassischer Lohnfertiger vor allem Kunden im Werkzeug- und Formenbau in den Bereichen Druckguss, Sandguss und Modellbau.   ©Mangner
Portrait MAPAL Redakteur Ostertag Mathias

Kontakt

Mathias Ostertag Public Relations mathias.ostertag@mapal.com Tel.: +49 7361 585 3566

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