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

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  • 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

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  • 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

    Mandrino a serraggio idraulico in un nuovo design 

    • Per applicazioni di alesatura e foratura e per la finitura di operazioni di fresatura
    • Interazione ottimale di proprietà geometriche e funzionali
    • Superfici eccezionali con un utilizzo migliorato allo stesso tempo
    • Massima flessibilità e produttività per la lavorazione di componenti dai contorni critici 

  • UNIQ Mill Chuck

    Mandrino a serraggio idraulico in un nuovo design 

    • Mandrino a serraggio idraulico per applicazioni di fresatura altamente dinamiche
    • Interazione ottimale di proprietà geometriche e funzionali
    • Risultati eccellenti con l’utilizzo di utensili con codolo HA
    • Massima sicurezza dei processi anche per i componenti di alta qualità 

  • HighTorque Chuck HTC

    Mandrino a serraggio idraulico 

    • Elevata trasmissione della coppia di serraggio
    • Proprietà di smorzamento ideali
    • Rigidità eccezionale dell’intero sistema
    • Precisione di concentricità ≤ 3 µm
    • Versione sottile a 3° per l’uso in applicazioni dai contorni critici 

  • MAPAL HydroChuck MHC

    HydroChuck MHC

    Mandrino a serraggio idraulico 

    • Eccezionale smorzamento delle vibrazioni
    • Elevata precisione di concentricità
    • Versione estremamente corta con struttura compatta per un’elevata rigidità

  • ThermoChuck MTC

    Mandrino a calettamento termico 

    • Lunga vita utile dell’utensile grazie all’impiego di acciaio per utensili resistente alle alte temperature 
    • Elevata trasmissione della coppia di serraggio e massima rigidità radiale
    • Sottoposto a bilanciatura fine come trattamento standard
    • Idoneo per la lubrificazione minimale
    • Con e senza regolazione assiale della lunghezza utensile 

  • MAPAL slip-on reamer arbor

    Mandrino per fresa a manicotto – MDA/MCA

    Mandrino per fresa a manicotto 

    • Versione con sistema antivibrante (MDA)
    • Idoneo per la rigidità di tutte le macchine più comuni
    • Funzionamento più silenzioso e più stabile nonostante le lunghe sporgenze per una migliore qualità delle superfici
    • Mandrino per fresa a manicotto (MCA) con superficie piana di appoggio maggiorata per operazioni di sgrossatura e prefinitura in grandi range di diametro

  • MAPAL HSK adapter

    Adattatore

    Prolunghe, riduttori e adattatori 

    • Svariate possibilità per sistemi di utensili modulari
    • Prolunghe a serraggio idraulico e a calettamento
    • Riduttori e prolunghe HSK
    • Adattatore per cono verticale KS

  • 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.

    Servizi MAPAL

    Grazie all'​​​​​​​Engineering, MAPAL garantisce una produzione rapida, precisa e sicura. Un ulteriore potenziale di risparmio può essere sfruttato nell'area della logistica e della​​​​​​​ manutenzione. E nel campo della​​​​​​​ formazione, MAPAL assicura che il know-how specialistico acquisito sia a disposizione del cliente in modo trasparente e completo, permettendo così ai clienti di godere di un decisivo vantaggio rispetto ai concorrenti.

    Tutti i​​​​​​​ servizi di MAPAL si concentrano su processi ottimali e su un’assistenza completa a metà strada verso l’industria 4.0. Sempre con l'obiettivo di contribuire in modo significativo a una produzione regolare, affidabile ed efficiente per il cliente.

    Vantaggi:

    • Soluzioni per lavorazioni complete, compresi utensili, attrezzature, programma NC e messa in servizio
    • Progettazione e implementazione completa del processo per un servizio chiavi in mano
    • Assistenza rapida e flessibile in loco in tutto il mondo
    • Tecnologia utensile efficiente e ottimizzata dal punto di vista economico
    • Coordinamento ottimale di utensili, pezzo, attrezzatura e macchina
    • Massima qualità del prodotto, sicurezza dei processi ed efficienza fin dall’inizio
    • Svolgimento rapido dalla pianificazione alla realizzazione nella totale sicurezza