• O Centro de Tecnologia da MAPAL na sede em Aalen.
  • Os engenheiros da Equipa de Peritos em Tecnologia da MAPAL são especializados na conceção de componentes especiais.
  • Soluções de usinagem para peças completas da MAPAL.

Vantagem tecnológica diretamente in loco para você

Como parceiro de engenharia acompanhamos você desde o planejamento até a produção. Você pode escolher livremente entre os nossos módulos de serviço ou contratar pacotes de serviços montados especialmente sob medida para sua demanda.

Em ambos os casos você se beneficia da nossa grande força inovadora e visão integrada do seu processo. Nossos engenheiros especializados dispõem de longa experiência nos mais diversos ramos de atividade. O mais moderno equipamento disponível em nosso centro de tecnologia permite simular com precisão qualquer processo produtivo em busca de soluções ainda melhores.
Os especialistas em engenharia familiarizam-se profundamente com os processos do cliente.

Reaja individualmente a diferentes situações iniciais

  • Você deseja reestruturar a sua linha de fabricação

    Concentre-se na sua principal competência. Assumimos o desenvolvimento de projeto de peças completas, planejamos e realizamos um processo seguro in loco, com rapidez e flexibilidade, custos transparentes e documentação completa.

  • Deseja reequipar sua linha de fabricação para novos componentes

    Continuar utilizando o maquinário existente economiza tempo e dinheiro. Com o nosso know-how garantimos a mais elevada segurança de processo. Prestamos suporte personalizado conforme os seus requisitos e, sob demanda, assumimos a responsabilidade completa pelo reequipamento.

  • Deseja otimizar suas ferramentas e processos

    Deseja introduzir modernas estratégias de usinagem e soluções inovadoras para ferramentas em sua linha de fabricação em operação? Assumimos esta tarefa para você. O resultado: maior durabilidade das ferramentas, qualidade melhorada do componente e aumento da produtividade.

Serviços de engenharia

  • Os especialistas da MAPAL analisam um componente em pormenor.

    E1 - Análise de projeto

    Com base nos desenhos da peça bruta e da peça acabada, bem como nos dados da máquina, analisamos a tarefa de fabricação em estreita colaboração com o cliente e desenvolvemos estratégias de usinagem efetivas para todas as etapas.
    ​​​​​​​
    • Propostas de usinagem para todas as etapas de usinagem
    • Lista de escopo de ferramentas
    • Esboços de ferramenta
    • Estudo de viabilidade
    • Coordenação com a situação da máquina
    • Elaboração do esquema de furação e superfícies

  • Well-founded design of the machining process by specialists from MAPAL.

    E2 - Process design

    Irrespective of whether the focus is on flexibility or productivity: with a sound design of the machining process, MAPAL supports its customers on the way to stable, economic manufacturing.

    Elements of process design:
    • Cycle time studies
    • Definition of technology data
    • Division of process over individual machines
    • Clamping principle sketches

  • he engineering specialists at MAPAL define the optimal tools for the customer's process.

    E3 - Tool solutions

    Outstanding performance, simple handling, cost-effective reconditioning: MAPAL specifically selects or develops the best, latest, cost-effective tools for the application.

    Elements of the tool solutions module:
    • Tool design
    • Tool engineering
    • Combination tools for reducing process steps
    • Design of clamping technology
    • Tool drawings
    • Assembly, setting and balancing (at MAPAL)
    • Delivery to the place of use
    • Professional support during breaking-in

  • The engineering specialists at MAPAL adapt the documentation to the individual customer.

    E4 -Documentation

    Upon request, the documentation prepared as part of the engineering services is specifically adapted to customers' requirements. This ensures the rapid implementation of the new processes and makes future changes easier.

    Documentation services:
    • Setting plans
    • Tool plans
    • Setting and installation instructions
    • Work instructions
    • Inspection and measurement logs/reports
    • Trials logs
    • Process capability reports

  • Clamping concepts are also part of the engineering services from MAPAL.

    E5 - Fixture solutions

    With individual solutions MAPAL ensures that as many workpieces and as many machining steps as possible can be reliably machined with μ-precision in one clamping system.

    Options within the module fixture solutions:
    • Preparation of drafts
    • Engineering
    • Manufacture/buying-in
    • Assembly and commissioning
    • Technical support
    • Pre-acceptance with clamping trial

  • Tool restriction studies are part of MAPAL's engineering services.

    E6 - Tool restriction study

    To prevent collisions and to identify optimisation potential, MAPAL simulates the planned machining process in advance and based on 3D models in a virtual environment.

    Tool restriction studies comprise:
    • Collision analyses
    • 3D study
    • Optimal harmonisation of tools to fixture, workpiece and machine compartment
    • Prerequisite: virtual models of tools, workpiece, clamping fixture and machine

  • n the engineering area, MAPAL also optimizes the machining parameters of the NC programming.

    E7 - NC Programming

    To design the process as productive as possible, MAPAL optimises the machining parameters during NC programming. In this way secondary activities such as loading/unloading and tool change can be accelerated.

    Elements in the module NC programming:
    • Preparation of NC program taking into account manufacturer-specific machine functions 
    • Preparation of special milling cycles (e.g. interpolation turning, trochoidal milling) 
    • Computer-based generation of machining contours (2D/3D)
    • Customer-specific program structure

  • MAPAL takes over the commissioning and running-in of the customer process on site.

    E8 - Breaking-in and commissioning

    To help customers produce reliably and without scrap, MAPAL offers to take over the commissioning and the breaking-in of the process on-site. If the schedule is tight, breaking-in can also be undertaken in the MAPAL technology centre.

    ​​​​​​​Services for breaking-in and commissioning:
    • Checking and logging the machine geometry
    • Installation of NC technology
    • Breaking-in the complete machining process
    • Preparation and implementation of process capability study
    • Transfer of process to the customer

  • MAPAL supports its customers at the start of production.

    E9 - Start-up support

    On-site support is also available as the production starts up. To guarantee a manufacture as productively and economically as possible, the machining specialists continuously check the tool lives and cutting data for the tools.

    ​​​​​​​Options of start-up support:
    • Support for production start-up
    • Troubleshooting
    • Technical support
    • Training on operation, programming and process sequence

  • The Technology Expert Team at MAPAL develops complete machining solutions for the customer component.
  • The picture shows the essential tool solutions of a MAPAL complete package for machining a steering rod.
  • A real production environment is available to customers in the MAPAL technology center in Aalen.

  • Solutions for complete workpieces

    The Technology Expert Team TET service package usually comprises the engineering modules 1-4. The TET experts take over the complete planning for the workpiece; customers and profit from MAPAL's engineering experience.

  • Process design and implementation from a single source: re.tooling

    For initial equipping or re-tooling existing machinery, MAPAL offers the re.tooling service package. As a rule this package comprises of the modules 1–9, however it will be specifically adapted to the customers' needs.

  • Real manufacturing environment for the customer: the MAPAL technology centre

    Simulating, testing and breaking-in processes without tying up capacity, for this purpose the MAPAL technology centre offers a real manufacturing environment with 11 modern machining centres, grinding machine and high-precision measuring systems, as well as the possibility of additive manufacturing. 50 engineers and technicians support and accompany customers from the idea to implementation.