• MAPAL offers complete machining solutions for the die and mould industry.

Decolar na fabricação de moldes e matrizes

Os fabricantes de moldes e matrizes esperam alto conhecimento em processos e produtos de seus fabricantes de ferramentas de corte. Isso porque a vida dos moldes a serem criados e a precisão das peças moldadas são extremamente importantes para a competitividade na produção em série. Portanto, eles exigem que suas ferramentas ofereçam os mais altos níveis de precisão, uma longa vida a ferramenta e - acima de tudo - confiabilidade do processo.
 

São justamente esses aspectos que tornam a MAPAL bem-sucedida nos setores como da indústria automotiva, engenharia de máquinas e a indústria aeroespacial. Agora, o fabricante de ferramentas de precisão também oferece soluções eficientes e econômicas para o processo completo de usinagem no setor de moldes e matrizes. Ferramentas versáteis e precisas de alto desempenho e porta-ferramentas especiais com contornos estreitos e um batimento radial preciso minimizam o esforço de polimento e retrabalho graças a um acabamento superficial constante no processo de fresamento.

Gama de ferramentas para moldes

The picture shows the MAPAL tool range for mould making

Frese in metallo duro integrale

  • OptiMill-3D-BN

    Frese a profilo sferico
    • Lavorazione ad alta precisione di contorni 3D
    • Range ø: 0,10 - 20,00 mm

  • OptiMill-3D-CR

    Frese a profilo torico
    • Fresatura a raggio angolare ad alta precisione
    • Range ø: 0,10 - 20,00 mm

  • OptiMill Frese a spallamento retto

    Frese a spallamento retto
    • Ideali per sgrossatura, finitura, fresatura trocoidale e fresatura di tasche
    • Range ø: 2,00 - 12,00 mm

  • OptiMill-3D-CS

    Frese ad ampio raggio per lavorazioni a 5 assi

    • Finitura di complesse superfici a forma libera e complicate geometrie del pezzo da lavorare
    • Range ø: 2,00 - 12,00 mm

  • OptiMill-3D-HF

    Frese ad elevato avanzamento
    • Ideali per la lavorazione ad alto avanzamento con grande volume di asportazione di materiale ed elevata sicurezza dei processi
    • Range ø: 2,00 - 16,00 mm

  • OptiMill-3D-Alu

    Frese a profilo sferico e torico
    • Lavorazione ad alta precisione di contorni 3D
    • Range ø: 1,00 - 20,00 mm

  • OptiMill-Graphite-MT

    Frese a profilo sferico e a spallamento retto
    • Frese multidente per sgrossatura per elevate velocità di asportazione con elettrodi di grafite
    • Range ø: 3,00 - 16,00 mm

  • OptiMill-3D-Graphite

    Frese a profilo sferico e torico
    • Adatte per la lavorazione di elettrodi di grafite
    • Versioni diverse a seconda della situazione di lavorazione
    • Range ø: 0,20 - 12,00 mm

  • OptiMill-3D-Copper

    Frese a profilo sferico e torico
    • Geometria speciale per la lavorazione di elettrodi di rame e leghe non ferrose dure
    • Range ø: 0,10 - 20,00 mm

  • OptiMill-Diamond

    Frese a profilo sferico, torico e a spallamento retto
    • Taglienti in PCD per un’elevata durabilità
    • Range ø: 3,00 - 12,00 mm

Frese con taglienti sostituibili

  • NeoMill-ISO-360

    Frese ad inserti tondi
    • Ideali per la sgrossatura e la prefinitura
    • Range ø: 10,00 - 160,00 mm

  • NeoMill-3D-Finish

    Frese di finitura
    • Ideali per la finitura di superfici a 90°, superfici piane e complesse
    • Range ø: 16,00 - 42,00 mm

  • NeoMill-3D-Ballnose/-Torus

    Frese a profilo sferico e torico
    • Un corpo base con inserti a profilo sferico o torico per prefinitura e finitura
    • Range ø: 8,00 - 32,00 mm

  • NeoMill-2/4-HiFeed90

    Frese a spallamento retto/90° a elevato avanzamento
    • Sistema di utensili universale per la massima produttività
    • Range di ø: 16,00 - 200,00 mm

Foratura | Svasatura

  • ECU-Drill-Steel

    Punta in metallo duro integrale  

    • Punta in metallo duro integrale a due taglienti con un ottimo rapporto qualità/prezzo
    • Vasto campo di applicazioni
    • Geometria collaudata per un’elevata precisione e sicurezza dei processi
    • Range di Ø: 1,00 - 20,00 mm

  • MEGA-Drill-Hardened

    Punta in metallo duro integrale ad alte prestazioni

    • Punta in metallo duro integrale a due taglienti con rivestimento e geometria ottimali per la lavorazione di materiali temprati nella totale sicurezza dei processi
    • Nuova micro e macro geometria
    • Range di Ø: 2,55 - 16,00 mm 

  • MEGA-Drill-Steel-Plus

    Punta in metallo duro integrale ad alte prestazioni 

    • Punta in metallo duro integrale a due taglienti con rivestimento e geometria ottimali per la lavorazione dell’acciaio
    • Geometria ottimizzata della scanalatura per trucioli e preparazione taglienti modificata
    • Range di Ø: 3,00 - 25,00 mm 

  • Tritan-Drill-Steel

    Punta in metallo duro integrale a tre taglienti 

    • Punta in metallo duro integrale a tre taglienti per il massimo avanzamento
    • Tagliente trasversale autocentrante per situazioni di foratura difficili
    • Pensata specificamente per la lavorazione dell’acciaio
    • Range di Ø: 4,00 - 20,00 mm

  • Tritan-Spot-Drill-Steel

    Punta a centrare
    • Punta a centrare a tre taglienti per situazioni di foratura iniziale impegnative
    • Pensata specificamente per punte a tre taglienti
    • Range di Ø: 4,00 - 20,00 mm

  • Tritan-Step-Drill

    Punta a gradino
    • Punta a gradino a tre taglienti con tagliente trasversale autocentrante
    • Lavorazione di fori del nucleo filettati senza movimenti oscillatori
    • Range di Ø: 4,25 - 14,15 mm

  • MEGA-Deep-Drill

    Punta per foratura profonda
    • Efficiente realizzazione di fori profondi fino a 40xD, nella totale sicurezza dei processi
    • Punta di foratura pilota MEGA-Pilot-Drill
    • Range di Ø: 1,00 - 16,00 mm 

  • MEGA-Drill-Reamer

    Foratore-alesatore
    • Due fasi di lavoro (foratura e alesatura) riunite in un unico utensile
    • Taglienti di alesatura ottimizzati
    • Riduzione dei tempi produttivi e non produttivi
    • Tolleranza di foratura ≥ IT7
    • Range di Ø: 4,00 - 16,00 mm

  • Svasatore conico ad alta precisione

    Svasatore con passo differenziato
    • Taglienti a passo estremamente differenziato
    • Maggiore precisione e valori di superficie migliorati
    • Forze assiali e radiali ridotte
    • Notevole riduzione delle vibrazioni
    • Incremento dei parametri di taglio per la massima produttività
    • Range di Ø: 4,30 - 31,00 mm 

  • MEGA-Drill-Reamer-Pyramid

    Foratore-alesatore con punta piramidale 

    • Foratura pilota, foratura e alesatura con un unico utensile
    • Proprietà di centraggio migliorate grazie alla punta piramidale
    • Riduzione dei tempi produttivi e non produttivi
    • Tolleranza di foratura ≥ IT7
    • Range di Ø: 4,00 - 16,00 mm 

  • Punta a cuspide QTD

    Punta in metallo duro integrale con sistema a testina intercambiabile 

    • Sistema conveniente con cuspidi intercambiabili
    • Sistema di serraggio con accoppiamento di forza e accoppiamento geometrico
    • Facile utilizzo
    • Elevata precisione di concentricità
    • Range di Ø: 8,10 - 49,00 mm 

Alesatura

  • FixReam – FXR

    Alesatore ad alte prestazioni con codolo cilindrico 

    • Alesatore ad alte prestazioni in metallo duro integrale
    • Con scanalatura dritta per foro passante e foro cieco
    • Con scanalatura obliqua sinistra per foro passante
    • Range di Ø: 3,00 - 20,00 mm

  • CPReam – CPR

    Alesatore a testina intercambiabile 

    • Massima stabilità e rigidità grazie al cono e alla superficie piana di appoggio
    • Elevata precisione di concentricità pari a 5 µm
    • Facile utilizzo
    • Range di Ø: 8,00 - 40,00 m

  • Alesatore a regolazione rapida – WN 50

    Alesatore manuale 

    • Alesatore a regolazione rapida con ampio range di regolazione
    • Particolarmente adatto ai lavori di riparazione
    • Set di lame di ricambio disponibili
    • Range di Ø: 6,40 - 95,00 mm 

  • Utensili con pattini di guida

    Utensili con pattini di guida 

    • Massima precisione con il principio MAPAL
    • Guida diretta nel foro attraverso i pattini di guida
    • Inserti con filettatura di precisione
    • Regolazione ad alta precisione per la lavorazione di fori con precisione al µm 

Sistemi di serraggio
  • MAPAL UNIQ Chuck

    UNIQ DReaM Chuck, 4.5°

    Hydraulic chucks with a new design 

    • For reaming and drilling applications as well as for finishing during milling operations
    • This is achieved through an optimal interplay of geometric and functional properties
    • Outstanding surfaces as well as improved handling
    • Increasing productivity during the machining of contour-critical parts

    To the shop

  • MAPAL UNIQ-MillChuck

    UNIQ Mill Chuck, HA

    Hydraulic chucks with a new design 

    • Hydraulic chuck for highly dynamic milling applications
    • This is achieved through an optimal interplay of geometric and functional properties
    • Excellent results when using tools with HA shanks
    • Process reliability – even on high-quality parts 

    To the shop

  • HighTorque Chuck HTC

    Hydraulic chuck 

    • High level of torque transmission
    • Ideal damping properties
    • Excellent rigidity of the entire system
    • Radial run-out accuracy < 3 μm
    • 3° slim design for use in contour-critical applications 


       

    To the shop

  • MAPAL HydroChuck MHC

    HydroChuck MHC

    Hydraulic chuck 

    • Excellent vibration dampening
    • High degree of radial run-out accuracy
    • Ultra-short and compact design for high rigidity





       

    To the shop

  • ThermoChuck MTC

    Shrink chuck 

    • Long tool life through the use of high-temperature tool steel 
    • High torque transmission and radial rigidity
    • Precision balanced as standard
    • MQL-suitable
    • With and without axial tool length adjustment 

       

    To the shop

  • MAPAL MillChuck

    Mill Chuck, System HB

    Side lock chuck
    • Easy to handle thanks to use of a differential screw
    • Maximum cost-effectiveness and precision
    • Axial tool positioning can be defined using spring system
    • Decentralised coolant outlets for maximum process reliability



       
    To the shop

  • MAPAL Precision-DrillChuck MPC

    Precision-DrillChuck – MPC

    Precision drill chuck 

    • Simple construction, straightforward to handle
    • Safe clamping independent of direction of rotation
    • High degree of spindle speed strength
    • Modular design allows drill chuck heads to be used with all tool connections 

  • MAPAL slip-on reamer arbor

    Milling cutter arbor – MDA / MCA

    Milling cutter arbor 

    • Vibration-cancelling design (MDA) with vibration dampening system
    • Adapted to the rigidity of all common machine types
    • Smooth, stable running despite long projections delivers better surface finish
    • Milling cutter arbor (MCA) with large face connection for roughing and pre-finishing operations in large diameter ranges

  • MAPAL MFS milling head holder

    MFS milling head holder

    Tool adapter for screw-in milling cutter 

    • Simple and fast clamping of screw-in milling cutters
    • Exact interaction of taper and face connection
    • Greatest possible stability and rigidity
    • Universally deployable for roughing and finishing operations

  • MAPAL HSK adapter

    Adapter

    Extensions, reducers and adapters 

    • Wide range of options for modular tool systems
    • Hydraulic extensions and tool extensions for thermal expanding chucks
    • HSK reducers and extensions
    • KS steep taper adapter



       

    To the shop

Components and workpiece material

From the unmachined to the finished part

Find the right tool with just a few clicks: Depending on the machining, the specific operation and the tool requirement, you can quickly find the tool you want.
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    2D surfaces

    On the one hand, this category includes machining processes carried out directly on the machine, such as face milling, milling of pockets and straight walls. On the other hand, it also includes operations for complex geometries that are programmed using CAM software.

    Go to the product range for machining 2D surfaces
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    2 / 8

    3D surfaces

    In the die & mould sector, the manufacture of increasingly complex forms is part of everyday life. Continuous further developments in machine tools and CAM software raise performance and productivity to an ever higher level. The tools used must therefore always be state-of-the-art. To achieve optimum results, each design starts with a process analysis.

    Go to the product range for machining 3D surfaces
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    Open pockets

    Mould inserts also have machining tasks that are required for casting or various attachment parts. Users are increasingly machining open pockets (circumferential machining) using trochoidal milling. This machining method helps to optimise machining times and to extend tool life.

    Go to the product range for machining open pockets
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    Closed pockets

    Closed pockets are usually produced by roughing in Z planes. When milling, a ramp is often selected as the machining entry. The tool selected depends on the depth of the walls and the mould incline to be generated on the component. MAPAL’s broad portfolio with modular systems also covers the machining of deep pockets with large diameters.

    Go to the product range for machining closed pockets
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    Helix milling

    A major focus in milling operations is on reducing the machining time. With specific tool geometries for machining closed, round pockets, it is often possible to eliminate the pre-drilling process. With helix milling, milling paths are programmed with helical entrances that are suitable for pocket dimensions.

    Go to the helix milling product range
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    Even surfaces

    Operations to create even surfaces occur very frequently and in different areas in the die & mould sector: It could be component-related, strategy-related due to the respective milling process or due to requirements for mould closing surfaces as well as sections and cutting dies. The right tool is then selected depending on the application and requirements.

    Go to the product range for machining even surfaces
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    Thin walls and ribs

    Plastic injection moulds and die casting moulds often have ribs and thin walls. Ribs, for example, are increasingly being milled, as this process is more cost-effective than EDM (spark eroding). As a rule, long or extra-long carbide tools with small diameters are used. Customer-specific solutions (RibCutter) to match the respective rib shape are also possible here.

    Go to the product range for machining thin walls and ribs
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    Small and large bores

    There is a wide range of full bore operations in the die & mould sector: From large bores for guide pillars and deep bores for the cooling system to high-precision bores for ejector pins. MAPAL offers a comprehensive portfolio of drilling and reaming tools for the individual production steps.

    Go to the product range for machining small and large bores

All from a single source

  • 1. Planning and purchasing

    Optimised purchasing management is important for a clear organisation of the tool stock.

  • 2. Tool logistics

    Cost-effectiveness even in the periphery of machining: Intelligent dispensing systems significantly reduce non-productive times.

  • 3. Engineering

    The machining specialists provide support with process engineering, e.g. in the form of CAM simulations, general advice and the development of economic machining strategies.

  • 4. Measuring and setting

    Reliable setting and measuring devices are convincing due to their accuracy and user-friendly operation when setting the tools.

  • 5. Tools and clamping technology

    From the spindle to the cutting edge – MAPAL offers a wide range of tools and clamping technology for the die & mould sector.

  • 6. Machining

    Efficient machining processes and customised machining strategies at the highest technological level.

  • 7. Digitisation and automation

    Quick and easy digitisation: The c-Connect Box digitally transmits measurement data from the setting fixture to the machine tool. It also monitors the machine status among other things.

  • 8. Reconditioning

    Customers receive their reconditioned tools back in manufacturer quality within a very short time. Also available with pick-up and delivery service upon request.

Engineering Workflow - Von der Theorie zur Praxis

Eine für die Kundenbedürfnisse perfekte Lösung zu finden, das ist der Anspruch von MAPAL. Neben individuellen Sonderlösungen und einem breiten Standard-Produktportfolio stehen dazu umfassende Serviceleistungen zur Verfügung, um von der Produktidee bis zum Span den gesamten Prozess optimal zu gestalten. Die Kunden können sich auf die langjährige Erfahrung des Technologieführers in der Zerspanung verlassen.
  • 3D Modell eines Werkstücks aus dem Werkzeug und Formenbau.

    1. Kundenanfrage

    Für individuelle Anfragen stehen die MAPAL Außendienstmitarbeiter direkt zur Verfügung. Im persönlichen Gespräch loten sie gemeinsam mit den Kunden die konkreten Anforderungen sowie den Umfang (Komplett- oder Teilbearbeitungen) aus und besprechen die Details direkt am 3D-Modell des Bauteiles.

    Das MAPAL Werkzeug- und Formenbau Team freut sich auf eine Anfrage per E-Mail und stellt schnellstmöglich den direkten Kontakt her.

  • 3D Modell eines Werkstücks aus dem Werkzeug und Formenbau.

    2. Projektanalyse

    Auf Basis von 3D-Modellen und Maschinendaten analysieren die Gesprächspartner die Fertigungsaufgaben und entwickeln effektive Bearbeitungsstrategien.

    Bestandteile der Projektanalyse sind: 
    • Bearbeitungsvorschläge für alle Bearbeitungsschritte
    • Werkzeugliste
    • Prozessoptimierung

  • 3. Prozessauslegung

    Unabhängig davon, ob Flexibilität oder Produktivität im Fokus steht: Die Zerspanungsspezialisten simulieren den erarbeiteten Prozess auf Basis der 3D-Modelle und zeigen so Optimierungspotenziale auf. Sie überprüfen und verbessern die Bearbeitungsparameter bei der CAM-Programmierung und stellen so eine stabile und wirtschaftliche Fertigung sicher.

    Die Prozessauslegung beinhaltet: 
    • Laufzeitanalyse des Bauteiles
    • Definition Technologiedaten
    • CAM-Programmierung

  • Übersicht aller MAPAL Werkzeuglösung für den Werkzeug- und Formenbau in einem Werkstück.

    4. Werkzeuglösung

    Das breit aufgestellte MAPAL Standardprogramm für den Werkzeug- und Formenbau bietet die optimale Werkzeuglösung für jeden Anwendungsfall. Bei Bedarf stehen auch individuelle Sonderlösungen zur Verfügung.

    Vorteile für den Anwender: 
    • Breites Standardprogramm
    • Bereitstellung von Werkzeugdaten

  • Das Bild zeigt einen technischen Berater von MAPAL im Gespräch mit einem Kunden.

    5. Werkzeugtests & Angebot

    Nach dem erfolgten Austausch über ihre Zerspanungsaufgabe, unterstützt MAPAL die Kunden beim Einsatz der im Prozess benötigten Werkzeuge. Das ist die Basis für ein fundiertes und auf den jeweiligen Anwendungsfall abgestimmtes Angebot.

  • Das Bild zeigt Dokumente zur Angebotserstellung auf einem Tisch mit drei Personen.

    6. Partnerschaftliche Zusammenarbeit

    Auch nach gemeinsamen Erfolgen stehen die Spezialisten von MAPAL weiter in engem Kontakt mit dem Kunden. Sollten sich mit der Zeit Optimierungspotentiale ergeben, oder andere Werkzeuge sich als besser herausstellen, unterstützt MAPAL gerne, um die Produktivität und Wirtschaftlichkeit weiter zu verbessern. 

    Um eine langfristig effiziente Fertigung sicherzustellen, bietet MAPAL auch umfassende Toolmanagement-Möglichkeiten an. 

    Optionen im Bereich Toolmanagement: 

    • Ausgabesysteme
    • Nachschliffservice
    • Umfangreiches Produktportfolio an Einstell- und Messgeräten

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