MAPAL Empower your aluminium machining

Empower Your Aluminium Machining

技术设计是关键

MAPAL凭着数十年对铝加工刀具的设计、生产和应用领域的富足经验，已成为铝工件加工方面具有领先地位的技术合作伙伴。为了向客户提供最佳的切削工艺流程，MAPAL除了提供全面的产品和应用组合之外，还提供针对市场、材料以及加工等方面的专业知识。只有通过对所有影响因素的融会贯通的认识，并秉承伙伴式的合作模式，才能让我们加工工艺的全部潜力得到充分发挥——而这就是MAPAL代表的全部信念。
MAPAL Empower your aluminium machining

用户至上

MAPAL customer in focus

行业和结构组件

铝质材料切削的挑战

  • MAPAL ALu machining FLEXIBILITY WITHOUT COMPROMISE

    毫不妥协地坚持灵活性

    整体硬质合金铣刀具有创新的端面几何形状和大容屑槽，可使用一把刀具实现铣削、斜坡铣和钻孔。

  • HIGHLY PRECISE AND DEFINED SURFACES AND SHAPES

    精度高且确定的表面和形状轮廓

    通过硬质合金铣刀、PCD 铣刀以及圆弧铣刀和成形铣刀的平面铣削系统可保证高精度表面和轮廓精度，即使在自由曲面上也能达到同样水平。

  • MAPAL challenges in aluminium machining

    复杂的工艺要求

    铣刀杆和定制化减振刀具系统确保在难加工条件下获得可靠的加工结果。

  • MAPAL challenges in aluminium machining

    大批量铣削

    铣削系统具有大的正前角和抛光的大切屑槽，可最大程度地提高材料去除率，同时降低切削力并提高表面加工质量。

  • MAPAL challenges in aluminium machining

    明确的断屑和切屑控制

    使用具有明确的断屑几何形状、高正角切削刃的刀片和可转位钻削刀片可确保产生短且可控的切屑。

  • MAPAL challenges in aluminium machining

    加工孔时大幅降低毛刺的形成

    用铣削代替钻孔以及使用埋头钻可最大程度地减少毛刺的形成，并实现在一个步骤中完成全部加工。

  • MAPAL challenges in aluminium machining

    批量加工中的最高生产率

    多刃整体硬质合金刀具、可换钻头以及组合刀具可大幅提高批量加工中的生产率。

  • MAPAL challenges in aluminium machining

    工艺可靠的深孔钻

    配套的整体硬质合金和 PCD 麻花钻和深钻刀具确保深孔的可靠加工。

产品和应用

采用整体硬质合金刀具铣削
  • MAPAL Schaftfräser OptiMill-Alu-HPC

    OptiMill-Alu-HPC

      方肩铣刀

    • 用于进行铝质材料高效加工的三刃型方肩铣刀
    • ø-范围：3.00 - 20.00 mm

    直接点击商店

  • MAPAL end milling cutter OptMill-Alu-HPC-Pocket

    OptiMill-Alu-HPC-Pocket

    方肩铣刀

    • 独特的端面几何形状，带有集成钻头，用于型腔铣削
    • ø-范围：5.00 - 20.00 mm

    直接点击商店

  • MAPAL end milling cutter OptiMill-Alu-Wave

    OptiMill-Alu-Wave

    方肩铣刀

    • 用于大批量加工的粗铣刀
    • ø-范围：12.00 - 25.00 mm

    直接点击商店

  • MAPAL end milling cutter OptiMill-SPM-Finish

    OptiMill-SPM-Finish

    方肩铣刀

    • 深型腔和精密组件结构的精加工
    • ø-范围：12.00 - 25.00 mm

  • MAPAL OptiMill-3D-BN-Alu milling cutter

    OptiMill-3D-BN-Alu

    球头铣刀

    • 适用于加工高强度铝合金。
    • ø-范围：1.00 - 20.00 mm

    直接点击商店

  • MAPAL OptiMill-3D-CR-Alu milling cutter

    OptiMill-3D-CR-Alu

    牛鼻铣刀

    • 适用于加工高强度铝合金。
    • ø-范围：2.00 - 20.00 mm

    直接点击商店

采用PCD刀具铣削
  • MAPAL milling cutter OptiMill-Diamond

    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

  • OF FACE SURFACES ƒ FaceMill-Diamond-ES PCD face milling cutter

    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 NeoMill-Diamond-Eco

    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
  • MAPAL large diameter milling machines NeoMill-Alu-Qbig

    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

  • MAPAL large diameter milling machines NeoMill-T-Finish

    NeoMill-T-Finish

    Finish face milling cutter

    • Finishing with maximum accuracy and without setting
    • ø range: 50.00 - 315.00 mm

Drilling
  • MAPAL Tritan-Drill-Alu Bohren

    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

    To the shop

  • 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

  • MAPAL reaming FixReam700

    FixReam 700

    Reamer

    • Reconditioning enables significant reduction in cost per part
    • ø range: 9,900 - 32,000 mm

  • MN reamer MAPAL reamer

    MN reamers

    Single bladed reamers

    • Tools for maximum precision

Clamping
  • 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 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 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

  • 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

    • Three face milling cutters from the FaceMill-Diamond series against a black background. 

      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.

    • A comparison of the paths milled with and without vibration dampers in the tool shank.

      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.

    • The PCD milling cutter FlyCutter from MAPAL clamped in the robot from KADIA in front of the battery tray.

      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.

    • The picture shows the plug-on milling cutter arbor with vibration damper from MAPAL in the machine with mounted milling cutter.

      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.

    • MAPAL-Wenzler_Bild01_800x533.jpg

      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.

    • The picture shows the interior of the bavius machine with a large aluminum plate and the clamped OptiMill-Alu-Wave milling cutter.

      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.

    • The semi-finishing tool for inner machining is surrounded by a bell-shaped outer tool.

      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.

    • The picture shows a group of tools from MAPAL that are designed for minimum quantity lubrication.

      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.

    • A look inside the machine reveals two PKD deep drills from MAPAL machining clutch housings on twin-spindle machines.

      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.

    MAPAL Services

    Mapal Services - Engineering, Logistic, Maintenance, Training

    With the engineering service module, MAPAL guarantees fast, precise and safe manufacturing. Further savings potential can be tapped in the area of logistics and maintenance. And in the area of training, MAPAL ensures that the specialist know-how it has gathered is transparently and completely available to the customer – this gives customers a decisive lead over their competitors.

    All of the services offered by MAPAL focus on optimal processes and comprehensive support on the way to Industry 4.0. The goal is to always significantly assist the customer in achieving smooth, productive and economical manufacturing.

    Advantages:

    • Solutions for complete workpieces including tools, devices, NC programs and commissioning
    • Complete process design and implementation from a single source
    • Fast and flexible on-site support worldwide
    • Efficient and cost-optimised tool technology
    • Optimum coordination of tool, workpiece, equipment and machine
    • Highest product quality, process reliability and cost-effectiveness right from the start
    • Fast throughput from planning to implementation with maximum planning security