Page 1 | MAPAL Impulse

Information, Ideas, Internals

No. 51 | June 2013

MQL technology:
Resource-saving and energy-efcient
400 visitors to the 3rd MAPAL dialogue Trochoidal milling tness program for the milling machine Optimisation in dialysis machine manufacture

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ABSOLUT PRZISION

Building on a good market position with new innovations.

EDITORIAL

ployees, are essential prerequisites for maintaining and further expanding our good market position with continuous innovations. MAPAL technology has therefore been the center of attention at many international trade fairs and congresses. The possibilities offered by MAPAL system solutions and indeed also by our high performance standard products for drilling, milling, reaming and turning are of great benet for the customer. Recently our development engineers developed a new tool for trochoidal milling; this tool is of unrivalled performance. The result is shorter machining times, better tool utilisation, as well as noticeably lower tool wear. In combination with the new hydraulic chuck, High TorqueChuck, which can withstand temperatures up to 170 C, milling becomes highly efcient in all aspects. With MQL technology we offer a fully mature product range for the machining process with minimum quantity lubrication; this technology is taking on an increased sense of importance given the current situation of ever increasing energy prices. Many customers use this technology, on the one hand to save around 30 % of the energy costs and to reduce the coolant consumption to a minimum, however on the other hand also to reduce the impact on the

environment and to create better working conditions for staff. During all MAPAL development work the maxims of cost-effectiveness, energy-efciency and conservation of resources are in the foreground to give our customers a technological lead and to make possible sustainable production. Have a good read Yours, Dr. Dieter Kress

Dear reader, dear business associate, After a very positive business year 2012 during which we were able to record growth of around 10 %, we are cautiously looking forward to 2013 with optimism despite the widely reported increasing sense of crisis. What is the reason for our generally positive mood? On the one hand MAPAL is out in front with the market leaders in many product areas, in particular ne machining, on the other hand we have a very broad base with our comprehensive product range and can better compensate for uctuations in some sectors. With our international production and sales network in 21 countries we can also offer a high degree of customer proximity and can react exibly to varying market requirements. Last but not least, as a family business we are independent of external investors and possible short-term shifts in strategy; we are therefore dependable as a longterm partner for our customers. All of these factors, combined with the high level of skill and ability of our em-

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News
MAPAL at international trade fairs News from the MAPAL Group

NEWSTICKER
MAPAL has a new Head of Marketing and Corporate Communications Since February 2013 Andreas Enzenbach (47) has been responsible for international product marketing as well as internal and external communication. Enzenbach has many years of experience in international capital goods marketing in the mechanical engineering and systems engineering sectors and is a specialist for communication strategies. Armin Kasper new Regional Sales Director for China and Taiwan Since April 2013 Armin Kasper has been the MAPAL Groups Regional Sales Director responsible for the important growth regions of China and Taiwan. As a long-serving sales manager from MAPAL WWS, a specialist for PCD tools and key account manager, Kasper has extensive expert knowledge and experience in international sales. He will therefore be able to provide very signicant support to our sales company MAPAL China on the sale of our tools.

175,000 visitors to CIMT in Beijing.

Turning and clamping areas in the spotlight: Turning Days in Villingen-Schwenningen.

MAPAL at CIMT in Beijing and Turning Days in Villingen-Schwenningen MAPAL addressed the increasing demand for energy-efcient, resourcesaving precision tools and machining methods during its successful appearance at CIMT in Beijing. It was possible to make many new customer contacts. Along with the product innovations, the ReTooling service, that is the re-tooling of existing machines for new parts, was a hot topic for our specialists. With a good 175,000 visitors, CIMT is the largest show for metal machining in China.

MAPAL also attended the trade fair Turning Days in Villingen-Schwenningen and was able to successfully demonstrate its competence in the area of tools for lathes and clamping tools. HSK-T, Versacut hard turning as well as MAPAL conversions for lathes to HSK-T were the focus of interest of the numerous visitors to the fair.

CONTENTS

MAPAL Group Product Highlights Reports from practicet

News from the MAPAL Group MAPAL dialogue: successful customer days Solid carbide TTD offer: yes, I will. Hybrid Tools Trochoidal milling PCD tools with lasered cutting edges MAPAL setting xture UNISET Fresenius Medical Care: custom-made tool solutions MAPAL Poland: LFP water pump housing MAPAL and Ford: optimal processes Imprint

Page 3 Page 8 Page 6 Page 7 Page 10 Page 12 Page 16 Page 18 Page 20 Page 22 Page 24

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Producing greater added value with lower energy usage by increasing the energy efciency of production processes.

News topics from the MAPAL Group

New building for MAPAL C&S The construction work on the new headquarters of MAPAL C&S s.r.o in the Czech city of Mlada Boleslav, near Prague, started in May. Our current building is too small for further development, says Petr Pokorny, General Manager of the subsidiary in the Czech Republic. The production facilities of the automotive manufacturer SKODA are also nearby. The new building for MAPAL C&S includes a twooor administration area and a 1,000 square metre production building. The result is a signicant increase in capacity for the manufacture of PCD tools and re-grinding solid carbide tools. MAPAL is investing around 1.2 million euros in this project, which is to be completed by the end of the year.

In touch with the latest trends with MAPAL Improved drilling processes for solid carbide drills, MAPAL tangential technology and universal high-pressure chucks were the key topics at the 8th Amberg tool seminar. In recent years the seminar in Oberpfalz has become established as an important specialist forum for industrial users. Around 120 participants from all sectors of the metal machining industry along with graduates and scientists listened to the presentations given by MAPAL speakers and saw for themselves the practical implementation of the information presented during demonstrations. Intensive use was also made of the opportunity to chat personally to our experts.

Tool applications are continuously changing. An edge in terms of knowledge will secure competitive advantages. Seminars, workshops, forums or conferences offer information rst hand. The experts from MAPAL regularly attend a large number of seminar events. In exciting presentations they convey new know-how and depict the latest trends and developments in tool technology. You will nd an overview of the upcoming seminars and events in which MAPAL will take part on our homepage at www.mapal.com/aktuel-les/fachvortraege. The list is continuously updated. Conversions for lathes offer higher accuracy with increased productivity In 2008 HSK-T was standardised specially for the usage of upright tools on lathes. It features high changeover and repetition accuracy, high tting accuracy, high rigidity, as well as exact radial positioning accuracy. The greatest advantage of HSK-T compared to existing systems is the very quick, straightforward tool change. While with the standardised connections used in the past, 10 to 15 minutes were often necessary for the tool change, with HSK-T the time required is reduced to less than 30 seconds. Paired with very high change-over accuracy, there is a signicant reduction in the machine downtimes and as a result a signicant increase in productivity for the user. Along with

3D view of the newly planned company headquarters MAPAL C&S in the Czech Republic.

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News
New building at MAPAL C&S in the Czech Republic Increasing productivity with HSK-T Technology report 2 on the topic of energy efciency

complete conversion, it is also possible to partially convert existing revolvers. On stations with frequent tool changes, conversion to HSK-T is particularly advantageous, as the investment is manageable and pays for itself in a short time. MAPAL offers conversions from all common connections on lathes to HSK-T, across machines and independent of manufacturer, as well as a wide range of turning holders.

TECHNOLOGY

REP RT
instance the usage of energy-efcient tools and optimal machining processes, to some extent signicant energy savings and therefore cost savings can be achieved. The technology report is included with this issue of Impulse. Would you like to continue to read regularly our scientic publications? Then make use of our free subscription. You will nd the registration form on our homepage at www.mapal.com/aktuelles/ technologiereport/anmeldung.-.

2nd MAPAL technology report Which factors affect the energy consumption of the machining process and how can energy be saved? This is the issue covered in the 2nd MAPAL technology report. Prof. Dr.-Ing. Eckehard Kalhfer, the Chair for Machining at the university in Aalen, and Dr. Jochen Kress, member of the senior management, have analysed the energy consumption of machine tools and individual process steps. Their report shows how, with only little investment, for

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Increasing raw material prices, lean inventories and the consideration of life cycle costs favour replaceable head systems.
TO CHANGE
without risk. Produce quickly and efficiently using the replaceable head drill TTD.**

YES, I WILL

Highlights from the product areas

Clever changing with the replaceable head drill TTD from MAPAL Replaceable head tool systems are now indispensable in modern production. Increasing raw material prices, lean inventories and the consideration of life cycle costs against the pure purchase price favour the usage of replaceable head systems. MAPAL has introduced on the market highly productive systems for all application areas; systems that are in no way inferior to monolithic tools quite the opposite. With a focus on highly precise, very stable connections it has been possible to limit the usage of expensive carbide to the tool head, and to make the machining stable and precise overall. In the area of drilling from the solid MAPAL relies on the replaceable head drill TTD. At the center is the torque transfer connection TTS (Torque Transfer Schnittstelle) which permits optimal torque transfer and at the same time high changeover and radial run-out accuracies. In this way the replaceable head drill TTD achieves the performance of a solid carbide drill with lower costs.

relation to the dimensional accuracy of the diameter. However the TTD also realises signicant saving potential by doubling the feed rate in comparison to the solid carbide drill used previously. With 1,430 mm/min and 140 m/min cutting speed, 200 bores can be reliably machined using a replaceable drill head. In an application from steel machining, clamps for folding machines made of ST52 are drilled using the replaceable head drill TTD. 83 bores with a diameter of 20 mm and a length of 106 mm are required per part. By using the MAPAL tool it was possible to reduce the machining time from 39.7 to 18.1 seconds this corresponds to reduction in the machining time of 54 %. Together with an increase in the tool life of 77 %, the TTD reduces the costs per bore by 60 % referred to the customers annual production volume! There are also examples of the successful usage of the replaceable head drill TTD in modern workpiece material combinations. For example the machining of bores for the connection of a ships CFRP drive shaft to a steel hub. Using a combination tool from MAPAL with a TTD solid drilling stage and a countersink step with PCD-tipped ISO indexable inserts it was possible to reduce the machining time by more than 80 %.

Test the MAPAL replaceable head drill TTD and exploit the performance of a solid carbide drill with lower costs.

Simply scan the QR code or go to www.mapal.com/aktion

*Valid on ordering a TTD replaceable head with tool holder. You will nd the full terms and conditions of the offer at www.mapal. com/aktion

Success stories from the different sectors and workpiece materials underline the performance of the replaceable head drill TTD. For example in gearbox housings made of GJL-200 the 28 mm xing bores are drilled using a replaceable head The current MAPAL replaceable head drill TTD camdrill TTD from MAPAL. paign will continue until the end of June. You will It is possible to optind more information on this topic on our homepage mally meet the requirewww.mapal.com ments of the customer in

YES, I WILL

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Pre-machining and ne machining intelligently combined

News
Yes, I will to change without risk Intelligent combination of machining systems

Pre-machining and ne machining intelligently combined Custom-made combination tools open up high potential for increasing productivity and process reliability. In the specic case of a MAPAL customer, it was necessary to pre-machine and ne machine particularly costeffectively two connection bores with diameters of 31 mm and 36 mm on an AlSiMg1 swivel bearing for a car. This requirement sets two challenges for the tool design. Firstly, the low silicon content of the aluminium alloy requires an innovative tool concept that ensures optimal chip breaking of the otherwise long continuous chips. On the other hand, to meet the cycle time requirements, particularly productive pre-machining and ne machining are required as both diameters require high stock removal. To solve this task, MAPAL developed two combination tools that combine both the pre-machining and ne machining on one tool body.

The pre-machining was designed on both tools as a solid drilling stage with replaceable ISO indexable inserts. The appropriate cutting edge geometry, as well as twisted and also polished chip spaces with a helix angle of 15 ensure reliable chip breaking and chip removal. Due to the large core cross-section of the solid drilling stage, the tools are stable and particularly smooth in operation. After the solid drilling stage, the stages for ne machining follow with the brazed PCD cutting edges. During process design, the machining operations were optimally distributed over the two tools. First tool one (see gure) is used to drill the large diameter using the indexable inserts. Then the next stage machines a spot face on the end of the bore using the related chamfers. Using tool two, the small diameter is drilled in the solid and then ne machined and chamfered using the following stages. Then the chamfer on the bore outlet is made using this

tool by circulating. The same tool then moves to the larger diameter, ne machines the bore and also produces the chamfer of the exit of this bore by circulating. MAPAL specialists have achieved maximum productivity and costeffectiveness in this machining task both in the process design and the tool design. The two combination tools complete all the machining tasks for which at least four tools would normally be required. Also the MAPAL hybrid tools combine the different machining systems in such a manner that excellent performance, simple handling and cost-effective reconditioning are achieved.

MAPAL hybrid tools combine different tool technologies

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400 visitors on 10 and 11 April 2013

MAPAL Di LOG
Erfolgreiche Kundentage bei MAPAL innovative technologies in use

Minimum quantity lubrication was the topic of the customer days at MAPAL this year. Around 400 participants came to Aalen, above all series production manufacturers and suppliers to the automotive industry; they came to obtain information on this environment-friendly and energy-saving form of material machining. By means of the minimum quantity technology, up to 80 % less coolant and up to 40 % less electrical power is consumed in comparison to conventional processes. At the end of the two-day event the participants were impressed by the diverse mix of broadly based presentations, practical tool demonstrations, a large exhibition of MQL components, as well as the tours through the MAPAL production buildings. Dr. Dieter Kress was pleased by the unexpectedly large number of visitors who travelled from all over Germany, Austria, Poland and Switzerland: With minimum quantity lubrication we have selected the right topic, he concluded. Minimum quantity lubrication (MQL) is in principle nothing

new. The rst bores were dry machined some 20 years ago. However, the keen interest shows that MQL is a very complex system. One, as Dr. Jochen Kress added, in which there has been signicant progress in recent years: We are now at the point that we can also use MQL technology on broad front. The increasing industrial interest in energy-efcient production is giving MQL technology additional lift: It is a comparatively simple way to save energy, says Dr. Jochen Kress. And businesses will increasingly exploit energy-saving potential in the future to lower their costs for energy and resources such as water and material, stated also Prof. Dr. Ing. Eckehard Kalhfer. The Chair for Machining at the university in Aalen has investigated the effect of MQL on energy efciency. The basic annual consumption of an operational machine tool is around 66,000 kWh. On the usage of central cooling lubricant systems, states Prof. Kalhfer, the energy demand

PRESENTATIONS | DEMONSTRATIONS | IN-HOUSE |

Page 9 | MAPAL Impulse

is high compared to the energy demand of the machining process itself. Using various model invoices he demonstrated that the electricity consumption can by reduced by up to 40 % by using minimum quantity lubrication. In this way it is possible to save a lot of money, the scientist stated. However MQL technology requires careful usage, says Dr. Jochen Kress. All components, that is the tool, machine, xture and above all the process must mesh optimally. Two acknowledged MAPAL specialists, Christian Schmidt and Joachim Vaas, provided information on the special features of MQL tools and correct process design in relation to lubrication, transport of chips and cooling. Suitable chucks were presented by Michael Neumann: MAPAL has developed a modular system for clamping tools. We accompany the customer during the entire process design,

from planning, through pilot trials, to production, Dr. Jochen Kress describes the product and service portfolio. MAPAL has a large array of machinery for tests and optimisation and has extensive experience with all materials. Even demanding processes such as connecting rod machining can be implemented using MQL. Peter Vogl, Director of Design & Technology at GROB Werke GmbH & Co. KG in Mindelheim and Werner Roth, Head of Application Engineering at Maschinenfabrik Heller, Nuertingen reported on how machine tools suitable for MQL should be designed. The manufacturers of machining centers, custom machines and transfer lines have already realised numerous MQL projects together with MAPAL. Currently around one in ve of the machines supplied by the business have MQL technology says Roth. Vogl spoke a slightly increasing tendency in large-scale series production manufacturing. The machines are designed such that lubricant can be supplied
Continued on next page.

| EXHIBITION | EXPERIENCE | EXCHANGE OF VIEWS

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The development of MQL system components is sufciently advanced that this technology can now be used on a broad front.

MAPAL Di LOG
innovative technologies in use

CONTINUED FROM PAGE 5.

through the tool as well as by means of single-channel or dual-channel systems. Dr. Dirk Sellmer, Head of the Research and Development department at MAPAL gave an overview of the different MQL feed units. Whether you select a single or dual-channel variant is essentially a question of philosophy the expert stated. The same applies to the choice of the right lubricant, a topic that is also the subject of frequent discussion. Fatty alcohols and ester oils are not equally suitable as lubricants in his opinion. It depends on the application. Aerosols are not ammable, however chip dust in combination with wall oil could cause an explosion. Modern extraction systems prevent this situation from occurring. Marcus Krauss, Sales Manager at Keller Lufttechnik, Kirchheim unter Teck, is observing a trend toward small, decentral systems. The advantages: They need little space, can be used exibly and can be controlled directly via the machine tool. Ford, for

example, uses an individual separator to blow the return air back into the room. The report from a user of MQL technology was equally exciting and informative for many participants to the MAPAL customer days. At Punch Powerglide, Strasbourg, around 300,000 gearboxes for cars are manufactured per year, for this reason around two years ago it was decided to change to minimum quantity lubri-

cation for the production of converter housings. Good environment management and cost savings were the key reasons explained planning manager Roland Muller. Initially we had a few problems with tool breakages and noise, but it was possible to address these issues quickly. It was possible to reduce the cycle time using MQL, the surrounding area is clean and attitudes are positive. Mullers conclusion: I am convinced we did the right thing.

PRESENTATIONS | DEMONSTRATIONS | IN-HOUSE |

Page 11 | MAPAL Impulse

Fit for manufacturing processes with minimum quantity lubrication

Andreas Bro (Gebr. Heller Maschinenfabrik GmbH, Nuertingen):

There has been a lot of information provided in a very short time.

Olaf Kiener (Julius Schle Druckguss GmbH, Schwaebisch Gmuend):

Interviews with visitors

It was a perfect event that has exceeded my expectations.

Wolfgang Mller (Opel, Kaiserslautern):

A very good mix of theory and practice. It was a great event because a large number of external manufacturers were also present.

Michael Zinz (Deutz AG, Ulm):

The presentations were informative, the works tour and the exhibition very interesting. We are satised all round.

Alexander Koch (Schunk GmbH Et Co. KG, Lauffen am Neckar):

The dialogue was very well organised, interesting and varied. I have learnt a lot about MQL technology.

Thank you for the feedback on this event you will also nd a summary of the customer days online at www.mapal.com/aktuelles/kundentage-mapal-dialog/ Your MAPAL Impulse editorial team

| EXHIBITION | EXPERIENCE | EXCHANGE OF VIEWS

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ABSOLUT PRZISION

Trochoidal milling also for machining centers

Fitness program for the CNC milling machine

With trochoidal milling signicant improvements in tool costs, clamping systems, machining times and the load on the machine components can be achieved in many applications compared to conventional milling. A comparison of the cutting data determined during a MAPAL milling trial already shows what is possible with this process, which is also known as wave milling: while during the conventional dry milling of case hardened steel (16MnCr5) a cutting speed of around 200 m/min at a feed of 0.05 mm/tooth was achieved, it was possible to tackle the same task with a cutting speed of 600 m/min at double the feed rate using the new trochoidal carbide milling cutter from MAPAL. Even on machining V2A steel it was possible to achieve a signicant increase in speed by changing the milling technology: at a feed of 0.05 mm/ tooth, a cutting speed of 250 m/min was achieved instead of the 60 to 100 m/min otherwise possible. This performance increase is made possible by a combination of high performance milling cutters specially developed by MAPAL for this process, the HighTorque Chuck (HTC) and the actual process. The advantage during movement is essentially the reduced tool contact. While during conventional milling of a slot the wrap angle is 180 (full cut), with trochoidal milling it can be selected as a function of the cutting depth and limited to maximum 70. This situation is made possible by a milling cutter with a smaller diameter that moves trochoidally at a

high spindle speed; each trochoid is deeper into the cut. Due to the smaller wrap angle, less heat is produced. The machining forces are also lower such that even spindles with low power and torque are suitable for the machining process. In addition, the chip load is lower with trochoidal milling. As the milling cutter does not completely ll the slot or pocket, chip congestion and renewed cutting of chips is as good as excluded. This aspect is of importance particularly for slots that are deep in relation to their width. During conventional milling, low feeds and cutting depths are used here due to the problems described. A maximum milling depth of 1.5 x D is normal. Not so with trochoidal milling: by avoiding the full cut, cutting depths of up to 2 x D are achievable even without specially developed milling cutters. For the user, this situation signies shorter machining times, better tool utilisation and noticeably lower tool wear. Due to the rapidly increasing carbide prices, the latter in particular is attracting the attention of metal machinists who can prot twice over on changing to trochoidal milling: from the longer tool lives and from the lower procurement costs for the milling cutter resulting from the smaller diameters.

If trochoidal milling is used in machining centers, additional cost savings are possible. Because widely varying slot widths or pocket sizes can be produced with only one tool, the tool needs to be changed less frequently and there is space left in the tool magazine. Trochoidal milling also offers advantages in relation to design. Due to the lower radial forces, signicantly more delicate parts and parts signicantly with thinner walls can be realised and greater accuracies achieved. At the same time the load on the spindle bearings is eased and the tool life is increased. The OptiMill product family from MAPAL includes milling cut-

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Customer benets
Feed motion

Shorter machining time and better tool utilisation Higher cutting volumes and feeds
fz
Machining area per trochoid. Chip per cutting edge.

r1

ae

ters suitable for dry trochoidal milling with DIN shank lengths 2 x D. For applications with even higher requirements, MAPAL has now developed and added to the product range an entirely new milling cutter with a cutting length of 3 x D and a diameter from 6 to 20 mm. Specially designed unequal spacing (EU spacing) of the ve cutting edges combined with an innovative geometrical design of the cutting wedge reduces the excitation of vibration here. Balancing (balancing quality 2.5) undertaken during the manufacturing process further reduces the risk of vibration. As such the patent-applied milling cutter can even be used at extremely high spindle speeds without problems. So that with the greater cutting depths

now possible, jamming does not occur due to the long chips produced in the process, the tool designers have also integrated a chip breaker that cuts the chips in half. This feature safeguards the trouble-free removal of the chips from the machine compartment. A special tool adapter is not required for trochoidal milling using the MAPAL milling cutters. However, if the potential of trochoidal milling and the new milling cutter is to be fully exploited, it is recommended to use the new MAPAL HTC chuck. The chuck combines the very good damping properties of hydraulic chucking technology with the high holding forces of shrinking technology. The HTC reliably transmits high torques. Even heating to 170 does not affect

the HTC chuck, as milling trials have conrmed. As a rule, cooling is therefore not necessary. Smaller or more delicate parts, higher accuracies and the continuing pressure to further reduce tool, operating and maintenance costs are making the call for more efcient milling processes louder. Thanks to the availability of more powerful tools such as the new MAPAL trochoidal milling cutters and the increasing usage of powerful CNC controllers and CAM software, there is now nothing to hinder the broad usage of the trochoidal milling process. The time is right for trochoidal milling!

MAPAL OptiMill milling cutter in use. Figure on right: Trochoidal milling cutter clamped in the MAPAL High-Torque Chuck.

Your contact person for further information:

Andreas Rinn | andreas.rinn@de.mapal.com

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ABSOLUT PRZISION

Innovative manufacturing technology for external machining tools: PCD tools with lasered cutting edges

Productivity and quality signicantly increased

Lasered cutting edges maintain the stability of the tool The specialists from MAPAL designed a PCD external machining tool of monoblock design to make the machining more stable and to improve the smooth running. The design permits high accuracies in length, shape and diameter. However, the special highlight is the machining of the cutting edges. Unlike in the past, these cutting edges are lasered instead of wire eroded. This innovative technology has signicant positive effects on machining quality and productivity with this complex form of external machining. To be able to wire erode the

Machining of a hose connection thoroughly revised In one application, production of a complex external contour on a hose connection made of AlSi7 was thoroughly optimised by MAPAL. The part is manufactured on a four-spindle machining center in high quantities, absolute process reliability and the high quality of the surfaces machined in relation to dimensional accuracy and surface nish must therefore

LASER-TECHNOLOGY

The competence center for PCD tools in the MAPAL Group, MAPAL WWS GmbH in Pforzheim, is the largest and most technologically advanced production facility for PCD tools in the world. In collaboration with LASERPLUSS AG, also part of the MAPAL Group, (see box on the right), another signicant development has been achieved on the production side: by using RayCutter 5-axis CNC laser machines for laser nishing PCD cutting edges, it has been possible to signicantly increase the stability and with it the productivity and quality of complex external machining tools. The engineers in Pforzheim are impressed with the new technology and are expanding the capacity. The RayCutters have been used in production for around three years. The development of the new machining method for external machining tools started in 2011, and the process was very successfully introduced in 2012. By the middle of 2013, ve RayCutters were in use in the production of PCD tool cutting edges.

be ensured. The complete external contour must also be produced in one machining cycle. The customer was dissatised with the part quality produced by the previous process. The machined area had a poor surface nish with clearly visible chatter marks. Also, the dimensional accuracy varied between the four spindles, an aspect that made it more difcult to meet the tolerances. The tool used originally comprised screw-mounted inserts and was correspondingly unstable. It was necessary to adjust the delicate inserts individually and there was a tendency for the adjustment to change during machining. This situation often resulted in only one of the two cutting edges actually cutting. At a spindle speed of 5,000 min-1 it was only possible to use a feed per tooth 0.1 mm.

cutting edge contours in monoblock tools in the conventional manner, the tool body must be relieved. As a result the area behind the cutting edge becomes very unstable. As a consequence, the tool tends to vibrate; the cutting data must be drastically reduced in some cases. If the cutting edges are nish lasered using the new process, the cutting edge pocket remains stable and vibration is prevented. It is only necessary to take into account any tool restrictions. The improved tool stability therefore makes possible signicant increases in the machining quality and productivity as well as an effective two cutting edge and multi-cutting edge capability. Christian Molch, General Manager at MAPAL WWS, says on this issue: This laser technology developed by MAPAL and LASERPLUSS is excellently suited to the production of complex, very delicate geometries on external machining tools. The process operates without

Picture from the cutting edge preparation on the RayCutter.

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Customer benets
High process reliability Deep axial recesses possible Signicantly higher cutting data

INFO
Cycle time reduced by 23 %

LASERPLUSS AG in Kirschweiler bei Idar-Oberstein has specialised in the manufacture of laser systems for precision applications for cutting metals and hard materials, for marking and engraving all materials, and for welding plastics. The company founded in 1997 with Dipl.-Ing. Werner Schulz as its head has been part of the MAPAL Group since 2009.

The RayCutter 5-axis CNC laser machine from LASERPLUSS AG.

physical contact and is practically unlimited in relation to geometry. As a result MAPAL is also technologically leading in the area of complex PCD external machining tools.

The potential of the new tool generation has been conrmed in series production at the customer. After machining, the part has a very good, chatter-free surface nish as well as good geometrical accuracy, and that with signicantly increased machining values (n = 8,500 min-1, fz = 0.16 mm). The customer has several positive effects due to the usage of the MAPAL PCD external machining

tool. It saves handling costs, as complicated and time-consuming setting is not required. The monoblock tool is also 50 % cheaper to procure than the competitor tool. However, the achievement of the highest diameter and length tolerances as well as the best surface nishes with high cutting data is decisive. As a result it is possible to reduce the cycle time by 23 %. Very deep axial recesses In a further example, very deep axial recesses are produced on a machining center. Originally the machining was undertaken using recess tools with clamped carbide inserts. The responsible member of the MAPAL sales team and the specialists in Pforzheim developed recess tools with lasered cutting edges for pre-machining and ne machining during this task. The pre-machining is undertaken into the solid using a twocutting edge tool with impressive cutting data: n = 6,000 min-1, fz = 0.05 mm and 300 mm/min feed rate. The tool for the ne machining is of single-cutting edge design and machines the workpiece with a spindle speed of 8,000 min-1, 0.1 mm feed per tooth and a feed rate of 800 mm/min.

Figure top: Cost-effective external machining with PCD tools from MAPAL. Figure bottom: Machined joint contour on a sample part.

Your contact person for further information:

Michael Hils | michael.hils@de.mapal.com

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ABSOLUT PRZISION

Measuring and setting complete machining tools

Setting xture UNISET-V vision developed for complete solutions

Planning new projects is time-consuming and expensive. More and more customers therefore make use of the comprehensive range of services offered by MAPAL related to part design and the delivery of the related components. As along with technologically leading and highly productive tools, MAPAL offers extensive know-how on machining. This aspect relates to both custom services as well as to high precision peripheral equipment for adjusting and measuring the tools. Process reliability and part quality due to exact measuring During the design of tools for complete machining, ne machining tools play a crucial role. As the tools are often used for the last manufacturing step, all tolerance requirements on the part in relation to surface nish, dimensional, contour and positional accuracy must be reliably met. As a specialist for ne machining, MAPAL relies on ne boring tools with guide pads that can be adjusted to the m. Very tight tolerances can be achieved with these tools. Due to the setting features on the tools it is possible to address exibly any special aspects related to the workpiece material or the machine. The exact measurement and adjustment of these tools is a prerequisite for high process reliability and part quality. These tasks are successfully undertaken using a precise measuring and setting xture that is integrated into the process chain.

Highest measuring accuracy with UNISET-V vision For cost-effective series production it is particularly important that tools can be measured and set to the highest precision both quickly and efciently to ensure constant availability at the machining center and to avoid downtimes. The example of a complete machining process on clutch and gearbox housing makes this aspect clear. The optimal machining of the often thinwalled, large aluminium cast parts requires comprehensive know-how during tool design. In particular there are high requirements on the shape, position, surface nish and diameter of the shaft bearing bores. The solution a complex, multi-stage combination tool that, along with high accuracy, signicantly reduces the machining times. Along with xed brazed PCD boring tools, these tools use adjustable inserts and guide pads, as well as face cutter heads with adjustable PCD milling cartridges for nish machining of the sealing faces. For setting the tools to the um, MAPAL has developed a CNC-controlled setting xture in the form of the UNISET-V series that is perfectly matched to the requirements placed on these tools due to the combination of tactile and optical measuring methods. Tactile measuring method for setting ne boring tool with guide pads The vertical setting xture UNISETV vision is equipped with electronic

measuring sensors that make it possible to exactly set ne boring tools with guide pads to within 1 m. Depending on the position of the guide pads and insert, either protrusion measurement or swinging lever measurement is used. As soon as the measuring sequence for a tool has been dened and saved once using the teach-in programming, from then on the measurement of the tool is undertaken automatically via the CNC controller. In this way it is possible to signicantly reduce the non-productive times in the measuring room, particularly in case of complex, multi-stage tools for shaft bearing bores. State-of-the art camera system for the optical measurement PCD face cutter heads in the EcoMill series are sophisticated, efcient tools. A prerequisite for their reliable usage and long tool lives are inserts

1.1

2.1

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Customer benets
Universal setting and measuring device for manufacturer-independent tool concepts Fully automatic measuring sequences using CNC controller Highest accuracy due to solid mechanical construction

The UNISET-V vision makes it possible to set and measure all tool concepts used for the complete machining of clutch and gearbox housings.

that move within dened tolerances. For nish machining PCD face cutter heads are used; here the exact and effective setting of the axial run-out on all cutting edges is necessary. Using the UNISET-V vision each PCD cassette on the face cutter head is moved to and measured using the optical camera system. If necessary, the axial run-out can then be simply and quickly corrected at the adjusting element on the milling cutter. In parallel the setting process is monitored optically on the touchscreen monitor for the UNISET-V vision. Also all other tools used for the complete machining process are measured using the optical measuring device. All rele-

vant measuring data, for example tool lengths or diameters, can be assigned to the tool using the UNISET-V vision. The measured data are either saved directly on the tool using a Baluff chip, or applied directly to the tool body in the form of a printed label. With both processes, it is ensured that no time-consuming corrections are necessary on the usage of the tools on the machining center. A single setting xture for all requirements The different measuring methods for a very wide range of tool systems, the high precision due to the solid basic

mechanical set-up and the CNC electronics make the UNISET-V vision an all-rounder in the tool setting room. In particular in the case of tools for complete machining the UNISET-V vision ensures real productivity advantages are obtained due to its high degree of exibility and ease of use, it is therefore an indispensable element of the complete process chain.

1.1 | During the protrusion measurement for setting ne boring tools with guide pads, the measuring sensors are rst moved to the position of the guide pads and the measuring range set to zero. Then the adjustable inserts are moved to and the measuring range is again set to zero at the highest point. Due to the low contact pressure on the insert and the reduced measuring force, delicate PCD-tipped inserts can also be measured reliably and without risk of damage. 1.2 1.2 | The operator now sets the dened nominal dimensions such as the overhang on the insert in relation to the guide pad and the diameter. 2.1 | Optical measurement of a PCD face cutter head in the EcoMill series. 2.2 | Setting the axial run-out at the adjusting element on the milling cutter. 2.2

Vertical setting xture UNISET-V vision.

Your contact person for further information:

Michael Hils | michael.hils@de.mapal.com

Page 18 | MAPAL Impulse

ABSOLUT PRZISION

Identifying and utilising optimisation potential in machining productivity increase due to custom tool solutions

Machining for dialysis equipment signicantly optimised

Unmanned machine tool operation safeguarded, machining time halved, tool life increased by 20 times, surface quality visibly improved - these are only some of the impressive results of the latest process optimisation in machining at Fresenius Medical Care on its site in Schweinfurt. Since 1979 the company has developed and manufactured dialysis machines for the international market with great success in this industrial city in Lower Franconia. Every year more than 40,000 systems leave the factory that maintains its position in relation to the international competition by means of efciency and clear work processes. The strategy of Fresenius Medical Care is to be better than the competition in relation to the quality of the dialysis products and production costs. To implement these goals the worldleading manufacturer of dialysis equipment has relied on know-how and tools from MAPAL for machining since 2000. In close co-operation we have managed to further streamline production processes, to reduce tool costs and to improve quality repeatedly in recent months, reports Ludwig Schmittlein, who is responsible for milling technical support in machining at Fresenius Medical Care Deutschland GmbH. Process optimisation makes possible unmanned production As such, a multiblock made of polypropylene can now also be manufactured unmanned and therefore

around the clock as a result of a tool change. Prior to the change the blind bores necessary on this assembly were realised in three steps: Due to the large diameter of 42 mm, rst the bore was pre-drilled using a standard drill, the bore was then drilled out and subsequently machined to the correct dimension using a milling cutter. This method has the disadvantage that long chips were produced during boring that, on the one hand, soiled the machine tool, and on the other hand took a lot of space in the chip bin. These two aspects together prevented unmanned operation at night, Benedikt Hetterich, head of the milling area and quality assurance in machining at Fresenius, describes the initial situation. As the machine conguration did not permit milling from the solid, based on experience in other applications MAPAL engineers suggested a solution with a carbide replaceable head drill TTD with 180 geometry and a PCD-tipped milling cutter with which the blind bore is circular milled in a helix after drilling. We have been working very successfully with this solution for approx. one year, Ludwig Schmittlein is pleased to state. The chips are space-savingly small, boring out is not required at all and the milling cutter can operate with much higher feed such that we can operate unmanned and also faster than before.

Another earlier optimisation project also made a signicant contribution to increasing through-put at Fresenius: The lter block, also manufactured from a block of polypropylene, for the therapy system 4008 from Fresenius needs a 91 mm deep blind bore. However, the walls of the bore are not straight, but taper at 1 degree downwards, at the transition from the at base of the bore to the side wall the bore has a radius; there is also a straight section to the opening. As for the multifunction block, until recently standard drills were used for pilot drilling and boring out. The 1-angle was then cut with 0.2 mm cutting depth and a radius milling cutter controlled by a CAD program. Just this one process took 30 minutes and transition marks and scoring could occur on the surface. Using the alternative developed by the MAPAL specialists in close co-operation with us, we only need 16 minutes for the complete machining

SOFT MI LLIN G

Drilling from the solid and circular milling with optimised chip breaking make possible unmanned production.

Page 19 | MAPAL Impulse

Customer benets
Unmanned production possible Tool costs reduced Machining timed reduced

of the part, reports Ludwig Schmittlein with pride. The chamber opening on the lter block is now drilled in one step using a replaceable head drill TTD with a special design. The drill has the MEGA-180 geometry that makes it possible a at bottom in bores in one machining step. The contour is then milled using a customer-specic carbide form cutter with one material removal rate. As a result with the new tools we have achieved short chips, a good surface nish and owing transitions also in this application, adds Benedikt Hetterich. Fresenius also benets from longer tool lives, as his colleague emphasises: While we could produce approx. 600 parts with a corner radius milling cutter, we have now passed the 1,500 mark and still do not need to change the replaceable head.

Fresenius was able to achieve an even more signicant increase in tool lives by means of tool optimisation in the case of a part made of polypropylene with 30 % glass bre content: Prior to the change a recess was produced with the aid of a conventional solid carbide circular milling cutter. Although the tool was economical to procure, it had to be replaced after only 600 parts due to wear, Benedikt Hetterich looks back. For the last two years we have used instead a circular milling cutter with PCD cutting material that cost almost three times as much, but that lasts for at least 16,000 parts! At an annual production rate of 36,000 pieces this means savings of almost 6,000 euros a year in tool costs alone. But that is not enough. In a partnership-based co-operation with the tool specialists at MAPAL, the responsible staff at Fresenius have been able to achieve other improvements in many

areas. We are therefore very happy with the support provided by MAPAL and the quality of the tools, Benedikt Hetterich and Ludwig Schmittlein agree.

Dialysis machine

Das fertig gefrste Werkstck.

Your contact person for further information:

Michael Neumann | michael.neumann@de.mapal.com

Page 20 | MAPAL Impulse

ABSOLUT PRZISION

Complete machining with minimum number of tools and minimum number of different indexable inserts.

Complete machining of water pump housings

MAPAL has been represented in Poland with a dedicated subsidiary since 2002. The team around General Manager Aleksander Zielonka comprises 27 staff in sales and service. Comprehensive local support to customers with technologically leading tool solutions is the premise of MAPAL Narzedzia Precyzyjne Spka z.O.O.. Here the focus is on partnership-based collaboration with customers and machinery manufacturers. An example of this aspect is a project realised at the end of 2012. Leszczy n ska Fabryka Pomp (LFP) was founded in 1868. The privatisation of the organisation and a new strategic direction placed the focus on development activities. Today LFP is the leading manufacturer of pumps and pump systems in Poland and one of the most modern manufacturers of cast parts in the world. SW (Schwbische Werkzeugmaschinen GmbH), as an important MAPAL technology partner, opened the door to LFP. In the past some small tool deliveries were made; deliveries that demonstrated the professional support and the quality of the tools. Fewer tools for higher productivity In 2012 SW was tasked by LFP to deliver the machine and the xture for machining new water pump housings made of EN-GJL250. In turn the machinery manufacturer suggested MAPAL Poland as a suitable tool and technology partner for meeting the

customers requirements: complete machining with a minimum number of tools and a minimum number of different indexable inserts. Robert Adamczak, Director of Technology and Innovation at LFP, describes the collaboration as very good and trouble-free: The water pump housings are machined on an SW BA600-2 machining center using MAPAL tool technology. Our requirements for a reduced number of tools as well as a lower cycle time compared to the competition have been met perfectly by the MAPAL solution. We also achieved our objectives signicantly more quickly and straightforwardly during the implementation phase. Latest tool technology in use The tool technology for the pump housing was the result of collaboration between Robert Adamczak and Piotr Nowacki (project manager) at LFP, Lukasz Barteczka, project engineer in Czech sales at SW, and the MAPAL team, comprising regional sales manager Piotr Jadrzyk, salesperson Marcin Wawrzonkowski and Martin Rottenbiller, who co-ordinated the activities in the headquarters in Aalen. The project features the following highlights: the main bore on the water pump housing is pre-machined using two multi-stage ISO boring tools based on tangential technology. In similar projects at LFP three tools were used for this purpose. In addition to this saving in tools, the machining using the MAPAL tools

is also signicantly faster. With a cutting speed of 120 m/min and a feed per tooth of 0.2 mm the pre-machining takes signicantly less time than predicted. For the main bore a circularity of 0.05 mm and a concentricity of 0.025 mm are required. For this reason the ne machining is undertaken using a multi-stage ne boring tool with guide pads at a spindle speed of 540 min-1 and a feed of 0.15 mm/ rev. In this way it, is possible to meet the quality requirements reliably and machine all steps in the main bore simultaneously. With the ISO boring bars used in the past at LFP, there were often problems with the concentricity of the individual steps in relation to each other. External recess is interpolated. The interpolation turning method is used to machine an external recess. Lower tool costs with high workpiece quality at the same time were the key arguments for this machining technology. The machine from SW used is very suitable for interpolation turning due to its dynamic performance and rigidity. Stockkeeping optimised MAPAL was also able to meet the requirement from LFP to minimise and standardise the inserts used: The same indexable inserts are used for all workpiece variants such that

COMPLETE MA CHINING

Page 21 | MAPAL Impulse

Customer benets
Leading tool technology Custom services Partnership-based collaboration

the stockkeeping is limited to only a few types. Different tool bodies are available for varying bore dimensions on the variants. A call warehouse in the process of establishment at MAPAL in Poznan for the necessary indexable inserts is intended to realise even more optimisation potential. Project realisation in record time Due to the smooth collaboration between the partners involved, the machining was accepted after just one

Partnership-based collaboration (f.l.t.r.): Piotr Nowacki (LFP chief technologist), ukasz Barteczka (project engineer at SW) and Piotr Jdrzyk (responsible salesperson at MAPAL Poland).

week, a task that normally takes up to two months. It was therefore possible to start production earlier than planned. Reason enough for LFP to involve MAPAL again in future projects, as Piotr Nowacki, chief technologist at LFP, conrms: Our decision to use MAPAL technology was denitely correct. We are convinced that this

collaboration will bring many technical and commercial advantages for efcient production also in future projects.

Pre-machining of main bore using a combination tool with ISO indexable inserts.

The ne machining is undertaken using a multi-stage tool with guide pads.

Your local contact in Poland: Interpolation turning is used to produce an external recess. Alexander Zielonka | alexander.zielonka@pl.mapal.com

Page 22 | MAPAL Impulse

ABSOLUT PRZISION

Machining of the Sigma engine in Taubat successful due to modern tool technology and close collaboration

Worldwide collaboration for optimal processes MAPAL and Ford

The Ford Motor Companys Taubat production site was founded in 1974 and is considered in Brazil to be a pioneer in the production of engines, gearboxes and other automotive parts. Ford Taubat produces 430,000 engines and 500,000 gearboxes per year. The latest production processes are used to machine and assemble the cast parts. In January this year Ford Taubat was able to achieve two major milestones: the total production of engines passed ve million, the production of gearboxes the four million mark. Ford launched a new series of Sigma engines in December 2009. This innovative engine generation was developed as a global platform. Ford describes the Sigma engine as light, durable, economical, low noise and low emission; the engine is manufactured in Germany, England, Romania and Brazil. 600 million US Dollars were invested in Taubat to manufacture the new engine. As a consequence it was possible to double the production capacity for engines. Collaboration at global level Ford approached MAPAL with the task of designing the machining process for the Sigma engine, the rst engine on which the engine block, cylinder head and gearbox housing are made of aluminium. To optimally address the requirements on the machining process and to ensure the usage of the

same technology on all production sites, several MAPAL sites around the world worked together. MAPAL England was responsible for the engineering and the overall co-ordination of the project. The tools were developed in Aalen and in the German competence centers, and then brokenin and tested in the test center. For the production in Brazil, Joo Paulo Souza is always on site in Taubat and, together with the team around Technical Manager Rogerio Rodrigues, is responsible for a smooth running process. Duilio Dalla Rosa was responsible for breaking-in at the machinery manufacturer; today he supports the Sigma Camaari Industrial Complex in Camaari. Ford Taubat had already established a partnership with MAPAL do Brazil in 2008; this partnership involved the delivery of technologically leading tools as well as optimisation services in production at Ford. Based on the example of the Sigma engine it is clear that signicant potential can still be tapped on site to make production more cost-effective and more reliable. Some highlights from the Sigma project in Taubat are presented in the following. Costs halved during the machining of the cylinder bores During the machining of the cast cylinder bores it was possible to reduce the machining costs by more than 50 % due to a continuous process

of improvement and optimisation. Originally a six-cutting edge tool with PcBN blades was used for the machining. The end of the tool life was reached after 250 parts per cutting edge. During optimisation the specialists from MAPAL do Brazil were able to reduce the number of cutting edges on the tool and at the same time to triple the tool life. The cycle time remains unchanged with the current machining values (n = 2,400 min-1 and vc = 583 m/min, vf = 1,296 mm/ min). More teeth bring higher milling speed and improved tool life The sealing faces between the engine block and cylinder block are machined using an EcoFeed face milling cutter with a diameter of 250 mm and 36 teeth. The EcoFeed face milling cutters are equipped with disposable milling cartridges and therefore involve signicantly less logistics effort during handling. The EcoFeed achieves perfect surface nishes due to exact positioning of the milling cartridges in the tool body and the sensitive wedge adjustment of the inserts. In surface machining at Ford Taubat it was possible to signicantly improve the performance of the EcoFeed by means of optimisation on site. While originally it

Page 23 | MAPAL Impulse

Customer benets
International project management Detailed local know-how for optimised processes Cost reduction by more than 50 %

was possible to machine 8,500 engine blocks and 3,700 cylinder heads, the tool lives are now even more impressive: one EcoFeed face milling cutter machines 25,000 engine blocks and 15,000 cylinder heads with a cutting speed of 3,000 m/min and feed rate of 11,000 mm/min. Successful teamwork The successful collaboration with Ford shows how MAPAL is available to assist customers worldwide with knowhow, commitment and a team of specialists. These days when projects are often transnational, it is essential to be able to offer the same product and

The team at MAPAL do Brazil from left to right: Technical Manager Rogerio Rodrigues, Duilio Dalla Rosa, General Manager Sidney Pimenta Paiva and Mairon Cezar from the engineering team as well as Joo Paulo Souza, the engineer responsible in the Taubat works.

engineering know-how in all markets. With subsidiaries in 21 countries, a continuous exchange of knowledge at all levels and the focus on a close relationship with the customer based on trust, MAPAL is predestined to become a dependable partner.

Before: New: Before: New:

Engine block machining: 8,500 25,000 Cylinder head machining: 3,700 15,000
3-times the tool life

Tool for machining valve seat and valve guide. Signicantly increased cost-effectiveness during the machining of face surfaces on engine block and cylinder head the EcoFeed. Engine production at Ford Taubat.

Your local contact in Brazil:

Sidney Pimenta Paiva | sidney.paiva@br.mapal.com

IMPRINT
Responsible for the content: Andreas Enzenbach Editorial team: A. Enzenbach , O. Munz, S. Raab, K. Rehor, S. Schmick Design: I. Rettenmaier Publisher: MAPAL Przisionswerkzeuge Dr. Kress KG P.O. Box 1520 D-73405 Aalen Phone +49 07361 585-0 Fax +49 7361 585-150 info@de.mapal.com www.mapal.com

IMP51-E-01-100-0613-WD Printed in Germany. Right of technical modication reserved.