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Technology
Energy-efficient
tool concepts
Save energy and costs with intelligent
process management

MAPAL technology:
Our contribution to energy efficiency
You do not need to be a great prophet to predict that
energy costs and, in particular, electricity prices will
continue to rise. In Germany industry needs more than
40 % of the entire consumption of the electrical power
produced. Approximately 60 % of this usage is down to
the operation of production machines. In the case of
machine tools the energy necessary for machining is very
low in comparison to the total energy required by the
machine. On these machines there are a number of
possible ways of increasing the energy efficiency, for
example by using regulators and controllers to suit the
specific task, as well as by using energy-saving units.
However, these approaches often involve large investments
or even new machines. On the other hand, a
significant energy saving and therefore cost saving can
be achieved with intelligent process optimisation on
existing machines.
changes can be saved. On the other hand, higher feed rates
and the related shorter machine running time bring
significant energy savings.
The conversion to minimum quantity lubrication (MQL) or
dry machining offers even more potential. Energy savings
from 20 to 30 % can be achieved, as the units necessary to
supply the cooling lubricant are not required. MAPAL also
offers complete solutions for MQL technology from the
clamping tool to the cutting edge.
MAPAL specialists optimise the process management
Of particular importance for energy efficiency is reduced
machine running time, that is shorter machining time. On
the one hand this objective can be achieved with reduced
non-productive times. MAPAL’s complete machining tools
combine the machining of various bores, chamfers and
flat surfaces such that often four, five or more tool
Less non-productive time Higher speeds Modern Technology MAPAL +++
A medium-size machine tool consumes approx. 165,000 kWh* per year in three-shift
operation. This signifies carbon dioxide emissions of 95 t CO2* and corresponds to the
emissions from 66 small cars covering a mileage of 12,000 km each.
Due to high performance tools and optimised machining processes, 15 to 20 % of the
total energy required can be saved.
The energy required can be reduced by a further 20 to 30 %, for example by converting
to MQL or dry machining.
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* Sources: Zäh, M.; Niehues, K.: Wie viel Energie verbraucht eine
Werkzeugmaschine? “fertigung” journal 09/2009 date 28.09.2009, page 30ff.
Umweltbundesamt, FG I 2.5., date March 2010

Energy-efficient tool concepts

Less non-productive time – shorter processes
MAPAL – the specialist for combination tools
The usage of combination tools is particularly effective for reducing the energy required
and at the same time increasing productivity. During process design, MAPAL specialists
always pay attention to combining as many machining operations as possible in one tool.
As a result tool changes and travels, that is non-productive times, are saved. Also the total
manufacturing time is significantly reduced by the simultaneous machining of various
bores, chamfers and flat surfaces. This method of working also brings higher accuracies in
relation to the concentricity and angle requirements, as on combination tools an offset
between the diameters cannot occur. A further positive effect on the usage of combination
tools is that stations are freed up in the tool magazine.
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Lower consumption due to combination tools
1. Combination tool for machining bores
and for circular milling (suspension
arm AlSi10Mg)
First the diameter (41 H8 ) is fine machined
from the cored state using a premachining
stage and fine machining
stage. Then the flat surfaces and chamfers
on both sides of the workpiece are
circular milled. Due to the soft cut of the
tangential inserts during circular milling
and the support from the guide pads
during the machining of the bore, it was
possible to combine the original two
machining tasks.
Savings/year (80,000 parts)
Cycle time:
289 hrs
Energy:
6,358 kWh
Emissions: 3.7 t CO 2 *
2. Complete machining using tangential
technology and solid carbide drill
(actuator GG25)
Three tools were necessary to machine a
connection and bearing bore in a grey
cast iron housing. All machining steps
were combined into a three-piece combination
tool. It was possible to save a
total of 16 sec. in non-productive time
and productive time solely by using this
tool.
Savings/year (25,000 parts)
Cycle time:
111 hrs
Energy:
2,440 kWh
Emissions: 1.4 t CO 2 *
*(= 11,800 km in a car)
*(= 31,100 km in a car)
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Energy-efficient tool concepts
The largest effects in relation to energy efficiency and increasing productivity can be
achieved during the design and optimisation of complete machining processes. It is during
this process that the MAPAL Tool Expert Team defines and plans the optimum tools and
aids for the machining. All the documents and studies necessary for perfect tool planning
are prepared. On request, the MAPAL tool experts will also supply specific NC programs
and provide support during the breaking-in of the tools. In this way it was possible during
process optimisation to save 12 of the 80 tools required originally for a gearbox housing.
The machining time was shortened by 25 % as a result with a corresponding reduction in
the total energy required by the machine.
Examples for increased energy efficiency and productivity
(gearbox housing Al)
1. PCD-tipped precision drilling tool in
lightweight design
Four tools combined in one tool. Maximum
diameter 150 mm and nevertheless
a low weight of only 5.7 kg due to titanium
tool body. Feed rate of 900 mm/min.
Savings/year (40,000 parts)
Cycle time:
171 hrs
Energy:
3,762 kWh
Emissions: 2.2 t CO 2 *
*(= 18,200 km in a car)
2. Guided fine boring tool for bearing
and location bores to the micron
Complete machining of seven different
features – diameters, chamfers, front
faces. Compliance with the tightest
tolerances with high productivity.
Combination with insertion tool for
further machining positions. It was
possible to replace three tools.
Savings/year (100,000 parts)
Cycle time:
388 hrs
Energy:
8,536 kWh
Emissions: 4.9 t CO 2 *
*(= 41,200 km in a car)
Advantages:
Complete machining tools for
shorter machine running times
Saving in additional tools, magazine
stations and changing times
due to machining at various
position
Significant reduction in the total
energy requirement of the machine
– 10 to 15 % are possible
Energy saving without investment
in new units and machines
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Higher speeds
MAPAL – the specialist for high performance tools
Newly developed tools from MAPAL, for example the MEGA-Speed-Drill or the FeedPlus
reamers, are able to reduce the machining times by up to 70 %. On the MEGA-Speed-Drill
the new arrangement of the guiding chamfers provides the crucial increase in cutting
speed. On the other hand, the innovative design of the FeedPlus reamer makes it possible
to accommodate significantly more blades than on conventional reamers, and as a result
enormously increase the feed rate. A large number of PCD blades are also the key for high
speeds and short machining times on the HP-FaceMill face milling cutter.
Together with the cutting edge geometries optimised for low cutting forces, the total
energy requirement for a machine tool can be reduced by up to 15 %.
Examples of energy-efficient MAPAL high performance tools
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1. MEGA-Speed-Drill for drilling in an
axle housing (GG30)
Due to the considerably reduced load
on the guiding chamfers, the machining
speed can be significantly increased. As
a result 32 sec. can be saved on the 13
bores per part compared to a conventional
carbide drill. The MEGA- Speed-Drill
also brought a 17 % longer tool life.
Savings/year (100,000 parts)
Cycle time:
889 hrs
Energy:
19,558 kWh
Emissions: 11.2 t CO 2 *
*(= 94,500 km in a car)
2. FeedPlus reamer for highest feed rates
18 teeth instead of the conventional
eight – that is how the FeedPlus reamer
realises such high feed rates. 66 % less
productive time is the result on machining
a bronze bush in a rocker arm.
3. HP-FaceMill provides energy saving
due to more PCD blades in a valve gear
casing (Al)
Due to the increased number of teeth,
the feed rate can be more than doubled,
for example during milling on valve gear
casings made of aluminium. Shortest
payback time ensured due to increase in
the productivity and energy efficiency.
Savings/year (400,000 parts)
Cycle time:
422 hrs
Energy:
9,284 kWh
Emissions: 5.4 t CO 2 *
*(= 44,000 km in a car)
Advantages:
Energy required by machine drops
in parallel with the shortened
productive times
Higher power consumption due
to the use of several inserts not
relevant
MAPAL high performance tools
in standard versions and custom
versions
Competent advice from
experienced specialists
Savings/year (50,000 parts)
Cycle time:
39 hrs
Energy:
858 kWh
Emissions: 0.5 t CO 2 *
*(= 4,200 km in a car)
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Energy-efficient tool concepts
Modern technology
MAPAL – the specialist for minimum quantity lubrication
and dry machining
Minimum Quantity Lubrication (MQL) and dry machining are particularly important features
for the energy efficiency of a machine tool. The reason is the high power consumption
of the high pressure pumps required for the cooling lubricant. Often these devices make up
20–30 % of the total energy required by the machine. By converting a cylinder head machining
operation to MQL, it was possible, for example, to completely do without a pump
that operates in the pressure range up to 50 bar and that has a motor power rating of
12 kW.
Example – cylinder head MQL project
1. PCD precision boring tool for the blind
bores for valve seat and valve guide
Due to the exact matching of the channel
cross-sections, medium is reliably
and evenly supplied to all cutting edges.
A special supply guarantees a response
time of

MAPAL the major specialist
Reaming and fine boring
Boring
Drilling
Milling
Turning
Actuating
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Setting and measuring
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MAPAL Präzisionswerkzeuge Dr. Kress KG
P.O. Box 1520 · D-73405 Aalen · Phone +49 (0) 7361 585-0 · Fax +49 (0) 7361 585-150
info@de.mapal.com · www.mapal.com
ENE-E-01-030-1110-WD Printed in Germany. Right of technical modifications reserved.