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Technology<br />
Energy-efficient<br />
tool concepts<br />
Save energy and costs with intelligent<br />
process management
<strong>MAPAL</strong> technology:<br />
Our contribution to energy efficiency<br />
You do not need to be a great prophet to predict that<br />
energy costs and, in particular, electricity prices will<br />
continue to rise. In Germany industry needs more than<br />
40 % of the entire consumption of the electrical power<br />
produced. Approximately 60 % of this usage is down to<br />
the operation of production machines. In the case of<br />
machine tools the energy necessary for machining is very<br />
low in comparison to the total energy required by the<br />
machine. On these machines there are a number of<br />
possible ways of increasing the energy efficiency, for<br />
example by using regulators and controllers to suit the<br />
specific task, as well as by using energy-saving units.<br />
However, these approaches often involve large investments<br />
or even new machines. On the other hand, a<br />
significant energy saving and therefore cost saving can<br />
be achieved with intelligent process optimisation on<br />
existing machines.<br />
changes can be saved. On the other hand, higher feed rates<br />
and the related shorter machine running time bring<br />
significant energy savings.<br />
The conversion to minimum quantity lubrication (MQL) or<br />
dry machining offers even more potential. Energy savings<br />
from 20 to 30 % can be achieved, as the units necessary to<br />
supply the cooling lubricant are not required. <strong>MAPAL</strong> also<br />
offers complete solutions for MQL technology from the<br />
clamping tool to the cutting edge.<br />
<strong>MAPAL</strong> specialists optimise the process management<br />
Of particular importance for energy efficiency is reduced<br />
machine running time, that is shorter machining time. On<br />
the one hand this objective can be achieved with reduced<br />
non-productive times. <strong>MAPAL</strong>’s complete machining tools<br />
combine the machining of various bores, chamfers and<br />
flat surfaces such that often four, five or more tool<br />
Less non-productive time Higher speeds Modern Technology <strong>MAPAL</strong> +++<br />
A medium-size machine tool consumes approx. 165,000 kWh* per year in three-shift<br />
operation. This signifies carbon dioxide emissions of 95 t CO2* and corresponds to the<br />
emissions from 66 small cars covering a mileage of 12,000 km each.<br />
Due to high performance tools and optimised machining processes, 15 to 20 % of the<br />
total energy required can be saved.<br />
The energy required can be reduced by a further 20 to 30 %, for example by converting<br />
to MQL or dry machining.<br />
7<br />
6<br />
5<br />
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3<br />
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* Sources: Zäh, M.; Niehues, K.: Wie viel Energie verbraucht eine<br />
Werkzeugmaschine? “fertigung” journal 09/2009 date 28.09.2009, page 30ff.<br />
Umweltbundesamt, FG I 2.5., date March 2010
Energy-efficient tool concepts
Less non-productive time – shorter processes<br />
<strong>MAPAL</strong> – the specialist for combination tools<br />
The usage of combination tools is particularly effective for reducing the energy required<br />
and at the same time increasing productivity. During process design, <strong>MAPAL</strong> specialists<br />
always pay attention to combining as many machining operations as possible in one tool.<br />
As a result tool changes and travels, that is non-productive times, are saved. Also the total<br />
manufacturing time is significantly reduced by the simultaneous machining of various<br />
bores, chamfers and flat surfaces. This method of working also brings higher accuracies in<br />
relation to the concentricity and angle requirements, as on combination tools an offset<br />
between the diameters cannot occur. A further positive effect on the usage of combination<br />
tools is that stations are freed up in the tool magazine.<br />
1<br />
2<br />
Lower consumption due to combination tools<br />
1. Combination tool for machining bores<br />
and for circular milling (suspension<br />
arm AlSi10Mg)<br />
First the diameter (41 H8 ) is fine machined<br />
from the cored state using a premachining<br />
stage and fine machining<br />
stage. Then the flat surfaces and chamfers<br />
on both sides of the workpiece are<br />
circular milled. Due to the soft cut of the<br />
tangential inserts during circular milling<br />
and the support from the guide pads<br />
during the machining of the bore, it was<br />
possible to combine the original two<br />
machining tasks.<br />
Savings/year (80,000 parts)<br />
Cycle time:<br />
289 hrs<br />
Energy:<br />
6,358 kWh<br />
Emissions: 3.7 t CO 2 *<br />
2. Complete machining using tangential<br />
technology and solid carbide drill<br />
(actuator GG25)<br />
Three tools were necessary to machine a<br />
connection and bearing bore in a grey<br />
cast iron housing. All machining steps<br />
were combined into a three-piece combination<br />
tool. It was possible to save a<br />
total of 16 sec. in non-productive time<br />
and productive time solely by using this<br />
tool.<br />
Savings/year (25,000 parts)<br />
Cycle time:<br />
111 hrs<br />
Energy:<br />
2,440 kWh<br />
Emissions: 1.4 t CO 2 *<br />
*(= 11,800 km in a car)<br />
*(= 31,100 km in a car)<br />
2<br />
1<br />
4
Energy-efficient tool concepts<br />
The largest effects in relation to energy efficiency and increasing productivity can be<br />
achieved during the design and optimisation of complete machining processes. It is during<br />
this process that the <strong>MAPAL</strong> Tool Expert Team defines and plans the optimum tools and<br />
aids for the machining. All the documents and studies necessary for perfect tool planning<br />
are prepared. On request, the <strong>MAPAL</strong> tool experts will also supply specific NC programs<br />
and provide support during the breaking-in of the tools. In this way it was possible during<br />
process optimisation to save 12 of the 80 tools required originally for a gearbox housing.<br />
The machining time was shortened by 25 % as a result with a corresponding reduction in<br />
the total energy required by the machine.<br />
Examples for increased energy efficiency and productivity<br />
(gearbox housing Al)<br />
1. PCD-tipped precision drilling tool in<br />
lightweight design<br />
Four tools combined in one tool. Maximum<br />
diameter 150 mm and nevertheless<br />
a low weight of only 5.7 kg due to titanium<br />
tool body. Feed rate of 900 mm/min.<br />
Savings/year (40,000 parts)<br />
Cycle time:<br />
171 hrs<br />
Energy:<br />
3,762 kWh<br />
Emissions: 2.2 t CO 2 *<br />
*(= 18,200 km in a car)<br />
2. Guided fine boring tool for bearing<br />
and location bores to the micron<br />
Complete machining of seven different<br />
features – diameters, chamfers, front<br />
faces. Compliance with the tightest<br />
tolerances with high productivity.<br />
Combination with insertion tool for<br />
further machining positions. It was<br />
possible to replace three tools.<br />
Savings/year (100,000 parts)<br />
Cycle time:<br />
388 hrs<br />
Energy:<br />
8,536 kWh<br />
Emissions: 4.9 t CO 2 *<br />
*(= 41,200 km in a car)<br />
Advantages:<br />
Complete machining tools for<br />
shorter machine running times<br />
Saving in additional tools, magazine<br />
stations and changing times<br />
due to machining at various<br />
position<br />
Significant reduction in the total<br />
energy requirement of the machine<br />
– 10 to 15 % are possible<br />
Energy saving without investment<br />
in new units and machines<br />
1<br />
2<br />
5
Higher speeds<br />
<strong>MAPAL</strong> – the specialist for high performance tools<br />
Newly developed tools from <strong>MAPAL</strong>, for example the MEGA-Speed-<strong>Dr</strong>ill or the FeedPlus<br />
reamers, are able to reduce the machining times by up to 70 %. On the MEGA-Speed-<strong>Dr</strong>ill<br />
the new arrangement of the guiding chamfers provides the crucial increase in cutting<br />
speed. On the other hand, the innovative design of the FeedPlus reamer makes it possible<br />
to accommodate significantly more blades than on conventional reamers, and as a result<br />
enormously increase the feed rate. A large number of PCD blades are also the key for high<br />
speeds and short machining times on the HP-FaceMill face milling cutter.<br />
Together with the cutting edge geometries optimised for low cutting forces, the total<br />
energy requirement for a machine tool can be reduced by up to 15 %.<br />
Examples of energy-efficient <strong>MAPAL</strong> high performance tools<br />
1<br />
2<br />
3<br />
1. MEGA-Speed-<strong>Dr</strong>ill for drilling in an<br />
axle housing (GG30)<br />
Due to the considerably reduced load<br />
on the guiding chamfers, the machining<br />
speed can be significantly increased. As<br />
a result 32 sec. can be saved on the 13<br />
bores per part compared to a conventional<br />
carbide drill. The MEGA- Speed-<strong>Dr</strong>ill<br />
also brought a 17 % longer tool life.<br />
Savings/year (100,000 parts)<br />
Cycle time:<br />
889 hrs<br />
Energy:<br />
19,558 kWh<br />
Emissions: 11.2 t CO 2 *<br />
*(= 94,500 km in a car)<br />
2. FeedPlus reamer for highest feed rates<br />
18 teeth instead of the conventional<br />
eight – that is how the FeedPlus reamer<br />
realises such high feed rates. 66 % less<br />
productive time is the result on machining<br />
a bronze bush in a rocker arm.<br />
3. HP-FaceMill provides energy saving<br />
due to more PCD blades in a valve gear<br />
casing (Al)<br />
Due to the increased number of teeth,<br />
the feed rate can be more than doubled,<br />
for example during milling on valve gear<br />
casings made of aluminium. Shortest<br />
payback time ensured due to increase in<br />
the productivity and energy efficiency.<br />
Savings/year (400,000 parts)<br />
Cycle time:<br />
422 hrs<br />
Energy:<br />
9,284 kWh<br />
Emissions: 5.4 t CO 2 *<br />
*(= 44,000 km in a car)<br />
Advantages:<br />
Energy required by machine drops<br />
in parallel with the shortened<br />
productive times<br />
Higher power consumption due<br />
to the use of several inserts not<br />
relevant<br />
<strong>MAPAL</strong> high performance tools<br />
in standard versions and custom<br />
versions<br />
Competent advice from<br />
experienced specialists<br />
Savings/year (50,000 parts)<br />
Cycle time:<br />
39 hrs<br />
Energy:<br />
858 kWh<br />
Emissions: 0.5 t CO 2 *<br />
*(= 4,200 km in a car)<br />
3<br />
2<br />
1<br />
6
Energy-efficient tool concepts<br />
Modern technology<br />
<strong>MAPAL</strong> – the specialist for minimum quantity lubrication<br />
and dry machining<br />
Minimum Quantity Lubrication (MQL) and dry machining are particularly important features<br />
for the energy efficiency of a machine tool. The reason is the high power consumption<br />
of the high pressure pumps required for the cooling lubricant. Often these devices make up<br />
20–30 % of the total energy required by the machine. By converting a cylinder head machining<br />
operation to MQL, it was possible, for example, to completely do without a pump<br />
that operates in the pressure range up to 50 bar and that has a motor power rating of<br />
12 kW.<br />
Example – cylinder head MQL project<br />
1. PCD precision boring tool for the blind<br />
bores for valve seat and valve guide<br />
Due to the exact matching of the channel<br />
cross-sections, medium is reliably<br />
and evenly supplied to all cutting edges.<br />
A special supply guarantees a response<br />
time of
<strong>MAPAL</strong> the major specialist<br />
Reaming and fine boring<br />
Boring<br />
<strong>Dr</strong>illing<br />
Milling<br />
Turning<br />
Actuating<br />
Clamping<br />
Setting and measuring<br />
Services<br />
V1.0.0<br />
<strong>MAPAL</strong> Präzisionswerkzeuge <strong>Dr</strong>. <strong>Kress</strong> <strong>KG</strong><br />
P.O. Box 1520 · D-73405 Aalen · Phone +49 (0) 7361 585-0 · Fax +49 (0) 7361 585-150<br />
info@de.mapal.com · www.mapal.com<br />
ENE-E-01-030-1110-WD Printed in Germany. Right of technical modifications reserved.