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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. 1 2 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) 2 1 4
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 1 2 5
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