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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 1 2 3 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) 3 2 1 6
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
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