Competence centre Pforzheim: Largest factory for PCD ... - Mapal.us

First-class know-how 

and technology from 

MAPAL – around the 

world 

39 April2009 

INFORMATION IDEAS INTERNALS 

Competence centre Pforzheim: 

Largest factory for PCD tools re-organised 

Tools in lightweight 

design reduce machining 

times 

Adjustable ISO tools 

for reliable processes

Page 2 | MAPAL Impulse 

EDITORIAL 

PCD – a cutting material with a 

great future 

Today PCD (polycrystalline diamond) 

is like a cutting material that has been 

well-known for a long time, but in fact 

it has only been in widespread use for 

20 years. It was this cutting material 

that actually made it possible to costeffectively 

machine non-ferrous 

metals, especially in the automotive 

industry and automotive supplier 

industry, and as a result made a crucial 

contribution to lightweight design in 

this sector. 

Crucial was and still is that the 

manufacture of the tools with PCD 

blades can be realised economically 

and with µm accuracy. To this end, 

over the years of its existence MAPAL 

WWS has undertaken fundamental 

development work to make it possible 

to also manufacture tool blades with 

very complex contours. This aspect 

is vital for reliable and cost-effect 

production using these tools. In 

conjunction with the HSK tool 

mounting, also developed to high 

precision in recent years, production 

is highly reliable, from the start – 

first part – good part. 

Considerable investments in Pforzheim bring even more 

advantages for MAPAL PCD tools. 

MAPAL has not only been involved in 

pioneering work on the development 

of the tools, but also on the manufacturing 

technology. This development 

is due to new structures and the 

new manufacturing organisation as 

a result of the recently completed 

factory extension. Due to this 

significant investment in Pforzheim 

and all the measures taken in the new 

organisation, it is possible for MAPAL 

WWS to supply highly precise, high 

performance PCD tools at short notice. 

So we look forward to continued, 

excellent co-operation. 

Dr. Dieter Kress 

Patrick Fabry new member of the 

senior management at MAPAL 

ISOTOOL 

On the first of January 2009 the senior 

management of MAPAL ISOTOOL 

GmbH, the specialist for actuating 

tools in the MAPAL Group, was 

strengthened with Patrick Fabry (42). 

Patrick Fabry 

Member of the senior management 

at MAPAL ISOTOOL 

The graduate engineer has many 

years of experience in the precision 

tool industry. During his professional 

life in this sector he has already 

worked in a wide variety of areas. 

Starting with demanding tasks in 

design, Fabry was promoted to project 

engineer in sales for complex tool 

systems. In this position he introduced 

a very technical orientation to sales. 

As head of the project department he 

was later responsible for key-account 

management, for project organisation 

and customer support. 

MAPAL 

MAPAL solid carbide drills 

High performance 

and efficiency ex

stock. 

MAPAL aims for solid success – 

sales team conference in 

Altenstadt on 09 January 2009 

The year 2009 began with the traditional 

sales conference for MAPAL's 

German speaking sales team. This year 

the event was organised under the 

motto "MAPAL aims for solid success" 

in Altenstadt at the subsidiary MILLER 

Präzisionswerkzeuge, the MAPAL 

competence centre for solid carbide 

tools that was significantly expanded 

in 2008. With the investment in 

Altenstadt the company has been able 

to completely re-organise the area for 

drilling from the solid. Along with the 

latest high performance drilling tools 

for all materials and applications, it is 

now also possible to deliver a more 

comprehensive range of standard tools 

Information from the MAPAL Group 

– MAPAL ISOTOOL: Senior management strengthened 

– MAPAL aims for solid success: sales conference in Altenstadt 

– High performance and efficiency ex stock 

from stock, and in the custom tool 

sector to address customer wishes 

quickly and flexibly. The sales 

specialists were able to see for 

themselves the excellent response 

and efficiency in relation to the tools 

available from stock. The focus on 

solid carbide tool sales is being 

supported with a comprehensive 

campaign among customers and 

potential customers, including a 

very informative, five-stage mailing. 

During the sales conference, the 

developments, trends and successes 

of the individual product lines were 

presented and discussed, and the 

objectives and focal points for sales 

set. The second major extension at 

MAPAL in Pforzheim in 2008 was also 

an important topic and will be covered 

in detail in this issue of Impulse. 

Overall an exciting day for the MAPAL 

sales team during which the prospects 

and opportunities for this special 

and very difficult year 2009 were 

highlighted. 

sales team conference in Altenstadt 2009 

Contents editor: 

Hermann Steidle 

Editing Team: H. Steidle, M. Berger, A. Duda, 

K. Looser, O. Munz, M. Winter 

Design: I. Rettenmaier 

MAPAL Impulse | Page 3 

Published by: 

MAPAL Präzisionswerkzeuge Dr. Kress KG 

Postfach 1520 D-73405 Aalen 

Tel. +49 (0)7361 585-0 Fax +49 (0)7361 585-150 

info@de.mapal.com www.mapal.com


MAPAL WWS in Pforzheim 

After the major investments in the 

MAPAL headquarters in Aalen in 2007, 

at the subsidiary MILLER Präzisionswerkzeuge 

in Altenstadt in 2008, it 

was also possible to complete the significant 

investments at the MAPAL 

subsidiary in Pforzheim at the end of 

2008. As a result probably the largest 

factory in the world for the development 

and manufacture of PCD tools 

took on a completely new form, with 

completely new capability. 

Due to the investment of more than 

2.2 million Euro in construction work, 

it has been possible to re-design the 

production processes for new products, 

as well as the reconditioning so 

important for PCD tools. In 

addition, a further 

approx. 1.8 million 

Euro were spent on 

With the start of operation of the new production 

hall in Pforzheim (MAPAL WWS), the extensions of 

the production sites in Germany are completed. 

Senior management of MAPAL WWS, from left to 

right: Alexander Raach - commercial director, Werner Stief – 

technical director, Christian Molch – member of the senior management. 

Largest factory for PCD tools re-organised 

the latest machinery and the building 

management systems that are 

important for the environment and 

the working conditions. 

The logistics processes were also 

re-designed with the objective of 

supplying all forms and classes of PCD 

tools quickly, reliably and on schedule 

to customers all over the world. 

As a result of the new production 

system it is now possible to 

manufacture and supply to the 

customer the demanding and to 

some extent very complex tools 

significantly more quickly. 

Important facts about MAPAL WWS 

in Pforzheim today: 

Total area: approx. 11,000 sq m 

Production and logistics: 

approx. 7,500 sq m 

Customer service, design and administration: 

approx. 3,500 sq m 

The organisation will address the special 

requirements of customers in these 

exceptional times with a whole series 

of newly developed tools. Faster, more 

cost-effective manufacturing is vital 

these days and MAPAL has fully 

adapted to this situation. 

From left to right: A view of the new production hall – Insight into the robot line – eroding in the state-of-the-art machine.

Completely new in the MAPAL 

Group: WTE Präzisionstechnik in 

Kempten 

The MAPAL Group is continuing its 

proven strategy of strengthening its 

in-house competence by integrating 

highly specialised businesses. WTE in 

Kempten has been part of the MAPAL 

corporate group since the start of the 

year. 

With around 60 staff on the Kempten 

(sales and consultancy) and Ehrenfriedersdorf 

near Chemnitz 

(production) sites, WTE Präzisionstechnik 

GmbH is a manufacturer of 

high accuracy chucks for tool 

clamping technology. As an international 

business, WTE Präzisionstechnik 

GmbH is a technologically 

orientated organisation that, with its 

design and development activities, 

produces innovations for the clamping 

technology sector. Core competencies 

are in precision drill chuck systems, in 

the hydraulic chucking sector and in 

shrinking technology. To ensure the 

Information from the MAPAL Group 

market position in the precision drill 

chuck sector can continue to be further 

expanded, highly qualified, committed 

employees and know-how are an 

important capability. 

Along with the backbone of the 

company – the loyal, long-serving 

staff of WTE – a very important issue 

is that the two owners Dipl.-Wirtschafts. 

Ing. Peter Tausend (commercial 

area, sales, strategy) and Dipl.-Ing. 

Hans-Ulrich Voigtländer (production) 

optimally complement each other in 

their abilities. 

High quality and a high level of 

innovation characterise the company, 

just like at MAPAL. As a highly 

specialised, small and therefore 

agile business, WTE is the optimal 

addition to MAPAL. 

Under the umbrella of the MAPAL 

Group, WTE will continue on its 

course and, with a powerful sales 

partner at its side, seek market 

leadership in core sectors also 

internationally. 


– Extension of the production capacity for a faster production 

– Modern production systems bring customer advantages 

– WTE – a new member of the MAPAL Group 

Dipl. Wirtschafts.-Ing. 

Peter Tausend 

General Manager 

(commercial, sales, strategy) 

Produktionshalle Ehrenfriedersdorf 2009. Dipl.-Ing. 

Hans-Ulrich Voigtländer 

General Manager (production)


MAPAL re.tooling® – the new MAPAL service 

Shorter machining cycles, flexible and 

multifunction machine tools as well as 

the economic environment we face at 

the moment including the reduction of 

indirect employees result in a new way 

to approach the investments arising 

from the machining of new workpieces. 

The continued usage of 

machinery for these new workpieces 

brings about substantial cost benefits. 

It requires however that the machines 

are re-tooled with regard to machining 

strategy, definition, acquisition and 

installation of the components and 

start-up. These steps tie up resources, 

and a high level of application knowhow 

is called for. MAPAL offers this 

technological re-tooling now as a new 

service called MAPAL re-tooling®. 

The existing machinery at the 

customer is analysed, the modification 

and start of production are quickly, 

flexibly and reliably planned and 

implemented. 

Re-tooling requires innovative 

processes 

MAPAL analyses the existing machines 

at the customer. As soon as draft 

planning with a feasibility study has 

been prepared, the costs for services 

and the necessary equipment (fixtures, 

tools, NC programs, etc.) are 

determined and the complete process 

and machining strategy defined. The 

design of suitable clamping fixtures 

with investigation of tool restrictions 

and the preparation of the NC 

programs are undertaken entirely by 

MAPAL and provided to the customer. 

All the tool design (initial equipment) 

is also undertaken by MAPAL. During 

this process attention is paid to the 

MAPAL re.tooling® – realising new projects with 

existing machinery by re-tooling. 

selection of the most cost effective 

tools to suit the specific conditions 

and to the minimisation of the number 

of tools. Already existing tools are 

integrated as far as possible. 

In the next step MAPAL prepares 

complete tool documentation, i.e. all 

tool drawings, tool plans, process 

sheets and adjustment and installation 

instructions as specified. In addition, 

the calculation of the time required for 

the process with the analysis of the 

productive times and non-productive 

times is prepared for the customer. To 

ensure precise cost transparency, the 

expected tool costs per workpiece/ 

clamping system are calculated and 

costed. After the delivery of all necessary 

tools, fixtures and NC programs, 

first the fixture is installed on site at 

Planning 

Pilot phase 

the customer and placed in operation. 

MAPAL also offers support and 

optimisation during the start-up of 

the NC programs and tools supplied 

to ensure reliable production when 

manufacturing is started. Finally, the 

complete manufacturing process is 

handed over to the customer on 

schedule as per the requirements. 

Why MAPAL? 

The success of a machining process 

with regard to quality and economic 

efficiency is largely dependent on 

the cutting edge of the tools in use. 

Consequently, for the above described 

service to re-tool existing machines for 

another workpiece, MAPAL as 

the major specialist for complete 

MAPAL – Complete Process Management 

Machining process 

MAPAL Customer services 

Engineering 

Optimisation 

Logistics 

Management 

Machining process 

Production 

Implementation 

MAPAL offers perfect services for the complete machining process. From planning through the 

pilot phase and implementation, and also during production, appropriate and cost-effective 

services are provided – always perfectly matched to the customer.

machining tasks is a very competent 

partner. Moreover, defining machining 

processes, acquiring and starting-up 

of corresponding components are not 

a new business to MAPAL: The Tool 

Expert Teams from MAPAL have exclusively 

been dealing with these 

aspects in the range of new projects. 

TET stands for more than 50 highly 

qualified employees with a high knowhow 

throughout the chain of metal 

machining. And MAPAL is also expe- 

Machining before 

rienced in creating NC programs. 

MAPAL re-tooling® 

is therefore an adapted and focused 

combination of existing competences 

that result in cost advantages for the 

customer. 

Perfect MAPAL services also 

while manufacturing is running 

While the manufacturing processes are 

running any further services required 

MAPAL 

re.tooling® 

Machining now 


The continued usage of existing machines brings cost advantages. 

MAPAL offers to undertake the whole re-tooling process as a 

service: status analysis – definition and acquisition of 

components – installation and start-up. 

such as logistics, optimization or 

complete tool management can be 

provided by MAPAL. The MAPAL 

machining specialists undertake every 

effort to implement all customer 

requirements quickly and flexibly and 

to present innovative, reliable and 

economic solutions to the customer. 

The chart on the left gives an overview 

of the complete service offer of 

MAPAL. 

Contact and information 

to MAPAL re.tooling®: 

Tel. +49 (0) 7361 585-3611 

re.tooling@de.mapal.com


Hard machining with MAPAL PCBN tools 

By machining hardened parts with a 

defined PCBN cutting edge, significant 

cost savings can be obtained compared 

to grinding. However PCBN is also 

increasingly gaining ground in modern 

manufacturing for machining sintered 

and cast materials. In parallel the 

development of the different PCBN 

grades is very dynamic. Unlike PCD, 

where there is a more straightforward 

range of PCD configurations on the 

market, there are more factors for 

PCBN. The combination of the CBN 

content, the particle size and binder 

define the properties and therefore the 

related application for the PCBN grade. 

But the PCBN grade is only one side of 

the coin. The correct design of the 

cutting edge, the correct edge preparation 

and the coating have a comparable 

influence of the performance 

of the PCBN cutting edge. 

Hard turning with PCBN 

MAPAL has been involved with the 

cutting material PCBN for a long time. 

The extensive knowledge and 

experience in this area are the basis for 

the MAPAL range of PCBN ISO inserts. 

Besides, a forceful team of specialists 

in the area of hard machining and 

hard turning has been built to ensure 

an efficient consultancy on site at the 

customer. For it is the correct combination 

of PCBN grade and cutting 

edge preparation that is crucial for 

increases in the tool life and, as a 

result, cost-effectiveness. 

New MAPAL PCBN reamers for hard reaming of 

small holes. 

The right PCBN grade and the best cutting edge 

preparation bring success in hard machining. 

MAPAL could achieve considerable results 

with hard turning with PCBN 

especially during the last year. A selection 

of successful application examples 

are shown by the in the table on the 

right side. 

Hard reaming with PCBN 

With unfavourable L/D ratios, small 

hole diameters or holes that are 

eccentrically arranged in hardened 

parts and can therefore only be 

machined on lathes with special 

fixtures, or cannot be machined on 

lathes, hard reaming with tools with 

guide pads or with fixed reamers 

with PCBN is a very good 

solution. In the case of 

multi-bladed reamers, sections of 

PCBN are usually brazed into a steel 

or carbide body. This technology is 

however limited to diameters greater 

than 6 mm and the number of blades 

is restricted. MAPAL has developed 

new tools for this sector; on these tools 

the PCBN is attached to the front face 

and the blades are produced from the 

PCBN.

In this way tools down to the range 

of 2 mm and below are possible with, 

for instance, four blades. Up to now 

these diameter ranges were the speciality 

of carbide reamers. Despite wearresistant 

substrates and coatings, carbide 

reamers are subject to very high 

wear; they have a limited tool life. 

In one example a bore with 

ø2.4 H7 is machined on a part 

with a hardness of 58 HRc, 

a circularity of 5 µm and a 

surface finish of R a 0.4 

µm is required. With cutting 

data of v c = 60 

m/min and f = 0.1 mm 

the circularity is 2.7 µm 

and the surface 

finish R a 0.15 µm. A tool life of 1,360 

parts is achieved. Compared to 50 

parts with carbide. 

A quantum leap! 

It was also possible to significantly 

improve the tool life when machining 

a hole ø7.7 H7 in a hardened pivot arm 

made of 16MnCr5 using a six-bladed 

PCBN reamer manufactured by 

Success stories: Hard turning with MAPAL PCBN inserts 


Longer tool lives bring increased efficiency to hard 

machining with PCBN. Whether with hard turning or the 

machining of small bores – MAPAL has the best solution! 

Competence hard machining: 

Product manager Michael Gebhard 

(middle) and his team show their 

experience and know-how on site 

to the customers. 

MAPAL. The tool used previously had 

to be replaced after 9,000 bores. With 

cutting data of v c = 150 m/min and 

v f = 1,460 mm/min, the MAPAL tool 

has a life of 12,000 holes, that is an 

improvement of more than 30 %. 

Part / Machining Planetary gear Drive shaft Drive shaft Spacer sleeve Thrust tube Inner gear Gear wheel 

ø183 G7 x 135 ø50 k6 x 110 ø254 h7 x 115 ø40 +0,08 x 40 ø160 x 1084 ø32 H8 x 14,5 

Material 20MnCr5 20MnCr5 16CrNi 16MnCr5 300M Sintered steel Sintered steel 

(Flugzeugbau) (aircraft insdustrie) 

Hardness (HRC) 58 – 62 58 – 62 58 – 62 58 – 63 53 – 55 ca. 60 

Required surface finish Ra 0,3 max. Rz 2 max. Ra 0,8 max. Rz 10 

Insert form and size CNGA120412 DNGA150608 CNGA120412 DCGW11T308 SNGA120408 CCGW09T304 DCGW11T308 

vc 210 m/min 90 m/min 240 m/min 120 m/min 100 m/min 230 m/min 150 m/min 

f (per cut) 0,1 / 0,07 mm 0,06 mm 0,16 mm 0,15 mm 0,2 mm 0,075 mm 0,08 mm 

ap (per cut) 0,5 / 0,3 mm 0,1 – 0,15 mm 0,05 mm 0,08 – 0,13 mm 3 mm 0,2 mm 0,2 mm 

PCBN-grade FP815 FU840 FP823 FP823 FU820 FU430 FU430 

Cutting edge design S52 S59 W40 T40 S08 T13 S56 

bevelled and bevelled and Wiper bevelled bevelled and bevelled bevelled and rounded 

rounded rounded rounded 

OLD 3 pcs 30 pcs 20 pcs 690 pcs 46 min. 800 246 pcs 

(2 cuts) – 1.000 pcs 

NEW 11 pcs 39 pcs 25 pcs 870 pcs 27 min. 1.540 pcs 705 pcs 

(1 cut) 

Improvement with MAPAL more 270 % more 30 % more 25 % more 26 % 40 % more 54 % more 190 % 

faster


MAPAL tools opimise series production 

and shorten the machining time by more than 25 %. 

GPM oil pumps – from the prototype to series production maturity 

GPM Geräte- und Pumpenbau GmbH 

with its headquarters in Merbelsrod / 

Germany can look back over a long 

tradition of successful development 

and production of coolant pumps, oil 

pumps, valve gear casings and 

mechanical seals. Since the 

organisation was founded in 1939, 

GPM has become established 

worldwide as a technology leader in 

the development and manufacture 

of pumps. 

GPM supplies almost all national 

and international automotive 

manufacturers with innovative, high 

quality pump systems. Customers 

benefit from the many years of 

experience in pump design as early 

as the start of the process chain. Based 

on the "simultaneous engineering" 

principle, GPM develops, together with 

the customer, solutions from the 

concept idea to the ready-to-install 

product. Very high value is placed on 

research and development. One in ten 

of the total of 515 staff is involved in 

the development of new products. The 

focus here is increasingly on fuel 

saving and CO2 reduction. The 

increasing demand for regulated oil 

pumps is addressed with variable flow 

rate and variable pressure systems 

that, due to their integration in the 

engine management, only generate 

the lubrication pressure the engine 

actually needs at any specific time. 

The innovative tool concepts from 

MAPAL covering the entire range of 

machining tasks have been demonstrating 

their performance in series 

production at GPM for some years. 

Together with the machine 

manufacturer ELHA and the product 

specialists from GPM and MAPAL, the 

particularly demanding machining 

requirements for a new pump system 

are now to be transferred from 

prototype manufacture to a fast, 

cost-effective and reliable machining 

process for series production. 

Joint know-how solves 

demanding tasks 

The pump system comprising several 

components represents a major 

challenge for machining in many 

respects. Different workpiece materials 

in combination with delicate part 

geometries and close tolerances place 

high demands on tool technology and 

require a particularly close co-operation 

between all involved in the 

project. The machining of a complex 

central part for the housing made of 

GG25 on a custom ELHA machine 

with an HSK-63 double spindle has 

attracted particular attention. Along 

with various milling, drilling and 

counter boring operations, the 

roughing and fine machining of two 

overlapping wheel chamber bores is 

particularly important. Due to the 

delicate, thin-walled contour, the part 

tends to twist during machining and 

is pressed into the clamping fixture. 

In addition, casting stress in the part 

result in further distortion during the 

fine machining. 

Intelligent design and sustainable 

optimisation for a safe process 

With the manufacturing know-how of 

the responsible project team at GPM 

under the leadership of Andreas 

Gundlach and the MAPAL 

application engineer 

Thomas Pfitzer, it was 

possible to introduce a 

reliable machining 

process suitable for series 

production taking into account all the 

components involved in the machining 

process – tool, machine and clamping 

system. 

Starting point for the optimisations 

were large variations in the diameter, 

an undesirable taper shape and 

additional cutting by the tools on 

withdrawal. In the first step the 

clamping system was expanded with 

two radial pressure cylinders. They 

reduce the pressure on the component 

and dampen vibrations. In the second 

step the machining sequence was 

optimised. The machining on the upper 

wheel chamber bore is now performed 

with the double spindle in the feed 

Machining time for the part made of GG25 

Pre-series technology prototype: 

On commissioning ELHA machine: 

Currently after optimisation:

direction of the fixed stops. The lower 

wheel bore is then machined using one 

spindle with the feed direction, but opposite 

to the fixed stops. By machining 

from the other side it is possible to exactly 

achieve the positional requirements 

placed on the wheel chamber 

using an ISO fine machining tool with 

PCBN inserts. The diameter is checked 

at regular intervals and adjusted if necessary. 

approx. 17 min 

approx. 1.9 min (complete machining MAPAL) 

approx. 1.4 min (complete machining MAPAL) 

For the complete machining 

of the housing part only ten 

MAPAL tools are required per spindle 

for the total of 15 different machining 

tasks. 

Evidence of renewed successful collaboration 

between MAPAL and GPM is 

also the impressive reduction 


Innovative tool solutions and a competent partner achieve 

dramatic reductions in machining times when machining 

complex and challenging parts. 

From left to right: Marco Liebau, production planning GPM, and Andreas Gundlach, 

head of process planning GPM, and Thomas Pfitzer, application engineer MAPAL. 

in the machining time from pre-series 

production to series production (from 

17 to 1.4 min). 

Note | conversion to TORX PLUS® 

With immediate effect all tool bodies and cartridges for MAPAL ISO tools will 

have the new TORX PLUS® system. You will find further details on the change 

on our web site www.mapal.com or request our information sheet. 

Compatibility 

The TORX® system and the TORX PLUS® 

system are compatible only from one 

side: with the conventional TORX® 

tool, a TORX PLUS® screw can also be 

operated to a certain extent. But the 

operation of a TORX® screw with a 

TORX PLUS® tool is not possible. 

TORX® TORX PLUS® 

Screws 

Screws


Significant optimisation due to 

intensive collaboration from the start. 

Successful machining of modern gearbox housing 

The ZF concern has been a reliable 

and competent partner to international 

vehicle manufacturers for more than 

90 years and is among the 15 largest 

automotive suppliers. With a global 

market presence and approx. 57,500 

employees worldwide, the concern 

offers its customers a dense network of 

competent local contacts, at all levels 

and in all regions. 

ZF Getriebe GmbH in Saarbrücken, 

with more than 6,000 employees, is the 

headquarters of the "Car Driveline 

Technology" division. In the automatic 

gearbox sector alone, around 1 million 

5-speed and 6-speed automatic 

gearboxes for cars are produced 

annually. 

High requirements to new 

developments – intensive 

collaboration necessary 

The demands placed on new 

generations of gearboxes are high. 

A reduction in the consumption and 

emissions must be met as well as a 

high power density and high 

efficiency. The functional requirements, 

for example gear changing 

or spontaneity, have also increased. 

And the requirements have been met: 

the average consumption of an 

automatic car gearbox has been 

reduced by around 15 % in the last 

16 years. At the same time the 

vehicles' performance has been 

significantly improved by shorter 

gear change times and improved 

acceleration figures. 

In order to continue to effectively and 

quickly meet the requirements, good 

collaboration between the production 

planners, machine manufacturers and 

tool manufacturers is necessary even 

during the development of a gearbox. 

This way, potentials can be sounded 

out, evaluated and implemented with 

the shortest delay. 

Intensive support is provided by the 

technical consultants from MAPAL 

right from the start of production of 

automatic gearboxes and as a result 

there is close collaboration in a very 

wide range of areas. The common goal 

during new projects and optimisations 

is always to improve cost-effectiveness 

and process reliability with innovative 

tool solutions. 

The specific application in this case is 

the machining of a gearbox housing 

for the 6-speed automatic gearbox, 

6HP26. The 6HP26 gearbox design 

features a single planetary gear set 

based on the Lepelletier principle with 

a downstream Ravigneaux gear set. 

Vehicle movement with converter slip 

is bridged significantly more quickly 

and therefore a more direct connection 

to the engine ensured. More agility 

and optimised consumption are the 

result. The reaction time has been 

reduced by 50 % (2nd generation of 

6HP) such that it is below the 

threshold of human perception. 

PCD tools in lightweight 

design allow machining on machining 

centre 

The requirements on the grooves to be 

made inside the gearbox housing are 

very high in relation to the tolerances 

and the exact positioning of the 

grooves in relation to one another. 

These operations are undertaken on 

CNC machining centres using circular 

milling tools. The advantage of 

complex circular milling tools from 

MAPAL is that it is possible to 

combine a wide range of operations 

on series production parts in one tool. 

The resulting special forms provide 

the required shapes and position 

tolerances for the grooves. At the 

same time the machining times are 

significantly reduced. 

The circular milling tool used on a 

Heller machining centre is of a design 

with three or six blades. As production 

is continuous, the cycle time and 

process reliability during continuous 

operation, along with the required 

tolerances, were the tools requirements 

placed on MAPAL. One problem, 

however, was the projection length 

of almost 350 mm with a tool diameter 

of 110 -150 

mm, which 

with a solid

tool design would have resulted in a 

tool weight of over 25 kg. As the 

maximum tool weight permitted on 

the machine was 20 kg, the entire tool 

body was hollowed out. The result was 

a weight reduction of approx. 9 kg. 

However, to provide a flow of coolant 

during machining, it was necessary to 

depart from the central supply of 

coolant and a type of "pipe system" 

was "laid" over the exterior walls of 

the tool to ensure an optimal supply of 

coolant to the individual blades. With 

the cycle time required the tool runs 

reliably in continuous operation at a 

speed of 10,000 rpm and a feed speed 

of 600 mm/min. 

The problem with tool weight 

resulted in the hollowing out of the 

tool body on a further MAPAL 

circular milling tool. As 

in this case, due 

“Tool solutions in lightweight design allow a considerable reduction 

in machine times: various machining steps can be combined; 

higher cutting values are possible.” 

On the left in the photograph, Guido Maas, machine operator at ZF Saarbrücken, on the right to the side, 

MAPAL sales representative Jörg Hemmerling as well as Thomas Paulus, tool planner ZF Saarbrücken. 

to the contours and diameter required, 

it was not possible realise a coolant 

supply over the exterior walls, a brass 

pipe was fitted in the tool body and in 

this way the central supply of coolant 

to the blades provided. On this tool the 

weight was reduced by approx. 6 kg. 

These examples 

given state that 

with innovative 

tool solutions in 

Multi-stepped PCD circular milling tool in lightweight design. 


lightweight design machining 

operations can today be carried out 

on a machining centre that up to now 

were not possible due to general 

conditions of the machine. Combining 

several machining steps into one tool 

furthermore reduces machine times, a 

considerable advantage for an efficient 

production.


High requirements on technology and reliability from Honda 

for the new production facility for crankcases and cylinder 

heads. 

MAPAL supplies 75 % of the tools for Honda Powertrain Brazil 

In May 2008 the new Honda Powertrain 

production facility in Sumaré City 

(Sao Paulo) started work – the result of 

an investment by the Japanese car 

maker of 45 million Euro. Raw parts 

are cast and machined in a building 

covering an area of 13,500 m². The 

facility has a capacity of 650 crankcases 

and cylinder heads per day and is 

the first car production facility in 

which these parts are manufactured in 

Brazil made of aluminium. 

An important detail in the planning to 

set up production in Sumaré was the 

decision by the project team to equip 

the hall with machines, tools and 

equipment manufactured locally. "As 

we planned this project from scratch, 

we decided to utilise the existing 

infrastructure in Brazil. After all there 

are first class suppliers here in Brazil 

who export to demanding markets such 

as the USA and Europe," says Sérgio 

Kawase, head of production, Honda 

Powertrain. Only one machine for the 

new factory was imported from Japan: 

a double-spindle machining centre that 

is produced by a special department in 

the Honda EG car assembly plant. 

All machining tasks to be undertaken 

in the Sumaré plant were prepared in 

collaboration with the suppliers. And – 

MAPAL do Brasil made a significant 

contribution: MAPAL do Brasil is 

responsible for 75% of the tools that 

are used for machining crankcases and 

cylinder heads. "We have developed 

and produced more than 130 tools for 

the production at Honda," explains 

Rogério Rodrigues da Silva, technical 

director at MAPAL do Brasil. "We have 

worked very closely with the machine 

manufacturers Grob and Heller who in 

turn have equipped the Honda plant 

with custom machinery and machining 

centres. Our know-how in relation to 

machining aluminium crankcases and 

cylinder heads is well known." 

Successful together since 2003 

The partnership between Honda and 

MAPAL in Brazil began before the 

"Sumaré project". The car manufacturer 

started to machine gearbox housings, 

clutches and oil sumps in Brazil in 

2003. "When we set up housing 

machining, the development department 

at MAPAL do Brasil was a great 

help and always provided excellent 

support", Kawase found. "The collaboration 

was very good from the start, 

particularly in relation to after-sales 

service and technical support. It was 

therefore obvious during the search 

for suppliers for machines and tools 

for Sumaré to involve MAPAL with 

their years of success and their 

dependability." 

Rogério Silva states that "the combination 

of as many machining tasks 

as possible in one tool is the highest 

priority for us if the issue is the 

machining of aluminium parts, that is 

with PCD tools. As a result we do not 

just reduce the number of tools in the 

magazine. During machining with PCD 

we work at very high speeds and as a 

result have very short machining times. 

We therefore "waste" the most time on 

tool and pallet changes.” Silva says 

that combination tools also make it 

possible to exploit the machine's 

limits in terms of speed and feed. 

Machining of mixed materials – 

tool highlights from production 

at Honda 

Many machining tasks at Honda have 

very tight tolerances. "And very strict 

conditions were placed on us. To be 

authorised for the production, we had 

to exceed the quality in the factories in 

Japan and Thailand, as the gearbox 

housings and cylinder heads were 

originally manufactured there and 

exported to Brazil", says Kawase. 

A highlight of the machining of the 

crankcase is the precision drilling tool 

used for fine machining the crankshaft 

bearing bore. The housing is made of 

aluminium, the bearing caps are cast 

iron. The tool must machine both 

materials at the same time. Da Silva: 

"The design of this tool was a 

challenge for MAPAL do Brasil. 

The two materials place completely 

different requirements on the 

machining. Nevertheless, we had to 

develop a tool that meets them all." 

The tool mentioned, ø 54 mm, is 

designed in the MAPAL equipped principle 

with four PCD blades based and 

carbide guide pads along the entire 

machining length of 270 mm. The 

guide pads support the tool during

the machining and the varying loads 

due to the materials. As a result the 

bearings are perfectly aligned. 

The machining is subject to high 

requirements: in both materials the 

surface quality must be below R z 4.0 

µm, and the cylindrical shape within 

a bearing has a tolerance of 3 µm. 

The tool is used a cutting speed of 

100 m/min and a feed speed of 

60 mm/min. 

Machining the hone clearance is also 

undertaken in both materials. In this 

case a circular milling tool with eight 

PCD blades brazed to the front face 

and eight PCBN indexable inserts on 

the periphery is used. The PCD blades 

perform an interpolation movement in 

the aluminium during which the length 

machined is divided into two times 

For machining the crankshaft bearings the tool was 

designed using proven MAPAL technology with 

indexable blades and guide pads. 

four blades. The tangentially arranged 

PCBN indexable inserts apply a 30° 

bevel to the cast iron. "The challenge 

with this tool was in the selection of 

the most suitable PCBN grade that also 

achieves the tool life of the PCD blades. 

We were able to rely on the know-how 

in the headquarters in Aalen", explains 

da Silva. 

Finally, another tool that attracted 

interest is used to rough the camshaft 

bearings. "The tool roughs the bore in 

one pass from the solid. Due to the tool 

dimensions, this machining task is very 

difficult (300 mm long with a diameter 


In Brazil and around the world, customers can rely on first-class 

know-how and technology from MAPAL – in all areas: 

engineering, production, sales and service. 

The PCD tool pre-machines the camshaft bearings in one pass from the solid. 

A view of the new Honda Powertrain production buildings in Sumaré / Brazil. 

Alex Meneguetti, left, application engineer at MAPAL, and Andre Lodi, right, responsible 

MAPAL sales representative, together with Sergio Kawase, production 

manager at Honda. 

ratio of 8xD)", says da Silva. "With 

brazed PCD blades and carbide guide 

pads in the body we have achieved 

excellent stability in this boring 

operation." And all this at a feed speed 

of 1,516 mm/min and a cutting speed 

of 440 m/min.

Reiben | Feinbohren | Aufbohren | Bohren Fräsen Aussteuern | Drehen | Spannen | Dienstleistungen 

Reaming | Fine Boring | Gun Boring | Drilling Milling Actuating | Turning | Clamping | Customer Services 

With MAPAL’s PCD circular milling tools operations of several tools can be combined. Even 

complex contours and axially offset grooves can be precisely defined. The result: high performance 

cutting with perfectly formed contours and extremely long tool life. No tool change 

and low stress on machine and spindle. 

MAPAL’s state-of-the-art technology will make you more successful, too. Because we are the 

specialists – for individual machining solutions with the highest precision and economic results. 

3 grooves with chamfers and radii. 

For 70,000 callipers in AlSi9Cu (Fe). 

At maximum speed. 

Perfectly yours. 

IMP39-E-01-080-0409-WD Printed in Germany. Right of technical modifications reserved.

Competence centre Pforzheim: Largest factory for PCD ... - Mapal.us

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