From its 480m² stand – A18 in Hall 4 – at EMO in September, tooling expert Mapal will focus on the automotive, aerospace, fluid power technology and die and mould making sectors, planned innovations for 2024, the recently launched online shop and the highly topical subject of sustainability.

"In addition to our innovations, we have numerous other news in store for our customers at the EMO show in Hannover," says Jacek Kruszynski, chief technology officer of the Mapal Group. These include, among other things, the new online shop, which is currently available to customers in Germany and Austria.

“The shop contains over 6,600 drilling, milling, countersinking, and clamping products. Our customers benefit from short delivery times, free delivery and state-of-the-art shop functionality."

Numerous machining solutions for different industries and applications will be exhibited on the Mapal stand. The focus is on the automotive sector, including solutions for electric vehicles, aerospace, fluid power technology and die and mould making. Mapal will also be showcasing innovative tools and clamping chucks that take into account the topics of energy efficiency, resource conservation and safety.

"We not only operate as sustainably as possible ourselves as an organisation – we also take responsibility for the benefit of our customers and employees,” Mr Kruszynski affirms. “We also want to provide our customers with the best possible support on the path to sustainable production."  

Product innovations at EMO: deep drilling and reaming

A highlight at EMO will be the new Mega-Deep-Drill-Steel product range up to 40 x D, which are specially designed for machining steel and cast iron. The solid carbide deep drills are optimally protected with an innovative coating using high power impulse magnetron sputtering (HiPIMS) technology in the cutting edge area which also ensures frictionless chip removal.

Mapal will present the Mega-Deep-Drill-Steel with length ratios 15 x D to 40 x D at EMO

The remaining length of the MEGA-Deep-Drill-Steel remains uncoated. Thanks to its innovative geometry, the new deep drills exhibit long tool lives and high productivity. Compared to its predecessors, up to 50% higher feed rates can be achieved.

Mapal is also presenting a series of new cylindrical shank reamers with brazed cutting edges. The special feature of the FixReam 700 reamers is their high usability via an expansion system. A tool can be reground up to two times before new cutting edges have to be brazed in. After that, it is possible to regrind the tool twice again, then replace the cutting edges again and regrind the tool twice more. One reamer therefore has nine tool lives.

Compared to a tool without expansion capabilities, tool costs can be reduced by up to 15%. Thanks to new, patented geometries, users achieve up to 30% better roundness and cylindrical form as well as improved chip removal when compared to other cylindrical shank reamers.

Milling cutters for the high-volume machining of aluminium

"With our two new milling cutters for high-volume machining of aluminium, we are presenting a real highlight, particularly for the aerospace industry," Jacek Kruszynski reveals.

“The series, in solid carbide and with indexable inserts, are particularly interesting for use on high-performance machines. With the new OptiMill-Alu-Wave solid carbide roughing milling cutter for aluminium materials, Mapal is taking full advantage of the performance of the fastest machines available on the market, thus achieving a material removal rate of up to 21 litres per minute.”

While it is of course possible to use the high-volume milling cutter on less powerful machines, Mapal is taking into account the fact that aircraft parts are often manufactured on machines with spindle outputs between 40 and 80kW, for which there was previously no suitable milling cutter in the portfolio.

For larger diameters, the new NeoMill-Alu-QBig indexable insert milling cutters are a highly economical solution. In order to achieve as much 18 litres per minute removal, the new aluminium volume cutter is designed for use at speeds of up to 35,000rpm (with a diameter of 50mm).

The NeoMill-Alu-QBig achieves surface finishes of Ra 0.8µm and Rz 4.0µm for roughing and finishing even with high chip volumes.

www.mapal.com