MAPAL Gets a Grip on Clamping With Additive Manufacturing

The onset of miniaturization is becoming more prominent in industry and the respective machining applications and production processes. This pattern is naturally seeing the necessity for clamping chucks to become smaller, more precise and more powerful. As these requirements cannot be met with conventional manufacturing, MAPAL is a cutting tool manufacturer leading the way by using additive manufacturing by selective laser melting to produce chucks and tool holders.

Whether in electrical engineering, medical technology, the aerospace, watch or robotics industries – many products are becoming ever smaller, smarter, more user-friendly and more powerful. The topic of space is therefore crucial, especially in the production halls of manufacturing companies and also in the area of clamping technology.

Perfect radial run-out and optimum balancing value

The radial run-out accuracy of clamping chucks for a chip thickness in the range of a few thousandths of a millimeter must be almost zero. This is the only way to achieve good surfaces at maximum spindle speeds with a long tool life. In addition, it must be ensured that any contamination due to micro-particles is excluded. Another important topic for machining in the miniature sector is the supply of coolant lubricant. Too much cutting fluid means complex downstream part cleaning and too little or no cooling leads to a loss in quality and productivity.

Furthermore, the smaller the tool and clamping chuck, the easier handling must be. This is because with each reduction in size, the handling of external peripheral devices becomes ever more complicated and difficult. With shrink or collet technology, it also takes considerably longer for the tools to be ready for use. In the case of multi-part attachments, the individual deviations of the components also add up to a considerable error chain.

Additive manufacturing by selective laser melting

At MAPAL, additive manufacturing by selective laser melting is now used in all product areas. This is particularly the case in all situations where additively manufactured products can offer clear added value for the customer. Thanks to this innovative manufacturing process, MAPAL has succeeded in manufacturing clamping chucks in miniature format with the HSK-E25 connection for direct clamping of tools with a diameter of 3mm whilst meeting the challenging criteria mentioned above.

The smallest clamping chucks with the best properties

In order to guarantee radial run-out accuracy, the clamping technology specialists have integrated innovative clamping chamber systems into the new clamping chucks that fit snugly against the tool shank. They are equipped with dirt grooves to displace microscopic particles. The required balancing value is guaranteed thanks to internal balancing geometries including support structures that also optimise the weight and strength distribution. Overall, the small format chucks can achieve a more homogeneous and spindle-friendly acceleration and deceleration for the entire tool system that consists of the clamping chuck and cutting tool.

Thanks to additive manufacturing, MAPAL has succeeded in equipping the clamping chucks for the miniature sector with decentralised coolant outlets. Using parameters such as coolant pressure, setting dimensions and spindle speed, these optimised outlets are designed in such a way that they convey the lubricant directly to the cutting point.  

Very easy handling without peripheral devices

The new small format clamping chucks from MAPAL enable simple and quick clamping of the tool with no training courses, high re-tooling costs or expensive peripheral devices required for implementation. This is because the hydraulic chucks are operated using a simple screw.

New possibilities – not only for tool clamping

The new small hydraulic chucks also open up new possibilities for workpiece clamping. For example, the external hydraulic clamping technology can be used for clamping hip joint balls. Specially shaped chip flutes inside the chuck and a special external geometry ensure that the balls are clamped very precisely and gently at the same time. In medical technology in particular, topics such as reproducible precision are of enormous importance.