New MAPAL chip breaker for machining low silicone content aluminium 

The machining of aluminium parts with low silicone content (silicone content less than three percent) results in long chips and stringy swarf. As this has a negative impact on the machining process in a number of ways, MAPAL has now developed a new chip breaker to ensure defined chip breaking during hole-making processes such as the boring and reaming aluminium components.

The issue for machine shops is many-fold, on the one hand there is a risk of the swarf wrapping around the tool and hence negatively influencing the surface finish and the dimensional accuracy of the bore. On the other hand, long chips cannot be reliably removed from the part or the clamping fixture during series production. This can lead to laborious reworking or the continuous checking and stopping of the machine tool to eliminate the risks associated with excessively long chips.

The new MAPAL chip breaker now ensures a defined chip breaking process during boring and reaming with its innovative PCD tools. The special topology developed in time-consuming 3D simulations ensures defined chip breaking and hence short chip patterns, which improve the swarf evacuation process.  Even with low feed rates and low stock removal, defined chip breaking and chip shape are ensured. This guarantees the highest possible performance level and process reliability.

The newly developed chip breaker can be integrated into the PCD cutting edge or PCD indexable insert, irrespective of the particular application. This makes the new technology universally available.