MAPAL Adds Creativity to Tool Design at MACH
Introducing additive manufacturing to the realms of cutting tool manufacture offers design, performance and tool life benefits that in many circumstances are beyond the possibilities of traditional production methods. For some time, MAPAL has been introducing new ‘Additively Manufactured’ product lines and at MACH 2020; this will continue with a host of new additive solutions on Stand 330 in Hall 18.
By reducing the weight of PCD cutting tools through additive methods, MAPAL is achieving significantly higher cutting data. As 3D printed cutting tool structures can be designed and manufactured to minimise weight without compromising strength or integrity, MAPAL engineers are increasingly pushing the boundaries of cutting tool design and development and this will be evident at MACH.
Demonstrating how MAPAL uses the advantages of 3D printing at MACH, the company will demonstrate its new bell tools with brazed PCD inserts. Frequently used in the hydraulic and automotive sectors, bell tools are the first choice for external machining of hose connections on turbochargers where complex contour requirements must be met with precision. This means that cutting tool production must be equally precise to ensure customers can achieve their cost-effective, precision machining requirements.
To meet the needs of the end-users, MAPAL has optimised the existing, conventionally manufactured bell tool by integrating selective laser melting process into its manufacturing processes. This allows the inside of the cutting tool to be modified and as a result, the tool is at least 30% lighter and the tool life is increased by upwards of 40%, credit to the enhanced vibration damping characteristics of additive manufactured tool designs. Customers using MAPAL’s additive manufactured tools are witnessing productivity improvements in the region of 50%.
Additionally, MAPAL experts are using the 3D printing technology to optimise the cooling channels, ensuring that cutting fluid is delivered to the cutting area via the most efficient possible route. Using selective laser melting, the new tool geometry is printed on a highly precise tool body with an HSK-63 connection. The additively manufactured tool body is subsequently machined to provide the precise platform for the PCD inserts to be brazed into place and then cut to shape using a laser.
With additively manufactured cutting tools, reliable chip breaking and optimal machining performance is a necessity. This is why MAPAL will also be using the showpiece UK manufacturing event to introduce its newly developed inserts for the chip guiding stage when machining steel. When undertaking the fine machining of steel, long chips can prove detrimental to machining performance and surface finishes, especially when machining with tools that incorporate guide pads.
To prevent long chips from wrapping around the tool and creating a negative impact on surface quality, MAPAL has introduced the new line of inserts with chip guides. The new chip guiding stage combats these very problems, credit to the new geometry design. With a special geometry that has been designed and optimised with extensive FEM analyses and practical testing, MAPAL now ensures that chips are broken reliably. This prevents automated workflows and production environments from being disrupted. The chip guiding stage is compatible with all indexable inserts with AS leads. Furthermore, the new chip guiding inserts are available with a wide variety of coatings to support the machining of a vast selection of material types. For more information on how the MAPAL tool design engineers can create additive cutting tool solutions for all your bespoke manufacturing requirements with inserts that guarantee performance and consistency, please visit Stand 330 in Hall 18 and meet the MAPAL technical engineering team.