Drilling | Milling | Reaming TOOLS FOR MODERN LIGHTWEIGHT MATERIALS

When something exceptional develops between us: That‘s the MAPAL effect. continously develop more innovative solutions so that flying becomes more efficient. supply you with machining solutions that give your production more momentum even with completely new materials.

TOOLS FOR MODERN LIGHTWEIGHT MATERIALS | Introduction

Introduction | TOOLS FOR MODERN LIGHTWEIGHT MATERIALS More and more applications are making use of lightweight materials Where weight reduction with consistent stability plays a major role, modern materials are capturing ever more applications. Products of lightweight design, particularly those made of fibre composite materials and multimaterial systems (CFRP-metal multilayer composites), are also becoming increasing common in the automotive sector, as they spread from their origins in the aerospace industry. Here lightweight design is also playing a crucial role in the introduction of electric...

TOOLS FOR MODERN LIGHTWEIGHT MATERIALS | Introduction | Materials The right tool for every material A wide range of lightweight materials is used, depending on the requirement on the part, and reliable machining represents a real challenge. For drilling and milling fibre-reinforced plastics such as CFRP and GFRP as well as difficult to machine materials such as titanium and Iconel, MAPAL has specially developed new tool solutions to address these specific requirements. The portfolio covers standard products made of solid carbide, PCD and CVD tipped tools and also customer-specific custom solutions....

Introduction | Materials | TOOLS FOR MODERN LIGHTWEIGHT MATERIALS Fibre-reinforced plastics (CFRP/GFRP) The specific properties of fibre materials such as glass fibre or carbon fibre can only be fully utilised with a matrix material. Here predominantly thermosetting epoxy resin, polyester resin, melamine resin and polyurethane or thermoplastic matrix materials such as PEEK, PPS and PTFE are used. The mechanical properties of fibre composi- te materials can be varied, e.g. via the portion of the volume formed by the fibres, the sequence of the layers and many other aspects. As the fibres, above...

TOOLS FOR MODERN LIGHTWEIGHT MATERIALS | Introduction | Materials High-volume milling cutter for aluminium machining – OptiMill®-SPM (Structural Part Machining) In the aerospace industry, aluminium structural parts such as frame elements or wing parts are generally milled from solid material. Often more than 90% of the raw part is cut away. New machine generations with sufficient drive power and the necessary spindle speeds allow for an efficient high-performance machining of aluminium parts. MAPAL has developed a new range of aluminium roughing milling cutters. The OptiMillSPM (Structural Part...

Introduction | Materials | TOOLS FOR MODERN LIGHTWEIGHT MATERIALS ADVANTAGES – igh material removal rate H > 8 l/min with 32 mm diameter with HSK – oft, low-vibration cutting thanks to S highly positive rake angle and increased axis angle: Higher quality, lower power consumption – mproved surface quality by reduced I power consumption – High stability thanks to optimally embedded PCD blades: No notching effects or protrusions – nhindered chip flow: No corners or U sharp edges in the chip flute Note: Tool programm can be found from pa

TOOLS FOR MODERN LIGHTWEIGHT MATERIALS | Introduction | Machine concept The right tools for every machine concept Machining centres / gantry machines with moveable gantry Properties High rigidity, stable machine design High spindle speeds, high torque Mostly HSK spindles with high radial run-out accuracy With internal coolant supply or MQL Variable feeds and spindle speeds Drilling cycles can be programmed – also with hiccup/pecking feed 5 axes Machining centre – machining compartment mostly enclosed -> working area extraction Gantry – mostly open design -> extraction mounted separately Parts...

Introduction | Machine concept | TOOLS FOR MODERN LIGHTWEIGHT MATERIALS Properties High spindle speeds and feeds possible depending on spindle Less stable system due to the toothed-belt drive for the axes Accuracy of repetition max 0.1 - 0.2 mm (makes it more difficult to find a hole already drilled) With internal coolant supply or MQL Drilling cycles can be programmed - also with hiccup/pecking feed Parts – Flexible during the machining of different parts – Larger parts Tools – Drilling tools with diameter > 8 mm only with leading stage for stabilisation – The length of the tools is mostly dependent...

TOOLS FOR MODERN LIGHTWEIGHT MATERIALS | Drilling

Drilling | TOOLS FOR MODERN LIGHTWEIGHT MATERIALS For machining bores in modern materials such as CFRP, GFRP, or CFRP-metal multilayer composites (titanium and aluminium), MAPAL has developed special tools that prevent delamination and fibre projections. Depending on the application, they have special geometries, high-performance diamond coatings or cost-effective replaceable head systems. Drill range selection aid 14 Drill range product tables 16 Replaceable head holders TTS 45 Thread adapters for drill feed units 48 Drilling tools for hand-held machines 50 Hand-held machines

TOOLS FOR MODERN LIGHTWEIGHT MATERIALS | Drilling | Selection assistant Suitable in some situations Material Material examples N1.1 Aluminium, non-alloyed and alloyed < 3 % Si Alloy 2024, Alloy 7075, Al99 MEGA- MEGA- MEGA-Stack- MEGA-Stack- MEGA-Drill- Stack-Drill-CA Stack-Drill-CT Drill-Robot-CA Drill-Robot-CT Composite-MD- N4.2 Plastic, thermosetting plastic (duroplast) PU, PF, EP, UP, VE, CR Plastic matrix, aramid fibre reinforced plastic (AKF) C1.2 Plastic matrix (thermosetting), CFK/GFK Plastic matrix (thermoplastic), CFK/GFK Nomex, Kevlar, Twaron, KOREX GMT-PP,...

Selection assistant | Drilling | TOOLS FOR MODERN LIGHTWEIGHT MATERIALS

TOOLS FOR MODERN LIGHTWEIGHT MATERIALS | Drilling Design: Drill diameter: Bore tolerance: Shank form: Coating: Number of blades: Guide chamfer: Tip angle: Helix angle: Application: Multi-layer out of CFRP / aluminium Dimensions in mm. Machining values see chapter technical information. Available ex stock Germany. O Standard tool not on stock (delivery on request).