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Additively Manufactured Hydraulic Expansion Chucks 2» |EDITORIAL MAPAL IMPULSE 58

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Additively Manufactured Hydraulic Expansion Chucks 2» |EDITORIAL MAPAL IMPULSE 58 EDITION 58 | OCTOBER 2015 MAPAL TECHNOLOGY MAGAZINE IMPULSE FROM THE COMPANY TECHNOLOGY HIGHLIGHTS PRACTICE REPORTS Cover story: Additively manufactured hydraulic expansion chucks 2» |EDITORIAL MAPAL IMPULSE 58 Dear readers, hydraulic clamping technology, we have managed to develop a globally dear business friends, unique product thanks to the use of an additive manufacturing method: the HighTorque Chuck with a narrow contour. This is a hydraulic clam- ping chuck that has the 3° contour associated with shrink fit chucks for at EMO too, we have again prepared for you a wide range of new and machining in areas with a critical interfering contour. “Here we have the improved products. We are not thinking just exclusively in terms product advantages of two worlds that combine the hydraulic clamping and the innovations, but are also focussing on new production and machining shrink fit technology into one product.” processes as well. Such product innovations are only possible because we have been wor- One focus of our development activities this year has been on further king for some time with the innovative technology of laser melting and developing our range of standard clamping technologies. In the field of already use this process in the series production of drills and reamers. “Regardless of whether it is a standard or a special tool, comprehensive services or new business models, with MAPAL as a partner, you will always get an economical and efficient solution that gives you a distinct competitive advantage.” Another main focus that we are engaged in is digitisation. Industrial always get an economical and efficient solution that gives you a distinct services are an important element of industry 4.0. Digitisation, this is competitive advantage. the recording and use of information for developing networked pro- duction processes, gives a new dimension to precision tools. A tool no We wish you an enjoyable read longer consists merely of hardware, but also of the accompanying data and services. We are developing corresponding models and are presen- ting the first milestones at EMO. Regardless of whether it is a standard or a special tool, comprehensive services or new business models, with MAPAL as a partner, you will Dr. Dieter Kress Dr. Jochen Kress 4 | MAPAL IMPULSE 58 13 06 10 12 14 2024 28 FROM THE COMPANY EMO 2015 | Milan _____________________________ 06 Innovations 2016 ______________________________ 08 MAPAL Dialog ________________________________ 10 New production site in Eppingen _________________ 24 MAPAL Group – growing worldwide _______________ 26 Technology day in Cologne ______________________ 32 Particulars ___________________________________ 34 Technology report _____________________________ 35 Press conference ______________________________ 48 CONTENTS 24 32 34 48 36 40 43 50 58 60 14 28 44 50 54 TECHNOLOGY HIGHLIGHTS PRACTICE REPORTS Modern materials sciences _______________________________12 Brabant Alucast: Successful together ___________________ 14 Tritan-Drill | Drilling heat-resistant steels economically _________20 TOYOTA Motorsport GmbH: En route at full throttle Additive manufacturing | Hydraulic clamping technology _______28 towards digitalising CNC production ___________________ 44 Networked complete solutions | Industry 4.0 _________________36 Boehringer Ingelheim microParts: Interview: Good prospects in aircraft manufacturing ___________40 Laser marking with an added advantage ________________ 54 Manufacturing micro tools reliably ________________________43 The future of HSK is dynamically balanced ___________________50 Productivity increase in valve machining ____________________58 Spotlight: Spring-loaded guide pads _______________________60 IMPRINT Edited by: Andreas Enzenbach (V.i.S.d.P.), Patricia Müller, Sabine Raab, Dr. Thomas Utz, Dieter Gsaenger, Christian Molch, Uwe Rein, Franz Joachim Roßmann Pictorial sources: fotolia, istockphoto, MAPAL, Franz Joachim Roßmann Layout and design: Inge Rettenmaier Publisher: MAPAL Präzisionswerkzeuge Dr. Kress KG P.O. Box 1520 | D-73405 Aalen | Telephone +49 7361 585-0 | Fax +49 7361 585-1029 | [email protected] | www.mapal.com Printing: Offizin Scheufele, Stuttgart | Print run: 16,000 copies in German, 14,000 copies in English © MAPAL Präzisionswerkzeuge Dr. Kress KG | reproduction, even in part, only with the approval of the publisher. 6 | MAPAL IMPULSE 58 THE HIGHLIGHT OF THE EXHIBITION YEAR EMO IN MILAN, ITALY This year Milan is the exhibition venue for EMO, Europe‘s largest contour will be included for the first time. The new cutting material exhibition for metal cutting. Under the slogan „Let‘s build the future“, series for the machining cast materials is celebrating its exhibition dé- around 1400 exhibitors are presenting themselves from 5 to 10 October but. MAPAL is presenting the powerful Tritan-Drill in numerous special 2015 to international visitors and showing new products and the latest designs, showing new chucks for micro cutting and presenting setting developments in rational and advanced metal cutting. devices as elements for digital tool data management. One of the hot topics at this year‘s EMO is additive manufacturing. As a At the MAPAL stand C08 D09 in Hall 10, you will learn about the leading manufacturer of precision tools in this area, MAPAL is introdu- innovations at MAPAL in the automotive, aerospace, wind energy and cing additively manufactured tools in a special presentation at its stand. services sectors. Additively manufactured hydraulic expansion chucks with a narrow TOOL TRADERS PARTNER BECK | MILLER | WTE ENGINEERING / AEROSPACE / INDUSTRIES WIND ENERGY AUTOMOTIVE AEROSPACE WIND ENERGY SERVICES VISIT US! HALL 10 C08 D09 LASERPLUSS AUTOMOTIVE / AUTOMOTIVE SERVICES 8 | MAPAL IMPULSE 58 NEWS AND HIGHLIGHTS… … FOR EMO – A SELECTION 1 REVOLUTIONARY COUNTERSINK PROGRAMME EXTENDED More diameters for excellent results Last year, MAPAL introduced a completely new generation of counter- Previously, countersinks which lifted the counterboring process to an sinks. The cutting edges of these countersinks are extremely unequally entirely new technological level were available in five different diame- spaced. Therefore, the axial force is reduced by more than 50 percent ters, from 6.3 to 25 mm. MAPAL has expanded this range significantly. compared to that of conventional countersinks. This results in less vibra- The new diameter range which are available from diameter 4.3 to tion of the tool. Furthermore, there is greater precision of the counter- 31 mm has been adapted to DIN standard 335C. bore, greater accuracy and better surface quality. In addition to the already available sizes, the following diameters The reduced load on the machine increases the service life of the tools. are also available: In addition, thanks to its smooth, stable operation, the countersink can 4.3 | 6.0 | 8.0 | 8.3 | 10.0 | 11.5 | 12.4 | 15.0 | 19.0 | 23.0 and 31.0 mm be driven with higher cutting parameters, resulting in significant time savings. 2 HPR RING REVOLUTIONISES VALVE SEAT MACHINING Process valve seat rings and guides quickly, effectively and with a high degree of accuracy Previously, tools for the machining of valve seats and valve guides in The cutting forces are optimally distributed on the tool. As a result, a cylinder heads were usually used with axially adjustable inserts. Setting tenfold service life of the cutting edge can be achieved. In addition, you them accurately is complex and demanding. Generally, only one cutting can work with more than three times the feed rate. The tool concept edge is used per angle in the valve seat ring. proves itself through higher cutting speeds and hard cutting materials and ensures higher quality. To simplify this process considerably and to perform it in a much shorter time, MAPAL has developed a tool concept which processes the three The tool for machining valve seats and valve guides is modular and angles on the valve seat ring, each with three brazed PcBN cutting includes two tool interfaces. On one hand, there is the above-mentioned edges, in just one step. The centrepiece is the machining ring with nine short taper connection for the machining ring. On the other hand, there cutting edges, i.e. three per angle. This machining ring is mounted with is an additively manufactured hydraulic clamping chuck for receiving a high degree of precision both radially and axially on a short taper con- the multi-bladed reamer with PCD cutting edges for finishing the valve nection, which results in the cutting edges being positioned precisely. guide. The tension is very easy to achieve through the pressure screw. For replacement, only the threaded disk needs to be loosened. This en- sures drastically reduced setting times and very easy handling. NEWS AND HIGHLIGHTS… … FOR EMO – A SELECTION 3 EXTREMELY RESISTANT EVEN UNDER HIGH LOADS New cutting material series based on a CVD coating for the drilling of all cast materials Tools with ISO cutting edges are the method of choice when it comes to HC725, HC730 and HC735 differ through the carbide substrate used. the drilling of cast materials. Considering the demand for high cutting All four are effective due to the extremely heat-resistant α-aluminium speeds and technologies for cooling, the demands placed on tools and oxide coating with excellent adhesion. Cutting inserts with the new cutting edges are increasing. Very good friction and wear behaviour as coating offers the potential for a substantial increase in the average well as a high degree of heat hardness on
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