MAPAL Ltd

The new high-precision CFS connection system from MAPAL, a world leader in precision machining solutions, now enables machine tool users to enjoy the substantial cost savings associated with replaceable-head tools without sacrificing accuracy or convenience. This development is particularly important in the light of the continually rising price of carbide cutting materials. Designed from the outset with ease of use in mind, the new MAPAL CFS connection guarantees a radial run-out accuracy of 5 µm or better. This means that tool holders incorporating the CFS connection can be used as the primary system for drilling and milling, as well as for reaming. In addition, replaceable head tools using the new connection achieve the same service life as monolithic tools and so significantly reduce process costs.

In response to the rapidly increasing demand for accurate and dependable machining of large parts, precision cutting tool expert MAPAL has developed two new approaches to tool design. The first uses welded construction to reduce tool weight, while the second relies on the use of carbon fibre reinforced polymer (CRFP) tool extensions not only to reduce weight but also to enhance machining accuracy.

Precision machining expert MAPAL has been awarded its largest contract to date for a wind power project. The contract covers the tooling needed for machining three different components that are used in wind-power gearboxes, all of the components being manufactured from GJS, a form of cast iron with spheroidal graphite.

With newly developed cutters and its novel helix milling technique, MAPAL is now able to increase material removal rates in the machining of large diameter bores by up to 40% compared with conventional circular milling cutters. Designed for roughing of bores 150 mm or more in diameter, MAPAL’s new tangential cutters feature economical indexable inserts and provide optimised chip removal to extend tool life.

MAPAL, the world’s largest specialist supplier of machining solutions for cubic solutions has won the prestigious 2010 Supplier Award for Best Innovation Performance from ZF Friedrichshafen AG, a globally renowned expert in the development and manufacture of driveline and chassis solutions for the automotive industry. The award is one of only five made this year by ZF Friedrichshafen to its best performing suppliers.

With the new UNISCALE-M measuring machine from MAPAL, machine tool users now, for the first time, have a convenient and dependable way of eliminating the losses in productivity and profitability that inevitably result from inadvertently using damaged or out-of-specification cutting tools.

MAPAL is now offering a comprehensive range of cutting tools specifically designed to deliver optimum performance with the novel composite materials that are currently being widely adopted throughout the aerospace sector. Included in the range are diamond coated and PCD-tipped milling cutters and routers, as well as solid carbide and PCD-tipped drills.

MAPAL has secured a contract to develop, manufacture and supply custom high-performance milling and scanning tools for a major new aircraft production line in the UK. The ultimate value of the contract, which initially runs for three years with an option of a further two years and beyond, depends on factors that can only be determined as the project progresses, but is confidently expected to be multi-million Pound.