MAPAL Inc

Port Huron,  MI 
United States
http://www.mapal.us
  • Booth: 1609

MAPAL designs special tools customized especially for our customers to their specific applications. Our tools satisfy incredibly tight tolerances, solve machining challenges and improve overall processes through creativity, engineering expertise and a familiarity with cutting technology. We offer a full line of drilling, PCD, Reaming, Fine Boring and ISO tools, as well as holders, setting devices and clamping systems.


 Press Releases

  • The fuselage, wing, flaps as well as the horizontal and vertical tail of the latest generation of aircraft are produced out of CFRP aluminium stacks. For the assembly of aircraft, innumerable bores including countersinking are drilled in these components for the rivet connections. In most cases drill feed units are used for machining. The dimensional accuracy of the bores is crucial. The bore must feature exactly the same diameter in both materials. Drilling always takes place from the outside to the inside - bore entrance and countersinking in CFRP, bore outlet in aluminium.

    Previously minimum quantity lubrication (MQL) was applied for this manufacturing step. After machining, the components had to therefore be disassembled, cleaned and remounted. In addition machining was often carried out in several successive machining steps. Different tools were used for drilling, reaming to the final diameter and countersinking. The complete process was therefore time-consuming, costly and the required dimensions were often not reliable. For example, the bore and countersinking often did not align on one axis.

    To optimise this process, MAPAL has developed a drill with countersink step for dry machining. The special geometry of the tool ensures that the heat caused by machining is not transferred to the component. As a result, MQL can be eliminated and neither the component nor the working environment are contaminated with coolant.

    The drill two cutting edges made of solid carbide combines the properties of a drill for machining aluminium with those of a drill for CFRP machining. It also has a double point angle. This ensures good centring of the drill and minimum burr formation at the bore outlet. Reliable removal of the chips is ensured by the specially designed chip spaces. Any delamination and fibre protrusion is to be avoided for the countersinking in the CFRP. MAPAL achieves this with a rake face correction at the countersink step. As CFRP is an extremely abrasive material, the drill is diamond-coated. This means that eight times the tool life is achieved compared with an uncoated drill.

    The drilling/countersinking tool for the dry machining of CFRP aluminium stacks has been successfully used by customers. A speed of 5,000 rpm and a feed of 0.1 mm are applied. The tool is not only impressive in practice because of the results with regard to process reliability, tool life and the machining result, but also because of the steady boring process. The drill is available with a diameter between 4.1 and 11.11 mm with the associated countersink step.

  • Strong clamping, simple handling, improved run-out

    In many production facilities, Weldon tool holders are used as the standard chuck for solid carbide milling cutters. However, the design of this type of chuck limits its application. Indeed, the tolerances of the fit for the tool adapter are high (at a clamping diameter of 20 mm, the maximum clearance is already 22 µm). This results in a large run-out error that causes imbalance, as well as wear on one side of the tool, creating adverse effects on machining quality. The tolerance of the tool’s clamping surface is not precise enough to be used for axial fixing, which means there isn’t always a secure connection between the clamping screw and clamping surface. This can hinder process reliability. Reliably clamping a tool in a standardized Weldon tool holder also requires a high clamping force, which can only be achieved by using a torque wrench.

    In contrast, the new side lock chuck from MAPAL impresses with its strong clamping, simple handling and greatly improved run-out. The locating bore is accurate down to the single-digit µm range, meaning that it is manufactured with far greater precision compared to previous versions. This reduces the radial clearance of the clamped tool and greatly improves the run-out. In addition, in order to compensate for the large tolerance on the lateral clamping surface, MAPAL has used a patented spring element in the tool holder, which makes it possible to achieve a well-defined form fit between chuck and tool. Also, cooling ducts in the clamping area, parallel to the axis, ensure better coolant distribution.

    A two-piece clamping element is used to make handling much easier. This allows the tightening torque to be reduced, while maintaining the same level of clamping force. As a result, the tool can reliably be clamped by hand, without using a torque wrench.  

    New side lock chucks for cylindrical shanks are available with clamping diameters of 12 to 32 mm for HSK-A100 and HSK-A63