4032 Dove Rd
Port Huron,  MI  48060-7442

United States
  • Booth: 1813

MAPAL is the leading international supplier of precision tools for the machining of practically all materials. The company founded in 1950 supplies leading customers from the automotive and aerospace industries and from machine and plant engineering. With its innovations the family-owned company sets trends and standards in production and machining technology. MAPAL sees itself as a technology partner, supporting its customers with the development of efficient and resource-conserving machining processes using individual tool concepts. The company is represented with production facilities, sales subsidiaries and representatives in 44 countries worldwide. 

MAPAL USA was founded in 1977 as the first sales subsidiary abroad. Along with the sale of the complete MAPAL product range, the tool specialists are trained in the engineering area. A fully equipped production facility produces tools for the American market to consistent quality standards. Design and production planning are also undertaken at MAPAL Inc. in close contact with production to ensure MAPAL quality.

 Press Releases

  • The international MAPAL Group posted growth of almost five percent in 2018. “The results that we achieved last year are quite satisfactory,” says Dr Jochen Kress, President of the MAPAL Group. Consolidated Group turnover climbed from €610 million in 2017 to €640 million in 2018. In addition to turnover, the number of employees also increased. The precision tool manufacturer now has more than 5,500 employees worldwide, with over 3,600 in Germany.

    MAPAL has consolidated and further expanded its position in all major regions. To achieve this, substantial investments in the locations were made in the past year. “In Asia, we founded a new joint venture in Vietnam and acquired the majority stake in ADICO, a manufacturer of PCD and PcBN cutting materials,” specifies Kress. Asia is still the second most important market for MAPAL after Germany, even though growth rates in China have decreased somewhat in line with the country’s overall economic growth.

    The Group is also strengthening its presence in the Americas. “We have expanded our location in Fountain Inn, South Carolina,” explains Dr Jochen Kress. A completely new plant was also opened in Mexico in February 2019. In Germany, capacity at the Centre of Competence for solid carbide tools in Altenstadt is currently being increased with a new production hall. In addition to new buildings and expansions, there are continuous investments in new machinery all around the world in order to maintain the highest level of quality and productivity.

    MAPAL is increasing its involvement in various industries, including tool and mould making. There are challenges ahead in the automotive industry, too, says Kress: “We intend to build on our leading position in machining components for electric vehicles.”

    There is also a continued focus on digitalisation and thus on MAPAL’s subsidiary c-Com, which has broadened its focus. “We have seen in practice what many companies are lacking, especially small companies, and that is something that makes access to the digital market easier for them,” says Kress. For this reason, c-Com offers a range of modules that help companies get started in this area. These include the module for efficient regrinding handling and the new c-Connect Box to make machine monitoring easy.

    “2019 is certainly going to be an interesting year, both economically and politically,” concludes Dr Jochen Kress. “Whatever it brings, we have confidence in our capacity for innovation and our flexibility, which are based on our employees’ skills.”
  • Vibration often occurs during machining. This leads to dynamic instability of the system. Inadequate surface finishes, insufficient accuracy, high machining noises, shortened tool lives and, in extreme cases, broken tools and cutting edges can be the result.

    In order to minimise these vibrations and their consequences, MAPAL has now developed an innovative system for vibration damping in the tool shank, as particularly tools for boring and milling with very long projection length tend to vibrate due to an inadequate dynamic rigidity of the overall system. When designing the new system, the developers took into account all factors arising from the interaction of the machine tool, the tool and type of clamping as well as the component. The result: A system for vibration damping that is matched to all common types of machine stiffness. It can be used for machining different materials with different tools.

    The self-contained system of auxiliary mass and several steel spring packages counteracts the deflection of the tool body and minimises it. The vibrations can be up to 1,000 times lower compared to tools without absorber system. Despite the long projection length, quiet, stable running is achieved. This makes it possible to work at higher cutting speeds and significantly increases the material removal rate.

    In addition, significantly better surface finishes are achieved thanks to vibration damping. When milling case hardened steel (16MnCr5), for example with a 250 mm long combination of milling cutter arbor and milling cutter with five cutting edges and ISO indexable inserts (diameter 50 mm), the Rz value was halved from 7.8 µm to 3.9 µm for material removal ae of 18 mm and ap of 3 mm compared to the same tool system without vibration damping.

    Milling cutter arbors with vibration damping in the shank are available with internal coolant supply for clamping diameters 16, 22 and 27 mm with a length of 200 and 300 mm for SK40, SK50, HSK-A63 and HSK-A100 connections.

  • Fine machining of small outer diameters is often dealt with using grinding processes. External reaming makes an interesting – and cost-effective – alternative. For example, if an IT6 fit needs to be created on a lathe in a series production setting, external reamers with adjustable insert and guide pads can be relied upon to get the job done. This requires the tool’s diameter and the back taper of the insert to be set with pinpoint accuracy.

    Making that as simple as possible was what MAPAL had in mind when it developed the EA (EasyAdjust) system. With the EA system, the back taper of the insert is already integrated in the cassette that serves as insert holder. So there is no need to go through the process of setting the back taper of the minor cutting edge. The only thing that needs to be set is the overhang of the insert with regard to the guide pads. This is generally a quick and simple task. However, that has previously been the case only up to a certain diameter. In the case of external reamers with small machining diameters, setting is still quite a challenge. A measuring sensor has to be inserted into the external reamer, zeroed to the guide pads and located at the cutting edge to set the corresponding overhang. A procedure that is aggravated by a very limited view of the inside of the tool. This calls for a certain amount of skill on the part of the worker, as well as the right training.

    New system for easy setting

    MAPAL has developed a new system to make setting external reamers with small diameters a much simpler process. This involves the cassette of the EA System being integrated in an additional cassette. This cassette can be removed, and the insert can be set quickly and easily using a micrometer or a surface plate. The appropriate setting dimension for the insert is engraved on the reverse of the tool. This dimension corresponds to the midpoint of the tolerance for the fit to be created.

    Once setting is complete, the cassette is mounted again. The changeover accuracy reaches 2–3 µm. Thanks to this changeover accuracy and the extraordinary simplicity of setting the insert, the new system means that it is now much easier to comply reliably with the required tolerances and extremely precise fits, even in the case of small diameters.

    The EA System can be used with indexable inserts with four or six cutting edges.

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