270 BORING | Custom solutions

CUSTOM SOLUTIONS FOR BORING

USING PCD TOOLS
Custom solutions with PCD cutting edges are
the first choice if it is necessary to machine
large quantities of aluminium and die cast
aluminium parts reliably and cost-effectively.
By using modern CNC controllers and laser
technology, today it is possible to manufac-
ture just about any cutting geometry reliably
– and that with manufacturing tolerances
from ≤ 3 µm on the tool diameter. The combi-
nation of several machining operations in one
tool is particularly worthwhile. The saving in
tools and reduction of non-productive times
increases the cost-effectiveness in production.
The manufacture of a stepped bore on which
all chamfers and radii are machined is solved
using a PCD boring tool with several steps. In
this way the concentricity of the individual
steps is guaranteed. The machining of axial
recesses or spot facing of contact surfaces
can also be solved cost-effectively using one
drilling tool. Flatness requirements or angular
accuracies can be achieved much more eas-
ily than with conventional turning or circular
movements, as there are no radial forces act-
ing on the workpiece.

Polycrystalline diamond - PCD Competence centre PCD Highest precision

PCD is very important for machining alumini-
um, non-ferrous metals and increasingly also
CFRP and other modern workpiece materials.
At approx. 1,500 °C and a pressure of approx.
60 kbar, synthetic diamond particles are sub-
jected to a sintering process together with a
carbide substrate. The result: a cutting mate-
rial with the hardness and wear resistance of
diamond, the hardest mineral on Earth. The
carbide substrate gives the cutting material
the necessary ductility and in daily machining
provides the best prerequisites for brazing the
cutting edges to a suitable carrier.
With an annual manufacturing capacity of
120,000 PCD tools, the MAPAL competence
centre for PCD tools in Pforzheim is the
world's leading development and production
facility for PCD tools. High quality standard in
conjunction with highly qualified staff guar-
antee first-class production results. Due to the
usage of the latest manufacturing technology
as well as the usage of laser technology, it is
possible to realise reliably almost any cutting
edge geometry.
The PCD cutting edges ground to the µm stand
for the highest precision. Manufacturing tol-
erances from ≤ 3 μm for the tool diameter are
reliably achieved. Highest machining quality is
guaranteed for dimensions, surface finish and
shape. Laser machined chip guiding stages,
chip breakers and chip formers make possible
optimal chip removal and prevent chip con-
gestion. The modular design ensures the high-
est radial run-out accuracy. Due to axial and
radial adjustment features the radial run-out
can be adjusted precisely and reliably.

Complex geometries
The usage of laser machining makes possible
the precise manufacture of highly complex
cutting edge geometries as well the realisa-
tion of extreme rake and helix angles. Twisted
PCD boring tools have crucial advantages over
their straight-fluted equivalents. They make
possible extremely short machining times and
very high machining quality. Highly positive
rake angles reduce the cutting forces required.
This aspect is very important on machining
delicate or unstable parts and in unstable
clamping systems.
Innovative solutions
Development of reliable solutions based on the
latest machining strategies such as minimum
quantity lubrication (MQL) for example. The
number of process steps is reduced and the
non-productive times shortened by the usage
of combination tools. PCD boring tools with
several steps guarantee the concentricity of
stepped bores. Precisely embedded PCD seg-
ments that are matched exactly to the related
step geometry ensure outstanding results in
relation to quality and productivity.
BORING | Custom solutions 271
Custom solutions
Boring
Reconditioning
With each reconditioning the service life of
the PCD boring tools is significantly increased
and costs for new tools saved. The customer
receives tools that can be used immediately
for the trouble-free achievement of the tool
lives already familiar. The tools are collected
from and delivered to the customer by courier.
The standardised process ensures straightfor-
ward, fast processing within a few days.
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Innovative tool concepts with PCD

MAPAL manufactures twisted PCD tools with crucial advantages com-

pared to straight-fluted tools. The tools can be flexibly designed to the
process, for example for minimum quantity lubrication. HSK designs
and modular systems that can be aligned ensure optimal results.

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Custom solutions PCD
1 Step drilling tool with adjustable and interchangeable reverse machining for
machining a differential housing made of aluminium
2 Multi-stage boring tool for machining a steering gear box / steering rack tube
made of AlSi9Cu3 with titanium tool body with a tool weight of only 5.5 kg
despite extreme dimensions. With this tool very high cutting values are possible
3 Custom PCD milling tool with several milling applications in one tool
4 Twisted step boring tool for machining a steering gear box made of AlSi9Cu3
with module interface that can be aligned. Due to the twisted design,
very soft cut and mechanical chip conveying
BORING | Custom solutions 273
Custom solutions
6
Boring
5 Step boring tool for machining a bearing bore with integrated fine adjustment
feature for the pilot on a camshaft bore in a cylinder head cover made of
AlSi9Cu3Fe for a process with minimum quantity lubrication
6 Boring tool of lightweight design for machining a compressor baseplate
made of AlSi0Cu3. Due to the low tool weight very high cutting values
are possible and the load on the spindle is reduced
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Innovative tool concepts with PCD

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Custom solutions
Boring

Custom solutions PCD

1 Circular application for duct machining for a throttle valve. High stability of the carrier
due to laser machined cutting edges, as a consequence very high machining quality
2 Combination tool with replaceable disc. The primary load on the milling cutter is
during face milling, for this reason the front cutting edge area has been designed as an
interchangeable "disc" to keep the repair costs low
3 Twisted step drilling tools for machining the bolt bore in an alloy wheel with Z=3
for higher machining quality and tool lives
4 Combination drilling-milling tool with PCD insert and ISO indexable inserts made
of carbide for machining a rear frame made of AlSiMg0.3. The cutting edges with
the most load are designed so they are interchangeable, as these machine
the raw cast iron and are therefore subject to the most load
5 Custom PCD milling tool for gearbox machining with several machining operations
in one tool
6 Circular milling cutter for machining a thermostat housing made of AL380.
The number of cutting edges is 1+1+1. Version for even higher machining quality
due to more stable design
7 Step boring tool for internal and external machining on a gearbox housing made
of AlSi9Cu3Mg
8 Multi-stage PCD boring tool for "one-shot machining" on an electric motor housing
made of AlSi9Cu3Fe of hollow design for weight reduction
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CUSTOM SOLUTIONS FOR BORING

USING ISO TOOLS
During the planning of new machining pro-
cesses as well as the optimisation of exist-
ing processes, the focus is on the assessment
of the machining time and the Cost Per Part
(CPP). By means of intelligent, multi-stage,
multi-cutting edge ISO combination tools or
complete machining tools, both the produc-
tive times and the non-productive times can
be significantly reduced. Here the design of
intelligent tool solutions is not limited to just
the ISO area. To prepare a solution that is op-
timal for the customer, different machining
systems are combined into so-called hybrid
tools.
ISO tools from MAPAL meet both the require-
ment for process reliability and the require-
ment for straightforward handling – with in-
telligent and precise adapter solutions along
with reliable, quick indexable insert mounting.
The reliable principle of operation of MAPAL
ISO tools is ensured by the latest design meth-
ods that make it possible to assess collisions
or to determine tool restrictions even during
the planning phase. Production in the latest
manufacturing facilities guarantees maximum
tool precision.

Process solutions Design and production Modular construction

To reduce productive and non-productive
times simultaneously, MAPAL offers particu-
larly high-performance complete machin-
ing tools. Reduced cycle times, lower energy
consumption and the related higher cost-
effectiveness are the result. Among the suc-
cess stories of processes optimised by MAPAL
specialists there are some applications where
it was possible to save up to 60% of the ma-
chining time.
The latest 3D design and computer-aided
studies make it possible to develop and de-
sign complex tangential tools. The data on the
insert seats and chip spaces exactly defined
in this manner and other machining tasks are
sent via a CAM interface to the controller for
high-accuracy, high-performance 5-axis ma-
chining centres. In this way MAPAL ISO tools
are produced with monitoring and control by
experienced staff. Highly accurate manufac-
turing tolerances are required and met. This
aspect guarantees a real multi-cutting edge
capability and the high performance of the
tools.
The modular design of ISO combination tools
makes it possible to machine entire part fami-
lies with a few tools as only one part of the
tool must be replaced. By using connections,
for instance a highly accurate HSK-C connec-
tion, particularly complex tools can be con-
structed. More machining steps are combined
into one tool and the productivity increased
further.

Tangential technology
Crucial for the high performance of the MAPAL
ISO tools is tangential technology. Compared
to the usage of radially mounted indexable
inserts, this technology permits the usage of
more cutting edges with the same power con-
sumption. As such, higher machining values
and a higher machining volume are possible.
Tangential tools also feature very smooth run-
ning. As a result excellent tool lives and very
good part qualities are achieved.
Cutting edges
In the area of ISO boring and milling tools
MAPAL offers a wide selection of geometries
and cutting materials. Due to the compre-
hensive programme it is ensured that the
right cutting edge can be used for every ap-
plication. Along with the different shapes and
sizes, this programme also includes cutting
materials such as carbide, ceramic and PCD
or PcBN-tipped indexable inserts. This vari-
ety has a positive effect on cost-effectiveness
and the efficiency of the usage of resources.
As depending on the application, up to eight
cutting edges on the indexable inserts ensure
that the cutting material is optimally utilised.
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Custom solutions
Boring
Exact adjustment
For the cases in which high-accuracy index-
able inserts and precision milled insert seats
are insufficient for the required accuracy,
MAPAL uses an adjustment system specially
developed for ISO inserts. Here the insert sits
on an adjusting wedge with a large contact
area. This feature is completely embedded in
the tool body and as a result offers the index-
able insert a stable seat. The adjusting wedge
has an angled surface and can be moved using
a left-hand - right-hand adjusting screw. This
design produces an indirect, very accurate and
easy to use setting feature.
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Innovative tool concepts with ISO indexable inserts

MAPAL ISO tools unfold their possibilities particularly in the context

of complete projects in which they are able to deliver significant
advantages due to the combinations and high productivity. Together
with tailored services and the complete tool package, MAPAL is able to
design parts optimally in accordance with customer requirements and
provide support.
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Custom tools for boring
1 Tool with guide pad technology for optimal support on machining a spindle on a
rotary table machine with a length of over 1000 mm
2 Tangential construction makes possible the complete countersinking of the shaped
contour on a rotor bore in a turbocharger made of highly heat-resistant materials
using minimum quantity lubrication
3 Machining the rotor bore in a compressor housing made of EN-GJL-250
with vibration damper on the face side
4 ISO combination tool with solid carbide insertion drill for brake bracket mounting
and for multi-step machining of a hub carrier made of EN-GJS-500-7
BORING | Custom solutions 279
Custom solutions
Boring
5 Special tool for steering knuckle manufacture for roughing and semi-machining,
incl. edge breaking and recess milling and additional insertion drill
6 Ultra lightweight combination tool with tool body parts made of CFRP, radial
and tangential indexable inserts for machining the main train in a gearbox housing
made of aluminium alloy with a silicon content between 7-9 %
7 Combination tool for the multi-stage machining a heavy-duty gearbox
made of EN-GJL-300
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Innovative tool concepts with ISO indexable inserts

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Custom tools for boring
1 Multifunctional ISO combination tool of modular construction machines, as well as
the complete contour on the output side from the inside, the contour of the protective
tube side opposite
2 ISO combination tool of monolithic construction for machining an automotive suspen-
sion arm. Four work steps, roughing and fine machining the bore as well as milling
the front and rear including chamfer machining are undertaken in one process
with this tool
3 Special tool with spring-loaded guide pads for roughing the main bearing bore and
the face surface as well as the external machining of an automotive stub axle made
of 38MnVs6 with interrupted cut at the bore outlet
4 Special tool for roughing and pre-machining the piston rod guide on a juice press
made of S355J0. The spring-loaded guide pads dampen and guide the tool over the
entire machining length of 3000 mm
5 Tool with spring-loaded guide pads for roughing and pre-machining the piston bore
with a length of 6xD on a large hydraulic valve in EN-GJS-500-7 while maintaining
the concentricity to an existing bore in opposite direction
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Custom solutions
Boring
5
Spring-loaded guide pads
Spring-loaded guide pads are a tool concept that makes the machining
of bores with medium to large diameters and long projection lengths
significantly more productive and above all more reliable compared to
spindle and turning tools. Spring-loaded guide pads make possible
smooth machining and high cutting values. The spring-loaded guide
pads are positioned such that the resulting spring force ensures that the
fixed guide pads lie perfectly against the material of the bore and sup-
port the tool. This guarantees smooth machining even with fluctuating
stock removals or wear of the inserts. Very good bore qualities are
achieved even with high cutting values.