In mid-May, the precision tool manufacturer Mapal invited 150 customers and people interested in machining to the "Dialog" expert day in Aalen, Baden-Württemberg. The two one-day events at the headquarters of the precision tool manufacturer focused on new developments in the machining of steel and cast iron materials. Mapal comes from steel and cast iron machining, said Dr. Jochen Kress, Managing Partner of Mapal: "This is where our roots lie, even if many users perceive us primarily in the field of aluminum machining." As part of the expansion of its core business, Mapal has focused intensively on these materials in recent years. On the one hand, the geometry of the tools was examined, and on the other, the use of new high-performance coatings. "We have built up a lot of expertise in the process," said Kress. The company has its own coating systems and a large analytical department. This means that not only the tools themselves, but also the materials can be analyzed in detail. Mapal also works closely with universities and scientific institutes in its development and research work.

Prof. Dr.-Ing. Dirk Biermann, Head of the Institute of Machining Technology at the Technical University of Dortmund, gave an insight into one of these research projects. The project was based on a central application, a component for a major car manufacturer. Biermann explained the optimum process strategy for helical deep drilling with solid carbide tools and the influence of minimum quantity lubrication on the temperature development during component machining. Biermann and his team also investigated the changes caused by the machining process on the edge zones of the components and how additively manufactured tool holders can be used for vibration damping during turning, with results that were as astonishing as they were interesting.

Ulrich Krenzer, Managing Director of Mapal's VHM Tools Competence Center in Altenstadt, and Jochen Schmidt, Mapal Product Manager Clamping Technology, presented "best practice" examples and new chucks. First of all, Krenzer demonstrated that a three-edged drilling tool delivers top performance in cast iron and steel. When machining an axial piston pump, the machining time was halved with a three-edged cutter compared to a two-edged drill, and the tool life also increased from 5,400 to 10,800 holes. Jochen Schmidt pointed out the advantages of additive manufacturing in hydraulic expansion technology. The clamping area can be placed closer to the point of action and the chucks offer more stability. This allows better cutting parameters to be achieved and increases process reliability. "This has a huge impact on the cost-per-part (CCP) calculation," emphasized Schmidt.

Markus Zapke, Team Leader Tooling, Equipment & Processes at the Siemens gas turbine plant in Berlin, reported on the challenge of machining the blade groove of a large gas turbine. Siemens usually uses broaching, a machining process for the production of internal and external profiles, to machine the groove. "In this case, the grooves were too deep and we would have had to purchase a new machine." They turned to Mapal. Within a short space of time, special tools were developed for milling, enabling the groove to be machined smoothly.

Other speakers devoted their presentations to increasing tool life through the use of high-performance coatings, as well as new tools and methods for chip removal. Another topic was the digitalization of manufacturing processes and the intelligent networking of machines.

At Mapal's research and development center, the participants saw the performance of the tools live on the machining centers. Among other things, trochoidal milling, high-performance machining with the MEGA-Speed-Drill-Steel and Tritan-Drill-Steel drill series and the OptiMill-Uni-Wave milling cutter series were presented. Also in focus: a new chip breaker for steel and a range of milling cutters with radial ISO indexable inserts for machining steel and cast iron. Mapal's development engineers and technicians provided visitors with information and answered questions.

During the breaks, participants were encouraged to exchange ideas with each other, but also to talk to the speakers, Dr. Jochen Kress and the product specialists from Mapal. An accompanying product exhibition showed other sectors and fields of application in which Mapal is active, such as tool and mold making, digital tool logistics and the field of e-mobility in the automotive and two-wheeler industry.