Under the product name OptiMill-3D, Mapal presented a new high-performance range of solid carbide milling cutters that have been specially developed for tool and mold making. © Mapal

New tools and indexable inserts

Under the product name OptiMill-3D, Mapal presented a new range of solid carbide milling cutters that have been specially developed for tool and mold making. "In addition to extremely heat-resistant coatings and special carbide substrates, these tools are characterized by dimensions and geometries specially adapted to mould making," explains Carsten Klein, who is responsible for the tool and mould making market segment at Mapal.

Mapal also presented a new range of milling cutters with ISO indexable inserts at EMO. This includes round insert milling cutters, high-feed and 90° corner milling cutters, ball nose and torus milling cutters as well as finishing cutters. © Mapal

At EMO, the tool specialist also presented a new range of milling cutters with ISO indexable inserts. This includes round insert milling cutters, high-feed and 90° corner milling cutters, ball nose and torus milling cutters as well as finishing cutters. The range of ISO indexable inserts covers cast iron, steel, stainless steel, non-ferrous metals and hardened materials up to 65 HRC. Different cutting materials and coatings are used depending on the material to be machined and the requirements.

"Today, we cover almost 100 percent of the needs of tool and mold makers," says Carsten Klein. This includes not only the aforementioned milling cutters, but also the complete range for drilling and reaming. For many milling tasks in tool and mold making, the focus is not only on tool technology. The programming of the machine, which is complex, is also crucial. Mapal supports users in this task and works closely with the relevant software manufacturers.

As a full-service provider, the company's offering also extends beyond the tool and its programming. Among other things, the company also supplies the appropriate clamping technology. "Our so-called 3-degree chuck has proven itself especially in tool and mold making," says Kress. The special feature of the high-performance chuck: with the HighTorque Chuck (HTC) with a slim contour, Mapal has succeeded in combining the advantages of hydraulic expansion technology with the three-degree taper familiar from shrink chucks.

Mapal has always offered tools that are also used in tool and mold making. © Mapal

Customized chucks

This is made possible by additive manufacturing. Thanks to it, the previously necessary soldered connection between the sleeve and base body can be dispensed with. This was not only a limiting factor in terms of chuck geometry, but also in terms of temperature resistance and torque transmission. Thanks to the geometric freedom, hydraulic expansion technology can also be used for large interfering contours on the component or for deep cavities in hard-to-reach places that were previously reserved for shrink chucks. "We adapt our chucks individually to the customer's machining requirements," explains Klein. In many cases, it is therefore possible to use standard tools instead of cost-intensive special tools.

One example of a service is Tool Management 4.0, which Mapal offers on the basis of the open cloud platform c-Com. © Mapal

In addition to tools, programming and clamping devices, the portfolio also includes the complete peripheral equipment for setting and measuring tools as well as output systems for storing and managing components. "We also support our customers with comprehensive services," says Klein. One example of such a service is Tool Management 4.0, which Mapal offers on the basis of the open cloud platform c-Com. "This means that the customer no longer has to worry about anything to do with the tools - we take care of storage, stocking, purchasing and reconditioning the tools," Klein explains. And all this with 100% transparency for the customer.

"Ultimately, the market will decide how well we will gain a foothold in tool and mould making," Dr. Kress points out. However, Mapal is hoping for good chances: "Not only can we score points as a complete supplier, we can also support our customers with our decades of experience." This is an aspect that has always characterized Mapal. Being on site, solving problems and meeting high expectations.
For the time being, the tool manufacturer is concentrating on tool and mold makers in Germany. "We want to gain even more experience in the industry," says Dr. Jochen Kress, "and then incorporate this when we increase our involvement worldwide."

According to documents from Mapal / ag