Cushioning in the tool shank
Better surface quality thanks to vibration damping
Vibrations often occur during machining. They lead to dynamic instability of the system. This can result in inadequate surface quality, insufficient accuracy, high machining noise, shortened tool life and, in extreme cases, broken tools and cutting edges.
In order to minimize these vibrations and their consequences, Mapal has developed an innovative system for vibration damping in the tool shank. This is because tools for boring and milling with very long overhangs in particular tend to vibrate due to insufficient dynamic rigidity of the overall system. When designing the new system, the developers took into account all factors resulting from the interaction between the machine tool, the tool and its clamping as well as the component. The result: a vibration damping system that is adapted to the rigidity of all common machine types. It can be used for machining different materials with different tools.
The self-contained system of auxiliary mass and several steel spring assemblies counteracts and minimizes the deflection of the base body. Compared to tools without an absorber system, the vibration amplitudes can be up to 1,000 times lower. This ensures smooth, stable running despite the long overhang. As a result, higher cutting speeds can be achieved and the metal removal rate can be significantly increased. In addition, considerably better surface qualities are achieved thanks to the vibration damping. When milling case-hardened steel (16MnCr5), for example, with a 250 mm long combination of milling cutter arbor and five-edged milling cutter with ISO indexable inserts (diameter 50 mm), the Rz value was halved from 7.8 µm to 3.9 µm with a 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 guidance for clamping diameters of 16, 22 and 27 mm with a length of 200 and 300 mm for holders SK40, SK50, HSK-A63 and HSK-A100.
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