Stator housings of an electric motor place particular demands on precision for machining . The weight-optimised fine boring tool with HPR400 technology for machining the stator housing fulfils all requirements for process reliability . © MAPAL
MAPAL has developed an extensive product and application portfolio thanks to many years of experience and countless proven solutions in the field of aluminium machining .
demands on process stability , consistent parts quality and attractive price levels .
One example of special requirements are the electric motor housings . The large stator bore with a diameter tolerance in the IT6 to IT7 range as well as circularity and cylindricity of 20 to 30 µ m or less , combined with other functional surfaces for accommodating rotors and transmission elements , requires the highest degree of precision with regards to shape and precision tolerances .
The large battery trays are another example . Their main structure consists of extruded profiles made of aluminium with low silicon content . The challenges here are to keep chip and burr formation under control and to machine the very large parts using economical cutting data without vibration . This also applies to the trend towards mega and giga casting where large-scale structural parts are no longer made of individual parts but are cast as a single piece . The components ’ large size and tendency to vibrate call for special tool geometries for low-vibration machining with a high degree of precision . New long-chipping aluminium alloys whose machining characteristics must first be mastered represent a further , related challenge .
Aluminium is also used in many other industries thanks to its properties . Depending on production volume and number of variants , manufacturers use standardised machining solutions for parts where a significant amount of machining is required . Here too there are aluminium parts produced in high quantities , which require very sophisticated customised concepts . In fluid power , for example , parts like pneumatic valve housings and pneumatic cylinders are produced in large quantities . For industries with high variance and small quantity , standardised tool solutions make sense .
Wide-ranging product and application portfolio for aluminium
MAPAL has developed an extensive product and application portfolio thanks to many years of experience and countless proven solutions in the field of aluminium machining . The range includes established bore machining applications like fine boring , reaming and boring . MAPAL ’ s guide pad technology for fine boring achieves the highest degree of precision for diameter , circularity and cylindricity . For tools with fixed blades for reaming and boring , MAPAL offers a one-of-a-kind range for PCD tools . It includes everything from tools for a single diameter with chamfer to very complex tools for multi-stage bore geometries . For drilling into solid , there is also a large selection of solid carbide drills and drills with indexable inserts . Deep drilling and dry drilling are a particular challenge as special geometries and expertise are required for both .
For the milling of aluminium , MAPAL offers a broad range that includes face milling cutters , highvolume milling cutters , end milling cutters and special designs . Series with cassettes , inserts or a fixed design are available for face milling cutters , for example . PCD and different varieties of carbide are used as cutting material and can be supplied for various cutting depths in combination with the required surface finishes and profiles . In this way special cross-cut structures can be created for sealing faces , for example . In addition to the universally applicable range of end milling cutters made of solid carbide or with PCD blades , MAPAL has products that cater to special requirements such as high precision , parts vulnerable to vibration or highvolume machining .
Engineering for perfect aluminium machining
The product range and extensive manufacturing expertise form the basis for optimal machining processes for aluminium parts . But the tool itself is not the only factor . Only through the art of engineering can the wide-ranging product and application portfolio provide the perfect solution . And this is where MAPAL ’ s true strength lies . Considerable experience developing new solutions time and again for the production of aluminium parts make the tool manufacture a first-class solution provider in this area . And the customer takes centre stage here .
According to the MAPAL philosophy , the perfect solution can only be the one that is precisely tailored to the needs and requirements of the customer . The expectation is not over-engineering but rather machining processes designed based on requirements . MAPAL sees itself as a solution provider and technology partner and , as opposed to a conventional tool supplier , does not only consider technical aspects but also tries to put itself in the customers shoes . This customercentred focus is behind the “ Basic - Performance - Expert ” solution approach and enables MAPAL to tailor the tools to the customer ’ s requirements .
For further information , please visit mapal . com / en-int /
Issue 70 PECM 81