While lightweight construction with suitable materials and structures has always been an important topic for aviation, the use of aluminum to reduce weight has also steadily increased in the automotive industry and has received a further boost with electromobility. With decades of experience in the design, production and use of tools for aluminum machining, MAPAL is the leading technology partner for the machining of aluminum components.
Material expertise is the key to optimum machining processes
Aluminum and aluminum alloys are easy to machine. Because the cutting forces are low, users can achieve high cutting values and, in particular, long tool life with the right process design. However, aluminum alloys also have special properties that need to be mastered. In addition, the geometries of the components and the ever-increasing demands on tolerances and process capability contribute to challenges in the machining of aluminum.
Basically, aluminum alloys can be divided into the main areas of cast alloys, wrought alloys and powder metallurgical alloys, whereby the first two are mainly used for machining. In the case of cast alloys, the desired properties of the components are set using various alloy components and taking into account the corresponding casting process. When casting, the aim is to get as close as possible to the final shape of the component in order to simplify machining. This “near net shape” technology has established itself in mass production in particular.
For the machining of cast parts, the silicon content is the main decisive factor with regard to the alloy components, as this has a strong influence on both wear and tool life. The desired properties of wrought alloys are also influenced by alloy components, although the silicon content is very low here in order to ensure chipless formability. In order to achieve high strength and stability, as well as permanent strength, other alloy components are used. The result is cold or heat-treatable alloys that are processed into semi-finished products and then machined.
Solutions for part manufacturing and assembly in the aerospace industry
The aviation industry uses MAPAL tools both for part machining, i.e. the production of components that are assembled into sections of the fuselage or a wing, and for final assembly, in which the individual sections are assembled to form the entire machine.
During part machining of aluminum components, the component is very often machined from the solid material. Machining rates of more than 90 percent require efficient volume machining in order to machine as much raw material as possible in the shortest possible time. High-performance tools are an important key here. During final assembly, the tools must be able to meet widely varying requirements. Here, not only aluminum is often machined, but also other lightweight materials such as titanium or fiber-reinforced plastics in the same machining sequence. These so-called stacks as a combination of materials are a particular challenge, as the machining properties of the combined materials are very different, and the tool must meet these mixed requirements.
The aviation industry has always used aluminum for components to reduce weight. In addition to the favorable ratio of stability to weight, the material also meets other requirements such as corrosion resistance, durability and low embrittlement. This means that there is a high demand for machining solutions for aluminum in parts production, but also particularly in the final assembly of aircraft.
Higher reach with every kilogram saved
Weight reduction is also a key focus in the development of electric vehicles: after all, every kilogram less means a higher reach and less CO2. In the mechanical processing of components for electric vehicles, there are also those that can be mastered very well with known processes and tools. However, there are inevitably new systems and components in electric vehicles that have to be redeveloped due to their function in terms of geometry and precision, and/or material properties. The tool industry must have answers, especially when it comes to scaling production volumes within the automotive industry and the associated demands for process stability, consistent component quality and low costs.
One example of special requirements are electric motor housings. The large stator bore with diameter tolerances in the range of IT6 to IT7 and roundness and cylindrical shape of 20 to 30 µm or less, in combination with other functional surfaces for holding the rotor and gear elements, requires maximum accuracy in terms of shape and position tolerances.
Another example is large battery trays, whose main structure consists of extruded profiles, for which low-silicon aluminum is used. Here, it is important to control chip and burr formation and to machine the very large parts with productive cutting values without vibrations. This also applies to the trend towards mega- or gigacasting, where large structural components are no longer made up of individual parts but are cast in one piece. The size and vibration tendency of the components require special tool geometries for low-vibration machining with high precision. Another challenge in this context is the new long-chipping aluminum alloys, whose machining properties need to be mastered.
Due to its properties, aluminum is also used in many other industries. Depending on the production volume and the number of variants, users are increasingly turning to standardized machining solutions for components with a high proportion of machining. However, large quantities of aluminum components can also be found here, which have a high demand for individual concepts. In fluid technology, for example, components such as pneumatic valve housings or pneumatic cylinders are manufactured in large quantities. Standardized tool solutions make sense for industries with high variance and small quantities.
Broad product and application portfolio for aluminum
MAPAL's many years of experience and countless solutions developed for machining aluminum have resulted in a broad product and application portfolio. For bore machining, the classic applications of fine boring, reaming and boring out are optimally covered. With the guide pad technology for fine boring, MAPAL achieves the highest accuracy in terms of diameter, roundness and cylindrical shape of components. For tools with fixed cutting edges for reaming and boring, MAPAL offers a unique portfolio in the field of PCD tools, ranging from simple tools for a diameter, with chamfer to very complex tools for multi-stage bore geometries. A large selection of solid carbide drills and drills with indexable inserts are also available for drilling into solid material. Challenges in this area are deep drilling and dry drilling, for which very special geometries and know-how are required.
MAPAL offers a wide range of face milling cutters, volume milling cutters, end milling cutters and special versions for milling aluminum. Series with cassettes or indexable inserts, as well as fixed versions, are available for face milling. PCD and carbide grades are used as cutting materials, which cover various cutting depths in combination with the required surface qualities and profiles. One example of this is the production of a special cross-cut pattern for sealing surfaces. In addition to the universally applicable range of end mills made of solid carbide or with PCD cutting edges, MAPAL has products that meet special requirements, such as increased accuracy, vibration-prone components or high-volume machining.
Engineering for perfect aluminum machining
The product range and the high level of manufacturing expertise form the basis for the optimum machining process for aluminum components. But the tools alone are not enough. Only the art of engineering can turn a broad product and application portfolio into a perfect solution. This is where MAPAL's absolute strength lies. Many years of experience and the development of ever-new solutions for the production of aluminum components make the tool manufacturer a first-class solution provider in this field. The focus is on the user.
According to MAPAL's philosophy, the perfect solution is one that is precisely tailored to the needs and requirements of the customer. What is expected is not over-engineering, but the requirements-oriented design of machining processes. MAPAL sees itself as a solution provider and technology partner and, in contrast to a pure tool supplier, not only considers the technical aspects but also puts itself in the position of the customer. This customer focus is behind the “Basic-Performance-Expert” solution concept and enables MAPAL to “tailor” the tools to the customer's needs.
