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TechnologyWorkpieces and processesin the automotive industryNew machining solutions for that extra productivityand cost-effectiveness

MAPAL technology:Tap the potential savings during themachining of car componentsNew machining solutions for that extra productivityand cost-effectivenessIf every second counts, major specialists are required. Specialists whoare familiar with the machining processes down into the detail andwho from this detailed knowledge develop innovations for real progressin machining. For this purpose we offer our experience frommany individual solutions for specific tasks in the automotive industry.And a willingness to take new and perhaps also unusual paths in thedialogue with the customer.

Workpieces and processes in the automotive industryCylinder heads for two to twelve-cylinder enginesNew developments for lowercutting costsThe complete machining of a cylinder head is a demanding task. Thechallenge is to meet high tolerance and quality requirements using precisetools that are as easy as possible to use, and that with low unit costs.The MAPAL tool package for the cylinder head includes many innovativesolutions that satisfy the current development trends in engine manufacture.Tool highlights on the cylinder head1. Reaming the valve guide and groovingthe valve seatCoupled tools with high stiffness makecomplete machining possible in one step.The optimum exploitation of the cuttingdata minimise the cutting material costs.2. Fine boring of the camshaft bearingsBest position accuracy and concentricityare guaranteed by the pilot tool and thefine machining tool.3. Boring the core plug boresThe special chip removal prevents chips inthe workpiece cavities.4. Deep hole drilling for the oil channelHigh position accuracy is achieved by thespecial drill geometry. Triple feed ratecompared to single-lip drill. Reliable chipremoval via optimised chip flutes.Advantages:Modern tool concepts matched tothe related manufacturing conceptUsage of exactly matched cuttingmaterials – for example during themachining of the valve seatSpecial solutions for small productionruns and prototypesComprehensive range of servicesincluding tool management13243

Clutch and gearbox housing for automatic gearbox and manualgearboxHigh productivity due to MAPAL technologyMAPAL tool specialists draw on particularly extensive experience duringthe design of complete processes for clutch and gearbox housings. Theoptimum machining of the large and often thin-walled parts requires alarge amount of know-how, starting from the design of complex combinationtools to the definition of housing clamping. The shaft bearing boresplace special requirements in the µ range on shape, position, surface finishand diameter.Tool highlights in clutch and gearbox housings1. Fine boring of the selector shaftcylinderA diameter tolerance of IT6 is achievedfrom the cored state.2. Forward and backward machining ofbearing boresThe outer and inner surfaces as well asthe bore are machined in one clampingposition.3. Drilling/countersinking combinationsfor oil filler boresThe multi-blade configuration permitshigh machining values and stable cuttingbehaviour. The tool is designed as a combinationwith a thread milling cutter.4. Face milling the joint faceDue to specially matched cutting edgegeometries, the defined surface roughnessand surface structures can be achievedexactly.Advantages:Reduction in the machining timedue to combination toolsHighly reliable manufacturing dueto many years of process experienceOptimum concepts for all processes– drilling, reaming, fine boring,circular/face milling and threadcuttingComplete support from planning tothe breaking-in of the tools4 1234

Workpieces and processes in the automotive industryComplete machining of turbochargersMAPAL with leading tool technologyDownsizing and turbochargers are now indispensable in modern enginedevelopment. In the past machining centres and lathes were oftennecessary for the production of the turbine and compressor housing forturbochargers. MAPAL has developed a manufacturing method that makescomplete machining possible on one machine. Contours and recesses aremachined using the mechatronic tool system TOOLTRONIC® and interpolationturning. Complete machining tools also combine a large numberof machining steps.Tool highlights for turbocharger housing1. TOOLTRONIC® for machining thecontourMAPAL TOOLTRONIC®, the interchangeableU axis, machines the inner contour,the diameter and various flat surfaces.2. Interpolation turning of recessesThe cycle time is reduced by 35 % comparedto milling. It was possible to improvethe tool life due to a continuous cut andshorter cutting time.3. ISO tangential tool for completemachiningOne tool reliably, cost-effectively and preciselymachines six machining features.Advantages:Machining of the main bore in theturbine housing in only four stepsTOOLTRONIC® instead of the latheCombination of a large number ofmachining steps due to tangentialtechnologyInnovative machining method forall machining tasks on parts forturbochargers1235

Brake calipers made of spheroidal graphite cast ironPotential for savings due to the latestmanufacturing technologyThe quality of the manufacture of this safety-related part defines thebraking forces via braking performance, stability under load and exactcontrol. The MAPAL tool package for machining the brake caliper guaranteesreliable manufacture with low manufacturing costs. These advantagesare provided, for example, by combination tools with which it is possible todrill, mill and deburr at various positions. In total up to 40 % of machiningtime can be saved using the MAPAL process.Tool highlights on the brake caliper1. Control cut for the fist hole, premachiningof the front of the area forthe piston, pilot bore for the pistonboreThe combination of several machiningsteps reduces the cycle time and increasesthe machining quality.2. Interpolation recessing of sealing ringgroove and base profileThe MAPAL tool reduces the machiningtime by 50 % compared to circular millingand improves the surface quality.3. Fine machining of the piston boreThe higher feed rate reduces the machiningtime by approx. 30 %. There is nosetting effort, as re-grinding is possiblethe tool costs are reduced.4. Fine machining of the rear of thebrake housingA MAPAL actuating tool for machiningcentres combines diameter turning, millingand external grooving. In comparison tothe previous process, the machine time isreduced by 12.5 sec. per workpiece.Advantages:Increased process reliabilityReduction in the manufacturingcosts per unit due to reducedmachining timesCost guarantee due to cost per partCompetent planning and reliablesupply of tools with MAPALComplete Process Management23416

Workpieces and processes in the automotive industrySteering knuckles made of grey cast iron or steelTangential technology for fast machiningand low unit costsSteering knuckles must withstand high loads. For this reason high toleranceson shape and position must be achieved during the manufacture of the part,predominantly manufactured from grey cast iron and less frequently fromsteel. Despite the demanding machining, low costs are still required, as thisis a mass produced part.By using multifunctional combination tools from MAPAL, tools and magazinestations are saved and therefore machining time and costs significantlyreduced. Particularly advantageous for complete machining is the use oftangential indexable inserts. These inserts have a soft cut due to theirpositive rake angle and, due to the compact mounting, are very suitablefor use on multi-insert tools with high feed rates.Tool highlights for steering knuckle machining1. Milling and drilling shock absorbermountingA combination of a disc-type millingcutter and insertion drill reduces thenumber of tool changes.2. Main bore, internal machiningUsing the multi-stage tangential combinationtool, semi-machining is saved.3. Main bore, external machiningThe multi-stage combination tool withfixed insert pockets without pre-adjustmentmanufactures tolerances of lessthan ±0.1 mm.4. External machining of journalPre-machining, semi-machining and finemachining from one source permits thehighest accuracies with the lowest scraprate.Advantages:Process suitable for standardmachines and custom machinesComplete machining with minimumnumber of toolsRapid payback of the tool costsMAPAL service competence, alsoduring the conversion of existingmachines32147

MAPAL the major specialistReaming and fine boringBoringDrillingMillingTurningActuatingClampingSetting and measuringServicesV1.0.0MAPAL Präzisionswerkzeuge Dr. Kress KGP.O. Box 1520 · D-73405 Aalen · Phone +49 (0) 7361 585-0 · Fax +49 (0) 7361 585-150info@de.mapal.com · www.mapal.comAUT-E-01-030-1110-WD Printed in Germany. Right of technical modifications reserved.