Time is money! Mapal introduces a time-saving separation joint at AMB

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MAPAL Fabrik für Präzisionswerkzeuge Dr. Kress KG

Taiwan Machine Tool & Accessory Builders' Association (TMBA)

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SIMTOS (Seoul International Machine Tool Show)

Mapal introduces at AMB 2024 a new, patent-pending, bayonet-like separation joint for particularly rapid tool changes.

Users benefit from the new Mapal bayonet separation joint due to its very simple handling, a rigid connection, and, not least, optimal cooling during machining, as stated by the AMB exhibitor who presents the innovative system in Hall 1. Additionally, the tool manufacturer saves on carbide at the separation joint, thus conserving resources.

 

With a quarter turn, the tool is securely fastened

The operating principle of the new coupling is quite simple, as emphasized by the company from Aalen. The interchangeable head is inserted and then rotated 90 degrees to lock it in place. This process is significantly easier than the previous system used for Mapal interchangeable head milling cutters or similar products, where the tool head is threaded and needs to be screwed in. Thanks to the large cylindrical contact surface, the bayonet system is also very stiff. Unlike the process of tightening a thread, where the forces always act on one side due to the pitch, the new Mapal system ensures symmetrical engagement and better distribution of forces.

Bayonet separation joint saves a lot of material

At the AMB in Stuttgart, the solid carbide interchangeable heads from Mapal also impress according to the exhibitor due to their high process reliability, as no cutting edges can loosen at higher temperatures. Should a tool breakage occur, the simple assembly of the coupling ensures a quick resumption of the machining process. Modular tool systems with a steel shank holder have been introduced to the market to reduce the consumption of carbide. However, Mapal takes it a step further with its bayonet coupling! It saves about 70 percent of material compared to previous couplings, aligning with the trend towards greater sustainability.

Two application cases will also be presented

The coupling is offered in seven different sizes with head diameters ranging from 11.8 to 22.5 millimeters and head lengths up to 1×D, which Mapal indicates covers a wide variety of applications. In addition to the interchangeable heads, the tool manufacturer can also custom-design the holders to optimize, for example, the coolant-lubricant supply for specific requirements. Along with the bayonet coupling, two initial applications are being introduced at AMB. A 5-edge solid carbide head will be used by users from the automotive industry as a ball track cutter in the production of homokinetic joints. The soft machining of these parts, which are installed in the drivetrain, demands high manufacturing precision. Another tool is a form cutter for machining spherical caps on drive shafts.

New tool holder design is stiffer than others

For the coupling, the tool expert also presents a new holder design. These holders feature a ring of coolant channel holes, which, as Mapal explains, allows for a considerably higher coolant volume than the previously used internal cooling. By directing the coolant lubricant directly to the area of the cutting edges, the lifespan of the tools and the quality of the machining are enhanced.

Because there is no central coolant channel drilling, this also results in extremely stable milling heads. Compared to other systems, the 10 to 15 percent higher stiffness allows for higher form and positional tolerances, more process stability, and longer tool life.