P.O.

Box 1520
D-73405 Aalen
Contact Hermann Steidle
Telephone +49 / 73 61 / 5 85 1 24
Fax +49 / 73 61 / 5 85 1 10
e-mail marketing@de.mapal.com
Date 28.04.2009
Press release no. 09-03-06-E
Page(s) 1 of 6
P
r
e
s
s
e
i
n
f
o
r
m
a
t
i
o
n

P
r
e
s
s

r
e
l
e
a
s
e

C
o
m
m
u
n
i
q
u

d
e

p
r
e
s
s
e

MAPAL
Przisionswerkzeuge
Dr. Kress KG
MAPAL tool technology for machining modern
materials such as CFRP and titanium

The subject of energy efficiency plays a crucial role in
the development activities of the automotive and
aerospace industries and in the energy sector. This fact
has been eclipsed somewhat by the currently uncertain
economic situation. But it will come to the fore again.

Energy needs are increasing. Important factors in this
respect are population growth, the increasing quality of
life of the world's population and long-term economic
growth. At the same time, there are limits on the
increase in the consumption of energy, whether due to
global warming, atmospheric and environmental
pollution or limited resources such as oil and bio-fuel,
and the resulting increasing prices for energy. The
consequence is that the increasing energy demand must
be covered by improved energy efficiency. The energy
efficiency necessary is acting as a technology driver in
many sectors. This statement also applies to stationary
consumers of energy. Energy saving regulations for the
insulation of buildings or energy figures on household
appliances have long been part of our everyday lives.

Mobile consumers of energy must also become more
efficient in the future to achieve improved effectiveness
of energy. Here motor vehicles and aircraft are of course
key candidates. In actual fact, it is aerospace, the
automotive industry and the energy sector that are the
primary driving sectors for the development of new
materials for reduced component weight. To achieve
lower weights, a lower power requirement and a higher
load capacity, materials are required with a favourable

P.O. Box 1520
D-73405 Aalen
Contact Hermann Steidle
Telephone +49 / 73 61 / 5 85 1 24
Fax +49 / 73 61 / 5 85 1 10
e-mail marketing@de.mapal.com
Date 28.04.2009
Press release no. 09-03-06-E
Page(s) 2 of 6
P
r
e
s
s
e
i
n
f
o
r
m
a
t
i
o
n

P
r
e
s
s

r
e
l
e
a
s
e

C
o
m
m
u
n
i
q
u

d
e

p
r
e
s
s
e

MAPAL
Przisionswerkzeuge
Dr. Kress KG
ratio between density and mechanical properties, in
short a low specific density. The most important
examples of these so-called lightweight materials are on
everyone's lips these days: CFRP and titanium, as well as
composites of the two. However, cast materials such as
vermicular graphite cast iron, SiboDur or ADI can be
allocated to this group of lightweight materials, if their
ratio of density to mechanical properties is considered.

The above mentioned lightweight materials have a
further feature in common: they are generally difficult to
machine. In the metal machining industry there is little
experience in these new areas, wider adoption is
progressing only slowly.

MAPAL has been very heavily involved in the machining
of lightweight materials for some years. For this reason
appropriate tool solutions for all applications are
available for machining vermicular graphite cast iron
and SiboDur. Last year very specific tool solutions were
tested and introduced for machining the materials CFRP
and titanium; these solutions make it possible to
machine reliably and cost-effectively.

Cost-effective drilling and trimming of CFRP
Carbon-fibre reinforced plastics, CFRP for short, with
high strength and stiffness along with low specific
weight, are lightweight materials par excellence. Initially
used for Formula 1 car chassis, the applications in
aerospace and in automotive manufacture are
continuously increasing. After initial working to close to
the final contour, the extremely abrasive materials are
further machined to produce finished components. To
prevent damage to the part (e.g. delamination,

P.O. Box 1520
D-73405 Aalen
Contact Hermann Steidle
Telephone +49 / 73 61 / 5 85 1 24
Fax +49 / 73 61 / 5 85 1 10
e-mail marketing@de.mapal.com
Date 28.04.2009
Press release no. 09-03-06-E
Page(s) 3 of 6
P
r
e
s
s
e
i
n
f
o
r
m
a
t
i
o
n

P
r
e
s
s

r
e
l
e
a
s
e

C
o
m
m
u
n
i
q
u

d
e

p
r
e
s
s
e

MAPAL
Przisionswerkzeuge
Dr. Kress KG
protruding fibres at the edge of the workpiece), special
requirements are placed on the tools.

Currently drilling rivet holes is the primary application in
CFRP and places high requirements on quality and tool
life. MAPAL uses solid carbide drilling and counterboring
tools with a diamond coating for this machining. Using
this tool, chatter marks on the countersink and
delamination at the exit are prevented. Very high
accuracies are achieved.

Application data for the diameter range
4,1 5,47 mm:
Bore tolerance: 8 m
v
c
= 85 m/min
f = 0.08 mm
v
f
= 440 mm/min

As an alternative solid carbide drills with a special
geometry are used.

For trimming CFRP various solid carbide milling tools
have been introduced in practice that are used with
parallel feed. To reliably achieve the required surface
finishes during trimming, MAPAL uses PCD-tipped end
milling cutters from the HP-EndMill range as an
alternative to these so-called routers. These powerful
tools have three or four blades and impress with low
wear. They are used with counter feed.

Cost-effective titanium machining with optimised tool
solutions
Primary application areas for titanium are in the
aerospace industry for components in engines, the
undercarriage and fuselage, in automotive manufacture,

P.O. Box 1520
D-73405 Aalen
Contact Hermann Steidle
Telephone +49 / 73 61 / 5 85 1 24
Fax +49 / 73 61 / 5 85 1 10
e-mail marketing@de.mapal.com
Date 28.04.2009
Press release no. 09-03-06-E
Page(s) 4 of 6
P
r
e
s
s
e
i
n
f
o
r
m
a
t
i
o
n

P
r
e
s
s

r
e
l
e
a
s
e

C
o
m
m
u
n
i
q
u

d
e

p
r
e
s
s
e

MAPAL
Przisionswerkzeuge
Dr. Kress KG
and also in the medical sector (implants). Titanium is a
long-chipping material. Due to the high temperatures
reached at the cutting edge, low cutting speeds are
necessary. In addition, clamping system and machining
must be absolutely stable, as otherwise minor vibrations
may occur.

Two tool solutions are in use for milling titanium. For
finishing a replaceable milling cutter with torque
transfer connection is used, which provides optimal
torque transfer and high reliability due to low radial run-
out error. The replaceable milling heads are easy to fit, a
MAPAL Module connection is fitted to the tool holder
that can be used to compensate for the radial run-out
error.

For roughing an ISO tangential milling cutter is used that
achieves enormous material removal rates.
Example application on a structural part (fuselage/wing
joint) in titanium Ti6Al4V with a cutting depth a
p
of 75
mm and a cutting width a
e
of 25 mm:
v
c
= 70 m/min
n = 350 min
-1

f
z
= 0.12 mm
v
f
= 168 mm/min
Material removal rate: 315 cm/min

The MAPAL high performance reamers from the HPR
range are particularly suitable for reaming in titanium as
they permit high cutting speeds and feeds. For example,
joint parts for the wing made of titanium Ti6Al4V are
reamed using a six-bladed HPR reamer 30.176 mm. To
achieve the required accuracies, additional guide pads
are fitted to the tool holder.


P.O. Box 1520
D-73405 Aalen
Contact Hermann Steidle
Telephone +49 / 73 61 / 5 85 1 24
Fax +49 / 73 61 / 5 85 1 10
e-mail marketing@de.mapal.com
Date 28.04.2009
Press release no. 09-03-06-E
Page(s) 5 of 6
P
r
e
s
s
e
i
n
f
o
r
m
a
t
i
o
n

P
r
e
s
s

r
e
l
e
a
s
e

C
o
m
m
u
n
i
q
u

d
e

p
r
e
s
s
e

MAPAL
Przisionswerkzeuge
Dr. Kress KG
Machining composite materials
Titanium is also becoming increasingly important as a
sandwich material in combination with CFRP or
aluminium, to significantly strengthen components with
heavy loads in structural parts, for example the
fastenings for wing flaps.

CFRP materials are often used in combination with
titanium, with aluminium or with aluminium and
titanium. For machining the tools must be optimally
designed for both or all three materials.

For drilling from the solid in these composite materials,
MAPAL uses PCD drills. The tool must achieve a high
constant diameter tolerance. At the same time the
formation of burrs on the titanium and aluminium as
well as protruding fibres and delamination of the CFRP
must be prevented. Low costs per bore and long tool life
complete the advantages of the PCD sandwich drill.

Example application 9.3 mm in CFRP-Ti multilayer:
v
c
= 27 m/min
n = 900 min
-1

f = 0.02 mm
v
f
= 18 mm/min

Summary
The increasing importance of energy efficiency is
undisputed. For this reason lightweight materials will be
used increasingly in the future. Despite the difficulties
that may arise during machining, the costs per part must
not increase.

For this reason new tool solutions are required that
permit a complete understanding of the process. At the

P.O. Box 1520
D-73405 Aalen
Contact Hermann Steidle
Telephone +49 / 73 61 / 5 85 1 24
Fax +49 / 73 61 / 5 85 1 10
e-mail marketing@de.mapal.com
Date 28.04.2009
Press release no. 09-03-06-E
Page(s) 6 of 6
P
r
e
s
s
e
i
n
f
o
r
m
a
t
i
o
n

P
r
e
s
s

r
e
l
e
a
s
e

C
o
m
m
u
n
i
q
u

d
e

p
r
e
s
s
e

MAPAL
Przisionswerkzeuge
Dr. Kress KG
same time, tools are required to have high productivity
and the machining must be of high quality to keep the
costs per part low or to reduce the costs. MAPAL has
tackled this issue and developed tailored tool solutions
for these requirements. The result is reliable, high
performance tools for all machining tasks and all
materials in the lightweight materials sector. MAPAL has
prepared itself for the future, in this sector as well.


Aalen, April 2009


Captions:
Pic 1: Rivet holes in CFRP are precisely machined with a
diamond coated drilling and countersinking tool.
Pic 2: A replaceable head milling cutter with TTS connection
is used for finish milling of titanium.
Pic. 3: The ISO tangential milling cutter for roughing
titanium achieves enormous material removal rates.
Pic. 4: A PCD-tipped drill is used for machining stacks of
CFRP/titanium or CFRP/aluminium.

Pictures


2009-03-06, pic 1



2009-03-06, pic 2



2009-03-06, pic 3

2009-03-06, pic 4