MAPAL Competence

VDMA ForumComposite Technology18. September 2013Messe Composites Europe / Stuttgart

Tools for Modern Materials

COMPOSITES

MAPAL Competence

Tools for Modern Materials

COMPOSITESContent:

Company profile Machine concept Tools for drilling Tools for milling Applications

MAPAL Headquarter in Aalen

MAPALPräzisionswerkzeugeDr. Kress KG

Obere Bahnstraße 13D - 73431 Aalen

www.mapal.com

Tools with guide pads Milling Heads Multicut ToolsPCD-Tools SC-Tools

Tools with

ISO-Elements

MAPAL

Indexable inserts

Clamping TechnologyActuating Tools

TOOLTRONIC

MAPAL Products

Setting devices and

Laser Systems

Production:

Tools with guide pads

PCD-Tools

ISO-Tools

Fixed Tools

Inserts

Ball nose milling cutters

Clamping devices

Setting fixtures

Production:

PCD-Tools

Production:

SC-Drills

SC-Milling cutters

The MAPAL Group in Germany

Production:

ISO-Tools

Actuating Tools

MAPAL Dr. Kress KG

Location: Aalen Employee: 1.560

MAPAL WWS GmbH

Location: Pforzheim Employee: 462

MILLER

Location: Altenstadt/Iller Employee: 309

MAPAL ISOTOOL

Location: SinsheimEmployee: 90

Production:

ISO-Tools

The MAPAL Group in Germany

Production:

Fixed Reamers

Production:

Hydraulic expansion chuck

Shrinking chuck

Precision drill chuck

Production:

Laser for labelling

Laser for cutting

August Beck

Location: WinterlingenEmployee: 173

Rudolf Strom

Location: VaihingenEmployee: 26

wte

Location: Ehrenfriedersdorf Employee: 111

LaserPluss

Location: Kirschweiler Employee: 26

The MAPAL Group in Germany

Since October 2012Member of

Group

Production:

SC- tools

PCD tools

Special tools

Weisskopf Werkzeuge GmbH

Location: Meiningen (Thüringen)Employee: 54

MAPAL worldwide

• Subsidiaries with regional production, sales and service in 21 countries

• 4,149 employees worldwide, of which approx. 2,900 are in Germany

• Sales representatives in 25 countries

• Turnover 2012: 440 million euro

Machinery Research & Development in Aalen

Engineers: 11

Technicians: 6

Specialised staff: 3

Prototype machining: 6

Tools for CompositesMAPAL Products

• The type of the Machining process is generally defined by the size of the component and the quantity of the components.

Machining Centers / Gantry Drill Feed units

Robots Hand-held Devices

MAPAL Products - machine concept

Tools for Drilling with Hand-Held MachinesMAPAL Products - machine concept

hydraulic brake

tripod

Tools for Drilling with Drill Feed UnitsMAPAL Products - machine concept

Tools for Machining with RobotsMAPAL Products - machine concept

Tools for Machining with Machining CentresMAPAL Products - machine concept

CFRP with

MEGA-Drill-Composite

MAPAL Competence

Tools for Modern Materials

DRILLING

Comparison of CFRP drilling

Are Special Drilling Tools Required?

Standard Drill MEGA-Drill-Composite

Hole exit-side MD- CFRP Hole exit-side MD- CFRP

Hole exit-side UD- CFRPHole exit-side UD- CFRP

Delamination

Point thinning and tip angle Size and shape of the chip flute Sharpness of the cutting edge Special diamond coating Guiding chamfer

Factors influencing hole-quality MEGA - Drill - Composite

Damaged bore outlet

DrillingMEGA - Drill - Composite

For GFRP / CFRP machining, diamond-coated (tool life)

L1

L2

D2

D1

-Type MD (for multidirectional CFRP / woven): Special CFRP geometry with arc land chamfer

-Type UDX (for unidirectional CFRP / non-woven): Special CFRP geometry with sharpening

Problems and managing them:

Entry Hole wall Exit

No changeSpecialtool feature

ProblemMirror-smooth surface finish on the hole wall and delaminated edge underneath

Special geometry of the guiding chamfer

Tool is reaching the end of its tool life

Fibres are not cut

Fibre protrusion and burnt resin are crushed into the hole wall

CausePushing cutting edge and large tip angle at the exit to the last layers

Fibres come loose from the composite material and the tool is unable to catch them

Small tip angle: 90° "pulling" cutting edge

Burrs

Delamination

MEGA-Drill-Composite Geometry

DLC Coating for CFRP Tools

Important factors:

Nanocrystalline diamond like carbon coating for up to 780°C

Layer thickness from 6µm to 12µm

Only chemical pretreatment – no abrasive blasting

100% input and output check

Carbide grade – only a few are optimal for coating

Problems with deflection during the coating process

Tool geometry is matched to the properties of the diamond coating. Experiments conducted by Mapal have demonstrated, that run-out errors of 46µm have no effectwhatsoever on the hole diameter. The drill is capable of centering itself.

Tool life increased by up to a factor of 8

MEGA-Drill-AramidSolid carbide twist drillSCD28 (5xD), external coolant supply

Design:Drill diameter: 3.00 - 12.00 mmShank form: HACoating: uncoatedNumber of cutting edges: 2Tip angle: 90°Helix angle: 30°

Special geometry for reliable drilling ofaramide-reinforced materials: Neat shearing of aramide fibres Prevents delamination at the exit No fibres are pulled out

Aramide Drilling

MAPAL Competence

Tools for Modern Materials

MILLING

CFRP with

OptiMill-Composite

Standard milling cutter OptiMill-Composite-Speed

Surface finish destroyed, pyrolised

Chips fused together Chips (dust) cut

CFRP layers in resin matrix

Are Special Milling Tools Required?

Milling ComparisonStandard milling cutter OptiMill-Composite-Speed

Fibre protrusion and delamination

Milling cutter does not separate fibres neatly and tears fibres out of the matrix

Neat edges with no imperfections

Tools must be adapted to the properties of the material:

Standard tool Modified tool

Fibre reinforcement (CFRP / GFRP / AFRP / hybrid / etc.) Semi-finished (woven / non-woven / braided / prepreg / etc.) Matrix (thermoset / thermoplastic / …) Manufacturing process (autoclave / RTM / wet presses / …)

Carbon fibre Non-woven + PE

sewing thread Epoxy (thermoset) Wet presses

Material

Glass fibre Woven (body) PA6 (thermoplastic) Hot presses

Factors That Affect MillingTrimming CFRP

- Milling direction (counter feed)- Cooling- Cutting parameters- Required surface finish- Clamping of the component

feed

climb milling conventional milling

Mapal Series of Milling Cutters

OptiMill-Composite-MT: Vc=100m/min, fu= 0.2-0.4- Inexpensive tool for roughing- Generally uncoated

OptiMill-Composite-Speed: Vc=180m/min, fu= 0.3-0.5- All-round milling cutter for one cut and good surface finish- Smooth running at high feed- Diamond-coated

HP-Endmill-PCD: Vc=350m/min, fu=0.1-0.2- Excellent surface finish with one cut- Extremely long tool life with high Vc- Higher price level (for series production)- Caution advised with unstable clamping (chipping)- Cooling required

OptiMill-Composite-Quadro: Vc=120m/min, fu=0.2-0.3- Milling cutter for finishing with top surface finish- No full-contact cutting

Neat cut faces in aramide-reinforced FRP: Geometrically separated pulling and pushing areas 2 straight fluted cutting edges cut the fibres and

ensure fast chip removal Combination of shearing and cutting effect

OptiMill-Composite-TwinCutSCM49 | HSC milling cutter for aramide

Design:Milling cutter diameter: 4.00 - 20.00 mmShank form: HACoating: uncoatedNumber of cutting edges: z = 2 - on alternate sidesPoint geometry: (180°)Helix angle: 0°

Aramide Milling

Aerospace Milling - CFRP Component4.5mm thick, external cooling with air

Before:Machining time per aircraft: 31.50 hours.

MAPAL:Machining time per aircraft: 18.43 hours.Number of milling cutters reduced by half

Advantages:

- Overall savings 60% with less reworking- No delamination in the edge area- Laminated glass layers are cleanly cut- Outer contour has a neat surface finish- Few or no protruding fibres on the cuting edges

Aerospace Milling - FinConsists of 2 shells each with a 15-m milling length, 3-6 mm thick

Before:PCD milling cutter Z=2Tool life: 1.5 –2 shellsFibre protrusion in some casesVc= 800m/minVf = 1,500mm/min

MAPAL:PCD milling cutter Z=4Tool life: 6 shellsNeat edgesVc= 800m/minVf = 3,000mm/min

Milling in Medical TechnologyX-ray insertion needle

MAPAL:Optimill Composite Speed Z=8 Tool life: 45 parts Top surface finish with neat edgesVc= 180 m/min.Vf = 1,920mm/min.

Before:VHM router → roughingPCD milling cutter Z=2 → finishingTool life: 38 parts Delamination in some cases

Milling for the Electrical IndustryResopal switchboard 1200 x 600 x 6mm

Before:D=6mm solid carbide milling cutter Z=1Tool life: 5 partsChipping at the exit in some casesVc= 320m/min.Vf = 1,500mm/min.

MAPAL:D=6mm PCD milling cutter Z=2Tool life: 85 partsNeat edges at the exitVc= 565m/min.Vf = 3200mm/min.

Automotive ApplicationsComponent:CFRP underside for Monocoque cell (sports car)

Material:Thin CFRP plates (1.2 mm to 3.0 mm)Non-woven carbon + epoxy resin (RTM process)

Task:Drilling / milling on a machining centre with vacuum clamping system

Problem: Part vibrates and springs back PE sewing threads are not neatly cut from the non-woven material and protrude

Tool solution:

• MEGA-Drill-Aramid

OptiMill-Composite-Speed (pushing)

Machining values:

• Vc = 130 m/minfu = 0.1 mm

Vc = 250 m/minfu = 0.5 mm

Automotive ApplicationsComponent:Hoop guard for engine compartment (series)

Material:PP/PA thermoplastic+ 30% short glass fibre(injection moulding)

Task:Drilling with manual drilling machine / bore sleeves (for threaded bush)

Problem: Thermoplastic matrix must not smudge or exhibit chipping Continuous feed must be ensured during drilling No chips which cannot be readily removed without suction Less force applied during the drilling process

Tool solution:MEGA-Drill-Aramid

Machining values:1600 rpmManual feed

Automotive ApplicationsComponent:Panelling and structural parts for motorsports (F1, DTM),sports cars,electric vehicles;Trunk lid, side plate, roof, convertible top cover, spoiler, etc.

Material:CFRP– woven/non-woven /braided /prepreg (RTM / Autoclave)

Task:Drilling / milling (trimming) with machining centre and robot

Problem: Instability of the robot; tool must not break off Roughing and finishing in one machining step with neat surface finish

Tool solution:• MEGA-Drill-Composite-MD Modified OptiMill-Comp.-Speed

MT with stable core and tooth geometry PCD milling cutter

Machining values:• Vc = 150 m/min

fu = 0.1 mm Vc = 250 m/min

fu = 0.5 mm

Automotive ApplicationsComponent:Interior and exterior parts for commercial vehicles / bussesInstrument panel, cab panelling

Material:Glass fibre-filled PUR foam + decorative film(LFI process)

Task:Milling sandwich components on robot + machining centre

The problem: Sandwich structure with different materials (hard + soft) Decorative film must be pressed against the foam core so that it can

be neatly cut with no protrusions (pulling design)

Tool solution: OptiMill-Mono-Plastic OptiMill-Composite-MT OptiMill-Composite-Speed

Machining values:Vc = 150 m/minfu = 0.1 mm

Vc = 250 m/minfu = 0.5 mm

Automotive Applications

Material:PP with 15% fibreglass + PU and TPO foam + genuine leather

Thickness 3.2 mm thick

Solid carbide end milling cutters Ø 6 x 6 x 76 Z = 1

Spindle speed 30,000 rpm

Feed rate 2.8 m/min – 4.2 m/min

Tool life 550 parts

Component:Instrument panel for cars

Summary

Tool: Carbide Geometry Coating Machining Values

Machine: Rigidity Performance Clamping System Extraction

Composites Part: Properties of the Material Thickness of the Material Dimension of the Part Design of the Part

Quality: Delamination Fibre Pull Out Formations of Burrs Dimensional Accuracy Surface Finish Process Reliability Tool Life

Thank you for your attention!

Contact:Hans-Peter WengertDipl.-Ing. (FH)

Business Development Key Account CompositesBU Aerospace & Composites

Phone: +49 7361 585-3016Mobile: +49 174 1633769hans-peter.wengert@de.mapal.com

MAPAL Competence

Tools for Modern Materials

COMPOSITES