Talking Tech: Tooling for Aerospace
wing skins, which will prove highly appealing to tier-one and tier-two manufacturers. “Due to tight profit margins, we find supply chain manufacturers very receptive to any new tooling innovations that can deliver genuine competitive gains,” explains Mark Radcliffe. “They seek out cost-effective tools able to reduce cycle times and cut costs, without any compromise in tool life or quality. Our new OptiMill-Alu-Wave scores on all fronts.” Drilling, reaming, milling and trimming are MAPAL’s core aerospace competencies, typically involving solid-carbide and indexable- insert cutters, as well as holders. Regarding the latter, a recent innovation is the company’s Mill Chuck for hard metal machining applications, which avoids the issue of shrink-fit holders that gradually loosen their grip on the cutter as heat increases. Mill Chuck provides physical contact with the tool, delivering 900 Nm of clamping force regardless of temperature. The result is no more pull-out or push-in during hard metal machining, resulting in a far more rigid process. As a matter of course, MAPAL benchmarks all new products against comparable offers from competitors, refusing to release any new innovations that are not among the top three performers. The company has many aerospace
case studies that highlight the gains available from such rigorously assessed tools. “We had a project involving titanium where we reduced cost per part by 200%,” states Mark Radcliffe. “Another example saw us reduce the cycle time of a process involving an indexable- insert cutter from 6.5 to 3.5 hours per part. Delivering an annual cost saving in excess of £250k. In all cases we scrutinise the whole process up front to identify the optimal way of generating savings for customers.” Many aerospace tools are of course specials, particularly those for OEMs. In these instances, MAPAL conducts a comprehensive review of the application and project objectives before delivering a proposal (with input from the company’s Competence Centres in Germany, if required). “The design and manufacture of specials takes place in the UK,” says Mark Radcliffe. “Once complete, customer trials take place as part of an iterative testing process that will continue until we meet the project’s objectives.” Tooling solutions for aerospace customers today represent 30-40% of MAPAL’s UK revenue. With even more growth anticipated moving forward, this is clearly a business in full flight. n
www.mapal.com “We use advanced geometries and coatings to overcome the challenge of simultaneously machining materials with very different properties, while still delivering impressive tool life.”
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Machinery & Manufacturing 29
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