Tooling technology
weight, alongside difficult-to-machine features such as deep bores, cross bores, or interrupted cuts. Additionally, the aluminium alloy used in aerospace, which contains low silicon, tends to produce long, hard-to-break chips, posing further machining challenges. Another generic component MAPAL has developed for the aerospace sector is a torsion link for an aircraft’s main landing gear. It connects two cylindrical landing leg parts, allowing the damper cylinder to extend and retract while preventing twisting. These critical structural parts also come in various designs. MAPAL’s medium-sized sample component simulates all the demanding conditions of real-world aerospace applications. Made from titanium due to the high mechanical loads involved, the component highlights another challenge. Titanium’s low thermal conductivity leads to elevated cutting temperatures and reduced tool life. Therefore, optimal coating, cutting-edge preparation, and a tailored machining strategy are all essential. With these aerospace-specific generic components, MAPAL continues a proven approach first established in the automotive industry. In that sector, key components were identified and modelled for tool development and testing. Today, most areas of automotive manufacturing are covered by corresponding generic parts. The same strategic concept is now being applied to aerospace, with MAPAL showcasing the full scope of its technological capabilities. n www.mapal.com
real-world aerospace applications. Drawing from global experience across the MAPAL Group, the result is a consolidated knowledge base reflected in one sample part. This component includes MAPAL’s expert recommendations for optimal machining strategies, tool selection, and cutting data. In many cases, multiple tool options are available to achieve a desired result. For instance, either a PCD tool or a fine boring tool can be used for reaming bores. Alternatively, multi-bladed reamers may be chosen. Each option presents unique benefits, and the ideal solution depends on the specific needs of the aerospace customer. Compared to hydraulic systems in industries like construction, aerospace valve
housings are far more complex. For one of the most intricate projects,
MAPAL utilized more than 130 customized tools for a single housing type. These components often feature ultra-thin walls to reduce aircraft
53 Machinery & Manufacturing
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