The Company.

The Company.
MAPAL Präzisionswerkzeuge Dr. Kress KG – a medium-sized family company –
has been for decades one of the leading suppliers of precision tools for the metal
machining industry. As a supplier MAPAL provides support for its customers from
project planning for individual processes to Tool Management.
The MAPAL Group headquarters
With the establishment of MAPAL by
Dr. Georg Kress in 1950 in Aalen, the
foundation stone was laid for the company which now operates worldwide.
The meteoric success of the company
began with the successful introduction
of single blade reamers with guide
pads (the MAPAL principle).
Based on this tradition the headquarters in Aalen is now the main production site for reamers and fine boring
tools with guide pads. With more
than 1.200 employees, multi-bladed
reamers, clamping systems and setting
devices are also produced in Aalen.
In addition to the general management, the central functions are also
located in the headquarters as coordination points for the whole MAPAL
Group. Along with the development
and marketing centre, the new customer services centre is also part of the
MAPAL Group central functions. In the
production area MAPAL Aalen supplies
the manufacturing daughter companies with tool bodies and numerous
additional parts. The headquarters
is also the venue for the wide variety
of MAPAL’s general and advanced training events. This includes technical
seminars and technical orientation as
well as offer training sessions, both for
customers and for employees from all
MAPAL’s daughter companies and
agents.
MAPAL Präzsisionswerkzeuge Dr. Kress KG
P.O. Box 1520 | D-73405 Aalen | Phone +49 (7361) 585-0 | Fax +49 (7361) 585-150
[email protected] | www.mapal.com
MAPAL Sites in Germany
MAPAL WWS GmbH in Pforzheim
MAPAL ISOTOOL GmbH in Sinsheim
MILLER GmbH in Altenstadt
August Beck GmbH & Co. KG in Winterlingen
WTE Präzisionstechnik GmbH in Kempten
Rudolf Strom GmbH in Vaihingen/Enz
The MAPAL Group in Germany
In addition to its headquarters in Aalen, there are six other
competence Centres of within the MAPAL Group in Germany:
The WWS company was set up in
Pforzheim in 1980 and has been part
of the MAPAL Group since 1994.
Today MAPAL WWS GmbH is the
leading manufacturer of tools with
PCD blades. Combination tools for
boring operations and circular interpolation milling are among their
highlights.
With the foundation of MAPAL
ISOTOOL GmbH in Sinsheim in 1997
MAPAL extended its range of products
with generating slide tools and slide
tools, together with special tools with
ISO elements.
MILLER GmbH, founded in 1991 has
been part of the MAPAL Group since
2003. MILLER produces precision tools
for drilling, milling and counterboring
in solid carbide and in Cermet.
August Beck GmbH & Co. KG was
founded as a mechanical workshop in
1906 in Winterlingen. A comprehensive standard programme of reaming
and countersinking tools forms the
basis of August Beck GmbH & Co. KG.
WTE Präzisionstechnik GmbH is a
developer and manufacturer of high
accuracy chucks for tool clamping
technology. Core competencies:
precision drill chuck systems, hydraulic
chucking sector and shrinking technology.
Rudolf Strom GmbH in Vaihingen/Enz
has been part of the MAPAL Group
since 1999 and produces special tools
with ISO elements for a wide variety of
applications.
MAPAL worldwide
Quality, close customer contact and early identification of the developments and demands of the market are MAPAL's
primary objectives. More than 3.000 people employed by the MAPAL Group work out perfect solutions every day for
customers' machining tasks.
Because of the ongoing general and advanced training of personnel and the constant exchange of experience,
MAPAL ensures high technical standards worldwide and guarantees MAPAL's legendary quality.
MAPAL Group sites
Australia | Valcor Australia Sales Pty. Ltd.
in Ballarat, Victoria
Brasil | MAPAL do Brasil –
Ferramentas de preçisão Ltda. in Belo Horizonte
China | MAPAL China Production und Trading Ltd.
in Shanghai
Germany
MAPAL Dr. Kress KG in Aalen
MAPAL WWS GmbH in Pforzheim
MAPAL ISOTOOL GmbH in Sinsheim
MILLER GmbH in Altenstadt
Rudolf Strom GmbH in Vaihingen/Enz
August Beck GmbH & Co. KG in Winterlingen
WTE Präzisionstechnik GmbH in Kempten
France
MAPAL France S.A.S. in Le Chambon Feugerolles
MAPAL France - Bureau Villepinte in Paris
MAPAL France – Bureau Toulouse
Great Britain | MAPAL Ltd. in Rugby
India | MAPAL INDIA Private Ltd. in Bangalore
Italy | MAPAL Italia S.R.L. in Gessate/MI
Japan | MAPAL KK in Tokyo
Korea | MAPAL HTT Co. Ltd. in Kyunggi-Do
Malaysia | MAPAL Malaysia Sdn. Bhd.
in Selangor Darul Ehsan
Mexico | MAPAL FRHENOSA S.A. de C.V.
in Monterrey
Poland | MAPAL Narzedzia Precyzyjne Spólka z o.o.
in Posen
Singapore | MAPAL Sales Office South East Asia
South Africa | MAPAL SPECTRA Carbide Tooling
Technology in Port Elizabeth
Taiwan | MAPAL Precision Tool System Co. Ltd.
in Tainan
Thailand | MAPAL THAILAND Co. Ltd. in Bangkok
Czech Republic | MAPAL CZ s.r.o. in Dlouhá Lhota
USA | MAPAL Inc. in Port Huron MI
MAPAL – always close to the customer, everywhere.
MAPAL
Reliably innovative
10 11
„How can one define a company, an
extremely lively organism, which has
developed further an further for more
than 50 years and with which so many
people - customers throughout the
world, employees and suppliers - are so
closely linked, in a brochure with just a
few pages?
We have dared to do so because we
know that in our Company it comes
down to just a few important
principles.
We want to be close to our customers,
be and remain in dialogue with them,
think and act for them.
Find and form a team which will feel
permanently committed to this idea.
At all levels of the company“
Dr. Dieter Kress
Chairman & Managing Director
„Quality, reliability and innovative
strength are also factors which play
a decisive role in the company - day
after day.
Using brief comments throughout we
hope to illuminate the various aspects
of our company and clarify what is
important to us.
Now and in the future.”
Dr. Jochen Kress
Member of the senior management
Branches and products
Perfect dialogue
14 15
“The customers expect us to provide them with a comprehensive,
reliable and innovative programme from our range of competences –
at all the principal production sites in the world. This is what we do.
This is how MAPAL is set up.“
Dr. Dieter Kress
Workpieces and processes in the automotive industry –
New machining solutions for that extra productivity and
cost-effectiveness
If every second counts, major specialists are required. Specialists who are
familiar with the machining processes down into the detail and who from this
detailed knowledge develop innovations for real progress in machining. For
this purpose we offer our experience from many individual solutions for specific tasks in the automotive industry. And a willingness to take new and
perhaps also unusual paths in the dialogue with the customer.
Reliable machining of modern lightweight materials
Where reducing weight while maintaining stability is a key issue, modern
materials are conquering ever more applications. Products of lightweight
design, particularly those made of fibre composite materials and multimaterial
systems (CFRP-metal multilayer composites), are becoming increasing
common in the key industry of vehicle manufacture, as they spread from their
origins in the aerospace industry. Lightweight materials are in the meantime
established in wind energy converters and are increasingly common in machine tools, industrial robots and the consumer sector. In intensive collaboration
with customers, for example from the aerospace sector, MAPAL has created a
comprehensive range of tools for the reliable machining of modern materials.
16 17
Short machining times, high process reliability and
high process quality when machining large parts
Increasing global passenger and freight traffic by road/rail, by sea and in the air,
as well as the generation of energy by alternative means, for example, wind
power and hydropower, are resulting in increasing demand for large parts. The
high costs of these parts require, on the one hand, a high level of accuracy, reliability and quality from the machining process. On the other hand, it is imperative
the efficiency of processes and productivity are increased, also during the manufacture of large parts. Here new types of tool concepts can sustainably increase
efficiency during the machining of large parts with the objective of reducing the
machining times, combined with increased process reliability and quality.
Custom-made services for a further
increase in efficiency
As a competent tool partner, MAPAL offers a comprehensive services sector. Cost
savings start in the planning stage for MAPAL customers. As a result of innovative
and reliable tool concepts, the specialists from MAPAL show the way for costeffective production of a part and savings with complex post-machining procedures Tool Management by MAPAL provides the right tool in the right quantity, at
the right time, at the right place and at the right price. Profitable production is
guaranteed.
18 19
Nowadays, customers expect suppliers
to be a technology partner with knowhow in all areas of the machining process. Due to advancing globalisation of
customers and the standardisation of
machines, the importance of the process is increasing.
Due to advancing globalisation of customers and the standardisation of machines,
the importance of the process is increasing
The metalworking industry has changed. Where previously the focus during
negotiations was on keywords like
quality, technology, employee qualification and delivery time, today it is the
topics of cost transparency, life-cycle
costs, cost per part etc. that matter.
There are several reasons for this development. Customers are increasingly
looking for technology partners with
which they can work together in all
areas of the process.
With our roots in custom tool production, we are a problem solver and
orientated closely with the customer.
Advice and support for machining tasks
and processes along with the related
know-how on the machining of workpieces are therefore also attributed
ever increasing importance. Accordingly, today MAPAL has a very high level
of workpiece competence. In addition,
MAPAL covers the complete range of
tasks for machining cubic parts inclu-
ding process analysis and planning,
tool technology and logistics services
and retooling tool machines for new
parts (re.tooling).
20 21
Reaming and
fine boring tools
For 60 years, using reamers and fine
boring tools with guide pads, MAPAL
has set the highest quality standards
for cutting with geometrically defined
cutting edges. The MAPAL principle
guarantees the dimensional stability
and form of the bore within just a few
microns, reliably and economically.
While the guide pads are specifically
designed for their task (guiding the
tool in the bore), the blades, which are
precisely matched to the machining
task in cutting material and cutting
lead, deal with cutting the material.
Whether cast iron, steel or other
materials, MAPAL tools always achieve
remarkable results.
Also in the area of multi-bladed, fixed
reamers MAPAL offers a versatile range
of high performance tools that address
the requirements of many customers
for high quality with easy tool handling.
The portfolio ranges from ø 0.6 - 300
mm and stretches from microreamers
through monoblock designs to the
innovative replaceable head systems,
the high performance reamers in the
HPR series.
Due to the HFS® replaceable head
system and the accuracies that can
be achieved with it, this modern,
modular tool system offers maximum
performance and flexibility, as well as
advantageous combinations of different cutting systems on custom tools,
and as a result totally new forms of
efficient production.
22 23
PCD tools
In the area of tools with PCD blades
MAPAL has emerged as one of the principal manufacturers in the last ten
years. The programme for this product
line includes precision gun boring
tools, circular interpolation milling
tools and end mills, and a successful
face milling head system with replaceable milling cartridges.
Modern and high-precision clamping
systems combined with precision
grinding quality for maximum dimensional stability and concentricity open
up numerous options for fixed and
brazed MAPAL PCD tools, not only
in HSC operations.
ISO tools
Tools with ISO elements represent efficient and reliable
solutions with all materials for pre-machining and fine
machining when boring and milling. ISO indexable inserts
and tool holders are used in a radial and preferably tangential form for the boring tools. The milling program includes
face and shoulder cutter heads, face end and disc milling
cutters as well as helix milling cutters for the cost-effective
and flexible machining of large bores. A wide range of selected substrates, geometries and coatings with suitable indexable inserts ensures that the optimal cutting edge can be
used for every application.
Actuating tools
Actuating tools are available for maximum rationalisation
and optimisation potential, particularly in mass production.
Different mechanical actuating principles combined with
facing heads allow for complex contours, various diameters,
flat surfaces or recesses to be machined with just one tool.
As a result of the mechatronic TOOLTRONIC® tool system
that is directly connected to the controller as a drive module, the machine has an additional axis available. TOOLTRONIC® opens even more possibilities for flexible and costeffective machining.
24 25
Solid carbide tools
To provide a complete range of competences in bore machining, MAPAL also
offers a product line of excellent special and standard tools in solid carbide.
This range from simple drills to the
latest high performance drill. Tools
which achieve reaming quality in a
single pass are a particular highlight
in this product line.
Coatings developed especially for
boring and the use of super cutting
materials PCD and PCBN are further
features which increase the performance of MAPAL solid carbide tools.
Clamping systems
MAPAL offers a complete system of
clamping devices for use on machining
centres, special machines and transfer
units, right through to multi-tasking
machines. The programme of precision
chucks is rounded off by a wide range
of extensions and reducing elements
plus adaptors and flange adaptors.
MAPAL´s programme of clamping
systems offers the perfect solution for
every application and a connection
which provides the tool with the concentricity and repeatable accuracy it
requires in use. Numerous options and
perspectives for modern production
technology open up.
Customer services
MAPAL provides perfect engineering
for the entire machining process.From
the pilot phase through design, planning and procurement of components,
to start-up, MAPAL provides appropriate, cost-effective services. The customer receive support during the manufacturing process and optimisation is
continuous.
MAPAL service guarantees optimum
results for your special applications –
and at reduced costs. Many years of
intensive and customer-orientated
collaboration make MAPAL a specialist
also in the service area.
Setting devices
The precision of surface, form and dimension which can be achieved with
MAPAL tools with guide pads are at the
top end of what is feasible with geometrically defined blades. To manufacture to micro-precision reliably and
repeatedly with every new blade and
every new tool, MAPAL offers special
tool setting devices which make setting easy. Mechanical and electronic
versions are included in the supply
programme.
Innovation
Realizing the impossible
28 29
“We believe that real innovations provide the thrust for the development of a company. But for innovations we must create freedom in our
employees’ thinking and acting. It is only freedom which will lead to
new ways that drive technology forwards.
And: Innovations must be presented to the customers with force,
courage and pace. Only then will they bring the company success.“
Dr. Jochen Kress
Minimal quantity lubrication
TOOLTRONIC®
MAPAL was and is decisively involved
in the development of new technologies. At the MAPAL development centre experienced specialists deal intensively with subjects such as minimal
quantity lubrication, high speed and
high performance cutting (HSC and
HPC) and the machining of special
materials. Today hardened steels,
sintered materials, CGI or ADI play
an important role in this. MAPAL customers profit from this technological
advance with tools which offer greater
economies and quality.
Innovations are a feature of all MAPAL
products. Many of these innovations
relate to the solution of tasks with
which our customers confront us
on a daily basis. Often unusual ways
are adopted for this and almost unachievable targets reached. In principle, the objective is to find new tool
ideas which achieve savings potential
of more than 30 %. A modern range
of machines in MAPAL's development
centre allows trials to be carried out as
closely as possible to how the operations will run subsequently at the customer's works.
Face milling heads with PCD
and PCBN replaceable cartridges
Hard machining
By working doggedly on new tasks,
but also by making large and small
steps with current problems, MAPAL
innovations repeatedly lead to new
paths and new opportunities in cutting
operations. Examples such as machining cast iron with PCD, hard machining with multi-bladed tools or the
development of the HFS® Head Fitting
System demonstrate expertise, a richness of ideas and creative potential.
Replaceable Head Systems:
left: Replaceable milling cutter CPMill
right: HFS® Head Fitting Systems with
radial clamping
Precision
Absolutely precise
32 33
“Precision is MAPAL's promise to the market and consequently an ongoing and self-evident obligation on our Company. Our customers can rely
on this. And they know it.“
Dr. Dieter Kress
The precision which can be achieved
on the part relates directly to the precision of the tool. With the diversity
and number of MAPAL's special tools
consistent and thorough quality assurance represents an indispensable and
fundamental principle for the products'
success. The use of modern machining
methods combined with decades of
experience guarantees that the tools
achieve the highest precision.
The high precision of MAPAL tools
reflects directly on the customers' production. For finish machining MAPAL
offers interesting tool concepts with
which previously necessary semifinishing operations and even additional
operations, such as grinding or honing,
can be dispensed with entirely. The reduction in production costs and the
simultaneous increase or assurance
of machining results under batch production conditions is the aim of every
MAPAL tool we offer.
The requirements for circular and
cylindrical form and surface finish
when producing valve bodies for
automatic transmission systems are
less than 4 µm, with additional SPC
limitations. MAPAL tools achieve this
quality thanks to their precision and
the MAPAL principle. In a further
example a critical surface requirement
is achieved when machining a steering
box with a particular cutting lead. The
result lies with a dominant waviness of
WDc at < 0,2 µm. This means that
there is no need for costly additional
machining on the bore.
Reliability
Absolutely dependable
36 37
“If one is constantly in dialogue with customers – as we are – reliability
in all areas and at all levels of the company is an essential maxim for
people’s dealings. How can one otherwise face the customer?“
Dr. Dieter Kress
The provision of process-orientated,
comprehensive and customer-focused
solutions defines the way MAPAL operates. This includes much more than
manufacturing efficient tools, precision blades or accurate clamping devices. Reliable customer services covering all products are ultimately the
guarantee of their sound and profitable
function. Service is an evermore important factor in MAPAL's understanding and the capacity which is reserved
for this is suitably large. MAPAL is open
to finding innovative ways when offering customer services. Considerable
experience in the machining of cubic
parts provides the necessary background.
Reliable partners and reliable tooling
bring about the appropriately high
process reliability for today's requirements. This means that when they are
fitted onto the spindle, the tools immediately produce the right quality,
the blade cuts for a long and precisely
determined time and the preparation
and tool supply is properly organised.
MAPAL has the right products to offer
for all these factors and as a result
provides reliable production.
The demands set by the customer with
regard to process reliability has a Cpk
value of 1,67. Production reliability
increases as the Cpk value increases.
3 to 4 times the values, for example, is
achieved when machining the cam
shaft bearing bore in cylinder heads.
Diameter tolerances and concentricity
results for the individual journals in
relation to each other are accurately
maintained, both for the cam shaft and
the crank shaft bearing bore, by means
of the guide pads in MAPAL tools.
Sharpening the senses
Dialogue with technology
40 41
“Dialogue with technology – constant, uninhibited and free. For this we
need to win over our younger employees. This is the only way we will
find the new ideas, pioneering solutions, real innovations which the
manufacturing economy needs.“
Dr. Dieter Kress
The people at MAPAL navigate the
conflicting fields of defining tasks
and applying possible solutions by
continuous dialogue. This dialogue
is with other people but also with
technology itself.
Chip form, wear or the surface of the
part – they all provide information
about possible improvements. And this
technical dialogue is conducted internationally. All personnel at MAPAL
sites in Europe, America and Asia
work responsibly together with and for
technology within their area of work;
by doing so they contribute to the
success of the MAPAL Group and to the
successful use of tools by customers –
worldwide.
A prerequisite for qualified personnel
is good general and advanced training.
Today, because developments are
moving even faster, it is important to
recognise this for the old and the
young. It is in acknowledgement of
this that MAPAL guides and challenges
its employees and offers general and
advanced training in the various areas
of work.
There is also dialogue and association
with universities and research institutes. By commissioned work or
working together on combined
projects, fundamental trends are
investigated and solutions worked
out together.
42 43
“We are constantly in dialogue with technology – at all levels of the
company, hour by hour, day by day. This means that opportunities are
explored which present themselves in a wide variety of technical fields
– to the customers' advantage and for constantly optimised and
efficient production processes.“
Dr. Dieter Kress
MAPAL-E-01-040-0911-WD Printed in Germany. Right of technical modifications reserved!
www.mapal.com