Press release no. 2014-06-05_4
Date:
08.02.2016
3D laser sintering: First series-production applications in the
tool sector
The possibilities of additive production are seemingly infinite. In the current
hype surrounding the new technology, researchers and developers are looking
for potential fields of application for the use of 3D printers. As one of the first
manufacturers of precision tools, MAPAL invested in a 3D printer in 2013 in
order to pioneer new ways of producing tools by means of laser sintering. The
first project has now been brought to series-production maturity: The
indexable insert drill QTD (patent pending) for the diameter range below 13
mm.
The technology of laser sintering offers manufacturers of precision tools large
degrees of design freedom. Within the space of the laser printer, tool geometries can
be created unhindered by machine clamps, tools and production means. A broad and
continually expanding range of materials is also available for the laser sintering
process. MAPAL has therefore tried to produce tools by laser sintering that cannot or
cannot optimally be produced by conventional means. One example are small
diameters of the indexable insert drill QTD originally brought to the market in 2013.
Optimum cooling channel design possible using laser sintering
The QTD has been available as standard from 13 mm diameter. Responsible for this
is among other facts the cooling duct in the basic tool body. Normally in tool bodies
with constant helical pitch for insert drills, the coolant is fed centrally to the front
where it is then distributed to the inserts via a Y-fork. The smaller the tool body, the
more this coolant supply system impairs the performance of the tool, because the
central coolant supply weakens the core of the drill and makes it unstable.
Furthermore, the coolant channels have to be made increasingly smaller. This results
in a decreasing flow rate of the coolant to the insert at the front. Steel tool bodies with
the spiral cooling ducts that are common in solid carbide tools are not yet common in
small diameters.
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Press release no. 2014-06-05_4
Date:
08.02.2016
The use of laser sintering for the production of the tool body opens up new degrees
of geometric freedom. Tool bodies in the diameter range from 9 to 12 mm with spiral
coolant channels are now being produced on the 3D printer. Compared with the
central coolant supply with diversions, this design permits a 100% increased coolant
flow rate, particularly thanks to the deviation from the circular coolant channel profile.
Furthermore, hybrid models are possible in which the conventional and the additive
sinter production are combined in order to further improve the cost-effectiveness of
the production process.
Illustration:
Ill 1:
Production of tool bodies for the indexable insert drill QTD using the 3D laser
sintering process.
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If published, please send a voucher copy
by mail to Mrs Kathrin Rehor or
by e-mail to kathrin.rehor@de.mapal.com.
Short profile MAPAL Dr. Kress KG:
MAPAL – tooling the customer's success
MAPAL Präzisionswerkzeuge Dr. Kress KG is one of the leading international suppliers of
precision tools for the machining of practically all materials. The company founded in 1950
supplies leading customers from the automotive and aerospace industries and from machine
and plant engineering. With its innovations the family-owned company sets trends and
standards in production and machining technology. MAPAL sees itself as a technology
partner, supporting its customers with the development of efficient and resource-conserving
machining processes using individual tool concepts. The company is represented with
production facilities, sales subsidiaries and representatives in 44 countries worldwide. In 2013
the MAPAL Group had 4,300 employees, generating sales of EUR 470 million.
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