MAPAL launches advanced modular drilling and indexable insert tools tailored for modern combustion and hybrid engines, aiming to enhance precision, reduce cycle times and lower costs in machining crankshafts, valve seats and automotive components.
MAPAL has introduced a range of advanced tooling innovations that are aimed, quite explicitly, at supercharging efficiency and cutting costs when it comes to machining crankshafts and valve seats, especially for today’s modern combustion and hybrid engines. As the automotive industry pushes relentlessly to trim cycle times and dial down per-part expenses, MAPAL’s latest breakthroughs—built around modular systems and the use of cutting-edge materials—seek to boost both manufacturing precision and overall productivity.
One of the standout innovations is a sort of “all-in-one” drilling and deburring system developed specifically for crankshafts. Now, traditionally, machining the central relief bore—this is the hole that helps make the crankshaft lighter and more fuel-efficient—involved multiple tool passes due to the complex shape of the part. And those long drills—sometimes stretching between 600 and 800 millimeters—are a headache, especially when deep bore processing is involved. MAPAL’s modular approach, however, offers a replaceable drill head that’s connected via a torque transfer system—TTS—that’s designed to deliver optimal torque and maintain accuracy in radial run-out. An interesting detail—developed in partnership with HEULE Precision Tools—is that this same tool includes a miniaturised deburring unit, so burr removal and drilling happen simultaneously. The SNAP18 chamfer insert, which uses a spring-assisted mechanism for precise deburring in both forward and reverse directions, means one less step in the cycle—saving time and space in the tool magazine.
In the area of valve seat machining, MAPAL has concentrated on boosting tool life and maintaining high precision with its new HNHX indexable insert. Building on a previous hexagonal model, these inserts have doubled the number of cutting edges from six to twelve by enabling a simple turn, which really helps optimise tool usage. For more heavy-duty jobs—say, large valve seats in trucks or big industrial engines—they’ve even designed these inserts to be reconditioned multiple times, up to 24 cut edges, by removing and repositioning worn edges—something handled easily thanks to a special coating that assists with ID and repositioning. Made from PcBN—high-performance coated ceramics developed by MAPAL—they’re built to last longer and resist wear, especially important given the tricky materials used in valve seats. The robust clamping star design ensures force is distributed evenly across the insert seat, which helps achieve reliable, uniform machining performance.
When it comes to surface finishes, especially the ultra-smooth kind needed for valve seats—important in hybrid engines where combustion efficiency and emissions are under scrutiny—MAPAL’s HNHX inserts are engineered to produce surface roughness values below Ra 2.0. That’s pretty tight, and it meets even the most demanding quality specs. They also recommend a combo tool that can machine both valve guides and seats in just one setup, which streamlines production flow and drives down costs even further.
But MAPAL’s expertise doesn’t stop with just combustion engines. They’ve also expanded into other automotive components where productivity is key. For instance, their multi-bladed PCD fine boring tools are used to machine valve housings for automatic transmissions, achieving tight tolerances for things like cylinder form and roundness—down in the micrometre range. Collaboration with companies like Triumph Motorcycles demonstrates how MAPAL’s tailored tooling strategies can greatly reduce the number of tools needed and cut cycle times, so production lines can run smoother and faster.
Even with the electric vehicle surge, the development of combustion engine parts remains very relevant—particularly for hybrid vehicles where combustion components still play a crucial role. MAPAL definitely sees itself as a partner in this space, providing a continually evolving suite of precision tools to tackle emerging challenges in automotive machining. Their comprehensive approach—from modular drilling systems and innovative inserts to versatile combo tools—makes it pretty clear that their goal is to help cut machining times, reduce tooling costs, and improve overall quality and sustainability in engine part manufacturing.
References for each paragraph:
- Paragraph 1—I’ve pulled from the initial company news and general industry info.
- Paragraph 2—Same sources, with a focus on the crankshaft innovations and modular tools.
- Paragraph 3—Details about valve seat inserts, coating tech, and finishing quality, based on the specialized product info from MAPAL.
- Paragraph 4—Further info on surface quality and combination tools, as well as broader automotive component applications, backed by recent industry reports.
- Paragraph 5—Insights into collaborations and applications in different automotives, especially transmissions and brands like Triumph, from recent tooling strategy articles.
- Paragraph 6—Final thoughts on hybrid relevance and MAPAL’s holistic approach, supported by industry trend analyses.
Source: Noah Wire Services
