With the second generation of the MEGA Deep Drill Alu, MAPAL sets new standards in aluminum machining. The new tool is designed to reliably master the typical challenges of large drilling depths – stable processes, secure chip removal, and high feeds.
The basis is a newly developed overall concept of cutting geometry, cooling, and cutting material. The new geometry covers a wide application spectrum from wrought alloys to high-silicon cast alloys. The straight main cutting edge ensures smooth, low-vibration processes and reduces breakout and burr formation, especially in demanding applications such as cross drilling or angled exits. A double point and optimized flutes ensure improved chip transport. The adapted core design also increases tool stability, thereby enhancing process reliability at large drilling depths.
Another central factor for process reliability is the precise tool guidance over the entire drilling depth. Four guiding phases stabilize the process even in cross drilling or angled exits and ensure reliable machining conditions even at high feeds.
Efficient cooling as a differentiating feature
A central differentiating feature is the cooling system: newly defined, 20 percent enlarged cooling channels deliver a higher volume of coolant to the main cutting edge and cutting surfaces. They significantly improve wear behavior, tool life, and process stability compared to other market solutions with lower cooling volumes. At the same time, stability, break resistance, and thus process reliability are maintained. The advantage of this improved cooling behavior is particularly relevant at great depths and in applications with minimal quantity lubrication.
High flexibility through a coordinated cutting material concept
A decisive contribution to the performance capability of the second generation MEGA Deep Drill Alu is made by the coordinated cutting material concept. The basis is an uncoated version with finely ground flutes. It enables process-safe machining of different aluminum materials and already offers a wide range of applications. For even more targeted adaptation to the silicon content of the aluminum alloy and the cooling lubricant strategy, two configurable head coatings are available. Thus, the MEGA Deep Drill Alu covers a wide spectrum of aluminum cutting materials and enables stable processes in various applications.
Proven in practice, presented at AMB
With the new MEGA Deep Drill Alu of the second generation, MAPAL combines large drilling depths, high process reliability, and flexible adaptation to different aluminum materials in a consistent tool concept. Extensive testing with users confirms the great potential of the new generation. The MEGA Deep Drill Alu achieved feeds of up to 0.4 mm per revolution and travel distances of up to 3.2 kilometers.
The new deep drill will be offered in the standard program with length variations from 15×D to 40×D and – depending on the respective length – diameters from 3 to 16 mm – especially for applications in the automotive industry and general mechanical engineering.
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