Mapal Regrinding service – use full potential
Reprocessed solid carbide tools that reach a cutting performance of up to 100 percent in comparison to new tools are an important factor for the company for lowering production costs.
Up to 65 per cent of the tool costs can thus be saved in comparison to new purchase. Due to this reason MAPAL has already been offering its customers to process the tools according to manufacturer's quality. And that too all over the world with extensive service and significant added value for the customers.
“Today we offer a uniform reprocessing service to our customers globally for tools made from solid carbide within a few days”, say Ulrich Krenzer, managing director of the MAPAL competence centre for solid carbide tools and Frank Dreher, managing director of the MAPAL competence centre for multi-bladed reamers. To achieve the full potential of the tools, the regrinding and recoating in manufacturer's quality is essential. Only then can we guarantee process secure and constant machining results and cutting performance of up to 100 percent in comparison to the new tools. The risk of tool breakage and thus the risk of damages to the component or the machine are minimized.
Globally standardised processes
To offer the same service and the same quality to customers all over the world, MAPAL has standardised the reprocessing process to 25 regrinding centers for solid carbide tools, reamers, drills and milling cutters. Due to the extensive distribution network of MAPAL, the direct connectivity of the customer to the respective regrinding center is ensured. The clearly defined process sequences ensure fast service in addition to high quality and shorter throughput times of the tools.
Upon request MAPAL undertakes the safe transport of the tools in special tool boxes. Before the regrinding the tools are inspected by a highly qualified expert. “To regrind the original geometry the original CNC programs and the original grinding wheels are used”, explains Krenzer. Apart from the grinding wheels even the machine layouts as well as measuring procedures and measuring equipment used in the MAPAL regrinding centers are standardised. All the relevant details are available at all the MAPAL locations in a data base. These details are always kept up-to-date. Even optimizations made to the tools are saved in it. In this way every customer tool is always in line with the latest technical standard.
Knowledge and experience are critical
Apart from all these pre-requisites even the know-how of the employees and their experience is a decisive factor for the quality of reprocessing. And this knowledge lies in the MAPAL competence centres. Tool experts have been working for decades over there with geometry, coating and grinding of tools. “To secure the know-how further to the top level, we train the employees continuously in our competence centres. If required, all the employees entrusted with the regrinding at any location can fall back on a product specialist in the competence centres”, declares Dreher.
For recoating the tools, MAPAL works together with an internationally active coating company which guarantees the same coating like that of the new tool even for the reprocessed tools. Naturally, pre- and post processing of the tool are identical to the re-manufactured piece.
Planning and process reliability for the customers
“With clearly defined standards and continuous monitoring of the procedures and tools, we offer our customers planning and process reliability. Tools reground by us can be operated with the same operating data as for the new tools. Changes must not be made to the process parameter”, explains Krenzer. After a short period the customer gets back his reamer, his drill or his milling cutter made of solid carbide in manufacturer’s quality. After the reprocessing the tools give the same performance as a new tool and that too for one third of the price of a new tool.