MAPAL'S BFS CONNECTION FOR REPLACEABLE HEAD MILLING SYSTEMS

MAPAL has introduced a new, patent-pending bayonet-type connection for milling cutter systems with a replaceable head at the AMB 2024. Users benefit from very easy handling with rigid connection and optimal cooling. The tool manufacturer also saves carbide with the connection, conserving resources.

The functional principle of the new connection couldn’t be easier: the replaceable head only must be inserted and turned 90 degrees to be locked. That’s a lot easier than the previous system for replaceable head milling cutters from MAPAL or comparable systems where the replaceable head is threaded and must be screwed in several turns.

The bayonet system achieves very high rigidity thanks to the large cylindrical face connection. While the force only acts on one side while tightening a thread due to the thread’s pitch, the new MAPAL system ensures symmetrical insertion and good distribution of force.

Increased tool life and better machining quality
Together with the connection, MAPAL is also presenting a new tool holder design. The tool holder has a ring of cooling channel bores, which enables a much higher volume of cooling than conventional internal cooling can provide. By channeling the coolant directly to the area of the cutting edges, the tool life is extended and machining quality improved.

In addition, by doing away with a central cooling channel bore, the milling head becomes much more stable. The tool holder is 10 to 15% more rigid than comparable systems, resulting in higher achievable form and position tolerances, smoother processes and longer tool life.

The solid carbide replaceable heads from MAPAL also impress thanks to their high process reliability as inserts cannot become loose at high temperatures. If tool breakage does occur, the connection’s simple assembly ensures that the machining process can be resumed quickly.

Modular tool systems with a steel-shank tool holder have also been marketed to conserve carbide. With the bayonet connection, MAPAL is going one step further. Compared to the previous connection, 70% less material is used, in keeping with the trend towards more sustainability.

Diverse range of applications
The connection is offered in 7 different sizes with head diameters from 11.8mm to 22.5mm and head lengths up to 1xD, which enables a variety of applications. In addition to the replaceable heads, the tool manufacturer can also custom design the tool holder to optimize the coolant supply for requirements, for example.

MAPAL is also exhibiting two initial applications together with the bayonet connection at the AMB. A solid carbide head with five cutting edges is being used by customers from the automotive industry as a ball nose milling cutter to manufacture homokinetic joints. The soft machining of this component, which is integrated in the power train, requires a high degree of precision. Another tool is a form cutter for machining ball joints on drive shafts.