MAPAL has introduced the second generation of its MEGA-Deep-Drill-Alu, designed to improve process reliability and machining performance when drilling deep holes in aluminium.
The new tool features an updated design that combines cutting-edge geometry, cooling and cutting materials to address key challenges in deep-hole drilling, including stable machining, efficient chip removal and high feed rates.
Its cutting geometry supports a broad range of aluminium alloys, from wrought materials to cast alloys with high silicon content. The straight main cutting edge helps minimise vibration, surface defects and burr formation, particularly when machining cross bores and angled exits.
Double point thinning and optimised chip flutes improve chip evacuation, while an adapted core diameter profile enhances tool stability at greater drilling depths.
The tool also incorporates four guide margins to maintain precise guidance throughout the drilling process. This helps ensure stable machining, including in applications involving cross bores and angled exits, even at high feed rates.
Efficient cooling as a differentiating feature
A key differentiating feature is the cooling system: newly defined cooling channels, enlarged by 20 percent, direct a higher volume of coolant to the main cutting edge and cutting edge corners. Compared with other solutions on the market with lower coolant volumes, they significantly improve wear behaviour, tool life and process stability. At the same time, stability, fracture strength and, therefore, process reliability are maintained. The advantage of this improved cooling behaviour is particularly relevant at large depths and in applications with minimum quantity lubrication.
High flexibility through a coordinated cutting material concept
The performance of the second-generation MEGA-Deep-Drill-Alu is significantly enhanced by the coordinated cutting material concept. The basis is an uncoated design with ultra-finely ground chip flutes. This enables process-reliable machining of different aluminium materials and already offers a broad range of applications. Two configurable head coatings are available for even more targeted adaptation to the silicon content of the aluminium alloy and the coolant/lubricant strategy. This means the MEGA-Deep-Drill-Alu covers a broad spectrum of aluminium cutting materials and enables stable processes in different applications.
Proven in practice, presented at AMB
The new second-generation MEGA-Deep-Drill-Alu from MAPAL offers large drilling depths, high process reliability and flexible adaptation to different aluminium materials, all in one integrated tool concept. Extensive trials with end-users confirm the great potential of the new generation. For example, the MEGA-Deep-Drill-Alu achieved feeds of up to 0.4 mm per revolution and tool lives of up to 3.2 kilometres.
The new deep drill was particularly developed for applications in the automotive industry and general machining. It is available in length versions from 15×D to 40×D and, depending on the respective length, in diameters from 3 to 16 mm.