Innovative Solution for Machining Long-Chipping Materials

Goodbye long chips! Mapal shows how to make short work of long chips

2025-07-07 Source: Mapal 2 min Reading Time

Machining long-chipping materials (such as stainless steels) is known to be a challenge when it comes to avoiding and removing chips. Now there is a solution!

The newly developed Mapal chip breaker technology for fine drilling not only improves the quality of the machined workpieces, it is said. It also increases the cost-effectiveness of production when it comes to machining long-chipping steels without annoying interruptions.(Bild: Mapal) — The newly developed Mapal chip breaker technology for fine drilling not only improves the quality of the machined workpieces, it is said. It also increases the cost-effectiveness of production when it comes to machining long-chipping steels without annoying interruptions.
(Bild: Mapal)

In metalworking, chip formation plays a central role in process reliability, tool life and surface quality, according to the company. Controlled chip formation is particularly important in the fine machining of unalloyed, alloyed and stainless steels. However, influencing this has been difficult until now. But with the development of a new, standardised chip breaker geometry for its fine boring inserts, the cutting tool manufacturer Mapal from Aalen has now taken a decisive step in this direction. The innovation is expected to bring both technical and economic advantages when it comes to machining long-chipping materials.

Chip breaking thanks to optimally coordinated tool geometries

The new development combines a precisely defined rake angle and chip angle geometry with optimally coordinated cutting values and cutting depths. This precise coordination perfectly influences chip formation and breaking behaviour — even with demanding materials. Machinists benefit from optimal chip removal, reduced heat generation and significantly increased process stability. The advantages of this innovation are not only evident in the machining quality of the workpieces, but also in the cost-effectiveness of the machining process. Previously, long chips had to be removed from the machine and/or the tool from time to time. This meant that the machine was at a standstill during this chip removal phase. This is now a thing of the past. In addition, tool wear is reduced and the workpiece is significantly more dimensionally accurate — a real advance in machining technology, as Mapal emphasises.

Gallery

Mapal has precisely coordinated the cutting angle and chip angle geometry and combined them ideally with cutting values and depths, according to the company. It now allows perfect chip formation and forced chip breaking in long-chipping steel materials.(Bild: Mapal)

Cutting geometry with that special touch! Comparison of chip formation during fine drilling with almost identical Mapal cutting edges. On the right, however, without chip breaker, and on the left, the result with new chip breaker geometry, which was machined on the same cutting edge type.(Bild: P. Königsreuther)

Defined chip breaking for long chips becomes standard process

The Aalen-based company admits that chip breakers are not a new invention. And until now, Mapal has tended to use chip breakers on an individual basis, i.e. tailored to the workpiece. But the idea of implementing standardisation for long-chipping steel materials in fine drilling is new. And the chip breaker geometry developed by Mapal combines decades of experience in this field with a clear focus on cost-effectiveness and application orientation. The fine-drilling inserts with chipbreaker geometry for unalloyed, alloyed and stainless steels will be available from autumn 2025 with defined geometries and coatings. The completely new approach to chip breaking will then be presented at EMO Hannover 2025 for the field of fine-drilling tools.

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