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New tooling line improves milling performance

Posted on 16 Jun 2020 and read 803 times
New tooling line improves milling performanceRugby-based Mapal Ltd (www.mapal.com) has expanded its high-performance milling portfolio with the new OptiMill SPM family of milling tools for processing aluminium and steel.

These tools are available in two formats — for roughing and finishing — and they can be used for machining aerospace structural parts made of aluminium and aerospace alloys.

The new three-flute OptiMill-SPM-Rough accommodates ‘optimised in-feed’ machining depths, as well as high feeds during roughing, thanks to a knurled roughing geometry which ensures that the power consumption during machining is significantly lower compared to tools with a straight cutting edge.

Furthermore, heat transfer to the part is minimised by the ‘excellent plunging characteristics’ of the tool. These cutters are available with diameters of 12, 16, 20 and 25mm, while corner radii of 2, 3 and 4mm help to prolong tool life and prevent edge chipping during heavy-duty cutting.

With a short flute length of 1.5xD and polished flutes, the OptiMill-SPM-Rough has been designed to achieve high rates of material removal rates, while minimising vibration and cutting forces.

The uncoated four-flute OptiMill-SPM-Finish, which has been designed for finishing contours and pocket walls (even at large depths in a single pass), prevents ‘swarf wrapping’ even when operating in corners with high levels of tool contact and high machining loads.

Furthermore, the cutting-edge geometry ensures that there is no vibration during machining — and the chip flutes are polished to optimise chip removal. Like the OptiMill-SPM-Rough, the OptiMill-SPM-Finish is available in diameters from 12 to 25mm (with imperial variants available on request).

These end mills are offered with corner radii from 2 to 4mm. Meanwhile, the new OptiMill-Uni-Wave is for full slot milling at machining depths up to 2xD in a variety of materials.

Incorporating central internal cooling for optimal chip removal and tool life, this PVD-coated cutter is available in diameters of 4, 6, 8, 10, 12, 16 and 20mm.

It is also available (in diameters from 6 to 20mm) as an extra-long version for roughing — even in deep cavities — offering ‘extremely stable cutting conditions’ due to its conically shaped neck.