Rugby-based Mapal Ltd has introduced the new OptiMill-3D series, a completely new line of high-performance solid carbide end mills targeted at the tool and mould-making industry. Along with extremely heat-resistant coatings and special carbide substrates, the new tools are characterised by the dimensions and geometries specifically adapted to mould making.

Suitable for milling hard parts in the domain of 45 to 66HRc, the new OptiMill-­3D-HF-Hardened offers either four or six cutting edges — Mapal has developed the two variants for high-feed milling on challenging materials.

To optimise performance and longevity on challenging tasks like interrupted cutting, Mapal has developed a special face geometry. The four-flute tool is the primary choice for roughing and pre-finishing. However, with fewer cutting edges and a wider chip gullet, rapid and reliable removal of swarf is ensured. Available from 2 to 16mm diameter, the four-flute tool is ideal for long overhang applications such as machining in deep cavities.

Also perfect for roughing and pre-finishing, the six-flute series demonstrates impressive characteristics when finishing flat surfaces with a high-feed rate. It produces the best surface finishes and flatness, and with a PVD coating, the tool dissipates heat generation to ensure tool life is prolonged.

Available from 6 to 16mm diameter the OptiMill-3D-HF-Hardened is complemented by the three- and four-flute OptiMill-3D-HF for softer material machining.

Also new to the solid carbide range is the new OptiMill-3D-CR-Hardened with a corner radius which is ideal for finishing 3-D mould tools up to a hardness of 66HRc; this line produces smooth, high-gloss surface finishes when machining at maximum feed rates. Offered in diameters from 4 to 12mm with highly accurate corner radii of 0.5, 1 and 2mm, the PVD coated tool is available with a selection of different lengths and corner radii to suit the machining demands of the end user.

The new circular radius milling cutters that are also known as ‘conical barrel tools’ have arrived at Mapal in the form of the OptiMill-3D-CS series. Perfect for mould-making applications in deep cavities, complex free-form shapes as well as the manufacture of turbine blades and impellers – the new OptiMill-3D-CS series is considered by Mapal to be a ‘game-changer’ in productivity and performance.

The special feature of the tools is the optimal geometric combination of radius and form that makes a larger path spacing during pre-finishing and finishing possible. The machining time can be significantly reduced and the quality of the surface finish on the parts noticeably improved.

For machining deep, difficult-to-access cavities, the OptiMill-3D-CS in droplet shape with diameters from 2 to 12mm and an effective radius up to 95mm is available. For machining large surfaces and surfaces with tool restrictions, the cutter is also offered in a tapered shape. These tools are available from 6 to 12mm with an effective edge radius of up to 250mm — the conical barrel tools require a high-performance CAM system to work effectively. However, with the addition of a suitable CAM system, the Mapal barrel tools can yield performance and material removal rate increases in the realms of 70% or more.