NeoMill® milling cutters combine productivity and cost-effectiveness

The radial NeoMill® standard milling cutter programme by MAPAL with its face, shoulder, slot, shell end face and high-feed milling cutters stands for maximum productivity and cost-effectiveness, especially in series production. The development was based on many years of experience with custom tools, which the industry uses to produce large quantities very efficiently with consistent quality.​
UNIQ Mill Chuck & UNIQ DReaM Chuck 4,5° recebem prémio de design 

Trabalhar no mundo de TI

Juntos, definiremos o rumo para o futuro. Apostamos numa abordagem humana, visão alargada e numa organização bem estruturada. Tudo isto constitui a base para uma perspetiva prospetiva e fiável, assim como para a qualidade dos nossos produtos e serviços. Como empregador e parceiro tecnológico, isto é algo de que sempre nos orgulhámos. Agora queremos crescer ainda mais – consigo na equipa.

Não é apenas um importante impulsor da digitalização – mas também escreve de raiz com cada linha de código. Isso faz de si um elemento perfeito para a nossa equipa: Porque colocámos a digitalização no centro das nossas competências e serviços. Trabalhamos internacionalmente, em equipas ágeis e com as mais recentes ferramentas e estruturas. Isto resulta em projetos desafiantes e oportunidades de desenvolvimento para si – para si connosco.

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O programa de fresagem radial standard NeoMill da MAPAL.

AT A GLANCE

  • Milling cutter range with compacted radial indexable inserts

  • Face, shoulder, slot and shell end face milling cutters
  • For roughing and medium machining with one tool
  • Positive and negative indexable inserts made from different PVD and CVD cutting materials
     

ADVANTAGES

  • Indexable inserts for maximum efficiency also in difficult machining conditions
  • Very high surface quality due to indexable inserts with wiper component
  • For all applications in cast iron, steel and stainless steel, as well as heat-resistant cast steel (turbocharger materials)
  • High cutting volume

NeoMill® standard programme

For all milling cutters, MAPAL offers a wide range of indexable inserts – each in a positive and a negative design. In addition, there are cutting edges with a wiper portion, which achieve good surface qualities even without being set. 

The negative inserts do not have a clearance angle and can therefore be designed with cutting edges on the contact surface. If the basic shape is the same, negative inserts thus have double the number of cutting edges compared with their positive counterparts. In combination with the high tool life of the indexable inserts, this makes the negative indexable inserts particularly cost-effective.

Applications

Download area:

  1. Brake caliper
  2. Swivel bearing
  3. Turbocharger
  4. Compressors
  5. Hydraulic pump
  6. Engine block
  7. Valve housing
  8. Transmission

Selection steps for the NeoMill® milling cutter

As a technology partner, MAPAL supports the selection and optimum use of the NeoMill® milling cutters with knowledge of tooling and processing.​​​​​​​.

  • 1. Component application and workpiece material

    Selection of application & workpiece material:

    Application: 
    Face milling, Shoulder milling, Ramping, Plunge milling, High-feed milling​​​​​​​
    Workpiece material:
    Steel, Stainless steel, Cast iron​​​​​​​


  • 2. Machining conditions

    The machine, clamping fixture and shape of the workpiece influence the machining conditions:

    • Interrupted cut
    • Low cutting width
    • Dry machining
    • Very heavy interrupted cut
    • Vibration-prone
    • Wet machining (thermal shock)

  • 3. Insert geometry / insert form

    Positive rake angle and low cutting forces are decisive in unstable conditions

    Negative rake angle: Particularly cost-effective due to double-sided use and high edge stability

  • 4. Number of cutting edges / spacing

    Number of cutting edges and spacing depends on ap and ae

  • 5. Cutting edge design

    Cutting edge design depends on the workpiece material and application
    R = Roughing
    M = Medium machining
    U = Difficult conditions

  • 6. Milling ratio ae / Ø

    Optimum ratio of the milling cutter diameter and the cutting width

    The ratio of the milling cutter diameter and the cutting width ae should be ae = 70% Dc or ae < 25% Dc.

  • 7. Milling strategy

    Run-in with one radius

    Running-in with a radius keeps the chips thin when they exit, reduces vibrations and results in optimum tool life.

  • 8. Calculation of the process parameters

    Process-relevant calculations

    • Calculation of the cutting force

    • Power and torque
    • Templates for test reports
    • Cost-effectiveness calculation

Innovative and reliable machining solutions require a holistic understanding of the process

  • Milling application / Clamping setup

    Component requirements and clamping concept

  • Machining strategy

    Tool selection and design of the milling strategy

  • Increase in productivity

    Analysis and optimization of cutting parameters and cycle time

  • Standard
    programme

    Tools and indexable inserts available from stock

  • Process reliability & cost-effectiveness

    Support during production and cost-effectiveness calculations

  • Cooperative partnership

    Close contact, work out and carry out optimizations

Avoid vibrations using a vibration dampening system

  • Challenges when milling

    • Double projection length corresponds to 8x higher deflection, this leads to vibrations and increased noise generation
    • Strain upon tool and machine spindle
    • Long machining times due to reduction of the cutting parameters

  • MAPAL solution

    • Self-contained system consisting of heavy metal core, spring package and oil bearing
    • Tool adapter with internal cooling
    • Plug & Play: No setting of the vibration dampening system in the tool adapter necessary
    • Applicable for both the standard programme and for customised solutions

    Added value for customers

    • ​​​​​​​Saving up to 50% due to an increased material removal rate
    • Up to 60% better surface finishes
    • Process reliability by avoiding cutting-edge chipping

Trabalhar no mundo de TI

Juntos, definiremos o rumo para o futuro. Apostamos numa abordagem humana, visão alargada e numa organização bem estruturada. Tudo isto constitui a base para uma perspetiva prospetiva e fiável, assim como para a qualidade dos nossos produtos e serviços. Como empregador e parceiro tecnológico, isto é algo de que sempre nos orgulhámos. Agora queremos crescer ainda mais – consigo na equipa.

Não é apenas um importante impulsor da digitalização – mas também escreve de raiz com cada linha de código. Isso faz de si um elemento perfeito para a nossa equipa: Porque colocámos a digitalização no centro das nossas competências e serviços. Trabalhamos internacionalmente, em equipas ágeis e com as mais recentes ferramentas e estruturas. Isto resulta em projetos desafiantes e oportunidades de desenvolvimento para si – para si connosco.

Request now!

O seu contacto direto

Heiko Rup, product manager at MAPAL.

Pessoa de contacto

Heiko Rup Product and Application Management heiko.rup@mapal.com Phone: +49 7361 585 3034