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 y UNIQ DReaM Chuck 4,5° reciben el Design Award 

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一緒に未来への道を切り開いていきましょう。そのためには人間性、先見性、そして考え抜かれた組織が必要です。これらはすべて、将来を見据えた信頼性の高い視点と、製品やサービスの品質の基礎を形成します。これに関して私たちは雇用主として、また技術パートナーとして、常に誇りに思っています。今、私たちはあなたと一緒にチームでさらに成長したいと考えています。

あなたはデジタル化の重要な推進者であるだけでなく、コードの一行一行によりゼロからデジタル化を実現しているのです。私たちは、デジタル化を自分たちの能力とサービスの中核に据えているので、あなたは私たちのチームに完全に適合します。私たちは、国際的に活動し、アジャイルチームで最新のツールやフレームワークを使って仕事をしています。その結果、やりがいのあるプロジェクトや開発の機会を私たちと一緒に得ることができるのです。

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MAPALのラジアル標準フライス盤NeoMill。

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

Notre service informatique

Ensemble, préparons l'avenir : misons sur des relations humaines, une vision sur le long terme et une organisation réfléchie. Ce sont là les fondements sur lesquels nous nous appuyons pour offrir des perspectives d'avenir solides et des produits et services de qualité. En tant qu'employeur et partenaire technologique, ces valeurs font notre fierté depuis toujours. À présent, l'heure est venue de poursuivre notre croissance, avec toi dans notre équipe.

Tu es non seulement un développeur important de la numérisation, mais tu la façonnes avec chaque ligne de code que tu écris. Tu es exactement la personne qu'il faut dans notre équipe : chez nous la numérisation s'inscrit en effet au cœur de nos compétences et de nos prestations. Nous travaillons à l'international, avec des équipes agiles, en utilisant les outils et les frameworks les plus récents. Par conséquent, te nous proposons des projets exigeants et des possibilités d'évolution avec nous.

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Votre contact direct

Heiko Rup, product manager at MAPAL.

Interlocuteur

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