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.​
Hydro Mill Chuck and Hydro Dream Chuck standing in a new design
UNIQ Mill Chuck et UNIQ DReaM Chuck 4,5° reçoivent le Design Award 

You are looking for a powerful milling cutter for your application?

Do you need a milling cutter with which you can achieve a high metal removal rate and increase your tool life? Then we have the perfect solution for you with our NeoMill milling program.

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The radial NeoMill standard milling cutter programme by 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. Kalkulatorische Ermittlung der Prozessparameter

    Prozessrelevante Berechnungen

    • Schnittkraftberechnung

    • Leistung und Drehmoment
    • Vorlagen für Versuchsberichte
    • Wirtschaftlichkeitsberechnung

Innovative und prozesssichere Zerspanungslösungen erfordern ein ganzheitliches Prozessverständnis

  • Fräsanwendung & Aufspannung

    Bauteilanforderungen und Spannkonzept

  • Bearbeitungs-
    strategie

    Werkzeugauswahl und Auslegung der Frässtrategie

  • Steigerung der Produktivität

    Analyse und Optimierung der Schnittparameter und Taktzeit

  • Standard-
    programm

    Ab Lager verfügbare Werkzeuge und Wendeschneidplatten

  • Prozess-
    sicherheit & Wirtschaft-
    lichkeit

    Unterstützung beim Einsatz im Prozess 

  • Partnerschaftliche Zusammenarbeit

    Enger Kontakt und Optimierungspotentiale verbessern

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

ITの世界で働く

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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担当連絡先

Heiko Rup, product manager at MAPAL.

担当者

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