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.

Request now!
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. 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

IT-世界的各种工作

和您一起，我们共同走向未来。我们构建了以人为本、具有发展远见和深思熟虑的组织架构。铸造了MAPAL发展的一切基础，从而不仅确保了我们的发展前景具有前瞻性，同时还具有可靠的保障。而这样的管理模式和组织架构也是我们为客户提供优质产品和服务的立足之本。作为雇主和技术合作伙伴，我们一直为此深感自豪。现在，我们希望您成为这个团队的一员——我们共谋发展。

您不仅是一个数字化进程的重要推动力——通过您的每一行代码，让我们共同书写春秋。欢迎您融入到我们的团队之中：因为，我们已经把公司数字化进程列为了提升我们综合实力和工作成效的核心工作。我们以国际化为导向，通过快速响应的团队，采用各种最新型的辅助工具和框架开展各项工作。因而可以为您带来多种多样的、富有挑战的项目和发展机会——为了自己的未来，请加入到我们的行列。

Request now!

您的直接联系方式

Heiko Rup, product manager at MAPAL.

联系人

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