• A pocket milling cutter clamped in a tool holder machining a component

OptiMill®-HPC-Pocket

Maximum efficiency in pocket plunge milling

The milling tools of the OptiMill®-HPC‑Pocket family offer the in ultimate precision and efficiency in pocket milling. Both tools are equipped with an built-in drill tip that is particularly well suited to versatile applications such as helix milling, grooving and inclined plunging. In both milling cutters, large chip spaces ensure rapid and reliable chip removal, even at high machining volumes.


OptiMill®-Uni‑HPC‑Pocket – for versatile applications in steel, cast iron and stainless steel
OptiMill®-Alu‑HPC‑Pocket – specially optimised for aluminium and non‑ferrous metals

A milling cutter machining a workpiece, with chips flying

Wide range of applications

High productivity through versatile applications: the OptiMill®‑HPC‑Pocket family combines multiple milling processes in a single tool, thereby sustainably reducing tool changes and costs.
  • The image shows a milling cutter machining a workpiece, also referred to as ramp milling.

    Ramps
    • Inclined plunging up to 45°

  • The image shows a milling cutter machining a workpiece, also referred to as pocket milling.

    Pocket milling
    • Efficient and precise

  • The image shows a milling cutter machining a workpiece, also referred to as groove milling.

    Groove milling

    • Up to a depth of 3xD

  • The image shows a milling cutter machining a workpiece, also referred to as helix milling.

    Helix milling
    • Process‑reliable with very high feed rates

  • A milling cutter machining a workpiece during a plunging operation.

    Plunging
    • Thanks to the integrated drill tip

Innovative point thinning

An image showing a milling tool with the tool tip visible and highlighted in red

Integrated drill tip specifically for plunge milling
The innovative point thinning with integrated drill tip enables helix milling, grooving and inclined plunging with very high feed rates and excellent process reliability.

OptiMill®-HPC-Pocket family

The OptiMill®-Uni-HPC-Pocket and OptiMill®-Alu-HPC-Pocket ideal tools for efficient and precise machining of steel, cast iron and aluminium.
The diagram shows an 80% reduction in machining time with MAPAL compared to a conventional market solution.

80% shorter machining time

When milling an aluminum structural component from the aerospace industry, a significant increase in productivity was achieved with the OptiMill-Alu-HPC-Pocket. Compared to a conventional market solution, the machining time was reduced from 70 minutes to just 14 minutes.

This performance is driven by the interaction of tool and strategy:

Ramping (45°) enables stable and process-reliable plunging
Full-slot milling (ae = 16 mm) maximizes the material removal rate
Increased cutting parameters and large depths of cut significantly boost efficiency

While the competitor tool requires multiple passes with low depths of cut, MAPAL fully utilizes the tool’s potential through deep engagement and highly dynamic machining.

Result:
Significantly reduced machining time combined with high process reliability – ideal for the cost-effective machining of large aluminum volumes.

Cutting data

Material: Aluminium 2124 External cooling: Emulsion 8 % | 20bar 

Competitor
End mill: Ø 16 mm | z3
Machining strategy: 20 passes required
Cutting data:
Vc: 300 m/min
fz: 0,110 mm
ap: 2 mm
ae: 16 mm
Result: Machining time 70 minutes

MAPAL
OptiMill-Alu-HPC-Pocket: Ø 16 mm | z3
Machining strategy: Ramping (45°) | Full-slotting
Cutting data:
Ramping (45°):     Full-slotting:
Vc: 220 m/min       Vc: 401,9 m/min 
fz: 0,100 mm         fz: 0,125 mm 
ap: 22 mm             ap: 17 mm 
ae:  16 mm            ae: 16 mm
Result: Machining time 14 minutes due to significatly increased cutting parameters and a stable plunging strategy.