Die and mould makers expect high process and product expertise from their cutting tools manufacturer. This is because the tool life of the moulds to be created and the precision of the moulded parts are extremely important for competitiveness in mass production. Therefore, they require their tools to offer the highest levels of precision, a long tool life, and – above all – process reliability.
It is precisely these aspects that make MAPAL successful in sectors such as the automotive industry, machine engineering and the aerospace industry. Now the precision tool manufacturer is also offering efficient and economical solutions for the complete machining process in the die & mould sector. Versatile and precise high-performance tools and special tool holders with narrow contours and a precise radial run-out minimise polishing effort and reworking thanks to a constant surface finish in the milling process.
Tool range for mould making
Fraises en carbure monobloc
OptiMill-3D-BN
Fraises hémisphériques
Usinage hautement précis de contours 3D
Plage ø : 0,10 - 20,00 mm
OptiMill-3D-CR
Fraises rayonnées
Fraisage avec rayon de raccordement hautement précis
Plage ø : 0,10 - 20,00 mm
OptiMill Fraises à dresser
Fraises à dresser
Idéales pour l'ébauche, la finition, le fraisage trochoïdal et le fraisage de poches
Plage ø : 2,00 - 12,00 mm
OptiMill-3D-CS
Fresas com raio de canto
Acabamento de superfícies complexas de forma livre e geometrias complicadas de peças
Gama ø: 2,00 - 12,00 mm
OptiMill-3D-HF
Fraises à grande avance
Idéales pour l'usinage grande avance avec un volume d'enlèvement de copeaux élevé pour une fiabilité des processus accrue
Plage ø : 2,00 - 16,00 mm
OptiMill-3D-Alu
Fraises rayonnées/hémisphériques
Usinage hautement précis de contours 3D
Plage ø : 1,00 - 20,00 mm
OptiMill-Graphite-MT
Fraises à dresser et hémisphériques
Fraises multidents d'ébauche pour un taux d'enlèvement élevé avec les électrodes en graphite
Plage ø : 3,00 - 16,00 mm
OptiMill-3D-Graphite
Fraises rayonnées/hémisphériques
Adaptées pour l'usinage d'électrodes en graphite
Différents modèles selon la situation d'usinage
Plage ø : 0,20 - 12,00 mm
OptiMill-3D-Copper
Fraises rayonnées/hémisphériques
Géométrie spéciale pour l'usinage d'électrodes en cuivre et d'alliages non ferreux durs
Plage ø : 0,10 - 20,00 mm
OptiMill-Diamond
Fraises à dresser, rayonnées, hémisphériques
Coupes PCD pour une durée de vie élevée
Plage ø : 3,00 - 12,00 mm
Fraises à plaquettes amovibles
NeoMill-ISO-360
Fraises à plaquettes rondes
Idéales pour l'ébauche et la semi-finition
Plage ø : 10,00 - 160,00 mm
NeoMill-3D-Finish
Fraises de finition
Idéales pour la finition des surfaces angulaires, des surfaces planes et des contours
Plage ø : 16,00 - 42,00 mm
NeoMill-3D-Ballnose/-Torus
Fraises rayonnées/hémisphériques
Un corps de base avec plaquette de coupe pour la finition et la semi-finition
Plage ø : 8,00 - 32,00 mm
NeoMill-2/4-HiFeed90
Fraises à dresser/grande avance
Système d'outil universel pour une productivité maximale
Plage de ø : 16,00 - 200,00 mm
Perçage | Chanfreinage
ECU-Drill-Steel
Solid carbide drill
Double-edge solid drill with a good price-to-performance ratio
Wide range of applications
Proven geometries for high precision and process reliability
Ø area: 1.00 – 20.00 mm
MEGA-Drill-Hardened
High-performance solid carbide drill
Double-edge solid drills with coating and geometry suitable for reliable machining of hardened workpiece material
New micro-geometry and macro-geometry
Ø area: 2.55 – 16.00 mm
MEGA-Drill-Steel-Plus
High-performance solid carbide drill
Double-edge solid drills with coating and geometry suitable for steel machining
Optimised chip flute geometry and modified cutting-edge preparation
Ø area: 3.00 – 25.00 mm
Tritan-Drill-Steel
Triple-edge solid carbide drill
Triple-edge solid drills for maximum feed
Self-centring chisel for challenging drilling situations
Specially adapted to steel machining
Ø area: 4.00 – 20.00 mm
Tritan-Spot-Drill-Steel
Pilot drill
Triple-edge pilot drill for demanding pilot drilling situations
Specially adapted to triple-edge drills
Ø area: 4.00 – 20.00 mm
Tritan-Step-Drill
Triple-edge step drill
Triple-edge step drill with self-centring chisel
For machining threaded core holes without oscillating movement
Ø area: 4.25 – 14.15 mm
MEGA-Deep-Drill
Deep drill
Process-reliable and efficient creation of deep bores up to 40xD
MEGA-Pilot-Drill
Ø area: 1.00 – 16.00 mm
MEGA-Drill-Reamer
Drill reamer
Two working steps – drilling and reaming – combined in a single tool
Optimised reaming cutting edge
Reduction of productive and non-productive times
Bore tolerance ≥ IT7
Ø area: 4.00 – 16.00 mm
Precision countersink
Countersink with unequal spacing
Extremely unequally spaced cutting edges
Higher degree of accuracy and improved surface values
Reduced axial and radial forces
Significantly less vibrations
Increased cutting parameters to ensure highest productivity
Ø area: 4.30 – 31.00 mm
MEGA-Drill-Reamer-Pyramid
Drill reamer with pyramid tip
Spot drilling, drilling and reaming – all with one tool
Improved centring properties thanks to pyramid tip
Reduction of productive and non-productive times
Bore tolerance ≥ IT7
Ø area: 4.00 – 16.00 mm
QTD indexable insert drill
Solid drill with replaceable head system
Cost-effective system with indexable inserts that can be swapped out
Force-locking and form-fit clamping system
Easy to handle
High degree of radial run-out accuracy
Ø area: 8.10 – 49.00 mm
Reaming
FixReam – FXR
High-performance reamers with a cylindrical shank
High-performance reamer made from solid carbide
Straight-fluted for through and blind bores
Left-hand fluted for through bores
Ø area: 3.00 – 20.00 mm
CPReam – CPR
Replaceable head reamer
Taper and face connection provide the greatest possible stability and rigidity
Highly precise radial run-out accuracy of 5 μm
Easy to handle
Ø area: 8.00 – 40.00 mm
Quick adjustment reamer – WN 50
Hand reamers
Quick-adjust reamer with wide adjustment range
Especially suitable for repair work
Spare blade sets available
Ø area: 6.40 – 95.00 mm
Guided tools
Tools with guide pads
Highest accuracy guaranteed with the MAPAL principle
Guide pads directly guide the tool into the bore
Precision-ground indexable inserts
High-precision adjustment for micrometre-precise bore machining
Parts that become more and more complex with increasingly deep cavities as well as moulded and reinforcement ribs in plastic injection moulds and pressure die casting moulds necessitate the use of extra long tools with diameters that can be very small. Complex part geometries and various material characteristics place the highest demands on machining and tool life.
For designing, engineering and constructing medium- and large-sized cold forming tools, cast iron is often used due to material properties such as compressive strength and easy machinability. The main components here are mould plates and mould inserts. Here, MAPAL has a lot of experience with milling (2D and 3D) and drilling operations (drilling, reaming, thread cutting).
When it comes to pre-series or prototype moulds, it is not unusual to use materials that are easy to machine. Aluminium alloys or uriol (plastics) are often used. In these cases, solid carbide tools with positive and partly polished cutting edges, or better still, PCD-tipped tools ensure high productivity and short machining times.
Manufacturing of electrodes for EDM processes requires machining of copper alloys and graphite materials. The selection of the electrode material depends on the requirements of the mould to be created. Copper alloys are comparatively expensive and are generally used for finishing the electrodes, when it comes to high surface quality and shape accuracy. Solid carbide end mills with special geometries by MAPAL guarantee high-precision machining results here.
Graphite has a highly abrasive effect on the tool and causes strong wear on the cutting edge. The profiles to be machined tend to burst with increasing wear. Therefore, a tool with suitable geometry and optimum cutting material is required. For machining graphite, MAPAL uses diamond-coated solid carbide tools or PCD-tipped tools.
Application example:
Electrodes for spark eroding (EDM)
From the unmachined to the finished part
Find the right tool with just a few clicks: Depending on the machining, the specific operation and the tool requirement, you can quickly find the tool you want.
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2D surfaces
On the one hand, this category includes machining processes carried out directly on the machine, such as face milling, milling of pockets and straight walls. On the other hand, it also includes operations for complex geometries that are programmed using CAM software.
In the die & mould sector, the manufacture of increasingly complex forms is part of everyday life. Continuous further developments in machine tools and CAM software raise performance and productivity to an ever higher level. The tools used must therefore always be state-of-the-art. To achieve optimum results, each design starts with a process analysis.
Mould inserts also have machining tasks that are required for casting or various attachment parts. Users are increasingly machining open pockets (circumferential machining) using trochoidal milling. This machining method helps to optimise machining times and to extend tool life.
Closed pockets are usually produced by roughing in Z planes. When milling, a ramp is often selected as the machining entry. The tool selected depends on the depth of the walls and the mould incline to be generated on the component. MAPAL’s broad portfolio with modular systems also covers the machining of deep pockets with large diameters.
A major focus in milling operations is on reducing the machining time. With specific tool geometries for machining closed, round pockets, it is often possible to eliminate the pre-drilling process. With helix milling, milling paths are programmed with helical entrances that are suitable for pocket dimensions.
Operations to create even surfaces occur very frequently and in different areas in the die & mould sector: It could be component-related, strategy-related due to the respective milling process or due to requirements for mould closing surfaces as well as sections and cutting dies. The right tool is then selected depending on the application and requirements.
Les représentants de MAPAL se tiennent en permanence à disposition pour toute demande sur mesure. À travers un entretien personnel avec les clients, ils étudient les demandes concrètes et leur étendue (usinage partiel ou complet) et discutent des détails en s'appuyant directement sur le modèle 3D du composant.
L'équipe Fabrication des moules et des matrices MAPAL se réjouit de recevoir votre demande par e-mail et établit un contact direct le plus rapidement possible.
2. Analyse du projet
Sur la base de modèles 3D et de données de machine, les spécialistes analysent les opérations à effectuer et développent des stratégies d'usinage adaptées.
Les éléments de l'analyse de projet sont :
Suggestions pour toutes les étapes de l'usinage
Liste d’outils
Optimisation des processus
3. Conception des processus
Que l'accent soit mis sur la flexibilité ou la productivité, les experts en usinage simulent le processus à l'aide de modèles 3D pour ainsi identifier les potentiels d'optimisation. Ils vérifient et améliorent les paramètres d'usinage pour la programmation FAO et garantissent ainsi une fabrication à la fois sûre et rentable.
La conception des processus comprend :
L’analyse de la durée de vie du composant
La définition des données technologiques
La programmation FAO
4. Solution Outils
Le grand catalogue de base de MAPAL pour la fabrication des moules et des matrices propose des outils parfaitement adaptés à tout type d'application. Le cas échéant, des solutions sur mesure sont également disponibles.
Avantages pour l'utilisateur :
Large programme de base
Mise à disposition des données d'outils
5. Test des outils & offre
Une fois l'opération d'usinage clarifiée, MAPAL aide le client à utiliser les outils nécessaires au processus. Ce point est essentiel pour proposer une offre exhaustive et adaptée au cas d'application.
6. Collaboration
Les succès communs passés n’empêchent pas les spécialistes de MAPAL de rester en contact étroit avec le client. Si d'autres potentiels d'optimisation sont identifiés ultérieurement ou s'il s'avère que d'autres outils sont plus adaptés, MAPAL aide le client dans cette démarche afin de renforcer la productivité et la rentabilité.
Pour assurer une production efficace à long terme, MAPAL propose également des possibilités complètes de gestion des outils.
Options dans le domaine de la gestion des outils :
CORMOL from Portugal manufactures stamping tools, for which it has been working closely with MAPAL since 2022. With the OptiMill-3D-HF, CORMOL has found a reliable and economical tool solution.
The mouldmaking company Krämer+Grebe optimises production with MAPAL reamers and milling cutters and ensures process reliability in international competition.
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