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.​
Standardowy program frezowania promieniowego NeoMill® 

Idealne rozwiązanie do Twoich zastosowań frezarskich

Potrzebujesz frezu, który pozwoli Ci osiągnąć wysoką wydajność skrawania i zwiększyć trwałość? W takim razie mamy dla Ciebie idealne rozwiązanie – nasz program frezów NeoMill.

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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. Warunki obróbki

    Warunki obróbki zależą od obrabiarki, mocowania i kształtu obrabianego przedmiotu:

    • Cięcie przerywane
    • Mała szerokość skrawania
    • Obróbka na sucho
    • Bardzo silnie przerywane cięcie
    • Podatność na drgania
    • Obróbka na mokro (szok termiczny)

  • 3. Geometria ostrza / kształt ostrza

    Dodatni kąt natarcia i niewielkie siły skrawania mają decydujące znaczenie w niestabilnych warunkach

    Ujemny kąt natarcia: szczególnie ekonomiczny dzięki dwustronnemu zastosowaniu i wysokiej stabilności krawędzi

  • 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

  • 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

Trabajar en el mundo de la TI

Juntos ponemos rumbo al futuro y durante este camino apostamos por la humanidad, la visión de futuro y una organización sofisticada. Todo esto forma la base para una perspectiva prospectiva y fiable, así como la calidad de nuestros productos y servicios. Por ello estamos orgullosos desde siempre como empleador y socio tecnológico. Ahora queremos seguir creciendo contigo en el equipo.

No solo es un controlador importante de la digitalización, sino que la escribe de arriba abajo con cada línea de código. Por ello te ajustas a la perfección en nuestro equipo, puesto que hemos situado la digitalización en el centro de nuestras competencias y servicios. Trabajamos a nivel internacional, en equipos ágiles y con las herramientas y marcos más novedosos. De aquí resultarán desafiantes proyectos y posibilidades de desarrollo para ti en nuestra empresa.

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Twój bezpośredni kontakt

Heiko Rup, product manager at MAPAL.

Osoba kontaktowa

Heiko Rup Zarządzanie produktami i zastosowaniami heiko.rup@mapal.com Telefon: +49 7361 585 3034