04.03.2025
High feed rate for high stock removal
CORMOL relies on milling cutters from MAPAL for tool making
Almost every stamping tool that CORMOL manufactures is unique and designed to achieve the highest performance. For large volumes in challenging geometries, CORMOL was looking for a reliable and economical tool solution. With the OptiMill-3D-HF from MAPAL, the mold maker has found the ideal milling cutter.
CORMOL, based in Águeda, Portugal, has been an expert in the manufacture of stamping tools for sheet metal forming for over 60 years. "Since our foundation in 1962, we have continuously invested and built up an extensive expertise," says CORMOL’s Managing Director João Marques. As a result, CORMOL offers its customers complete solutions and, in addition to stamping tools, also manufactures prototype tools, spare parts and checking fixtures. "For our customers, we often act as a problem solver - we don't want to be just another supplier, but a long-term partner," Marques emphasizes.
Being a long-term partner is a claim that CORMOL has in common with MAPAL. For MAPAL, that is also a top priority. The two companies have been working together since 2022. "We are constantly faced with the challenge of being competitive in terms of price and lead times without compromising our high quality standards," says João Marques. There is potential for savings in the production of the stamping tools, especially in the machining time. Complex geometries are often milled in processes that take hours. This is where MAPAL came into play in 2022.
Herausforderung für CORMOL: Wettbewerbsfähig bleiben ohne Qualität zu beeinträchtigen
„An einigen Strukturbauteilen aus Baustahl mit einer Härte von 180 bis 195 HB müssen wir mit hohem Materialabtrag komplexe Geometrien erzeugen“, erläutert João Marques den Ausgangspunkt. Bei hohen Abtragsraten setzt CORMOL generell auf Fräser mit Wendeschneidplatten. Allerdings ist das aufgrund enger Geometrien und damit erschwerter Spanabfuhr sowie kleinen Eckenradien in einigen Fällen nicht möglich. „Wenn dieser Fall in der Vergangenheit auftrat, setzten wir statt Fräsern mit Wendeschneidplatte Torusfräser mit Eckenradius ein“, erinnert sich João Marques. Laut einer CAM-Simulation eines solchen Vorgangs an einem einzelnen Beispielteil wären für dieses Bauteil jedoch etwa 15 Stunden Bearbeitungszeit erforderlich gewesen.
„Ob ein Werkzeug für uns die richtige Lösung ist, bestimmt die Kombination aus Standzeit, Materialabtragsrate und Werkzeugkosten – immer mit einem Fokus auf der Gesamtbearbeitungszeit“, fasst es João Marques zusammen. Wesley Reis, Mecatronic Engineer bei MAPALs portugiesischer Vertretung ÁLAMO schlug CORMOL vor, für diesen Einsatzfall den OptiMill-3D-HF Hochvorschubfräser von MAPAL zu testen. Er ist speziell auf Hochvorschubbearbeitungen und große Zeitspanvolumina, Anforderungen in der Stahlbearbeitung, ausgelegt. „Die spezielle Stirngeometrie unseres Fräsers sorgt dafür, dass er auch bei schwierigen Einsatzbedingungen prozesssicher arbeitet“, sagt Reis.
OptiMill-3D-HF mit vier Schneiden und Durchmesser von 8 mm als Fräser der Wahl
Bei CORMOL empfahl sich der OptiMill-3D-HF mit vier Schneiden in einem Durchmesser von 8 mm. Denn dank der geringen Schneidenanzahl sind die Spanräume großzügig dimensioniert. Damit ist der sichere Abtransport der Späne auch bei komplexen Geometrien gewährleistet. CORMOL kann den Fräser auch bei langen Auskragungen und in tiefen Kavitäten einsetzen. „Wir setzen den OptiMill für die Schruppbearbeitung ein – die erzeugten Oberflächen sind dabei nicht das entscheidende Kriterium. Wohl aber, dass alle Maß- und Toleranzanforderungen erfüllt werden“, erläutert João Marques.
The MAPAL tool not only fulfilled these reliably in the first tests. The machining time was also convincing. "The OptiMilll-3D-HF mills all the intended geometries in just 75 minutes," Marques is enthusiastic. With the previous solution, the process had taken a whole 15 hours. In addition, the tool had to be changed during the process because it had reached the end of its service life. In this application, the OptiMill worked at a cutting speed of 120 m/min and a feed rate of 4,775 mm/min. In combination with a cutting depth of 0.144 mm, CORMOL thus achieved a significantly higher stock removal rate than with the previous tool from a competitor of MAPAL.
First collaboration between CORMOL and MAPAL in 2022
"With the MAPAL milling cutter we not only have a tool that is characterized by the highest performance, but also achieve a reliable process," says João Marques. Machining times have also been significantly reduced. "Not only in this application." adds Marques. Since the first tests in 2022, CORMOL has tested other MAPAL tools and implemented them in its processes.
The ÁLAMO team around Wesley Reis provides unlimited technical support. "Both the field service as well as our design engineers and the research and development department support CORMOL in the search for solutions in difficult cases or in optimizing processes and thus saving further processing times," emphasizes Wesley Reis. CORMOL also attaches particular importance to this. Because: "Our goal is to get the best out of every investment. In doing so, it is essential to receive qualified, technical support and to have a partner who helps us to master new challenges as well. We have found this partner in the area of cutting tools with MAPAL," says Marques.
About ÁLAMO:
In Portugal, MAPAL is represented by the company ÁLAMO Ferramentas. Portugal is home to a large tool and mould making industry with which ÁLAMO has an excellent network and distributes the MAPAL range there. Managing Director Rui Moreira founded the sales agency in 2009 in order to concentrate exclusively on the sale of the MAPAL tool and service programme. Other products, such as metering pumps, are offered on a smaller scale. The company is based in Marinha Grande and employs nine people who provide support for customers throughout the country. A second office is located in Oliveira de Azeméis.
Contact
Mathias Ostertag Public Relations mathias.ostertag@mapal.com Phone: +49 7361 585 3566
