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.
Challenge for CORMOL: Staying competitive without compromising quality
"On some structural components made out of structural steel with a hardness of 180-195 HB, we have to create complex geometries with high material removal rates," João Marques explains the starting point. For high material removal rates CORMOL generally uses milling cutters with indexable inserts. However, in some cases, due tight geometries and thus difficult chip removal as well as small geometry corner radii, this is not possible. "When this occurred, instead of insert mills, we used torus cutters with corner radius," Marques recalls. However, according to a CAM simulation of such operation on a single example part, around 15 hours of machining time were required for said component.
"Whether a tool is the right solution for us is determined by the combination of tool life, material removal rate and tool costs - always with a focus on the total machining time," summarizes João Marques. Wesley Reis, Mechatronic Engineer at MAPAL's Portuguese representative ÁLAMO suggested that CORMOL test the OptiMill-3D-HF high feed milling cutter from MAPAL for this application. It is specially designed for high feed machining and large metal removal rate requirements in steel machining. "The special face geometry of our milling cutter ensures that it works reliably even under difficult operating conditions," says Reis.
OptiMill-3D-HF with four cutting edges and a diameter of 8 mm as the milling cutter of choice
At CORMOL, the OptiMill-3D-HF with four cutting edges in a diameter of 8 mm was recommended. Thanks to the low number of cutting edges, the chip spaces are generously dimensioned. This ensures the safe removal of chips even with complex geometries. CORMOL can also use the milling cutter for long projections and in deep cavities. "We use the OptiMill for rough machining - the surfaces produced are not the decisive criterion here. But that all dimensional and tolerance requirements are met," explains 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
