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
Solid carbide end mills
OptiMill-3D-BN
Ball nose milling cutter
High-precision machining of 3D contours
ø range: 0.10 - 20.00 mm
OptiMill-3D-CR
Corner radius milling cutter
Milling with a very precise corner radius
ø range: 0.10 - 20.00 mm
OptiMill Shoulder milling cutter
Shoulder milling cutter
Ideal for roughing, finishing, trochoidal milling and milling pockets
ø range: 2.00 - 12.00 mm
OptiMill-3D-HF
High-feed milling cutter
Ideal for high-feed machining with a high material removal rate and high process reliability
ø range: 2.00 - 16.00 mm
OptiMill-3D-Alu
Ball nose and corner radius cutters
High-precision machining of 3D contours
ø range: 1.00 - 20.00 mm
OptiMill-Graphite-MT
Ball nose and shoulder milling cutter
Multi-tooth milling cutter for roughing graphite electrodes with high removal rates
ø range: 3.00 - 16.00 mm
OptiMill-3D-Graphite
Ball nose and corner radius milling cutter
Suitable for machining of graphite electrodes
Different designs depending on the machining situation
ø range: 0.20 - 12.00 mm
OptiMill-3D-Copper
Ball nose and corner radius milling cutter
Special geometry for machining copper electrodes and tough non-ferrous alloys
ø range: 0.10 - 20.00 mm
OptiMill-Diamond
Ball nose, corner radius and shoulder milling cutter
PCD cutting edges for a long tool life
ø range: 3.00 - 12.00 mm
Milling cutters with indexable inserts
NeoMill-ISO-360
Rundplattenfräser
Ideal zum Schruppen und Vorschlichten
ø-Bereich: 10,00 - 160,00 mm
NeoMill-3D-Finish
Schlichtfräser
Ideal zum Schlichten von 90°-Flächen, Planflächen und Konturen
ø-Bereich: 16,00 – 42,00 mm
NeoMill-3D-Ballnose/-Torus
Ball nose and corner radius milling cutter
One tool body with indexable insert for ball nose and corner radius milling for finishing and pre-finising
ø range: 8.00 - 32.00 mm
NeoMill-2/4-HiFeed90
High-feed/90° shoulder milling cutter
Universal tool system to ensure maximum productivity
ø range: 16.00 - 200.00 mm
Drilling | Countersinking
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
Alésoir haute performance à queue cylindrique
Alésoir haute performance en carbure monobloc
Goujure droite pour l'alésage débouchant et l'alésage borgne
Goujure oblique à gauche pour l'alésage débouchant
Plage de ø : 3,00 – 20,00 mm
CPReam – CPR
Alésoir à tête amovible
Stabilité et rigidité maximales grâce au cône et à l'appui plan
Précision de concentricité maximale de 5 µm
Maniement simple
Plage de ø : 8,00 – 40,00 mm
Alésoirs à réglage rapide – WN 50
Alésoir manuel
Alésoir à réglage rapide avec grande plage de réglage
Particulièrement adapté aux travaux de réparation
Jeux de lames de rechange disponibles
Plage de ø : 6,40 – 95,00 mm
Outils guidés
Outils avec patins de guidage
Précision maximale grâce au concept MAPAL
Patins de guidage permettant un guidage direct dans le trou d'alésage
Plaquettes réversibles rectifiées
Réglage de haute précision pour un usinage au µm près
Les composants toujours plus complexes dotés de cavités et de nervures de renforcement de plus en plus profondes dans le cas du moulage par injection de pièces en plastique et du moulage sous pression obligent à utiliser des outils extra-longs présentant un diamètre en partie très réduit. Les géométries de pièce complexes et les différentes propriétés de matériau compliquent les tâches d'usinage et sollicitent fortement la résistance des outils.
Pour les moules de présérie ou de prototype, il n'est pas rare d'employer des matériaux faciles à usiner. Des alliages d'aluminium ou de résine sont fréquemment utilisés. Les outils en carbure monobloc à coupe positive et polis, ou mieux encore les outils à insert PCD, garantissent alors une productivité renforcée et de courts temps d'usinage.
Pour les moules de présérie ou de prototype, il n'est pas rare d'employer des matériaux faciles à usiner. Des alliages d'aluminium ou de résine sont fréquemment utilisés. Les outils en carbure monobloc à coupe positive et polis, ou mieux encore les outils à insert PCD, garantissent alors une productivité renforcée et de courts temps d'usinage.
La fabrication d'électrodes pour les processus EDM nécessite l'usinage d'alliages de cuivre et de graphite. Le choix du matériau d'électrode dépend des propriétés du moule à fabriquer. Les alliages de cuivre sont relativement chers et sont généralement utilisés pour réaliser les finitions des électrodes afin d'obtenir une qualité de surface et une précision de forme élevées. Les fraises à queue en carbure monobloc avec géométrie spéciale de MAPAL garantissent des résultats d'usinage hautement précis.
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.
Plastic injection moulds and die casting moulds often have ribs and thin walls. Ribs, for example, are increasingly being milled, as this process is more cost-effective than EDM (spark eroding). As a rule, long or extra-long carbide tools with small diameters are used. Customer-specific solutions (RibCutter) to match the respective rib shape are also possible here.
There is a wide range of full bore operations in the die & mould sector: From large bores for guide pillars and deep bores for the cooling system to high-precision bores for ejector pins. MAPAL offers a comprehensive portfolio of drilling and reaming tools for the individual production steps.
Optimised purchasing management is important for a clear organisation of the tool stock.
2. Tool logistics
Cost-effectiveness even in the periphery of machining: Intelligent dispensing systems significantly reduce non-productive times.
3. Engineering
The machining specialists provide support with process engineering, e.g. in the form of CAM simulations, general advice and the development of economic machining strategies.
4. Measuring and setting
Reliable setting and measuring devices are convincing due to their accuracy and user-friendly operation when setting the tools.
5. Tools and clamping technology
From the spindle to the cutting edge – MAPAL offers a wide range of tools and clamping technology for the die & mould sector.
6. Machining
Efficient machining processes and customised machining strategies at the highest technological level.
7. Digitisation and automation
Quick and easy digitisation: The c-Connect Box digitally transmits measurement data from the setting fixture to the machine tool. It also monitors the machine status among other things.
8. Reconditioning
Customers receive their reconditioned tools back in manufacturer quality within a very short time. Also available with pick-up and delivery service upon request.
Engineering Workflow – da teoria à prática
Encontrar uma solução perfeita para as necessidades do cliente – este é o desafio da MAPAL. Além de soluções especiais individuais e um amplo portfólio de produtos standard, estão disponíveis serviços abrangentes para projetar de forma otimizada todo o processo, desde a ideia do produto até as aparas. Os clientes podem contar com os muitos anos de experiência do líder tecnológico em usinagem.
1. Pedidos de clientes
Os representantes de vendas da MAPAL estão diretamente disponíveis para pedidos individuais. Em discussões pessoais, sondam os requisitos concretos e o âmbito (usinagem completa ou parcial) juntamente com o cliente e discutem os detalhes diretamente no modelo 3D do componente.
O time de fabricação de moldes e matrizes da MAPAL ficaria muito feliz em responder as suas perguntas por e-mail e entrará em contato o mais rápido possível.
2. Análise de projetos
Com base em modelos 3D e dados de máquinas, os interlocutores analisam as tarefas de fabrico e desenvolvem estratégias de usinagem eficazes.
Os componentes da análise do projeto são:
Propostas de usinagem para todas as etapas de usinagem
Lista de ferramentas
Otimização do processo
3. Conceção de processos
Independentemente de o foco ser a flexibilidade ou a produtividade: Os especialistas em usinagem simulam o processo desenvolvido com base nos modelos 3D e identificam assim o potencial de otimização. Verificam e melhoram os parâmetros de usinagem durante a programação CAM e asseguram assim uma fabricação estável e económica.
O projeto do processo inclui:
Análise do tempo de execução do componente
Definição dos dados de tecnologia
Programação CAM
4. Solução de ferramentas
A vasto programa standard MAPAL para a fabricação de moldes e matrizes oferece a solução ideal de ferramentas para cada aplicação. Se necessário, estão também disponíveis soluções especiais individuais.
Vantagens ao usuário:
Amplo programa standard
Fornecimento de dados de ferramentas
5. Testes e oferta de ferramentas
Após a troca de informações sobre a sua tarefa de usinagem, a MAPAL apoia os clientes na utilização das ferramentas necessárias no processo. Esta é a base para uma oferta bem fundamentada e adaptada à respetiva aplicação.
6. Parceria de colaboração
Mesmo após sucessos em conjunto, os especialistas da MAPAL permanecem em contato direto com o cliente. Se houver potencial de otimização ao longo do tempo, ou se outras ferramentas se tornarem melhores, a MAPAL terá prazer em fornecer suporte para melhorar ainda mais a produtividade e a relação custo-benefício.
Para garantir uma produção eficiente a longo prazo, a MAPAL também oferece opções abrangentes de gerenciamento de ferramentas.
Opções de gerenciamento de ferramentas:
Sistemas de distribuição
Serviço de reenvio
Extenso portfólio de produtos de dispositivos de ajuste e medição
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.
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