Mapal’s OptiMill-3D series suits tool and mouldmaking applications

​Mapal’s OptiMill-3D series is a new programme of solid carbide milling cutters specially developed for the tool and mouldmaking industry. Along with extremely heat-resistant coatings and special carbide substrates, the new tools are characterised by the dimensions and geometries specifically adapted to mould making.

Suitable for milling hard parts of 45 to 66 HRc, OptiMill-3D-HF-Hardened is the new tool of choice. Offered with four or six cutting edges, there are two variants for high feed milling of particularly challenging materials. To optimise performance and longevity on challenging tasks like interrupted cutting, Mapal has developed a special face geometry.

The four-flute tool is the primary choice for roughing and pre-finishing. However, with fewer cutting edges and a wider chip gullet, rapid and reliable removal of swarf is ensured. Available from 2 mm to 16 mm diameter, the four-flute tool is ideal for long overhang applications such as machining in deep cavities.

The OptiMill-3D-HF-Hardened is also perfect for roughing and pre-finishing, with the six-flute series demonstrating impressive characteristics when finishing flat surfaces with a high feed rate. It produces the best surface finishes and flatness, and with a PVD coating, the tool dissipates heat generation to ensure tool life is prolonged. Diameters are from 6 to 16 mm diameter.

The new OptiMill-3D-CR-Hardened with a corner radius is perfect for finishing 3D mould tools up to a hardness of 66 HRc. This line produces smooth, high-gloss surface finishes when machining at maximum feed rates. Offered in diameters from 4 to 12 mm with highly accurate corner radii of 0.5, 1 and 2 mm, the PVD-coated OptiMill-3D-CR-Hardened is available with a selection of different lengths and corner radii to suit the machining demands of the end user.

The OptiMill-3D-CS series new circular radius milling cutters, or ‘conical barrel tools’, are perfect for mould making applications in deep cavities, complex free-form shapes as well as the manufacture of turbine blades and impellers – the new OptiMill-3D-CS series is a game changer in productivity and performance.

Machining time can be significantly reduced and the quality of the surface finish on the parts significantly improved. For machining deep, difficult-to-access cavities, the OptiMill-3D-CS in droplet shape with diameters from 2 to 12 mm and an effective radius up to 95 mm is the first choice. For machining large surfaces and surfaces with tool restrictions, the cutter is also offered in a tapered shape. The tapered shape tools are available from 6 to 12 mm with an effective edge radius of up to 250 mm.

Conical barrel tools require a high-performance CAM system to work effectively. However, the combination of a suitable CAM system and the Mapal barrel tools can yield performance and material removal rate increases in the realms of 70% and more.