Mapal OptiMill solid-carbide end mills have been available for a number of years, but MACH will be the UK introduction for no fewer than nine OptiMill product lines. One of the key products in the expanded milling portfolio is the OptiMill SPM tools for processing aluminium and steel.
OptiMill-SPM milling cutters are available in two formats, the ‘Rough’ and the ‘Finish’ series. Both tool designations have characteristics that are said to excel during the machining of structural aerospace parts made of aluminium and aerospace alloys.
For instance, the OptiMill-SPM-Rough has a novel knurled roughing geometry which ensures that power consumption during machining is significantly lower compared with tools featuring a straight cutting edge. Furthermore, heat introduction into the part is minimised due to the plunging characteristics of the tool.
The three-flute OptiMill-SPM-Rough is available in diameters of 12, 16, 20 and 25 mm, with corner radii of 2, 3 and 4 mm to prolong tool life and prevent edge chipping during heavy-duty cutting. With a short flute length of 1.5xD and polished flutes, the OptiMill-SPM-Rough has been designed for high material removal rates.
For finishing contours and pocket walls, Mapal will introduce the OptiMill-SPM-Finish at MACH. This end mill prevents swarf wrapping, even when operating in corners with enormous tool contact and high machining loads, says the company. Like the OptiMill-SPM-Rough, the OptiMill-SPM-Finish is available in diameters from 12 to 25 mm, with imperial variants available upon request. The uncoated four-flute end mill is offered with corner radii from 2 to 4 mm, and is aimed at aluminium machining applications.
For full slot milling, Mapal will be showing the OptiMill-Uni-Wave, another tool launched for cutting at depths up to 2xD in a range of materials. Credit to its geometry, high machining rates are possible.
Machinists are often faced with inconsistent chip removal when cutting beyond 1.5xD. To eradicate this issue, the OptiMill-Uni-Wave incorporates central internal cooling to ensure optimal removal of the chips and longer tool life. The PVD coated series is offered in diameters of 4, 6, 8, 10, 12, 16 and 20 mm. Moreover, OptiMill-Uni-Wave is also available in an extra-long version that provides a solution for roughing in deep cavities. Availability is in diameters from 6 to 20 mm.
For machining composite materials, Mapal will introduce the OptiMill-Composite-Speed-Plus, a logical extension to the existing OptiMill-Composite-Speed. This diamond-coated solid-carbide milling cutter has a newly developed substrate that combines with a reinforced core diameter and eight cutting edges. Fracture strength has been increased by 50%, while the optimised groove profile ensures fast, reliable removal of dust and process heat. Overall, the tool life of the OptiMill-Composite-Speed-Plus is 20% higher than for the previous model.
For the tool and mould-making industry, Mapal will release the OptiMill-3D series of solid-carbide milling cutters. Along with heat-resistant coatings and special carbide substrates, these tools are characterised by dimensions and geometries specifically adapted to mould making. For hard parts from 45 to 66 HRc, the OptiMill-3D-HF-Hardened is Mapal’s latest tool of choice. Offered with four or six cutting edges, the company has developed the two variants for high-feed milling on challenging materials. The four-flute tool is the primary choice for roughing and pre-finishing. Available from 2 to 16 mm diameter, the four-flute tool is suitable for long overhang applications, such as machining in deep cavities.
Also suited to roughing and pre-finishing, the six-flute series demonstrates impressive characteristics when finishing flat surfaces with a high feed rate. The tool produces good surface finishes and flatness and, with a PVD coating, the tool dissipates heat generation to ensure tool life is prolonged. This range will be accompanied at MACH by the newly developed OptiMill-3D-CR-Hardened. Suitable for finishing 3D mould tools up to 66 HRc, this line produces smooth, high-gloss surface finishes when machining at maximum feed rates, reports Mapal.
The latest evolution in Mapal’s milling portfolio is the arrival of circular radius milling cutters or ‘conical barrel’ tools. At MACH, the company will be introducing its form conical barrel tools with the latest OptiMill-3D-CS series. The cutters are aimed at mould-making applications in deep cavities, the production of complex freeform shapes, and the manufacture of turbine blades and impellers. As a point of note, these conical barrel tools require a high-performance CAM system in order to work effectively.
Alongside its latest solid-carbide milling platform, Mapal will be introducing a vast array of innovations that stretch from cloud-based platforms and vending technology, through PCD and solid-carbide tooling, to special application-based solutions.
