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ATAGLANCEMillingcutterrangewithcompactedradial indexableinsertsFace

詳細介紹

The radial NeoMill standard milling cutter programme by MAPAL.

AT A GLANCE

Milling cutter range with compacted radial indexable inserts
Face, shoulder, slot and shell end face milling cutters
For roughing and medium machining with one tool
Positive and negative indexable inserts made from different PVD and CVD cutting materials

ADVANTAGES

Indexable inserts for maximum efficiency also in difficult machining conditions
Very high surface quality due to indexable inserts with wiper component
For all applications in cast iron, steel and stainless steel, as well as heat-resistant cast steel (turbocharger materials)
High cutting volume

NeoMill® standard programme

For all milling cutters, MAPAL offers a wide range of indexable inserts – each in a positive and a negative design. In addition, there are cutting edges with a wiper portion, which achieve good surface qualities even without being set.

The negative inserts do not have a clearance angle and can therefore be designed with cutting edges on the contact surface. If the basic shape is the same, negative inserts thus have double the number of cutting edges compared with their positive counterparts. In combination with the high tool life of the indexable inserts, this makes the negative indexable inserts particularly cost-effective.

Face milling cutters

POSITIVE BASIC SHAPE

NeoMill®-8-Face

Eight-edged indexable insert / 45°
First choice for P and M
ø range: 63 - 200 mm / ap max. 5 mm
Use for vibration-prone parts

NEGATIVE BASIC SHAPE

NeoMill®-16-Face

16-edged indexable insert / 45°
First choice for K and heat-resistant cast steel
ø range: 63 - 200 mm / ap max. 4 mm
Low cutting forces despite a negative shape
Maximum cost-effectiveness for face milling

Shoulder milling cutters

POSITIVE BASIC SHAPE

NeoMill®-2-Corner

Double-edged indexable insert / 90°
Highly suitable for P, M and K
ø range: 20 - 63 mm / ap max. 11 mm
Use for ramping (3-axis machining)

NeoMill®-4S-Corner

Four-edged indexable insert / 90°
First choice for P and M
ø range: 40 - 160 mm / ap max. 7 mm
More cutting edges for diameters of 40 mm and over

NEGATIVE BASIC SHAPE

NeoMill®-4-Corner

Four-edged indexable insert / 90°
Highly suitable for P, M, K and heat-resistant cast steel
ø range: 25 - 100 mm / ap max. 10 mm
Multipass milling of high shoulder dimensions
Very low cutting forces despite a negative shape

NeoMill®-8-Corner

Eight-edged indexable insert / 90°
First choice for K
ø range: 50 - 200 mm / ap max. 8 mm
Maximum cost-effectiveness for shoulder milling

Shell end face milling cutters

POSITIVE BASIC SHAPE

NeoMill®-2-Shell

Double-edged indexable insert / 90°
Highly suitable for P, M and K
ø range: 25 - 45 mm / ap max. 51 mm
Use for ramping (3-axis machining)

NEGATIVE BASIC SHAPE

NeoMill®-4-Shell

Four-edged indexable insert / 90°
Highly suitable for P, M and K
ø range: 32 - 63 mm / ap max. 62 mm
Use of very high shoulder dimensions

High-feed milling cutters

POSITIVE BASIC SHAPE

NeoMill®-2-HiFeed

Double-edged indexable insert, highly suitable
for P, M and K
ø range: 10 - 160 mm / ap max. 0,7 - 1,4 mm
Highest possible feed per tooth (up to fz = 3.0 mm with SDMT 18)
Screw-in milling cutters in combination with solid carbide
extensions minimise vibrations at extreme projection lengths

NeoMill®-4-HiFeed

Four-edged indexable insert, highly suitable
for P, M, K and H
ø range: 16 - 200 mm / ap max. 1 - 3,5 mm
Very high machining rates with good process reliability
Smooth cutting even in full slots
Reliable machining for long projections

Applications

Download area:

Brake caliper
Swivel bearing
Turbocharger
Compressors
Hydraulic pump
Engine block
Valve housing
Transmission

Selection steps for the NeoMill® milling cutter

As a technology partner, MAPAL supports the selection and optimum use of the NeoMill® milling cutters with knowledge of tooling and processing.???????.

1. Component application and workpiece material

Selection of application & workpiece material:
Application:
Face milling, Shoulder milling, Ramping, Plunge milling, High-feed milling???????
Workpiece material:
Steel, Stainless steel, Cast iron???????
2. Machining conditions
The machine, clamping fixture and shape of the workpiece influence the machining conditions:
Interrupted cut
Low cutting width
Dry machining
Very heavy interrupted cut
Vibration-prone
Wet machining (thermal shock)
3. Insert geometry / insert form

Positive rake angle ａnd low cutting forces are decisive in unstable conditions
Negative rake angle: Particularly cost-effective due to double-sided use and high edge stability
4. Number of cutting edges / spacing

Number of cutting edges and spacing depends on ap and ae
5. Cutting edge design

Cutting edge design depends on the workpiece material and application
R = Roughing
M = Medium machining
U = Difficult conditions
6. Milling ratio ae / ?

Optimum ratio of the milling cutter diameter and the cutting width
The ratio of the milling cutter diameter and the cutting width ae should be ae = 70% Dc or ae < 25%="">
7. Milling strategy

Run-in with one radius
Running-in with a radius keeps the chips thin when they exit, reduces vibrations and results in optimum tool life.
8. Calculation of the process parameters
Process-relevant calculations
Calculation of the cutting force
Power and torque
Templates for test reports
Cost-effectiveness calculation

Innovative and reliable machining solutions require a holistic understanding of the process

Milling application / Clamping setup

Component requirements and clamping concept
Machining strategy

Tool selection and design of the milling strategy
Increase in productivity

Analysis and optimization of cutting parameters and cycle time
Standard
programme

Tools and indexable inserts available from stock
Process reliability & cost-effectiveness

Support during production and cost-effectiveness calculations
Cooperative partnership

Close contact, work out and carry out optimizations

Avoid vibrations using a vibration dampening system

Challenges when milling
Double projection length corresponds to 8x higher deflection, this leads to vibrations and increased noise generation
Strain upon tool and machine spindle
Long machining times due to reduction of the cutting parameters
MAPAL solution
Self-contained system consisting of heavy metal core, spring package and oil bearing
Tool adapter with internal cooling
Plug & Play: No setting of the vibration dampening system in the tool adapter necessary
Applicable for both the standard programme and for customised solutions
Added value for customers
~~???????~~Saving up to 50% due to an increased material removal rate
Up to 60% better surface finishes
Process reliability by avoiding cutting-edge chipping

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AT A GLANCE

ADVANTAGES

NeoMill® standard programme

Applications

Download area:

Selection steps for the NeoMill® milling cutter

1. Component application and workpiece material

2. Machining conditions

3. Insert geometry / insert form

4. Number of cutting edges / spacing

5. Cutting edge design

6. Milling ratio ae / ?

7. Milling strategy

8. Calculation of the process parameters

Innovative and reliable machining solutions require a holistic understanding of the process

Milling application / Clamping setup

Machining strategy

Increase in productivity

Standardprogramme

Process reliability & cost-effectiveness

Cooperative partnership

Avoid vibrations using a vibration dampening system

Challenges when milling

MAPAL solution

Added value for customers

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