Aluminum and Steel Machining Milling From Solid - High Performance in Aluminum

Mapal is expanding its portfolio in the area of high-performance milling cutters in the OptiMill family for aluminum and steel machining.

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Machining of Structural Aluminum Parts

The full potential of new, powerful machines can be used with the new OptiMill-SPM milling cutters "Rough" and "Finish". They exploit their strengths especially during the machining of structural parts made of aluminum.

High infeed depths as well as the highest feeds during roughing are possible with the new OptiMill-SPM-Rough. The reason for this performance is its knurled roughing geometry that ensures the power consumption during machining is significantly lower compared to tools with a straight cutting edge. Furthermore, the heat introduction into the part is minimal due to the good plunging characteristics of the tool.

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Process Overview

Automotive Structural Parts made in HPDC

For finishing contours and pocket walls – even at large depths in one pass – Mapal is announcing the OptiMill-SPM-Finish with newly developed geometry. It operates without problems even with large wrapping – also in the corners with enormous tool contact and a high load, the tool remains stable. The optimally designed cutting edge geometry ensures there is no vibration during the machining. The chip flutes are polished; as a consequence chip removal functions optimally.

Optimal for Slot Milling in Steel

The OptiMill-Uni-Wave is the tool of choice if the issue is full slot milling with a groove depth up to 2xD in different materials. Due to its geometry, the highest machining rates are possible. Irrespective of all the advantages of the OptiMill-Uni-Wave, machinists often faced the difficulty that chip removal was not reliable, particularly in steel materials during the machining of slots with a depth ≥ 1.5xD. For this reason, Mapal now offers the OptiMill-Uni-Wave also with central internal cooling. This feature ensures optimal removal of the chips and longer tool lives. In addition, the company is announcing the OptiMill-Uni-Wave as an extra long version. An efficient solution for roughing even in deep cavities is therefore now available. Despite its length, the new milling cutter is extremely stable due to its conically shaped neck.

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