Mapal has introduced a completely new line of solid-carbide end mills – the OptiMill-3D series – which has been specially developed for the tool and mould-making industry. Along with extremely heat-resistant coatings and special carbide substrates, the new cutting tools are characterised by dimensions and geometries specifically adapted to mould making.

Suitable for milling hard parts in the domain of 45 to 66 HRc, the OptiMill-3D-HF-Hardened is offered with four or six cutting edges. Mapal has developed the two variants for high-feed milling on particularly challenging materials. In addition, to optimise performance and longevity on challenging tasks like interrupted cutting, the company has developed special face geometry.
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 designed for roughing and pre-finishing, the six-flute series is said to demonstrate impressive characteristics when finishing flat surfaces with a high feed rate. Moreover, with a PVD coating, the tool dissipates heat generation to ensure tool life is prolonged. Available from 6 to 16 mm diameter, the OptiMill-3D-HF-Hardened is complemented by the three and four-flute OptiMill-3D-HF for softer material machining.
Also new to the solid carbide range is the new OptiMill-3D-CR-Hardened with a corner radius. Suitable 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 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 to suit the machining demands of users.
For further information www.mapal.com

Mikron Tool has expanded its CrazyMill Cool P&S plunge-milling cutter programme with the inclusion of new dimensions to achieve even deeper machining cycles.

Now available in the UK from Floyd Automatic, the latest CrazyMill Cool P&S is characterised by the ability to plunge (drill) vertically into the material, mill slots or pockets into solid material in small spaces, and conclude milling operations with finishing cycles.
Although the milling depth in the short version (2.5xD) was based on the machining of keyways, the extended range has been developed to mill the deepest possible slots and pockets with a single tool, reaching more distant machining areas of a workpiece with one cutter. The new version of the solid-carbide plunge mill is based on the same technology as the short version, transferred directly to the new line. Now, it is possible to plunge perpendicularly into the material and reach the maximum milling depth of 5xD.
Good chip removal plays an important role at this depth. There is a higher risk that chips remain in the milling zone, are broken-up and subsequently damage both the milling cutter and the milled surface. The special cutting-edge geometry of CrazyMill Cool P&S and its extended chip area provide a remedy, ensuring lateral chip removal during plunging and tool stability during deep milling.
Alberto Gotti, head of the technology and customer project centre at Mikron Tool, says: “Customers can work with this tool at high speeds and feeds, and an axial infeed of 0.5xD, achieving extremely high chip-removal rates. For the user, this means up to five times shorter machining processes and significantly longer tool life compared with other milling cutters on the market.”
The CrazyMill Cool P&S is available in diameters from 1 to 8 mm, and for a maximum milling depth of up to 5xD.
For further information www.floydautomatic.co.uk

Working closely with companies like Rolls-Royce, Collins Aerospace, Safran, Bombardier, ITP Aero, Marshall and Incora, Romford-based Xcel Aerospace is a subcontract manufacturer with an aerospace pedigree that few in the supply chain can match.

As part of its drive to ensure cost-effective manufacturing, the company recently invited tooling manufacturer Guhring to review the machining process on an aerospace valve component. The problem for Xcel was the cost efficiency of its existing Woodruff-type cutters when machining the cast aluminium component, which features 9% silicon content.
Only capable of completing 10 components before tool replacement, the abrasive aluminium was creating productivity, cost and surface finish issues for this aerospace expert.
“We explained to Xcel that Guhring has a new method of manufacturing PCD tools by printing them on a MarkForged Metal X 3D-printing machine,” says Guhring’s regional sales manager Dewar McKinlay. “We made a three-flute tool that was similar to the current tool but with brazed PCD tips. Despite the PCD tips lasting considerably longer on the abrasive high-silicon aluminium than the previous tool, we wanted to go further.”
The new design increased the number of cutting edges from three to five, allowing Xcel to increase the feed rate, while extending tool life.
“The previous solid-carbide tool was worn and required a changeover after 10 parts, but we have machined more than 180 parts with the new 3D-printed PCD Woodruff cutter and it is still performing well,” says McKinlay.
“Putting five cutting edges on a 21.7 mm diameter Woodruff tool with a solid-carbide body would create significant manufacturing challenges,” he adds. “The main benefit of printed tools is that we can produce multiple designs very quickly.”
For further information www.guhring.co.uk

The new Accure·tec vibration damping technology from tooling expert Walter GB ensures vibration-free and low-noise cutting in difficult-to-machine turning and milling applications using long – up to 10xD – tools.

These applications include the milling of components with deep cavities, as widely found throughout all sectors, and turning in the energy industry (oil industry valves, for instance), as well as aerospace landing gear.
Pre-set by Walter and delivered ready for use, the axially and radially positioned damping element allows turning operations up to 10xD with high process reliability and surface finish using, for example, A3000 boring bars.
Examples include H7 engineering tolerances and the counterboring of generator shafts to finishes of Rz 6.3. Moreover, the also new QuadFit quick-change heads enable rapid tool change to repeat accuracies of ±2 µm.
When milling, Accure·tec AC001 adaptors of up to 5xD can be applied with cutting data up to three times higher than with conventional tools, says Walter. The adaptors are particularly suited to Walter’s high-feed milling cutters, which exhibit their main cutting forces in the axial direction of the spindle.
Also promising longer tool life and higher productivity rates, Accure·tec AC001 (milling) and A3000 (turning) are supplied with all popular interfaces, including Walter Capto, HSK/HSK-T, SK, MAS-BT and parallel shank.
For further information www.walter-tools.com

Mapal has expanded its milling portfolio with the OptiMill SPM family of tools for processing aluminium and steel, which is available in two formats, the ‘Rough’ and ‘Finish’ series.

Optimised infeed machining depths, as well as the highest feeds during roughing, are possible with the OptiMill-SPM-Rough, reports Mapal. The reason for this performance is the novel knurled roughing geometry that ensures the power consumption during machining is significantly lower in comparison to tools with a straight cutting edge. Furthermore, heat introduction into the part is minimal due to the plunging characteristics of the tool.
The three-flute OptiMill-SPM-Rough is available with 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 with vibration and cutting forces minimised due to the smooth cutting action of the tool.
For finishing contours and pocket walls, even at large depths in a single pass, Mapal has revealed the OptiMill-SPM-Finish. Mapal says this new end mill prevents swarf wrapping, even when operating in corners with enormous tool contact and high machining loads. Optimally designed cutting-edge geometry ensures there is no vibration during machining. The chip flutes are polished and, as a consequence, chip removal is optimal. Like the OptiMill-SPM-Rough, the new 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 first choice for aluminium machining.
In addition, Mapal is announcing the OptiMill-Uni-Wave as an extra-long version for roughing even in deep cavities. Availability is in diameters from 6 to 20 mm.
For further information www.mapal.com