New generation of the PCD face milling cutters EcoMill ... · test possible productivity for face...

EcoMill-Blue and RapidMill-BlueNew generation of the PCD face milling cutters

A clean solution for high-speed aluminium machining

EcoMill-Blue and RapidMill-Blue

Part cleaning represents a significant cost fac-tor in series production. This is where the new generation of PCD face milling cutters comes into its own. In order to come as close as pos-sible to the goal of a dirt-free finished part, an innovative PCD milling insert has been de-veloped. The special chip guidance geometry keeps the chips reliably away from the work-piece surface.

The integrated coolant outlets in the milling inserts ensure optimum cooling and lubrica-

tion of the PCD blades, particularly with mini-mum quantity lubrication. The significantly reduced work of subsequent cleaning of the parts is particularly important for machining processes without the use of cooling lubricants.

The construction is similar to that of the pro-ven EcoMill principle. Here the inserts are in the form of replaceable milling inserts and are securely fixed by a highly precise dovetail

guide. Replacement of the milling inserts is extremely easy. Adjustment is very user-friendly with radially accessible, wedge-shaped adjusting elements.

With the same basic design and even more blades (Z = 28 at tool diameter 125 mm), the new RapidMill-Blue series achieves the grea-test possible productivity for face milling.As a special service, MAPAL offers milling head management, as well as reconditioning in ori-ginal quality.

EcoMill-Blue and RapidMill-Blue | New generation of the PCD face milling cutters

New generation of the PCD face milling cutters

2

1

2

3

4

5

6 87

Tool features in detail

Economic basic design

― Significantly improved surface quality ― No passage scoring on the component surface, because chips are routed to the outside ― High process reliability as less chips and dirt in the finished part ― No abrasion on the milling tool body (chip removal)

― Direct cooling and lubrication of the blades, thus suitable for dry machining and MQL applications ― Reduced noise level through minimisation of the blade projection (0.5 mm)

― Inserts are in the form of replaceable milling inserts ― Stable guidance thanks to highly precise dovetail guide ― High productivity through maximum number of teeth ― Monoblock variant for increased rigidity

Effective chip removal for higher quality, productivity, process reliability and tool life.

Tool features in detail | EcoMill-Blue and RapidMill-Blue

EcoMill-Blue RapidMill-Blue

1 Minimal blade projection– Minimal noise development– Extremely quiet operation

2 Special cutting geometry – Facing blades– Corner blades– Wide face milling blades– PT blades for defined surface uniformity

3 Tool Body of high-strength aluminium– Wear-resistant– Lightweight design enables use at extremely high speeds

4 High-precision wedge adjustment– Easy handling– μ-precise adjustment of axial run-out

5 Balancing screws– Perfect concentricity thanks to balanced milling cutter body

6 Integrated coolant outlets– Direct cooling and lubrication of the blades– Suitable for dry machining and MQL applications

7 Replaceable PCD milling inserts– PCD blades enable extremely tool life– Special chip guidance geometry for effective removal transport of chips

8 Dovetail guide– Precise positioning of the blades over the entire tool life

Innovative chip guidance geometry

Optimised for dry machining

3

EcoMill-Blue | Face milling cutters4

EcoMill-Blue

Face milling cutters | EcoMill-Blue

The EcoMill-Blue series represents the further development of the

EcoMill series. The essential difference to the EcoMill series is the

milling insert. An innovative chip guidance geometry ensures effective

removal transport of the chips. Thus a significantly improved surface

quality and a considerable increase in tool life are realised. Integrated

coolant outlets enable use for dry machining and minimum quantity

lubrication.

The new milling inserts of the EcoMill-Blue series are available as

corner blades, facing blades, PT blades or wide face milling blades and

they can also be used in the bodies of the EcoMill standard series.

5

EBC...

d1

160200 - 400315 - 400

ISO 4762 - M12x45-12.9ISO 4762 - M16x50-12.9 ISO 4762 - M20x50-12.9

100065941000777510080371

7-03002-03

7-03002-04

7-03002-05

d1 50 - 125

d1 160 - 400

63 5 22 48 48 26 48 0,43 33.000 CFM901-063-CA22-Z05R-EBC-A 30545037

80 6 27 50 60 34 50 0,71 33.000 CFM901-080-CA27-Z06R-EBC-A 30545038

100 8 32 50 78 43 50 1,13 29.500 CFM901-100-CA32-Z08R-EBC-A 30545039

125 10 40 63 89 54 63 2,08 25.500 CFM901-125-CA40-Z10R-EBC-A 30542646

160 12 40 63 96 116,5 63 2,52 22.200 CFM901-160-CA40-Z12R-EBC-A 30545040

200 16 60 63 134 156,5 63 3,80 18.100 CFM901-200-CA60-Z16R-EBC-A 30545041

250 20 60 63 134 206,5 63 6,11 14.500 CFM901-250-CA60-Z20R-EBC-A 30545042

315 24 60 80 232 271,5 80 12,15 11.500 CFM901-315-CA60-Z24R-EBC-A 30545052

400 28 60 80 232 356,5 80 19,00 9.000 CFM901-400-CA60-Z28R-EBC-A 30545044

63 5 22 48 48 26 48 0,96 33.000 CFM901-063-CA22-Z05R-EBC-S 30569914

80 6 27 50 60 34 50 1,63 33.000 CFM901-080-CA27-Z06R-EBC-S 30569915

100 8 32 50 78 43 50 2,60 29.500 CFM901-100-CA32-Z08R-EBC-S 30569916

125 10 40 63 89 54 63 4,85 25.500 CFM901-125-CA40-Z10R-EBC-S 30569917

160 12 40 63 96 116,5 63 6,58 22.200 CFM901-160-CA40-Z12R-EBC-S 30569918

d 3

d 2 d 4

d 1

l1 = EM

ap

Dimensions in mm.

* d1 depending on milling insert type, see page 9. ** Included in the scope of delivery.

For cutting value recommendations, see page 18.

Face milling cutter EcoSpeed-BlueCoarse pitch Maximum cutting depth ap = 2 mm

Aluminium body

Accessories Spare parts**

Dimensions Settingdimension

EM (±0,05)

Weight [kg]

max. speed [min-1]

Specification Order No.

d1* Zeff d2 l1 d3 d4

EcoMill-Blue | Face milling cutters


EM (±0,05)

Weight [kg]

max. speed [min-1]



Steel body

Milling insert Page 9

Milling cutter arborsSee catalogue "MAPALCompetence Clamping

technology"Milling cutter clamping screws Order No.

Clamping screw for milling insert

TORX® M5x11 TX25

Order No.

Threaded spindleM5x0.5LH/RHx17

Order No.

Adjusting wedgeM5x0.5

Order No.

Milling cutterclamping screws Page 15

Coolant cover andfastening screws

M6x20Page 15

6

7-03002-03

7-03002-04

7-03002-05

d1 50 - 125

d1 160 - 400

EBC...

d1

160200 - 400315 - 400


100065941000777510080371

50 6 22 48 45 16 48 0,28 35.000 CFM901-050-CA22-Z06R-EBC-A 30545045

63 8 22 48 48 26 48 0,45 33.000 CFM901-063-CA22-Z08R-EBC-A 30545046

80 10 27 50 60 34 50 0,73 33.000 CFM901-080-CA27-Z10R-EBC-A 30545047

100 14 32 50 78 43 50 1,17 29.500 CFM901-100-CA32-Z14R-EBC-A 30545048

125 18 40 63 89 54 63 2,14 25.500 CFM901-125-CA40-Z18R-EBC-A 30519037

160 24 40 63 96 116,5 63 2,60 22.200 CFM901-160-CA40-Z24R-EBC-A 30545049

200 28 60 63 134 156,5 63 6,11 14.500 CFM901-200-CA60-Z28R-EBC-A 30545050

250 36 60 63 134 206,5 63 6,22 14.500 CFM901-250-CA60-Z36R-EBC-A 30545051

315 46 60 80 232 271,5 80 12,29 11.500 CFM901-315-CA60-Z46R-EBC-A 30545043

400 58 60 80 232 356,5 80 19,21 9.000 CFM901-400-CA60-Z58R-EBC-A 30545053

50 6 22 48 45 16 48 0,59 35.000 CFM901-050-CA22-Z06R-EBC-S 30569919

63 8 22 48 48 26 48 0,95 33.000 CFM901-063-CA22-Z08R-EBC-S 30569920

80 10 27 50 60 34 50 1,61 33.000 CFM901-080-CA27-Z10R-EBC-S 30569921

100 14 32 50 78 43 50 2,59 29.500 CFM901-100-CA32-Z14R-EBC-S 30569922

125 18 40 63 89 54 63 4,81 25.500 CFM901-125-CA40-Z18R-EBC-S 30569923

160 24 40 63 96 116,5 63 6,54 22.000 CFM901-160-CA40-Z24R-EBC-S 30569924

d 3

d 2 d 4

d 1

l1 = EM

ap

Dimensions in mm.



Face milling cutter EcoFeed-BlueClose pitch Maximum cutting depth ap = 2 mm

Aluminium body



EM (±0,05)

Weight [kg]

max. speed [min-1]



Face milling cutters | EcoMill-Blue


EM(±0,05)

Weight [kg]

max. speed [min-1]



Steel body

Milling insert Page 9


technology"Milling cutter clamping screws Order No.


TORX® M5x11 TX25

Order No.

Threaded spindleM5x0.5LH/RHx17

Order No.


Order No.



M6x20Page 15

7

7-03002-03

d1

32 - 4050 - 100

7-03002-077-03002-04

d1

32 - 4050 - 100

7-03002-067-03002-05

30326006

d 1

l2

ap

l1 = EM

32 4 63 100 73 100 0,51 27.000 CFM901-032-A063-Z04R-EBC-S 30545054

40 6 63 100 73 100 0,57 27.000 CFM901-040-A063-Z06R-EBC-S 30545055

50 6 63 100 73 100 0,67 27.000 CFM901-050-A063-Z06R-EBC-S 30545056

63 8 63 100 73 100 0,89 27.000 CFM901-063-A063-Z08R-EBC-S 30545057

80 10 63 100 73 100 1,16 25.000 CFM901-080-A063-Z10R-EBC-S 30545058

100 14 63 100 73 100 1,51 20.000 CFM901-100-A063-Z14R-EBC-S 30545059

32 4 40 100 80 100 0,54 27.000 CFM901-032-S040-Z04R-EBC-S 30545060

40 6 40 100 80 100 0,62 27.000 CFM901-040-S040-Z06R-EBC-S 30545061

50 6 40 100 80 100 0,73 27.000 CFM901-050-S040-Z06R-EBC-S 30545062

63 8 40 100 80 100 0,90 27.000 CFM901-063-S040-Z08R-EBC-S 30545063

80 10 40 100 80 100 1,16 25.000 CFM901-080-S040-Z10R-EBC-S 30545064

100 14 40 100 80 100 1,47 20.000 CFM901-100-S040-Z14R-EBC-S 30545065

EBC...

Face milling cutters EcoFix-Blue Close pitch, monoblock variant Maximum cutting depth ap = 2 mm

EcoMill-Blue | Face milling cutters

Body with ISO connection

Body with HSK-A connection



EM (±0,05)

Weight [kg]

max. speed [min-1]


d1* Zeff Nominal size HSK-A l1 l2


EM (±0,05)

Weight [kg]

max. speed [min-1]


d1* Zeff Nominal size ISO l1 l2

Dimensions in mm.



EBC... Milling insert Page 9


technology"


TORX® M5x11 TX25

Order No.

Threaded spindle

M5x0.5LH/RHx15M5x0.5LH/RHx17

Order No.

Adjusting wedge

M5x0.5M5x0.5

Order No.

Connection HSK

Coolant tubeHSK63

Order No.

8

12 m

m

γ16,5 mm

N C

0° ≤ 5 1-2 EBC-731-0-PU611 30559589

0° ≤ 10 1-2 EBC-732-0-PU611 30559591

0° ≤ 20 1-2 EBC-733-0-PU611 30559595

0° > 20 1-2 EBC-734-0-PU611 30559599

6° ≤ 5 1-2 EBC-711-0-PU611 30502818

6° ≤ 10 1-2 EBC-712-0-PU611 30559592

6° ≤ 20 1-2 EBC-713-0-PU611 30559596

6° > 20 1-2 EBC-714-0-PU611 30559600

max

. 1

90°

d1 + 1 mm

d1 = Nenn ø

0° ≤ 5 1-2 EBC-631-0-PU611 30559590

0° ≤ 10 1-2 EBC-632-0-PU611 30559593

0° ≤ 20 1-2 EBC-633-0-PU611 30559597

0° > 20 1-2 EBC-634-0-PU611 30559601

6° ≤ 5 1-2 EBC-611-0-PU611 30518869

6° ≤ 10 1-2 EBC-612-0-PU611 30559594

6° ≤ 20 1-2 EBC-613-0-PU611 30559598

6° > 20 1-2 EBC-614-0-PU611 30559602

75°

45°

d1

R

0° ≤ 5 1-2 rechts PKD EBC-831-0-PU611 30542645

15°

15°

d1 - 1 mm

d1

0° ≤ 5 1-2 rechts PKD EBC-931-0-PU611 30559603

max

. 175°

d1

d1 + 1 mm

75°

45°

d1

R

0° ≤ 5 1-2 EBC-831-0-PU611 30542645

15°

15°

d1 - 1 mm

d1

0° ≤ 5 1-2 EBC-931-0-PU611 30559603

Milling inserts for face milling cutters of theEcoMill-Blue series

Note: Suitable for bodies of the EcoMill and EcoMill-Blue series

Milling insert with facing blade

Chipangle γ

Rz value[µm]

ap max.

Runningdirection

Cuttingmaterial


Milling inserts | EcoMill-Blue

Dimensions in mm.

Chipangle γ

Rz value[µm]

ap max.

Runningdirection

Cuttingmaterial


Chipangle γ

Rz value[µm]

ap max.

Runningdirection

Cuttingmaterial


Milling insert with corner blade

Milling insert with wide face milling blade

Milling insert with PT blade

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Chipangle γ

Rz value[µm]

ap max.

Runningdirection

Cuttingmaterial


max

. 1

90°

d1 + 1 mm

d1 = Nenn ø

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

75°

45°

d1

R

Right PCD

15°

15°

d1 - 1 mm

d1

Right PCD

9

RapidMill-Blue | Face milling cutters10

RapidMill-Blue

Face milling cutters | RapidMill-Blue

The RapidMill-Blue series with the RapidFeed-Blue and RapidFix-

Blue versions opens up a new dimension of productivity for face

milling. Thanks to an optimal configuration we have also succeeded in

implementing the EcoMill-Blue series as a variant with a significantly

increased number of blades. Thus even higher feed rates can be

achieved and productivity can be increased.

The new milling inserts of the RapidMill-Blue series are available as

corner blades, facing blades, PT blades or wide face milling blades and

are used exclusively in the bodies of the RapidMill-Blue series.

11

50 10 22 48 45 16 48 0,29 35.000 CFM901-050-CA22-Z10R-RBC-A 30547876

63 13 22 48 48 26 48 0,47 33.000 CFM901-063-CA22-Z13R-RBC-A 30547877

80 16 27 50 60 34 50 0,75 33.000 CFM901-080-CA27-Z16R-RBC-A 30547878

100 22 32 50 78 43 50 1,18 29.500 CFM901-100-CA32-Z22R-RBC-A 30547879

125 28 40 63 89 54 63 2,16 25.500 CFM901-125-CA40-Z28R-RBC-A 30547880

160 34 40 63 96 116,5 63 2,61 22.200 CFM901-160-CA40-Z34R-RBC-A 30547881

200 44 60 63 134 156,5 63 3,91 18.100 CFM901-200-CA60-Z44R-RBC-A 30547882

50 10 22 48 45 16 48 0,57 35.000 CFM901-050-CA22-Z10R-RBC-S 30547886

63 13 22 48 48 26 48 0,93 33.000 CFM901-063-CA22-Z13R-RBC-S 30547887

80 16 27 50 60 34 50 1,59 33.300 CFM901-080-CA27-Z16R-RBC-S 30547888

100 22 32 50 78 43 50 2,55 29.500 CFM901-100-CA32-Z22R-RBC-S 30547889

125 28 40 63 89 54 63 4,76 25.500 CFM901-125-CA40-Z28R-RBC-S 30547890

160 34 40 63 96 116,5 63 6,51 22.200 CFM901-160-CA40-Z34R-RBC-S 30547891

l1 = EM

d 1d 3

d 2

d 4

ap

Face milling cutter RapidFeed-Blue Close pitch Maximum cutting depth ap = 1 mm

RapidMill-Blue | Face milling cutters

Steel body


EM (±0,05)

Weight [kg]

max. speed [min-1]



Aluminium body



EM (±0,05)

Weight [kg]

max. speed [min-1]



Dimensions in mm.* d1 depending on milling insert type, see page 14. ** Included in the scope of delivery.


RBC... Milling insert Page 14


technology"d1

160200 - 400315 - 400

Milling cutter clamping screws


Order No.

100065941000777510080371


TORX PLUS® M4X8.5-TX15-IP

Order No.

30412229

d1

5063 - 200

Threaded spindle


Ordern No.

7-03002-07 7-03002-04


Order No.

30557564

d1 50 - 125


d1 160 - 400


M6x20Page 15

12

30412229

d1

32 - 5063 - 100

7-03002-077-03002-04

30557564

30326006

RBC...

32 4 63 100 73 100 1,29 27.000 CFM901-032-A063-Z04R-RBC-S 30547893

40 6 63 100 73 100 1,45 27.000 CFM901-040-A063-Z06R-RBC-S 30547894

50 10 63 100 73 100 1,72 27.000 CFM901-050-A063-Z10R-RBC-S 30547895

63 13 63 100 73 100 2,16 27.000 CFM901-063-A063-Z13R-RBC-S 30547896

80 16 63 100 73 100 2,81 25.000 CFM901-080-A063-Z16R-RBC-S 30547898

100 22 63 100 73 100 3,55 20.000 CFM901-100-A063-Z22R-RBC-S 30547899

32 4 40 100 80 100 1,47 27.000 CFM901-032-S040-Z04R-RBC-S 30547902

40 6 40 100 80 100 1,64 27.000 CFM901-040-S040-Z06R-RBC-S 30547903

50 10 40 100 80 100 1,91 27.000 CFM901-050-S040-Z10R-RBC-S 30547904

63 13 40 100 80 100 2,40 27.000 CFM901-063-S040-Z13R-RBC-S 30547905

80 16 40 100 80 100 3,10 25.000 CFM901-080-S040-Z16R-RBC-S 30547906

100 22 40 100 80 100 3,90 20.000 CFM901-100-S040-Z22R-RBC-S 30547907

d 1

l2

ap

l1 = EM

Face milling cutter RapidFix-BlueClose pitch, monoblock variant Maximum cutting depth ap = 1 mm

Face milling cutters | RapidMill-Blue

Body with ISO connection

Body with HSK-A connection



EM (±0,05)

Weight [kg]

max. speed [min-1]




EM (±0,05)

Weight [kg]

max. speed [min-1]



Dimensions in mm.



RBC... Milling insert Page 14


technology"

Clamping screw for milling insertTORX PLUS® M4X8.5-TX15-IP

Order No.

Threaded spindle


Order No.

Adjusting wedge

M5x0.5Order No.

ConnectionHSK

Coolant tubeHSK63

Order No.

13

γ

10 m

m

18,5 mm

N

0° ≤ 5 1-2 rechts PKD RBC-631-0-PU611 30560073

0° ≤ 10 1-2 rechts PKD RBC-632-0-PU611 30560077

0° ≤ 20 1-2 rechts PKD RBC-633-0-PU611 30560081

0° > 20 1-2 rechts PKD RBC-634-0-PU611 30560085

6° ≤ 5 1-2 rechts PKD RBC-611-0-PU611 30547874

6° ≤ 10 1-2 rechts PKD RBC-612-0-PU611 30560078

6° ≤ 20 1-2 rechts PKD RBC-613-0-PU611 30560082

6° > 20 1-2 rechts PKD RBC-614-0-PU611 30560086

max

. 1

90°

d1 + 1 mm

d1 = Nenn ø

0° ≤ 5 1-2 rechts PKD RBC-731-0-PU611 30560072

0° ≤ 10 1-2 rechts PKD RBC-732-0-PU611 30560075

0° ≤ 20 1-2 rechts PKD RBC-733-0-PU611 30560079

0° > 20 1-2 rechts PKD RBC-734-0-PU611 30560083

6° ≤ 5 1-2 rechts PKD RBC-711-0-PU611 30547873

6° ≤ 10 1-2 rechts PKD RBC-712-0-PU611 30560076

6° ≤ 20 1 rechts PKD RBC-713-0-PU611 30560080

6° > 20 1-2 rechts PKD RBC-714-0-PU611 30560084

75°

45°

d1

R

0° ≤ 5 1 RBC-831-0-PU611 30560087

0° ≤ 5 1 RBC-931-0-PU611 30560088

0° ≤ 5 1 RBC-731-0-PU611 30560072

0° ≤ 10 1 RBC-732-0-PU611 30560075

0° ≤ 20 1 RBC-733-0-PU611 30560079

0° > 20 1 RBC-734-0-PU611 30560083

6° ≤ 5 1 RBC-711-0-PU611 30547873

6° ≤ 10 1 RBC-712-0-PU611 30560076

6° ≤ 20 1 RBC-713-0-PU611 30560080

6° > 20 1 RBC-714-0-PU611 30560084

max

. 1

90°

d1 + 1 mm

d1 = Nenn ø

0° ≤ 5 1 RBC-631-0-PU611 30560073

0° ≤ 10 1 RBC-632-0-PU611 30560077

0° ≤ 20 1 RBC-633-0-PU611 30560081

0° > 20 1 RBC-634-0-PU611 30560085

6° ≤ 5 1 RBC-611-0-PU611 30547874

6° ≤ 10 1 RBC-612-0-PU611 30560078

6° ≤ 20 1 RBC-613-0-PU611 30560082

6° > 20 1 RBC-614-0-PU611 30560086

max

. 175°

d1

d1 + 1 mm

Milling inserts for face milling cuttersof the RapidMill series

Milling insert with facing blade

TypPlanmesser

Span- winkel γ

RZ-Wert µm

ap max.

Lauf- richtung

Schneid-stoff

Spezifikation Bestell-Nr.

RapidMill-Blue | Face milling cutters

C

Dimensions in mm. Note: Suitable for bodies of the RapidMill-Blue series.

Chip angle γ

Rz value[µm]

ap max.

Running direction

Cutting material


Chip angle γ

Rz value[µm]

ap max.

Running direction

Cutting material


Chip angle γ

Rz value[µm]

ap max.

Running direction

Cutting material


Chip angle γ

Rz value[µm]

ap max.

Running direction

Cutting material


75°

45°

d1

R

Right PCD

15°

15°

d1 - 1 mm

d1

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

max

. 1

90°

d1 + 1 mm

d1 = Nenn ø

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Right PCD

Milling insert with PT blade

Milling insert with wide face milling blade

Milling insert with corner blade

14

EBC... 7,2 M5 11 T-25 60° 7-03002-03

RBC... 5,7 M4 8,5 15IP 60° 30412229

50 M10 16 21,5 10,5 8 30543340

63 M10 26 20 10,5 10 30543341

80 M12 34 22 23,5 12 30543342

100 M16 43 28 20,5 14 30543344

125 M20 54 32 30,5 14 30543345

160 M12 18 45 12 10 10006594

200-400 M16 24 50 16 14 10007775

315-400 M20 30 50 20 17 10080371

M5x0.5LH 17 6 M5x0,5 6 2,5 7-03002-04

M5x0.5LH 11,5 5,5 M5x0,5 4 2,5 7-03002-07 11,34 M6 20 4 90° M6x20 - 10,9 7-03001-04

160 115 30569889

200 155 30569890

250 205 30569891

315 270 30569892

400 355 30569893

EBC... M5x0,5 7 7 M5x0.5 LH 7-03002-05

EBC... M5x0,5 7 6,5 M5x0.5 LH 7-03002-06

RBC... M5x0,5 6,8 7 M5x0.5 LH 30557564

l

M d

l1

SWl2 l3

M1

M2

M

l1 l2

d k

SW

l1

M

TORX® / TORX PLUS®

αd k

SW

M

l1

d k α

d 1

Face milling cutter | EcoMill-Blue and RapidMill-Blue

Spare parts for face milling cuttersClamping screw

Adjusting wedge

Threaded spindleMilling insert(FE)

Milling cutter clam-ping screw

Coolant cover

Fastening screw forcoolant cover

Milling cutter clamping screw

Threaded spindleFastening screw for coolant cover

Coolant cover

Dimensions Order No.

d* M dk l1 l2 SW


M1 l l1 M2 l2 SWDimensions Countersunk screw

in acc. with ISO

10642

Order No.

dk M l1 SW α


d* d1

Dimensions in mm.


Adjusting wedge

FE type Dimensions Order No.

dk M l1 TX α

FE type Dimensions Designation Order No.

M d l

d* = Diameter of face milling cutter

15

lA EM

Adjusting and handling instructions for EcoMill-Blue and RapidMill-Blue face milling cutters

Changing and adjusting the PCD milling inserts

1. Turn threaded spindle with a hexagon socket wrench AF 2.5 one turn counterclockwise.

5. Turn threaded spindle with a hexagon socket wrench one half turn clockwise. Result: Pre-tension is built up.

2. Unscrew the clamping screw of the milling insert and take it up and out of the dovetail guide.

6. With the setting fixture, optically adjust a milling insert -0.01 mm before the setting dimension EM: To do this, record the cutting edge with optical measurement device, and turn the threaded spindle with the hexagon socket wrench clockwise until EM -0.01 mm is reached. Note: Clean all blades of the milling inserts with cleaning compound to avoid measurement inaccuracies. Tip: For a purely optical adjusting, repeat this procedure for the rest of the milling inserts (then proceed with step 8).

3. Clean the seat of the milling insert with compressed air. Introduce the new milling insert into the dovetail guide from above.

4. Insert the clamping screw of the milling insert and tighten with 1-2 Nm. Note: When tightening lightly press on the milling insert so that the adjusting wedge is engaged.

EcoMill-Blue and RapidMill-Blue | Adjusting and handling instructions

To achieve optimal surface quality it is essen-tial that all blades run perfectly in the axial plane. MAPAL uses a special adjusting system for the EcoMill-Blue and RapidMill-Blue face milling head systems. Via a high-precision wedge adjusting element the axial run-out

can be effortlessly adjusted in the μ-range. The accuracy that can be achieved in conjunc-tion with the easy handling characterises this system.

For easy, convenient, fast and precise adjus-ting, the use of a MAPAL setting fixture is recommended. For example, with the new UNISET-P with measuring sensor* the axial run-out can be easily adjusted in record time and with μ-precision.

Note:The setting dimensions are specified on the appropriate product pages.The setting dimension EM refers exclusively to the body of the milling cutter incl. milling inserts. If a milling cutter with receptacle is adjusted, then the height of the receptacle lA must always be taken into account. In this case the setting dimension is lA+EM.

*While optical systems reach their limits at μ-precise adjusting, high-precision adjusting of the axial run-out can be easily realised with the aid of the tactile measuring sensor.

16

SpannschraubeBestell-Nr.

Abmessungen[M]

TORX®/TORX PLUS®- Antriebsgröße

Anzugsdrehmoment[Nm]

7-03002-03 M5 T-25 8

30412229 M4 15IP 4

30543340 50 M10 8 20

30543341 63 M10 8 50

30543342 80 M10 10 80

30543344 100 M12 12 100

30543345 125 M16 14 200

10006594 160 M12 10 70

10007775 200 - 400 M16 14 7010080371 315 - 400 M20 17 70

7. Position dial gauge on the adjusted milling insert and set it to zero. Adjust milling inserts with dial gauge -0.01 mm before EM: To do this, turn threaded spindle with the hexagon socket wrench clockwise until the zero dimension is reached.

8. Tighten the clamping screw of the milling insert with a torque wrench (see the table "Tightening torque for clamping screws" for tightening torque).

Note: During the handling step, the measuring sensor must not sit on the milling insert.

9. With the setting fixture, optically determine the milling insert with the highest cutting edge and set dial gauge to zero. Adjust all milling inserts to the highest cutting edge with dial gauge: To do this, turn threaded spindle with the hexagon socket wrench clockwise until the zero dimension is reached (tolerance ± 2 μm).

Tightening torque for milling cutter clamping screw

Tightening torque for clamping screws

Adjusting and handling instructions | EcoMill-Blue and RapidMill-Blue

Comment: Only for trained personnel.

Clamping screw

Blade

Adjusting wedge

Threaded spindle Dovetail guideMilling insert

Clamping screwOrder No.

Dimensions[M]

TORX®/TORX PLUS®- Actuator size

Tightening torque [Nm]

Tightening screw Order No.

For milling headdiameter [mm]

Dimensions [M]

SW[mm]

Tightening torque [Nm]

17

N

N1.1 Alloy 2024, Alloy 7075, Al99 max. 6.000

0,1 - 0,2 0,05 - 0,1

max. 6.000

0,05 - 0,2

N1.2 AlSi7 max. 6.000 max. 6.000

N1.3 AlSi9, AlSi9Cu max. 6.000 max. 6.000

N1.4 AlSi12, AlSi17 max. 2.000 max. 2.000

N2.1 SE-Cu < 300 max. 6.000 max. 6.000

N2.2 CuSn6 > 300 max. 2.000 max. 2.000

N2.3 CuZn33, CuAl9Mn3 < 1.200 max. 2.000 max. 2.000

N3.1 – max. 2.000 max. 2.000

N4.1 PA, PE, PC, PS, PVC, PP, PTFE, POM, PMMA max. 2.000 max. 2.000

N4.2 PU, PF, EP, UP, VE, CR max. 2.000 max. 2.000

C

C1.2 IMS, HTA 100 - 500

0,1 - 0,4 0,1 - 0,2

C1.3 GMT-PP, PEEK 100 - 500

C2.1 CF222, CF225, CF226, CF227, CF260 100 - 300 0,1 - 0,2 0,05 - 0,1

Cutting data recommendations

EcoMill-Blue and RapidMill-Blue | Cutting data recommendations

The specified work values are guide values. The optimal data for each machining case should be determined in trials.


Material examples Strength [N/mm2] vc [m/min] fz [mm/Z] vc [m/min] fz [mm/Z]

Materials Cutting depth ap < 1,0 mm

Cutting depth ap 1,0 - 2,0 mm

Cutting depth ap ≤ 1,0 mm

N

Aluminium, unalloyed and alloyed < 3 % Si

Aluminium, alloyed ≤ 7 % Si

Aluminium, alloyed > 7-12 % Si

Aluminium, alloyed > 12 % Si

Copper, unalloyed and low-alloy

Copper, alloyed

Brass, bronze, red brass

Graphite

Plastic, thermoplastics

Plastic, thermoset plastics

C

Plastic matrix (thermosetting),CFRP/GFRP

Plastic matrix (thermoplastic),CFRP/GFRP

Carbon matrix, carbon fibre reinforced (CFC)

18

N

N1.1 Alloy 2024, Alloy 7075, Al99 max. 6.000

0,1 - 0,2 0,05 - 0,1

max. 6.000

0,05 - 0,2

N1.2 AlSi7 max. 6.000 max. 6.000

N1.3 AlSi9, AlSi9Cu max. 6.000 max. 6.000

N1.4 AlSi12, AlSi17 max. 2.000 max. 2.000

N2.1 SE-Cu < 300 max. 6.000 max. 6.000

N2.2 CuSn6 > 300 max. 2.000 max. 2.000

N2.3 CuZn33, CuAl9Mn3 < 1.200 max. 2.000 max. 2.000

N3.1 – max. 2.000 max. 2.000

N4.1 PA, PE, PC, PS, PVC, PP, PTFE, POM, PMMA max. 2.000 max. 2.000

N4.2 PU, PF, EP, UP, VE, CR max. 2.000 max. 2.000

C

C1.2 IMS, HTA 100 - 500

0,1 - 0,4 0,1 - 0,2

C1.3 GMT-PP, PEEK 100 - 500

C2.1 CF222, CF225, CF226, CF227, CF260 100 - 300 0,1 - 0,2 0,05 - 0,1

Cutting data recommendations | EcoMill-Blue and RapidMill-Blue


Material examples Strength [N/mm2] vc [m/min] fz [mm/Z] vc [m/min] fz [mm/Z]

Materials Cutting depth ap < 1,0 mm

Cutting depth ap 1,0 - 2,0 mm

Cutting depth ap ≤ 1,0 mm

N

Aluminium, unalloyed and alloyed < 3 % Si

Aluminium, alloyed ≤ 7 % Si

Aluminium, alloyed > 7-12 % Si

Aluminium, alloyed > 12 % Si

Copper, unalloyed and low-alloy

Copper, alloyed

Brass, bronze, red brass

Graphite

Plastic, thermoplastics

Plastic, thermoset plastics

C

Plastic matrix (thermosetting),CFRP/GFRP

Plastic matrix (thermoplastic),CFRP/GFRP

Carbon matrix, carbon fibre reinforced (CFC)

19

Face milling of the head side of a cylinder crankcase

With the new EcoFeed-Blue for rough milling the head side of an aluminium cylinder crank-case at constant surface quality, significantly higher quantities could be reached with pro-cess reliability.

Relative to the previously used, conventional face milling cutter, it was possible to incre-ase quantities virtually by a factor of 7; from 5,000 to more than 34,500 crankcase parts.

Due to the high costs of cleaning parts, for the machining of a cylinder crankcase in serial production, a component that not only has a high surface quality, but that is also as dirt-free as possible is required. By using the new EcoFeed-Blue both requirements are satisfied.

Compared with conventional face milling cut-ters, a significantly improved surface quality is visually achieved. Moreover, it was possible to significantly reduce the danger of scoring.

Machining examples –competence face milling

EcoMill-Blue | Machining examples

CAPACITy DATA

Material: EN AC-46200 (AlSi8Cu3)Tool: EcoFeed-Blue ø125 Z = 18Allowance: 0,6 - 0,8 mmSpeed: 8.000 min-1

Cutting speed vc: 3.015 m/minFeed vf: 15.000 mm/minQuantity, old: 5.000 partsQuantity, new: 34.600 parts

EcoFeed-Blue ø 125, Z = 18

20

Face milling of the sealing and labyrinth surface of a transmission housing

Die-cast aluminium and magnesium are being used increasingly as a construction material for modern motor vehicles in order to achie-ve weight reductions and concurrent higher stability. Today's die-casting methods are ex-tremely precise and efficient; even extremely complex workpiece geometries can be pro-duced. Transmission housings represent one example in this regard. A major challenge

with the economical manufacturing of this transmission housing is the machining of the sealing and labyrinth surfaces. Pre-defined Rz values, as well as close toleran-ces, in parallelity and angularity impose spe-cial requirements on the tools. MAPAL offers the optimal solution for these applications.

With the new EcoFeed-Blue the required sur-face qualities for sealing surface (Pt = 15) and labyrinth surface (Rz = 8, Rmax = 10) are achieved with process reliability. The extreme-ly quiet operation has a particularly positive effect on the machining of thin-wall compo-nents that are susceptible to vibration. Rela-tive to the previously used, conventional face

milling cutter, at a uniform surface quality of Pt = 6 - 7 as well as Rz = 3 - 5, it was possib-le to significantly increase the quantity. With an increase from 600 - 800 to 2,100 housing parts, three times the quantity has been achieved. Moreover, customers profit from the reduced effort for component cleaning.

Machining examples | EcoMill-Blue

CAPACITy DATA

Material: EN AC-46000 (AlSi9Cu3)Tool: EcoFeed-Blue ø 63 Z = 8Allowance: 0,9 - 1,2 mmSpeed: 14.200 min-1

Cutting speed vc: 2.810 m/minFeed vf: 7.200 mm/minQuantity, old: 600 - 800 partsQuantity, new: 2.100 partsSurface quality achieved: Rz = 3 - 5, Pt = 6 - 7

EcoFeed-Blue ø 63, Z = 8

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MAPAL Maintenance Services –reconditioning for face milling heads

EcoMill-Blue and RapidMill-Blue | Services

Considerable cost savings thanks to reliable,fast and precise reconditioning

For machining, customers must be able to rely on their tools, particularly after a regeneration, over the entire process. Cleanliness, care and precision are the essential factors that MAPAL focuses on for reconditioning the milling heads. With reconditioning in original quality and milling head management, MAPAL offers two reconditioning systems for face

milling heads that guarantee precise and reliable tools with the full performance range. Through each reconditioning, the life of tools is significantly extended and costs for new tools are saved. The customer receives tools that are immediately ready for use and that easily reach the already known tool life. The tools are picked up from or delivered directly

to the customer via a parcel service. The standardised process ensures uncomplicated and fast processing within a maximum of five days.

ADVANTAGES

- Increased tool life

- Reduced tool costs

- Operational tools in original quality

- On-time pick-up and delivery

- Increased process reliability

- Reduction of capital commitments*

* in conjunction with milling head management

with reconditioning (new price + n x reconditioning price)

* depending on the customer-specific application

with reconditioning in milling head management (mixed price)

Tool costs

New tool 2 x recon-ditioning

4 x recon-ditioning

6 x recon-ditioning

8 x recon-ditioning

10 x recon-ditioning

Number of reconditionings

22

Services | EcoMill-Blue and RapidMill-Blue

Reconditioning in original quality Milling head management

After dismantling, MAPAL thoroughly cleans the tools, wear parts are replaced and the system is built up again from the ground up. Worn milling inserts go through a repair cycle and the tool is refitted with stockable, regenerated blades. After assembly with the appropriate milling cutter receptacle, the milling inserts are adjusted to the original setting dimension (EM). Within 5 days the customer receives tools that are immediately ready for use and that easily reach the already known tool life.

Reconditioning cycle Reconditioning cycle – milling head management

Comment: As a technology partner, MAPAL supports you in selecting the optimal reconditioning process for your specific machining case.

1 Provision of the milling head systems to be reconditioned in the delivered packages

2 On-time pick-up of the milling head systems through parcel service

3 Reconditioning of the complete milling head systems, incl. repla-cement of all wear parts

4 Adjustment of the milling head systems to the original setting dimensions (EM)

5 On-time delivery of immedi-ately operational milling head systems

1 Provision of the milling head systems to be reconditioned in the delivered packages

2 On-time pick-up of the milling head systems through parcel service

3 Reconditioning of the com-plete milling head systems, incl. replacement of all wear parts

4 Adjustment of the milling head systems to the original setting dimensions (EM)

5 On-time delivery of immedi-ately operational milling head systems

6 Stock keeping of the operatio-nal milling head systems

max.5 days

max.48 h

Milling head management includes stock keeping in addition to the reconditioning in original quality. Customers profit from 24 h tool availability at the implementation site, as well as reduced capital commitments. Billing is based on withdrawal at a calculated mixed price. The customer maintains full cost control. Expensive procurement costs for new tools are dispensed with. Bottlenecks due to tool availability are a thing of the past. Through a customer agreement, a specific workflow is defined that enables delivery times of a maximum of 48 hours.

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