MILLING Milling cutters with replaceable inserts

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2 9 FACE MILLING CUTTERS WITH PCD MILLING CARTRIDGES Introduction to the technology EcoMill and PowerMill EcoMillBlue and RapidMillBlue FlyCutter 4 Reconditioning face milling heads, milling head management PowerFeed PowerFix 9 PowerSpeed 7 EcoMill EcoFeed 7 EcoFix 7 EcoSpeed 74 PCD face milling cutters PowerMill FlyCutter FlyCutter, weightreduced design 7 EcoMillBlue EcoFeedBlue 7 EcoFixBlue 77 EcoSpeedBlue 7 RapidMillBlue RapidFeedBlue 79 RapidFixBlue FaceMill FaceMillDiamond _FRAESEN _DE_EN_V.indd 9.. :

3 EcoMill and PowerMill series Proven in practice HSC machining to the highest perfection High removal rates, defined surface roughnesses or special requirements on the flatness of the part irrespective of which requirements are placed on the tool during face milling, the EcoMill and PowerMill series provide the solution. Different numbers of teeth make possible the optimal selection of the tool with the goal of achieving the highest costeffectiveness for the milling process. Disposable milling cartridges for the series EcoMill or economical 4hour regrinding service for the PowerMill design both variants are available. _FRAESEN _DE_EN_V.indd EcoMill This series includes many innovations. Due to the usage of disposable milling cartridges, the logistics effort is reduced. During handling the simple positioning of the milling insert in the aluminium body impresses. The centrifugal forces that occur during machining are compensated by an exact dovetail guide. Integrated chip deflectors significantly increase the service life of the milling cutter body. Perfect surface finishes are achieved with this milling cutter by the sensitive, effective wedge adjustment of the inserts in the Z direction. The milling head primarily designed for finishing operations impresses due to the very smooth running that is achieved without problems despite the high feed rates. PowerMill The parts reduced to a sensible minimum in conjunction with the simple, but robust construction are a guarantor for the uncomplicated and extremely fast adjustment of the tool. The significant difference to the EcoMill series is in the milling cartridge. On the PowerMill series the milling cartridges are designed with larger PCDtipping. Along with the greater cutting depth of up to max. mm; this feature also makes regrinding possible. The highly accurate milling cartridge guarantees a perfect insert diameter due to the accurate manufacture in the aluminium body... :

4 Tool features in detail EcoMill Replaceable PCD milling cartridges Inserts made of PCD ensures very high tool lives Special chip guiding geometry for removal of the chips in a controlled manner Body material made of highstrength aluminium Wearresistant Lightweight design makes it possible to use very high spindle speeds 7 7 PCD milling cartridges Robust and can be reground Safety screws Perfect seating of the milling cartridge in the body material Dovetail guide Exact positioning of the inserts over the whole tool life 4 Balancing screws Perfect radial runout due to balanced milling body Highaccuracy wedge adjustment Simple handling Setting of the axial runout to the μ Adjusting screw Exact, reliable adjustment of the axial runout even in extreme conditions Simple handling Replaceable chip deflector Significant increase in the service life of the aluminium body Balancing screws Perfect radial runout due to balanced milling body PCD face milling cutters Special cutting edge geometry Face milling insert Corner milling insert Wide finishing milling insert PT milling insert for defined surface roughnesses PowerMill EcoMill PowerMill Custom solutions Light aluminium body Particularly sensitive adjustment for finishing operations Economical disposable inserts with smaller PCD cutting edges than on the PowerMill series Simple, robust construction Replaceable chip deflectors for extremely long life of the milling body Milling cartridges that can be reground for high costeffectiveness Basis for customerspecific custom solutions Disc milling cutters for complete machining operations during which face surfaces and spacings are to be produced in one pass Beam milling cutters for machining centres with restricted tool diameter or machining operations that require a large diameter Along with the milling heads with custom dimensions, milling cartridges can be adapted to the specific machining task Comprehensive standard programme for all requirements. _FRAESEN _DE_EN_V.indd.. :

5 EcoMillBlue and RapidMillBlue New generation of PCD face milling cutters A clean solution for highspeed aluminium machining Part cleaning represents a significant cost element in series production. This is where the new generation of PCD face milling cutters comes into its own. To come as close as possible to the goal of a finished part free of residual soiling, an innovative PCD milling cartridge has been developed. The special chip guiding geometry keeps the chips away from the workpiece surface in a controlled manner. Thanks to the new milling cartridges, a significantly improved visual surface finish is achieved with ductile and longchipping materials and the risk of score formation has been greatly reduced. This has advantages particularly during dry machining and with minimum quantity lubrication. _FRAESEN _DE_EN_V.indd The integrated coolant outlets in the milling cartridges ensure optimum cooling and lubrication of the PCD inserts, particularly with minimum quantity lubrication. The significantly reduced effort for the subsequent cleaning of the parts is particularly important for machining processes without the use of cooling lubricants. With same basic setup and even more cutting edges (z = with tool diameter mm) the new RapidMillBlue series achieves the highest possible productivity during face milling. As a special service, MAPAL offers milling head management as well as reconditioning in original quality. The construction is similar to that of the proven EcoMill principle. The cutting edges are implemented in the form of milling cartridges and are securely fixed by a highly precise dovetail guide. Changing the milling cartridges is quite straightforward. Adjustment is userfriendly with radially accessible, wedgeshaped adjusting elements... :

6 Tool features in detail Minimum cutting edge overhang Low noise Very smooth running Special cutting edge geometry Face milling insert Corner milling insert Wide finishing milling insert PT milling insert for defined surface roughnesses Body material made of highstrength aluminium Wearresistant Lightweight design makes it possible to use very high spindle speeds 4 Highaccuracy wedge adjustment Simple handling Setting of the axial runout to the μ 4 7 Integrated coolant outlets Direct cooling and lubrication of the cutting edges Suitable for dry machining and MQL applications 7 Replaceable PCD milling cartridges Inserts made of PCD for long tool lives Special chip guiding geometry for removal of the chips in a controlled manner Dovetail guide Exact positioning of the inserts over the whole tool life Innovative chip guiding geometry Optimised for MQL machining Economical basic design Direct cooling and lubrication of the cutting edges Very suitable for dry machining and MQL applications Reduced noise level due to minimisation of the cutting edge overhang (. mm) Cutting edges formed as replaceable milling cartridges Stable guiding due to highly precise dovetail guide High productivity due to maximum number of teeth Monoblock variant for increased rigidity EcoMillBlue PCD face milling cutters Balancing screws Perfect radial runout due to balanced milling body RapidMillBlue Significantly better surface finish No transport scoring on the part surface as the chips are discharged to the outside High process reliability with fewer chips and less residual soiling in the part No abrasion of the milling cutter body through the chip discharge Controlled chip removal for more quality, productivity, process reliability and tool life. _FRAESEN _DE_EN_V.indd.. :

7 4 FlyCutter Lightweight HSC milling cutter for surfaces as smooth as glass The tool weight plays a decisive role In a very wide range of sectors, small machines are used to manufacture aluminium housings. These machines have very precise spindles that permit very high spindle speeds. They are not designed for high torques and often have a maximum tool weight of kilograms. Nevertheless the requirements for machines and tools are high. Surfaces as smooth as glass with roughness figures smaller than Ra. μm and flatnesses with maximum.4 mm must be manufactured reliably. With the FlyCutter, MAPAL has developed a milling tool that is precisely matched to these requirements. The innovative design and the usage of aluminium ensure the milling head _FRAESEN _DE_EN_V.indd 4 has a particularly low weight. Nevertheless, the system has excellent strength values even at large diameters. All different milling head diameters from to mm can be mounted on the same milling cutter arbor. This aspect also contributes to the low weight of the overall system. With a diameter of millimetres, together with a milling cutter arbor BT, the FlyCutter weighs only. kilograms. Milling head and milling cutter arbor are finely balanced. The milling head has an additional balance plane to balance the complete system precisely. The milling cutter clamping screw is designed for internal coolant supply. As a result it is ensured that chips are flushed radially outwards and away from the surface produced, among other things. The sensitive wedge adjustment makes it possible to adjust the milling cartridges to the µ. The dovetail guide and an additional worm screw ensure perfect seating and accuracy of repetition on the assembly of the milling cartridges. Due to the special, highly positive cutting edge geometry, there are only low forces acting on the part, in this way stress and deformation are avoided... :

8 ss Tool features in detail Highaccuracy wedge adjustment Simple handling Setting of the axial runout to the μ Replaceable PCD milling cartridges Inserts made of PCD ensures very high tool lives Easy handling 4 Balancing screws Perfect radial runout due to balanced milling body Additional balance plane to balance the complete system 4 Special cutting edge geometry Face milling insert Corner milling insert Wide finishing milling insert PT milling insert for defined surface roughnesses Dovetail guide Exact positioning of the inserts throughout the entire tool life 7 7 Optimised for small connections BT BBT BT BBT HSKA PCD face milling cutters Body material made of highstrength aluminium Wearresistant Lightweight design makes it possible to use very high spindle speeds Perfect surface finishes For small machines Modular construction The selection of the PCD milling cartridges is dependent on the part or on the surface to be produced Setting of the PCD milling cartridge to the µ Additional balance plane to balance the complete system exactly Stressfree machining of the part due to highly positive cutting edge geometry Specially developed for very soft, longchipping aluminium Suitable for machining of vacuumclamped, thinwalled parts Simple, robust construction All milling head diameters from to mm can be mounted on the same milling cutter arbor Milling cutter clamping screw designed for internal coolant supply Optimal for usage in BT spindles. _FRAESEN _DE_EN_V.indd.. :

9 MAPAL Maintenance Services reconditioning for face milling heads Significant cost savings through reliable, quick and precise reconditioning During machining, customers must be able to rely on their tools over the entire process, particularly after reconditioning. Cleanliness, care and precision are for MAPAL the essential factors in the foreground during the reconditioning of the milling heads. With reconditioning in original quality and milling head management, MAPAL offers two reconditioning systems for face milling heads that guarantee precise, reliable tools with full performance. With each reconditioning the service life of the tools is significantly increased and costs for new tools saved. The customer receives tools that can be used immediately for the troublefree achievement of the already familiar tool lives. The tools are collected from and delivered to the customer by courier. The standardised process ensures straightforward, fast processing within a few days. ADVANTAGES 4 %* Increase in the tool life Tool costs Reduction of the tool costs Tools in original quality ready for use With reconditioning as part of milling head management (mixed price) Punctual collection and delivery Increase in the process reliability Reduction of capital tiedup* With reconditioning (price new + n x price for reconditioning) New tool x reconditioning 4 x reconditioning x reconditioning x reconditioning x reconditioning Number of reconditioning processes * In conjunction with milling head management _FRAESEN _DE_EN_V.indd * Depending on the customerspecific application.. :

10 7 PCD face milling cutters Reconditioning in original quality Milling head management At MAPAL, after disassembly, the tools are thoroughly cleaned, wearing parts replaced and the system reassembled from the ground up. Worn milling cartridges are submitted to a repair cycle. The tool is equipped with new, reconditioned inserts from stock. After assembly with the related milling cutter holder, the milling cartridges are set to the original setting dimension. Within five days, the customer receives tools that can be used immediately for the troublefree achievement of the already familiar tool lives. The milling head management includes, along with reconditioning in original quality, also stockkeeping. Customer profit from 4hour tool availability at the place of use as well as less capital tiedup. Charging is at a calculated mixed price on withdrawal. The customer has full control of the costs. Expensive procurement costs for new tools are not incurred. Bottlenecks due to tool availability are a thing of the past. By means of a customer agreement, a fixed procedure is defined that makes possible delivery times of maximum 4 hours. Reconditioning cycle days * Reconditioning cycle milling head management Milling head systems to be reconditioned made ready for collection in the packaging supplied Milling head systems to be reconditioned made ready for collection in the packaging supplied Punctual collection of the milling head systems by courier Punctual collection of the milling head systems by courier Reconditioning of the complete milling head system incl. replacement of all wearing parts 4 h * Reconditioning of the complete milling head system incl. replacement of all wearing parts 4 Setting of the milling head to the original setting dimension (EM) 4 Setting of the milling head to the original setting dimension (EM) Punctual delivery of the milling head systems ready for immediate use Punctual delivery of the milling head systems ready for immediate use Stockkeeping of milling head systems ready for use * Applicable in Germany. Additional shipping days may need to be taken into account for shipping abroad * Applicable in Germany. Additional shipping days may need to be taken into account for shipping abroad Note: As a technology partner, MAPAL provides support on the selection of the optimal reconditioning process for the specific application. _FRAESEN _DE_EN_V.indd 7.. :

11 PowerFeed PCD face milling head, close spacing PowerMill l = E M (±. ) d 4 d d d * ap Tool body made of steel Dimensions zeff Weight incl. milling car spindle speed [min] tridge [kg] d* d d d4 l 4 4,. CFM9CAZRPMCS Tool body made of aluminium ,7,.. CFM9CA7ZRPMCA CFM9CAZRPMCA 7,. CFM9CAZRPMCA 97 7,. CFM9CAZRPMCA 94 9,. CFM9CAZRPMCA 9 4,. CFM9CAZRPMCA 9 4 4,. CFM9CAZ4RPMCA 9 7,. CFM9CAZRPMCA 9 4, 7. CFM9CAZRPMCA 94,. CFM9CAZRPMCA 9 Accessories Spare parts** PMC... Milling cartridge Clamping screws for milling cartridge Mx Page 9 See MAPAL catalogue "CLAMPING" d Fastening screw for milling cutter arbor ISO 47 Mx4.9 ISO 47 Mx Dimensions in mm. Counterclockwise design on request. Special design with increased number of teeth on request. * d Depending on the milling cartridge type, see page 9. ** Included. Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd Adjusting screw Mx Chip deflector Chip deflector for clockwise Chip deflector for counterclockwise Clamping screw for chip deflector Mx7. 97 d Coolant screw Page 7 d Coolant cover and fastening screw Mx Page 7.. :

12 9 PowerFix PCD face milling cutter, monoblock design PowerMill l = E M (±, ) d * ap Body material with HSKA connection d* Nominal size HSKA l Weight incl. milling cartridge [kg] spindle speed [min] 4,. CFM9AZ4RPMCS 97, 4. CFM9AZRPMCS 974,. CFM9AZRPMCS 97,7 9. CFM9AZRPMCS 99 zeff Weight incl. milling cartridge [kg] spindle speed [min] PCD face milling cutters zeff Dimensions Body with SK connection Dimensions d* Nominal size SK l 4,7. CFM9SZ4RPMCS 97, 4. CFM9SZRPMCS 97 Accessories Spare parts** PMC... Milling cartridge Page 9 d Clamping screw for milling cartridge Mx (flat head) Mx Adjusting screw Mx Connection HSK Locking screw Mx 99 Coolant screw Page 7 Coolant tube HSKA Dimensions in mm. Counterclockwise design on request. Special design with increased number of teeth on request. * d Depending on the milling cartridge type, see page 9. * Included. Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd 9.. :

13 7 PowerSpeed PCD face milling head, wide pitch PowerMill l = E M (±. ) d 4 d d d * ap Tool body made of steel Dimensions zeff Weight incl. milling car spindle speed [min] tridge [kg] d* d d d4 l 4 4,. CFM9CAZRPMCS ,. CFM9CAZRPMCS 9,7,7.. CFM9CA7ZRPMCA CFM9CA7ZRPMCA Tool body made of aluminium ,. CFM9CA7Z7RPMCA 9 9 4,. CFM9CAZRPMCA ,. CFM9CAZRPMCA 9 7,. CFM9CAZRPMCA 94 7,. CFM9CAZRPMCA 97,. CFM9CAZRPMCA 9 4, CFM9CAZRPMCA 94 9, 4.99 CFM9CAZRPMCA 99 4,. CFM9CAZRPMCA 944 4,. CFM9CAZRPMCA 94 94,7 9.7 CFM9CAZRPMCA, 7.7 CFM9CAZRPMCA 94 4,. CFM9CAZ4RPMCA 944 4, 4. CFM9CAZRPMCA 9444 Dimensions in mm. Counterclockwise design on request. * d Depending on the milling cartridge type, see page 9. ** Included. Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd 7.. :

14 Spare parts** PMC... d Milling cartridge Clamping screws for milling cartridge Mx Page 9 See MAPAL catalogue "CLAMPING" Adjusting screw Mx Fastening screw for milling cutter arbor ISO 47 Mx4.9 ISO 47 Mx Chip deflector Chip deflector for clockwise Chip deflector for counterclockwise Clamping screw for chip deflector Mx7. Locking screw Mx _FRAESEN _DE_EN_V.indd PCD face milling cutters Accessories d Coolant screw Page 7 d Coolant cover and fastening screw Mx Page 7.. :

15 7 EcoFeed PCD face milling head, close spacing EcoMill l = E M (±, ) d 4 d d d * ap Tool body made of aluminium Dimensions zeff Weight incl. milling car spindle speed [min] tridge [kg] d* d d d4 l 49 4,4. CFM9CAZREMCA ,7. CFM9CA7ZREMCA , 9. CFM9CAZ4REMCA 97 7,. CFM9CAZREMCA ,. CFM9CAZ4REMCA 4,. CFM9CAZREMCA 9, 4. CFM9CAZREMCA 9 4,. CFM9CAZ4REMCA 9, 9. CFM9CAZREMCA 94 Accessories Spare parts** EMC... Milling cartridge Clamping screws for milling cartridge Mx Page See MAPAL catalogue "CLAMPING" Threaded spindle Mx.LH/RHx7 d Fastening screw for milling cutter arbor ISO 47 Mx4.9 ISO 47 Mx Adjusting wedge Mx d Coolant screw Page 77 d Coolant cover and fastening screw Mx Page 77 Dimensions in mm. Special design with increased number of teeth on request. * d Depending on the milling cartridge type, see page. ** Included. Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd 7.. :

16 7 EcoFix PCD face milling cutter, monoblock design EcoMill l = E M (±, ) d * ap Body material with HSKA connection d* Nominal size HSKA l Weight incl. milling cartridge [kg] spindle speed [min], 7. CFM9AZREMCS 9, 7. CFM9AZREMCS 94,. CFM9AZREMCS 9 4,. CFM9AZ4REMCS 97 zeff Weight incl. milling cartridge [kg] spindle speed [min] PCD face milling cutters zeff Dimensions Body with SK connection Dimensions d* Nominal size SK l, 7. CFM9SZREMCS 9, 7. CFM9SZREMCS 9 Accessories Spare parts** EMC... Milling cartridge Clamping screws for milling cartridge Mx Page Threaded spindle Mx.LH/RHx7 Connection HSK 94 9 Adjusting wedge Mx. 9 Coolant screw Page 77 Coolant tube HSKA Dimensions in mm. Special design with increased number of teeth on request. * d Depending on the milling cartridge type, see page. ** Included. Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd 7.. :

17 74 EcoSpeed PCD face milling head, wide pitch EcoMill l = E M (±, ) d 4 d d d * ap Tool body made of aluminium Dimensions zeff Weight incl. milling car spindle speed [min] tridge [kg] d* d d d4 l 49 4,. CFM9CAZREMCA ,7. CFM9CA7ZREMCA 9 9 4, 9. CFM9CAZREMCA 99 7,. CFM9CAZREMCA 97 9,. CFM9CAZREMCA 97 4,. CFM9CAZREMCA 97 97,7 4. CFM9CAZREMCA 4,9. CFM9CAZ4REMCA 974, 9. CFM9CAZREMCA 97 Accessories Spare parts** EMC... Milling cartridge Clamping screws for milling cartridge Mx Page See MAPAL catalogue "CLAMPING" Threaded spindle Mx.LH/RHx7 d Fastening screw for milling cutter arbor ISO 47 Mx4.9 ISO 47 Mx Adjusting wedge Mx d Coolant screw Page 77 d Coolant cover and fastening screw Mx Page 77 Dimensions in mm. * d Depending on the milling cartridge type, see page. ** Included. Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd 74.. :

18 7 FlyCutter PCD face milling head, weightreduced design EcoMill d * (±. ) d d l = E M Tool body made of aluminium zeff Weight incl. milling cartridge [kg] spindle speed [min] d* d d l 7 4,. CFM9CA7ZRFMCA ,99. CFM9CA7ZRFMCA 9 7 9,4. CFM9CA7ZRFMCA ,7. CFM9CA7ZRFMCA ,. CFM9CA7Z4RFMCA ,49. CFM9CA7Z4RFMCA 9 Accessories PCD face milling cutters Dimensions Spare parts** FMC... Milling cartridge Clamping screws for milling cartridge ISO 4Mx.KL Page 4 See MAPAL catalogue "CLAMPING" Threaded spindle Mx.LH/RHx7 Adjusting wedge Mx. Locking screw ISO M4x4HKL d Coolant screw and washer Page 77 Dimensions in mm. * d Depending on the milling cartridge type, see page 4. ** Included. Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd 7.. :

19 7 EcoFeedBlue PCD face milling cutters, close spacing EcoMillBlue l = E M (±. ) d d 4 d d * ap Tool body made of aluminium Dimensions zeff Weight [kg] spindle speed [min] 4 d* d d d4 l 4 4,. CFM9CAZREBCA 4 4,4. CFM9CAZREBCA 4 7 4,7. CFM9CA7ZREBCA ,7 9. CFM9CAZ4REBCA 9 4,4. CFM9CAZREBCA 97 9, 4,. CFM9CAZ4REBCA 49 4,, 4. CFM9CAZREBCA 4,, 4. CFM9CAZREBCA 7, 4,9. CFM9CAZ4REBCA 4, 9, 9. CFM9CAZREBCA 4 4,9,9.. CFM9CAZREBCS CFM9CAZREBCS Tool body made of steel ,. CFM9CA7ZREBCS ,9 9. CFM9CAZ4REBCS ,. CFM9CAZREBCS 99 9, 4,4. CFM9CAZ4REBCS 994 Accessories Spare parts** EBC... Milling cartridge Clamping screws for milling cartridge TORX Mx TX Page 4 See MAPAL catalogue "CLAMPING" Threaded spindle Mx.LH/RHx7 d Fastening screw for milling cutter arbor ISO 47 Mx4.9 ISO 47 Mx Dimensions in mm. * d Depending on the milling cartridge type, see page 4. ** Included. Cutting data recommendation see page. _FRAESEN _DE_EN_V.indd 7 Adjusting wedge Mx d Coolant screw Page 77 d Coolant cover and fastening screw Mx Page 77.. :

20 77 EcoFixBlue PCD face milling cutters, monoblock variant EcoMillBlue l = E M (±, ) d * ap Body material with HSKA connection d* Nominal size HSKA Weight [kg] l spindle speed [min] 4, 7. CFM9AZ4REBCS 4,7 7. CFM9AZREBCS,7 7. CFM9AZREBCS,9 7. CFM9AZREBCS 7,. CFM9AZREBCS 4,. CFM9AZ4REBCS 9 zeff Weight [kg] spindle speed [min] PCD face milling cutters zeff Dimensions Body with SK connection Dimensions d* Nominal size SK l 4,4 7. CFM9SZ4REBCS, 7. CFM9SZREBCS,7 7. CFM9SZREBCS,9 7. CFM9SZREBCS,. CFM9SZREBCS 4 4,47. CFM9SZ4REBCS Spare parts** Accessories EBC... Milling cartridge Clamping screws for milling cartridge TORX Mx TX 94 d Threaded spindle Mx.LH/RHx Mx.LH/RHx d Adjusting wedge Mx. Mx. 9 9 Connection HSK Coolant tube HSK Page 4 Dimensions in mm. * d Depending on the milling cartridge type, see page 4. ** Included. Cutting data recommendation see page. _FRAESEN _DE_EN_V.indd 77.. :

21 7 EcoSpeedBlue PCD face milling cutters, wide spacing EcoMillBlue l = E M (±. ) d 4 d d d * ap Tool body made of aluminium Dimensions zeff Weight [kg] spindle speed [min] d* d d d4 l 4 4,4. CFM9CAZREBCA 7 7 4,7. CFM9CA7ZREBCA 7 4, 9. CFM9CAZREBCA 9 9 4,. CFM9CAZREBCA 44 9,,. CFM9CAZREBCA 4,,. CFM9CAZREBCA 4 4,, 4. CFM9CAZREBCA 4 7, 4,. CFM9CAZ4REBCA, 9, 9. CFM9CAZREBCA 44,9,.. CFM9CAZREBCS CFM9CA7ZREBCS Tool body made of steel , 9. CFM9CAZREBCS ,. CFM9CAZREBCS 997 9,,. CFM9CAZREBCS 99 Accessories Spare parts** EBC... Milling cartridge Clamping screws for milling cartridge TORX Mx TX Page 4 See MAPAL catalogue "CLAMPING" Threaded spindle Mx.LH/RHx7 d Fastening screw for milling cutter arbor ISO 47 Mx4.9 ISO 47 Mx Dimensions in mm. * d Depending on the milling cartridge type, see page 4. ** Included. Cutting data recommendation see page. _FRAESEN _DE_EN_V.indd 7 Adjusting wedge Mx d Coolant screw Page 77 d Coolant cover and fastening screw Mx Page 77.. :

22 79 RapidFeedBlue PCD face milling cutters, close spacing RapidMillBlue l = E M (±. ) d 4 d d d * ap Tool body made of aluminium d* d d d4 zeff Weight [kg] spindle speed [min] l 4 4,9. CFM9CAZRRBCA ,47. CFM9CAZRRBCA ,7. CFM9CA7ZRRBCA 7 4, 9. CFM9CAZRRBCA ,. CFM9CAZRRBCA 47 9, 4,. CFM9CAZ4RRBCA 47 4, 44,9. CFM9CAZ44RRBCA 47 PCD face milling cutters Dimensions Tool body made of steel ,7,9.. CFM9CAZRRBCS CFM9CAZRRBCS ,9. CFM9CA7ZRRBCS 7 4, 9. CFM9CAZRRBCS ,7. CFM9CAZRRBCS 479 9, 4,. CFM9CAZ4RRBCS 479 Accessories Spare parts** RBC... Milling cartridge Page 4 d See MAPAL catalogue "CLAMPING" d Fastening screw for milling cutter arbor ISO 47 Mx4.9 ISO 47 Mx Dimensions in mm. * d Depending on the milling cartridge type, see page 4. ** Included. Cutting data recommendation see page. _FRAESEN _DE_EN_V.indd 79 Clamping screws for milling cartridge TORX PLUS M4X.TXIP 49 Threaded spindle Mx.LH/RHx Mx.LH/RHx7 9 9 Adjusting wedge Mx. 74 d Coolant screw Page 77 d Coolant cover and fastening screw Mx Page 77.. :

23 RapidFixBlue PCD face milling cutters, close spacing, monoblock variant RapidMillBlue l = E M (±, ) d * ap Body material with HSKA connection zeff Dimensions d* Nominal size HSKA Weight [kg] l spindle speed [min] 4,9 7. CFM9AZ4RRBCS 479,4 7. CFM9AZRRBCS 4794,7 7. CFM9AZRRBCS 479, 7. CFM9AZRRBCS 479,. CFM9AZRRBCS 479,. CFM9AZRRBCS 4799 zeff Weight [kg] spindle speed [min] Body with SK connection Dimensions d* Nominal size SK l 4,47 7. CFM9SZ4RRBCS 479,4 7. CFM9SZRRBCS 479,9 7. CFM9SZRRBCS 4794, 7. CFM9SZRRBCS 479,. CFM9SZRRBCS 479,9. CFM9SZRRBCS 4797 Spare parts** Accessories RBC... Milling cartridge Page 4 d Clamping screws for milling cartridge TORX PLUS M4X.TXIP 49 Threaded spindle Mx.LH/RHx Mx.LH/RHx7 9 9 Adjusting wedge Mx. Connection HSK Coolant tube HSK 74 Dimensions in mm. * d Depending on the milling cartridge type, see page 4. ** Included. Cutting data recommendation see page. _FRAESEN _DE_EN_V.indd.. :

24 PCD face milling cutters _FRAESEN _DE_EN_V.indd.. :

25 FaceMillDiamond Design: Milling cutter diameter: Cutting material: Number of cutting edges: Helix angle: PCD face milling cutters with internal cooling SHM/9.. mm 4 Application: For face milling, especially with high stock removal. For cutting depths of up to mm. d SHM: Surface quality Rz µm SHM9: Surface quality Rz > µm a p l Body material with HSKA connection SHM Dimensions Order number Radius. mm.4 mm zeff Weight [kg] spindle speed [min] *,4. SHMBZR[Form]A Chamfer. mm d Nominal size l,7. SHMBZR[Form]A ,9. SHMBZ4R[Form]A ,9. SHMBZR[Form]A ,. SHMBZR[Form]A ,. SHMBZR[Form]A ,,.. SHMBZR[Form]A SHMBZR[Form]A ,4. SHMBZR[Form]A mm Body with SK connection SHM,,9.. SHMBZR[Form]S4 SHMBZR[Form]S ,. SHMBZ4R[Form]S ,. SHMBZR[Form]S ,. SHMBZR[Form]S ,. SHMBZR[Form]S Body with BT connection SHM,.. SHMBZR[Form]B4 SHMBZR[Form]B ,. SHMBZ4R[Form]B ,. SHMBZR[Form]B ,. SHMBZR[Form]B ,. SHMBZR[Form]B Dimensions in mm. * plus required cutting edge design (see table and example on next page) Cutting Data recommendation see page. _FRAESEN _DE_EN_V.indd.. :

26 Selection of the cutting edge design Edge design Chamfer Radius Size [mm],,,4, Shape F R R R Corner design, chamfer Chamfer size.x4 Example: SHMBZRFA Corner design, radius Radius.4 mm or Example: SHMBZRRA Body material with HSKA connection SHM9 Order number Radius. mm.4 mm zeff Weight [kg] spindle speed [min] *,4. SHM9BZR[Form]A Chamfer. mm d Nominal size l,7. SHM9BZR[Form]A ,9. SHM9BZ4R[Form]A ,9. SHM9BZR[Form]A ,. SHM9BZR[Form]A ,. SHM9BZR[Form]A ,,,4... SHM9BZR[Form]A SHM9BZR[Form]A SHM9BZR[Form]A mm PCD face milling cutters Dimensions Body with SK connection SHM9,,9.. SHM9BZR[Form]S4 SHM9BZR[Form]S4 4,. SHM9BZ4R[Form]S ,. SHM9BZR[Form]S ,. SHM9BZR[Form]S ,. SHM9BZR[Form]S Body with BT connection SHM9,.. SHM9BZR[Form]B4 SHM9BZR[Form]B ,. SHM9BZ4R[Form]B ,. SHM9BZR[Form]B ,. SHM9BZR[Form]B ,. SHM9BZR[Form]B _FRAESEN _DE_EN_V.indd 9.. :

27 4 CUSTOM SOLUTIONS PCD custom tools for face milling and circular milling As an addition to the standard series, custom solutions for PCD milling tools are also often produced at MAPAL for a special application. The latest manufacturing technologies, for exampling finish lasering, make it possible to solve highly demanding machining tasks. In this way tool solutions with complex cutting geometries and extreme rake and helix angles can be reliably and reproducibly manufactured to suit the manufacturing task. Particularly during milling, the advantages of the cutting material diamond can be used optimally. The extreme hardness of the diamond insert in conjunction with the highly polished rake face ensure low forces on shearing off the chip and reduce the heat introduced to the workpiece during movement. These are optimal prerequisites for the highest machining qualities for dimension, surface finish and shape, with outstanding productivity and the highest tool lives, as well as optimal process reliability. 4 _FRAESEN _DE_EN_V.indd 4.. :

28 9 7 Custom solutions Application examples for customer milling cutters Face milling cutter for cylinder head machining, combustion chamber side, varying radial arrangement of the PCD inserts for lowburr surface Circular milling cutter for machining the connection side of a fuel nozzle Along with the milling heads with custom dimensions, milling cartridges can also be adapted to the specific machining task 4 Disc milling cutter for face milling camshaft bearing pillars Chamfer milling cutter with CFS connection Circular milling cutter for machining on a stabilising frame for aircraft lifting system _FRAESEN _DE_EN_V.indd 7 Circular milling cutter for machining on a stabilising frame for aircraft lifting system Face milling cutter for machining on a brake caliper, reverse milling at the face surface for the main bore 9 Combination milling cutter for machining on a gearbox housing Face milling cutter for doublesided machining on a bearing frame in one clamping system Milling cutter for external machining of turbocharger hose connection Circular milling cutter for machining on a throttle flap housing.. :

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30 7 PCD MILLING CARTRIDGES Introduction Product overview, model key PCD milling cartridges 9 EcoMill milling cartridges EMC FlyCutter milling cartridges FMC 4 EcoMillBlue milling cartridges EBC 4 RapidMillBlue milling cartridges RBC 4 PCD milling cartridges PowerMill milling cartridges PMC 4_FRAESEN _DE_EN_V.indd 7.. :4

31 Product overview PCD milling cartridges PMC EMC FMC EBC RBC Replaceable chip deflector Integrated chip deflector Integrated chip deflector Integrated chip guiding geometry Integrated chip guiding geometry Central via tool body Central via tool body Central via tool body Technical design cutting depth [mm] Chip removal Coolant supply Can be reground Direct at the cutting edge Direct at the cutting edge Series PowerMill EcoMill FlyCutter EcoMillBlue RapidMillBlue Page Model key milling cartridges P M C Series Type Rake angle P U Cutting edge form Running direction PMC PowerMill Corner milling insert Rz value µm / radius* Clockwise EMC EcoMill 7 Face milling insert Rz value µm Counterclockwise FMC FlyCutter Wide finishing milling insert Rz value µm EBC EcoMillBlue 9 PT milling insert 4 4 Rz value > µm RBC RapidMillBlue X Custom Cutting material PU PCD * Only with wide finishing milling insert type. 4_FRAESEN _DE_EN_V.indd.. :4

32 9 Milling cartridges PMC m m γ m m Milling cartridge face milling inserts Cutting direction right Cutting direction left Rz value [µm] Cutting material > > > PMC7 PMC7 PMC7 PMC74 PMC7 PMC7 PMC7 PMC74 PMC7 PMC7 PMC7 PMC PMC7 PMC7 PMC7 PMC74 PMC7 PMC7 PMC7 PMC74 PMC7 PMC7 PMC7 PMC > > > PMC PMC PMC PMC4 PMC PMC PMC PMC4 PMC PMC PMC PMC PMC PMC PMC PMC4 PMC PMC PMC PMC4 PMC PMC PMC PMC a p m a x Rake angle γ [ ] d d + m m 9 a p m a x Milling cartridge corner milling insert d + m m d = N e n n ø Milling cartridge wide finishing milling insert d < PMC 9 PMC 9 < PMC 9 PMC 97 PMC9 9 β α PCD milling cartridges R Milling cartridge PT milling insert α β d mm d Dimensions in mm. 4_FRAESEN _DE_EN_V.indd 9.. :4

33 m m Milling cartridges EMC γ, m m Milling cartridge face milling inserts Rz value [µm] Running direction Cutting material > > > EMC7 EMC7 EMC7 EMC74 EMC7 EMC7 EMC7 EMC74 EMC7 EMC7 EMC7 EMC > > > EMC EMC EMC EMC4 EMC EMC EMC EMC4 EMC EMC EMC EMC a p m a x Rake angle γ [ ] d d + m m 9 a p m a x Milling cartridge corner milling insert d + m m d = N e n n ø Milling cartridge wide finishing milling insert d < EMC 9 < EMC 97 EMC9 9 β α R Milling cartridge PT milling insert α β d mm d Dimensions in mm. 4_FRAESEN _DE_EN_V.indd.. :4

34 4 Milling cartridges FMC m m γ, m m Milling cartridge face milling inserts Rz value [µm] Running direction Cutting material FMC7 47 > FMC74 47 FMC 47 FMC Rake angle γ [ ] d d + m m Milling cartridge corner milling insert 9 d + m m Milling cartridge wide finishing milling insert 9 R PCD milling cartridges d + m m Dimensions in mm. 4_FRAESEN _DE_EN_V.indd 4.. :4

35 4 Milling cartridges EBC m m γ, m m Milling cartridge face milling inserts Rz value [µm] Running direction Cutting material > > EBC7 EBC7 EBC7 EBC74 EBC7 EBC7 EBC7 EBC > > EBC EBC EBC EBC4 EBC EBC EBC EBC m ax Rake angle γ [ ] d d + m m 9 m ax Milling cartridge corner milling insert d + m m d = N en n ø Milling cartridge wide finishing milling insert d < EBC 44 EBC9 9 β α R Milling cartridge PT milling insert α β d mm d Dimensions in mm. 4_FRAESEN _DE_EN_V.indd 4.. :4

36 4 m m Milling cartridges RBC γ, m m Milling cartridge face milling inserts Rz value [µm] Running direction Cutting material > > RBC7 RBC7 RBC7 RBC74 RBC7 RBC7 RBC7 RBC > > RBC RBC RBC RBC4 RBC RBC RBC RBC m ax Rake angle γ [ ] d d + m m 9 m ax Milling cartridge corner milling insert d + m m d = N en n ø Milling cartridge wide finishing milling insert d < RBC 7 RBC9 β α R PCD milling cartridges Milling cartridge PT milling insert α β d mm d Dimensions in mm. 4_FRAESEN _DE_EN_V.indd 4.. :4