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

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

2 EcoMill-Blue and RapidMill-Blue New generation of the PCD face milling cutters EcoMill-Blue and RapidMill-Blue New generation of the PCD face milling cutters A clean solution for high-speed aluminium machining Part cleaning represents a significant cost factor 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 possible to the goal of a dirt-free finished part, an innovative PCD milling insert has been developed. The special chip guidance geometry keeps the chips reliably away from the workpiece surface. The integrated coolant outlets in the milling inserts ensure optimum cooling and lubrication of the PCD blades, particularly with minimum 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 proven 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 userfriendly with radially accessible, wedgeshaped 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 greatest possible productivity for face milling. As a special service, MAPAL offers milling head management, as well as reconditioning in original quality.

Tool features in detail EcoMill-Blue and RapidMill-Blue 3 Tool features in detail 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 1 2 3 4 5 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 6 7 8 8 Dovetail guide Precise positioning of the blades over the entire tool life Innovative chip guidance geometry Optimised for dry machining Economic basic design EcoMill-Blue RapidMill-Blue 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.

4 EcoMill-Blue Face milling cutters

Face milling cutters EcoMill-Blue 5 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.

6 EcoMill-Blue Face milling cutters Face milling cutter EcoSpeed-Blue Coarse pitch Maximum cutting depth a p = 2 mm l 1 = EM a p d 2 d 4 d 3 Aluminium body * Z eff d 2 l 1 d 3 d 4 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Steel body * Z eff d 2 l 1 d 3 d 4 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Accessories Spare parts** EBC... Milling insert Page 9 Clamping screw for milling insert TORX M5x11 TX25 7-03002-03 in mm. 160 200-400 315-400 Milling cutter arbors See catalogue "MAPAL Competence Clamping technology" Milling cutter clamping screws ISO 4762 - M12x45-12.9 ISO 4762 - M16x50-12.9 ISO 4762 - M20x50-12.9 10006594 10007775 10080371 50-125 Threaded spindle M5x0.5LH/RHx17 Adjusting wedge M5x0.5 Milling cutter clamping screws 7-03002-04 7-03002-05 Page 15 * depending on milling insert type, see page 9. ** Included in the scope of delivery. For cutting value recommendations, see page 18. 160-400 Coolant cover and fastening screws M6x20 Page 15

Face milling cutters EcoMill-Blue 7 Face milling cutter EcoFeed-Blue Close pitch Maximum cutting depth a p = 2 mm l 1 = EM a p d 2 d 4 d 3 Aluminium body * Z eff d 2 l 1 d 3 d 4 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Steel body Setting Weight dimension EM [kg] speed * Z eff d 2 l 1 d 3 d 4 (±0,05) [min -1 ] 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 Accessories Spare parts** EBC... Milling insert Page 9 Clamping screw for milling insert TORX M5x11 TX25 7-03002-03 in mm. 160 200-400 315-400 Milling cutter arbors See catalogue "MAPAL Competence Clamping technology" Milling cutter clamping screws ISO 4762 - M12x45-12.9 ISO 4762 - M16x50-12.9 ISO 4762 - M20x50-12.9 10006594 10007775 10080371 50-125 Threaded spindle M5x0.5LH/RHx17 Adjusting wedge M5x0.5 Milling cutter clamping screws 7-03002-04 7-03002-05 Page 15 * depending on milling insert type, see page 9. ** Included in the scope of delivery. For cutting value recommendations, see page 18. 160-400 Coolant cover and fastening screws M6x20 Page 15

8 EcoMill-Blue Face milling cutters Face milling cutters EcoFix-Blue Close pitch, monoblock variant Maximum cutting depth a p = 2 mm l 1 = EM l 2 a p Body with HSK-A connection * Z eff Nominal size HSK-A l 1 l 2 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Body with ISO connection * Z eff Nominal size ISO l 1 l 2 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Accessories Spare parts** EBC... Milling insert Page 9 Clamping screw for milling insert TORX M5x11 TX25 7-03002-03 Milling cutter arbors See catalogue "MAPAL Competence Clamping technology" 32-40 50-100 Threaded spindle M5x0.5LH/RHx15 M5x0.5LH/RHx17 Adjusting wedge 7-03002-07 7-03002-04 32-40 50-100 M5x0.5 M5x0.5 7-03002-06 7-03002-05 in mm. Connection HSK Coolant tube HSK63 30326006 * depending on milling insert type, see page 9. ** Included in the scope of delivery. For cutting value recommendations, see page 18.

Milling inserts EcoMill-Blue 9 Milling inserts for face milling cutters of the EcoMill-Blue series N C 12 mm γ 16,5 mm Milling insert with facing blade Chip angle γ R z value [µm] a p Running direction Cutting material + 1 mm 75 1 0 5 1-2 Right PCD EBC-731-0-PU611 30559589 0 10 1-2 Right PCD EBC-732-0-PU611 30559591 0 20 1-2 Right PCD EBC-733-0-PU611 30559595 0 > 20 1-2 Right PCD EBC-734-0-PU611 30559599 6 5 1-2 Right PCD EBC-711-0-PU611 30502818 6 10 1-2 Right PCD EBC-712-0-PU611 30559592 6 20 1-2 Right PCD EBC-713-0-PU611 30559596 6 > 20 1-2 Right PCD EBC-714-0-PU611 30559600 Milling insert with corner blade Chip angle γ + 1 mm = Nenn ø 90 1 R z value [µm] a p Running direction Cutting material 0 5 1-2 Right PCD EBC-631-0-PU611 30559590 0 10 1-2 Right PCD EBC-632-0-PU611 30559593 0 20 1-2 Right PCD EBC-633-0-PU611 30559597 0 > 20 1-2 Right PCD EBC-634-0-PU611 30559601 6 5 1-2 Right PCD EBC-611-0-PU611 30518869 6 10 1-2 Right PCD EBC-612-0-PU611 30559594 6 20 1-2 Right PCD EBC-613-0-PU611 30559598 6 > 20 1-2 Right PCD EBC-614-0-PU611 30559602 Milling insert with wide face milling blade Chip angle γ R z value [µm] a p Running direction Cutting material 45 75 0 5 1-2 rechts Right PCD PKD EBC-831-0-PU611 30542645 R Milling insert with PT blade Chip angle γ R z value [µm] a p Running direction Cutting material 15 15 0 5 1-2 rechts Right PCD PKD EBC-931-0-PU611 30559603-1 mm in mm. Note: Suitable for bodies of the EcoMill and EcoMill-Blue series

10 RapidMill-Blue Face milling cutters

Face milling cutters RapidMill-Blue 11 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.

12 RapidMill-Blue Face milling cutters Face milling cutter RapidFeed-Blue Close pitch Maximum cutting depth a p = 1 mm l 1 = EM a p d 2 d 4 d 3 Aluminium body * Z eff d 2 l 1 d 3 d 4 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Steel body * Z eff d 2 l 1 d 3 d 4 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Accessories Spare parts** RBC... Milling insert Page 14 Clamping screw for milling insert TORX PLUS M4X8.5-TX15-IP 30412229 Milling cutter arbors See catalogue "MAPAL Competence Clamping technology" 50 63-200 Threaded spindle M5x0.5LH/RHx15 M5x0.5LH/RHx17 Ordern No. 7-03002-07 7-03002-04 160 200-400 315-400 Milling cutter clamping screws ISO 4762 - M12x45-12.9 ISO 4762 - M16x50-12.9 ISO 4762 - M20x50-12.9 10006594 10007775 10080371 50-125 Adjusting wedge M5x0.5 Milling cutter clamping screws 30557564 Page 15 in mm. * depending on milling insert type, see page 14. ** Included in the scope of delivery. For cutting value recommendations, see page 18. 160-400 Coolant cover and fastening screws M6x20 Page 15

Face milling cutters RapidMill-Blue 13 Face milling cutter RapidFix-Blue Close pitch, monoblock variant Maximum cutting depth a p = 1 mm l 1 = EM l 2 a p Body with HSK-A connection * Z eff Nominal size HSK-A l 1 l 2 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Body with ISO connection * Z eff Nominal size HSK-A l 1 l 2 Setting dimension EM (±0,05) Weight [kg] speed [min -1 ] 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 Accessories Spare parts** RBC... Milling insert Page 14 Clamping screw for milling inserttorx PLUS M4X8.5-TX15-IP 30412229 Milling cutter arbors See catalogue "MAPAL Competence Clamping technology" 32-50 63-100 Threaded spindle M5x0.5LH/RHx15 M5x0.5LH/RHx17 7-03002-07 7-03002-04 Adjusting wedge M5x0.5 30557564 in mm. Connection HSK Coolant tube HSK63 30326006 * depending on milling insert type, see page 14. ** Included in the scope of delivery. For cutting value recommendations, see page 18.

10 mm γ 14 RapidMill-Blue Face milling cutters Milling inserts for face milling cutters of the RapidMill series N C Milling insert with facing blade 18,5 mm Typ Planmesser + 1 mm 75 1 Span- Chip R Zz -Wert value a p Running Lauf- Schneidstoff Cutting Spezifikation Bestell-Nr. winkel angle γ [µm] direction richtung material 0 5 1-2 1 rechts Right PCD PKD RBC-631-0-PU611 RBC-731-0-PU611 30560073 30560072 0 10 1-2 1 rechts Right PCD PKD RBC-632-0-PU611 RBC-732-0-PU611 30560077 30560075 0 20 1-2 1 rechts Right PCD PKD RBC-633-0-PU611 RBC-733-0-PU611 30560081 30560079 0 > 20 1-2 1 rechts Right PCD PKD RBC-634-0-PU611 RBC-734-0-PU611 30560085 30560083 6 5 1-2 1 rechts Right PCD PKD RBC-611-0-PU611 RBC-711-0-PU611 30547874 30547873 6 10 1-2 1 rechts Right PCD PKD RBC-612-0-PU611 RBC-712-0-PU611 30560078 30560076 6 20 1-2 1 rechts Right PCD PKD RBC-613-0-PU611 RBC-713-0-PU611 30560082 30560080 6 > 20 1-2 1 rechts Right PCD PKD RBC-614-0-PU611 RBC-714-0-PU611 30560086 30560084 Milling insert with corner blade + 1 mm = Nenn ø 90 1 Chip angle γ R z value [µm] a p Running direction Cutting material 0 5 1-2 1 rechts Right PCD PKD RBC-731-0-PU611 RBC-631-0-PU611 30560072 30560073 0 10 1-2 1 rechts Right PCD PKD RBC-732-0-PU611 RBC-632-0-PU611 30560075 30560077 0 20 1-2 1 rechts Right PCD PKD RBC-733-0-PU611 RBC-633-0-PU611 30560081 30560079 0 > 20 1-2 1 rechts Right PCD PKD RBC-734-0-PU611 RBC-634-0-PU611 30560083 30560085 6 5 1-2 1 rechts Right PCD PKD RBC-611-0-PU611 RBC-711-0-PU611 30547873 30547874 6 10 1-2 1 rechts Right PCD PKD RBC-612-0-PU611 RBC-712-0-PU611 30560076 30560078 6 20 1 rechts Right PCD PKD RBC-613-0-PU611 RBC-713-0-PU611 30560080 30560082 6 > 20 1-2 1 rechts Right PCD PKD RBC-614-0-PU611 RBC-714-0-PU611 30560084 30560086 Milling insert with wide face milling blade Chip angle γ R z value [µm] a p Running direction Cutting material 45 75 0 5 1 Right PCD RBC-831-0-PU611 30560087 R Milling insert with PT blade Chip angle γ R z value [µm] a p Running direction Cutting material 15 15 0 5 1 Right PCD RBC-931-0-PU611 30560088-1 mm in mm. Note: Suitable for bodies of the RapidMill-Blue series.

Face milling cutter EcoMill-Blue and RapidMill-Blue 15 Spare parts for face milling cutters Clamping screw Milling insert (FE) Threaded spindle Milling cutter clamping screw Coolant cover Adjusting wedge Fastening screw for coolant cover Clamping screw for milling insert FE type d k M l 1 TX α EBC... 7,2 M5 11 T-25 60 7-03002-03 RBC... 5,7 M4 8,5 15IP 60 30412229 d* M d k l 1 l 2 SW 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 l M d Adjusting wedge FE type Designation M d l 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 1 M 1 M 2 M d k TORX / TORX PLUS M l 1 α d k Milling cutter clamping screw SW l 1 l 2 M d k α Coolant cover d* 160 115 30569889 200 155 30569890 250 205 30569891 315 270 30569892 400 355 30569893 l SW 2 l 3 SW l 1 Threaded spindle Fastening screw for coolant cover M 1 l l 1 M 2 l 2 SW Countersunk screw in acc. with ISO M5x0.5LH 17 6 M5x0,5 6 2,5 7-03002-04 d k M l 1 SW α 10642 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 in mm. d* = Diameter of face milling cutter

16 EcoMill-Blue and RapidMill-Blue Adjusting and handling instructions Adjusting and handling instructions for EcoMill-Blue and RapidMill-Blue face milling cutters To achieve optimal surface quality it is essential 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 conjunction with the easy handling characterises this system. For easy, convenient, fast and precise adjusting, 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. Changing and adjusting the PCD milling inserts 1. Turn threaded spindle with a hexagon socket wrench AF 2.5 one turn counterclockwise. 2. Unscrew the clamping screw of the milling insert and take it up and out of the dovetail guide. 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. 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 l A must always be taken into account. In this case the setting dimension is l A +EM. 5. Turn threaded spindle with a hexagon socket wrench one half turn clockwise. Result: Pre-tension is built up. l A EM 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). *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.

Adjusting and handling instructions EcoMill-Blue and RapidMill-Blue 17 Milling insert Threaded spindle Dovetail guide Blade Clamping screw Adjusting wedge 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). Comment: Only for trained personnel. Tightening torque for clamping screws Clamping Spannschraube screw Bestell-Nr. Abmessungen [M] TORX /TORX PLUS - Antriebsgröße Actuator size Anzugsdrehmoment Tightening torque [Nm] 7-03002-03 M5 T-25 8 30412229 M4 15IP 4 Tightening torque for milling cutter clamping screw Tightening screw For milling head diameter [mm] [M] 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 70 10080371 315-400 M20 17 70 SW [mm] Tightening torque [Nm]

18 EcoMill-Blue and RapidMill-Blue Cutting data recommendations 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/mm 2 ] Materials N1.1 Aluminium, unalloyed and alloyed < 3 % Si Alloy 2024, Alloy 7075, Al99 N1.2 Aluminium, alloyed 7 % Si AlSi7 N1.3 Aluminium, alloyed > 7-12 % Si AlSi9, AlSi9Cu N1.4 Aluminium, alloyed > 12 % Si AlSi12, AlSi17 N N2.1 Copper, unalloyed and low-alloy SE-Cu < 300 N2.2 Copper, alloyed CuSn6 > 300 N2.3 Brass, bronze, red brass CuZn33, CuAl9Mn3 < 1.200 N3.1 Graphite N4.1 Plastic, thermoplastics PA, PE, PC, PS, PVC, PP, PTFE, POM, PMMA N4.2 Plastic, thermoset plastics PU, PF, EP, UP, VE, CR Plastic matrix (thermosetting), C1.2 IMS, HTA CFRP/GFRP C Plastic matrix (thermoplastic), C1.3 GMT-PP, PEEK CFRP/GFRP C2.1 Carbon matrix, carbon fibre reinforced (CFC) CF222, CF225, CF226, CF227, CF260

Cutting data recommendations EcoMill-Blue and RapidMill-Blue 19 EcoMill-Blue RapidMill-Blue v c [m/min] f z [mm/z] v c [m/min] f z [mm/z] Cutting depth a p < 1,0 mm Cutting depth a p 1,0-2,0 mm Cutting depth a p 1,0 mm 6.000 6.000 6.000 6.000 6.000 6.000 2.000 2.000 6.000 6.000 0,1-0,2 0,05-0,1 2.000 2.000 0,05-0,2 2.000 2.000 2.000 2.000 2.000 2.000 2.000 2.000 100-500 100-500 0,1-0,4 0,1-0,2 100-300 0,1-0,2 0,05-0,1

20 EcoMill-Blue Machining examples Machining examples competence face milling 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 crankcase at constant surface quality, significantly higher quantities could be reached with process reliability. Relative to the previously used, conventional face milling cutter, it was possible to increase quantities virtually by a factor of 7; from 5,000 to more than 34,500 crankcase parts. Capacity Data 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 dirtfree as possible is required. By using the new EcoFeed-Blue both requirements are satisfied. EcoFeed-Blue ø 125, Z = 18 Compared with conventional face milling cutters, a significantly improved surface quality is visually achieved. Moreover, it was possible to significantly reduce the danger of scoring. Material: EN AC-46200 (AlSi8Cu3) Tool: EcoFeed-Blue ø125 Z = 18 Allowance: 0,6-0,8 mm Speed: 8.000 min -1 Cutting speed v c : 3.015 m/min Feed v f : 15.000 mm/min Quantity, old: 5.000 parts Quantity, new: 34.600 parts

Machining examples EcoMill-Blue 21 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 achieve weight reductions and concurrent higher stability. Today's die-casting methods are extremely precise and efficient; even extremely complex workpiece geometries can be produced. 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 R z values, as well as close tolerances, in parallelity and angularity impose special requirements on the tools. MAPAL offers the optimal solution for these applications. Capacity Data With the new EcoFeed-Blue the required surface qualities for sealing surface (P t = 15) and labyrinth surface (R z = 8, R max = 10) are achieved with process reliability. The extremely quiet operation has a particularly positive effect on the machining of thin-wall components that are susceptible to vibration. Relative to the previously used, conventional face EcoFeed-Blue ø 63, Z = 8 milling cutter, at a uniform surface quality of P t = 6-7 as well as R z = 3-5, it was possible 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. Material: EN AC-46000 (AlSi9Cu3) Tool: EcoFeed-Blue ø 63 Z = 8 Allowance: 0,9-1,2 mm Speed: 14.200 min -1 Cutting speed v c : 2.810 m/min Feed v f : 7.200 mm/min Quantity, old: 600-800 parts Quantity, new: 2.100 parts Surface quality achieved: R z = 3-5, P t = 6-7

22 EcoMill-Blue and RapidMill-Blue Services MAPAL Maintenance Services reconditioning for face milling heads 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* Tool costs with reconditioning in milling head management (mixed price) with reconditioning (new price + n x reconditioning price) * in conjunction with milling head management New tool 2 x reconditioning 4 x reconditioning 6 x reconditioning Number of reconditionings 8 x reconditioning 10 x reconditioning * depending on the customer-specific application

Services EcoMill-Blue and RapidMill-Blue 23 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. 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. Reconditioning cycle Reconditioning cycle milling head management 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 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 5 days 3 Reconditioning of the complete milling head systems, incl. replacement of all wear parts 4 Adjustment of the milling head systems to the original setting dimensions (EM) 48 h 3 Reconditioning of the complete 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 immediately operational milling head systems 5 On-time delivery of immediately operational milling head systems 6 Stock keeping of the operational milling head systems Comment: As a technology partner, MAPAL supports you in selecting the optimal reconditioning process for your specific machining case.

Discover tool and service solutions now that give you a lead: Reaming and fine boring Boring Drilling Milling Turning Clamping Actuating Setting and measuring Services www.mapal.com 10138918 V1.1.0 CFM-EN-PC-020-0914-WD Printed in Germany. Right of technical information reserved. MAPAL Präzisionswerkzeuge Dr. Kress KG Reprints, even of excerpts, require the consent of the publisher.