OptiMill-Uni-Wave

Vor allem in den Branchen Werkzeug- und Formenbau sowie im allgemeinen Maschinenbau sind Vollhartmetallfräser zum Nutfräsen, trochoiden Fräsen oder zur schnellen Schruppbearbeitung gefragt. Im Vordergrund steht dabei neben der Prozesssicherheit vor allem die Wirtschaftlichkeit. Für all diese Bearbeitungen hat MAPAL im vergangenen Jahr den OptiMill-Uni-Wave vorgestellt. Neben den genannten Einsatzgebieten können Zerspaner den Vollhartmetallfräser zudem zum Rampen bis zehn Grad nutzen.

Der OptiMill-UniWave ist für viele Werkstoffe einsetzbar. „Vor allem Bauteile aus Stahl und Edelstahl werden mit unserem Fräser bearbeitet“, sagt Ulrich Krenzer, Geschäftsführer des MAPAL Kompetenzzentrums für Vollhartmetallwerkzeuge in Altenstadt.

Als Substrat kommt für den OptiMill-Uni-Wave ein Hartmetall mit besonders hoher Zähigkeit und Warmfestigkeit zum Einsatz. Die Beschichtung auf Aluminiumchromnitrid-Basis sorgt unter anderem ausgezeichnete Verschleißfestigkeit und verleiht dem Werkzeug eine extreme Thermoschockstabilität.

“We have developed a new knurl roughing geometry that is optimally matched to the cutting
material,” explains Krenzer. This geometry ensures perfect chip formation. Short, tightly rolled chips are produced during machining, which are reliably removed. In addition, the new geometry distributes the cutting forces very favourably, which enables high feeds per tooth. The radial forces are reduced and higher axial forces are applied. The rounding of the cutting edges protects them against chipping and therefore are particularly resilient and stable. In addition, the groove profile has been further developed.

But that is not enough. “We took a close look at the entire geometry,” Krenzer explains. Both the
unequal spacing of the cutting edges and the unequal pitch of the tool ensure significantly
improved smooth running. “During machining with the redesigned OptiMill-Uni-Wave, we significantly reduced vibrations compared to other roughing milling cutters,” says the Managing
Director.

• 30 percent better tool life in steel*
• 37 percent higher feed rate at significantly higher cutting depths (up to 2xD)*
• 15 percent lower spindle drive power due to lower cutting forces**
• 40 percent lower pull-out forces**

* compared to the OptiMill-Uni-HPC-Rough roughing milling cutter (in 42CrMoS4)
** compared with a milling cutter with straight cutting edges

When machining steel (42CrMoS4), for example, a cutting depth of 24 mm (2xD) can be removed for a tool diameter of 12 mm with a cutting speed of 160 m/min and a feed rate per tooth of 0.045 mm. A material removal rate of 864 cm3 per minute is achieved. The use of the complete cutting edge length – together with the high cutting data and machining rates -guarantees the high cost-effectiveness.

The OptiMill-Uni-Wave can also be reground. “In order to make the best possible use of the
cost-intensive carbide, we recommend that the milling cutter be reconditioned exclusively by the manufacturer,” emphasises Krenzer. To exploit the full potential of the tools, re-grinding and
re-coating to original manufacturer quality are essential. Only then is it possible to guarantee reliable, consistent machining results and machining performance of up to 100 percent compared to a new tool. The risk of a tool fracture and the related risks of damage to the part or machine are minimised.