OptiMill-SPM: High Performance Mills for the High Volume Machining of Aluminium Structural Parts

MAPAL has developed a new range of aluminium roughing mills

In the aerospace industry, aluminium structural parts, such as wing parts and frame elements are generally milled from solid material. A buy-to-fly ratio of 22 (95 %) is not uncommon here.

New machine generations that have sufficient drive power and the necessary spindle speeds make the high-performance machining of aluminum parts cost effective. MAPAL has developed a new range of aluminium roughing mills especially for these machines.

The OptiMill-SPM (structural part machining) high performance mill is equipped with a cutting edge that makes up 60%-80% of its diameter. This represents the maximum contact depth for the high-performance milling of aluminum.

Thanks to a highly positive cutting edge geometry and optimised chip flutes, the cutting force of PCD mills is reduced by up to 15%. Even when milling on standard machines, this reduction in cutting force results in more efficient machining parameters, and hence in improved performance.

​The bottleneck form of the mill prevents the tool from bending during the machining process. Another advantage of this stable design 
is the clearance that is created between the wall of the part and the mill shank. This prevents chips from scratching the wall of the part, particularly if it has deep pockets.

OptiMill-SPM tools with internal cooling are available in a solid carbide design with a diameter range of 6 to 32 mm or in a PCD design with a diameter range of 6 to 50 mm as part of the standard range. The range of products also includes variants with the well-known CFS replaceable head system.

OptiMill-SPM Roughing Tool Features in Detail

OptiMill SPM Solid carbide design

1. Uniform point thinning - Improved plunging capability
2. Optimal cutting edge length - Optimal ratio between the length of the cutting edge and the diameter.
3. Highly positive rake angle - Reduced cutting force and high surface quality thanks to a highly positive rake angle
4. Polished chip flutes -  Unhindered chip removal  and no corners or sharp edges in the chip flute
5. Conical neck - High rigidity thanks to conical design

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More Designs for Roughing

OptiMill SPM

Solid carbide design with corrugated profile

• Low vibration roughing
• Uniform material removal rate for each tooth
• Polished chip flutes
• Reduction of cutting power required

OptiMill Diamond SPM

PCD design

• High stability during machining thanks to optimally embedded PCD blades
• No notching effects or protrusions
• ​Increased axis angle

CPMill SPM

Solid carbide design with replaceable head system

• ​Cost effective thanks to CFS -replaceable head system