The enemy is waste Action against waste in practice

MAPAL NEWSLETTER

04

MAPAL WWS HP-FaceMill

HP-FaceMill reduces the costs per part by 59 %

On a Heller MCI25 with HSK-A 63 connection, two oilpans in Gd-AlSi9 at a time are milled in one clamping set up. With a cutting depth of ap = 1.5 mm and a milling path of 3,812 mm, the surface roughness is fixed at an Ra max. = 1.8 m with a waviness of max. 10 m.

Face milling of the gasket surface of an oilpan with a maximum number of PCD blades

Face milling the gasket surface of an oilpan

Material: Diameter face milling head: No. of blades: Milling path (2 oilpans): Cutting depth ap: Machining values: Gd-AlSi9 100 mm 18 3,812 mm 1.5 mm n = 12,000 RPM fz = 0.1 mm vf = 21,600 mm/min vc = 3,770 m/min

Reduction the main time to 27.2 sec.

to 10.6 sec. (-61%)

Unstable process with competitor's tool with 6 milling cartridges Face milling the gasket surface was first carried out with a face milling cutter with six exchangeable milling cartridges. With a feed per blade of 0.1 mm and a spindle speed of 14,000 RPM, milling the two workpieces took 27.2 seconds. The milling process was unstable, and the required workpiece quality could not be achieved. Moreover at the end of the tool life, additional costs arose from changing and adjusting the cartridges a 20 minutes loss of production time. Stable machining process with the HP-FaceMill from MAPAL WWS The applied HP-FaceMill has 18 blades and was selected with the corresponding cutting lead to ensure

that all surface requirements are safely met. At a spindle speed of 12,000 RPM the feed per blade could remain constant. As a consequence, the feed rate was more than doubled. The milling process is stable, and with regard to down-time, this is where the HP-FaceMill shows its strength: for a defined

The enemy is waste Action against waste in practice

MAPAL NEWSLETTER

04

The cost advantage which counts:

Machining time
MAPAL WWS HP-FaceMill: 10.6 seconds

Costs per part

Procuring costs

NEWSLETTER 04-E-02/03-015-1006-WD Printed in Germany. Right of technical modifications reserved.

Production costs*

- 59 %
Adjustable face milling cutter: 27.2 seconds

Production costs*

Procuring costs
*calculated using the average machine-hour rate in accordance with VDMA statistic

utilisation fee, through a special service package, the customer receives a tool with identical dimensions which is immediately ready for use. The machine parameters need not to be adjusted. Tool life increased by 25 % whilst reducing the production time by 61 % The high stability of the milling process in combination with the large number of blades of the HP-FaceMill resulted in a 25 % increased tool life. The machining time could be reduced to 10.6 seconds or by 61 % due to the significantly increased feed rate. Nevertheless, the predefined surface finish requirements are achieved reliably and without problems. In relation to the costs per part, this results on a savings of 59 %.

The MAPAL solution the main facts ...

HP-FaceMill from MAPAL WWS for milling the gasket surface of an oilpan:
I Costs per part reduced by 60 % I Machining time reduced by 61 % I Tool life increased by 25 % I Non-productive time minimized

Perspective: The HP-FaceMill is conceived for applications in HPC machining. This is where it is clearly superior over face milling cutters with diamond-coated inserts and under certain circumstances, also face milling cutters with interchangeable, adjustable milling cartridges. With sufficient power at the spindle of the machining tool, feed rates and stock removal rates can be realized like with no other face milling cutter. The HP-FaceMill brings additional savings in equipment and personnel costs since adjusting is dropped. Furthermore, the customer does not have any investment costs and enjoys better cost transparency due to the service package he merely pays a utilization fee.

We have the right solution for your machining tasks!