Perfect combination for structural parts – faster, better, lower cutting forces
F. Zimmerman GmbH relies on high volume milling cutters from MAPAL in combination with their machining centre FZH, which therefore raises performance to a whole new level.
The optimum machine tool + the optimum tool = the perfect combination. And that makes cost-effective processes and impressive machining results possible. One good example of this is the cooperation between the machine manufacturer, F. Zimmermann GmbH, and MAPAL. For demonstrations and machine acceptance tests, Zimmermann equips its new horizontal machining centre with milling cutters from MAPAL.
The beginning: The milling tools used are not suitable for the machine's performance level
The interaction: machine, milling head and MAPAL SPM milling cutter raise performance to a new level
“Our goal was to choose the optimum tools from our portfolio for the machining operations on the Zimmermann machine,” explains Dietmar Maichel, Project Manager 3D-Milling at MAPAL. The tool manufacturer’s portfolio contains different milling cutters for the different tasks during the high-volume machining of aluminium structural parts. The tools are perfectly designed for use on such high-performance machines as the Zimmermann machine. The SPM milling cutters are available in a solid carbide design and with PCD and ISO inserts. A total of four tools are used today at Zimmermann for the different demands of the roughing and finishing operations.
“The perfect combination – the machine, the 3-axis milling head and the tools from MAPAL – give the user a real performance boost,” said a delighted Steffen Nüssle, Sales Director Export and Head of Applications Engineering at Zimmermann, immediately after the first tests. “With the SPM-Rough ISO shoulder milling cutter, we achieved the best results that we have ever achieved with a tool with indexable inserts.” The ISO tools with polished indexable inserts are the latest addition to the MAPAL SPM product range. The SPM-Rough with wave profile also surpassed the expectations for material removal with excellent smooth running. “The complete machining of a 190x190x40 mm pocket is now effectively possible in less than a minute,” explains Nüssle.
The experts at F. Zimmermann GmbH are convinced by the MAPAL tools. “The use of the SPM milling cutters has given us a quantum leap forward in the aluminium machining. And it shows us what the perfect combination of tool and machine means in terms of performance,” says Nüssle. In the meantime, the tools are therefore first choice when it comes to machine acceptance tests or demonstrations for customers from the aerospace industry at Zimmermann.
The future: Zimmermann and MAPAL manufacture test components from composite materials
Key data of the tools used at Zimmermann:
Roughing – solution for diameter ranges above 25 mm
SPM-Rough ISO shoulder milling cutter with indexable inserts
- Diameter 40 mm
- Feed rate 21 m/min
- Material removal rate 6.9 l/min
10 percent lower cutting forces with the best surface finish compared with the milling cutters from competitors previously used.
Roughing – solution for diameter ranges up to 25 mm
SPM-Rough solid carbide milling cutter with wave profile
- Diameter 25 mm
- Feed rate 13 m/min
- Material removal rate 7.3 l/min
- Cutting depth ap 37.5 mm, cutting width ae 15 mm
High material removal rates with the highest machining values.
Multi-stepped semi-finishing of thin-walled structures
OptiMill-SPM solid carbide milling cutter
- Diameter 16 mm
- Feed rate 12 m/min
- Projection length 66 mm
- Extremely sturdy thanks to conical form
Time savings of over 40 percent are possible in combination with the 3-axis milling head.
Finishing of deep pockets and delicate structures in a single pass
SPM-Finish solid carbide milling cutter
- Diameter 12 mm
- Feed rate 3 m/min
- Best surface finish
- Cutting depth ap 40 mm
- Special finishing geometry
- No vibrations
Perfect results even with large machining depths and practically complete wrapping of the milling cutter.