Tooling requirements in series production
Series production machining places consistent demands on cutting tools, particularly in terms of process reliability, predictable tool life, and cost per component. In face and shoulder milling operations, manufacturers must balance surface quality, dimensional accuracy, and productivity while ensuring tools integrate smoothly into existing machining processes. MAPAL has expanded its NeoMill program to address these requirements across semi-finishing, finishing, and roughing applications.
Finishing accuracy with NeoMill 16 Finish
The NeoMill 16 Finish is designed for face milling operations where surface finish and dimensional accuracy are critical. The system combines two indexable insert types: a pre-machining insert with 16 cutting edges and a finishing insert with eight cutting edges. This configuration allows roughing and finishing steps to be carried out with coordinated tool geometry, supporting stable and reproducible processes.
The face milling cutters are available in standard diameters ranging from 63 to 200 mm. MAPAL states that the finishing inserts can be set easily, enabling controlled finishing operations and surface qualities of up to Rz 4 µm on steel and cast-iron components. The design targets applications where consistent surface integrity must be achieved across large batch sizes.
Cost-focused pre-machining with NeoMill 16 Face
For pre-machining face milling operations, MAPAL adds the NeoMill 16 Face to the portfolio. This series also uses the 16-edge indexable insert, which is intended to reduce tooling costs per component while maintaining stable cutting conditions. The cutters are available in diameters from 32 to 100 mm.
The NeoMill 16 Face is positioned for series production of cast-iron and steel parts with relatively low stock removal, specified at up to 2 mm. By focusing on insert edge utilization and robust tool geometry, the system addresses productivity and cost efficiency in preparatory milling steps.
Aluminium roughing with NeoMill Alu Rough
The NeoMill Alu Rough series targets roughing operations on cast aluminium components in sectors such as automotive manufacturing, aerospace, and mechanical engineering. MAPAL offers the system as both a shoulder milling cutter and a shell end face milling cutter. In the standard configuration, single-row insert cutters are available with diameters from 50 to 160 mm, while multi-row shell end face cutters are offered in diameters of 63, 80, and 100 mm. Customer-specific configurations can also be implemented.
The tool design incorporates large chip spaces and tangential indexable inserts to support stable machining at high material removal rates. A broad selection of cutting materials—including PCD, coated or uncoated carbide, and CVD diamond—allows adaptation to different aluminium alloys and process requirements. According to MAPAL, this combination supports reliable chip evacuation and consistent stability, even under high chip volumes.
Integration into existing machining environments
MAPAL has positioned the expanded NeoMill program as an extension of a tooling platform established for series production over many years. The new cutter series focus on semi-finishing and finishing of steel and cast iron, as well as aluminium roughing, covering a broad range of standard milling tasks in industrial manufacturing.
The tools are designed to be technically refined yet straightforward to integrate into existing machining setups, supporting cost-effective operation without requiring fundamental process changes.
