Flexible and powerful Innovative milling tool system with monoblock performance features

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Users previously had to choose between the flexibility of modular tools with interchangeable inserts or the precision and power of monoblock tools. The new Simmill 9W series from Simtek combines both, offering replaceable inserts with near-monoblock precision and power at a lower cost.

The starting point of the Simmill 9W family, which is now available in different versions, is the Simmill 9W4 milling system, which was originally developed for a complex component in the automotive industry and represents a significant advancement in the field of milling tools. Norbert Seifermann, CEO at Simtek, emphasises: “Many industrial customers want to take advantage of the flexibility of modular milling tools, but until now this was often associated with limitations in terms of accuracy and load capacity. With the Simmill 9W4 system, we now offer a high-performance solution for slot, parting and slotting operations that eliminates the need for this compromise in many cases.”

Development and technical details

Simmill 9W4 was developed to meet a specific need in the automotive industry and is the result of intensive development work. For the production of a complex component, a tool was needed that could work precisely and stably even under difficult conditions, such as limited space with high overhangs. To meet these requirements, the experts at Mössner developed a milling tool that uses interchangeable cutting inserts and yet almost achieves the stability and precision of a monobloc tool.

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The Simmill 9W4 system is based on highly developed serration technology that offers a range of advantages. The high stability of the serration, the Simmill 9W4 system is suitable for applications with high torques and, thanks to the ground serration, ensures high precision in terms of radial and axial run-out, while at the same time minimising wear at the interface between the holder and the cutting insert.

Advantages and possible applications

The Simmill 9W4 system is suitable for milling depths of up to 16.5 mm in the standard range, which is well above the capabilities of many other comparable tool solutions. The exchangeable cutting inserts are available in cutting widths from 0.5 mm to 6.0 mm. The 12 straight or cross-cut cutting edges guarantee high cutting performance and thus shorter primary processing times.

The system is also convincing when used in confined spaces: the shank diameter is up to three times smaller than the diameter of the cutting insert. The integrated coolant supply contributes to longer tool life and ensures efficient cooling.

Sustainability and resource efficiency

Another aspect that sets the tool system apart, according to the manufacturer, is its sustainability. The durable and robust tools ensure economical and environmentally friendly production. The modular design of the tool system also significantly reduces material consumption compared to monoblock tools. While worn monoblock tools after one or more regrinds have to be disposed of completely, with the Simmill 9W4 system, only the actual cutting insert needs to be changed after multiple regrinds. This not only saves resources, but also reduces production costs and the CO₂ footprint.

Variants and further developments

Since its introduction, the Simmill 9W4 milling tool system has continued to develop and now includes various variants with different diameters and cutting geometries. In addition to Simmill 9W4, the 9W1 variant is currently available with a maximum milling depth of 9.3 mm and cutting widths from 1.2 mm to 2.5 mm. Steel and carbide holders are available for both variants and carbide holders are available for both variants. Further versions and intermediate sizes are already in use today in the area of customer-specific solutions, with great success. “These further developments underline the flexibility of the system and its ability to close the gap between conventional interchangeable tools and monoblock tools,” explains Simtek board member Seifermann.

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