Related: Automotive Production
ISCAR: Six Ways to Cut
Columns From: 3/8/2009
ISCAR (www.iscar.com) has long been known for its innovations in cutting tools. Arguably, its approach to developing new productive tools is completely driven by imagination, the proverbial "What if?". Here is a half-dozen of some of the latest from the company, at least one of which you may find to be a clever way to address some of your machining challenges.
CHAMSLIT grooving cutters.
They're said to offer 50% higher insert density than the competition, which means they're going to provide faster machining. What's more, because there is greater density, if one cutting edge fails, the cutter keeps working safely; the inserts are made of carbide grade IC 908. The cutters can handle square, round, and chamfer grooves, as well as thread profiles, and because the TRI insert sits slightly tilted in the pocket, and because of the cutters' low-profile, the tools can get close to the bottom of the groove. The tools are available in a diameter range of 1.25 to 3.15-in. and can cut grooves up to 1.89-in. deep. All cutters have cooling holes.
Here's something you don't see every day: a comparison with a company's own product. ISCAR has developed a new carbide grade for machining titanium and high-temperature alloys. This grade is used for its FINISHRED IC300 endmill, which is engineered for rough and finish end milling, side milling, slotting, cavity work, and orbital milling. It was put to the test in a titanium milling application against ISCAR's own FINISHRED IC900 cutter and a competitive endmill from another supplier. The FINISHRED IC300 lasted 90 minutes; the IC900 lasted 50 minutes; the competitor's mill lasted 25 minutes.
These solid-carbide deep hole drills are said to (1) be able to drill to 22 times diameter; (2) get to the bottom 10% faster than competitive solid-carbide drills; (3) reach the bottom six times faster than HSS drills. The last two points mean, of course, that in operations where deep-hole drilling tends to be a bottle-neck application (think powertrain transfer lines), this tool can expedite things. The drill has a high-strength core that not only provides a durable point (specifically, a 140° positive point with a four-margin design), but allows deeper flutes to be made in the drill, thereby facilitating chip evacuation. The helix is 30°, which also aids chip evacuation. There are internal coolant holes. The drills are available in standard diameters from 0.197 to 0.394 in. in 20- and 22-length-to-diameter ratios. They're made of a 10% cobalt submicron carbide grade, and have a TiAlN PVD coating.
If you're operating Swiss automatics, you may find these new tools to be of interest. GEHSR/L shanks, 0.75 and 1.0-in., permit GEMI/GEPI inserts to perform ID and OD grooving, turning, profiling, and threading. The GDMY 1050 utility insert, which is 1-mm wide and has a Y-type chipformer for high-feed grooving and turning. And a new line of parting inserts with a wider choice of lead angles to permit burr-free cutting on left- and right-hand cuts.
HELIDO UPFEED milling inserts.
This line of tools has been expanded so it now covers the diameter range of 1.00 to 5.00 in. The trigon-shaped, double-sided inserts offer six cutting edges and can be used in integral shank endmills, tools with FLEXFIT threaded connections, and face mills. They can handle chip loads up to 0.060 in./tooth. The SUMO TEC coating is used on the inserts, which is said to reduce heat, friction, and cutting forces, and to extend insert life by up to 35%.
These chip-spilling inserts, HM 90 APCR 220605-CS, are specifically designed to address the chip clutter common to rough-milling aluminum. The 0.866-in. inserts work in tandem, as there are two grooved helical cutting edges on each insert, each in a different location, the A and B edges, to create the chip-splitting effect. The inserts work best in cutters with an even number of flutes, and are designed so that they can only be inserted into the cutter in one way.