Page 46 - MTW NOVEMBER 2021 - Digital Magazine_Neat

TECH INNOVATION

Additionally, in machining superalloys, repeatable results.
ceramics - another tool material that In machining superalloys by solid
enables substantially increased cutting carbide endmills and exchangeable heads,
speeds – are already in active use. grade IC902, which combines ultra-fine
If tool materials are connected mostly grain substrate and nano-layer PVD TiAlN
with material sciences and metallurgy, coating, ensures extremely high wear
cutting geometry is more in the tool resistance and prolongs tool life. This
design field. Ensuring high-performance grade has demonstrated very good results
geometry requires deep engineering in producing devices for replacement knee
knowledge and technology skills. On the and hip joints that are made from difficult-
one hand, to minimize heat generation and to-cut cobalt-chrome alloys (Fig. 2).
work hardening, a positive rake angle, a ISCAR has significantly extended the
large enough clearance angle, and a sharp range of products for ISO S applications
cutting edge are needed. On the other made from various cutting ceramics such Fig. 2 – Machining a femoral knee
hand, such a shape weakens the cutting as silicon nitride, SiAlON, and whisker- implant component with a MULTI-
edge that should withstand a considerable reinforced grades. The newly introduced MASTER endmill and exchangeable
mechanical load. Therefore, the correct ceramic items have replenished both taper barrel head.
designed cutting-edge condition becomes indexable inserts & solid endmills (Fig. 3).
a critical success factor. Sintered carbide The latest rake face designs F3M and
inserts have the advantage of enabling F3P for ISO standard turning inserts are
complex chip forming and chip breaking intended specifically for hard-to-machine
shapes for insert rake faces. Today, austenitic stainless steel and superalloys
computer modeling of chip formation and (Fig. 4). Their positive rake-angle
pressing processes using finite element geometry reduces the cutting force and
methods provide an effective tool to ensures smooth cutting action, while the
optimize the shapes that are already in the set of deflectors on the rake face improves
design stage. In solid endmills, a variable chip control.
pitch design results in improved vibration In ceramic double-sided inserts for
strength. Cutting edges of these endmills turning and milling tools, ISCAR has added
are produced by grinding operations, and new chamfered and combined (chamfered
to eliminate flaking and edge defects, and rounded) cutting-edge condition Fig. 3 – Milling cutters with indexable
strict adherence to technological process options for tough applications. round inserts from ceramics provide
requirements is highly important. ISCAR has enriched the range of considerably increased cutting speeds
for higher productivity.
Cutting tool manufacturers pay a lot solutions intended for high-pressure
of attention to improving their product cooling by new indexable cutter bodies
portfolios intended for machining and tool holders. For example, thermal
superalloys. ISCAR’s news can be shrink chucks with polygonal taper shanks,
excellent indicative examples. which have coolant jet channels along the
Carbide grade IC806, which had was central bore, have been replenished by the
introduced over the last few years for toolholder product line.
face grooving superalloys and austenitic In conclusion, the need for increased
stainless steel, was successfully adopted productivity in machining HTSA is a
by ISCAR’s threading and deep drilling continuous challenge for cutting tool
lines. This grade has a hard submicron manufacturers, and new effective tool
substrate and PVD TiAlN/AlTiN coating developments are likely to come in the
with post-coating treatment according to near future. Fig. 4 –ISCAR’s recently introduced
ISCAR’s SUMO TEC technology. IC806 M3M (left) and F3M (right) chipbreakers
for ISO standardized turning inserts
provides notable resistance to flaking For more information, designed specifically for ISO S and ISO
and chipping and maintains reliable and Website: www.iscar.in M groups of application.

40 MACHINE TOOLS WORLD NOVEMBER 2021 www.mtwmag.com