Product category:
Tooling materials and inserts
News Release from: Iscar Tools | Subject: 3P Sumo Line tooling and inserts
Edited by the Manufacturingtalk Editorial
Team on 29 October 2007
Metal cutting tooling to boost
productivity
Aiming to improve metal cutting productivity, profitability and performance, a range of tools and inserts feature tungsten carbide grades for drilling, milling, turning and grooving.
In Iscar's latest range of metal working tools and inserts, called 3P Sumo Line, the prefix indicates that productivity, profitability and performance have been improved The core products of the 3P range, Sumo TEC, feature premium tungsten carbide grades for drilling, milling, turning and grooving
This article was originally published on Manufacturingtalk on 17 Jul 2008 at 8.00am (UK)
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Extra insert rigidity enables rampdown milling
Iscar has changed the geometry of its T290 tangential inserts to increase rigidity, clamp more inserts peripherally on a milling tool body and raise metal removal rates.
Iscar claims that the new grades extend tool and insert life as a result of innovations in the substrate and in the CVD (chemical vapour deposition) and PVD (powder vapour deposition) coatings.
The PVD process is composed of the company's AL-TEC coating technology while the CVD coating is based on its Alpha-TEC technology, both of which have been shown to provide superior wear resistance.
An additional insert manufacturing process deposits a further layer on top of the PVD and CVD coatings to provide a very even, low-stress layer that improves tool life further, said Iscar.
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To keep the machining of advanced aerospace alloyed metals cool, Iscar has developed tools that release 360 bar of pressure and it guarantees the cutting fluid arrives in a liquid state.
Five-side insert grooves, recesses and parts-off
For grooving and recessing applications, precision ground inserts are available in a width range of 0.50 to 3.18mm and a width tolerance of +/-0.02mm and come with a variety of standard corner radii.
The smooth surface contributes to uninterrupted chip flow and hence less friction and heat generation.
The new process also improves toughness and chipping resistance, reducing friction and built-up edge, which in turn prolongs tool life at elevated machining speeds and feeds for all types of workpiece material.
* Milling - Sumomill insert range has tangentially clamped inserts that feature high positive cutting angles.
The Sumomill T290 family of end mills is the next generation of milling cutters and inserts which utilise a maximum number of cutting edges on a small tool diameter.
This feature enables a tool design with a large core diameter, providing high resistance to torsion.
The tangentially helical inserts are clamped peripherally on the tool body, on which the large number of teeth enables increased feed rates, thus raising metal removal and productivity levels.
Iscar has also expanded the double-sided helical positive geometry inserts.
Helido H600 Upfeed insert is designed for machining at high feed rates of up to 3.5mm/tooth.
It is a high feed insert on a standard 90 deg tool for top productivity milling.
The products feature new, double-sided inserts designed for machining at high feed rates, providing six effective cutting edges.
It is an economical solution using thick inserts and rigid clamping for high feed performance.
Added to the range are the Helido 845 and Helido 490 families.
Featuring tangentially clamped inserts, four cutting edges and a positive geometry for machining steel and steel alloys at high feeds, the expanded Helitang 490 inserts are available in various sizes.
They cover all areas from end mills to face mills, with fine and coarse pitch cutter configurations and extended flute cutters for heavy duty milling.
All of the latest Helido, Helitang and Sumomill lines, including the existing designs, are available in the latest Sumo TEC PVD IC800 series grades.
* Hole production - Iscar has extended its existing DR drilling range at the lower and upper size limits to provide a range from 10mm (the Mini DR-Twist) to a large diameter of 60mm.
These drills feature twisted coolant holes and large gullets for chip evacuation, combined with the advantages of the Sumo TEC grades.
Completing the line of indexable DR drills, Iscar has added the Sumodrill.
The drill is a heavy duty product with replaceable, adjustable cartridges combined with the new Sumo TEC PVD grades.
The drill rough drilling of large diameter holes, ranging from 61mm to 80mm diameter.
Iscar, in a report to Manufacturingtalk, said that the tool represents the best economical solution for large sized drilling operations.
The reasons are the following.
* High metal removal rates.
* Wide gullets for improved chip evacuation.
* Minimises the use of coolant using the MQL (minimum quantity lubrication) method.
The drill accommodates modular, interchangeable cartridges carrying optional spacers of varying thicknesses to suit the required diameter.
* Deep hole drilling - for deep hole drilling applications, the Chamgun exchangeable gun drill head can be used to drill hole depths of up to 30 x diameter (D).
Iscar said that the Chamgun offers the following advantages.
* Enables the replacement of a drilling head on a machine.
* Eliminates the need to remove the drill for indexing.
* Saves set-up time and increases productivity.
* The G-profile head can be re-ground to a maximum of ten times to extend tool life.
Another option for higher productivity deep hole drilling is the 30 x D solid carbide drill with polished flutes for reduced friction and improved chip flow.
The drill produces a high surface finish within the hole and superior cylindricity, assisted by using either emulsion or MQL.
* Turning - a series of tools and inserts for heavy duty turning operations has been introduced, known as Sumoturn.
They feature large single- and double-sided inserts for heavy duty turning.
CNMM, CNMG and SNMG geometries combined with new Sumo TEC grade inserts can produce large chips.
The inserts are made from the Sumo TEC 5000 grades for cast iron and Sumo TEC 8000 grades for machining steel and stainless steel.
Iscar has also expanded its Heliturn LD family by adding new WNMX, DNMX and CNMX type inserts.
These inserts are designed with very positive radial helical cutting edges and positive rake angles, a combination that substantially reduces cutting forces and facilitates higher productivity, said Iscar.
The Heliturn LD line combined with the new lever clamping tools enables better chip flow, particularly when performing longitudinal turning, undercutting and round profiling.
* Parting off - the Tang-Grip line for parting-off is based on an exclusive tangential insert design for high productivity that provides superior flatness and surface finish, using the latest Sumo TEC 800 series grades.
The single-ended insert excels at parting off, grooving and interrupted grooving operations, said Iscar to Manufacturingtalk, and features very rigid clamping in a tangentially oriented pocket that enables machining at high feeds and extends tool life.
Tang-Grip tools have no upper clamp, which guarantees unobstructed chip flow.
Due to the design, the insert cannot be pulled out during retraction.
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