Product category:
Milling cutters
News Release from: Iscar Tools | Subject: Sumomill T290 insert milling cutter at MACH 2008
Edited by the Manufacturingtalk Editorial
Team on 02 May 2008
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 has extended the application range of milling cutters with tangentially clamped inserts The company has changed its T290 tangential inserts geometry of to make room for a thicker, more torsion-resistant core, A larger number of inserts can now be clamped peripherally on the Sumomill tool body
This article was originally published on Manufacturingtalk on 19 Mar 2003 at 8.00am (UK)
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For any cutter size, the width of the body core, i e, the section not machined to accommodate the inserts, is 65% larger than if radially-mounted (laydown) inserts are used, said Iscar.
The tool is therefore much stronger and can withstand higher impact loads, minimising risk of fracture.
Iscar told manufacturingtalk that the advantages of mounting inserts tangentially are well known.
Further reading
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Family of cutters facilitate milling at very high feed rates - up to 3.5mm/tooth - for high-speed metal removal and use trigon-like shaped positive inserts having a large radiused cutting edge.
Round insert mills ramp down into workpieces
In addition to face milling, these new face mills use securely clamped round inserts and are able to ramp down, perform undercutting and machine in an upwards direction.
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.
Forces generated during machining are transmitted directly to the cutter body, without applying undue stress on the tightening screw, so higher metal removal rates are attainable.
During recent trials, Sumomill T290 achieved significant metal removal rates relative to cutter diameter; Iscar recorded figures as high as 60cm3/min using a 12mm diameter end mill in full slotting operations, with feed rates of 0.1mm per tooth.
* Improved surface finish - more rigid tangential mounting of the inserts, and clamping them using a larger tightening screw, greatly decreases the risk of plastic deformation of the insert pocket and improves the surface finish on the machined component.
The overall loading that the tool can withstand is higher, leading to increased metal removal rates.
Owing to its extreme rigidity, Sumomill T290 is the only tool on the market with tangential indexable inserts capable of ramping, even into hardened steels, claimed Iscar.
Iscar said that such productivity benefits used to be only available to users of bigger diameter milling cutters, as the relatively large tangential inserts would not fit smaller tool bodies.
It restricted widespread use of the technology, as most milling applications use small diameter cutters, said Iscar.
By redesigning its tangentially mounted, indexable carbide inserts, which have two helical cutting edges and a highly positive rake normally associated with solid carbide cutters, Iscar said, at last week's UK MACH 2008 machine tool exhibition that it had solved the problem.
The company has curved the insert into a convex shape and achieved a tangential angle that is significantly larger than is possible on tools with conventional laydown inserts.
Iscar said this design lowers cutting forces and improves tool stability.
The design also reduces heat generated at the interface between cutting edge and workpiece during machining, prolonging tool life and further promoting high quality surface finish.
The convex shaped, tangential T290 insert has enabled the development of end mills as small as 8mm diameter, rising in increments to 80mm diameter.
Two, three or five inserts are used according to cutter size.
Edge lengths of the inserts are 5, 10 and 15mm.
All grades use Iscar's Sumo Tec coating, which has an extra coating deposited on top of the PVD and CVD coatings to provide a smooth, low-stress layer.
Iscar told manufacturingtalk that the layer prolongs tool life and contributes to uninterrupted chip flow, reducing friction and heat generation.
Sumomill T290 face milling cutters and long-edge cutting systems (porcupine milling cutters) will follow the current introduction of the end mill range.
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