TOOLING & WORKHOLDING SUPPLEMENT
ISCAR’S GLOBAL ‘MACHINING INTELLIGENTLY’ ROADSHOW
times, are another element in boosting
productivity, and ISCAR has examples to
offer in this area, too. For example, Multi-
Master SolidMill solid carbide end-mills with
replaceable tips that require no toolholder
removal from the machine or presetting;
also, the Swiss-Cut turning tool that can
have its insert changed without the need to
remove a screw – “it takes just a second to
replace an insert”.
Another area of development is in
reducing the power/energy required to cut
metal, which Harpaz refers to as ‘easy cut’.
This also has the effect of prolonging tool
life, he advises. An associated cutting byproduct
is vibration, another area where
ISCAR has developed solutions.
A further key theme is chip evacuation:
“If you solve the problem of chip evacuation,
you can go to much higher feeds,” he offers,
adding that surface finish is also improved.
And chip evacuation is achieved via coolant
delivered directly to the cutting edge, a
feature of many of the new products.
Why be concerned about cutting tool
innovation, though? Cutting tools represent
just 3-4% of production costs. True, but they
have a leveraging effect on other costs.
So, in citing a part that takes 18 seconds to
machine, a 30% discount on cutting tool
costs gets you a 1% part cost reduction,
doubling tool life gets you 1.5%, but
increasing speed and improving the process
can deliver a 15% cost reduction, Harpaz
underlines – that is ‘machining intelligently’
with the new ‘Logiq Chess Line’ tools.
Turning first to Grip systems for parting
and grooving, he says that while others also
can offer double-ended parting inserts,
ISCAR’s system has the capability to allow
for depths that exceed the insert length, due
to its twisted Do-Grip insert design that
protects the reverse end. While still retaining
the same insert, which can cut through 100
mm in 35 seconds, by delivering coolant
through the holder (JHP style) from above
and below the insert cutting edge to improve
chip evacuation, that 35 seconds becomes
25 seconds, with no need to use high
pressure coolant, unless cutting challenging
aerospace materials. Other inserts are
available that have coolant delivery holes in
them, further aiding chip evacuation.
Moving to single-ended inserts for parting
off, in 1978, 100 mm took four minutes,
using brazed tip tools, but ISCAR developed
a system that had a chip breaker and that
cut the time to 1 minute 30 seconds.
Then, in 1982, an indexable system was
developed that cut that to 1 minute 5
seconds. This was followed by the Tang Grip
system, in 2004, that delivered 45 seconds,
which was bettered by Jet Line insert
toolholders having coolant delivery that
reduced that to 35 seconds. Then, with the
flat-top Tang-Grip-IQ blade, the current
product, the time to part-off through
100 mm is 25 seconds.
Now, with a combination of both new
toolholder (‘the hardware’) and insert (‘the
software’), the Tang-F-Grip system that is
only for high feed cutting sees that 25
seconds becomes 15 seconds. Although
that’s for traditional X-axis direction parting;
for Y-axis direction parting using the same
insert, that is slashed again, to 10 seconds.
Of course, coolant to the cutting edge is key.
But that’s not the end of it; there is also a
holder that will allow Y-axis benefits for
X-axis parting that will deliver a cutting time
of just 7.5 seconds.
For deep parting and grooving in long
overhang situations, a new holder having an
anti-vibration feature counteracts vibrations
– Whisperline. Offered with 5.5, 7.7 and
8 mm wide inserts, tool life is four times
greater than the alternative, says Harpaz.
Coolant delivery to the insert through the
blade body again features.
ISCAR’s Pentacut, cost-effective five-edge
single, ‘star-type’ insert system for grooving
and parting has proved successful, but the
company has introduced a system for
smaller parts, called Pentacut Miniature
Master, that uses a size 17 insert system
(previous systems were 24 and 34). Insert
widths are 0.25 to 3.18 mm. Coolant
delivery above and below the insert again
features. Swiss-type sliding-head machines
are a key target.
Logiq-5-Grip, pushes this five-edge,
solid insert system further on economy
and performance. The current blade
can employ existing 2-3 mm wide
Tang-Grip inserts and can cut
diameters up to 45 mm. Coolant
directed at the cutting edge again
features. But a new system is
smaller, employing 0.8-1.6 mm wide Logiq-
Slim inserts for parting diameters up to
22 mm – “The smallest width indexable
insert for parting off and grooving.” When
using 3 m bar and parting off components
10 mm in length, a 2 mm width insert will
support production of 250 parts; 0.6 mm
width inserts offer 283. Inserts are easily
replaced with a simple tool in both cases –
no set-up time.
Extra-long inserts for the Swisscut system
are also pointed up. This range supports
threading, parting, turning, back turning and
groove turning. Parting off up to 20 mm,
rather than the previous 7.5 mm is key, but
also underlined is the ease with which
inserts can be replaced. Two screws are
loosened (not removed) and the insert
withdrawn – zero set-up time.
Moving to milling and a miniature slitting
cutter, Min-Slit, is claimed to be the
smallest diameter indexable insert such tool
available – 16-28 mm diameter with insert
The narrowest indexable insert slitting
saw, Slim-Slit, a 32 mm diameter blade
that holds inserts 0.6-1.2 mm wide
www.machinery.co.uk @MachineryTweets May 2018 51