Iscar – Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control

New Milling Development Benchmarks From ISCAR

Christellee — Tue, 19 Mar 2024 05:51:49 +0000

While milling is driven by the increasing demands of manufacturing, there are specific aspects that uniquely impact its advancement, Andrei Petrilin, ISCAR’s Senior Technical Manager explains.

Milling as a metal cutting method, originated in the late 18th century and quickly became one of the primary machining technologies today. It is hard to imagine any machine shop without milling machines on the shop floor. It is an essential process in manufacturing.

Today, we are witnessing significant changes in manufacturing that with profound consequences on the development of directions of milling. These changes are driven by various factors such as the increasing accuracy of metal shaping through precision investment cutting and precision forging, the widespread adoption of 3D printing, the growing usage of new composite and sintered materials, the need to enhance productivity in machining hard-to-cut superalloys and titanium grades, and the strong focus on electric and hybrid cars in the automotive industry, contributing to these changes.

Advancements Driving Productivity, Precision, and Sustainability

In addition, advancements in multi-axis machine tools have opened up new possibilities for precise machining of complex parts and enabled implementing new cutting strategies to improve productivity. In modern technological processes, there is a tendency to significantly reduce the amount of machining stock intended for milling operations, simultaneously increasing the requirements for surface finish and accuracy.

Therefore, the advancement in milling is driven by the need for higher productivity, more precision, and sustainability in operations. Consequently, the main developments in can be characterised as follow:

Fast metal removal focuses on boosting the metal removal rate (MRR) to achieve higher productivity by significantly increasing cutting speed or feed per tooth. This is achieved through techniques such as high speed milling (HSM) and, in rough operations, high feed milling (HFM).
Precision Milling Provides Higher Accuracy
Multi-axis milling is characterised by utilising multi-axis machining centres to enable complex milling operations.

Read more here in Page 15.

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ISCAR’s Forward Focus: Advancements In Metalworking Materials, Sustainable Solutions, And Digital Innovations For 2024 And Beyond

Christellee — Tue, 12 Mar 2024 04:28:49 +0000

With the prevailing economic climate which is nothing less than challenging, ISCAR is certainly doing what it can to be agile and adapt to the changing needs of metal fabrication world.

ISCAR strives to comprehend the economic conditions in each market to offer advanced technologies that guarantee the competitiveness of its customers. World events in recent years prompted ISCAR to increase its investment in tool research and development. As the materials and workpieces constantly evolve, it is crucial to correctly implement new cutting tools.

Therefore, the need for training becomes essential. ISCAR addressed this by establishing training centers in each of its subsidiaries worldwide — providing training to customers, enabling them to effectively utilise the latest methods and technologies for efficient tooling.

Tools are not enough, the ability to handle advanced materials in accordance to market demands are paramount. Advanced materials are in demand by aerospace, defense, and automotive industries.

To identify the most suitable tools and machining processes for newly developed advanced materials, ISCAR collaborates closely with material sciences companies that specialise in cutting tools research. This collaboration takes place before the new materials are introduced to the metalworking markets.

Into The Future

ISCAR’s focus in the upcoming years will be on tools and cutting processes for new workpiece materials. Sustainability and environmental responsibility are central to ISCAR’s development of metalworking tools. This includes designing and producing cutting tools with unique geometries that require lower power consumption, generate less heat, and minimise the need for finishing operations. The goal is to achieve higher throughput with reduced machining time and lower energy requirements.

Automation and digitalisation have been and continue to be a part of ISCAR’s mindset. ISCAR’s World App is the digital gateway for which the company offers 24/7 on-line technical support, e-Catalogue, e-Comm and other advanced solutions and services which support customers’ need any time, any place with multi language access.

The advanced ‘NEO-ITA – ISCAR’s hybrid salesman’ is part of ISCAR’s Digital World ‘go to market’ solution which provides the best tooling offer for any machining task with just limited input requirement. NEO-ITA also provides tool assemblies for digital twins, tool collision checks, NC programming with additional technical adviser calculators. ‘All in one’ the most VALUABLE and advanced digital package in service.

Read more here

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The post ISCAR’s Forward Focus: Advancements In Metalworking Materials, Sustainable Solutions, And Digital Innovations For 2024 And Beyond appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Sustainability Machining With ISCAR’s Cutting Tools

Christellee — Wed, 10 Jan 2024 04:33:26 +0000

The term “sustainability” has become increasingly popular in recent years — frequently seen in headlines, featured in forms of news media, scientific research, and practical seminars. Is this word merely a trending or the question of the hour?

The emphasis on sustainability stems from global growing awareness intended for critical environmental issues and climate change, largely caused by human activity. The focus on sustainability reflects our deep commitment to the principles of securing a better future for the planet and generations to come.

Consequently, sustainability has gained prominence in various fields, ranging from everyday life and business to transportation, urban planning, and manufacturing. Manufacturing should unquestionably be sustainable.

Today, there is widespread recognition and agreement regarding the correctness of this statement. Manufacturing processes consume natural resources, energy, create waste, and pollute the environment. We can mitigate the negative environmental impact only by adopting sustainable production technologies.

Cutting Tools — Key To Sustainability

Machining remains a primary method for producing parts of machines and mechanisms. Therefore, the question of how to make machining sustainable is more relevant than ever.

A cutting tool contacts the machined workpiece directly and shapes it to its required form, removing the rest of the unnecessary material in the form of metal chips. Can a cutting tool be a key factor for improving sustainability? The answer to the above question is undoubtedly a resounding, yes!

Read more here

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The post Sustainability Machining With ISCAR’s Cutting Tools appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

ISCAR Explains The Complex Decision In Metalworking Tool Selection

Christellee — Mon, 02 Oct 2023 02:21:19 +0000

ISCAR addresses the challenges of selecting the right cutting tool for a specific application, incorporating additive manufacturing into the mix.

When deciding on the appropriate cutting tool for a particular application, it is difficult to determine whether a standard tool or a special tool is preferable. The ideal tool selection is contingent on various factors, such as the nature of the business situation, the manufacturing program, the production type, and sometimes personal preferences.

Versatility Vs Precision

Standard cutting tools, produced by a specific tool manufacturer, offer high versatility and are appropriate for machining a diverse range of parts that come in different shapes. Furthermore, the tool exhibits excellent performance capabilities when cutting various engineering materials.

To ensure seamless production processes, it is crucial to have the cutting tools delivered in a timely manner. This is why standard tools are the foundation of tool stock management on metalworking production floors.

A special cutting tool is designed for specific operations on a particular part, made of a specific material, and used on a machine that requires a specific work holding fixture. This custom-engineered tooling solution aims to provide the best possible performance and outcome.

However, there is a downside to this solution as it limits the tool’s versatility, making it less adaptable to different applications. As a result, special tools are primarily used for high-volume mass production, especially in the automotive industry.

Read more here https://shorturl.at/gjlnX

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The post ISCAR Explains The Complex Decision In Metalworking Tool Selection appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

ISCAR’s Shrink Upgrade: Empowering Precision with Advanced Tool Holding

Christellee — Fri, 28 Jul 2023 09:20:29 +0000

Tool holding is the most conservative field of cutting tools, for which groundbreaking ideas seldom sprout. Have tool holding systems reached a cul-de-sac, with no new trends in sight? ISCAR offers its takes.

Tool holding is perceived as being stagnant in metalworking. Experts may claim that that true revolutionary changes in tool holding is associated with the HSK adaptation which ended three decades ago.

Tool holding systems lack progress and their pace of continuing progression may be slow. The process is evolutional and reflects modernage metalworking requirements. New technologies form new demands for machines and cutting tools.

As a result, deliver tool holding solutions remain an integral link to machining processes. The link physically connects the cutting tool with the machine.

Hence, the statement that tool holding developments are stagnant is incorrect. Although there are no real changes in this branch of metal cutting, major strides are being made to stay abreast of new technologies.

New Developments

New developments aim to enhance the capabilities of toolholders and their mechanical systems. Improving the main functional characteristics of the mechanical systems are attributed to strength, rigidity, gripping forces, accuracy, and vibration damping properties.

Another advancement relates to the new age metal cutting techniques paving the way to new horizons.

Read more here —–> https://t.ly/j7pSn

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Complex Machining Involving Face & Shoulders Milling

Christellee — Tue, 06 Jun 2023 06:17:31 +0000

Complex machining processes are unimaginable without the utilisation of face milling operations. ISCAR illustrates the world of metalworking is undergoing major changes.

Face milling processes facilitate the preparation of datum surfaces by producing planes and flats, and enable improving precision and surface quality parameters. Moreover, the production of many rotating parts is incomplete without face milling. Face milling is the very operation that cannot be undermined.

Art Of Creating Flat Surfaces

In face milling, the axis of a cutter is normal to the machined surface. A large majority of face mills or surface milling cutters are common indexable tools in shell mill configuration.

They feature various tool cutting edge angles (entering angles) such as 45°, 60°, 65°, 75°, 90°. Face mills intended specifically for productive rough machining by use of high feed milling (HFM) methods have a significantly smaller cutting-edge angle, typically 10°-17°. In some cases, shell mills that mount round inserts enable extremely strong cutting edges.

The cutting-edge angle has an impact on the decomposition of the cutting force, which acts on the plane of the cutter axis, on radial and axial components referred to as radial, and axial cutting forces. With all else being equal, this angle defines the maximum depth of cut.

The cutting-edge angle largely determines the application field of a face mill making 45° face mills most versatile. Such mills have an important advantage that stipulates a first-choice selection of 45° cutters in face milling, specifically when machining open plane surfaces.

These cutters assure a good balance of radial and axial cutting forces, a high-quality machined surface, and favorable cutting conditions when a tool enters or exits the material being machined. The most common face mill types are 45° cutters.

Read more here —–> https://t.ly/q3EHn

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The post Complex Machining Involving Face & Shoulders Milling appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

ISCAR’s Promising Segment With Five Axis Machining

Christellee — Mon, 15 May 2023 06:57:36 +0000

ISCAR explains how their five-axis machining can be simpler when paired with an optimum portfolio of milling tools.

Five axis machining is increasingly popular in modern metal cutting. It provides significant advantages such as machining complex-shaped parts by use of one set-up without changing the location of the workpiece, high machining accuracy, and reduced cycle time.

A Layer Deeper

Advanced technology of workpiece fabrication has led to increased capabilities of precise forging, casting, and mainstreaming additive manufacturing (AM). This resulted in the increased complexity of workpiece geometry, decreasing machining allowance and material by cutting operations and achieving end results which reflect the final shape of the workpiece.

The requests for high-performance cutting tools intended for finishing and semi-finishing geometrically complex surfaces are now vitally important. Ball-nose milling cutters are considered traditional tools for machining 3D surfaces.

Ball-nose cutters are the most common tools for semi-finishing and finishing profile in milling operations. Progress in the field of five-axis machining centres, and a significant step forward in modern CAM systems have emerged tools with a different cutting geometry, referred as segment or barrel-shape endmills.

Even though these tools are well known to machinists, they remain ignored. Five-axis machining combined with CNC software and computer modeling of complex tool configurations reemerged the use of circular segment endmill applications.

In All Directions

The cutting edge of these endmills is an arc that represents a segment of a circle with a radius larger than the nominal radius of a tool. For comparison purposes, in ballnose cutters the tool radius is the radius of the cutting edge.

Machining surfaces using ‘passes technique’ segment-type endmills enables a substantially increased step size compared to ball-nose cutters, thus reducing the cutting time. A three-axis CNC controlled cutting process cannot guarantee the correct position of a barrel shaped cutting tool when machining complex surfaces.

The five-axis machining concept allows taking full advantage of segment endmills. Depending on the orientation of the cutting edge relative to the tool axis, segment endmills possess various configurations such as pure barrel, tapered barrel, lens, and oval or parabolic shapes.

The form of the tool cutting edge determines the tool application. For example, lens-shaped tools are suitable for both five and three-axis machines, while endmills with a tapered barrel profile are intended for five-axis machines.

Segment cutter designs appear in multi-flute solid endmills that deliver ultimate tool accuracy and maximise the number of teeth on the cutting tool.

Read more here —–> https://t.ly/9yqt

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The post ISCAR’s Promising Segment With Five Axis Machining appeared first on Asia Pacific Metalworking Equipment News | Manufacturing | Automation | Quality Control.

Cutting Tools For Orthopedic Medical Components

Christellee — Mon, 27 Mar 2023 04:00:08 +0000

ISCAR illustrates new solutions to contend with machining parts for the medical industry.

Machining continues to be a main process for the production of medical parts. The medical industry is a major consumer of cutting tools.

What are the specific features of the industry from the tool manufacturer’s point of view? Which medical components are most challenging to the machine?

Which cutting tools are common today for machining medical parts? Why are tools for machining orthopedic components at the forefront of technology? What are the cutting tool trends for tomorrow?

Complexity Of Medical Equipment

The medical industry specialises in producing a wide range of healthcare equipment. These equipment are intended for solving a broad spectrum of health protection problems and it contains numerous parts that vary in dimensions, accuracy, material, and shape complexity. To make these parts, the medical industry utilises diverse technological processes in which machining still plays an essential role.

The general principles of machining healthcare equipment parts do not differ from similar parts of non-medical mechanisms. However, there are components that require intricate machining processes.

These processes are challenging and require process planning, essential machinery, and selecting the right cutting tools. Cutting tool manufacturers contend with developing unique tools to assure effective productivity and profitability solutions for medical parts production.

Read more here —–> https://t.ly/G7xW

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At The Parting Of The Ways – ISCAR’s Takes On Parting Systems

Christellee — Wed, 01 Feb 2023 07:27:16 +0000

Andrei Petrilin, ISCAR’s Senior Technical Manager walks APMEN through the advantages of using wide array of revolutionary parting systems which created unique milestones in metalworking.

Back in the 70s , ISCAR introduced SELF-GRIP, the brand name of the original blockbuster parting tool design concept. According to the design concept of the SELF-GRIP tool, a pressed carbide insert was clamped into a tool blade using the blade’s elastic forces without the need for mechanical securing elements. At that time, other manufacturers also attempted to clamp inserts into a parting tool using the same principle.

However, it was ISCAR that invented a reliable, truly workable concept that set the benchmark for parting applications. It was a plethora of revolutionary parting systems.

Starting The Trend

The SELF-GRIP tool proved to be a game changer in parting. Shortly after its inauguration, similar designs by other producers appeared in the metal cutting market.

ISCAR had established its name as the authority in parting applications and quickly became the unrivaled leader in the industry. Today, there is no question why ISCAR’s ongoing inventions of new parting systems and tools attract great interest and deserve such close attention.

Read on for more —-> https://rb.gy/metjmd

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Looking for the Optimum Tool

Christellee — Fri, 02 Dec 2022 00:00:24 +0000

An insightful piece by ISCAR points the way to find the optimum tool, subject to different requirements and effectiveness.

How can we define the manufacturer’s expectations from cutting tool producers? Cutting tool producers are expected to provide optimal cutting tool solutions for a given application.

So, how is an optimal cutting tool defined for a specific application? It is obvious that standards must be set to achieve a formidable solution. Cutting tool standards are also defined by principles to enable choosing the best possible tool for a given application.

Technical literature often states one tool or another as being optimal for an application. Therefore, a clear definition of the optimality standard is essential. The criteria for finding the optimal cutting tool depends on various factors.

The type of manufacturing (short-run, large-scale, mass), product range, machined materials, machinery used, cutting strategies and more have a direct impact on the manufacturer’s selection of the most effective tool. The manufacturer is interested in a tool that guarantees the highest performance levels.

This can be achieved by optimising the tool geometry and producing the tool from the most relevant cutting material grade. But the chosen geometry and grade are tool key elements associated with the type of machined material.

So, what is the ideal tool for cutting? An example of an effective tool for machining cast iron, will most probably not be the best solution for machining heat-resistant superalloys.

Read on for more ISCAR insights —> https://rb.gy/f5famt

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