HE AV Y
ISCAR'S MACHINING SOLUTIONS FORHEAVYMACHINING

w w w. i s c a r. c o m

HEAVY

Heavy Machining

ISCAR, A World Leader in the
Heavy Machining Industry

The demand for heavy machining solutions
grows exponentially as the use of large size partsrises in the oil and gas, power generation, and railway
wheels industries.
The major challenge is to withstand changing cutting
depths and high feed rates, generally under dry machining.
Choosing the right solution has a dramatic effect on thefunction and durability of the insert.

ISCAR offers unique solutions for new generationindustries. As a leader in providing productive andcost effective machining solutions,
ISCAR strives to be up to date with all the new trends andtechnologies which are a part of a brighter, greener future.

2

ISCAR

DIE AND MOLD

HEAVY

POWER
GENERATIONRAILWAYOFF ROADHEAT EXCHANGERS

IRON AND STEELOIL AND GAS

POWER
GENERATION

3HEAVY

Heavy Machining

Turning
ISO standard tools perform most of the metalworking
industries machining with a high applications range.
ISCAR ISO turning line provides a complete solution for
all types of applications and materials, with innovative
insert geometries combined with the world´s leading
Carbide grades designed to meet high customer
demands for increased tool life and productivity.

Key Factors:
1. Inserts size, 19mm and above
2. Strong cutting edge with dedicated land geometry
3. Single sided inserts ensure rigidity
4. Inserts shape with a large point angle
5. Rigid clamping systems
6. Holders with small entry angles

Typical Applications

4

ISCAR

RCMM

SNMM

LNMX

Typical Round Inserts

Typical Square Inserts

Typical Tangetial Inserts

Roughing/Heavy Turning Chip Formers
Ap (mm)

Heavy
Heavy
Heavy

H6P

Roughing/
Heavy

H5P
H4P

Roughing
H3P
R3P

Heavy duty
T3P

Feed (mm/rev)
5

Heavy Machining

HEAVY

Roughing/Heavy Turning Chip Formers
T3P Chipformer
10°

19°

0.3

Double-sided 6˚ negative flank trigone insert for high feed turning on steel.

R3P Chipformer
0.12

13.5°

Chipbreaker for rough machining on steel with a positive rake angle andreinforced cutting edge for better performance and longer tool life.
H3P Chipformer

0.25• For heavy roughing applications.
• Low cutting force for low horse power machines.
• Excellent chip control due to changeable land and a flexible chip breaker.

20°

H4P Chipformer
0.3• For heavy roughing applications.
• For large depth of cut and high feed.
• Strong cutting edge credit to a wide land and large land angle.

15°

H5P Chipformer
0.3• For heavy roughing applications.
• For large depth of cut and high feed.
• Extremely strong cutting edge credit to a wide land and large land angle.
• Suitable for high cutting conditions.

20°

H6P Chipformer
15o
0.31

14

o

Tangential insert with 4 cutting edges for high metal
removal on steel up to 35 mm DOC.
NR Chipformer

0.26
0.28
17°

4°

Round 7° inserts with a positive flank andstrong cutting edge for rough turning.

Turning Geometries
Ap (mm)Double Sided
Negative inserts

Double Sided
Dovetail Insert

Single Side Insert

Single Side
Dovetail Insert

Feed (mm/rev)
Ap (mm)

CNMM
190616

CNMM
250624CCMT
380924

Feed (mm/rev)

Grades Position
Speed (m/min)
IC8150IC8250IC8350

IC807

IC830

Toughness Related to Interrupted Cut
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Heavy Machining

HEAVY

Key Codes
The chipformer code key consists of three characterssuch as: LOMX - 402224 - H6P

2. Chip Load

1. Application
Feed (mm/rev)

ap (mm)R

Roughing

0.35-0.70

3.00-7.00

H

Heavy Roughing

0.60-1.50

6.00-20.0

ISO Standard Designation

LOMX 40

22

24

-

2

for special cases

3

general recommendation for all applications

4

for special cases

1

2

3

H

6

P

3. Workpiece Material Group

8

ISCAR

P

Steel

M

Stainless SteelK

Cast Iron

A Tangential LOMX 402224-H6P Insert
for Very Heavy Turning Aapplications
The tangentially clamped insert with 4 cutting edges
is made from the tough grade IC8250. It can machineat up to 35 mm depth of cut and up to 2 mm/rev feed.
The insert is clamped on a very rigid lever lock pocket
equipped with a protective seat.

Tangentially Clamped Insert

Clamping Surfaces

2

1

Double-sided with
4 cutting edges
3

Protective Seat

4

Lever Lock Accessible
from Both Tool Sides

9

Heavy Machining

HEAVY

The DOVE-IQ-TURN clamping mechanism canfirmly mount double-sided inserts that feature
double negative prism flanks. The dovetail pocket
and insert prismatic flanks prevent the insert
from being lifted by the cutting forces.

The Cutting Forces Tend to Cause the Standard Insert
to Tilt in Standard Lever Clamp Tools

The DOVE-IQ-TURN double-sided inserts
can be used under heavy chip load conditions.
There are three insert geometries withprismatic flanks: WOMG-R3P-IQ, COMG-R3P-IQ
and SOMG-R3P-IQ designed with a new R3P
chipformer for rough turning of steel. The new
system enables 50% higher metal removal rates,
compared to NMG double-sided insert.

Double-Sided Dovetailed Prismatic Flank Inserts
are Firmly Held in Place

D.O.C.

0.1

D.O.C.

0.3

0.5

0.7

0.9

1.1 f (mm/rev)

Standard NMG Type Inserts

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ISCAR

0.1

0.3

0.5

0.7

0.9

1.1 f (mm/rev)

New Dovetail OMG-R3P-IQ Inserts

PCB...

PCL...

ISCAR has developed an innovative dovetailpocket combined with a lever clamping
mechanism. The new system provides very
firm and rigid insert clamping that eliminates
the need for the top clamp, which interfereswith chip flow.

7

PCB...

PCL...

8

1

Insert

2

Shim

3

4
6

7°

5

4 Cutting Edges for 80° and4 Cutting Edges for 100°

Dovetail Clamping

A Single Insert for Two Applications
Either 80º or 100º Insert Corners
Tool for 100° Insert Corner

Tool for 80° Insert Corner

PCBOR/L..

PCLOR/L..
75°

95°

11

HEAVY

Heavy Machining

FEEDTURN Insert for 18.5º
Lead Angle Tools
PWXOL 3232P-10-TF-IQ lever lock toolholders
with a 18.5° lead angle, for fast feed.
The new tools carry a new insert
WOMG 100716-T3P-IQ with a new T3P chipformer,
double-sided 6° negative flank trigon, for highfeed turning of steel, up to 3 mm/rev and up to
2.8 mm D.O.C. longitudinal turning.

Up to 3 mm/rev feed

Enables high feed, new tools reducemachining time and costs.

ISCAR Offers Tools for
the Same Insert, that Feature aStandard 95º Entry Angle for
WOMG 100716-T3P-IQ Inserts
Traditional trigon insert for lateral turning,shouldering and facing
Up to 0.65 mm/rev feed

12

ISCAR

WOMG 100716-T3P-IQ Double-Sided
Dovetail Insert for Two Main Heavy
Duty Turning Applications

PWXOR/L.. 10-TF-IQ

PWLOR/L .. 10-IQ

FEEDTURN Tool

Standard Orientation Tool
18.5°

95°

ap ap

mmmm
5.55.5
5.0 5.0
4.5 4.5
4.0 4.0
3.5 3.5
3.0 3.0
2.5 2.5
2.0 2.0
1.5 1.5
1.01.0
0.5 0.5

ap ap

mmmm
3.5 3.5
3.0 3.0
2.52.5
2.0 2.0
1.5 1.5
1.01.0
0.5 0.5
0.5 0.51.01.0 1.5 1.5 2.0 2.0
2.5 2.53.03.03.5 3.5

F (mm/rev)
F (mm/rev)

F (mm/rev)
F (mm/rev)
0.1 0.1
0.150.15
0.20
0.20
0.250.25
0.300.30
0.350.35
0.400.40
0.450.45
0.500.50
0.550.55
0.600.60
0.65
0.65
0.700.70

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HEAVY

Heavy Machining

Type Of Wear And Remedy
Flank Wear

possible causes:• cutting speed too high• heat development too high• Carbide grade too low-wear

Crater Wear

possible causes:• cutting speed too high• heat development too high• feed too low

Notch Wear

possible causes:• cutting speed too high• Carbide grade too low-wear

Chipping

possible causes:• Carbide grade too wear-resistant• cutting edge too positive• formation of edge

possible remedy:

possible remedy:

possible remedy:

possible remedy:• reduce cutting speed• harder Carbide grade• smaller lead angle• reduce cutting speed• harder Carbide grade• increase feed

• reduce cutting speed• harder Carbide grade• vary cutting depth• tougher Carbide grade• higher cutting speed• choice of more stable
cutting edge

Fracturepossible causes:• cutting edge too positive• Carbide grade too rigid• vibrations

possible remedy:• reduce cutting depth• lower feed
• more stable cutting wedge

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ISCAR

Comb Cracks

possible causes:• heat alternating voltage• strongly interrupted cut• thermal shock through coolant

possible remedy:• choice of tougher Carbide grade• improved coolant supply• dry machining for interrupted cuts

Built-up Edge

possible causes:• low cutting speed• feed too low• cutting edge too negative

possible remedy:• high cutting speed• increase feed
• smooth, positive cutting edge

Plastic Deformation

possible causes:• feed too high• cutting speed too high• Carbide grade too toughpossible remedy:• reduce cutting speed• reduce feed
• choice of harder Carbide grade

15

HEAVY

Heavy Machining

Axle Pin(Gearless)
A conical cast steel axle connects
the rotor hub and the annulargenerator directly as a fixed unit
without gears made of alloy steel.

16

ISCAR

1

2

3

Rough External Turning

Rough External Turning

External Turning (Finishing)

A line of external and internal
tools, as well as large-sized
inserts for heavy duty applications.

Tangentially clamped insert with aunique helical shaped cutting edge.
Provides an exceptional solution
for turning and enables very large
depths of cut at high feeds.

A line of external and internal
tools, as well as large-sized inserts
for heavy duty applications.

1
3

2

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HEAVY

Heavy Machining

1

2

3

External Rough Turning

O.D. Rough Turning

External Turning (Finishing)

Tangential inserts with 4 cuttingedges for high metal removal of
up to 35mm D.O.C. on steel.

A line of external and internal
tools, as well as large-sized
inserts for heavy duty applications.

Tangentially clamped insert withunique helical shaped cutting edges.
Provides an exceptional solution
for turning, enabling very large
depths of cut and high feeds.

Main Shaft
The main shaft of the wind turbine is usually forged from hardened andtempered steel. The main shaft transmits low speed rotational force
from the rotor hub. Kinetic wind energy to the gearbox enables highspeed rotation, which spins the generator and creates electrical energy.

18

ISCAR

4

External Turning (Finishing)
A line of external and internal tools,
as well as large-sized inserts forheavy duty applications.

4

2

3

1

19

HEAVY

Heavy Machining

Grooving
Single-ended inserts for deep heavy grooving, and turning
applications designed for extra rigidity required for liver
slot and rotation conditions.

Key Factors:
1. Tangentially oriented pocket, with very rigid clamping
2. High feed rates (up to 1.0 mm/Rev)
3. Machining large diameter parts and heavy interrupted cuts
4. No upper jaw for unobstructed chip flow

Typical Applications

20

ISCAR

Typical Round Inserts

TIGER Inserts

TIGER “V” Inserts

H-Type chipbreaker for heavy
profiling negative T-land for extraedge toughness suitable for heavyinterrupted machining width - 12 mm

Utility single-ended inserts
for external heavy grooving
and deep machining

CW-Type chipformer for heavy
grooving on carbon and alloy steels
width range 14, 17 and 20 mm

Grades position
Speed (m/min)

IC807
IC808

IC8250
IC830

Toughness Interrupted Cut
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HEAVY

Heavy Machining

Blade Adapter
The rotation platform of the blade pitchsystem is made of cast iron. ISCAR provides
technological solutions for blade adapters.

22

ISCAR

1

2

3

Heavy Grooving and Turning

Heavy Duty Grooving

Heavy Goorving

Single-ended insert for heavy grooving
and turning applications is based on
the very successful TANG-GRIP family.

Deep heavy grooving with a uniquefrontal locking mechanism.

Heavy grooving chipformer
for on carbon and alloy steels
width range 14, 17 and 20 mm.

3

2
1

23

HEAVY

Heavy Machining

Heavy Milling
Heavy milling involves machining processes of complicatedcastings with hard forging skins often polluted by sand.
The milling of large parts requires high metal removal
rates. The main priorities for such operations are HFM High
Feed Milling and Face Mill cutters which are proven to bestable for high feeds and large depths of cut.

Key Factors:
Cutters with 90� and 45� and round insertswith a large radius.
1. Inserts with strong cutting edges
2. High metal removal rates
3. Reduced cutting forces and power consumption
4. Cutter diameter range

Typical Applications

24

ISCAR

ONMU 1008

Economical octagonal
double-sided 45° insert
with 16 cutting edges

T465 LNHT/LNMT 2212

S845 SNMU 2608

Tangentially clamped insert
with 4 cutting edges. Used on 65°
cutters, for up to 19 mm depth of cut

Heavy duty double-sided
insert with 8 cutting edges

Grades Position
Speed (m/min)

IC808
IC5400
IC830

IC845

Toughness Interrupted Cut
25

HEAVY

Heavy Machining

Diagram of Different Cutter Concepts
30° Milling Cutters:

Ap

Optimal metal removal and machining
uneven, wavy surfaces

90˚

45–90° Milling Cutters:

For tough conditions in larger machining
centers suitable for medium-duty face

45˚

Cutters for Round Inserts:

30˚

Cutter with strong edges for tough conditions,milling cavities and interrupted cutting

Fz

Cutting Forces Direction for Different Entry Angles

30°
90°

45°
ROUND

26

ISCAR

Face Milling
Next to Square Shoulder• It is recommended that the width of cut be
no more than diameter DC in order to prevent
tooth overloading, due to excess machining
allowance in cusps produced after stepdown• Down (climb) milling is preferable

Entry into Material• In milling, an approach cut by arc (“rolling in”)
is preferable. When a milling cutter enters a machinedmaterial by use of an arc, chip thickness grows to
a maximum value progressively and then graduallydiminishes to zero. It significantly contributes to machining
stability, improves tool life, and reduces vibrations

Milling Hole of Diameter D by Helical Interpolation• Maximum and minimum hole diameters
Dmax and Dmin correspondingly:• Dmax = 2 x DCX – 1, Dmin = DCX + DC
• Down (climb) milling is recommended, however
if chip evacuation is problematic, up (conventional)
milling provides better results• Helical pitch should not exceed maximum depth of cut APMX• Helix angle should not exceed maximum ramping angle RMPX
• It is recommended to reduce feed per tooth fz by 30-40%

APMX

DC
DCX

Ramp Down Milling• Depth of ramping per pass should not exceed
maximum depth of cut APMX
• Ramping angle should not exceed
maximum ramping angle RMPX
• Down (climb) milling is preferable• It is recommended to reduce feed per tooth fz by 30-40%

APMX
RMPX

27

HEAVY

Heavy Machining

Mold Base
A mold base is the structural steel
prismatic part of the mold that holds
the cavity and core inserts.
ISCAR offers a wide range of standard
face mills, drills, reamers, threadmills and rough fine boring tools for
producing of mold bases.

28

ISCAR

1

2

3

Milling

Milling

Milling

F45NM 45° face mills which
mount octagonal ONHU/MU 0806...
inserts with 16 cutting edges.

SOF45-26 heavy duty 45°
face mills mount square oroctagonal double-sided insertswith 8/16 cutting edges.

FF FWX and MF FWX
face mills mount hexagonal
inserts with 6 cutting edges.

1

3
2

29

HEAVY

Heavy Machining

HFM - High Feed MillingHigh feed milling refers to milling at very fast feed
rates with relatively small depths of cut. These highfeed rates are possible due to a small approachangle of the cutting edge, in a way which maintains
uniform chip thickness. ISCAR provides diverse
high feed milling tools and inserts, which
cover a wide range of applications.

Key Factors:

1. Positive tool rake angle assuressmooth cutting, reduced cutting forces
and power consumption
2. High metal removal rates
3. Large diameter range of milling cutters

Typical Applications

30

ISCAR

FFQ8 SZMU
Square double-sided
inserts with 8 cutting edges
for high feed milling

FFX4 XNMU“Bone shaped” inserts with
4 cutting edges for fast feed milling

H600 WXCU
Double-sided inserts with 6 cuttingedges for fast feed machining

Grades Position
Speed (m/min)

IC808
IC5500
IC830

IC845

Toughness Interrupted Cut
31

HEAVY

Heavy Machining

Pressure Valve
Pressure valves are popular component
in pressure control systems for heavy
duty conditions intended for surface andsubsea operations. The high strength ofstainless steels, duplex and super duplex
alloys assure long lasting pressure
systems and are very common in thepressure control system field.
ISCAR offers a wide range ofstandard and special mills for the
production of pressure valves.

1

Rampdown Milling
Interpolation
Double-sided, 6-edged insert
combines HELIDO’s strength and
FEEDMILL’s special geometry tofacilitate milling at very high feed
rates of up to 2 mm (0.078”)/toothfor high volume metal removal rates.

1

2

32

ISCAR

33

HEAVY

Heavy Machining

Hole Making
Holemaking is characterized by large diameter
drills and boring systems able to withstandhigh cutting conditions.

Key Factors:

1. Large diameter drilling for
demanding cutting conditions
2. Drilling without a pilot hole
3. Interrupted-cutting
4. Exchangeable PVD inserts
5. Indexable drilling inserts
6. Exchangeable drilling heads

Typical Applications

34

ISCAR

DR-DH
Large drilling depth: L=5xD
and higher – up to 800 mm (31.5”)
mount standard indexable inserts

DFN A-1.5D-IQ
Drilling range of 33 to 40 mm
with 1.5, 3, 5 and 8 length
to diameter ratios

ITS Bore System
TCH AL Aluminum twin
cutter heads for rough andfine boring operations

Grades Position
Speed (m/min)

IC8080IC808/908
IC5500Toughness Interrupted Cut
35

HEAVY

Heavy Machining

Blade Adapter
The rotation platform of the blade pitchsystem is made of cast iron. ISCAR has
the right technological solutions for the
production of blade adapters.

36

ISCAR

1

1

2

Drilling

Drilling

Drilling

The CHAM-IQ-DRILL features aunique design, eliminating theneed for clamping accessories.
The robust structure of the drill
with the concave cutting edge
design enables drilling at highfeed rates, providing very accurate
IT8 – IT9 hole tolerance.

SUMOCHAM comprises a
revolutionary clamping systemthat enables improved productivity
output rates, while enabling
more insert indexes.

Drills designed with twisted coolant
channels, allows a strong body withexcellent resistance to torsion andvery efficient chip evacuation.

2

1
1

37

Technicahl Data

HEAVY

Key Codes
MetricMetricMetricMN - SUMOCHAM heads
MNC - COMBICHAM
MF - CHAM-IQ-DRILL
M3N - LOGIQ-3-CHAM
MD - IDI Heads
MR - XOMT/SOMT/SOMX Inserts
MC - AssemblyMH - Combi Holder

#.##

#.##

Inch

IN
INC
IF
I3N
ID
IR
IC
IH

Inch

Inch

- SUMOCHAM heads- COMBICHAM- CHAM-IQ-DRILL- LOGIQ-3-CHAM- IDI Heads- XOMT/SOMT/SOMX Inserts- Assembly- Combi Heads

#.##

#.##

Line

Drilling Depth

M

Drill Diameter
R

3

4

8

-

0

6

Other Characteristics

F
A
R
L
B
S
T
C
H
P
Y
M

- Cartridge- Adjustable Cartridge- No Cartridge- Left-Hand Drill- Boring Tool
- Stacked Plates- Flat Bottom- Frontal Coolant- Heavy Metal- Combi Head
- Combi Assembly- Twisted

A
F
H
K
T
P
Q
R
J
I
L
N
E

- 2
SOMT 06- 3
SOMT 09- 4
SOMT 12- 5
SOMT 16- 4
AOMT 04- 5
SOMX 05- 6
SOMX 06- 7
SOMX 07- 10
SOMT 10- 11
SOMT 11- 14
SOMT 14- DCN/D3N Pocket- DCM Pocket

ANSI

Shank/Flange CodeInsert Size

Insert
Qty

Other

9

-

4

R

N

D

Shank Type Code
40 mm

68.7 mm

Ø34.75mm
InsersSOMX 060304-DT

F
D
E
N
Whistle notch
L
R
W
M
H
X
P
B
K
C
V

- One Parallel Flat
- Two Parallel Flats (DZ Metric Type)- Extended Lengh (For Coolant Ring)- Whistle Notch (DR Metric Type)- One Flat (ISO 9266 Cham Shank)- Round (Fully Rounded)- Weldon- Morse- HSK- Special- CLICKFIT- BBS (ABS Compatible)(1)- IM (ISO 26622-1 standard)- CAMFIX- VDI (ISO 26623-1 standard)
Other types on request(1) The trademark ABS® is owned by the KOMET GROUP

38

ISCAR

ISO

Q

Shank/Diameter Type Code

P
S
Q
R
H
A
B
C
D
E
F
G
X

- 10 mm- 12 mm- 14 mm- 16 mm- 18 mm- 20 mm- 25 mm- 32 mm- 40 mm- 50 mm- 63 mm- 80 mm- Special

Z
T
V
W
U
J
K
L
M
N
2
3
4
5

-

.375"
.437"
.500"
.562"
.625"
.750"
1.000"
1.250"
1.500"
2.000"
MT2
MT3
MT4
MT5

General - Calculations
Spindle Speed (min-1)

Examplev ∙1000
n= cπ ∙ D

Drill DR 220-044-25-07-2D-N (Ø22 mm) - Material No. 4
kc=2200 N/
k=90º, sin k=1
mm2
vc=200 m/min CMh=50 $/h η=0.75
km=1 kf=1
f=0.15 mm/revL=25 mm h=10 mm

Cutting Speed (m/min)π∙D∙nvc = 1000n=

Table Feed (mm/min)vf = f ∙ nMaterial Removal Rate (cm3/min)v ∙ π ∙ D2
Q= f 4000

vf = f ∙ n=0.15 ∙ 2894 = 434 mm/min
Q=

vf ∙ π ∙ D2
434 ∙ 3.14 ∙ (22)2
=
4000
4000

= 165 cm3/min
Q

Pc = 60.000 ∙ η ∙ Kc ∙ sin k

Power Requirement (kW)Q

Pc = 60.000 ∙ η ∙ kc ∙ sin k
Torque (Nm)f∙kvc ∙ 1000 200 ∙ 1000
∙ π ∙ 22 = 2894 min-1
π∙DD2

Mc = 1000c ∙ 8 ∙ sin k∙km
Feed Force (approx.) (N)D

65= 60.000 ∙ 0.75 ∙ 2200 ∙ 1 =8.06 kW
f ∙ Kc

Mc = 10000 ∙=D2
8 ∙ sin k

0.15 ∙ 2200 222∙ 8 ∙ 1 ∙1 = 20 Nm
10000
D

Ff = 0.63 ∙ 2 ∙f ∙ Kc ∙ sin k

22= 0.63 ∙ 2 ∙ 0.15 ∙ 2200 ∙ 1 ∙1 = 2286 n

Ff = 0.63 ∙ 2 ∙ f∙kc∙sin k∙kf

Tc =

L+h
25+10
Vf = 434 = 0.08 min/piece

Machining Time (min/piece)

Cc =

CMh
50 ∙ 0.08
60 ∙ Tc =
60

Tc =

L+h
vf

Machining Cost ($/piece)= 0.067 $/piece

kc ValuesC

Mh
Cc = 60∙Tc

39

HEAVY

Drilling Tool Wear

Edge Chipping
Cause• Low wear resistance Carbide grade• Built-up edge has been formed• Insufficient coolant fluid
Remedy• Reduce feed rate
• Increase cutting speed• Increase coolant pressure• Improve jet direction in case of external coolant supply• Change to different geometry• Check tool and part clamping rigidity

Corner Fracture
Cause
Caused by excessive insert wear
before indexing the insert• The grade and geometry may be
too weak for the applications• Excessive load on the insert• Built-up edge has been formed on the insert
Remedy• Check radial run-out• Reduce feed rate
• Increase the speed• Check tool and part clamping rigidity• Check if pocket gripping forces are
too low, replace the holder• Increase coolant pressure• Improve jet direction in case of external coolant supply

Chisel Chipping
Cause• Chisel run-out is too big• Combination of high feed and low speed
Remedy• Reduced feed rate and increased cutting speed• Check that chisel misalignment
does not exceed 0.02 mm• Check tool and part clamping rigidity• Check if pocket gripping forces are too
low - if so, replace the holder

40

ISCAR

Land Wear
Cause• Cutting speed too high
• Low wear resistance Carbide grade• Radial run-out is too highRemedy• Check that the correct geometry is used
• Check that T.I.R. run-out does not exceed 0.02 mm• Reduce cutting speed• Increase coolant pressure• Improve jet direction in case of external coolant supply• Check and improve tool and part clamping rigidity• Check if pocket gripping forces are too
low - if so, replace the tool bodyCorner Chipping
Cause• Radial run-out is too high• Insufficient coolant fluid
Remedy• Check radial run-out• Reduce feed rate, increase the speed• Check tool and part clamping rigidity• Check if pocket gripping forces are too
low - if so, replace the holder• Increase coolant pressure• Improve jet direction in case of external coolant supply

Built-up Edge
Cause
• Cutting zone temperature is too low• Negative cutting geometry• Machining of very sticky materials such as
low-carbon steel, stainless steels, and aluminum
Remedy• Increase feed
• Increase cutting speed• Increase coolant pressure• Check oil percentage in the coolant fluid

Land Wear
Cause
• Cutting temperature is too highRemedy• Check cutting parameters• Reduce cutting feed
• Increase coolant pressure/volume• Use harder grade• Check that the correct geometry is used

Crater Wear
Cause
• Excessive cutting temperatures andpressures on the top of the insert
Remedy• Reduce cutting feed
• Check that the correct geometry is used

Thermal Cracking
Cause• Excessive variations in surface
temperature, intermittent machining,or variations in coolant supply
Remedy• Increase coolant pressure/volume• Increase oil concentration percentage

Flank Wear
Cause
• High cutting speed• Low wear resistance Carbide grade
Remedy• Check that the correct geometry is used
• Increase coolant pressure• Change to harder grade• Increase oil concentration percentage• Reduce cutting speed and increase feed

41

HEAVY

Heavy Machining

Turning - Test Reports
Test Parameters
Tool

MCLNR 32-8

Insert

SNMM 866-H4P

Carbide grade

IC8250Cutting speed (m/min)

190 (m/min)Feed (mm/rev)0.64 (mm/rev)

Depth of cut (mm)12.7 (mm)Number of passes

1

Parts per cutting edge

1.5

Number of pieces

1000

500

0

Competitor

ISCAR

Test Parameters
Tool

PSBNR 4040S-2509

Insert

SNMM 250924-R3P

Carbide grade

IC8150Cutting speed (m/min)

65 (m/min)Feed (mm/rev)

0.7 (mm/rev)

Depth of cut (mm)7.5 (mm)

Number of passes

2

Parts per cutting edge

3

Number of pieces

1000

42

500

0

Competitor

ISCAR

ISCAR

Test Parameters
Tool
Insert

SNMM 250924-R3P

Carbide grade

IC8150Cutting speed (m/min)

140 (m/min)Feed (mm/rev)

0.9 (mm/rev)

Depth of cut (mm)

8 (mm)

Number of passes

5

Parts per cutting edge

1.5

Number of pieces

1000

500

0

Competitor

ISCAR

Test Parameters
Tool

MCLNR 32-8

Insert

SNMM 866-H4P

Carbide grade

IC8250Cutting speed (m/min)

190 (m/min)Feed (mm/rev)0.64 (mm/rev)

Depth of cut (mm)12.7 (mm)Number of passes

1

Parts per cutting edge

1.5

Number of pieces

1000

500

0

Competitor

ISCAR

43

HEAVY

Heavy Machining

Grooving - Test Reports
Test Parameters
Tool
InsertTIGER 1415Y-IQ

Carbide grade

IC808

Cutting speed grooving (m/min)

120 (m/min)Feed grooving (mm/rev)

0.32 (mm/rev)

Depth of cut groove (mm)14 (mm)Number of passes grooving

5

Parts per cutting edge

4

Material removal rate grooving (cm3/min)

5.9

Test Parameters
Tool

44

InsertTAGB 1260

Carbide grade

IC808

Cutting speed grooving (m/min)

220 (m/min)Feed grooving (mm/rev)

0.7 (mm/rev)

Depth of cut groove (mm)

4 (mm)

Number of passes grooving

1

Parts per cutting edge

1

Machining time (min)

8.5

ISCAR

Test Parameters
Tool

THDR 3232-14T20-IQ

InsertTIGER 1415Y-IQ

Carbide grade

IC808

Cutting speed grooving (m/min)

120 (m/min)Feed grooving (mm/rev)

0.32 (mm/rev)

Depth of cut groove (mm)14 (mm)Number of passes grooving

5

Parts per cutting edge

4Machining time (min)5.9

Test Parameters
Tool

TGBHL 25-12

InsertTAGB 1260Y

Carbide grade

IC8250Cutting speed grooving (m/min)

120 (m/min)Feed grooving (mm/rev)

0.6 (mm/rev)

Depth of cut groove (mm)

6 (mm)

Number of passes grooving

5

Parts per cutting edge

8

Machining time (min)1245

HEAVY

Heavy Machining

Milling - Test Reports
Test Parameters
Tool
Diameter (mm)Total no. of teeth
Effective no. of teeth
InsertCarbide grade
Cutting speed (m/min)Spindle speed (rpm)Depth of cut (mm)Width of cut (mm)Feed per tooth (mm/t)
Table feed (m/min)
Parts per cutting edge
Material removal rate (cm3/min)

SOF45WG D200-12-60-R26
200
88S845 SNMU 2608ANR-RM
IC808
157
250
10
186
0.5
1500
320
2790

Test Parameters
Tool
Diameter (mm)Total no. of teeth
Effective no. of teeth
InsertCarbide grade
Cutting speed (m/min)Spindle speed (rpm)Depth of cut (mm)Width of cut (mm)Feed per tooth (mm/t)
Table feed (m/min)
Parts per cutting edge
Material removal rate (cm3/min)

46

ISCAR

T465 FLN D315-12-60R-22ST
315
12
12
T465 LNMT 2212-ZNTR
IC810
175
177
10
250
0.43
912
0.2
2281.22

Test Parameters
Tool
Diameter (mm)Total no. of teeth
Effective no. of teeth
InsertCarbide grade
Cutting speed (m/min)Spindle speed (rpm)Depth of cut (mm)Width of cut (mm)Feed per tooth (mm/t)
Table feed (m/min)
Parts per cutting edge
Machine load (%)

SOF45 D160-08-40-R26
160
8
16
ONMU 100816-N-HL
IC810
251
500
120
0.43
1720
2
52

Test Parameters
Tool
Diameter (mm)InsertCarbide grade
Cutting speed (m/min)
Depth of cut (mm)Width of cut (mm)Feed per tooth (mm/t)
Tool life (min)Proccessing time (min)FFQ8 D080-07-27-12
80mm/z=7
FFQ8 SZMU 120520T
IC808
160
1.5
60 (mm)
1.5
20
38

47

HEAVY

Heavy Machining

Holemaking - Test Reports
Test Parameters
Drill
InsertInsert grade
Tool/insert material
Hole diameter
Hole depth
Cutting speed (m/min)Spindle speed (rpm)Feed (mm/rev)
Table feed (m/min)Holes per cutting edge
Chip type
Material removal rate (cm3/min)

DFN 380-304-32A-8D-IQ
HFN 380-IQ-P
IC08
Carbide Uncoated
38
200
113
947
10
331
195
Comma/Helical375.73

Test Parameters
Drill
InsertInsert grade
Tool/insert material
Hole diameter
Hole depth
Cutting speed (m/min)Spindle speed (rpm)Feed (mm/rev)
Table feed (m/min)Holes per cutting edge
Chip type
Material removal rate (cm3/min)

48

ISCAR

MNC 490-245 A40-259-12
HCP 259-IQ
IC908
49
45
120
480
0.2744214
540
Comma/Helical403.37

Test Parameters
Drill
InsertInsert grade
Tool/insert material
Hole diameter
Hole depth
Cutting speed (m/min)Spindle speed (rpm)Feed (mm/rev)
Table feed (m/min)Holes per cutting edge
Chip type
Material removal rate (cm3/min)

MD-DR-DH 380 070707-06
SOMX 070305-DT
IC908
Carbide Coated
38
421
85
712
0.15
107
30
Spiral121.13

Test Parameters
Drill
InsertInsert grade
Tool/insert material
Hole diameter
Hole depth
Cutting speed (m/min)Spindle speed (rpm)Feed (mm/rev)
Table feed (m/min)Holes per cutting edge
Chip type
Material removal rate (cm3/min)

MNB 0600-050 X25-20-T10
TOGT 100305-DT
IC908
60
420
90
477
0.14
67
8
Comma/Helical189

49

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