Tool Craft for Aircraft

Selecting the right cutting tool for efficientmachining of aluminum [pg. 4]

Barrel Cutter Shapes a New Milling Trend
Wavy cutting-edge shape considerably reducesdelamination and burrs [pg. 12]

On High RPM

HSM toughens accuracy, reliability, and safety
requirements for spindle extensions [pg. 24]

CNC Technology Requires Digitized Tools

Smart manufacturing and network technologies [pg. 34]

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

2w w w. i s c a r. c o mTable of Contents
Tool Craft for Aircraft 4

To Hold Effectively 

12Super Effectiveness is Required for Machining Superalloys

18

On High RPM24

High-End Multi-Presence 28

CNC Technology Requires Digitized Tools

34

ISCAR

3

TOOL
CRAFT FOR
AIRCRAFT

In machining aerospace components, the main challenges relate tocomponent materials. Titanium, high-temperature superalloys (HTSA),
and creep-resisting steel are difficult to cut and machining is a real
bottleneck in the whole aircraft supply chain. Poor machinabilityof these materials results in low cutting speeds, which significantly
reduces productivity and shortens tool life. Both these factors are
directly connected with cutting tools. In fact, when dealing with
hard-to-machine typical aerospace materials, cutting tool functionality
defines the existing level of productivity.
4Modern aircraft, especially unmanned aerial vehicles(UAV), feature a considerably increased share ofcomposite materials. Effective machining composites
demand specific cutting tools, which is the focus of atechnological leap in the aerospace industry.
Aircraft-grade aluminum continues to be a widelyused material for fuselage elements. It may seem thatmachining aluminum is simple, however, selecting theright cutting tool is a necessary key to success in highefficiency machining of aluminum.
A complex part shape is a specific feature of theturbine engine technology. Most geometricallycomplicated parts of aero engines work in highly

corrosive environments and are made from hard-tocut materials, such as titanium and HTSA, to ensure
the required life cycle. A combination of complex
shape, low material machinability, and high accuracy
requirements are the main difficulties in producing
these parts. Leading multi-axis machining centersenable various chip removal strategies to provide
complex profiles in a more effective way. But a cutting
tool, which comes into direct contact with a part,has a strong impact on the success of machining.
Intensive tool wear affects surface accuracy, while
an unpredictable tool breakage may lead to thediscarding of a whole part.

Selecting the right cutting tool
is a necessary key to successin high-efficiency machiningof aluminum

ISCAR

5

Advanced multitasking machines, Swiss-type lathes,and live tooling lathes have profoundly changed
manufacturing small-size parts of various hydraulicand pneumatic systems, actuators, and accessories,
which are used in aircrafts. Consequently, theaerospace industry requires more and more cutting
tools that are designed specifically for such machines
to achieve maximum machining efficiency.
A cutting tool – the smallest element of amanufacturing system – turns into a key pillar for
substantially improved performance.

Therefore, aerospace part manufacturers and machine
tool builders are waiting for innovative solutions for a
new level of chip removal processes from their cutting
tool producers. The solution targets are evident: moreproductivity and more tool life. Machining complex
shapes of specific aerospace parts and large-sized
fuselage components demand a predictable tool life
period for reliable process planning and a well-timed
replacement of worn tools or their exchangeable
cutting components.

The smallest element of amanufacturing system, turns
into a key pillar for substantially
improved performance6

Coolant jet
In machining titanium, HTSA and creep-resisting
steel, high pressure cooling (HPC) is an efficient
tool for improving performance and increasing
productivity. Pinpointed HPC significantly reduces
the temperature at the cutting edge, ensures betterchip formation and provides small, segmented chips.
This contributes to higher cutting data and better
tool life when compared with conventional coolingmethods. More and more intensive applying HPC
to machining difficult-to-cut materials is a clear
trend in manufacturing aerospace components.
Understandably, cutting tool manufacturers consider
HPC tooling an important direction of development.
ISCAR, one of leaders in cutting tool manufacturing,has a vast product range for machining with HPC.
ISCAR has expanded its range by introducing new
milling cutters.

In the 1990’s, ISCAR introduced the HELIMILL – afamily of indexable milling tools, which carried insertswith a helical cutting edge. The new design provides
constant rake and relief angles along a mill cuttingedge and results in a smooth and light cut with asignificant reduction in power consumption. The
HELIMILL principle turned into a recognized concept
in the design of the 90° indexable milling cutters.
The HELIMILL was modified and underwent changes
which led to additional milling families and inserts withmore cutting edges. The excellent performance andits close derivatives of the original tools ensured theirphenomenal popularity in metalworking. Therefore,
by adding a modern HPC tool design to the proven
HELIMILL family was a direct response to customer
demand and the next logical tool line to develop.

ISCAR

7

In Turning Solutions, ISCAR considerably expanded its
line of assembled modular tools comprising of bars andexchangeable heads with indexable inserts. With theuse of a serrated connection, these tools fit a wide rangeof heads with a range of different insert geometries,
including threading and standard ISO turning inserts fordifferent applications for greater flexibility.
The bars have both traditional and anti-vibration
designs and differ by their adaptation: cylindrical or
polygonal taper shank. A common feature for themodular tools is the delivery of internal coolant to besupplied directly to the required insert cutting edge.

8

Depending on the diameter of a cylindrical-shanktool, the maximum coolant pressure varies from30 to 70 bars, while the tools with polygonal taper
shank facilitate ultra HPC at a pressure of up to 300
bars. The efficient distribution of coolant increases
the insert’s tool life by reducing the temperatureand improving chip control and chip evacuation,
substantially increasing this application line in theaerospace industry.

30XD

Drilling solutions
ISCAR developed a range of new drills that are
intended especially for composite materials. To
increase abrasion resistance, these drills have a
cutting part made from extra hard polycrystalline
diamond (PCD) or diamond coating. Depending on the
drill diameter, the PCD cutting part is known as a nib
or a wafer; and in both cases is suitable for regrinding
up to 5 times. The CVD diamond-coated solid carbide
drills are attractive because of another specific design
feature, the wavy shape of main cutting edges. In
machining composite materials, a tool produces morechattering than a cutting effect. The wavy shape of the
cutting edge considerably reduces delamination andburrs, especially when drilling carbon fiber reinforced
plastics (CFRP) and carbon laminates.

In addition to composites, the diamond-coateddrills are suitable for machining otherhigh-abrasive engineering materials.
If necessary, these drills can be delivered
with optional tool through coolant holes.
Drilling deep, small-in-diameter holes is acommon operation in manufacturing aerospacecomponents. ISCAR's new solid carbide drills in the
diameter range of 3-10 mm (0.125"-0.391") are intended
specifically for such an operation. The combinationof a split point geometry, a double-margin design,
polished flutes, a multi-layer coating and coolant
holes provides a noteworthy tool family for effective
one-pass drilling holes with a depth of up to 50 holediameters in difficult-to-cut austenitic and creepresisting steels and ferrum-based alloys.

The wavy shape of the cutting edge
considerably reduces delamination
and burrs, especially when drillingcarbon fiber reinforced plastics
and carbon laminates

ISCAR

9

Complex Shaped Parts
Airfoils of aero-engine turbines and compressors,
impellers, and integrally bladed rotors (IBR) havea complex shape that is defined by aerodynamic
requirements. New developments, which are directed on
improving aero-engine efficiency, add to this complexity.
Advancement of technology brought new methods
for producing formed parts, in particular 3D printing,which significantly diminishes material stock for chip
removal. However, machining remains the most common
method for the final shaping method in manufacturinggeometrically complex aerospace components.
The progress in 5-axis machining and CAD/CAM
systems has enriched the manufacturer's solution poolto overcome difficulties in component production.
Barrel-shaped milling cutters have good prospects in
5-axis machining of aerospace components with complex
surfaces. ISCAR has developed a series of barrel-shaped
cutters of 8 - 16 mm (.312" - .500") in two designed
configurations: solid carbide endmills and exchangeable
heads with a MULTI-MASTER threaded connection.
The introduction of these tools into themachining processes is a major advantage
of intensifying blade manufacturing.

10

Promising multitasking
Effectiveness of chip-removal processing on compact
multi-tasking machines and Swiss-Type lathes
depends largely on correct tool selection. Demands
to increase productivity require maximum tool holding
stiffness and limited working space to minimize tool
overhang. Recently, ISCAR introduced NEOCOLLET, a
new tool holding family, which provides an alternative
to clamping tools with spring collets. One of the typical
toolholders in this family has a tapered shank that canbe mounted in a collet chuck directly, ensuring a rigid
and reliable connection to improve tool performance.
The new family includes the holders for ISCAR T-SLOT
exchangeable slot and face milling heads from
cemented carbide.
As mentioned, applying high pressure cooling cansubstantially change machining results especiallywhen deal with titanium, HTSA and difficult-tocut stainless steel – the main materials for aircraft
hydraulic and pneumatic systems and light-sizedaccessories. The new turning tools with a squareshank and a reliable screw clamping mechanism for
55° rhombic insert facilitate HPC in longitudinal, faceand profile turning operations on small-diameter parts.

ISCAR

11

TO HOLD

EFFECTIVELY

12

Toolholders were designed for mounting cutting tools reliably.
They also facilitate the torque transmission from a machine spindle
to a rotating tool. Indeed, well-established tool clamping principles,
the need for wide interchangeability and unification, and normalized
designs of machine tool adaptations have resulted in well-defined
standards, which specify detailed toolholder parameters.
Time places new demands on machining, which has transformed to
new requirements for machine tools, cutting tools and toolholders –both elements of a chain that enables the recognition of machine toolcapabilities possible when machining part of a surface. The toolholder
relates to the most "conservative" link of the chain and has undergone
fewer revolutionary changes.

Smart manufacturing of tomorrow demands
intelligent toolholders to exchange data in
the formed Internet of Things (IoT). This willlead to creating new information capabilities
of toolholders by adding more and more
electronic units. Even today, built-in chips
provide various data about a toolholder that
communicates with machine tools, industrial
robots, storage devices, and more.
Adding a new data function is no doubt an
extremely important direction in toolholding
development. However, it does not cancel
the common way of an improved mechanicaldesign, which may look a little bit prosy whencompared to the enthusiastic data intelligenceof smart tooling.

ISCAR

13

Recent improvements in toolholder designs
are distinctly seen in the following areas.
1. Heat-shrink chucks
High-speed machining (HSM) methods havebrought tool balancing requirements to newheights. In HSM, the dynamic characteristics ofa tool cannot be separated from a toolholder,
and a particular focus must be given to theassembly on the tool and the toolholder.
Minimizing the unbalance of such an assemblyis one of the challenges tool developers face.
They have tried to guarantee the requiredbalance parameters at the design stage
before production. This engineered balance
design cannot replace "physical" balancing ofa real assembly, but it substantially diminishes
the mass unbalance of a future product andmakes "physical" balancing much easier.
Axisymmetricheat-shrink chucks optimally meet therequirements of a balanced toolholder
for HSM already in the design stage.
This explains why the advance ofheat-shrink chucks is of priority.
2. Coolant supply
A pinpointed coolant supply through a tool
body, when a coolant flow is directed to a
cutting zone, significantly improves
machining performance.
3. Modular quick-change tooling
A modular design principle considerably
simplifies finding the optimal configuration ofa tool assembly and diminishes requests for
special tools.
4. Long-reach applications
Long-reach machining applications, which
require high overhang of a tool assembly,
feature poor stability. Increasing vibration
strength of the assembly is one more trendof toolholder development.
5. Polygonal taper connection
The ISO-standardized polygonal taper
adaptation has proven itself and becomecommon in multitasking machines andturning centers.

14

Time puts new demands on
machining, which has transformed
to new requirements for machine
tools, and, consequently, to cutting
tools and toolholders
ISCAR

15

Recently, ISCAR expanded its family of heat-shrink
holders by adding new chucks with C8 polygon taper
shank. The chucks offer several bore sizes from 6 to
32 mm (.25-1.25"). The introduced products feature
coolant channels along the chuck bore to provide
effective coolant supply to the cutting edge of aclamped tool.

Due to increasing popularity of the polygon taper
adaptation, ISCAR has developed a new tool family
for external and internal turning and threading
applications. A modular concept of the family enables
various tool assemblies using a wide range of cutting
heads with indexable inserts that are mounted on
toolholders with polygon taper shanks by serrationface connection.

What else can be new in ER spring collets? Tool
manufacturers have developed a rich variety of precise
collets that offer coolant supply capability. For example,
ISCAR's new updated ER rubber sealed collets withan extremely narrow collapse range ensure better
clamping force, maintain high runout accuracy of 0.005
mm (.0002"), and facilitate 4 cooling jets.
ISCAR's integral collets, tools with a tapered shank fordirect mounting in ER chucks, are accurate and rigid
tools, and are considered toolholders themselves: thefront of the collet has its own adaptation for mounting
cutting heads with indexable inserts or are fully madefrom cemented carbides.

16

Hydraulic chucks ensure high gripping torque thatis vital for heavy-duty machining. During the lastyears, ISCAR extended its product range of hydraulicchucks, and they are now available with BT-MAS,
DIN 69871, and HSK shanks. In addition to a hightorque transmission and fast tool-change capabilities,
the hydraulic chucks are characterized by excellent
vibration damping properties and high accuracy.
ISCAR developed a system of quick-change
assembled tools specifically for turning aluminum
wheels. A tool assembly comprises of a cutting
head and a holder.

The head is mounted on the holder by use of adovetail connection. The dovetail mechanism assuresfull-face contact between the holder and the head withvery high clamping forces and can resist tough cutting
conditions when turning the wheels. The holders areproduced with VDI40, VDI50 or round shanks.
We can see that progress in toolholding is far fromexhausting the resources of advanced designing.
Although high-quality toolholders have reached
the right level of performance to meet the needs oftoday’s manufacturers, the smart factory of tomorrow
ISCAR
demands an even higher level.

17

SUPER
EFFECTIVENESS
is Required for
Machining Superalloys

Superalloys - metal alloys, which reflect their complex alloyed structure,
have become one of the main engineering materials for a long time.
They feature extremely high elevated temperature strength, andtherefore often are referred to as high-temperature superalloys (HTSA)or heat-resistant superalloys (HRSA). The history of superalloys started
with the development of gas-turbine engines that required reliablematerials for high operating temperature ranges. As a result of intensive
research and progress in metallurgy, modern superalloys (SA) provide
a long service life for working temperatures more than 1000°C.
18

Understandably, the largest superalloy consumers
today are aero - and marine engine producers.
Superalloys are also very common in the medical
industry, which effectively use them for prosthetic
implants in orthopedic surgery. In addition, superalloys
have become widespread in power generation andthe oil and gas industries as crucial materials foressential parts of various devices.

ISCAR

19

Exceptional high-temperature strength and corrosion
resistance are the undeniable advantages ofsuperalloys. However, there are two sides to thecoin: superalloys are not only highly priced, but theirmachinability is poor, which can pose challenges
to manufacturing. The specific cutting force thatcharacterizes the resistance of the material tochip removal and defines the mechanical load on
a cutting tool is high for superalloys. Although themain difficulty is heat, superalloys have poor thermal
conductivity. Elemental and loose chips, which are
generally generated when machining superalloys,
do not provide adequate heat dissipation from thecutting zone. A tendency to work hardening makes
the situation worse.
The manufacturer deals with various SA workpieces:cast, wrought, sintered, etc. The workpiece
fabrication methods also have an impact onmachinability. For example, abrasiveness of forgedworkpieces higher that cast ones substantially lower
in comparison with sintered workpieces.
Consequently, a cutting tool is under significant
thermal and mechanical load, which dramaticallyreduces tool life. Therefore, in machining superalloys,20

the cutting speed directly connected with the heatgeneration during chip removal is considerably
lower when compared to other common engineering
materials such as steel or cast iron. The direct resultof the cutting speed limitation is poor productivity.
Overcoming machining difficulties and increasing
productivity are the main challenges for the
manufacturer of SA parts.
According to ISO 513 standard, superalloys together
with titanium alloys relate to the ISO S groupapplication. Depending on the prevailing element,
superalloys are divided into three types: iron (Fe),nickel (Ni) and cobalt (Co) based alloys. Machinability
drops in the specified order; from the iron-based
alloys, which can be compared with austenitic
stainless steel, to cobalt-based alloys that represent
the most hard-to-cut materials in the group.

Increasing efficiency of machining superalloys has
become the focus of various scientific researchand technological improvements. Their result wasa significant advance in producing SA components.
Manufacturing has effectively embraced newmachining strategies and innovative methods of
cutting coolant supply, such as high-pressure cooling(HPC), minimum quantity lubrication (MQL) and evencryogenic cooling has successfully been introduced.
This has taken the productivity of machining
superalloys to a new level. However, like in the caseof titanium alloys, the key element for improving the
productivity of SA machining is a cutting tool that
directly removes material layers from a workpiecethat produces chips.

The key element
for improving the
productivity of
SA machining is
a cutting tool
Today, coated cemented carbides are the mostcommon materials for cutting tools for machining
superalloys. The development of a carbide grade, inwhich strength and wear resistance will be mutuallycomplemented is a tricky process that requires anappropriate carbide substrate, coating composition,and coating method.
If tool materials are connected mostly with materialsciences and metallurgy, cutting geometry is morein the tool design field. Ensuring high-performancegeometry requires deep engineering knowledge
and technology skills. On the one hand, to minimize
heat generation and work hardening, a positive
rake angle, a large enough clearance angle, anda sharp cutting edge are needed. On the other
hand, such a shape weakens the cutting edgethat should withstand a considerable mechanicalload. Therefore, the correct designed cutting-edge
condition becomes a critical success factor. Sinteredcarbide inserts have the advantage of enabling
complex chip forming and chip breaking shapes
for insert rake faces. Today, computer modelingof chip formation and pressing processes using
finite element methods provide an effective tool to
optimize the shapes that are already in the design
stage. In solid endmills, a variable pitch design
results in improved vibration strength. Cuttingedges of these endmills are produced by grinding
operations, and to eliminate flaking and edge
defects, strict adherence to technological process
requirements is highly important.

ISCAR

21

Carbide grade IC806, which had was introduced overthe last few years for face grooving superalloys andaustenitic stainless steel, was successfully adopted
by ISCAR’s threading and deep drilling lines. This
grade has a hard submicron substrate and PVD
TiAlN/AlTiN coating with post-coating treatment
according to ISCAR’s SUMO TEC technology. IC806
provides notable resistance to flaking and chippingand maintains reliable and repeatable results.
In machining superalloys by solid carbide endmills
and exchangeable heads, grade IC902, which
combines ultra-fine grain substrate and nano-layer

22

PVD TiAlN coating, ensures extremely high wear
resistance and prolongs tool life. This grade has
demonstrated very good results in producing devices
for replacement knee and hip joints that are madefrom difficult-to-cut cobalt-chrome alloys.
ISCAR has significantly extended the range of
products for ISO S applications made from various
cutting ceramics such as silicon nitride, SiAlON, andwhisker-reinforced grades. The newly introduced
ceramic items have replenished both indexable
inserts and solid endmills.

ISCAR has enriched the range ofsolutions intended for high-pressure
cooling by new indexable cutter
bodies and tool holders

The latest rake face designs F3M and F3P for ISO
standard turning inserts are intended specificallyfor hard-to-machine austenitic stainless steel andsuperalloys. Their positive rake-angle geometry
reduces the cutting force and ensures smooth
cutting action, while the set of deflectors on therake face improves chip control.
In ceramic double-sided inserts for turning andmilling tools, ISCAR has added new chamfered andcombined (chamfered and rounded) cutting-edge
condition options for tough applications.
ISCAR has enriched the range of solutions
intended for high-pressure cooling by newindexable cutter bodies and tool holders. For
example, thermal shrink chucks with polygonal
taper shanks, which have coolant jet channels
along the central bore, have been replenishedby the toolholder product line.

ISCAR

23

On High
RPM

24

High-speed machining (HSM) has not only led to a significant
difference between machine tools but has also brought awarenessto the high-speed spindle; perhaps, the most important and centralcomponent of high-speed machine tools and a key factor for the
success of HSM.
Operating a spindle with high rotation speed and gaining the optimalbalance between the provided speed and torque is the main task ofhigh spindle engineering. The spindle’s performance depends on
several different factors. One of the main factors relates to the designconcept of a single- or combined twin-motor bearing system, seal
components, and a tool retention method.

When machining, the spindle is not in direct contact
with the workpiece but interacts with it throughanother technological system – the cutting tool.
This connection acts as a conductor and should
transform the impressive capabilities of a high-speed
spindle into improved machining results. Anotherelement between the cutting tool and the spindle
is the toolholder which is fitted into the spindle.
The poor performance of this small assembly, thecutting tool and toolholder, may reduce the functionof the spindle to zero. Therefore, HSM toughens theaccuracy, reliability, and safety requirements for theassembly of the spindle extension.

High-speed rotation generates centrifugal forces.
In HSM, when compared with traditional machining
methods, these forces grow exponentially andturn into a significant load on a cutting tool which
determines the tool’s durability. In indexable milling,high centrifugal forces may cause insert clamping
screws to break, inserts to loosen and a cutter bodyto fail. Formed fragments can not only damagea machine and a machined part but can be very
dangerous to the operator.

HSM toughens the accuracy,
reliability, and safety
requirements for the assemblyof the spindle extension

ISCAR

25

ISCAR's milling cutters HSM90S FAL-22 are intended
for efficient milling of aluminum at high-speed rates.
They carry large-size inserts that enable up to 22 mm(0.866") depth of cut. The cutter insert pocket has a
protruding ridge on the seat bottom surface, and thelower face of the insert has a matching groove whichfits into a ridge when assembled. This eliminates
insert radial displacement due to strong centrifugal
forces at high-speed milling and improves load
distribution on the insert clamping screw. The cutter
design facilitates reliable milling in a rotational speed
range of up to 31000 rpm.

26

To reduce centrifugal forces, a cutter body should
be axially symmetric and highly balanced. There
are international and national standards and norms
that specify tool balancing grades. When designingindexable milling tools intended for HSM, it is very
important to ensure the mass distribution of the bodyis symmetrical with the body axis. As this theoreticalbalance relates to a virtual object, it cannot replace thephysical balancing of a real body if needed but can
substantially diminish the mass unbalance of future
products making the “physical” balance much easier.

Solid tools feature higher accuracy and betteraxial symmetry when compared with indexable
cutters. Typically, solid tools are less in diameterand naturally require higher RPM even for thesame cutting speed. This explains why the
majority of HSM tools are solid.
Normally, such tools are made from coatedcemented carbides, although in recent times cutting
ceramics as a tool material has become popularfor high-speed machining of high-temperature
superalloys. Nevertheless, selecting a solid tool,
especially milling cutters for HSM may be difficult.
Normally, the overhang-to-diameter ratio for solid
carbide endmills (SCEM) is greater when comparedwith indexable tools. Such a feature, in combination
with a flute shape that weakens a tool cross-section,
demands specific attention to the vibration strengthof a SCEM.
To improve chatter stability, tool engineers often
make a tooth angular pitch unequal, and a flute helix
variable. This violates the principle of axial symmetry
and may give a reverse result. Therefore, an optimal,
intelligent design for solid carbide endmills requires
engineer ingenuity and appropriate compromising
Modern CAD/CAM systems ensure estimating the
dynamic behavior of various products based on
their 3D models. Providing such models for cutting
tools, toolholders and various accessories is a typicalfeature of today’s serious tool manufacturer.

To conclude, high-speed machining has influenced
the need for specific requirements of a cutting tooland toolholder. By meeting these demands, HSM
has become a trusted highly engineered, high-speed
spindle operation with maximum efficiency.

ISCAR

27

HIGH-END
MULTI-PRESENCEINDEXABLE HEADS

Back in the early 2000s, the introduction of ISCAR's
MULTI-MASTER system of rotating tools with interchangeable carbide
heads played a significant role in the development of cutting tools.
Tool assemblies with exchangeable heads were known long before
ISCAR’s MULTI-MASTER.
28

Within the MULTI-MASTER product line, heads are
secured by using a thread connection. Cemented
carbide is a very hard and wear-resistant material andhas lower impact strength when compared to highspeed steel. In a threaded carbide part, the thread isa source of stress concentrators that is crucial for tool
functioning, especially under cyclic loading. Rotating
tools with exchangeable carbide heads are reasonable
in a relatively small diameter range, typically 6-25 mm(.25"-1.00"), which limits appropriate thread diameters
and the height of a thread profile.
The above points make it problematic to use standard
threads and strongly determine a special thread shape
to comply with the specifications of the connection.
Tools with threaded heads have significant advantages
as they demonstrate impressive versatility, provide
rational utilization of cemented carbide and are userfriendly with a simple head replacement.

ISCAR

29

40,000 Indexable Solid
Carbide Endmill Options
Aside from the benefits outlined above, which are
crucial for tools with exchangeable threaded heads,
the MULTI-MASTER provides high dimensional
repeatability with its face-contact design concept.
This concept holds the "no setup" principle forreplacing a worn head - no additional setup
operations for adjustment are necessary and thehead can be changed without removing the toolfrom the machine.

30

Another unique aspect of the MULTI-MASTER is
its very wide variety of heads that cover a broadspectrum of applications in milling, hole making,engraving, and gearing. In milling operations,these cover square shoulders, faces, 3D surfaces,chamfers, cavities and pockets, slots and grooves,threads, and machining by high-speed- and highfeed milling methods. And in holemaking operations,center and spot drilling, countersinking, etc.

Combining two types of heads is a beneficial
combination of two design approaches fully
ground heads from solid blanks and heads frompre-shaped sintered inserts. Together with awide choice of shanks, adaptors, and reducers
significantly simplifies the process of finding thebest tool configuration for a variety of metal cutting
operations. Apart from that, the line and its products
are ideal for tailor-made products, which makes tool
customization much easier.
A new horizon of applications starts with ISCAR’s
new thread size T12, intended for end milling heads
with a 32 mm (1.25") diameter. Even though solid
carbide endmills in this diameter are not common
due to their high cost, there are industrial sectors,
such as aerospace that need such tools.
Assemblies with exchangeable heads provide
a much more cost-efficient solution and ISCAR
is enthusiastic about its prospects of new
developments. It’s important to note that among
ISCAR’s introduced products, there are 5-fluteendmill heads with variable helix that were
designed specifically for machining difficult-to-cut
titanium alloys and high temperature materials (ISOS group of application). The heads have a cornerradius of 4 and 5 mm (.120", .250", .375"), which are
typical for aircraft part production.

ISCAR

31

In the aerospace industry, the line was enhanced with
6-flute endmill heads in diameters of 8-25 mm (.315"1.00") for machining titanium, including hard-to-cut β- andnear β-alloys especially by the trochoidal milling method.
The heads feature a combination of different helix andvariable angular pitch to improve chatter stability.
A typical aircraft countersunk screw requires a 100°countersink. The same angle is often needed for
riveting. The MULTI-MASTER provides an appropriate
solution with its newly developed 2-flute countersink
heads with 100°-point angle in diameters 9.525-19.05
mm (.375"-.750"). The heads are also suitable forchamfering and spot drilling.
The growth of 5-axis CNC machines has brought new
efficient strategies for milling complex 3D shapes.
This has increased the demands for cutting tools
with a specific geometry, i.e., barrel endmills.
In hole making, the recently introduced precise flatbottom drilling heads have considerably expanded theline applicability in shallow drilling operations for steel,stainless steel, and cast iron (ISO P and K groups ofapplication) including direct drilling inclined surfaces
The head diameter tolerance meets the accuracy
grade h7, while the head drilling capabilities extend
up to 1.2 of the diameters.

32

An advantage of the MULTI-MASTER is thatthe heads are excellent to produce special
profiles. This line contains several threaded blanks
from uncoated cemented carbides for tailor-madeproducts. A short time ago the range of available
blanks was expanded by disc-shape semi-finishedheads which are successfully used for customized
solutions in milling slots, grooves, threads, splines,
and many more.
The needs of modern manufacturing bring more andmore requests and open new application fields that
require an appropriate tooling response. The historyof ISCAR’s MULTI-MASTER concludes with highversatility of tools with exchangeable heads
and highlights their ability to meet growing
industrial demands.

ISCAR

33

CNC Technology
Requires

Digitized
Tools

34

Rows of CNC machine tools sharing their workspace with industrial
robots that transport machined parts, accompanied by a minimal
number of machine operators, are already a common scenario that
depict modern metalworking plants and shops. CNC machines are
the catalyst which created progressive computer data engineering
to enable this new reality. Advanced multi-axis machines facilitate
the production of very complicated shapes with minimal setups.
Advanced milling and turning capabilities, coupled in multitasking
machines, open new opportunities for effective process planning.
A quantum leap in CNC technology enables the practicalunderstanding of machining methods that have been theoreticalfor a long time, such as power skiving.

The contemporary evolution of smart manufacturing
is based on network technologies. In a smart factory,
CNC machines perform under the conditions ofreal-time and combine mutual information exchange
from an environmental context that blends both
real and virtual worlds. The systems interact withthe context via the Internet of Things referred to as
IOT. For example, the real world shows the positionof a cutting tool and acting cutting forces, whilethe virtual world specifies 3D tool paths during an
operation combined with predetermined machinestock allowance. Subsequently, the real and virtualworlds find themselves in a cutting tool where theynaturally complement each other.

A digital tool component possesses vast information
or data. Its elements are comprised of 3D and 2Dmodels, estimated tool life, accumulated cutting
time, possible limitations such as maximum
rotational speed, optimal machining data andadditional essential information.

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For centuries, technical drawings wereconsidered a common language for defining
tool features. Computer aided engineering(CAE) and CNC systems require anothermeans for data exchange. Cooperative
efforts of world specialists from various
engineering and scientific fields have resulted
in the creation of the ISO 13399 standard,
which specifies computer representationsof information related to cutting tools, theirholder which makes the lexicon base of thelanguage. Adherence to this standard meansthat the tool digital component's platformremains independent, and computerized
systems can utilize the data seamlessly. The
smart factory will require additional smarter
manufacturing systems and smarter tools
for these systems. Information about tool
properties, such as the remainder of its tool
life period, a specific tool identification, service
limitations, necessitates uniform rules for
specifying the information and its computer
representation like the ISO 13399 standard,
yet much more comprehensive.

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ISCAR is aware of the key importance of tool digitalelements. The new company's developments relate
to both cutting tools and the tool informational
essentials as well. Tool assembly options in 3D and
2D formats in ISCAR's electronic catalog; NEO-ITA,
the ISCAR digital tool adviser, on-line engineering
calculations and MATRIX, the automated tool
dispenser that is an integral part on the shop-floorsof a smart factory.

From technologists working on process planning,
engineers designing tool assemblies or preparing
the tooling part of a complex key project, CNC
programmers checking a tool path in a CAD/CAM
environment, to application specialists optimizing
machining operations, and even sales managers
assisting in selecting a more effective tool – allmight spend hours adopting the tool manufacturers’
tool data to integrate with the customer’s software.
ISCAR's electronic catalog provides a digital twin
representation of the tool assembly based on the
ISO 13399 standard. This guarantees the successfulcommunication between current and future software
support in a digitized smart factory. The virtual
assembly ensures fast, reliable simulation of theoperation as well as collision (interference) bychecking and tool path optimization and the designof workholding fixtures. As the selected machining
method affects the forces acting on workpieces,
and a tool configuration influences the shape of
workholding elements, simulating the operationby use of the tool assembly model may be also
considered an effective instrument for jig andfixture design.

ISCAR's electronic catalog
provides a digital twin
representation of the tool
assembly based on the
ISO 13399 standard

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The ISCAR tool adviser which assists users inselecting the right tool, is now reborn under thebrand name NEO-ITA which features advanced
analytics based on artificial intelligence and a bigdata platform. The upgraded adviser version utilizes
new capabilities such as new machine brands,material libraries, integrated machining calculations,and the ability to export p21-files as an integral partof tool recommendations.
One more useful digital assistant is the 4-PRO‎an online product information and machining
recommendation tool which enables tool andinsert information at your fingertips. 4-PRO scansthe 2D data matrix barcode on an ISCAR tool orinsert packaging label while assuring access tothe necessary data on a CNC shop floor. Diverse
4-PRO options provide product geometricalinformation presented in accordance with the ISO
13399 standard, and tie together inserts and tools
to match up with recommended cutting speeds andfeeds. 4-PRO also bonds the insert geometry and its
coating to the correct type of metal, allowing better
choices at the planning stages of a given process.
Intelligent CNC machines, network technologies,
information real-time exchange and virtual twins ofphysical objects are the necessary bricks for building
manufacturing in the era of INDUSTRY 4.0.

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4-PRO also bonds the insert
geometry and its coating to thecorrect type of metal, allowing
better choices at the planningstages of a given process
App Store

Play Store

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