ISCAR'S MACHINING SOLUTIONS FOR
Power Generation

WIND ENERGYw w w. i s c a r. c o mPower Generation

Wind Energy

ISCAR, A World Leader in the
Renewable Energies Industry

Renewable Energy is collected from clean resources thatare naturally replenished on a human time scale suchas sunlight, wind, rain, tides, waves, and geothermal heat.
Wind energy is the use of wind to provide mechanical power
through wind turbines to turn electric generatorsfor electrical power.

ISCAR, a company with many years of experience in theproduction of metal cutting tools, offers unique solutions
for the new generation of industries. As a leader in providing
productive and cost 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.

2ISCAR

3

Power Generation

Rotor Blade

Rotor Blade
Modern commercial turbines are
typically a three-blade designs andmanufactured from fiberglassreinforced polyester with an
epoxy resin binder. New materials
such as carbon fiber are being
introduced and provide the highstrength-to-weight ratio needed
for modern wind turbine blades.
The length of a typical turbine blade
can reach 60 meters in height,
installed in 5 MW machines!

1Milling/Slotting (Roughing)
Slotting cutters with tangentiallymounted inserts for precision shallow
grooving and slotting applications.
Semi-standard PCD tipped inserts
are available on request.

1

3
4

2

4ISCAR34

Face Milling (Finishing)

Drilling

Drilling

High speed dynamic balanceable
face mills for machining aluminum
casting and carbon fiber materials,
with interchangeable PCD
brazed cartridges.

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

Drills designed with twisted coolant
channels, allowing a strong bodywith excellent resistance to torsion
and very efficient chip evacuation.
Semi-standard PCD tipped
inserts are available on request.

25

Power Generation

Blade Adapter

Blade Adapter
The rotation platform of
the blade pitch system
is made of cast iron.
ISCAR has all the righttechnological solutions
for the production ofblade adapters.

6ISCAR

1

2

Face Milling

Face Milling

HELIDO is a family of tools for90° milling. The HELIDO H490
ANKX rectangular inserts have
4 helical right-hand cutting edges.

Multifunctional face mill foroctagonal square and round insert
contours with various entry angles.

33

4Drilling

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 high feed
rates, providing very accurate
IT8 – IT9 hole tolerance.

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

Drills designed with twisted coolant
channels, allowing a strong bodywith excellent resistance to torsion
and very efficient chip evacuation.

34127

Power Generation

Blade Bearing

14

Gear Gashing Slotting
Radius Profile Roughing
Gear slotting cutters with
tangentially mounted inserts are
excellent for roughing and finishinga variety of teeth profile modules.

3Drilling

External Rough Turning

Drills designed with twisted coolant
channels, allowing a strong bodywith excellent resistance to torsion
and very efficient chip evacuation.

Double-sided rhombic inserts
for heavy turning.

Blade Bearing
Adjusts the angle of the blades by rotating a bearing at the root of eachblade. Blade bearings enable power control and rotor braking. Made ofbearing steel.

8ISCAR

54Inner Boring of Bearing Roll
A line of external and internal
tools, as well as large-sized inserts
for heavy duty applications.

6Ceramics - Hard Turning
Finishing Operation

CBN - Hard Turning
Finishing Operation

IN23 - 40 - 50 HRc
IN22 - over 50 HRc
IN420 - over 50 HRc

IB50 - 45 - 65 HRc(interrupted cutting)
IB10H - 58 - 65 HRc
IB10HC - 58 - 65 HRc(continuous cutting)1253469Power Generation

Rotor HubINDEXABLE SOLID CARBIDE LINE

123Shouldering

Chamfering

Rough Pocketing

4 cutting corners, tangential
geometry for fast metal
removal (FMR) at very highmaterial removal rates.

A family of tools with shanks thathave unique interchangeable heads
for a variety of milling applications
including ball nose, straight shoulder,slitting and slotting applications.

FFQ4 D...
FFQ4 SOMT 1205RM-HP IC830
Square single-sided inserts withfour cutting edges designed
for reducing cutting forces andlong overhang applications.

Rotor Hub
The rotor hub, made of a cast iron case, is the component that generally
holds and connects the three-blade rotational assembly to a linear low
speed shaft that connects to the turbine›s gearbox. Most modern turbine
hubs contain a pitch system to adjust the angle of the blades by rotationof a bearing at the root of each blade, to control power and slow down
the rotor as required.

10ISCAR4

6

5

Threading

Drilling

Back Milling

Solid carbide thread mills forthe production of small internal
threads. The thread mills feature a
short 3-toothed cutting edge with 3flutes and a released neck between
the cutting zone and the shank.

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

(FST slotting cutters) ISCAR’s
tangential slot milling cuttersuse cutting inserts with 4
cutting edges. They are suitablefor high table feeds, resulting
in increased productivity.

56
1

2
4
3

11

Power Generation

Rotor Hub87

Face Milling

9

Helical Interpolation
Rough Boring

S845 SNMU 1305... - square
double-sided inserts with 8
cutting edges, or ONMU 0505...
octagonal, double-sided insertswith 16 cutting edges. Enables
highly efficient milling.

4 cutting corners, tangential
geometry for fast metal removal(FMR) at very high material removal
rates on the sides of the blades.

Drilling
Drills designed with twisted
coolant channels, which allow astrong drill body with excellent
resistance to torsion and very
efficient chip evacuation.

117810912ISCAR1011Threading

Fine Boring

Indexable threading endmills with aweldon shank and coolant holes.

TCH AL Aluminum twin cutter heads
for rough and fine boring operations.

13Power Generation

Axle Pin (Gearless)Axle Pin(Gearless)
A conical cast steel axle
connects the rotor hub
and the annular generator
directly as a fixed unit
without gears. Made ofalloy steel.

14

ISCAR

1

2

Rough External Turning

Rough External Turning

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.

45External Turning (Finishing)

Drilling

Drilling

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

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

Drills designed with twisted coolant
channels, allowing a strong bodywith excellent resistance to torsion
and very efficient chip evacuation.
Semi-standard PCD tipped inserts
are available on request.

31342515

Power Generation

Main Shaft

123

External Rough Turning

O.D. Rough Turning

External Turning (Finishing)

Tangential inserts with 4 cuttingedges for high metal removal ofup 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
and tempered steel. The main shaft transmits a low speed rotational
force from the rotor hub. Kinetic wind energy to the gearbox enableshigh speed rotation, which spins the generator and creates
electrical energy.

16ISCAR546

External Turning (Finishing)

External Grooving

Deep Drilling

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

Turning with groove-turn tools
provide a surface quality far
superior to anything normallypossible when turning withstandard ISO tools. Turning with
GRIP tools can produce a surface
quality comparable to grinding.

BTA System
DTS – Double Tube System
Range: Ø18.41 - 168.99 mm(Ø.724 - 6.65”), IT9-IT10
STS – Single Tube System
Range: Ø14.51 - 245.99 mm(Ø.571 - 9.68”), IT9

43

52
1617

Main Shaft

Power Generation

798

Face Milling (Finishing)

Face Milling (Finishing)

Drilling

4 cutting corners, tangential
geometry for fast metal removal(FMR). at very high material removal
rates on the sides of the blade.

16 economical cutting corners forfast metal removal (FMR). Finepitch 45° face mills designedfor high table speed.

Drills designed with twisted coolant
channels, allowing a strong bodywith excellent resistance to torsion
and very efficient chip evacuation.
Semi-standard PCD tipped inserts
are available on request.

97810111218ISCAR

101112

Face Milling

Drilling

Threading

S845 SNMU 1305... - square doublesided inserts with 8 cutting edges,
or ONMU 0505... octagonal doublesided inserts with 16 cutting edges.
Enables highly efficient milling.

SUMOCHAM comprises
a revolutionary clamping
system that enables improved
productivity output rates, whileenabling more insert indexes.

Solid carbide thread mills forthe production of small internal
threads. The thread mills feature a
short 3-toothed cutting edge with 3flutes and a released neck between
the cutting zone and the shank.

19Power Generation

Main Bearing Housing

Main Bearing
Housing
Materials:
Stainless steel
13Cr4Ni
16Cr5Ni
The main bearing housing
absorbs the residual
bending loads, while therotor shaft transmits therotational torque to thegearbox.

20ISCAR

12Drilling

Threading

SUMOCHAM comprises
a revolutionary clamping
system that enables improvedproductivity output rates, while
enabling more insert indexes.

Solid carbide thread mills forthe production of small internal
threads. The thread mills feature a
short 3-toothed cutting edge with 3flutes and a released neck between
the cutting zone and the shank.

INDEXABLE SOLID CARBIDE LINE

345

Chamfering

Face Milling

Deep Drilling

A family of tools with shanks thathave unique interchangeable heads
for a variety of milling applications
including ball nose, straight shoulder,slitting and slotting applications.

HELIDO is a family of tools for
90° milling. The HELIDO H490
ANKX rectangular inserts have 4
helical right-hand cutting edges.

Deep drills for milling centersand lathe machines with a drilling
ratio of up to 7xD.

1234521

Power GenerationMain Bearing Housing

Option 1Option 2

7

6

Roughing by HelicalInterpolation
4 cutting corners, tangential
geometry for fast metal
removal (FMR) at very highmaterial removal rates.

Extended Flute Cutter

ITS Bore System

P290 SM shell mills carring 12and 18mm long-edged insrets.

TCH AL Aluminum twin cutter heads
for rough and fine boring operations.

67822

ISCAR

8Drilling
Drills designed with twisted coolant
channels, allowing a strong bodywith excellent resistance to torsion
and very efficient chip evacuation.
Semi-standard PCD tipped inserts
are available on request.

23

Power Generation

Planetary Carrier

Planetary Carrier
The rotary gear planetary
carrier, made of nodular
cast iron, is a part of thegear assembly. It functions
to increase the slow
rotation speed of the main
shaft, transferred as higher
rotation to the generator.

24

ISCAR

Gear Sub-Component

132

Face Milling (Finishing)

ITS Rough Boring

ITS Fine Boring

16 economical cutting corners
for fast metal removal (FMR).
Fine pitch 45° face mills designed
for high table speed.

TCH AL Aluminum twin cutter heads
for rough and fine boring operations.

TCH AL Aluminum twin cutter heads
for rough and fine boring operations.

23

125

Power Generation

Planetary Carrier

Planetary Carrier
The rotary gear
planetary carrier, madeof nodular cast iron,is a part of the gear
assembly. It functions
to increase the slow
rotation speed of themain shaft, transferred
as higher rotation
to the generator.

45Turning

Turning

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

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

85

4
626

ISCAR

7

678

Rough Helical Interpolation

Finish Helical Interpolation

Fine Boring

Milling cutters that can carry either
round inserts with a serrated cuttingedge or regular round inserts.

HM390 endmiils carrying triangularinserts with 3 helical cutting edges.

BHF fine boring heads used on
an MB modular boring system.
Slider: BHFH... Insert holders: IHRF..

27

Power Generation

Support BaseSupport BaseA very large casting ofhigh quality metallurgicalductile iron supports theentire turbine drive train
and transmits the load ofnacelle components tothe tower.

1

Face Milling
HELIDO is a family of tools for
90° milling. The HELIDO H490
ANKX rectangular inserts have 4
helical right-hand cutting edges.

28ISCAR2

Roughing by HelicalInterpolation
4 cutting corners, tangential
geometry for fast metal
removal (FMR) at very highmaterial removal rates.

435Fine Boring

Face Milling

Face Milling

ITSBORE System
Shank: BHF MB80-125x114
Boring holders: BHFH in size
40x133, 40x200, 40x300.

Multifunctional face mill foroctagonal square and round inserts
contours with various entry angles.

S845 SNMU 1305... - square
double-sided inserts with 8
cutting edges, or ONMU 0505...
octagonal, double-sided insertswith 16 cutting edges. Enables
highly efficient milling.

451

42329

Power Generation

Yaw System

312Gear Gashing Slotting
Radius Profile Roughing
Gear slotting cutters with
tangentially mounted inserts areexcellent for roughing and finishinga variety of teeth profile modules.

4Drilling

External Rough Turning

Drills designed with twisted coolant
channels, allowing a strong bodywith excellent resistance to torsion
and very efficient chip evacuation.
Semi-standard PCD tipped inserts
are available on request.

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

Yaw System
The yaw system of wind turbines is the component responsible forthe orientation of the wind turbine rotor towards the wind. This is amechanism that rotates the nacelle to face the changing wind direction.
Made of alloy or bearing steel.

30

ISCAR

55

6Rolling Bearings
Inner Boring

Ceramics - Hard Turning
Finishing Operation

CBN - Hard Turning
Finishing Operation

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

IN23 - 40 - 50 HRc
IN22 - over 50 HRc
IN420 - over 50 HRc

IB50 - 45 - 65 HRc(interrupted cutting)
IB10H - 58 - 65 HRc
IB10HC - 58 - 65 HRc(continuous cutting)42356131

Power Generation

Tower Flange

Tower Flange
The vast majority of commercial windturbines use tubular steel, towers. In
some circumstances lattice towers areused for smaller capacity turbines. Towerheights depend on rotor diameter and thewind speed conditions of the site. Towerheights range from 50 meters for a 1
MW turbine to as high as 125 meters andmore for very large turbines. The flange
comprises a large scale of rolled steel
that connects the tower’s conical links.

1Drilling
Large diameter full effective
indexable drills with a pilotdrilling head and one flat shank.
Drilling depths of 7xD and8xD. High drilling rates, highaccuracy and surface finish.

32ISCAR23

External Turning (Finishing)
A line of external and internaltools, as well as large-sized inserts
for heavy duty applications.

4Ceramics - Hard Turning
Finishing Operation

CBN - Hard Turning
Finishing Operation

IN23 - 40 - 50 HRc
IN22 - over 50 HRc
IN420 - over 50 HRc

IB50 - 45 - 65 HRc(interrupted cutting)
IB10H - 58 - 65 HRc
IB10HC - 58 - 65 HRc(continuous cutting)

213433Find The NEOLOGIQNEOLOGIQAL
AL Tool
For Your Application!
• The virtual tool advisor features advanced AIand ‘Big Data’ analytics• Supports complicated machining tasks and challenges• Offers a wide range of functions and recommendations
to operate machining centers• Features online service 24/7 in more than 30 languages• Functions according to ISO13399

w w w. i s car. co m

Av a i l a b le n ow o n I S C A R . C O M

NEO ITA System
Workflow
Select a Machine

Define and customize
machine specifications

Search material by groups
or by random choice

Choose a Tool Recommendationa n d t h e I S C A R Wo r ld A p p

NISCAR'S MACHINING SOLUTIONS FOR

3408844 G 05/2021 © ISCAR LTD All rights reserved

Power Generation

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