ISCAR’s

Solutions for Manufacturing

Turbochargers

Machining Intelligently

ISCAR HIGH Q LINESw w w. i s c a r. c o mTurbocharger Industries

Turbine Housing
Turbine Wheel

2Compressor Housing
Bearing Housing

In today’s modern world, engine downsizing continues
to dominate the automotive industry. Nowadays,
turbochargers not only appear in large diesel engines
but also in gasoline engines.
A turbocharger can significantly boost the engine’s
horsepower without significantly increasing
its weight, and provides high-performanceand added benefits for modern cars.
The turbocharger provides many advantages fordrivers, yet places a challenge for OEMs.
Surviving extreme operating conditions, very hightemperatures and spinning at high speed revolutions
per minute (rpm) are just some of the circumstancesthat drive OEMs to look for new materials andinvestigate new technologies during real time.
ISCAR’s global industry experiences place thecustomer at the forefront, aiming to provide higher
Productivity, Profitability and Performance gains.
In the automotive industry and field of turbochargers,
ISCAR presents innovative solutions and full stableprocesses for turbocharger related components.
ISCAR views OEMs as high-priority customers andundertakes to build long-term cooperation.
ISCAR partnership goals recommend efficient andeconomical solutions and consequently provide
high-quality products and long lasting support.

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Bearing Housing
Material: Cast Iron

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Cutting conditions
Vc=250 m/min (820 sfm)
f=0.25 mm/rev (0.0098 inch/rev)

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Integral Groove Turn•• Extremely rigid clamping•• Quick insert change•• Face grooving, turning and boring

HFPR 4… IC5010•• Double-ended insert•• Twisted geometry•• Increased tool life•• Increased cutting speed

2Cutting conditions
Vc=200 m/min (656 sfm)
f=0.15 mm/rev (0.0059 inch/rev)
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1

GIF 4.00E... IC5010•• Precisely ground insert•• Excellent chipping resistance•• Built-up edge elimination•• Increased cutting speed

Combined Groove Turn•• Axially adjustable for
precise grooving•• Strong gripping forces•• Quick insert replacement

Internal Grooving•• Easy and fast edge indexing•• Rigid clamping system provides
improved performance•• Excellent surface finish•• High grooving repeatability

GIF 8.00E... IC5010•• Double-ended insert•• Excellent chipbreaker•• High toughness

PENTA 24… IC907•• 5 cutting edges (economical)•• Precise profile•• Durable insert design

Cutting conditions
Vc=150 m/min (495 sfm)
f=0.1 mm/rev (0.0039 inch/rev)

4WNGP 04… IC908•• Double-sided inserts•• Positive rake•• Low cutting forces

Cutting conditions
Vc=130 m/min (426 sfm)
f=0.1 mm/rev (0.0039 inch/rev)

5456

RM-SEI… IC907•• 2 cutting edges•• High cutting speed•• Versatile lead and rake
geometries selection•• Precisely ground insert
Cutting conditions
Vc=80 m/min (263 sfm)
f=0.25 mm/rev (0.0098 inch/rev)

6Internal Turning•• Enables boring small diameters•• Rigid screw clamping•• Excellent finish surface•• Coolant nozzle directedto the cutting edge

Indexable Reaming•• Adjustable system•• Extreme accuracy(for IT5 tolerance and up)•• Suitable for reaming
interrupted holes•• High surface finish

MIGR 8… IC908•• Unique convenient screw clamping•• Efficient in grooving atsmall diameters•• Wide range of insert profiles

Cutting conditions
Vc=110 m/min (360 sfm)
f=0.02 mm/rev (0.0007 inch/rev)

Internal Profiling•• Provides versatility advantages•• Coolant nozzle directedright to the cutting edge

5Turbine Wheel/Shaft
Shaft Material: Steel
Wheel Material: Inconell, TiAl Alloy
1

DNMG... IC8250•• Double-sided insert•• Positive rake for low cutting forces•• High toughness
Cutting conditions
Vc=180 m/min (590 sfm)
f=0.25 mm/rev (0.0098 inch/rev)

High Pressure Rough Turn•• High pressure coolant directedright to the cutting edge•• Shiftable telescopic coolant tube foreasy and fast insert replacement•• Quick change lever lock mechanism

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2High Pressure Finish Turn•• High pressure coolant directedright to the cutting edge•• Shiftable telescopic coolant tube foreasy and fast insert replacement•• Quick change lever lock mechanism

Cutting conditions
Vc=180 m/min (590 sfm)
f=0.1 mm/rev (0.0039 inch/rev)

3Slot - Groove-Turn•• Excellent surface finish•• High grooving repeatability•• High pressure coolant for chip
evacuation and longer tool life6VCMT… IC8250•• Moderated chipbreaker•• Precisely ground insert•• Excellent repeatability

PENTA 24… IC908•• 5 cutting edges (economical)•• Precise profile•• Durable insert design•• Pressed chipbreaker for
effective chip control
Cutting conditions
Vc=160 m/min (525 sfm)
f=0.08 mm/rev (0.0031 inch/rev)

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PENTA 24… IC908•• 5 cutting corners•• High cutting speed•• Unique pressed chipformer•• Wide range of threading types

Cutting conditions
Vc=15 m/min (50 sfm)
f=Pitch5High Pressure Threading•• Extreme accuracy•• Excellent surface finish•• High pressure coolant for effective
chip control and longer
tool life

RXCR 07...- IC808•• Low cutting forces•• High stability cutting•• Moderated chipbreaker

Cutting conditions
Vc=35 m/min (115 sfm)
fz=0.1 mm/t (0.0039 inch/t)

Milling (Dynamic balance)•• Indexable profiling tool•• High material removal rate7

Turbine Housing

Material: Austenitic Heat-Resistant Cast Steel

1

OR
1
ONMU… IC5400
S845 SNHU 13... MS32•• For ap ≤ 3.5 mm•• For ap ≤ 6 mm•• Economical: 16 cutting edges•• 8 cutting edges•• Precisely ground or utility insert•• Precisely ground insert
Face Milling (Roughing)
Option 2. Special solution
Option 1. Standard solution•• Axially adjustable runout for•• Well-secured inserts
precise overhang / uniform wear•• Durable cutter body•• Versatile face mill (suitable for both inserts)
Cutting conditions
Cutting conditions
Vc=150 m/min (495 sfm)
Vc=150 m/min (495 sfm)
fz=0.25 mm/t (0.0098 inch/t)
fz=0.2 mm/t (0.0078 inch/t)

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IQ845 SYHU… IC5400•• 8 cutting edges•• Smooth and stable cut•• Low power consumption•• Strong and durable design•• Excellent surface finish
Cutting conditions
Vc=115 m/min (378 sfm)
fz=0.18 mm/t (0.0070 inch/t)38

14Face Milling (Finishing)•• High-positive pocket inclination•• Extremely rigid clamping due to dovetail pocket•• Axial adjustment for fine surface finish•• Fine pitch for increased metal removal rate

Slot Milling•• Tangential clamping for
maximum stability•• Safe clamping (no insert pullingout during machining)•• Self clamping mechanism(without screw)•• Designed for high speed machining

2TAG N..MF IC5400•• Durable tangential insert design•• Unique chipformer provides chip control•• Reinforced cutting edge for longer tool life
Cutting conditions
Vc=70 m/min (230 sfm)
fz=0.07 mm/t (0.0027 inch/t)* For SiMo, Ductile Cast ircon and other materials,
insert grades to be selected accordingly* All the tools are available for dry machining, MQL and coolant

4HTP LN… IC808•• 4 cutting edges•• Positive rake - low
cutting forces•• Tangential durable design
Cutting conditions
Vc=100 m/min (330 sfm)
fz=0.16 mm/t (0.0062 inch/t)

55Plunging (Roughing)•• One path solution (combined tool)•• Excellent surface finish•• Efficient utilization of the insert edges

GIP… IC806•• Precise profiling•• Double - ended insert•• Excellent surface finish
Cutting conditions
Vc=90 m/min (295 sfm)
f=0.2 mm/rev (0.0078 inch/rev)

Interpolation Turning (Finishing)•• Rigid clamping method•• Adjustable design for high precision

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HTP LN… IC808•• 4 cutting edges•• Positive rake - low cutting forces

6

SVMT-SM... IC8150•• Smooth cut•• High wear resistanceCutting conditions
Vc=100 m/min (330 sfm)
fz=0.1 mm/t (0.0039 inch/t)

Spot Facing & Chamfering•• High effective solution•• One path solution

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Turbine Housing

Material: Austenitic Heat-Resistant Cast Steel1

ICP… IC908•• Exchangeable drill heads•• NO setup time•• High repeatability•• High productivity
1

Drill & Chamfering•• Indexable head drills withchamfering inserts•• Drilling and chamfering in one tool•• No setup time•• High productivity

AOMT 06...-45DT IC908•• Optimal chipformation•• 2 cutting edges•• Suitable for chamfer andboring operations
Cutting conditions
Vc=100 m/min (330 sfm)
f=0.1 mm/rev (0.0039 inch/rev)

2Reaming•• Unique quick-changebayonet mechanism•• High cutting speeds and feeds•• Low runout (maximum 3µm)•• No setup time

Cutting conditions
Vc=40 m/min (130 sfm)
f=0.6 mm/rev (0.0023 inch/rev)

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Drill & Chamfering•• Two tools in one operation•• Excellent performance

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RM-BN…LBS IC908•• Interchangeable solid carbide heads•• Quick change bayonet mechanism•• ZERO setup time•• For IT6 tolerance and up•• Coolant access to each cutting edge

SCDT… IC908•• Stepped drill for prethreading (standard)•• Reduced cycle time•• Coolant throughCutting conditions
Vc=60 m/min (197 sfm)
f=0.08 mm/rev (0.0032 inch/rev)* For SiMo, Ductile Cast ircon and other materials,
insert grades to be selected accordingly* All the tools are available for dry machining, MQL and coolant

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HTP LN… IC808•• 4 cutting edges•• Positive rake - lowcutting forces•• Tangential durable design

Cutting conditions
Vc=100 m/min (330 sfm)
fz=0.16 mm/t (0.0063 inch/t)

5

LNET… IC908•• 2 cutting edges•• Precisely ground insert

Cutting conditions
Vc=80 m/min (263 sfm)
fz=0.11 mm/t (0.0043 inch/t)
4Plunging Roughing•• Reduces cut-to-cut time•• Several operations with one tool•• Adjustment mechanism for precise face4

Circular Interpolation Finishing•• Shortest possible cycle time•• Suitable for machining in places
with limited approach•• Rigid tangential clamping method656

LNET… IC928•• 4 cutting edges•• Reduced cutting forces•• Precision grooving•• Reduced chatter

Cutting conditions
Vc=65 m/min (215 sfm)
fz=0.2 mm/t (0.0078 inch/t)

Grooving (safety cut)•• Tangentially clamped inserts•• High efficiency and economy•• Coolant through11Compressor Housing
Material: Aluminum Alloy

21•• High accuracy•• Brazed PCD tips•• Precisely ground profile•• High machining parameters
Cutting conditions
Vc=600 m/min (1970 sfm)
fz=0.08 mm/t (0.0032 inch/t)

External Form Milling•• Prolonged tool life•• Excellent surface finish•• High speed machining of aluminum alloys•• Coolant through for improved chip control

2•• Brazed PCD tips•• Precisely ground profile•• Improved wear resistanceCutting conditions
Vc=400 m/min (1300 sfm)
fz=0.12 mm/t (0.0047 inch/t)

Internal Form Boring•• High effective solution•• Excellent surface finish•• High profile repeatability•• Coolant through for improved chip control

3

XNUW…/ TCMT… ID5•• Brazed PCD tips inserts•• Increased cutting parameters
Cutting conditions
Vc=700 m/min (1970 sfm)
fz=0.2 mm/t (0.0078 inch/t)

Integral Boring•• Quick insert change•• No need for regrindings•• Extremely rigid clamping•• Coolant through

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CA-SPM… ID5•• PCD tipped cartridge•• High accuracy Ra0.4µm•• Wide range of insert types•• High machining parameters
Cutting conditions
Vc=2500 m/min (8200 sfm)
fz=0.07 mm/t (0.0028 inch/t)

6Face Miling•• Lightweight body•• Unique coolant system through a cover•• Axially adjustable cartridges
for runout ellimination•• User-friendly adjustment system•• High speed machining

445•• Brazed PCD tips•• Smooth top surface•• Precisely ground profile
Cutting conditions
Vc=1200 m/min (3900 sfm)
fz=0.08 mm/t (0.0032 inch/t)
Slot Milling•• Excellent surface finish•• Excellent part straightness•• Coolant supply to eachcutting edge356•• Excellent tool life•• High cutting speed
Cutting conditions
Vc=600 m/min (1970 sfm)
fz=0.1 mm/t (0.0039 inch/t)

External Forming••Extreme accuracy•• High surface finish•• Coolant through13

ISCAR's High Productivity Solutions
for the Automotive Industry

Indexable drilling heads
for high productivity
and extended tool life

Dovetail clamped milling insert with 8 edges, forless power consumption and smooth finish

Unique 5 cornered insert for larger parting
diameter and deeper grooving capacities

Machining Intelligently

ISCAR HIGH Q LINESNo Timefor Downtime!

Interchangeable solid carbide reaming headsystem for accuracy and high productivity

Wide range of ISOTURN small sized
inserts for increased profitability

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3320962 G 05/2016 © ISCAR LTD All rights reserved