February - 2020

Not a Small Challenge
Cutting Tools for Miniature
Dental and Medical Parts
Innovative and dynamic partsin today’s miniature dental andmedical components [pg. 4]

From CAD/CAM to
Tool Assembly

The ISO 13399 standard
specifies data representation
for cutting tools and tool
holders [pg. 30]

High IQ Tools
Optimize Metalworking
in a Digital WorldThe digitization of manufacturing– a key element of Industry 4.0[pg. 34]w w w. i s c a r. c o m

The Temperature Effectin Turning

Supplying coolant directly to the
cutting edge [pg. 38]

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DUSTRY 4.0

App Store

Play StoreTable of Contents
Not a Small Challenge 

4Tool Holding 

12Forming a Chipformer 

16Tools for Large Part Manufacturing 

22

From CAD/CAM to Tool Assembly 

30High IQ Tools Optimize Metalworking in a Digital World 34

The Temperature Effect in Turning 

38

Industrializing 4 Die and Mold Making 

42

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Not a Small Challenge
Cutting Tools for
Miniature Dental andMedical Parts
Successful development of innovative and dynamic parts in today’s
miniature dental and medical components industry presents
a formidable and equally dynamic challenge to cutting tool
manufacturers.
The fast-growing field is driven by enterprisingorthopedic surgeons and dental professionals
together with medical device manufacturers,
who work in cooperation with machine and tool
manufacturers to transform their inventions into
parts that are revolutionizing medical anddental procedures.

The materials for producing medical screws andimplants are titanium superalloys, although stainlesssteel hard materials are utilized when a special ratio
of depth of cut to chip thickness is required. Thesematerials are gummy and cause built - up edge
(BUE), which tends to wear down edge sharpness,while the high temperatures generated during chipbreaking shorten tool life and damage surface quality.
ISCAR applies unique geometries, tools, and grades
to resolve these issues and create custom tool
assemblies for the complex series of operations
involved in machining miniature medical parts, suchas dental screws and hip joint replacement implantcomponents.

ISCAR applies uniquegeometries, tools, andgrades to create custom tool
assemblies for the complex
series of operations

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Dental Screws
For rough OD (outer dimension) turning, ISCAR
developed a SWISSCUT compact tool designed for
Swiss-type automatics and CNC lathes,
which enables reduced setup time andeasy indexing without having to remove
the toolholder from the machine.
Another option features SWISSTURN
toolholders, with a clamping mechanism
to optimize insert clamping and replacement
on Swiss-type machines, and JETCUT highpressure coolant tools. SWISSCUT tools performthe turn threading.
CHATTERFREE endmills are utilized for the slot
milling stage to maximize stock removal rate,eliminate vibration and reduce cycle time. The
ground geometry provides excellent surface and tool
life, while machining at high material removal rates.
PENTACUT parting and grooving inserts performthe cut-off operations. With 5 cutting edges andvery rigid insert clamping, PENTACUT is astronger insert for higher machining parameters
particularly on soft materials, parting of tubes,
small and thin-walled parts.
SWISSCUT tools are used for face and
OD turning (screw head turning), andSOLIDDRILL solid carbide drills, with
3xD and 5xD drilling depths and righthand cut, for the drilling. The drills feature
coolant holes.
The thread milling stage uses SOLIDTHREAD
thread mills, whose short 3-tooth cutting zone with
3 flutes and released neck between the cuttingzone and the shank enable precise profiles and highperformance. The extremely short profile
exerts a low force which minimizes tool
bending, facilitating parallel and highthread precision for the entire length.
Solid carbide SOLIDMILL endmills with 2flute, 30° helix medium length, perform the key
head milling operation.

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Hip Joint Implant Parts
Femoral Head
The machining required for a femoral head involves
rough turning or rough grooving, semi-finish profile
turning, rough drilling, semi-finish milling, semi-finish
internal turning, internal grooving (undercut), cut-off,rough turning, and semi-finish turning.
ISOTURN offered in all standard geometries, thetrigon (semi-triangular) turning inserts for axial andface turning features six 80° corner cutting edges.
For profile machining, ISCAR provides intricate andprecise V-LOCK V-shaped special profile grooving
inserts for the range of 10-36 mm (.375-1.415 in).
Precision ground and utility CUT-GRIP full-radiusinserts are employed for the semi-finish turning stage.
SUMOCHAM integrates a clamping system thatenables improved productivity output rates, a shankdesigned with twisted nozzles, and a durable andstable body.
CHATTERFREE 4-flute endmills are utilized forsemi-finish milling; the endmills feature 38° helix andvariable pitch for chatter dampening with 3xD neckrelief. CHAMGROOVE internal grooving inserts areapplied for semi-finish grooving. The inserts possess
extremely small bore diameters starting at just 8 mm(.315 in) (the other diameters are 11 mm (.433 in) and
15 mm (.591 in)) and incorporate internal coolant.
Semi-finish internal turning is done by ISOTURN
inserts with SWISSTURN toolholders and thecut-off operation uses DO-GRIP twisted doublesided parting inserts, which feature double-ended
twisted geometry for no depth of cut limitation.
For rough turning, the SWISSTURN ISO standard
insert range with small shank sizes is used.
Semi-finish turning is performed by CUT-GRIP
inserts. In addition to the large variety of general-use
precision ground and utility inserts in the CUT-GRIP
family, there is a vast range of inserts for specificapplications and materials.

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Acetabular Shell
Machining of the acetabular shell component
consists of rough internal turning, finish profile
milling, shouldering, upper and bottom chamfering,
drilling, thread milling, external rough turning,and external grooving.
HELI-GRIP double-ended inserts are used for roughinternal turning, as the twisted design allows them togroove deeper than the insert length. Internal finish
milling is performed by SOLIDMILL 3-flute, 30° helix
short solid carbide ball nose endmills. SOLIDMILL
endmills with 4 flutes, 38° helix, and variable pitch forchatter dampening, perform the finish shouldering
operations, and a special-shaped endmill is utilized
for the upper and bottom chamfering that follows thedrilling stage.
SOLIDDRILL solid carbide drills with 3-20 mm(.185-.765 in) range and 3xD and 5xD drilling depths
are used for the drilling process. SOLIDDRILL tools
feature a right-hand cut with and without internal
coolant nozzles and advanced TiAlN coating for
optimum hole quality, high performance reliability andeconomical output.
Thread milling is done by SOLIDMILL solid carbide
internal threading endmills, which integrate coolant
holes for ISO thread profiles. ISO standard insertswith SWISSTURN toolholders with JETCUT highpressure coolant are used for rough turning, andexternal grooving is performed with CUT-GRIP
precision inserts.
SOLIDMILL endmills with 4 flutes, 38° helix andvariable pitch for chatter dampening with 3xD
relieved necks, and SOLIDMILL 3 flute, 30° helix
short solid carbide ball nose endmills perform thefinal milling operations.

The machining required fora femoral head involves
different operations,
including rough turningand drilling, internal grooving
and milling
SOLID CARBIDE LINE

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Femoral Stem
Machining the femoral stem involves slotting, spot
milling, drilling, chamfer milling, turning, face andprofile milling.
MULTI-MASTER endmills with indexable solid
carbide heads in the diameter range of 12.7-25 mm(.500-1.000 in) are used for slotting. Spot millingis performed by means of SOLIDMILL endmills
with 4 flutes, 38° helix and variable pitch for chatterdampening with 3xD relieved necks. The drilling
operation uses SOLIDDRILL solid carbide drills
with a range of 3-20 mm (.185-.765 in) and3xD / 5xD drilling depths.
Chamfer milling uses MULTI-MASTER endmills withindexable solid carbide heads in the diameter range
of 9.1-20 mm (.360-.750 in). ISO standard geometry
inserts with precision ground cutting edges are usedwith SWISSTURN toolholders featuring JETCUT highpressure coolant for the turning stage.
SOLIDMILL 3 flute, 30° helix short solid carbide
ball nose endmills with a 3-25 mm (.125-.625 in)diameter range are employed for profile milling, andSOLIDMILL endmills with 4 flutes, 38° helix andvariable pitch for chatter dampening with 3xD relieved
necks with a 1-8 mm (.125-.312 in) diameter range
are utilized for face milling.

INDEXABLE SOLID CARBIDE LINE

Bone Plate
For rough milling, the FINISHRED endmill geometries
allow the tool to perform roughing and finishing at
the same time. MULTI-MASTER interchangeable
solid carbide tapered heads are applied to the finish
milling operation, whereby the curved surfaces canbe machined by tilting the tool and applying a large
corner radius at small cutting depths. Shouldering isdone with CHATTERFREE endmills, which enablehigh material removal rates, eliminate vibration, andreduce cycle time.
The final milling stage engages MULTI-MASTER
4 flute, 30° helix short solid carbide ball nose endmillsin the 5-25 mm (.190-1.000 in) range. SOLIDDRILL
solid carbide drills, with no coolant holes and 4xD
drilling depth, ensure stable and accurate drilling. Millthreading is achieved with SOLIDTHREAD 55° or 60°
profile solid carbide taper thread mills.

Carbide Grades
Carbide grades specifically designed for machining
applications on stainless steel and super alloys suchas IC900, IC907, IC806, IC908, IC328, and IC928
are ideal for milling and turning titanium and nickel
based alloys, such as Nitinol, commonly found in
medical components.
It is no small challenge to manufacture miniatureparts for dental and medical devices but ISCAR
has succeeded in developing highly effective cutting
tools for this field that adhere to the stringent
standards of quality and precision essential for
medical industry applications.

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Tool Holding
New Demands
New Solutions

Toolholders act as an interface between cutting tool andmachine, and they should ensure proper clamping of the cutting
tool and also be suitable for mounting in the fitted spindle or toolchanger magazine of a machine tool. The metalworking industry
has compulsory standards to strictly specify the matchingsurfaces for both these purposes. These standards define a wide
range of existing tooling systems to meet different manufacturer
requirements: simple holders for manual tool changing forconventional machines with hand control, precise high - grade balanced adaptors for high-speed machining centers, etc.
Tooling today is evolving along with metalworking
industry developments in the world of Industry 4.0 and
its impact on state-of the-art manufacturing and newtechnological horizons.
Implementation of new technologies in high speed
machining has necessitated a new level of toolbalancing to ensure performance and reliability in asignificantly expanded range of rotational speeds, withthe objective of improving strength, rigidity, accuracy
and other technical parameters of the traditionallydesigned toolholders. High - efficiency milling of difficult- to - cut aerospace materials, like titanium alloys, has
increased the need for durable toolholders working in
hard conditions.

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High-efficiency milling ofdifficult-to-cut aerospacematerials, like titanium alloys,
has increased the need fordurable toolholders working
in hard conditions

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Clamping and Cooling
ISCAR’s range of arbors, holders, adaptors, blocks,
thermal and power chucks are designed for effective
tool clamping. For example, SHRINKIN thermal shrink
chucks with HSK 100 shanks features G2.5 balance
quality and a residual unbalance of less than 1.0 g·mm(.00139 oz·in) at 20000 rpm, MAXIN 32 power chucks
ensure clamping torque up to 1760 N·m (1300 lbf·ft),
and FINEFIT radial and angular alignment tool holders
for high speed reamers maintain radial and axial runout
adjustment to 0.001 mm (.00004 in).
Cooling is critical in operations such as machining
titanium or exotic high temperature superalloys (HTSA),
which are common for the aerospace industry.

A series of new tooling families ensures an effective
pinpointed coolant supply, including X-STREAMSHRINKIN, a family of thermal shrink chucks with
coolant jet channels along the shank bore.
The patented design combines the advantagesof high-precision heat shrink clamping with
coolant flow directed to the cutting edges.
X-STREAM SHRINKIN has already shown excellent
performance in milling aerospace parts such astitanium blades and blisks (bladed discs), particularly
in high speed milling. In machining deep cavities,
the efficient cooling provided by the new chucks
substantially improves chip evacuation anddiminishes chip recutting.

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Turning
ISCAR has developed a new concept for highpressure coolant supply for VDI DIN 69880 quickchange adaptation systems, intended for turning
machine tools. The JETCUT concept is based onbottom-fed high pressure coolant channels andprovides coolant supply internally through the tool andexternally through the flange.
A wet coolant can act as an excellent tool in a radicallydifferent field: increasing the rotational speed of atool. ISCAR’s SPINJET family of coolant-driven highspeed compact spindles for small diameter tools helps
upgrade existing machines to high speed performers.
The SPINJET spindles are recommended for tools
up to 7 mm (.275 in) in diameter; however the optimal
diameter range is 0.5-4 mm (.020-.157 in). Depending
on pressure and coolant flow rate, the spindles
maintain a rotational speed of up to 55000 rpm.

Reaming
In reaming, floating chucks are used in high-precision
hole making to correct any misalignment between thecentral axes of a reamer and a hole. Precise alignmentis essential for optimal performance and holeaccuracy. To this end, ISCAR added a new design of
GFIS floating chucks for high speed reamers to the
ER COLLET chuck family.

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Forming a
The rake face determines the cutting geometry of a tool and its
formation represents a key element of insert design.
Over the years, technological constraints have largely
dictated the shape of the rake face. Breaking a longchip when turning by tools carrying these inserts often
required using additional cover parts mounted in thetools above the inserts. Another common solution
for flat-face turning inserts was to produce a chipbreaking dimple by grinding. The dimple facilitatedcurling the chip in a spiral and then its breaking into
smaller segments.
The chip breaking cover part obstructed chip flow, while
the chips caused intensive abrasion of the part andsignificantly reduced its tool life.
The technology of sintered carbide products facilitatedthe shaping of insert rake faces in various forms andbroke the dependence of a chip breaking surface
on the dimple or the cover part. The rake face took
on an appearance that combined concave andconvex portions, local protrusions, etc. This complex
geometry was designed to provide the necessary chip
formation and effective chip control.

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CAD Impact
CAD provides tool designers with a powerful tool forcomplicated 3-D modelling, engineering calculations
and analyzing possible limitations of a designed insert
and, of course, its rake face.
The combination of state-of-the-art sintered producttechnology, CAD systems and CNC machines
marked a quantum leap in the cutting tool industry,enabling production of a wide variety of inserts withgeometrically complex faces as well as a shorter
design process.

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Design for Milling
In the case of milling inserts, the rake face shapeis considered mainly from the point of view of chip
forming only - milling is a process of interrupted cutting
and therefore chip breaking creates no difficulties.
The rake face of the turning insert is also intended
mainly for chip formation, though it should enable chipbreaking. In the context of geometry, the rake face ofevery indexable insert is a combination of concave andconvex areas.
Effect of 3D Modelling
Three-dimensional chip formation modelling represents
a new powerful design tool for the cutting tool industry.
Further development, based on the finite element
method (FEM), raised cutting action modelling systems
to a whole new level.
Today, cutting tool designers utilize advanced software
to simulate chip formation processes with a sufficientapproximation to reality.

Even though the softwarestill cannot replace machining
tests, it can contribute greatly
to the effective design of theindexable inserts and, mostof all, their rake faces

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Matching Geometry to Operation
ISCAR has implemented modelling
practices that allow R&D
engineers to determine whichinsert geometry is appropriate
for which operation, even at thedesign stage. When designing
the CNMG 120404-F3P turning
insert, for example, it was foundthat simulating cutting action was
useful for shaping the insert’s
top surface.

Drilling hard-to-cut austenitic and duplex
stainless steel presents difficulties,
especially if the depth of a hole issubstantial. To improve performance inthese types of drilling operations, ISCAR
developed ICG exchangeable carbide
heads with chip splitting geometry. The
head diameter range is 14-25.9 mm(0.551-1.02 in) and the heads aremounted in standard SUMOCHAM drill
bodies to provide high-quality holes withdepth up to 12×D.

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NANMILL Milling Cutters
ISCAR recently introduced a series of indexable millsin the small-diameter range (up to 20 mm or 0.75 in).
Although this range is traditionally considered as moresuitable for solid carbide tools, the new indexable mills
represent an attractive and cost-beneficial alternative.
The NANMILL family of indexable milling cutters within
the diameter range of 8-16 mm (0.315-0.625 in)integrates a new design concept, with a clamping
screw located above the insert and a screw head thatfunctions as a wedge.

NANMILL

NANO ENDMILL

Further progress in modelling cutting action should bring
tool designers closer to achieving optimal chip forming
geometries and improve the quality of the designed tool.

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Tools For
Large Part
Manufacturing
In principle, machining large parts involves the same cutting
action and chip formation process as for small or mid-sizeparts. However, large dimensions demand a specific approachto machining, and manufacturers need to plan technologicalprocesses and choose more effective cutting tools in order toproduce heavy parts that take up a great deal of space.
Machining large parts involves removing a lot ofmaterial that may cause significant deformations due
to unrelieved stresses. Another factor, which leads todimensional problems, is thermal expansion caused byheat generation during cutting.
Single setup machining represents an absolute ideal
for machining a large part, and producers from fields
such as power generation, aerospace, railway, dieand mold making, and heavy industry make every
effort to approach this ideal.

Large part manufacturers expect the same fromcutting tools as any other producer using metal cutting
technologies: excellent performance, good tool life, andhigh reliability. The latter two are especially essential
because the large sizes lead to increased machining
time, but replacing a worn tool in the middle of a passand unpredictable breakage of the tool during cutting
are totally unacceptable.

The key for overcoming thedifficulties lies in technology,
based on effective processplanning and utilizing themost suitable machine tools

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Heavy-Duty Facing
It is hard to machine a large part without face milling
operations. Rough and fine machining of free andbounded planes and preparing datum surfaces
require various indexable face mills. ISCAR’s
standard face mills possess nominal diameters up
to 315 mm (12 in), while special tailor-made tools
might feature higher values. Significant removal ofmachining stock by milling is primarily an issue forthe production of large parts from steel and cast ironand, slightly less, from titanium and aluminum.

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ISCAR’s line of standard face mills includes many
tool families for large part manufacturing. HELITANG
T465 features cutters with a 65° cutting edge angle
and carrying tangentially clamped inserts. The robust
design enables productive machining with a depth of
cut up to 19 mm (.750 in). The HELIDO 890 family
features 89° face mills with lay-down square double sided inserts which provide 8 indexable cutting edges
for depth of cut up to 9 mm (.354 in), offering
an important economic advantage.

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Extended Flutes
ISCAR’s line of indexable extended flute cutters varies
in design configuration, integrating a shank- andarbor-type mounting method and a radial or tangential
insert clamping principle. Intensive material removal
requires the appropriate volume of a tool chip gullet toensure effective chip evacuation. The situation can bedramatically improved by applying ISCAR’s extended
flute cutters carrying inserts with chip splitting geometry
to divide a wide chip into small segments. As a result,cutting forces are reduced, vibrations are stabilized,
and thermal problems are eased.
Although 90° tools are the most commonly used
cutters, machining large parts also requires roughmilling of inclined and 3D surfaces, for which ISCAR
provides a family of tapered extended flute cutterswith 22.5°-75°cutting edge angles. The DROPMILL
3 extended flute ball nose mills were designed
specifically for such applications.

XQUAD

EXTENDED FLUTE

Producing large-size aerospace components fromhard-to-machine titanium alloys is an extremely metalintensive process with a significant buy-to-fly ratio.
The eventual weight of a part may be only 10%,or even less, of the original weight of a workpiece.
The XQUAD extended flute cutter family, one of
ISCAR’s newest products, is intended for highefficiency milling of deep cavities and wide edgesin titanium parts. The tools have already proved
themselves: for example, component producers haveachieved a 700-1000 cm³/min (43-61 in³/min) metal
removal rate (MRR) by using an 80 mm (3 in) diameter
XQUAD cutter.

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Productive MillingHigh feed mills machine at shallow depths of cut butwith a feed per tooth that is far higher than the usual
rates - millimeters as opposed to tenths of millimeters.
Fast feed mills are applied mainly to rough machiningof plane faces, cavities and 3D surfaces.
ISCAR has a wide choice of fast feed mill families,
intended for cutting various materials in different
applications. The “world” of ISCAR’s high feed
milling cutters encompasses tool families in diameter
ranges of up to 160 mm (6.3 in) that can meet therequirements of the most demanding customer.
Large part manufacturers often have heavy, powerful
but slow machines that are not suitable for high feed
face milling. For these customers, ISCAR developed
moderate feed cutters. Compared with fast feedmills, moderate feed cutters feature a higher cuttingedge angle; they move slower but machine at higher
depths and need more power to make them suitable
for applying to heavy machines.
The welded part structure and the process of
repairing worn parts by spraying fillers or soldering,
add materials that are not easy-to-machine either.
Originally applied in die and mold making, highspeed milling was developed as a productive methodof milling hard steel that led to decreasing a part
relocation, lessening setup, minimizing manual finish
and polish, and, as a result, reducing cycle time.
The most suitable high speed milling tool is a solid
carbide endmill and ISCAR’s MULTI-MASTER familyof assembled endmills, which carry cemented carbide
exchangeable heads, also represents a viable option.
ISCAR’s line of solid carbide endmills offers multi-flute
tools in diameters of up to 20 mm (.750 in) for highspeed milling materials with hardness up to HRC 70.

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HIGH FEED28

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Exchangeable Heads
ISCAR’s families of rotating assembled tools withexchangeable heads - MULTI-MASTER mills and
SUMOCHAM drills - enable substantial decreases in
downtime, a critical parameter particularly for small
volume and individual manufacturing.
Face contact between a head and a tool bodyensures that the head overhang is within strict
tolerance limits, resulting in high dimensional
repeatability of the assembly.
Turn Milling
Turn milling is a good option for machining heavyrotary parts. In turning, the cutting speed is a functionof rotating velocity. If the main drive of a machine
tool does not allow rotation of large masses with therequired velocity, due to limitations of its working
characteristics, then the cutting speed is far from theoptimal range and turning performance will be low.
When turning large eccentric parts like crankshafts,
off-center masses of the parts cause unbalanced
forces that adversely affect performance. Turn millingfeatures low rotary velocity of a part, which prevents
this negative effect.
The majority of ISCAR’s indexable face milling cutters
are suitable for turn milling. The success of theirapplication depends on cutter positioning with respect
to the machined part, choosing optimal geometry of
inserts, and cutting data calculation.

Most of ISCAR’s indexable
face milling cutters canbe used for turn milling,depending on the cutter
position in relation to themachined part, optimal
insert geometry, and cutting
data calculations

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From CAD/CAM
to Tool Assembly
Digitizing of manufacturing industries is one of the distinct
technological breakthroughs stimulated by the “fourth industrial
revolution” - the implementation of INDUSTRY 4.0 standards.

The ISO13399 standard specifies data representation
for cutting tools and tool holders, in a manner that will
ensure platform independence universally.
The main target is to create a computer representationof the tools and the holders that is unified andunderstandable for various elements of metalworking
technology, whether they are real or virtual, including
computer aided design and manufacturing(CAD/CAM) systems.
Immediate and simple access to digitized tool data
has become of strategic importance in the service

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provided by a tool producer. From process planningtechnologists, tool design engineers and CNC
programmers to application specialists and sales
managers - all might spend hours adopting tool
manufacturers tool data to the customer's software.
Data transfer is conducted via a STEP file with .p21
extension, which stores text code related to theparametric values of the product. In addition,
the .p21 file provides the name of the 3D file ofa specific product. ISO13399 stipulates the .p21
file which can be transferred between computer
platforms for CAD and CAM users.

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E-CAT Competencies
Recognizing the value of providing accessible andaccurate tool data for pre-machining on the shop
floors, ISCAR incorporated tool assembly options into
the electronic catalog. This option enables users tobuild a tool assembly from various ISCAR products
represented in E-CAT and then easily integrate thetool assembly data into their CAD/CAM system,
which allows users to continue the analysis ofapplying the assembly to specific operations
with the use of simulation software functions.

OnlineAssembly Options

ISO 13399
Standard

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E-CAT integrates an advanced filtering system toenable the selection of the most suitable tools for theplanned operation, based on machining parameters.
The tool assembly includes the tool, exchangeable
inserts or cutting heads, a toolholder and, if
necessary, a reducer or an extension - all of which
will optimally meet assembly specifications.
A digital twin representation of the tool assemblyis generated based on the ISO13399 standard,
which is a guarantee of successful communication
between current and future software support ina digitized smart factory.

P21 file

ISCAR E-Catalog

The assembly ensures fast and reliable simulation of
the operation as well as collision (interference) checking,tool path optimization, and the design of workholding
fixtures. As the selected machining method results inthe value of forces acting on workpieces and a tool
configuration influences the shape of workholding
elements, simulating the operation with the use of thetool assembly model represents an effective instrument
for workholder design.
The analysis is performed in a virtual manufacturing
environment and not on the shop floor, which
minimizes and even prevents possible errors during
real cutting. The assemblies created are accessiblefor downloading in both 3D and 2D formats tofacilitate the preparation of drawings, drafts and otherengineering documents.
The tool assembly model is platform-independentand is intended to be integrated into the user’s own
CAM software, to prevent errors on the shop floor
during machining.
The ability to plan and examine single- and multiple
tool assemblies in the early stages of manufacturing is
an extremely valuable source of time and cost saving.
The tool assembly options offer an appropriate
and effective answer to the needs of modern
metalworking, and more E-CAT tool assembly
applications are near at hand to assist metalworking
manufacturers in the evolving world of INDUSTRY 4.0.

E-CAT integrates an advanced
filtering system to enable
the selection of the mostsuitable tools for theplanned operation, based onmachining parameters

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High IQ Tools

Optimize Metalworking
in a Digital World
INDUSTRY 4.0 is redefining production methods and themetalworking industry is taking note.

New demands have affected and influenced
almost every related technology: from planning andcommunication networks to machinery and cutting
tools - arguably the most conservative element in a
manufacturing system.
Digitization in the cutting tool field has two emerging
trends. The first trend is to enable the cutting tool tocommunicate with advanced machinery and cyber
physical production systems in order to advise about
tool wear, predictable tool life, total time of the tool
involved in cutting etc.
The second trend relates to information about the toolthat should be provided by a cutting tool manufacturer.

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A good illustration is the ISO13399 standard, which
specifies computer representation and data exchange
for information about the cutting tools and theirholders - a first step for making the tool digital data
platform-independent. Only tools digitally specified inaccordance to this standard will be utilized by smart
factories, making comprehensive digitized data sources
an important direction for cutting tool manufacturers;
this integration of data will form an inseparable partof a cutting tool.
ISCAR recognizes the central importance of developing
and adopting digitized solutions for metalworking
operations.

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MATRIX, an automated tool dispenser that is an integral
shop-floor-level element of a smart factory, tool assembly
options in 3D and 2D formats in E-CAT, ISCAR’selectronic catalog – these are a few examples of products
intended to unify the material and virtual worlds of smart
manufacturing.

Virtual Assembly
In addition to the existing milling tool assembly
option, E-CAT has enriched its instrumentsfor virtual manufacturing by introducing a newassembly option that relates to drills and taps.
This new function allows creating the twin
representation of a drilling or tapping tool assembly
based on the ISO13399 standard. The assemblies
are accessible in both 3D and 2D files, which
can be downloaded from E-CAT on the ISCAR
website and incorporated directly to a user's CAM
system. As a result, various simulations of cutting
operations, collision checking, finding an optimal
tool configuration etc. can be performed.

Smart Scan
Data on ISCAR's tool dimensions, inserts,
appropriate tool holders and recommended cutting
data is accessible via the ISCAR 4.0 Pro mobile
application, developed for maximizing toolingutilization. ISCAR 4.0 Pro is a smart 2D
M barcode scanner that acts as a digital gateway toadvanced tooling resources of the company, so that
customers can make better decisions regarding tool
selection and their realization on the shop floor. The
information corresponds to the ISO13399 standard
and to the tool assembly, cutting conditions, tool
material grades, weight, user manuals, and otheritems. The data is accessible by scanning the 2D
Data M barcode, which appears on ISCAR tools
and product packages.

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A World of Information
ISCAR recently launched ISCAR WORLD, an
expanded application that embraces all ISCAR's
online apps, interfaces, and product catalogs
in a single space. The app gives instant accessto E-CAT, ISCAR 4.0 Pro, E-Commerce (anonline tool ordering system), a media channel,
ISCAR Tool Advisor – an expert system for tool
selecting, technical data, machining calculations,frequently asked questions and more, enablingusers to review, compare, check, and select thetooling solutions that are right for their needs.
The application constantly updates and expands
its store of knowledge by collecting new data,
opening a virtual doorway to a whole world of
updated information.
Smart manufacturing in the INDUSTRY 4.0 era
features a combination of real and virtual worlds,
based on network technologies, for every linkof the manufacturing chain including cutting
tools. Advanced manufacturing systems require
cutting tools to “possess” a rich world of relevant
data – a high IQ - as a necessary condition
for incorporating the tool into their intelligent
machining processes.

App Store

Play Store

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The Temperature
Effect in Turning
In the last few years, the concept and implementation of coolingsolutions for cutting tools has enjoyed a surge of popularityand enthusiasm as if it had never existed before. CNC machine
manufacturers throughout the world have invested time andresources to develop solutions that can supply coolant at highpressures and today all new machines are supplied with ahigh-pressure coolant option.
Manufacturers from industries such as aerospace,automotive, and large part production appreciate theimmense advantage of supplying coolant directly to the
cutting edge and are only ordering machines for milling
centers or turning centers with high pressure coolant
capabilities - minimum 70 bar and up to 300 bar. Mass
production manufacturers are also benefiting from theintegration of ISCAR’s JETCUT tools into their processes.
One of the most serious enemies of carbide inserts is
the high temperature of the materials that results fromthe machining process. The average temperature duringmachining can range from 300°C to 900°C.
As the temperature rises, the lifespan of the inserts isshortened. Increased wear can damage workpiece
quality and negatively affect machining properties:
the heat generated between the insert and theworkpiece can cause a change in chip shape andplastic deformation of the insert. High pressure
starting at 70 bar can be effective in breaking
chips and, in cases when it is difficult to breakchips and the chip formed is long and curled,
coolant applied correctly and under highpressure can solve this problem.

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Cooling has a major influence on machining exotic
materials such as Inconel, titanium, Hastelloy, Moneland other alloys, which are all used in the aerospaceindustry. These workpiece materials are difficult tomachine as they have a very high nickel level andpossess a tendency to stick to cutter edges due to theirelastic, sticky and ductile properties - which is one of
the reasons that parts for the aerospace industry are
extremely expensive. Machining these types of materials
without coolant is almost impossible, as the hightemperatures and stickiness cause instantaneous
wear and premature failure for carbide inserts.

Machining these types ofmaterials without coolant isalmost impossible, as the hightemperatures and stickinesscause instantaneous wear
and premature failure for
carbide inserts

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In addition to reducing temperatures for exotic metals,
the use of coolant creates a shielded area between
the insert and the workpiece material, so preventing
material from sticking to the cutting edge – which is amajor factor in premature failure for inserts.
In groove turn operations, it is particularly important toselect the right grade for chip breaking. An incorrect
choice of grade or chip breaker can spell disaster forthe manufacturer.
ISCAR developed and integrated external and internal
tools to deliver coolant directly to the cutting edge,
including the JETCUT range. This has succeeded inincreasing dramatically tool lifespan and productivity,
even at low pressures such as 10 or 20 bar.

HIGH FEED40

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Manufacturers who work with problematic exotic
materials such as Inconel, titanium and stainless steels
have also managed to achieve higher productivity byincorporating JETCUT tools.
To answer to the growing demands of the manyindustry sectors, ISCAR expanded its jet high pressureline by adding turning tools fitted with the JET-R-TURN
hollow rigid clamp, which also acts as a coolant nozzle.
Until now, ISCAR’s ISOTURN range of tools featuring
a jet high pressure cooling option were designed with alever clamping mechanism, as an upper clamp would
obstruct the coolant jet from reaching the cutting edge.
The new design enables jet high pressure coolant toreach the cutting edge without any obstacles.
ISCAR offers tools with JET-R-TURN rigid clamp
mechanism for the most popular standard CNMG,
WNMG and DNMG insert geometries.

GRIP HOLDER

Features
Strong and reliable clamping mechanism
prolongs tool life
Coolant jet directed to the cutting edge
Excellent corner location repeatability
Excellent performance in heavy cut machining

The new external tools feature three coolant
connection options
Rear threaded inlet
Bottom threaded inlet
Bottom inlet for adjustable shank overhang,
as in ISCAR’s JHP-MC tools

What is a second in our life?
Every second can be multiplied and translated tomillions of seconds when considering mass productionof standard parts. Saving a single second multiplied bya million parts is equivalent to a whole working month,which represents a major saving and is the dream ofevery mass production manufacturer.
ISCAR today provides a wide range of JETCUT
tools for a variety of applications, from turning andgrooving to parting.

ISCAR

41

Industrializing 4

Die and Mold
Tool Material Grades, Methods,
and Digital Options for Production EffectivenessThe die and mold industrial branch not only consumes more andmore tools but constantly puts forward new demands, which havea significant impact on advances in cutting tools. These demands
are typical for every metalworking sector.
Specific features of die and mold manufacturing
necessitate special design considerations beyond
the general requirements.
Materials, machined shapes, and machining
strategies are three distinctive hallmarks of die andmold making, and have a substantial influenceon cutting tool demands. Only a holistic tool
development concept basedon these features, combined withintegration of INDUSTRY 4.0
inspired developments,
will lead to successful
solutions for the die andmold sector.

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Challenging Materials
The main material for the die and mold industry is steel
that is often hard to machine. Workpiece hardness
is a principal factor in influencing tool material andcutting geometry. Further machining of these surfaces
requires a cutting tool to remove a material stock
combining very hard and relatively soft layers. Thiscondition significantly reduces tool life and requires tool
manufacturers to make extra efforts to compensate
and ensure the necessary durability.

Intricate shapes
A three-dimensional (3D) profile is typical for theworking surfaces of a mold (die) set, and the ability
to machine 3D surfaces effectively is an important
requirement for cutting tools. A tool is expected toprovide the required parameters for shape accuracy
and surface finish, and to ensure the appropriate levelof tool life needed to complete machining the shape or
its pattern in one operation.

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43

Machining
Manufacturing molds and dies requires various
machining processes: turning, milling, drilling, reaming
and others, although cutting tools for die and moldmaking are associated primarily with mills. The specificcharacter of the die and mold industry - predominanceof non-rotating parts, the complex shape of machined
surfaces, the necessity to produce a lot of cavities
that require considerable material stock removal, etc.
- positions milling cutters in the first place among tools
utilized by this branch.
In their constant need to boost productivity in
manufacturing molds and dies for new products,
the die and mold industry was one of the first adoptersof advanced machining methods such as high speed
milling (HSM) and high feed milling (HFM), and todevelop efficient machining strategies.
Tool Material Grades
In die and mold making, indexable extended flute(also referenced as long-edge) milling cutters areoften applied to rough machining cavities and wide
edges. The cutters work in high-load conditions, andthe material of the indexable insert is a key factor for
improving tool life. To achieve this objective, ISCAR
recently introduced IC845, a cemented carbide
grade, that features a new tough substrate and a newnanolayer PVD coating with applied SUMO TEC postcoating treatment technology.
The grade was designed especially for cutting at
significant impact load. ISCAR’s solid carbide endmillline has been enhanced by adding the IC702 carbide
grade, which is intended for efficient machining ofhard materials (up to HRC 65).

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Advanced Profiling
In machining complex surfaces, the real workhorses
are milling cutters of toroidal - (button) and ball nose shapes. ISCAR offers die and mold makers
an extensive line of these cutters in the following
designs: tools with indexable inserts, endmills withexchangeable cutting heads, and solid carbide
endmills. They differ in nominal sizes, accuracy,
mounting method (shank - or arbor - type) andapplication range, according to whether the
workpiece hardness is low, moderate or hard.

A TOR6MILL cutter can carry inserts in four different
geometries. Mounting the appropriate insert in the
cutter transforms it to a toroidal, 90°, 45° or high feed
milling tool. The cutter can be applied to machining 3D
surfaces, square shoulders, plane faces, chamfers, oruse as a productive high feed rougher.
Innovative Technologies
High feed milling and high speed milling proved to be
powerful methods for dramatically increasing machining
productivity while reducing manual operations,consequently shortening production time significantly.

3
6

TR45

TR90

TRFF

TR6

4

5
1

2

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45

2

3

High Feed Milling
ISCAR’s standard high feed milling line comprises morethan 10 tool families that differ in their design principle(indexable, solid, with replaceable heads), nominal
diameter, cutting geometry, mounting method andapplicability (machining faces, pockets, deep cavities).
NAN3FEED and MICRO3FEED, two of the latest
ISCAR families of indexable high feed milling tools,
feature an 8-16 mm (.315-.625 in) diameter range.
Even though solid carbide endmills traditionallydominate this range, ISCAR’s specialists believe thatthe advantages of the indexable-insert concept forrough machining will position the families as serious
cost-effective alternatives to the solid carbide designs.

4

1

The LOGIQ4FEED family of fast feed cutters features“bone-shape” double-sided inserts. This unusual insert
profile provides four cutting edges, with an exceptional
ramp-down capability that defines the main applicationof the family: high-efficiency rough milling of cavities,
particularly deep cavities. The cutters are suitable formachining workpieces with hardness up to HRC 50.

FAST FEED MILLING

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High Speed Milling
Expanding the range of products intended for highspeed milling, ISCAR introduced multi-flute solid carbide
endmills in 2-20 mm (.250-.750 in) diameters for highspeed finish and semi-finish milling. The endmills areproduced from the ultra-fine IC902 carbide grade,which was developed to machine hard materials, andhave a cutting-length-to-diameter ratio of up to 6. They
are operated at rotational speeds up to 20000 rpm.
MULTI-MASTER Options
ISCAR’s MULTI-MASTER family of assembled tools
with exchangeable cutting heads is a good choice fordie and mold making. The MULTI-MASTER head is
suitable for mounting on different tool bodies (shanks),
and the shank can carry different heads. The heads arevaried in shape, cutting geometry and sizes and aredesigned for machining 3D surfaces and shoulders,faces and slots, chamfers and holes. The cylindricaland taper-neck shanks feature different dimensions fora broad-ranging overhang; their design options ensure
clamping in toolholders, collet chucks or in a machine
tool spindle directly.

The MULTI-MASTER, with its rich variety of heads,
shanks, reducers and extensions, enables thousandsof possible tool configurations. The MULTI-MASTER
tools wholly meet the requirements of the important“no setup time” principle, as replacing a worn head
does not require additional setup operations.
The head can be changed without removing a tool froma machine, which significantly decreases downtime.
Advances in industrial branches such as the automotive
industry have had a major impact on die and moldneeds, leading to new levels in cutting tool demands
that should be heeded by tool manufacturers.

INDEXABLE SOLID CARBIDE LINENo Setup
Time

ISCAR

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ISCAR's Electronic Catalog
Features INDUSTRY 4.0
Milling Tool Assemblies Online
www.iscar.com

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