ISCAR’S MACHINING SOLUTIONS FOR
Heat Exchangers

LOGI

THREE FLUTE

3CHAM
CHAMDRILLHEAT EXCHANGERS

www. i s c a r. c o m

2Table of Contents
Machining Solutions

4

Tube Sheet Preparation

6

Milling...........................................................................................................................................................6
Turning......................................................................................................................................................... 7

Machining Tube Sheet and Baffles

8

Drilling..........................................................................................................................................................8Three Flute Exchangeable Head Drills

12

Deep Drilling

14

Machining Tube Sheets

16

Grooving......................................................................................................................................................16
Reaming......................................................................................................................................................17
Drilling.........................................................................................................................................................18

Profitability Test Report

20

Drilling Tool Wear

22

3

Heat Exchangers

Machining Solutions

A heat exchanger is a system used to transfer heat
between two or more fluids. Heat exchangers areused in both cooling and heating processes. The fluids
may be separated by a solid wall to prevent mixing,or they may be in direct contact. Both gasses andfluids can be transferred through heat exchangers.
There are three main types of heat exchangers;
shell & tube, plate & frame, and air-cooled.
Heat exchangers are critical in modern industries such

FlangeCoverø4-32.9 mm(.157-1.299")
1.5xD, 3xD, 5xD,
8xD, 10xD, 12xD

FlangeShell

Stacked Baffle
Platesø12-60 mm(.472-2.362")
2xD, 3xD, 4xD, 5xD

as automotive, aerospace, and power. Many engineeringresources are required to create optimal heat exchanging
solutions for industrial demands. Advanced designs of heatexchangers are examined by using finite element methods.
ISCAR has developed a range of full solutions forthe production of heat exchangers for drilling,turning, milling, and grooving operations.

Tube
Sheetsø12-32.0 mm(.472-1.102")
10xD, 15xD, 25xD

Heat
Exchangerø12-25.9 mm(.472-1.019")
1.5xD, 3xD, 5xD, 8xD

ø57-80 mm(2.24-3.15")
2.5xD

LOGI

THREE FLUTE

4

ISCAR

3CHAM
CHAMDRILL

Flanges

Shell and CoverTube Sheetø25-83 mm(.984-3.2678")
10-100xD

Baffles

ø33-40 mm(1.299-1.575")
1.5xD, 3xD, 5xD, 8xD

ø8-300 mm(.315-11.8")
10-100xD

ø26-50 mm(.984-2.165")
5xD

5Heat Exchangers

Tube Sheet Preparation
Milling

Family of face mills carrying double
sided inserts with 8 cutting edges, withpositive inclination for a soft and light cut,and high surface during machining.

6

FFQ4 SOMT 0904

H1200 HXCU 0606

IQ845

ONMU/ONHU 07...

Square singlesided Inserts with
4 cutting edges forfast feed milling

Double-sided hexagonal
inserts with 12
cutting edges

Square milling inserts
for general use

Octagonal insertswith 16 helical righthand cutting edges for
economical face milling

ISCAR

Heat Exchangers

Tube Sheet Preparation
Turning

Heavy duty turning applications feature relatively
large depths of cut, high feeds, and rough,non-uniform surfaces to be machined. These
applications require both tough carbide grades
and specifically designed chipformers.

DOVE-IQ

CNMG-R3M

RCMX

LOMX

Double-sided insertswith R3P double-sided
7° negative side flank
80° rhombic inserts forheavy turning of steel

Double-sided 80°
rhombic inserts, first
choice for roughmachining of stainlessand low carbon steel

Round 7° inserts witha positive flank andstrong cutting edge
for rough turning

For heavy super turn
tangential inserts with
4 cutting edges for highmetal removal of up to
35 mm D.O.C. on steel

7

Heat Exchangers

Machining Tube Sheet and Baffles
Drilling

SUMOCHAM is the Ultimate Solution for
Drilling Tube Sheets and Baffles• Submicron carbide grade IC908• TiAlN PVD coating• Available in the diameter range of
4-32.9 mm (.157-1.299”), depending on geometry• Unique ground flute for smooth chip flow
• Unique ground gash for improved penetration• Unique honed cutting edge for improved
performance and increased tool life
• Positive flute rake angle for excellent chip formation• High penetration rates• Double-margin inserts for high quality holes

HCP

QCP

ICM

ICP

ICG

Concave cuttingedges which
substantiallyenhance the selfcentering capabilityof the drill

Enhanced centering
capabilities,
improved surface
finish and overall
quality of themachined hole

Improved
productivity output
rates. Use on
stainless and hightemperature alloys.
Negative land on
the cutting edge

Designed formachining the
ISO P materials
group, with anultimate shape forhigh productivity
and outstanding
chip forming
on soft steel

Serrated drillinghead enables
splitting thechips to small
segment forfluent evacuation.
An excellent
solution fordrilling titanium,
stainless steel,
Ti-based alloys

Drill Body Features• Robust high quality pocket for prolonged tool life
• Frontal coolant near to the cuttingedge for increased tool life
• Twisted coolant nozzles through the drill body and not
through the center core for optimized flute volume• Highest grade of tool steel that features superior
body hardness for excellent wear resistance

Twisted Coolant
Nozzles8

ISCAR

For Every Typeof Material

Innovative
Ergonomic Key• Polished flutes and drill bodyfor improved chip evacuation• Available with cylindrical shankand flat shank• Helical margin on body preventschip adhesion• Unique flute geometry• High helix flute angle

Cost Effective
Insert

1.5xD

3xD

5xD

8xD

10xD

12xD
and upOption 1
With a pre-hole
Drilling procedures for tube sheet
and stacked baffle plates (L/D ≥ 5)

Step 1• Drilling a pre-hole• Holder: SUMOCHAM- 1.5xD or 3xD• Insert: ICP/ICM/ICG/FCP• Pre-hole depth: 1xD• In case of clad tube sheet, the prehole should penetrate into thesecond material by 1 mm (.04”)

Step 2• Penetrating the guide hole
• Holder: SUMOCHAM- 8xD,
10xD, 12xD and up• Insert: ICP/ICM/ICG/FCP• Low speed rotation and cutting feed should
be applied while penetrating the guide hole
• Stop axial movement 2 mm (.08”)
above guide hole bottom

Step 3• Drilling through hole
• Holder: SUMOCHAM- 8xD,
10xD, 12xD and up• Insert: ICP/ICM/ICG/FCP• The drill should break through the tube
sheet by 2 mm (.08”) before retracting

Option 2
Without a pre-hole• Drilling procedures for tube sheet
and stacked baffle plates (L/D ≥ 5)
• Drilling through hole
• Holder: SUMOCHAM5xD, 8xD, 10xD, 12xD and up• Insert: HCP / QCP• The drill should break through the tube
sheet by 2 mm (.08”) before retracting

9

PL

LF

QCP-2M

Double Margin Drilling Heads for
DCN Drills for Machining Steelwith High Surface Finish Results

SIG

DC

METRIC
Dimensions
PL

SIG

SSC(1)

8.07
10.56

4.04
5.42

136
136

19.0
25.0

•
•

Designation
QCP 0759-2M
QCP 1011-2M

IC908

LF

19.27
25.67

DC

LF

PL

SIG

SSC(1)

.759
1.011

.318
.416

.15900.21300

136
136

19.0
25.0

•
•

IC908

DC

IC908

Designation
QCP 1927-2M
QCP 2567-2M

INCH
Dimensions• Can provide high surface finish of up to 1.6 (64 microinches) Ra hole cylindricity and straightness of up to 0.05 mm (.002”)(1) Seat size code

PL

KCH

HCP-IQ

CHW

Exchangeable DCN Drill
Self-Centering Heads for
Alloy Steel and Cast Iron

DC

LF

NEW

DC

LF

PL

CHW

KCH

SSC(1)

16.05
19.27
25.65

5.39
6.34
8.80

3.910
4.660
5.700

0.62
0.75
0.67

30.0
30.0
30.0

16.0
19.0
25.0

•
•
•

INCH
Dimensions
Designation
HCP 0632-IQ
HCP 0759-IQ
HCP 1010-IQ

DC

LF

PL

CHW

KCH

SSC(1)

.632
.759
1.010

.212
.250
.346

.15393.18346.22440

.024
.030
.026

30.00
30.00
30.00

16.0
19.0
25.0

•
•
•

IC908

NEW

Designation
HCP 1605-IQ
HCP 1927-IQ
HCP 2565-IQ

IC908

METRIC
Dimensions(1) Seat size code

LF

ICG

Exchangeable Chip Splitting
Drill Heads for Stainlessand Alloyed Steel

DC

PL

SIG

METRIC
Dimensions(1) Seat size code

10

ISCAR

DC

LF

PL

SIG

SSC(1)

IC908

Designation
ICG 193
ICG 257

INCH
Dimensions

19.30
25.70

6.89
9.18

3.81
4.92

130
130

19.0
25.0

•
•

Designation
ICG 0760
ICG 1012

DC

LF

PL

SIG

SSC(1)

.760
1.012

.271
.361

.15000.19370

130
130

19.0
25.0

•
•

PL

LF

ICP

Exchangeable DCN Drill
Heads, for Carbon and Alloy
Steel (ISO P Materials)

SIG

DC

PL

LF

SIG

SSC(1)

2.05
2.93
2.93
3.93
4.02

5.55
8.07
8.07
10.57
11.05

140
140
140
140
140

13.0
19.0
19.0
25.0
26.0

IC908

DC
13.50
19.27
19.30
25.70
26.40

•
•
•
•
•

Designation
ICP 0531
ICP 0759
ICP 0760
ICP 1012
ICP 1039

DC

PL

LF

SIG

SSC(1)

.531
.759
.760
1.012
1.039

.08070.11535.11535.15472.15826

.219
.318
.318
.416
.435

140
140
140
140
140

13.0
19.0
19.0
25.0
26.0

•
•
•
•
•

IC908

NEW

Designation
ICP 135
ICP 1927
ICP 193
ICP 257
ICP 264

IC908

INCH
Dimensions

METRIC
Dimensions(1) Seat size code

LF

PL

ICP-2M

Double Margin Drilling Heads for
DCN Drills for Machining Steelwith High Surface Finish Results

SIG

DC

INCH
Dimensions

DC

LF

PL

SIG

SSC(1)

13.50
19.25
19.27
19.30
25.67
25.70

5.14
7.50
7.49
7.49
10.58
9.82

2.46
3.50
3.51
3.51
3.92
4.68

140
140
140
140
140
140

13.0
19.0
19.0
19.0
25.0
25.0

•
•
•
•
•
•

Designation
ICP 0531-2M
ICP 0758-2M
ICP 0759-2M
ICP 0760 2M
ICP 1011-2M
ICP 1012-2M

DC

LF

PL

SIG

SSC(1)

.531
.758
.759
.760
1.011
1.012

.202
.295
.295
.295
.417
.387

.09685.13779.13818.13818.15433.18425

140
140
140
140
140
140

13.0
19
19.0
19.0
25.0
25.0

•
•
•
•
•
•

IC908

NEW

Designation
ICP 135-2M
ICP 1925-2M
ICP 1927-2M
ICP 193-2M
ICP 2567-2M
ICP 257-2M

IC908

METRIC
Dimensions(1) Seat size code

LF

ICM

Exchangeable DCN Drill
Heads, for Stainless Steeland High Temperature Alloys(ISO MandS Materials)

SIG

DC

INCH
Dimensions

NEW

NEW

DC

PL

LF

SIG

SSC(1)

16.05
19.25
19.27
19.30
25.65
25.67

2.430
3.500
2.920
3.510
3.960
3.960

6.87
7.50
8.08
7.49
10.54
10.54

140
140
140
140
140
140

16.0
19.0
19.0
19.0
25.0
25.0

IC908

METRIC
Dimensions
Designation
ICM 1605
ICM 1925
ICM 1927
ICM 193
ICM 2565
ICM 2567

PL

•
•
•
•
•
•

Designation
ICM 0632
ICM 0758
ICM 0759
ICM 0760
ICM 1010
ICM 1011

DC

PL

LF

SIG

SSC(1)

.632
.758
.759
.760
1.010
1.011

.09566.13779.11496.13818.15590.15590

.270
.295
.318
.295
.415
.415

140
140
140
140
140
140

16.0
19.0
19.0
19.0
25.0
25.0

•
•
•
•
•
•

(1) Seat size code11

Heat Exchangers

Three Flute Exchangeable Head Drills
LOGI

THREE FLUTE

3CHAM
CHAMDRILLLOGIQ-3-CHAM - Three flute exchangeable drills
line designed to significantly increase productivity
and reduce machining cycle time by up to 50%
compared to conventional two flute drills.
ISCAR introduces a new LOGIQ-3-CHAM drill
family which raises drilling performance levels
to new heights. This family was designed byutilizing highly advanced technologies, based on
ISCAR’s successful SUMOCHAM drill families.
The range is 12 to 25.9 mm (.472-1.02”), withdrilling depth ratios of 1.5XD, 3XD, 5XD, and 8XD.
LOGIQ-3-CHAM applies the user-friendly drillingsystem for easy handling in accordance withthe company motto “No Setup Time”.

D3N Drilling Holder

Patented pocket design• Available in 1.5, 3, 5, and 8D diameterto drilling length ratios• 3 high flute helix and polished flutesurfaces provide a smooth andeasy chip evacuation process• Helical margin to prevent chip adhesion between
the body and the hole during machining• Internal coolant channels supply efficient coolingand lubrication during the drilling process• Tool body made from highest grade of steel withsuperior hardness for high wear resistance• Drilling head pocket designed to withstandhigh machining cutting conditions,allowing easy and fast head indexing• Variable flute angle design provides durable
tool structure to withstand high axial forces

Self Centering
Insert12

ISCAR

For Steel andCast Iron

Dovetail ShapeHigh Productivity

Radial Stoppers

Cost Effective
InsertContact Surface(axial stoppers)

H3P Drilling Heads• Available in the drilling range of 12-25.9 mm (.472-1.02”)
diameters with 0.1 mm (.004”) increments• Single type geometry suitable for both ISO P
and ISO K materials• H3P drilling heads are made from IC908 TiAlN PVD nanolayer coating grade, for prolonged and predictable tool life
• Unique wavy and honed cutting edges enable best chip
form and easy evacuation process• Patanted concave cutting edges enable smooth
penetration, excellent centering and stable drilling process• Patent-pending robust and precise chisel point and gash
angle to withstand high cutting forces (Fig. 1)• 15° corner chamfer increase wear resistance andstrengthen the cutting corner (Fig. 2)• Unique dovetail clamping to prevent the head from being
extracted from the pocket during retraction• Wiper land to strengthen the cutting corner (Fig. 3)

Enlarged flute surface for easychip evacuation

Cylindrical shank

Polished
flute
MarginVariable flute angle** Optimized chip evacuation* Strengthens the tool(especially during exit with high feed)

3 coolant nozzles directedto the cutting edges

PL
KCH

BCH

H3P

Exchangeable 3 Flute Drilling
Heads for Carbon and Alloy Steel(ISO P) and Cast Iron (ISO K)

DC

LPR

Designation
H3P 135-IQ
H3P 1927-IQ
H3P 193-IQ
H3P 2565-IQ
H3P 257-IQ

DC

METRIC
Dimensions
LPR
PL

KCH

BCH

13.50
19.27
19.30
25.65
25.70

7.58
10.92
10.92
14.11
14.11

15.0
15.0
15.0
15.0
15.0

0.40
0.40
0.40
0.40
0.40

2.910
4.100
4.100
5.310
5.310

IC908

•
•
•
•
•

Designation
H3P 0531-IQ
H3P 0759-IQ
H3P 0760-IQ
H3P 1010-IQ
H3P 1012-IQ

DC

INCH
Dimensions
LPR
PL

KCH

BCH

.531
.759
.760
1.010
1.012

.298
.430
.430
.556
.556

15.00
15.00
15.00
15.00
15.00

.016
.016
.016
.016
.016

.11456.16141.16141.20905.20905

IC908

•
•
•
•
•

13

Heat Exchangers

14

Deep Drilling

Serrated Cutting Edges
Small Diameter Range:
12-13.99 mm(Ø.472”-.550”)

Serrated Cutting Edges
Small Diameter Range:
14-32.0 mm(Ø.551”-1.102”)

Small Diameter Deep
Drills with New Chip
Splitting Insert Concept

Small Diameter Deep
Drills with 3 Chip
Splitting Cutting Edges

Indexable LOGT inserts and
TRIDEEP drill bodies for drilling
diameters down to
12 mm (.472”) featuring highperformance and drillingconsistency, and easy insert
replacement. The inserts have 2
cutting edges and a chip splitting
insert.
The wiper on the insert assures
excellent surface finish. In deepholes, the serrated cutting edge
splits the chips into small parts
to enable quick evacuation.

The TOGT inserts feature 3 chip
splitting cutting edges, a positive
rake chipbreaker and a wiper forhigh hole surface quality.
These inserts are available in
7 sizes, made from IC908, a
versatile PVD coated grade. The
chip splitter produces narrow
chips for efficient chip evacuation,
enabling high feed rates and highly
accurate peripherally groundinsert. Direct insert mount - noadjustment needed for accurate
hole diameter.
The drills carry the new economic
solid carbide guide pads.

ISCAR

Deep Hole Drilling System
Used for solid drilling in a single
operation. Drilling heads areavailable with brazed or indexable
inserts. Brazed head diameter
range: 8-65 mm (.315-2.56”),
Indexable head diameter range:
8-300 mm (.315-11.8”) and larger
upon request.
Special form heads for performing
any other special contours.Head
type connection configurations:external threaded heads,
internal threaded heads.

Shank Types andCooling Methods
Single Tube System: Cooling
fluid is induced through the gap
between the drill and the hole,conveying the chips through the
tube. Requires the use of dedicatedmachines.
Double Tube System: Cooling
fluid is induced between the
coaxial tubes, conveying the chips
through the inner tube. Can beapplied on standard machines.

Indexable Drills• For high volume production• Wide chip gullet for betterchip evacuation• High accuracy• Ceramic guide pads available
upon request, for titanium
and stainless steel• Range: 16-40 mm (.63-1.57”)

Brazed Drills• For short production series• Multiple tips for chip splitting• For difficult-to-machinematerials, high temperaturealloys, hardened steel, risky
applications (low cost heads)• Recommended for use by
an experienced operator• Range: 12.6-65 mm (.5-2.56”)

Trepanning Drills• Require lesspower than solid drilling
applications• Trepanning leaves a core thatcan be used for material analysis
and production of other parts• Hole tolerance is not as
accurate as with solid drilling• Range: 120-350 mm (4.72-13.78”)

15

Heat Exchangers

Machining Tube Sheets
Grooving

INDEXABLE SOLID CARBIDE LINE

Slitting Applications
Double Groove-Mill System for Internal
Slitting Main Features

Chamfering ApplicationsMM Chamfering Head
• A part of ISCAR’s MULTI-MASTER family• Up to 6 flutes• The heads are characterized by a 45°
and 60° head point angle• For internal slitting of small grooves• Inserts are available in diameters of 15.5,
18.5 and 24.5 mm (.61, .728 and .965”)• Slitting widths are 3 mm (.118”) at grooving
depths of up to 0.5 mm (.02”)• No debarring operation is needed, as noburr remains on grooved edge
• Unique CHATTERFREE design for improved
material removal rate and low vibration• Part of ISCAR's MULTI-MASTER family• Standard steel holder• Simple and fast clamping of MM SLIT insert• Conical surface for improved rigidity and accuracy• Face contact for groove accuracy
and minimum axial run-out• Unique insert clamping systemallows use at higher feeds• Adjustable tool overhang

Boost productivity
by performing two grooves
in a single operationA

MM TS-DG

Double-Groove Internal
Grooving Heads with Threaded
Connection for Tube Sheetsof Heat Exchangers.118

DRVS THSZMSDCONMS

RE.012 Typx4

.024
.236

(1) For minimum tube outer diameter (2) Number of flutes (3) Clamping wrench size

A

.118

Dimensions

Designation
DC DCONMS PHD(1) LF
L3L DRVS(3)16.00
15.88 34.00 18.10 14.10 10.0
MM TS155-04T10-8238 15.50
18.45
19.05 34.50 18.30 14.50 13.0
MM TS185-04T12-8239 18.50
23.90
25.40 37.40 11.00 14.40 20.0
MM TS245-04T15-8240 24.50

ISCAR

LF

DC±0.0019

METRIC

16

L

DC
.610
.728
.965

DCONMS PHD(1)
.630
.726
.941

L3

INCH

.625
.750
1.000

LF

L3

L

1.339 .713 .555
1.358 .720 .571
1.472 .433 .567

* Optional, should be ordered separately

DRVS(3) THSZMS NOF(2)
.394
.512
.787

T10
T12
T15

4
4
4

IC908

.018 max.
depth of cut

MM KEY 10X7* •MM KEY 13X8* •MM KEY 20* •Heat Exchangers

Machining Tube Sheets
Reaming

Reaming Applications
Technical Advantages• High cutting speeds and feeds(for higher productivity)• Low run-out - maximum 3μm (.00012”)• Diameter range: 11.5 to 32 mm(.453 to 1.26”)• L/D = 1.5, 3, 5, 8xD• One shank can be used for a wide range of diameters,
various types of cutting edges and grades• Indexing repeatability - maximum 3μm (.00012”)• Durable, due to the combination of a solid
carbide head with a flexible steel shank• No fear of losing any clamping parts which
could possibly fall during indexing• Suitable for minimum quantity lubrication (MQL)• Internal coolant is directed optimally to the
cutting edges for the most efficient headlubrication and extremely long tool life

Interchangeable left-hand solid carbide reaming
heads (shell reamers) with a quick changebayonet mechanism for H7 hole tolerance
high speed reaming of through holes

Interchangeable straight flute left-hand, solid
carbide reaming heads (shell reamers) with aquick change bayonet mechanism for H7 holetolerance high speed reaming of blind holes

17Heat Exchangers

Machining Tube Sheets
Drilling

Fully Effective Large Diameter Drill• Excellent chip evacuation, improved
surface finish and hole cylindricity• Excellent solution for drilling stacked plates• Standard inserts• High rigidity due to integral tool
• No need for pre-hole• Full program from diameter 26 to 50 mm (1.023
to 2.165”) in increments of 1 mm (.04”)• Standard program tools of 5xD drilling depth• Indexable inserts are available with several chipformer
types in the following grades: IC808 and IC908• Indexable SUMOCHAM and SUMOCHAM-IQ
heads are available with ICP/ICM/HCP geometries
in ISCAR`s IC908 TiAlN PVD grade

L=5xD and up• High feed drilling• Excellent surface quality• High hole accuracy• Large drilling depth: L=5xD
and higher– up to 800 mm (31.5”)• Carries standard SOMX/SOMT indexable
inserts with 4 cutting edges• No dedicated machine or extra setup needed• Standard coolant pressure as used for general drilling• Standard indexable, double-sided guiding pads

18

ISCAR

• Highest steel grade with a bodyhardness of up to 55 HRC• Drilling depth to diameter ratios
of 2xD, 3xD, 4xD and 5xD• Twisted coolant holes• Diameter range of 12 to 60 mm (.472 to 2.36”)• Carries standard SOMX/SOMT indexable inserts with
4 cutting edges with DT, GF and HD chipbreaker• Optimal flute shape for easy chip flow

CHAMIQDRILL drill family for the drilling range of 33
to 40 mm (1.3-1.574”) with 1.5, 3, 5 and 8 length todiameter ratios. The CHAMIQDRILL features a uniquedesign, utilizing the carbide’s flexibility for selflocking; eliminating the need for clamping accessories.
The robust structure of the drill with the concave
cutting edge design enables drilling at high feed rate,
providing very accurate IT8 – IT9 hole toleranceFully Effective Specially Tailored Core Drill• Fully effective tool which requires
less power than solid drills• Solid core left after drilling can beapplied as a workpiece• Standard double-ended, self clamped GRIP inserts• Inserts are available with several chipformer
types and in ISCAR`s new SUMO TEC
grades IC807, IC808, and IC830• Diameter: 60 mm (2.36”) and up• Drilling depth to diameter ratio up to 2xD

MD-DR-DH Modular Heads• Known and proven design combined withthe advantages of a modular system• Carry standard SOMX indexable inserts with 4
cutting edges, providing an economical solution• Standard indexable, double-sided guide pads
• Suitable for low to medium feed machining• Suitable for semifinishing and roughing applications

MD-DFN Modular Heads• Carrying HFP-IQ CHAMIQDRILL solid carbide heads• Robust structure with concave cutting edge
design enables drilling at high feed rates,
providing very accurate IT8-IT9 hole tolerance• Unique pocket design enables many drilling head indexes• Special axial stopper prevents the drilling headfrom being extracted during retraction• Large radial head stoppers provide high resistance tocutting forces, enabling very high cutting conditions• Diameters: 33.2, 36.2, 39.2 mm• 2 effective cutting edges for high productivity• 2 guide pads for improved stability during machining• New drilling ratio: 7 and 8 xD
• The HCP central drilling head provides a self-centering
ability for premium hole accuracy No pre-hole is needed.
• Peripheral SOMT/X wiper inserts feature 4 cuttingedges and ensure premium surface quality

19

Heat Exchangers

Profitability Test Report

Workpiece Tube Sheet Material ASTM A516-70 150-180 HB
ISCAR - SUMOCHAM

Competitor

Drill
InsertCutting speed m/min / SFM
Feed mm/rev / IPR
Table feed mm/min / IPM
Drilling depth mm / inch
Tool life (number of holes)

DCN 190-152-25A-8D / DCN 0748-598-100A-8D
ICP 1927-2M IC908 / ICP 0759-2M IC908
120 / 400
0.33 / .013
660 / 2675 / 3
1000

Savings

50%

Replaceable head
110 / 360
0.3 / .012
560 / 2275 / 3750

Workpiece Tube Sheet Material AISI 316L
ISCAR - SUMOCHAM

Competitor

Drill
InsertCutting speed m/min / SFM
Feed mm/rev / IPR
Table feed mm/min / IPM
Drilling depth mm / inch
Tool life (number of holes)

DCN 190-095-25A-5D / DCN 0748-374-100A-5D
ICM 193 IC908 / ICM 0760 IC908
60 / 200
0.25 / .01
250 / 1060 / 2.36
800

Savings

66%

Stacked baffle plates• Maximum total thickness = 150 mm• Optimal thickness of each plate = 6÷12 mm• Peripheraly welded• Bolted with minimum 4 bolts• Speeds and feeds should be 10÷20% lower than tube sheet
General notes:• Optimal coolant pressure ≥ 50 bar• Optimal oil concentration = 10%• Hydraulic or power chuck adaptations are
preferable for fully cylindrical shanks.
• Side lock adaptation is preferable for Weldon type shanks• For best performance and tool life, head runout
should be ≤ 0.02 mm, inspected in the machine• Pre-hole should be done (if needed) with the same
geometry and diameter as the longer drill

Nomemclature:
D = Drill Diameter
V = speed [m/min]f = feed [mm/rev]
General formulas:
RPM = (1000 x V)/(3.14 x D)
Table feed = RPM x f [mm/min]

20

ISCAR

Solid carbide
50 / 160
0.22 / .009
181 / 7.1
60 / 2.36
600

SUMOCHAM Speeds and Feeds Chart
Tube Sheet drilling:
Group Designation

Optimal Carbide
Geometry GradeP

Low Carbon
Steel

HCP (*)M

Stainles
steel

ICM

M

Duplex
2205

ICM

M

Super
DuplexS
S

150

0.35-0.560

0.22-0.32 0.22-0.35

50

0.2-0.3

0.22-0.32

ICM45

0.2-0.28

0.22-0.3

InconelICM

30

0.18-0.25

0.2-0.28

TitaniumICM

35

0.2-0.28

0.22-0.3* HCP geometry does NOT require pre-hole

IC908

Optimal Feed per drill diameter(mm/rev)Vc(m/min) Ø19-19.6 Ø25-26.4

IC907/
IC908

0.35-0.55

LOGI

THREE FLUTE

3CHAM
CHAMDRILL

Workpiece Tube Sheet Material ASTM A76.5
ISCAR - LOGIQ-3-CHAM

Competitor

Drill
InsertCutting speed m/min / SFM
Feed mm/rev / IPR
Table feed mm/min / IPM
Drilling depth mm / inch
Tool life (number of holes)

D3N 0748-374-1002-5D/D3N 190-095-25.4R-5D
H3P 0750-IQ IC908 / H3P 1905-IQ IC908
113 / 359
0.42 / 0.0167
775 / 30.51
107 / 4.2
833

Savings

26%

LOGI

THREE FLUTE

Indexable inserts drill
122 / 388
0.29 / 0.0114
572 / 22.51
107 / 4.2
581

3CHAM
CHAMDRILL

Workpiece Tube Sheet Material ASTL 516
ISCAR - LOGIQ-3-CHAM
Drill
InsertCutting speed m/min / SFM
Feed mm/rev / IPR
Table feed mm/min / IPM
Drilling depth mm / inch
Tool life (number of holes)

D3N 160 5D
H3P 163 IQ IC908
115/365
0.5/0.02
1100/43
60/2.36
580

Savings

75%

Competitor
Indexable inserts drill
120/380
0.25/0.009
625/24.5”
60/2.36
480

Stacked baffle plates• Maximum total thickness = 6"
• Optimal thickness of each plate = .250"÷.500"• Peripheraly welded• Bolted with minimum 4 bolts• Speeds and feeds should be 10÷20% lower than tube sheet
General notes:• Optimal coolant pressure ≥ 700 psi• Optimal oil concentration = 10%• Hydraulic or power chuck adaptations are preferable
for fully cylindrical shanks. Side lock adaptation
is preferable for Weldon type shanks• For best performance and tool life, head runout
should be ≤ .008" inspected in the machine• Pre-hole should be done (if needed) with the same
geometry and diameter as the longer drill

SUMOCHAM Speeds and Feeds Chart
Tube Sheet drilling: Optimal Carbide Optimal Feed per drill diameter (IPR)Group Designation Geometry Grade SFM Ø.750”÷.772” Ø1.008”÷1.032”

P

Low
CarbonSteel

HCP (*)M

Stainles
steel

ICM

M

Duplex
2205

ICM

M

Super
Duplex

S
S

IC908

500

.014"-.020".014"-.022"

200.009"-.013".009"-.014"

170.008"-.012".009"-.013"

ICM

150

.008"-.011".009"-.012"

InconelICM

90.007"-.010".008"-.011"

TitaniumICM

110.008"-.011".009"-.012"

IC907/IC908* HCP geometry does NOT require pre-holeNomemclature:
D = Drill Diameter
V = speed [SFM]f = feed [IPR]
General formulas:
IPM = RPM x IPR
RPM = SFPM x 3.82 / D
SFPM = RPM x .262 x D

21

Heat Exchangers

Drilling Tool Wear

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

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

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

22

ISCAR

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

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

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

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

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

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

23

ISCAR’S MACHINING SOLUTIONS FOR
Heat Exchangers

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