VER 1 - 2019

Parting 4 Productivity withLOGIQ-F-GRIP
A revolutionary system
integrating a comprehensive
range of highly effective partingand grooving solutions [p. 4]

Fast Feed Milling
Tools For High Metal
Removal Rates

Four new Fast Feed toolfamilies and existing line
upgrades have been developed
to maximize efficiency [p. 16]

Exchangeable 3 Flute
Head Drills

The new LOGIQ3CHAM
family, designed to significantly
increase productivity and reducemachining cycle time [p. 22]

w w w . i s c a r. c o mMaking Tracks: New Cutting
Tools for the Railway Sector

ISCAR's projects for this key sector
incorporate essential elements tofulfill the need for layout solutions andefficient productivity [p. 34]

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

SCAN MEw w w . i s c a r. c o mTable of Contents
Parting 4 Faster with LOGIQ-F-GRIP 

4

LOGIQ Tooling Solutions for Oil and Gas Applications 

10Fast Feed Milling Tools For High Metal Removal Rates

16

Exchangeable 3 Flute Head Drills 

22

Jet Engine Part Production - An Aerospace Industry Challenge 26Making Tracks: New Cutting Tools for the Railway Sector

34

Connecting New Genereation Tools to New Gen Machining Centers

40

ISCAR INDUSTRY 4.0 PRO

46

ISCAR

3

PARTING

FASTER

with LOGIQ-F-GRIP
Always at the cutting edge of developments in the field of cutting
tools, ISCAR introduces a revolutionary system for parting andgrooving operations.

Parting and grooving are essential aspects of theturning process and the metalworking industry faces
a constant challenge to integrate methods that will
increase efficiency and decrease downtime for these
popular operations.
ISCAR fully understands the importance of partingand grooving operations in the turning process
and that multiple factors need to be considered forevery application, including machine tool selection,
the type of material being parted/grooved, required
depth of cut, and feed and speed rates. ISCAR has
responded to these complex needs by developing a

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MACHINING INTELLIGENTLY

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comprehensive range of highly effective parting andgrooving solutions that include an extensive choiceof insert geometries, chip breakers, and carbide
grades - and the range continues to expand.
With Industry 4.0 demands and standards fuelingindustry development at extraordinary rates,
ISCAR has introduced new parting and grooving
technologies capable of integrating seamlessly with
the new wave of machining centers that work withincredibly high speeds and feeds. LOGIQ-F-GRIP
has been designed to answer these needs and toachieve high productivity and lower costs.

PARTING

FASTER
Pockets
Profitability
Productivity
Performance

TWISTED 2-SIDED

ISCAR

5

Reinforced and Robust Tool Provides
Extra Stability and Higher Productivityhh

L=EXTRACounter
Force
Left Side View

6

Robust Supporting Spinal
System for Increased Feed andUnbeatable Tool Life

MACHINING INTELLIGENTLY

DUSTRY 4.0

Right Side View

A revolutionary parting system designed forincreased productivity, LOGIQ-F-GRIP comprisesa robust tool block carrying square blades thatfeature four pockets, with a unique parting concept
capable of parting off up to 120mm bar diameter to
optimize performance.

straightness, and features high stability - especiallywhen parting large diameters. The new patented
blades reduce cutting time which leads to materialsavings - for instance, a 120mm bar can be cut with a
3mm blade with HF (high feed) inserts at a feed rate of
up to 0.4 mm/rev (.0157ipr).

LOGIQ-F-GRIP is simple to mount and operate on
all machine types, including multi-task and machining
centers on X-AXIS, without any need for special
adjustment. The system enables the mountingof both TANG-F-GRIP and DO-F-GRIP blades on
the same blocks.

The HF‎tangential single-ended insert was developed
to enable highly efficient parting at very high feed
rates, by use of a unique chipformer technology. A
secure clamping design uses a tangentially orientatedpocket to facilitate pocket life that is three times longer
than that of any other conventional self-grip system.
This robust clamping method enables machining athigh feed rates and provides excellent straightness
and surface finish characteristics, while the flat top
configuration prevents chip obstructions under all
possible machining conditions. The HF insert features a
new insert chipformer to allow unobstructed chip flow,which increases insert and blade tool life and leads tovery high productivity gains.

The square blades possess a support system thatprovides totally vibration-free grooving and parting.
LOGIQ-F-GRIP also saves on setup time as, in casesof pocket damage, the block’s configuration allows ablade to be rotated to a new pocket without setup.
TANG-F-GRIP is intended for high feed parting.
It extends insert life, improves surface finish and part

ISCAR

7

The DO-F-GRIP DGN double-sided twisted parting
insert provides the largest choice of parting widths
available in today's market, covering all application
ranges. ISCAR offers a wide variety of chipformers
and the most advanced grades to ensure unbeatableperformance and extended tool life, even whenmachining exotic materials.
When machining materials such as stainless steel orhigh temperature alloys, the temperature near the
cutting edge area becomes extremely high. In addition,these material types tend to adhere to the tools cuttingedge, causing built-up edge. These problematic
phenomena can be moderated by targeting highpressure coolant directly to the cutting zone.

TWISTED 2-SIDED

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The JETCUT system incorporates ingeniously
designed through coolant channels to deliver coolant
close to the cutting edge, which improves chip
formation and slashes flank and cratering rates.
ISCAR maintains its unrelenting progress as a result of
the company’s continuous development of innovative,
high-quality products, based on the expertise of thecompany’s R&D Department and prompted by the
evolving needs of global industry. This desire to provide
customers with the very latest, most efficient metal
cutting technology is reflected in the introduction of
TANG-F-GRIP solutions to ISCAR’s comprehensive
GRIP range of parting and grooving tools.

Reinforced and Robust Tool Provides
Extra Stability and Higher Productivity
TWISTED 2-SIDEDhh

L=EXTRACounter
Force
Left Side View

Robust Supporting Spinal
System for Increased Feedand Unbeatable Tool Life

Right Side View

ISCAR

9

LOGIQ Tooling
Solutions for
Oil and Gas
Applications
The oil and gas industry has suffered considerably over the
past years, due to the global economic crisis that left the major
manufacturing players - both from the upstream and downstream
sectors - having to meet low market requirements for new
reserves, while cutting severely their workforce, machinery output
and further development.

A positive shift in 2017 set new demands from wellknown offshore deep-water oil and gas explorationcompanies for rig components such as pressure
heads and valves, Xmas-tree and wellhead valves,and manifolds, which all are made from or withnickel-based exotic materials that can resist extreme
conditions such as high-low temperatures, highpressure, and most - if not all - abrasion andcorrosion side-effects.

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To meet the call from oil and gas component
producers for increased productivity and goods output
while maintaining a high degree of quality, reliability
and safety in the manufacturing process with a low
rate of reject parts, ISCAR has developed a wide
range of innovative tooling solutions that are designed
to simplify production, reduce costs, and maximize
productivity in this challenging sector.

MACHINING INTELLIGENTLY

DUSTRY 4.0

ISCAR

11

JETCUT Parting Technology
The JETCUT line provides advanced parting
technology for welded and seamless steel pipes
at the OCTG (Oil Country Tubular Goods) industry.
The JETCUT high-pressure coolant nozzle outlet is
pinpointed to the cutting zone, to extend insert edge
life and eliminate built-up edge while cutting heat
resistant alloys as well as stainless steels. In addition to
improving chip control at higher cutting speed rate, theself-clamping parting off system reduces setup
and machine downtime with favorable improvement
in machining time.

WHISPERLINE – Anti-Vibration Boring Bars
with Exchangeable Heads
ISCAR’s WHISPERLINE anti-vibration boring bars
were designed to significantly reduce and eveneliminate chattering - vibrations - when working withextended overhangs in turning, boring and grooving
operations with length ratios of 7xD to 14xD diameter.
The anti-vibration boring bar system integrates withseveral types of indexable head configurations, witha “live” inner dampening mechanism that can beapplied on standard lathes, VTL and multi-tasking
mill-turn or turn mill machines for large scale parts
including manifolds, valves, wellhead, coupling andtubing components. These factors enable increased
productivity and improved surface quality while using
pinpointed internal coolant technology to the insert’s
cutting edge with improved chip control and edge life
for high quality finishing operations.
A N T I - V I B R AT I O N

12MACHINING INTELLIGENTLY

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SUMOCHAM ICG Chip Splitting Drilling Heads
ISCAR’s SUMOCHAM ICG geometry is recommended
particularly for deep drilling operations when chip
evacuation can be a problem. The drilling heads aredesigned with a chip splitting notch technology tocreate short and narrow chip segments, which caneasily be extracted out of the hole through the drill
spiral flute and the use of internal coolant. Made with ahigh wear resistant nano-coated grade to ensure holesurface quality and accuracy in steels, stainless steel
and high nickel-based materials, the ICG heads can bemounted on any SUMOCHAM standard drill body withthe appropriate pocket size, at diameters ranging from
14 to 25.9 mm, ensuring IT9-IT10 hole tolerance.

TANG4FEED for High Feed Milling
Producers of oil and gas exploration equipment suchas frac pump fluid ends used in hydraulic fracturing
procedures, BOP (blow out preventers) and valve
blocks, have shown great interest in the high feed
milling solutions offered by ISCAR.
The latest addition to a wide range of feed milltechnologies, TANG4FEED is a family of high feedshell mill cutters carrying tangentially clamped rhombic
inserts with 4 cutting edges. TANG4FEED cutters aredesigned for milling rough/semi-finish and sculptured
surfaces, in diameters ranging from 40 to 100 mm,
with up to 1.5 mm depth of cut. These unique features
provide a good ramp down and side plunging capability
with excellent chip flow and a high metal removal rate,
due to a small entrance angle that enables high table
feed at shallow depth of cut and materials that aremachined on oil and gas exploration equipment.

ISCAR

13

Customized Tooling for Seal Ring Grooves
The most common operations on valve bodies, valve
blocks, valve seats and bolt holes, fluid ends andmanifolds are seal ring grooves, which are typically
produced on challenging materials such as duplex,
stainless steels and Inconel-based components.
Seal ring grooves are an example of a component
featuring precise dimensions and high-quality
surface finish. The sealing areas in API threads arecomparatively small with limited contact areas thatneed to hold the required sealing pressure. Secureand stable machining is essential to ensure a smooth,flexible and efficient process.
To withstand the unknown variables that affect the
global oil and gas market, ISCAR works closely with
its leading oil and gas customers to continue todevelop innovative, efficient, productive andcost-effective solutions.

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ISCAR

15

FAST FEED MILLING

Tools For High Metal
Removal Rates
The method of rough machining with significantly increased feed per
tooth – known as fast feed (FF) milling or high feed milling (HFM) –found its industrial application in the 1990’s. Die and mold making
was one of the first industries to adopt HFM into its production
practices, following a massive increase in customer demands for
reduced die and mold manufacturing time.

The FMR method is based primarily on two
principles: the geometry of a milling cutter andthe high-speed feed drive of a machine tool.
A typical fast feed tool features a small cutting edge
angle, normally 9-17°. This design characteristic
results in three important outcomes. The first is thepossibility of considerably increasing feed per tooth
due to a chip thinning effect. For example, in face
milling low-alloy steel, 0.2 mm/tooth (.008 ipt) is anear maximum value feed, but high feed milling thesame material with a 2 mm/tooth (.08 ipt) feed isnormal. The second is a shallow depth of cut (DOC)
that ensures this geometry for the tool. Milling with
reduced DOC diminishes cutting force and power
consumption. And the third point relates to minimizing
the radial component of the cutting force combinedwith maximizing its axial component, which acts
toward the axis of the machine tool spindle, i.e. thedirection of the maximum machine tool rigidity. This
improves machining stability.
Increasing feed per tooth means greater feed speed
that requires the appropriate feed drive of the machinetool. In the above example of high feed milling lowalloy steel, the feed speed may be 7000-9000 mm/
min (275-355 ipm) – the next-higher order versus
conventional values.
Introducing FMR substantially changed the conceptof rough milling. Instead of intensive material removal
at large depths and width of cut by using high-powermachines, the method proposed extremely productive
milling at shallow depths by low-power machines
fitted with a cutting tool that runs very fast.

HIGH FEED

ISCAR

17

In its latest “LOGIQ”
campaign, ISCAR introduced
four new Fast Feed toolfamilies and upgraded several
existing lines
The fast feed milling method has since undergone
some interesting changes. Originally considered as
an effective way for rough machining cavities andpockets that was typical for die and mold making,
FMR soon proved advantageous in face milling(“fast feed facing” or “triple F”). The diameter rangeof the FF milling cutters was increased and thegroup of engineering materials suitable for cuttingby the FMR method, expanded. Steel and cast ironmay be known as the main “consumers” of fast
feed milling, but stainless steel, titanium, and evenhigh temperature superalloys can be successfullymachined by the method as well. This in turn led
tool manufacturers to introduce a variety of fast feed
milling cutters in different forms. Indexable or solid inconcept, they can have shank or arbor type design
configurations, integral or modular body structures,and cutting geometry that varies according to themachined material group.

HIGH FEED18

MACHINING INTELLIGENTLY

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HIGH FEEDISCAR’s line of high feed milling cutters illustrates thisdiversity with almost dozens of fast feed mill families;
today it is unique in the field with an extensive range
of options. Already in the late 90’s, the company
introduced a family of indexable tools with onesided inserts for fast feed milling, and continued
to expand their line by adding more indexable
milling families, with designs that provided added
value to customers. In one case, the tools carriedcost-beneficial double-sided inserts; in another, anadvanced cutting geometry considerably improved
ramp-down abilities for better performance in millingby helical interpolation. For applications requiring

small-size cutters, the company developed FF solid
carbide endmills and replaceable milling heads forthe company’s “Multi-Master” products. Efficient useof FMR tools in face milling operations generated
new demands, and the company not only introduced
appropriate cutter families but suggested an original
additional solution: the specially designed inserts.
These inserts, intended for mounting in generalpurpose cutters in the standard milling line,transform the latter to FF tools.
In its latest LOGIQ campaign, ISCAR introduced
four new FF tool families and upgraded several
existing lines.

The first noticeable feature of the new families isa substantial decrease in the size of indexable FF
cutters. For example, the diameter range of FFT302 NAN3FEED endmills is 8-10 mm (.315-.394”)– “classical” dimensions for solid carbide tools.
These endmills are characterized by theoriginal clamping method of miniature
carbide inserts. The inserts do not havea traditional central through-holethat weakens the insert structure.
A screw head, which acts asa wedge, secures the insert
allowing insert indexing to bequick and simple. As theinsert is very small in size,
it is placed in the pocket
via a key with a magnetic
boss on the key handle. The
design ensures a multi-toothtool configuration: 2 and 3 teeth fordiameters 8 and 10 mm (.315-.394”)
correspondingly; and 3 indexable cuttingedges of the insert provide cost-effective
using cemented carbide.

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Smallest Indexable Insert
for High Feed MillingTANG4FEED is a family of fast feed shell mills
carrying tangentially clamped rhombic inserts.
The mills are designed mostly for rough machining
medium- and large-size cavities and pockets. The
tangential clamping principle, combined with adovetail profile of matching surfaces for secure insert
mounting, ensures a durable mill structure. The
insert’s rhombic shape significantly improves mill
performance in ramping-down andside-plunging operations. The
TANG4FEED inserts
are doublesided, resulting
in 4 cuttingedges.
The inserts of both
mentioned families

are provided in several cutting geometries for optimal
milling of different engineering materials.
Developing FF milling cutters is still far from its highpoint, though the newly introduced tool families offer
logical answers to real manufacturer demands. FMR,
as a productive method of rough machining, has
optimistic prospects, and the metalworking industry
will continue to require faster and fastermilling cutters for high metal removal
rates.

Unique Tangential Insert
for High Feed Face Milling
ISCAR

21

Exchangeable
3 Flute Head
Drills
ISCAR introduces the new LOGIQ3CHAM drill family to raise
drilling performance levels to new heights, featuring threeflute exchangeable drill lines designed to significantly increase
productivity and reduce machining cycle time by up to 50%
compared to conventional two-flute drills.
This new family was developed by utilizing highly
advanced technologies based on ISCAR’s successful
SUMOCHAM drill families. The
diameter range is 12 to 25.9 mm
with drilling depth to diameter
ratios of 1.5XD, 3XD
and 5XD.
The new D3N drills can increase
productivity by 50%, maintaining
the excellent performance of the
SUMOCHAM drills.
LOGIQ3CHAM applies the user-friendly
drilling system for easy handlingin accordance with the company mottoof “No Set-up Time”.

LOGI

THREE FLUTE

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3CHAM
CHAMDRILLH3P Drilling Heads• Available in the drilling range of 12-25.9 mm
diameters with 0.1 increments• Single type geometry suitable for both ISO P
and ISO K materials• H3P drilling heads are made from IC908 TiAlN
PVD nano layer coating grade, for prolonged
and predictable life
• Unique wavy and honed cutting edges enable
best chip form and easy evacuation process• Patanted concave cutting edges enablesmooth penetration, excellent centeringand stable drilling process• Patent-pending robust and precise chisel pointand gash angle to withstand high cutting forces• 15° corner chamfer increases wear resistanceand strengthens the cutting corner• Dovetail clamping prevents the head from being
extracted from the pocket during retraction

ISCAR

23

D3N Drilling Holder• Available in 1.5, 3 and 5 diameter todrilling length ratios• 3 high flute helix and polished flute surfaces provide
a smooth and easy chip evacuation process• Helical margin prevents chip adhesion between
the body and the hole during machining• Internal coolant channels supply efficient coolingand lubrication during the drilling process• Tool body is made from highest grade of steel
with superior hardness for high wear resistance• Drilling head pocket is 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

Patented pocket design

Dovetail

RadialStoppers

Contact Surface(axial stoppers)• For optimal performance, it is recommended
to adjust runout of outer points or chisel witha maximum of 0.02 mm• Large runout will influence drill performance
tool life and hole quality• LOGIQ3CHAM drills can be used either on
milling centers or lathe machines• LOGIQ3CHAM drills can be used on sloped
surfaces up to 12°. When drilling sloped surfacesof more than 12°, reduce feed by 30-50% duringpenetration of up to 5 mm depth; or use a spot or
pre-hole drill to avoid drill deviation or poor
drill performance• Interrupted cut has a direct influence on holeaccuracy, quality and drill life
• Includes a new LOGIQ3CHAM drill head key

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Enlarged flute surface for easychip evacuation

Cylindrical shank &DIN 9266 shank
Polished flute
MarginVariable flute
angle** Optimized chip evacuation* Strengthens the tool(especially during exit with high feed)

3 coolant nozzles aimed
to the cutting edges

Self Centering
InsertFor Steel &Cast Iron

High
Productivity

Cost Effective
Insert

ISCAR

25

Jet Engine Part
Production - An
Aerospace Industry
Challenge
The requirements for materials used in jet engine parts are necessarily
very exacting. They must survive extremes of temperature and force,
while being as light as possible and ultra-reliable.

A turbojet engine can be divided simply into three
sections – the compressor, the combustor and theturbine. The compressor pressurizes the air flowing
through the engine before it enters the combustion
chamber, where the air is mixed with fuel, ignited andburnt. The compressor components are predominantly
made from titanium alloys, while the combustor andturbine components are typically made of a nickelbased superalloy such as Inconel 718.

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ISCAR

27

Nickel-based alloys
The excellent physical properties that characterize
nickel-based high temperature alloys make them ideal
for use in the manufacture of aerospace components.
Properties such as high yield strength and ultimate
tensile strength, high fatigue strength, corrosion andoxidation resistance even at elevated temperatures
enable the usage of nickel-based high temperaturealloys in many applications and over a very wide
temperature spectrum.
The aerospace industry accounts for about 80% of
the nickel-based high temperature alloys used in
manufacturing rotating parts of gas turbines, including
disks and blades, housing components such as
turbine casing), engine mounts, and components forrocket motors and pumps.
Nickel-based high temperature alloys contain
35-75% Ni and 15-22% Cr; they constitute

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about 30% of the total material requirement in the
manufacture of an aircraft engine and are also used as
structural material for various components in the main
engine of space shuttles.
The very same properties that make nickel-based
alloys such a great choice for jet engine parts also
cause substantial machining difficulties.
The cutting forces and temperature at the cuttingzone are extremely high due to the high shear
stresses developed and the low thermal conductivity.
This, coupled with the reactivity of nickel-based hightemperature alloys with the tool material, leads togalling and welding of the chips on the work piecesurface and cause excessive tool wear, which canlimit cutting speeds and reduce useful tool life.
All these characteristics contribute to low material
removal rates and short tool life, resulting inmassive machining costs.

Titanium-based alloys
Due to their high strength to weight ratio and excellent
corrosion resistance, titanium alloy parts are ideallysuited for advanced aerospace systems. Titaniumbased alloys which contain 86-99.5% Ti and 5-8%
Al, are immune to almost every medium to which theywould be exposed in an aerospace environment.
Very large quantities of titanium can be found in jetengines, where titanium alloy parts make up to
25-30% of the weight, primarily in the compressor.
The high efficiency of these engines is obtained byusing titanium alloys in components such as fan
blades, compressor blades, rotors, discs, hubs, andother non-rotor parts - for instance inlet guide vanes.
Titanium’s superior properties and light weight allow
aeronautical engineers to design planes that can fly
higher and faster, with high resistance to extreme
environmental conditions. However, titanium hashistorically been perceived as a material which isdifficult to machine due to its physical, chemical
and mechanical properties.

The material’s relatively high temperature resistanceand low thermal conductivity do not allow generated
heat to dissipate from the cutting tool, which causes
excessive tool deformation and wear. Titanium alloys
retain their strength at high temperatures, resulting in
relatively high plastic deformation of the cutting tool
resulting in depth of cut notches. During machining,
the high chemical reactivity of titanium alloys causes
the chips to weld to the cutting tool, leading to builtup cutting edges and chip breakage problems.
Over the past few years, ISCAR has invested many
resources in R&D to resolve these obstacles andoptimize the machining of nickel-based and titaniumhigh temperature alloys, with solutions that include thecreation of customized grades and implementation ofhigh pressure coolant technologies to develop cutting
tools that will handle the heat issues.

ISCAR

29

For high material removal
rates, ISCAR developed
ceramic grades to facilitate
machining nickel-based
alloys at cutting speeds of
200 – 400 meters per minute

Newly Designed Box to Protect Inserts
The new insert box possesses exclusive design
characteristics, including a ribbed translucent structure anda single end opening for the lid with a stopper on the box.
The box features a two tone color scheme and the tinted
gray-colored lid bears the warning notification.
The unique design differentiates and distinguishes
ISCAR’s insert packages, DUSTRY
making our 4.0
products
stand MACHINING
out from the competition.
30
TELLIGENTLY

IN

IW7 - Whisker-reinforced ceramic grade, provides
high hardness with excellent toughness used forroughing and semi-finishing continues operations at
8-10 times faster cutting speeds when comparedwith carbide grades.

P M K N S H
3IS35 - Reinforced SiAlON composite grade, excellent
for machining Ni based high temperature alloys at lightand heavy interrupted applications.
A series of carbide grades was developed specificallyto create tools for machining nickel-based andtitanium alloys:

P M K N S H
3IC804 – Same TiAlN PVD coating on a harder
submicron substrate designed especially for machining
Ni based alloys used in newly designed jet engine parts
that feature very high hardness (40-47 HRC).

P M K N S H
3 3 3 3 3P M K N S H
3 3

IS25 - Reinforced SiAlON composite grade,
excellent for machining Ni based high temperaturealloys at continuous and light interrupted applications

P M K N S H
3IC806 - A hard submicron substrate combined with athin TiAlN PVD coating. The unique coating procedure
which involves a special post coating treatment
creates a thinner and smoother coating layer providing
the insert with the best characteristics suitable formachining nickel-based and titanium alloys.

P M K N S H
3IC20 – An uncoated carbide grade which is highly
recommended for machining aluminum and titanium.
IC20 provides very high performance and is mostly
used for continuous cut applications.

ISCAR

31

High pressure coolant tools
Although high pressure coolant features have been in
existence for a long time in the metal removal world,
today high pressure coolant tools play an increasingly
significant role in the machining process, facilitating
enhanced productivity and chip control especiallyfor hard to machine materials such as titanium andnickel-based alloys. Incorporating high pressure is the
key to directing coolant to exactly where it is neededin order to flush the chips away from the cut.
ISCAR was one of the first cutting tool producers
to respond to market needs by developing andmanufacturing tools for the optimal use of high32

MACHINING INTELLIGENTLY

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pressure coolant in lowering high temperatures andregulating chip flow, including JETCUT custom
high-pressure coolant tools.
While the aerospace parts OEM/PMA sector is underconstant pressure to keep costs down, the quality
and life expectancy of the parts produced cannot
be compromised – and this represents an enormous
challenge for all involved. ISCAR’s enhanced cutting
tools allow jet engine manufacturers to utilize the ideal
materials for the production of high quality parts, withminimum wastage and maximum efficiency.

ISCAR33

Making Tracks:
New Cutting Tools
for the Railway
Sector
The railway industry is one of the main consumers of cutting tools and
ISCAR is increasing its role as a supplier of complex projects for thiskey sector that incorporate essential elements to fulfil the need forlayout solutions, efficient productivity, and a reduction in machining
time and costs – all demanding a large variety of both standard andtailor-made solutions.

Machining railway parts represents a challenge for
manufacturers and cutting tool producers alike, whomust contend with a host of constraints - such as therelatively large size workpieces, complex structures, andcomplicated final machined profile - along with the needto remove a large volume of material, ensure predictable
tool life, and avoid high maintenance costs.
When selecting the correct tools and inserts foreach job, certain parameters need to be taken into
consideration, for example the type of material to
be machined, the condition of the part, the available
machine tool, its condition and power characteristics,
clamping fixtures, etc.
A central factor in optimal tool development is thecreation of a virtual manufacturing environment thatsimulates machining processes and cutting conditions,

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to ensure that the tools produced will overcome
material and manufacturing limitations and that they
will provide the best solutions to the specific needs ofrailway parts producers.
As an example of this dynamic, it is useful to consider
how new tools and processes are adapted to machinebogie components and switchers. The bogie frame
is utilized in each of the three main categories in therailway sector: urban transit rail, passenger rail, andfreight rail. The switcher is one of the most common
parts produced, with typical switchers including
crossover, switch diamond, and three-way switch.

ISCAR35

Rotating tools
Many operations for railway part machining involve
rotating tools, especially for milling and drilling functions.
In milling, due to the high volume of removed material,conical and profile indexable extended flute cutters
are used. The cutters with tangentially clamped inserts
feature better possibilities for improving tool strengthand ensuring higher tooth density that result in increased
productivity. In many cases, milling the railway parts
requires long-reach tools with different overhang.
Modular shell mill design configuration offers a flexible
and economical alternative to large-size extended flute
cutters with integral body (integral-type design).

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T490 – A modular solution
Extended flute shell mills
The combinations of the base units and extensions
ensure a variety of extended flute shell mills withdifferent cutting lengths. The modular extended fluteassembly possesses another advantage in improving
operations. As the first-row inserts in extended flute
cutters, which are located near a cutter face, areinvolved not only in side milling but also in face milling,
they experience harder loading and their wear is more
intense compared with the other inserts of the cutter. In
integral-type cutters, a sudden breakage of a first-row
insert can cause serious damage of the cutter and evenrender it inoperable. In the modular assembly, eachdamaged insert can be replaced individually, whichenables efficient operation and extended tool life.
ISCAR's new cutters are designed with coolant
through to extend tool life and improve chip evacuationin problematic areas such as slotting and deepshouldering. This is especially valuable for tangential
clamping as the special profile extended flute cuttersensure a reduction in machining time.
In some cases, the profile in the switcher can bemachined in one single pass; in other cases it isnecessary to divide the machining into
several passes to produce the rightprofile and diameter with thecorrect dimensions.

Extra Strong Tangential Insert
for Deep Milling37

Face milling
The newly introduced T890 line represents a range offace mill cutters for rough and semi finish machining thatcarry tangentially clamped inserts with 8 cutting edges,
intended for facing and shouldering operations in theswitchers and bogie frames. The inserts feature different
cutting geometry, designed for machining various
engineering materials.
FFQ4 for high feed machining
A new family of high feed mills that carry square singlesided inserts with 4 cutting edges, the FFQ4 is designed
to reduce cutting forces when used on low powermachines or long overhang applications. The cutters areavailable in different design configurations: shell mills in
40 to 100 mm diameters, and end mills and replaceable
milling heads in smaller diameters. The cutters areintended for roughing operations, such as machining
plane surfaces, cavities and pockets, including ramping
by line and helix.

HIGH FEED

Square Insert for High
Feed Face Milling

Drilling
Old traditional bridge-type machines sometimes require
high overhang and the drills often need to operate inconditions of reduced rigidity.
The new SUMOCHAM drills with exchangeable drill
heads, cylindrical shank and internal coolant holes
enable high feed drilling, high accuracy and goodsurface finish.
Exchangeable ICP-type drill heads are recommended
for carbon and alloy steel (ISO P material group),
commonly used in producing railway components, andhave already received good marks in drilling operationsin producing bogie frames.
Combined drills enable users to perform drilling andchamfering operations with the use of the same tool.
Manufactured in different diameters, cutting depths
and overhangs, the design of the drills facilitates anincrease in cutting range conditions and a reduction
both in cycle time, as well as in the number of drills
involved in the process.

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MACHINING INTELLIGENTLY

DUSTRY 4.0

ISCAR proposes a variety of special drill solutions
for this sector, in particular for connections between
the rails and the switchers, which result in significant
reductions in machining costs.
The railway sector’s distinctive characteristics anddemands impact on cutting tool development in many
ways. ISCAR has responded accordingly by designinginnovative, productive and reliable solutions intended
for heavy-duty applications, that have already been
adopted with enthusiasm by manufacturers to improvetheir processes.

ISCAR proposes a varietyof special drill solutions forthis sector, in particular forconnections between the rails
and the switchers

ISCAR

39

Connecting New
Generation Tools
to New Generation
Machining Centers
Modern industry demands fast and effective solutions for mass
production. The new generation of multi-spindle machining
centers responds to this need; they can increase productivity by
the simultaneous machining of two to four workpieces. ISCAR
has correspondingly developed tooling solutions for this type ofmachine to ensure precision and quality in minimal setup time.

Tool builders need to adapt to developments in theaerospace, aviation and medical industries that havenecessitated machining high-temperature or exotic
materials with maximum efficiency. In particular, theapplication of coolant with high (or ultra-high) pressure,directly to the working area to increase efficiency andchip flow, requires a suitable tooling solution.
Vertical pick-up turning machines have wide
applications for manufacturing of automotive,
hydraulic and general industry parts, and their value inmaximizing efficiency should not be underestimated.

40

MACHINING INTELLIGENTLY

DUSTRY 4.0

Tools for Multi-Spindle Machining Centers
A multi-spindle machining center saves space at a
manufacturing facility and reduces tool inventory byusing combined tools for sequential operations anddecrease setup time by assembly and adjustment of
the same tool for each spindle.
The principal aim for using multi-spindle machines
without Z-axis compensation is to facilitate the axial
adjustment needed to achieve overlength precision.
This ensures part repeatability over all spindles andreduces cutting time, due to a more precise cut pass.

There are several existing methods for this purpose:• Grinded spacers, commonly applied on face milling
cutters to provide a simple technique for length
adjustment• Adjustable wedges on inserts for fine turning ofoverlapping (sometimes in addition to grinded spacers)
commonly used for face milling of the finish operation• Tools for drilling or boring operations, with exact holedepth, which can be adjusted by cartridges (there
is also an option for radial adjustment). For simple
solid carbide drills, the tool can be mounted on an
adjustable holder.
• Complex tools, incorporating different types of
instruments, which can be combinedly adjusted bysome (or all) aforementioned methods.

Adjustable
cartridges

Combined
systemadjustment

The adjustment of complicated technical systems tomeet customer requirements necessitates additionaltime and human resources for assembly and finetuning procedures.

ISCAR

41

A leading supplier of cutting tools and related
accessories, ISCAR provides completely assembled,adjusted, balanced and well packed tools.
MQL Applications
Minimum Quantity Lubrication (MQL) technology is
widely applied to multi-spindle machine tools, as
it circumvents the problem of liquid leakage frommachine and does not require additional equipment forcoolant return. MQL helps to maintain the machine's
condition during continuous usage, improves chip
quality, evacuation and recycling, and represents a"green" technology for a healthier environment.

42

MACHINING INTELLIGENTLY

DUSTRY 4.0

Tools with High Pressure Coolant
Applying high-pressure coolant in grooving andparting operations provides excellent chip breaking
results on all materials, reducing or even eliminating
built-up edge phenomenon, particularly whenmachining stainless steel and high temperaturealloys. To harness these capabilities, ISCAR designed
a wide range of tools for turning, grooving andparting applications with high pressure coolant, withdifferent sizes, adaptations and machine interface
connections.
The MODULAR-GRIP systems for high pressure
coolant were developed to reduce tooling costs andinventories, taking into consideration many yearsof experience in working with leading machine toolbuilders. Cooperation with significant players in themachine tool manufacturer market has led to thedevelopment of standard lines of dedicated tools
A complete solution fromcutting edge to machinefor each MTB interface, such as VDI, Dove tail (DT),CAMFIX, and a wide range of specific interfaces.
CNC turning machines with disc-type turrets use
different interfaces and often require
adjustment of the tool’s overhang.
ISCAR provided an answer to this need with theMulti Connection (MC) JHP line for turning, parting,grooving and threading tools mounted on holders
with a bottom fed coolant system, which allows
simple and rigid clamping and is widely used by
European, Japanese, Korean, USA, Chinese andTaiwanese MTBs. The multi connection tools
enable clamping on quick change tool holder andalso directly on the turret with different coolant
connections. Tools with a jet high pressure (JHP)
coolant outlet also deliver an advantageous
performance when conventional pressure is applied.

Tool overhang adjustment forbottom feed holders

Minimum
Tool Overhang

Maximum
Tool Overhang

ISCAR

43

UHP Solutions
Ultra-high pressure coolant (UHP) tools facilitate
effective machining of titanium and heat resistantmaterials utilized by the aerospace industry, in order toachieve high machining rates while maintaining small
chip sizes. ISCAR provides a variety of special UHP
solutions for different types of machine interfaces andvarious applications.
Tools with CAPTO connections without
automatic tool changers (ATC)Vertical pick-up turning machine turrets can beequipped with instruments without ATC, whichenables tools to be manufactured with as shortan overhang as possible. This in turn increases
machining process rigidity and stability, and lowers
tool production costs.
ISCAR has developed dedicated CAPTO blanks
with no ATC flange or inner thread, specifically for
producing these types of instrument.

Example of a tool without
automatic tool changers

44

MACHINING INTELLIGENTLY

DUSTRY 4.0

ISCAR45

ISCAR

INDUSTRY

The metal cutting tool industry is becoming increasingly moredigitized. Valuable cloud information to support your daily
production environment is simply a click away.

ISCAR introduces 4 PRO‎, a new online productinformation and machining recommendation tool.
4 PRO‎characterizes the enormous impact ofIndustry 4.0 on smart factory operations, maximizing
connectivity to increase productivity and reduce
costs. Combining new technologies with manageable
applications, 4 PRO‎provides customized machining
recommendations.

46

MACHINING INTELLIGENTLY

DUSTRY 4.0

4 PRO‎is now compatible with any operating system,enabling you to view vital process planning data inreal time before beginning the machining process,ensuring that the selected tools and inserts delivermachining results to meet your needs.

The Catalog option introduces product geometricalinformation, presented according to the ISO 13399 standard,
including the product, pack size, and production order number
for traceability at your end.

The ISO PMKNSH option
provides recommended
cutting speeds and feeds formachining any type of metal
according to the suggested
ISCAR grade.

The More Info option
provides additional productinformation which may beessential for your work andprocess planning.

The Relations option ties together
inserts and tools to match them up.
Complete information is provided
about every product.

The Grade Optimizer option
bonds the insert geometry andits coating to the correct typeof metal, allowing you to makebetter choices at the planningstages of the process.

ISCAR

47

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for ANDROID

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