VER 1 - 2018

The LOGIQ of
Machining Intelligently

Taking the concept of machining
intelligently even further byapplying logical improvements
to tool development [p. 4]

Industry 4.0 for Cutting
Tool Manufacturers

What does Industry 4.0 signify
in practical terms and how do
we apply related technologies
to our processes? [p. 8]

Indexable Tools
Challenge Solid Carbide
For Small Diameters

Precision and performanceadvantages position indexable
solutions competitively against
solid carbide tools [p. 30]

Industry 4.0
Strategies To Inspire
Metalworking
Solutionsw w w . i s c a r. c o m

A Road Map For Effective
Cutting Tools In The
Automotive Industry

Pinpointing automotive OEM
needs to create smart combined
tools that improve productivity
and reduce cost per unit [p. 44]

Become an
INDUSTRY 4.0 Master!
SystemIntegration
IoT

RobotsBig Data

Cloud

3D
Simulation

ISCAR’s Easy to Use Digital World of Applications
Web Apps
E-CAT

Mobile Apps

CLOUD

Table of Contents
The LOGIQ of Machining Intelligently 

4Industry 4.0 for Cutting Tool Manufacturers

8

A New Look for Gear Milling?

18

Harmonizing Vending Systems with Industry 4.025

Indexable Tools Challenge Solid Carbide for Small Diameters

30

Machining Miniature Medical Parts

36

A Road Map for Effective Cutting Tools in the Automotive Industry44

The Right Grade for Industry 4.0 Productivity

50

ISCAR

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The LOGIQof Machining
Intelligently
This year has seen ISCAR launching its new LOGIQ line with aseries of major events at ISCAR locations around the globe,
where thousands of customers and ISCAR salespeople havebeen captivated by ISCAR CEO and IMC president Jacob Harpaz’s
comprehensive and compelling presentation featuring ISCAR'slatest cutting tool developments.

An industry leader and innovator in the world ofmetalworking, ISCAR has taken the IQ concept ofmachining intelligently even further by applying logicalimprovements to tool development. The result is the
LOGIQ range of tooling solutions that both predicts
and fulfils customer needs. LOGIQ represents asmart logical progression in a series of strategic
moves to implement Industry 4.0 standards while
ensuring continuity and stability.
Industry 4.0 directives - to integrate interoperability,
technical task assistance and decentralized decisionmaking into factory practices - challenge machining
centers to review their operations and adopt

procedures to meet these objectives. Machining
logically responds to this need. ISCAR provides
the tools to make it happen.
LOGIQ applications have created new toolfamilies, upgraded existing lines, and inspired
innovative product ranges to maximize equipment
utilization and optimize performance. Listening tocustomer concerns and staying ahead of market
developments, ISCAR’s product managers, R&D
engineers and designers have combined theirexpertise and experience to develop highly effective
and logical tool solutions that meet today’s machining
center demands.

MACHINING INTELLIGENTLY

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4

ISCAR

IMC President and CEO of ISCAR, Jacob Harpaz
ISCAR

5

LOGIQ Campaign Launch at ISCAR Headquarters

In an industry where every second makes a difference
and every movement counts, logical strategic design
and tactical enhancement of even the most basic
cutting tool can contribute to increased productivity,
less wastage and lower costs.
LOGIQ's unrivalled, out of the box tool innovations
include new cutting geometries and locking
mechanisms for stable, vibration free machining
with higher repeatability. The indexable inserts
are equipped with sophisticated chip formers andcontain geometries that facilitate soft cuts at highfeed rates.
Solid carbide tools are enriched with new designs
that feature substantially increased anti-vibration

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strength – a key factor for boosting productivity inunfavorable cutting conditions. The latest cemented
carbide grades reflect ISCAR’s forward looking
knowledge and know-how in powder metallurgy andcoating technologies. The toolholding line includes
new heat-shrink-fit and vibration-dampening devices,which significantly improve performance when tool
rigidity is critical.
The new LOGIQ milling solutions include strong,
durable inserts and milling heads with enhanced
capabilities. The LOGIQ turning applications offer
new solutions to decrease machining loads, produce
thinner and wider chips, and resolve vibration issues
and coolant flow capabilities.

The LOGIQ drilling tool concepts provide advanced
productivity solutions for high accuracy andrepeatability, to reduce machine cycle time andproduce high-end machined components.

From concept to realization, LOGIQ-inspired tools
reflect ISCAR’s commitment to create and deliver
high quality products that contribute to increasing
productivity and profitability.

The LOGIQ lines feature LOGIQ3CHAM tosignificantly improve drilling productivity;
LOGIQ4TURN for enhanced performance in generalduty turning operations; LOGIQ4FEED, whichenables rough milling at high metal removal rates;
LOGIQ8TANG, a new 90° square milling shoulder;
LOGIQ5GRIP, a versatile and high-efficiency solution
for parting and grooving, and other tool families
comprising hundreds of new products; each
designed and developed to perform essential
tasks in the most efficient possible method.

The fourth generation of the Industrial Revolution
has unveiled new standards and requirements formachining metals.
ISCAR is at the forefront of this important industry
trend, developing relevant technologies andimplementing methods of effective machining toreflect and respond to the dynamic needs of themetalworking industry.

LOGIQ Campaign Launch in Las Vegas, U.S.A.

ISCAR

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Industry 4.0 for
Cutting Tool
Manufacturers
The term “Industry 4.0” has already entered our everyday
lexicon in many spheres: from journalism and appliedscience to vocational training and industry.

Concepts such as “smart factory”, “Internet of Things”,“cyber physical systems” and “machine to machine”
are no longer considered science fiction and we may
soon be meeting the reality behind these phrases
in metalworking plant processes. Yet there remains
a world of misinterpretation and miscomprehension
between terminology and implementation. What does
Industry 4.0 signify in practical terms and how do weapply and optimize Industry 4.0-related technologies inour manufacturing processes?
Industrial Revolutions
Originally, “Industry 4.0” (“Industrie 4.0”) was a German
governmental initiative to digitize manufacturing

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industries. A source of irresistible inspiration toeven the most cynical industry players, the Industry
4.0 concept has brought the ideas of complex
computerization and production automation, interobject data exchange, and decision-making processes
to formerly unattainable levels. “Industry 4.0”
epitomizes the fourth industrial revolution.
The first industrial revolution saw the transition frommanual labor to machine production and the second
industrial revolution – the technological revolution –transformed mass production. The third industrial
revolution replaced analog with digital electronics,
also causing radical changes not only in
manufacturing but in everyday life.

“Industry 4.0” is how we refer to the fourth industrial
revolution, which encompasses cyber physicalsystems - integrating digital components into physicalprocesses, the Internet of Things (a concept of
networking physical objects with embedded informatic
technologies), 3D modeling and printing, virtual
reality applications and other concepts; some already
implemented and some waiting in the wings.

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ISCAR Industry 4.0

MACHINING INTELLIGENTLY

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Smart Factory
The smart factory represents the central model for
smart manufacturing. Cyber physical production
systems perform under the conditions of real-time
information exchange in an environmental context
that combines real and virtual worlds, with systems
interacting via the Internet of Things. For example,
the physical system shows the position of a cutting
tool and acting cutting forces, and the virtual system
specifies the tool’s 3D path during operation and set
machine stock allowance.

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Integrating IoT
The main principle of a cyber physical system (CPS)
involves the integration of digital resources into physicalprocesses and their reciprocal interaction – the Internetof Things (IoT). IoT ensures data exchange between
the systems and so interconnects the objects or“things”, which are then able to understand each other,intercommunicate, and make decisions depending on
a current situation. Introducing IoT in manufacturing

processes increases flexibility and adjustability,with the potential to improve efficiency considerably.
Today’s cutting tools and toolholders containmicrochip sensors to automatically control tool
identification and changing, and a range of devices
and machine-tool blocks offer automatic tool wear
monitoring, temperature changes, and more: the tool
evolves to become a component of the emerging
cyber physical system.

The main principle ofa cyber physical system(CPS) involves the integrationof digital resources into
physical processes

ISCAR

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ISCAR Adopts
3D Printing
Technologies

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MACHINING INTELLIGENTLY

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Virtual Manufacturing (VM) integrates digitalmodelling and technical process simulation. VM
started as a production design tool and a means forcollision checks during machining; it is considereda textbook “Industry 4.0” solution, combining virtual
processing with things (including the manufactured
product), based on data capture from sensors.
The third industrial (digital) revolution opened thedoor to a new technological method – additive
manufacturing (AM) or 3D printing. Currently utilized
mainly for prototyping, this technology is beginning tobe adopted as a means of fabrication.
3D printing accuracy limitations cannot replace finemachining. Yet AM is already a significant elementof the Industry 4.0 concept: it is enough to send thecomputer model of a part to a 3D printer, which may
be located remotely, and then produce the part there.
This feature takes customer service to another leveland may significantly reduce delivery factors.
Cutting tool manufacturers are their own customers,
which means they can tap into customer needs
directly from one important source - themselves.
A good example is the MATRIX intelligent
computerized tool storage unit, developed by ISCAR
to improve manufacturing efficiency in its own
production divisions. Realizing that MATRIX could
resolve similar issues at customers facilities, thesystem is today regarded as a typical component ofan Industry 4.0 directed factory.

ISCAR

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MACHINING INTELLIGENTLY

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United by a common language
The first step towards unified intercommunication has
been taken already. The ISO 13399 standard specifies
computer representations and data exchange related
to cutting tools and their holders - the lexicon of thelanguage. Tool digital data is platform-independentand CAD/CAM and VM systems can utilize the data
seamlessly. With Industry 4.0 linking physical andvirtual things, cutting tool manufacturers are having torethink how data is supplied to the customer and toadjust accordingly.
A smart factory requires smarter tools that will
digitally store data related to tool properties, such aspredictable tool life, accumulated cutting time, andtool designation, as well as limitations like maximal

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rotational speed. The need for uniform rules - toclassify data and its computer representation - will
require the cooperation of both companies andgovernmental agencies.
Understanding the importance of informationinteroperability is critical. A meaningful data exchange
requires the things to “speak” the same language andthe data should be represented in a single format;
manufacturers need to bring their product informationin line with the new language rules and implement it
in a unified way. This is the cornerstone for building asmart factory and tool producers who do not learn tospeak the language may find themselves outside thesmart factory walls.

ISCAR

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MACHINING INTELLIGENTLY

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A meaningful data exchange
requires the things to “speak”
the same language and thedata should be represented ina single format

Moving ahead with Industry 4.0
Cutting tool manufacturers would do well to integrate
Industry 4.0 elements into their processes, to improve
production quality and increase tool reliability andtool life predictability. Developing tools that cancommunicate with other devices via IoT technologies
will require systematic cooperation between
manufacturers to establish a common language,
uniform specifications and standard
data implementation.

Tool design engineers will have to enrich their theoriesof metal cutting, mechanical design and technology
bases by acquiring knowledge of the communicative
abilities of things and an understanding of how to
implement Industry 4.0 directives into their practices.
The fourth industrial revolution started building thewalls of the smart factory and manufacturers should
not ignore these momentous changes. “Smart tools
for a smart factory” is not just a buzz phrase but a realguideline for savvy manufacturers to move production
processes in the right direction - forward.

ISCAR

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A New Look
for Gear Milling?
Technology and its products are often causative: atechnology might be applied to develop more effective andintelligent products, which in turn can play an importantrole in advancing that technology.
Over the last few years, leading-edge technology has
resulted in multitasking machine tools and machining
centers with impressive working possibilities. At thesame time, this progress in machine tool engineering
is significantly changing metal cutting technology.
The advanced multifunctional machine tools
increasingly widen the range of machining operations
that can be performed. Technological processes
developed for these machines are oriented tomaximize machining operation for one-setup
manufacturing, creating a new source for moreaccurate and productive manufacturing. Milling
gears and splines is one of the operations suitablefor performing on the new machines.
Traditionally, gear (and spline) making is acomplicated process that involves milling,chamfering, grinding and other operations.
With batch manufacturing, the majority is made on
specific machines: gear hobbing, gear shaving, gear
grinding and so on. Developments in technology
have changed the limits of hardness for cutting andconsiderably increased operational accuracy.

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This in turn has reduced abrasivemachining in gear making while
decreasing rough cutting. The modern
multifunctional machines, which meet therequirements of one-setup manufacturing, have
proved to be perfect for various gear making operations.
These new machines require appropriate toolingand cutting tools manufacturers should prepare their
response accordingly, which is why producers ofgeneral-purpose rotating cutting tools are reconsidering
the role of gear-milling cutters in their program forstandard product lines.
ISCAR, a leader in the cutting tool industry, isembodying this trend with a three-point program forform gear-making tools:• Milling cutters carrying indexable inserts• Milling cutters with replaceable cutting heads
based on the T-SLOT concept• Milling cutters with replaceable MULTI-MASTER
cutting heads

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MODUGEAR Application

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4.0
DUSTRY 4.0

MODUGEAR, the family of indexable gear-milling
cutters, reflects a conventional design approach,comprising disk-type tools with tangentially clamped
LNET inserts. The tangential clamping principle
provides an extremely rigid and durable cutter
structure that results in stable and precise enoughmachining tooth or spline profiles. Its principal
application is producing involute gears of relatively
low accuracy and rough gear-milling operations thatfeature a 1-1.75 mm (039-.069") gear module range.
The cutters with replaceable heads have two
significant advantages compared with gear milling
tools carrying indexable inserts: they offer better
precision and allow the design of gear-milling cuttersthat are small in diameter but feature quite a large
number of teeth. The replaceable heads are mounted
in bodies (shanks), which are standard-line products
suitable not only for the gear-milling heads but also
for other types of head (for milling slots and grooves,for example). This enables customers to increase
operating efficiency of the versatile shanks and to
reduce tool stock, providing added value.
The replaceable solid carbide heads of the T-GEARSD D32-M…-SP15 family are mounted in standard
T-SLOT SD-SP15 cylindrical shanks and transformthe latter into 32 mm (1.26") diameter gear milling
cutters. The precise profile of the cutters’ teeth andthe accurate and reliable SP-connection between theshank and the head define its range of use: milling
involute gears featuring a 1-2 mm (.039-.079") module.

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T-Gear Application

Both types of milling cutters (those with indexable
inserts and those with replaceable heads) meet therequirements of standard DIN 3972, basic profile II.
There are two types of MULTI-MASTER splineand gear making solid carbide heads.
The first type is represented by the MM SS heads thatwere specially designed for milling involute spline shafts,
specified by DIN 5480 and ANSI B92.1 standards.
These heads are intended for 1, 1.25, 1.5 …, 3 mm(.039, .049, .059...,.118") module (DIN 5480) and 8, 10,
12 …, 24 diametral pitch (ANSI B92.1).
The heads of the second type, MM SG, are usedin milling spur gears in accordance with DIN 3972
(module 1-1.75 mm (.039-.069")) and ANSI B6.1
(diametral pitch 15-24) standards.
The main application field for MULTI-MASTER heads isthe efficient production of small to medium batches of
spline and spur gears in various industrial branches.

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The world of gears encompasses a wide variety
of external and internal gears: spur, helical, bevel,
hypoid, and more. Manufacturing these gears
involves an entire industrial sector with its own
methods, equipment and tooling. The introduction ofmultitasking machines in gear milling - asa serious alternative to a dedicated machine - could
shake up this sector and producers of commonlyused cutting tools should “gear up”
for the challenge.

The connection ensuresa very durable assemblythat withstands considerable
cutting forces duringslot milling

T-SLOT, a family of modular milling cutters
SD-SP…, was originally developed for milling
relatively narrow slots and grooves.
A cutter comprises a shank and an interchangeable
solid carbide head, mounted on the shank with the useof a specially designed SP-connection. The connection
ensures a very durable assembly that withstands
considerable cutting forces during slot milling, evenin cases when a tool works with high overhang. The
heads of the same diameter vary in their width. The
cutting geometry of the heads is intended for efficientslot milling of different engineering materials.
The design features of the heads do not limit theirfield of application by milling slot and grooves. The
subsequent development stage introduced T-GEAR –a family that uses a SP-connection but is intended
for form milling gear teeth.

A MULTIMASTER
end milling toolcomprises a shank carrying
interchangeable solid carbide
cutting head with treaded rear area for quickchange connection with the shank. MULTI-MASTER
benefits include minimum setup time and more than
15000 possible configurations of tools assembled
from the standard shanks and heads. If necessary, theassembly can be completed by extensions. The shanks
have been developed in a variety of materials: steel
for general-duty applications, tungsten carbide having
higher rigidity, and heavy metal featuring increased
vibration resistance, which considerably expands
assembly options.

ISCAR

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MATRIX family

WIZ

MINI
ToolPort 8D/4D

DLS 8D/4D
MAXI

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4.0
DUSTRY 4.0

Harmonizing
Vending Systems
with Industry 4.0
New vending and vending-related solutions, inspired in partby Industry 4.0, have been appearing on the horizon recently,
with a shared aim of providing manufacturers with better andleaner ways to manage and dispense items to
the shop floor.

Here is a brief overview of some of the most relevant
and exciting developments to maximize – andharmonize - production efficiency.
Compact Smart Vending
Big bulky machines have their place, but they will
never be fully point of use, or provide the smart
manufacturing cell with its own autonomy. Some
suppliers offer bench top units which are compact insize but pack a punch well above their weight when it
comes to features. They typically offer a full software
suite and provide 100% control and accountability perbin or per individual item. This makes them ideal forthe modern shop floor, where the machining process
and selection of cutting tools cannot be compromised.
MobilityThis has been one of the catch words of the last
decade or so. Today we take it for granted that our
office, social activities and more sit in our pocket.
Users expect to be able to transact and track tool
crib activity on the go. A new generation of Android
based hand-held devices – each one loaded witha rich menu of reports and data presented in a
mobile- friendly format – allows users to see what’s
happening. These devices can be a full substitutefor those old cumbersome Windows CE hand-helddevices that had to be carted around to issue items
from warehouse or tool room stock. The UI is what
one would expect of an Android-based app, witha clear uncluttered interface that offers just enoughinformation for users to promptly and easily carry out
daily transactions.
And there’s some more good news – the Android
devices are usually a fraction of the cost of the older
Windows-based systems. There are also some great
devices out there that combine a professional 2D
scanner with a rugged hand-held device, which haveboth changed the limits of hardness for cutting andconsiderably increased operational accuracy.

RFID

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IoT – the Internet of Things
Some unique ideas have surfaced that bring theInternet of Things to the shop floor in a manner that
doesn’t require complicated and expensive installation,or subscription fees that can virtually
break the bank.
One such innovation is the integration of real timelocation systems – or RLTS - into a host of production
assets that tend to be very nomadic, such as gauges,
fixtures, measuring devices, test equipment and more.
Knowing where they hide out can save money bylowering capital investment and reducing downtime.
There are different technologies out there, using RFID

(passive) and BLE (active Bluetooth low energy). The
trick with all this stuff is to make it simple to use andfocused on what the end user really needs. Flashy
dashboards with tons of graphs and analytics lookgreat, but it’s usually just a simple location ID thatallows the user to quickly locate an asset. Accuracy
can be affected by the physical environment, andwhere and how many gateways are deployed toreceive data transmissions. However, knowing thegeneral position, within a meter or so, will normally beenough, and the current technologies can deliver on
this. Metrics that log and analyze location history allow
for greater optimization in the use of production assets
for further indirect cost savings.

MATRIX on production floor

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MATRIX on production floor

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Smart Manufacturing
RFID chips on tooling and adapters can be loadedwith tool assembly and other production data toallow for an error-free experience at the point ofuse. Tooling is placed in a modular housing where
the chip data is read and transmitted to the tool
management software, which then limits vending totools authorized for the job. The cost of using
the wrong tool can be exorbitant and lead toscrapped parts, delayed orders and risks that could
compromise the manufacturer’s reputation.
In aerospace, for example, it is critical to eliminate
the risk of using the wrong tool.

Cloud Tool and Data Management
Several companies already offer cloud-based
applications to find, select and assemble the righttools for the job. Many cutting tool manufacturers
develop and offer their own digital catalogs andtool selection apps. Integrating all of these with job
planning and vending platforms makes sense andsome vending systems offer this important feature.

Real-Time Data Analysis
Pulling it all together with advanced reporting
options, analytics and customization is essential
for targeted and efficient navigation through thehuge quantities of data that a vending system
can generate. This includes thousands of SKU’s,
hundreds of thousands of transactions, multiple
users, cost centers, logistics parameters and more.
Mining out what you need and calculating theperformance metrics will make all the difference
between staying ahead or drowning in all that data.

What’s next
The above innovations already provide us withtangible advances, bridging the gap between the pastand the future smart factory - where AGV’s, artificial
intelligence and robotics will probably deliver tools tothe point of use just in time.
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Indexable Tools
Challenge Solid
Carbide for Small
Diameters
Rotating one-piece solid carbide tools traditionally dominate themarket for diameter ranges of up to 20 mm (.75”) and indexable
tool manufacturers have not yet succeeded in penetrating this solid
stronghold. Several important factors contribute to the historicalperception of solid carbide as a better bet for tooling reliability.

Solid carbide tool accuracy compares favorably withthat of indexable tools, particularly for small-diameterendmills and for tools with diameters beyond therange. However, the role of reduced accuracy fortools of small diameter (for example, a milling cutter’sradial run-out) increases in significance as a factor
affecting tool life.
An indexable tool is made up of a tool body,
replaceable inserts, and mechanical parts suchas clamping screws or wedges, which secure theinserts in the body. Decreasing the tool diameter
necessitates reducing dimensions of the assemblycomponents. Reducing the size of the securing
elements leads to weakening their strength and thetool becomes unable to withstand cutting loads
under normal machining data. This seriously limits
the tool application; further decreasing may cause
degradation of the entire assembly structure.
The prices of small rotating tools are often highcompared to the assembled concept, which adds
to the perceived limitations of indexable tools in thesmall diameter range.

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NANMILL

NANMILL

NANO ENDMILL

An indexable tool is made up
of a tool body, replaceable
inserts, and mechanical parts
such as clamping screws or
wedges, which secure theinserts in the body.

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The Indexable Option
Indexable tools possess several distinct advantages
that makes applying these tools within the above
range very attractive in the eyes of the customer.
In many cases, especially in rough machining,changing a worn cutting edge by simple indexing
provides economic benefits compared with having
to replace a whole life-expired solid tool with a new
tool. In addition, there is no need to use up time andresources on regrinding and recoating worn-out onepiece cutters.
Tool manufacturers have made significant progressin developing reliable designs that could becommercially viable against the solid carbide
concept. Work in this direction has shown results
already, and assembled mills and drills withinterchangeable cutting heads are proving to bea realistic alternative to solid carbide tools.

Competitive performance
The introduction of tools with replaceable solid carbide
cutting heads signifies a change in focus. ISCAR provides
two examples of this concept with the ISCAR MULTIMASTER milling line and the CHAMDRILL line in drilling.
Performance and accuracy characteristics havepositioned the new tools to be functionally competitive
with solid carbide designs. Versatility of these lines,
where a head can be mounted in different bodies andvice versa where a single body can carry different
heads, facilitates various assembly combinations andcontributes to reducing items in tool stock.
Another important design approach - “no set-up
time” - characterizes these lines, as a worn-out head
does not require spending time on set up and can be
replaced while the tool is still clamped in the machine
tool spindle. This cuts cycle time and, consequently,
reduces production costs. In contrast, replacing aworn-out solid carbide mill or drill inevitably leads
to a new set-up procedure.

No SetupTime

MULTI-MASTER Applications

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SUMOCHAM Application

In addition, the concept ensures sustainable use of
cemented carbide with all the associated advantages.
The principle of “indexable” carbide tools has distinct
merits and features strongly in tool design within the
diameter range that is under discussion. The minimal
diameter of MULTI-MASTER milling heads is
5 mm (0.2") and that of SUMOCHAM drilling heads is
6 mm (0.236"), while the MULTI-MASTER combinedcountersink heads for center drilling feature a minimal
1 mm (0.04") diameter.

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The LOGIQ factor
ISCAR has recently introduced a new range of small
size indexable rotating tools under its LOGIQ range,
featuring cutters with a nominal diameter of up to
20 mm (.75"). The new families of indexable milling
cutters within the diameter range of 8-16 mm(.315-.625") attract the most interest and possess
several common features: the cutters carry triangularshape inserts with 3 cutting edges and the mechanicalpart that secures the inserts is represented by a screw.
These families are intended for milling square shoulder
or fast feed (high feed) milling. But here the similarity
ends, and the difference begins.
While the design of the HELI3MILL and
MICRO3FEED families for tool diameter 10-16 mm(.375-.625") secures the insert by clamping thescrew through the central hole of an insert, the
NANMILL and NANFEED families for tool diameter
8-10 mm (.315-.394") adopt a different concept, asa central clamping screw is not feasible within sucha small diameter range.
According to the new concept, the screw is locatedabove the insert, and the screw head plays the roleof a wedge. This approach provides reliable andrigid clamping, ensures a durable homogeneous
insert structure with no hole, and allows insert
indexing to be quick and simple.

HELI3MILL Application

MICRO3FEED Application

NANMILL Application

It is predicted that these new families will be
particularly effective in manufacturing compact
parts and in machining small-size cavities,
pockets and small parts utilized in industrial
sectors such as die and mold making, as wellas in producing miniature components.

NANFEED Application

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Small change, large impact
A 1 mm change in size: is this a lot or a little? For
indexable tools in the small diameter range, it makes
a noticeable difference. ISCAR’s new SUMOCHAM
4 mm (.039") diameter drilling head represents animportant step ahead in expanding the application
fields of indexable drills.

SUMOCHAM Application

Within the small diameter range, indexable tools
can offer precision and performance advantages
that position them competitively against the more
traditional solid carbide tools. Indexable tools are
beginning to shear their way into metalworking
practices - and the industry is taking note.

These new families will
be particularly effective inmanufacturing compact parts
and in machining
small-in-size cavities, pockets
and small parts utilized
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Machining
Miniature
Medical Parts
The miniature medical manufacturing industry is one of the world's
fastest growing industrial sectors and the demand continues toincrease for smaller, more intricate and accurate medical industry
parts. Machining intricate and minute devices, often using hard-tomachine metals such as titanium, represents a major challenge formetalworking shops, who need to develop a range of advanced
capabilities to meet these specialized demands, especially when
involved in small batches and prototype work

ISCAR conducted numerous research and field trials
to develop a new range of cutting tools for miniatureparts production in the medical industry. In addition, aseries of modifications were applied to existing popular
tools to enable the efficient and economical machiningof miniature parts.
The expanded range of machining solutions for small
scale cutting tools was made possible by developinguser-friendly quick indexing inserts, suitable toolgeometries, and by designing ultra-secureclamping systems.

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ISCAR

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CUTGRIP Application

Tools for Miniature Medical Parts
High Pressure Coolant Channel for
Grooving and Turning
Incorporating a jet high pressure (JHP) coolant
channel, the GHSR/L-JHP-SL tool family is an
improved version of the popular GHSR/L screwclamped tools. The tools are designed for Swiss-type
and screw machines.
The insert clamping system enables the inserts to befastened using a key from either side of the tool: thetorx screw is inserted on one side, while a speciallydesigned plastic screw blocks the opposite sideto prevent chip entry. If indexing is required fromthe other side, the screw can be switched to the
opposite side of the tool.

The GHSR/L-JHP-SL tools are manufactured in 10,
12 and 16 mm(.375, .5 and .63") shank sizes to hold
GEPI and GEMI inserts carrying different chip former
geometries, and the inserts range from 2.2 to 3.2 mm(.087 to .126") widths. Integrated jet high pressure
coolant channels extend tool life and improve chip
evacuation.
Turning small parts requires light cutting parameters,
making small sized economical inserts more suitable
than large inserts for this type of machining. The
shorter head design of the GHSR/L tools allows
higher rigidity and improved machining stability, whichenables the application of higher cutting conditions toenhance surface finish.

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SWISSCUT XL INNOVAL
A new SWISSCUT XL line featuring up to 10 mm(.394") grooving depth capability has been designed
to enable deeper machining than that provided by the
SWISSCUT INNOVAL line, with the aim of reducing
the number of items needed by half and cutting users’
inventory costs.
The clamping design uses a special screw that can beaccessed and operated from both sides of the tool,
enabling inserts to be indexed without the need to fully
remove the screw.
This represents a significant improvement over existing
tools, where the clamping screw must be fully removed
for insert indexing and can easily fall and get lost.

SWISSCUT Application

PENTACUT
The popular PENTACUT line now includes 17 mm(.67") diameter PENTA inserts, designed with 5
cutting edges for machining miniature parts with up
to 4 mm maximum grooving depth capability.
The inserts are produced in a range of widths from0.25 to 3.18 mm, with different edge configurations
for parting, grooving, turning and threading.

PENTACUT Application

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PICCO Inserts
ISCAR expanded its range of PICCO inserts’application options and insert sizes by adapting
insert geometry and a carbide grade especiallyfor machining medical parts made from titanium,
stainless steel, and other difficult to machinematerials, including hardened steel up to 65 HRC.
The family includes profiling inserts for minimum
bore diameter range of 0.5 – 4.0 mm, with 0.02 mm
corner radii and an internal cooling channel close to
the cutting edge.
Advanced PICCOACE Tool Holders
The growing demand for high accuracy and flexibility
in clamping orientation brought about an advanced
new series of tool holders developed by ISCAR, the
PICCOACE range. Featuring a patented clamping
system, the tool holders set new standards inthree highly important areas - accuracy, rigidity andclamping orientation flexibility.
PICCOACE’s fast action and very secure clamping
system increases machining efficiency by saving time
when replacing an insert, ensuring rapid indexing andguaranteeing extremely high clamping repeatability of
0.005 mm.
The wide variety of Swiss-type machines available
today has increased the need for multi-orientatedclamping; however most of the existing tools provide
a single clamping orientation. In contrast, ISCAR’s
PICCOACE offers a high-quality, universal solutionthat is suitable for all Swiss-type machines, enabling
operators to install and remove the boring tool fromany desired direction.

ISCAR’s PICCOACE offersa high-quality, universal
solution that is suitable for
all Swiss-type machines,
enabling operators to installand remove the boring toolfrom any desired direction
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PICCO Application

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MINCUT Application

MINCUT Grooving Line
New MIFR 15 inserts and tools for face grooving
up to 15 mm depths and turning operations play asignificant role in maximizing the possibilities for small
scale tooling.
The new MIFR 15 inserts are screw-clamped into along pocket on the MIFHR -15 bars with very rigid
clamping, enabling high machining parameters andresulting in prolonged tool life.
The MINCUT line includes MIFR 15 inserts in 2.5, 3.0
and 3.5 mm widths, as well as full radius 2.5 and 3.0
mm inserts made from IC908 grade.

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Turning Miniature Parts
To accommodate small boring diameters, ISCAR has
developed positive and negative boring tools withsteel and solid carbide shank options, new small size
inserts, and coolant channels directed precisely to theinsert’s cutting edges.
The tools carry new positive (single-sided) ground
EPGT and CCGT inserts. The EPGT insert has a
75°geometry designed for a minimum bore diameterof 4.5 mm, and the CCGT insert features an 80°
geometry for minimum bore diameter of 5.0 mm, withshank sizes in a diameter range of 4 to 7 mm.
Tools for negative (double-sided) inserts Dmin=12 mm
carry ground WNGP and DNGP inserts. WNGP has an
80° geometry for a minimum bore diameter of 12 mm
and DNGP features a 55° geometry for minimum bore
diameter of 13 mm, with shank sizes in a diameter
range of 10 to 20 mm for forward and back turning
operations.

Drilling with SUMOCHAM
The small diameter range of ISCAR’s SUMOCHAM
hole making line includes new drilling heads and tools
covering diameters of 4 mm up to 5.9 mm, with 0.1
mm increments. The 4 to 5.9 mm drilling range iscovered by 4 sizes of SUMOCHAM DCN drill bodies
in 3xD and 5xD length to diameter ratios; and isdesigned especially for this industry. A user-friendly key
was specifically developed to enable easy mounting
with no set-up time.
The medical device and implant industries have mademajor and highly significant advances in miniaturizing
medical parts; it is up to cutting tool manufacturers
to enable the realization of these achievements byproviding the tools for the job, however small.

The VNGU, CNGX, CNGG and CXMG double-sided
inserts with 4 cutting edges present an alternative tothe conventional ISO standard positive inserts with
only 2 cutting edges; operating similarly to positive
inserts with the same corner angles, they provide theadded advantage of double cutting edges.

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43

A Road Map
For Effective
Cutting Tools
In The Automotive
Industry
Developing artificial intelligence applications and self-drive vehicle
algorithms aren’t the only challenges facing OEM automotive
companies today. Consumer demand is increasing for new cars to
be fully equipped with the latest accessories and technologies.
International authorities and environmental
protection agencies try to keep pace with
automotive developments by introducing relevant
legislation and specifying automotive engineeringand manufacturing standards that, at the end of
this chain, affect vehicle costs.
Meanwhile, automotive OEMs are expected
to supply consumers with state of the art
equipment and enhanced car performance and all for an affordable price.
Automotive OEMs are expected to supply
consumers with state of the art equipment
and enhanced car performance - and all for
an affordable price.
To achieve this complex goal and reduce theend price without compromising on quality,
OEMS are constantly investigating how tolower production costs, which represent themost significant part of the total manufacturingcost. Global cutting tool making companies
have been charged with identifying effective
methods to lower production costs and ISCAR,44

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following intensive task analysis and research,
recommended first breaking down the overall
goal into two objectives:• Increase production floor productivity byimplementing process efficiency measures• Decrease cost per unit (CPU) by improving
cutting tool architecture
ISCAR’s expanded range of machining solutions
for small scale cutting tools was made possible
by developing user-friendly quick indexing inserts,
suitable tool geometries, and by designing ultrasecure clamping systems.

Increasing productivity
The metal cutting process can bedivided into two states: the cutting
tool operation during material removalfrom the stock part and the air motion of
the tool. This stage combines approach,retract and tool changing movements.
Cutting operation
Proper cutting conditions represent an
important parameter while cutting. Cutting
tool manufacturers provide their own
recommendations for cutting parameters
based on their rich experienceand understanding of metal
cutting processes at the
microstructural level.

To meet these needs, ISCAR developed
the ITA – ISCAR Tool Advisor application,a set of online adviser tools for users toenter desired job parameters and limitations,to obtain appropriate machining solutions for eachjob. The software selects the best available solution
for the inputted application, providing cutting tool
recommendations (including depth and width ofcut and number of passes), cutting data, power
requirements and productivity results for eachsolution option.
All parameters are expressed in the parameter MRR(Metal Removal Rate) and a higher value indicateshigher productivity. Users can utilize the primaryknowledge database to machine applications
with optimal technology and cutting
conditions, to achieve high productivity
with maximum efficiency and minimum
wastage.

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45

Air motion
The air motion mode in the cutting process cannot
be neglected in mass production, as idle movement
time is costly. ISCAR approaches this issue byadvising manufacturers to review their technologicalprocesses and to utilize a combined tools approachin order to reduce retract and tool changing
movements.
Combined tools
As a modern full-solution technological process
comprises dozens of tools, this contribution to
production optimization is highly significant. Every
combined tool design takes in account a machine
center parameter, such as maximum cutting
diameter, spindle speed limitations, spindle motor
power, and more.
The picture on the right shows a combined tool
designed by ISCAR, for machining a cast ironsteering knuckle part. The tool combines drilling,
front chamfering, back chamfering, shouldering,and bottom shouldering. By using this tool,cycle time is reduced significantly, and thecustomer can decrease chip-to-chip timeby up to 60%.

As a modern full-solution
technological process
comprises dozens oftools, this contribution to
production optimization ishighly significant

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Saving space
Combined tool designs also offer a solution fortool storage magazine capacity issues, particularly
when production floor space is limited. Tool storage
magazine capacity is proportional to the machine
footprint and the machine size affects costs.

PRE-THREAD DCNT

Shown on this page are a selection of ISCAR
combined tools:
PRE-THREAD DCNT (M8-M24) Indexable headdrills with chamfering inserts, used mainly for
pre-thread holes.
MULTI-MASTER MM EDF Interchangeable 3
flute solid carbide heads for upper and bottom
chamfering.
SSB-LN15-R/L Single-side cutting, disk typeslotting cutters carrying tangentially clamped
LNKX 1506 inserts.

SSB-LN15-R/L

MULTI-MASTER MM EDF

ISCAR

47

New Concepts for Cost Reductions
The number of cuttingedges per insert represents
a significant parameter fortools with interchangeable
inserts, with a higher
number of cutting edges
decreasing the CPU.

Leading metalworking companies applied thisconcept to create new generation products withmultiple cutting edges, with ISCAR developing a
range of multi-edged products that includes theHELIQMILL, a tool family with three cutting edges
that “evolved” from the well-known HELI2000 family.
The HELIIQMILL HM90 ADCT 1505 HELI2000 radial
clamped insert with two helical cutting edges wasadapted to integrate three edges, resulting in theHM390 TDKT 1907 HELIIQMILL radial clamped
triangular insert with three helical cutting edges
while retaining the same price level.
A wide range of intellectual properties, stable
insert production process, proper cutting-edge
treatment and tight quality control: these points
are considered essential for staying competitive andresearch and development of new materials andtheir implementation is an integral component of thismultipurpose objective.

Profitability Per Unit

Cost Per Unit (CPU) reduction
The bottom line for automotive OEM manufacturers
is the cost of producing a part and cutting tools
represents a variable cost factor in setting a cost
per unit parameter.

No. of Cutting Edges
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HM390 Application

S845 Application

Turbine Housing
Synergic cooperation between OEM andmetalworking companies regarding turbo-chargers
illustrates this strategy, where both parties aimed to
optimize and stabilize the technological process ofturbine housing production. The most common raw
material used was steel DIN 1.4848 – an austenitic
heat-resistant casting steel – but rationalization forces
and cost reduction pressure necessitated a switch tocheaper alternatives: austenitic heat-resistant casting
steels DIN 1.4837 and DIN 1.4826, which are moredifficult to machine.
Leading metalworking companies were asked tofind solutions to this new challenge. ISCAR achieved
this with the integration of new insert material grade
MS32 together with cutting edge geometry andtreatment to produce tools with improved cutting
conditions and maximum insert tool life, including theS845 SNHU 13 MS32 radially clamped insert with 8
helical cutting edges. And the market benefited fromreceiving new, dedicated tools for turbine housing
production.
On the right track
This development shows how the collaborative
manufacturer-OEM customer model has led to a
new road in tool development, and how ISCAR
applies its intellectual resources to create smart
combined tools for improved productivity andreduced cost per unit. The automotive market
benefits from the new applications and everybody
stays on track in keeping down prices while
optimizing performance.

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49

The Right Grade
For Industry 4.0
Productivity
Cutting tools have different design configurations. Some ofthem are assembled comprising a body with replaceable cutting
elements (indexable inserts, for example), another is wholly
produced from solid material. Functionally, a cutting tool may
be divided into a cutting part that is involved in cutting, and amounting part, which is necessary for mounting the tool in a holder
or a machine spindle.

A tool material is the material from which the cutting
part of a tool is produced. This is the material that
directly contacts a workpiece during cutting.
The tool material must be harder than the workpiecematerial so that it can cut the workpiece.
In machining, the tool material needs to withstandmechanical and thermal loads, and oxidation.
These factors cause gradual loss of the tool material
or a change in its original shape: this is known as“tool wear”. When wear reaches a certain limit, thecutting part cannot work, and the tool fails. The
machining time interval, within which the tool cuts
normally from its original (new) state to a failure, isknown as “tool life”. The tool must meet appropriate
requirements of hardness, strength, and thermal andoxidation resistance to withstand wear and ensure an
acceptable tool life.

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Cutting tool manufacturers produce a variety oftools from different tool materials according to thedesired tool application. “Which material is moresuitable for my specific needs? Is the material of one
producer better than another?” Customers often ask
themselves these questions when selecting the toolor choosing their cutting tool supplier.
Industry utilizes the following tool material groups
to produce cutting tools: high speed steel (HSS),
cemented carbide (hard metal, HM), ceramics,
cermet, and ultra-hard materials such as cubicboron nitride (CBN) and polycrystalline diamond(PCD). Each group features various types within thegroup; these are referred to as “tool material grades”
or simply “grades”.

Classification
International standard ISO 513 classifies tool material
based on their reasonable applicability with respect
to the materials. ISCAR adopted this standard anduses the same approach in tool development. In
accordance with the standard, the tool material
grades are characterized by a class of engineering
materials, to which a tool produced from the grade
can be applied successfully. Each class has a specificidentification letter and color:steel and cast steel
except stainless steel
with austenitic structurealuminum and othernon-ferrous metals andmaterials

austenitic and duplex(austenitic/ferritic) stainlesssteel and cast steel

high-temperature
superalloys and titanium

cast iron

hard materials likehardened steel and castiron, chilled cast ironA classification number follows the letter to show thehardness-toughness ratio of the grade according toa conventional scale. Higher numbers indicate anincrease in grade toughness, while lower numbers
indicate an increase in grade hardness. Higher
numbers represent increasing feed and lower
numbers represent increasing speed.

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51

Cemented carbide
Cemented carbides are very hard materials andcan cut most engineering materials, which aresofter. Some carbide grades demonstrate better
performance than others when applied to machining
a specific class of materials.
A carbide grade is the result of combining cemented
carbide, coating and post-coating treatment. Carbide
is an essential component of the grade, while
integration of integration of coating and post-coating
elements depends on the grade application’s main
field. Produced by powder metallurgy technology,
cemented carbide is itself a composite material andcomprises hard carbide particles “cemented” by abinding metal, which is principally cobalt.
Main types of cemented carbide include tungsten(wolfram) carbide (WC), tungsten carbide andtitanium carbide (TiC), and tungsten carbide, titanium
carbide and tantalum carbide (TaC). Mixed binders,containing not only cobalt but additional elements
such as ruthenium, may significantly improve
grade performance.

A carbide grade is the resultof combining cemented
carbide, coating andpost-coating treatment

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Spider MachineMost cemented carbides used for producing cutting
tools integrate wear-resistant coating and are known
as “coated cemented carbides”. Applying a thinlayer coating to a cemented carbide considerably
improves the carbide’s working characteristics andthe coating may be one- or multi-layer, dependingon the number of coating materials. These include
TiC, alumina (Al2O3), titanium carbo-nitride (TiCN),
and titanium aluminum nitride (TiAlN). Post-coating
treatment processes are applied to already coatedcemented carbide, for example, to the rake surface
of an indexable insert.
Coating Processes
Two methods may be utilized for coating: Chemical
Vapor Deposition (CVD) and Physical Vapor
Deposition (PVD). CVD coating is based on chemical
reactions in a vaporized medium and PVD uses
material sputtering. Technology development
allows both methods to be combined for coating
cemented carbides, as a means of controlling
coating properties. For example, ISCAR’s carbide
grade DT7150 features a tough substrate and adual MT CVD (Medium Temperature CVD) and TiAlN
PVD coating. The grade was originally developed to
improve machining special-purpose hard cast iron.

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53

A New Levelof Productivity

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Nano layered PVD coating
PVD coatings were introduced during the late 1980’s.
Applying advanced nanotechnology, PVD coatings
performed a gigantic step in overcoming complex
difficulties. Scientific developments resulted in a newclass of wear-resistant nano layered coatings - a
combination of layers with a thickness of up to 50 nm(nanometers) that demonstrate significant increases incoating strength compared to conventional methods.

Examples from ISCAR’s material groupclassification system:

Applying SUMO TEC technology
SUMO TEC is a specific post-coating treatment
process developed by ISCAR to improve both CVD
and PVD coatings: CVD and PVD. In CVD coatings,
the difference in thermal expansion coefficients
between the substrate and the coating layers causesinternal tensile stresses and micro cracks. PVD
coatings produce surface droplets. These factors
negatively affect the coating and shorten insert
tool life. The SUMO TEC treatment has the effectof making coated surfaces even and uniform by
reducing and even removing the defects - minimizing
inner stresses and droplets in the coating.

LetterDefinition

IB

CBN

IC

Cemented carbide and cermet

ID

PCD

IS

Ceramics

DT

Cemented carbide with dual
(CVD+PVD) coating

Classifying Grades
ISCAR, which produces a variety of cutting tools
with cutting parts mainly fabricated from coatedand uncoated cemented carbide, developed atool material grade characterization system withdesignated letters indicating the material group andnumbers representing identity codes. The numbers
also provide quick information on the grade type for example a two-digit number following “IC” in thedesignation of a cemented carbide grade means that
it is an uncoated grade, while a three-digit number
relates to a coated grade.
Occasionally, misconceptions occur concerning
grade designation for a coating type. IC300, forexample, relates to the specific grade in its entirety– including both the grade substrate and coating.
Wording such as “grade IC328 but with coating
IC300” is inaccurate; the correct definition would
be “substrate as in grade IC328 and coating as
in grade IC300”.

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55

“The best grade is a grade you have now”
When a new insert (solid carbide tool or replaceable
cutting head) is developed, it is necessary to decidefrom which grade it will be produced. The answer
to this question depends on the insert’s designatedapplication and this represents a starting point for tool
designers in their work. Grade properties and theirrelative hardness-toughness ratio will be the main
determinants to take into consideration.
In some cases, stock availability and delivery
terms may be the significant factors in thedecision-making process.
As people engaged in production like to say, the best
carbide grade is the grade that you have in your stock.
This statement can be applied to the cutting tool asa whole; it is probably true if it relates to a production
situation that requires an immediate decision. However,productive process planning - or effective tool stock
management - requires a more in-depth applicative
analysis of the pros and cons of the proposed
carbide grades.

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ISCAR

57

Selecting a grade is strongly connected with the
cutting geometry of a tool and other factors. The
cutting tool manufacturer should provide thecustomer appropriate information about grade
properties to assist in their correct selection. While
computerized grade selection systems are impressive
and effective, often simple graphical figures, charts
and tables can act as a good information “compass”
to visualize a grade position in the field of applicationin accordance with standard ISO 513, andcharacterizing the grade properties comparedwith other grades.

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ISCAR uses charts and tables to specify the cuttingarea of milling tools and proposes suitable grades for
replaceable inserts in indexable milling cutters, solid(mainly solid carbide) endmills, and replaceable solid
milling heads with Multi-Master adaptation.
ISCAR characterizes the grades as main andcomplementary. The main grades are more popularin machining specific engineering materials, but
complementary grades can be effective as well in
certain cases. When a main grade is not available for
producing a certain product, a complementary grade
provides an acceptable alternative.
The tables provide summary data for grade
applications and the charts show “an applicative mapof grades”, in coordinates of classification numbers
from standard ISO 513. The figures often prioritize
the main grades by numbers in brackets below
the designation of a grade. Prioritizing is general incharacter and is intended to assist in selecting thecorrect grade when there is insufficient information
about the application.

The basic principle for selecting the grades is thatwhen abrasive wear is dominant, a hard grade
should be used, whereas a tough grade is needed
for substantial mechanical loading during cutting.
For example, for finish milling with typically small
machining allowance (machining stock), high cutting
speed and low feed, hard grades will be more
efficient. However, tough grades will be required forheavy-duty roughing that removes significant volume
of material and features considerable cutting load.
Even with the myriad of digital options available
today, tool manufacturers often prefer the simplicity
and clear visuals offered by traditional tables andcharts that provide important data in an easilyinterpretable and effective way, allowing optimal
selection of the right tool materials for eachapplication.

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DUSTRY 4.0

w w w . i s c a r. c o m3360509 RG 8/2018 © ISCAR LTD All rights reserved

MACHINING INTELLIGENTLY