2021

Logical Extension
Machining with noboundaries [pg. 4]

Barrel Cutter Shapes a
New Milling Trend
Efficient tools for machining
3D surfaces [pg. 12]

Choosing theRight Threading Insert

The most productive
and common methods
for producing threads [pg. 22]

The Best is Now

BETTERw w w. i s c a r. c o mElectrification in the
Automotive Industry

ISCAR's cutting edge technology
ahead of the industry [pg. 28]

Find The NEOLOGIQNEOLOGIQAL
AL Tool
For Your Application!
• The virtual tool advisor features advanced AIand ‘Big Data’ analytics• Supports with complicated machining tasks and challenges• Offers a wide range of functions and recommendations
to operate machining centers• Features online service 24/7 in more than 30 languages• Functions according to ISO 13399

Table of Contents
Logical Extension 

4Barrel Cutter Shapes a New Milling Trend 

12Cast-Iron LogIQ 

16

Choosing the Right Threading Insert 

22Electrification in the Automotive Industry 

28Machining Exotica 34

www.isc a r.c o m

Av a i l a b le n ow o n I S C A R . C O M

ISCAR

3

LOGICAL
EXTENSION
Today, ISCAR introduces NEOLOGIQ,
a logical extension to the previous
campaign comprising of an entire rangeof advanced products and technologicalsolutions for metal cutting tools - aquantum leap in the field.
What are the main targets of the
NEO product lines?
ISCAR believes that NEOLOGIQ provides theanswers to typical questions that modern
metalworking faces today due to the latest
changes in technology. Today, we are witnessing
serious upheaval with far-reaching effects
on manufacturing.
A distinct course for electric and hybrid cars willlead to a gradual abandonment of traditionalcars with an internal combustion engine and a
lot of parts that need to be machined.
A rise of accurate metal shaping methods,
such as precision investment casting,precision forging, and 3D printing, which are
all capable of shaping a part very close toits final profile, significantly diminishes thestock that is traditionally intended for chipremoval processes. A logical result of this is
the considerably reduced share of machining
operations in a part manufacturing cycle and thistrend is already noticeable in the market today.
Does it mean that a few good metalworking
shops, factories, or even whole branches
will abandon machining? Of course not, but
the requirements for machining operations inengineering processes will be changed.

4

MACHINING INTELLIGENTLY

DUSTRY 4.0

The role of productive and accurate cutting witha small allowance at high speeds and feeds will
substantially grow, and metalworking industries
will require a wide range of suitable tools that are
expected to be more precise and durable. Digitizedmanufacturing, which is dictated by INDUSTRY 4.0
momentum, has its own demand and expects a

new level of a cutting tool "intellect" to besuitable for smart manufacturing.
In preparing for the upcoming changes,
ISCAR considers NEOLOGIQ as the next logicalstep to the cutting tool for the smart factory.
‘Machining with no Boundaries’ is themotto of ISCAR’s NEOLOGIQ products.
ISCAR

5

INDEXABLE SOLID CARBIDE LINEV I DE OV I DE O

https://www.youtube.com/watch?v=I1-bJRC0v5Q

https://www.youtube.com/watch?v=x56Qy-oHL1E

ISCAR has an extremely wide range of HFM
products to meet the requirements of a customer.
However, even in this niche of products, there isplace for new innovations.
LOGIQ4FEED, a family of high feed milling
cutters carrying specific bone-shaped inserts,
was enriched by new tools with greater insert
sizes. These new tools have several features that
substantially improve performance in high feed
milling, especially when machining big cavities
and pockets in steel parts.

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MACHINING INTELLIGENTLY

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https://www.youtube.com/watch?v=3Y87bmrM28o

The progress in 5-axis machining and CAD/
CAM systems opens new horizons for machining
3D surfaces using barrel-shaped endmills.
Although such endmills are still not common in
the metalworking industry, advanced accurate
metal shaping methods will dramatically increase
the demand for these barrel-shaped endmills.
Therefore, the development of effective "cutting
barrels" is one of ISCAR’s highest priorities. In
the NEOLOGIQ product range, the barrel-shaped
endmills are represented by two configurations: asolid carbide design and a MULTI-MASTER head.
Combining MULTI-MASTER advantages with theprecise barrel profile of a cutting-edge will resultin a cost-effective and sustainable solution forfinishing complex-shape surfaces by milling withminimum machining stock.

Logical Milling

Another HFM product that provides the customer
with a reasonable cost saving solution is
NEOFEED, a family of mills with square, doublesided inserts. This insert has 8 indexable cuttingedges to use on cemented carbide and a dovetailshaped insert pocket that ensures reliable
mounting to withstand heavy loads to enablehigher cutting data and increased productivity.

V I DE OV I DE O

https://www.youtube.com/watch?v=lYMXBSLXSmk

The MULTI-MASTER family has expanded theboundaries of its product range by introducing
a new threaded connection size, T21, whichenables increasing the nominal diameter of an
exchangeable endmill head to 32 mm (1.25").
ISCAR

7

Intelligent Turning
In internal turning, a boring bar is the main factor oftool rigidity. A large bar overhang to diameter ratio
leads to the tool deflection and vibrations; and is
the bane of machining accuracy and surface finish.
WHISPERLINE, a family of anti-vibration boring
bars, was developed to exceed the ratio bounds.
These bars have a specially designed built-in
absorber and a vibration-dampening mechanismthat enables stable cutting with an overhang of up
to 14 diameters.
WHISPERLINE bars are important elements of
the new versatile modular system NEOMODU,
providing a rich variety of assembly options forturning tools. A combination of different system
units such as shanks, anti-vibration capsules, andinterchangeable heads with indexable carbide
inserts result in a tool assembly, which is maximallycustomized to a specific application.

The shanks may be cylindrical, square, or with apolygon taper interface in accordance with ISO
26623 standard.

A N T I - V I B R AT I O N

Speaking of new turning products, one cannot passthe XNMG insert. It is a beneficial combination of
two famous ISO rhombic insert shapes: CNMG and
DNMG inserts with 80° and 55° including angles.
This intelligent integration resulted in the XNMG 70°
angle insert that features improved clearance andramping angles, when compared to the CNMG, andstrengthened cutting corners against DNMG. The
advantages of the new insert are visible in efficient
multi-directional turning applications. The cartridges
carrying insert XNMG, which are intended for
mounting on NEOMODU units, are available as well.

V I DE O

https://www.youtube.com/watch?v=KXzpNO0VIKM

NEOTURN

ISOTURNINGV I DE O

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https://www.youtube.com/watch?v=IxPOjgNeqGc

ISCAR

9

Efficient Holemaking
One of the more impressive product lines introducedin the LOGIQ campaign is LOGIQ3CHAM, a family ofdrills with replaceable carbide heads and three cuttingedges, providing an effective tool for significantly
increasing productivity for drilling depths up to five drill
diameters.
In drilling, especially in drilling deep holes, efficient chip
evacuation is extremely important. It is not enoughto optimize chip control by an advanced design ofthe head geometry. The flute shape should ensure
seamless chip flow. Undoubtedly, the need to organize
three grooves weakens the body: when comparing
a two-helical-flute drill of the same diameter, thethree-flute body is less rigid. When the depth grows,
longitudinal vibrations may occur, and this reduces tool
life and adversely affects the accuracy and roughnessof a machined hole. It was the decrease in stiffness that
determined the barrier for the drilling depth and limiting
it by five diameters maximum.
A new design of the three-flute drill body is based on avariable flute helix angle. Such a concept considerably
improves the dynamic behavior of the drill and results in
expanding the drilling depth boundaries: the maximum
depth can now reach eight diameters.

V I DE O

https://www.youtube.com/watch?v=_3n8u4pfiRo

Competent Parting
ISCAR began its leadership with just parting tools.
That is why every company's innovation in parting
gains special interest.
Adapters and holders occupy a prominent place
among ISCAR’s NEOLOGIQ parting products. The
concept of the LOGIQFGRIP family is based on a
4-pocket adapter that is clamped in a reinforced
tool block. High rigidity of such an assembly in
combination with an inner high-pressure coolant
supply (HPC) option facilitates productive cuttingwith extremely high feed rates.
In parting, one of the secrets to success is welldirected high-pressure cooling. If an adaptor has
no HPC channels, mounting a specially designed
crown-shaped accessory pushes the boundaries ofapplication limits and enables effective pinpointed
coolant flow to the active cutting edge of an insert.

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Growing capabilities of modern multitasking
machines and turning centers pushed the common
boundaries of cutting strategies. Particularly, theybrought the method of efficient turning along Y-axis.
In quite a few cases, it is a worthy alternative to the
traditional X-axis machining. In Y-axis turning, thedissipation of cutting force components is morefavorable, and the main load is directed to a holder.
The cutting process becomes more stable, andthis facilitates increasing cutting data to improve
productivity.

LOGI

THREE FLUTEISCAR believes that new innovative solutions, whichtake machining to a whole new level, can become
the new “Ariadne's thread”. NEOLOGIQ, a logic ofdevelopment for a new range of tools, has expanded
the boundaries of intelligent machining.

3CHAM
CHAMDRILLV I DE O

https://www.youtube.com/watch?v=sNFDeFYj2yo

ISCAR

11

Barrel Cutter
Shapes a New
Milling Trend
Endmills featuring a cutting edge that is
actually the segment of a large-diameter arc
were introduced approximately 25 years ago.
As the cutting-edge shape of these endmills
is reminiscent of a barrel profile, terms suchas "barrel milling cutters", "barrel endmills"
or, in shop talk, often simply "barrels" soon
became common when referring to thesetypes of endmill.

At first, the use of these barrel-shape mills waslimited more or less to a few specific applications,such as machining 3D surfaces of complex dies andturbomachinery components. However, advancesin 5-axis machining and in CAM systems havesignificantly expanded the boundaries of barrel
endmill applications.
Traditionally, ball-nose and toroidal cutters
perform these machining operations. However,the large-diameter arc of the endmill cuttingedge results in a substantial reduction of
the cusp height generated between passes
machined by a ball-nose or toroidal cutter.
Another advantage of this type of cuttingedge versus ball-nose and toroidal
cutters is a significant increase in the
distance between passes (a stepoveror a stepdown, depending on the
direction of a cutter displacement
after every pass) - at least five times
more without degradation of thesurface finish parameters! Thismeans that the number of passes

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MACHINING INTELLIGENTLY

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and, subsequently, machining time can benoticeably reduced. Increasing the distance
between passes also improves tool life and,
therefore, diminishes tool cost per part.

When compared with a common taper endmill, thetaper barrel provides theoretically pinpoint contact
between the major cutting edge and a machined
surface that decreases accuracy errors and prevents
recutting of a produced shape. The taper shape also
contributes to reducing tool overhang – an importantfactor for improving tool performance.
Barrel and oval endmills are mainly utilized for cuttingside surfaces. If machining a complex bottom surface
is needed, a lens-shape endmill offers a goodsolution. This tool features barrel cutting edges on its
end surface to ensure milling with a large stepover.

The barrel endmills - classical barrel-, oval- and lensshaped cutters - provide efficient tools for machining
3D surfaces. Nevertheless, for a long time thecomplexity of CNC programming for applying barrel
endmills was a constraining factor in actively integratingthese promising tools into the appropriate branchesof the metalworking industry. The growing use of
5-axis machine tools and the latest progress in CAM
software has changed the situation dramatically, andtoday we see intensive utilization of barrel endmills in
manufacturing various parts with geometrically complex
surfaces. The main consumers of these "cutting
barrels" are producers of aerospace, die and mold,medicine, turbine and compressor components.
ISCAR

13

The MULTI-MASTER Advantage
ISCAR offers oval- and lens- shape endmills indiameter ranges of 8 - 16 mm and .312" - .500". In
addition to their availability in sold carbide design
configurations, the new barrel endmills have been
manufactured as exchangeable carbide heads with
MULTI-MASTER threaded adaptation.
Additional factors in favor of applying the MULTIMASTER concept to barrel endmills are economic
feasibility and sustainability. Due to the complicatedshape of its cutting edges, a barrel endmill is designed
as a throwaway tool - when the wear limit is reached,
the entire carbide endmill simply becomes waste. In
contrast to solid tools, the MULTI-MASTER design
provides a valuable option for careful and costeffective use of cemented carbide materials. And,of course, a rich variety of available MULTI-MASTER
shanks, reducers and extensions enables optimal
assembly of a required tool from these elements.
At present, barrel milling cutters are not in incrediblyhigh demand by the metalworking industry; they
are intended for very specific parts and effective
application of such cutters requires highly engineered
multi-axis machines and, especially important,leading-edge CAM systems. However, advanced
workpiece manufacturing technologies (such as metal
injection molding, 3D printing, investment casting andclose-tolerance forging), innovative machine tools,
and a quantum leap in digitizing of manufacturing
will increase the needs for finishing complex surfaces
with minimum machining stock. In this light, ISCAR's
specialists estimate that barrel endmill consumption in
the metalworking industry will increase exponentially,
and cutting tool manufacturers should be shaping up
to what is evidently a promising new industrial trend.

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ISCAR

15

CAST-IRON
LOGIQ
As can be construed from its name, cast ironis intended for castings. Machining cast ironparts involves removal of non-uniform andvariable stock - for example sand inclusions,
casting skin, blowholes, hot tears and othercasting defects, which affects cutting tools.
From a machining point of view, the higher
graphite content also has a disadvantage: it
accelerates abrasion wear. This means that the
cutting tools must have good wear resistanceto ensure high productivity. It is also worth
noting that the term “cast iron" may in factrefer to different types of ferrous alloy, forwhich machinability can vary significantly.
The latter is often neglected, which can leadto wrong choice of cutting tools and incorrect
definition of cutting data.
There are several types of cast iron. Grey, nodular andmalleable cast iron form the application group K (redidentification color) in accordance with the ISO 513
Standard classification. Hardened and chilled castiron relate to group H (grey identification color). These
specifications offer clear guidelines for manufacturers
regarding the application of cutting tools - correct tool
material, cutting geometry and cutting data selection.

For example, machinability of Ni-resist cast iron can becompared with grey cast iron; however, the required
cutting geometry seems more suitable for austenitic
stainless steel. Workpieces from austenitic ductile iron
(ADI) are delivered in different material conditions andhardness level that impact on selecting right cutting
tools. Machinability of ADI before hardening is sufficientand is similar to cutting high-alloy steel. Nevertheless, if
this cast iron is machined in a high hardness condition,
only the tools intended for the ISO H application groupwill meet the customer's expectations.
The situation with cast iron of high hardness in ISO
H group is challenging. Machining cast iron with ahardness of HB 400…440 is usually less of a problem
for manufacturers. However, the picture changes
radically when dealing with hard abrasion-resistanthigh-chrome cast iron. The general hardness may
be around HRC 52…54 but in the thin-wall areas ofa machined part, the hardness can reach HRC 60
and even more. In combination with the high chrome
content, it makes machining extremely difficult andsignificantly diminishes tool life.

Usually, machining ISO K cast iron is not a problem for
manufacturers. Ferritic grey cast iron, for example, isan easy-to-cut material. However, machining ISO H
cast iron is more difficult. Although similar to conditions
for machining hard steels, the material’s specificfeatures demand appropriate solutions from cutting
tool producers. In addition, some types of cast irondemonstrate a certain duality in their machinability,emphasizing the broadness and heterogeneity ofthe definition "cast iron".
16

ISCAR

17

Table 1 shows the averaged machinability rating fordifferent cast iron types. Pearlitic grey cast iron, whichis specified as 100% rating, provides a basefor comparison.

Table 1- Machinabilty rating of cast iron (averaged data)
Material

Condition

ISCAR
Mat. group*

Machinability%Greycast iron (GCI)

Ferritic
Pearlitic
Ferritic-Pearlitic
Pearlitic
Ferritic
Pearlitic
Soft

15
16
17
18
19
20
~17
~10

130
100
75
70
115
93
80
80

Hardened

41

35

Nodularcast iron (NCI)
Malleable
cast iron (MCI)
Compacted grathite iron (CGI)Austempered
ductile iron (ADI)
Ni-resist austentic CI

90

Chilled cast iron

HB 400...440

40

50

Hardened cast iron

HB 550...600

41

25* ISCAR material group in accordance with VDI 3323 standard

Selecting the most suitable cutting tool for machining
cast iron should be based on a detailed studyof a cast iron type and its hardness. Cutting tool
application specialists, who are involved in selecting
right tools, need to be fully accurate when specifying
characteristics of the cast iron that is intended formachining. In turn, cutting tool manufacturers make18

MACHINING INTELLIGENTLY

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every effort to find the most effective solutions formachining cast iron, taking into account the diversityof the cast iron world. Among the main consumers ofcast iron are the automotive, die and mold, machine
tool, and heavy industries – all demanding increasingly
efficient products from their cutting tool partners.

On a firm basis
The previously mentioned difficult-to-cut hard/high chrome cast iron produces serious barriers formachining productivity. A cutting tool experiences highmechanical and thermal loading. In milling this castiron by cemented carbide tools, for example, a typicalcutting speed is low: 40-50 m/min (130-160 sfm).
Intensive heat generation often forces manufacturers toapply wet coolant. As a result, the tool operates underconditions of a heat shock effect, which considerably
shortens the tool life.
ISCAR developed the DT7150 grade especially forthis type of operation. DT7150 is a "DO-TEC" carbide
grade that has a tough substrate and combines
medium-temperature CVD and PVD coating processes.
Due to its extremely high wear and chipping resistance,
DT7150 provides customers with an effective tool
material for cutting hard cast iron.
A fundamental significant change in productivity canbe reached with the use of cubic boron nitride (CBN),

which enables a considerable increase in cutting
speeds. In machining hard cast iron, for instance, thespeeds are 2-5 times higher when compared withcemented carbide. ISCAR's high-performance milling
cutters carrying tangentially clamped inserts with CBNtips are extremely popular in the automotive industry.
For hard turning applications, the company expanded
the range of CBN tipped ISO-type inserts for both
continuous and interrupted cut
In ISO K applications (machining grey, nodular andmalleable cast iron) in medium-duty loading, ceramic
tools have demonstrated good results. Peripherally
ground tangentially clamped TANGMILL millinginserts, made from the silicon nitride (Si3N4) gradeIS8, ensures increasing cutting speed up to 3 times
and provide excellent surface finish. In turning, cutting
speeds of up to five times faster can be achieved byusing the CVD-coated silicon nitride inserts, even forroughing operations.
ISCAR

19

The role of geometry

Customized solutions

Cutting geometry and edge preparation are crucial
for tool performance. There are several types of
cutting-edge preparations: rounded, chamfered andso on. Although selecting the required preparation
might appear to be a simple task, it is not so easy.
Which width or angle of chamfering will be the mosteffective? How to ensure the defined angle during tool
production? These questions are particularly criticalwhen using ceramic or CBN inserts. The answers
require appropriate professional skills and experience.

The automotive industry is one of the largest
producers of cast iron parts. In efforts to reduce
cost per part in the mass production of automotive
components, cutting tool manufacturers havedeveloped customized highly engineered tools that
perform specific machining operations with maximum
productivity and lead to reducing the non-cutting
component of cycle time.
A customized solution for machining steering knuckles
provides an excellent example of these combined
tools. ISCAR proposed this solution as a part of aturnkey project for one of the biggest car producers.
The combined assembled tool performs several
operations - cutting inner thread in holes for dust
shield by tapping; milling two grooves (for snap ringand grease seal) by helical interpolation; and millingthe outer face. The tool carries different radiallyand tangentially clamped inserts and has a tapping
attachment with a misalignment compensating
mechanism. The strict tolerance limits for linear
dimensions ensure successful utilization of the toolin multi-spindle machines.

Extra fine finisher
ISCAR's recent launch of new products in its“LOGIQ” marketing campaign included the TANGFIN
family of face milling cutters designed for extra
fine surface finish which has been of great interest
to producers of cast iron parts. The tangentiallyclamped inserts are positioned in a TANGFIN cutter
with a gradual displacement in both radial and axial
directions. The design causes each insert to cut
only a small portion of the material. This concept,
together with the high-rigidity tangential clamping
principle and the long wiper edge of the insert,
results in an impressive machined surface finish,with an Ra up to 0.1 μ (4 μin) roughness parameter.

20

It turns out that machining cast iron is not such asimple matter after all, as is sometimes believed.
Understanding the colorful world of this material
and following the cast-iron rules for correct cutting
tool application will ensure maximum efficiency anddemonstrate the tool’s "IQ" capabilities to achieve –and sustain - highly effective machining practices.

ISCAR

21

Choosing the Right
Threading Insert

A N T I - V I B R AT I O N

The production of thread connections is acommon application in the metal working
industry. Most metal working industries
produce parts that are characterized byexternal or internal threads, from tiny dental
screws to large thread joints for pipelines
associated with the oil and gas industry.
There are a wide variety of thread types produced in
National and International Thread Type Standards.
Thread types differ in shape and dimension, where
each standard defines a specific thread type. In
many cases, a thread type standard characterizes
a specific requirement for an industrial branch or
main field of application. For example, UNJ andMJ thread type standards are associated with the
Aerospace industry, and NPT and BSPT standards
are associated with the oil and gas industry forpipelines, pipe connectors, and fittings.
Thread turning applications are one of the mostproductive and common methods for producing
threads in rotary workpieces.
A successful thread type turning application depends
on the selection of the right threading tool. There
are simple steps to selecting an indexable threading
tool correctly; first, identify if the thread is external orinternal for which to choose a right- or left-hand tool.
After choosing the feed direction corresponding to thethread type, the thread designation will be determinedaccording to the part drawing and application.

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ISCAR

23

There are two types of threading inserts:
full profile and partial profile.
Full profile inserts produce specific thread types, i.e.,
round (Rd) in accordance with DIN 405, British Standard
Whitworth (BSW). Partial profile inserts require a
precise pre-turning operation.
ISCAR’s laydown family of inserts offers a wide rangeof thread type standards for both internal and external
applications. Laydown inserts can be divided into 3
main types:
G-type – General duty inserts with deflector formachining various engineering materials, including the
production of short chips.
M-type – Press-to-size inserts with sintered-shaped
chipbreaker for efficient chip control. Although these
inserts are press-to-size, they ensure the same thread
accuracy as the
G-type insert. When threading at too small depths of cut,the chipbreaker efficiency drops and the M-type inserts
are less recommended.
B-type – Peripherally ground inserts with a pressed
chipbreaker. Efficient chip control with a sharp cuttingedge is the ultimate combination for long chip materials
and the first choice for ISO M stainless steel. Whenmachining small parts, it is beneficial to use sharp-edged
inserts with a chipbreaker to reduce cutting forces andconsequently prevent vibrations.
Before using the multi tooth insert, it’s important toensure the thread area is not next to the shoulder, or that
there’s a wide release groove to complete a full thread
along the part.
In addition to the ISO Standard laydown insert, ISCAR
has a diverse group of captive pocket inserts. Captive
pocket inserts are divided into internal threading andexternal threading types according to their application.
Contrary to the ISO Standard laydown insert family, theclearance angles are already ground.

Typically, the thread designation is in accordance withmetric or imperial systems depending on the thread
type standard. In most cases, the thread designation
includes the following parameters:• Standard classification• Thread pitch• Number of starts• Nominal diameter• Thread length• Tolerance class
The moment we have the values of the thread
diameter, thread pitch, and the number of starts, we
can calculate the thread lead (Helix) angle φ. This value
will be very important for the next steps of the anvil
selection if a possible solution relates to lay-down
inserts. For such a tool, the found lead (Helix) angle
determines the choice of anvils.

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MACHINING INTELLIGENTLY

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Aside from setting the correct lead (helix) angle, theanvil also supports the insert’s cutting edge andprotects the tool in case of insert breakage.

ISCAR

25

PENTACUT is one of ISCAR’s successful captive pocket
insert families. PENTACUT threading inserts have a wide
assortment of benefits:
5 cutting edges and a cost-effective solution!
Equipped with a molded chipbreaker for efficient
chip control.
Strong design for better conditions and productivity.
Sub-family of partial profile inserts specially designed
for working close to the shoulder with diverted
cutting edges.
For right- and left-hand threading.
Ability to machine between walls.

ISCAR's wide diversity of inserts covers most of
the market’s demand for threading standards. Withadvanced solutions per specific applications, ISCAR
can offer tailor-made solutions according to any
customer request.

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MACHINING INTELLIGENTLY

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ISCAR

27

Electrification in
the Automotive
Industry
Public awareness of global warming,
together with a pressing concern to create
and maintain a clean environment, has led
to a series of legislations worldwide thatis forcing automakers to decrease CO2
emissions. A rapid increase in battery
electric vehicle (BEV) development,
manufacture, and implementation, showsthat electric vehicles are not only the
future but are, in fact, the present.
The following is a list of some of the common
component machining processes in the BEV
industry and some of the leading possible
machining solutions and recommendations
for each part.

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ISCAR

29

Stator housing machining

Bearing Seat Reaming After Assembly

One of the most notable trends of the electricvehicle powertrain is its simplicity. There are far
fewer moving parts compared to the traditional
internal combustion engine (ICE), therefore
manufacturing time, and cost dramatically dropwhen producing BEV's.
One of the main components of an electricmotor is the motor (stator) housing madefrom aluminum. A special approach isneeded to achieve this part’s critical key
characteristics of lightweight, durability,
ductility, surface finish and precision,
including geometrical tolerances. The partiallyhollow form represents an additional challenge
and maintaining low cutting forces is essential forroughness and cylindricity requirements.
ISCAR’s complete machining solution for thisprocess has facilitated the transformation fromthe standard costly lathe-based process to an
economical machining center. Our aim is to reduce
scrapped parts and reach an optimal CPK ratio.
(Process Capability Index- producer's capability to
produce parts within the required tolerance.)

Unlike the ICE, the electric motor generates its maximum
torque from a standing start. This means it does not
require a complex transmission system to operate. A
simple reduction gear is enough for the average electricvehicle. This reduction gear sits between the stator
housing and the gear cover.
To maintain concentricity between bearing seats of thestator and gear cover, the reaming operationmust be performed in the same machining sequence.
For this operation, ISCAR provides a special "push andpull" reaming type tool with adjustable PCD blades thatmanage to retain the geometrical tolerances required indifferent inner diameterson this Aluminum part.

Main Diameter Reaming
The most challenging operation in machining theAluminum stator housing is the main diameter
boring and reaming. Because of the trend
to use low power machines, the tool's
large diameter and long overhang require
creative thinking to minimize weight andspindle load while maintaining rigidity. Exotic
materials such as titanium and carbon fiber
are used for the tool body, as well as thewelded frame design.
The use of Finite Element Method (FEM)
helps resolve the obstacles associated withthis challenging application by enabling theconsideration of many parameters, such as cutting
forces, displacement field during machining, natural
frequency, and maximum deformation.

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MACHINING INTELLIGENTLY

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Rotor Turning
The rotor consists of many stacked plates of electric
steel. Lamination sheets are used instead of a solid bodyto reduce current loss. The surface must be completely
clean of chips, oil, water, dust or dirt, and coolant fluid
cannot be used, only air. This is a challenge as a lot ofheat is generated on the cutting area and the fragmented
chips stick to the surface. Surface finish requirements forthis interrupted turning operation remain strict.
ISCAR has overcome these challenges by developing
a combined tool with coolant holes both on top andbottom of the cutting edge to cool and blow away thechips. The two round inserts are positioned for semi
finish and finishing operations, generating an excellent
surface finish.

ISCAR

31

ICN - Std. range
Ø10-19.5 (.394-.768")

ICG - Std. range
Ø14-25.9 (.551-1.020")

AOGT - Small sharp
polished insert

Battery Case Drilling
As batteries are replacing fuel as an energy sourcefor vehicles, the battery case is an integral componentof the car design. Large size and light weightrequirements make aluminum a natural choice for
manufacturing this part. But, when dealing withhigh-end supercars or sport cars, every unit of weight
counts. That is why some automakers turn to theuse of carbon fiber reinforced plastic (CFRP), which
offers lighter weight, high rigidity, and lower thermal
conductivity than aluminum.

Using ISCAR's cutting edge technology andinnovative solutions will keep the part manufacturer
ahead of the industry and help him adapt fast to thegrowing changes for a cleaner, greener, and healthierplace to live in.

ISCAR has a wide array of tools specially designed
to machine aluminum and CFRP, which provide
productive and economical solutions for any
application. For example, for the required drilling
holes, the SUMOCHAM indexable head drilling line
offers a variety of geometries suited for specificmaterials. For drilling Aluminum, ICN heads aredesigned with a sharp cutting edge and polishedrake face. ICG heads feature a chip splitter for betterchip removal when working with a long overhang.
For drilling CFRP, special ICF geometry is available
with diamond coating - this drilling head is designed
to overcome all the typical CFRP machining failures
such as delamination.

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MACHINING
EXOTICA
Mainstream engineering materials areiron-based alloys such as steel, stainlesssteel, and cast iron. Another group of
regularly used materials includes alloys
based on nonferrous metals, such asaluminum alloys, brass, and bronze.
In addition, there are exotic types ofmaterial that were developed to answer
specific demands. These exotic materials
feature a dedicated application; they arerare and not commonly used and are
generally more expensive to fabricate.
A strict agreed definition of an exotic material
does not exist. Many experts refer to them as
metals like Beryllium, Zirconium, etc. and their
alloys, ceramics, composites, and superalloys.
When considering the use of structural
materials, superalloys and composites should
be distinguished first. The metalworking industry
mainly deals with these types of materials due
to several reasons, one of which is machining
exotic materials is problematic. Superalloys, ormore specifically, high temperature superalloys(HTSA), are intended for operating under aheavy mechanical load in combination withhigh temperatures. They are largely used in gas
turbines and in various valves and petrochemical
equipment. The "exoticism" of superalloys is their
metallurgical design, which provides high creep
resistance to keep strength at high temperatures.
According to the main component, HTSA
can be divided into three groups: Nickel (Ni)-,
Cobalt (Co)-, and Iron (Fe)-based superalloys. A
superalloy chemistry, especially in case of Ni- andCo-based HTSA, results in poor machinability.

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Composites are multicomponent materials.
When compared with a traditional engineering
material, such as steel or Aluminum, composites
workpieces are nearer-to-net shape and do not
require significant material removal. Nevertheless,the components of a composite have different
properties, and when combined, they produce aheterogeneous structure that makes machining
problematic. The process of machining composites
differs from machining metals and it often looks
more like shattering than cutting. High composite
abrasiveness can lead to intensive tool dulling,
and various performance problems such as adegradation of accuracy or non-repairable
machining defects.
An impressive leap forward in 3D printing, which
may significantly diminish machining operations,looks very promising. But there is one "exception",
which still limits taking full advantage of theconsiderable increase of machine tool capabilities.
This "exception" is the cutting tool. Despite thedistinct progress, cutting tools remain the bottleneckfor machining efficiency. Hence, the plans of abreakthrough in the productive machining of exotic
materials have much to do with the cutting tool.
Recent ISCAR developments, which were introduced
during the last years, give a good example of suchproducts and ISCAR’s attempt to resolve the existingbottleneck and find new ways to move forward.

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Cutting Diamond
In manufacturing parts from composites, drillingis widely regarded as the major cutting operation.
Improving capabilities of drilling tools has had a direct
impact on the effectiveness of machining composites
and composite stacks.
Most recently, ISCAR introduced a series of new
solid drills, in the diameter range of 3.3-12 mm(.130-.500"), which are specially designed forcomposites. The common feature of these tools isthe use of polycrystalline diamond (PCD) or diamondcoating to ensure high abrasion wear resistance. There
are several types of these new drills; one of them isbased on using a PCD nib as a central point of a drill,
and another type has a diamond wafer. Both drill types
offer a large area for multiple regrinding.
The third type of drills are solid carbide tools with adiamond-coated cutting area. Their wavy cutting edge
facilitates reducing burr formation, specifically whendrilling carbon fiber reinforced plastics (CFRP) and
CFRP-Aluminum stacks.

Exotic for Exotic: advantageous ceramics
Cemented carbide is still the main cutting material formachining. Introducing carbide tools revolutionized
the metalworking industry ensuring a significant
growth of productivity due to sharply increased cutting
speeds. However, despite this, even today cutting
speeds for difficult-to-machine Ni- and Co-based
high-temperature superalloys (HTSA) are low: typicallywithin the range of 25-50 m/min (80-160 sfm). How
do we expand the speed boundaries?

ceramics. The mills are intended mostly for roughand semi-finish machining of planes and 3D surfaces
at extremely high cutting speeds. The economical
double-sided insert design provides high ceramics
utilization. The inserts are made from several ceramic
grades such as "black" ceramics, whisker reinforced
ceramics and SiAlON (a type of silicon-nitride-based
ceramics). Applying the new mills is directed on
maximizing metal removal rate (MRR) and dramatic
reduction in cycle time.

Exotic ceramic materials have already foundthemselves as cutting materials. Using exotic ceramicmaterial ensures a totally different level of cutting
speeds. For example, machining the superalloys byceramic tools, the cutting speed 1000 m/min (3300sfm) is completely real. Therefore, ceramic tools
become more and more common in machining HTSA.
Recently, ISCAR developed a family of indexable
shell mills carrying double-sided inserts made from

One more example of successful usage of cutting
ceramics is another of ISCAR's latest products: afamily of solid endmills from SiAlON. The endmills
were designed specifically for productive roughmachining Ni-based superalloys such as various
grades of Inconel, Incoloy, Haynes, etc. in theaerospace industry. In comparison with typical solid
carbide endmills, SiAlON endmills allow an increase in
cutting speed of up to 50 times!

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Coolant Solver
In machining exotic superalloys, effective coolant
supply is a cornerstone of success. Pinpointed highpressure cooling (HPC) can be a significant tool
to improve cutting performance. It is a real sourcefor greater tool life, better chip control, and higher
productivity.
One of the latest ISCAR's developments is a family ofturning tools with ISO-type indexable inserts. The tool
design utilizes an upper clamp for reliable securing of
the inserts even during heavy and interrupted cuts.
The previous turning tools with the HPC option had
a lever clamping mechanism as an upper clamp
would obstruct a jet of coolant from reaching the
cutting edge.
The newly developed tools integrate a hollow upper
clamp that allows for solving two problems:• strong and rigid insert clamping• eliminating any obstacle for the coolant jet
on its way to the cutting edge
Hence, the clamp, which serves in the new tools asa coolant nozzle, received an additional importantfunctional feature.
The new products with through-tool coolant supply
are beneficial not only in machining with HPC. Their
applying to turning with conventional external "low"pressure cooling (10-15 bars) also provides better
performance.
In parting and grooving, especially in deep grooving,
efficient chip forming has crucial significance.
Pinpointed high-pressure cooling of a cutting edge
significantly diminishes chip jamming and reduces
built-up edge. Within the past year, ISCAR expanded
the range of its HPC products by introducing newface grooving tools with HPC option. These tools are
suitable for coolant pressure of up to 140 bars.

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ISCAR's new chipformer F3S for finish turning exotic
superalloys was designed for popular ISO-type inserts(CNMG, WNMG etc.). A typical finishing operation ischaracterized by shallow depth of cut and low feed.
Therefore, the success of a chipformer lays in a small
area that adjoins the insert cutting edge. It will take realengineering "art" and a lot of effort to redesign this area
for much better performance when compared with theexisting inserts.
F3S gives an example how to do this successfully. It
has a reinforced cutting edge to prevent notch wear aswell as a specially designed deflector for efficient chip
control in finish turning HTSA. In combination with apositive rake, these features ensure a smooth and easy
cut, notable chip breaking capabilities, and significant
reduction in cutting forces.

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LOGI

THREE FLUTE

HIGH FEED

3CHAM
CHAMDRILLGRIP HOLDERw w w. i s c a r. c o m