Cutting tools: Turning tools metal tech report
- May 16, 2013
CVD coated diamond tools
CVD thick-film tools are harder than PCD and twice as wear-resistant.
The extremely long tool life of diamond tools combined with an optimized chip breaker on the CVD diamond cutter can increase machining productivity by up to 35 per cent and reduce processing costs by up to 80 per cent. Various inserts with wiper geometries have been developed for high performance machining and continuous turning.
Iscar’s new Dove IQ Turn features a dovetail pocket combined with a lever clamping mechanism that provides firm and rigid insert clamping, eliminating the need for a top clamp, which interrupts chip flow. The clamping mechanism can firmly hold double-sided inserts featuring double negative prism flanks. The dovetail pocket and insert prismatic flanks prevent the insert from being lifted by the cutting forces.
Available are three insert geometries with prismatic flanks: WOMG-R3P-IQ, COMG-R3P-IQ and SOMG-R3P-IQ, designed with a new R3P chipformer for rough turning of steel.
New insert geometries
New insert geometries for steel, stainless steel and HRSA material and customized toolholders have been added to the company’s range of options to apply coolant in the machining process. When using low pressure (7-10 bar/100-150 psi) the CoroTurn HP holders with high precision nozzles outperform regular toolholders that have an tendency to flood coolant, claims the company. The new -SMC, -MMC, -PMC insert geometries in combination with the CoroTurn HP nozzle technology, provide greater productivity for demanding materials such as duplex stainless steel and HSRA material, which require higher coolant pressures of 70-80 bar (1000-1200 psi).
Turning cast iron
The Duratomic-coated TK1001 and TK2001 insert grades achieve versatility, reliability and exceptional wear resistance in cast iron machining. They also allow for faster cutting speeds and reduce the number of grades needed in cast iron applications.
TK1001 is a hard, fine-grained tungsten carbide turning grade with low binder phase content. Designed primarily for tackling gray cast iron up to semi-stable conditions and nodular cast iron under stable conditions, it also works on hardened steels in the 40 – 45 Rc range. TK2001 is a fine-grained tungsten carbide turning grade with high toughness. It offers strong performance in interrupted finishing operations due to its tough substrate and extra edge toughness.
Nexus Tools is a new line of turning and boring tools with negative and positive toolholders and boring bars. The new tooling provides greater rigidity and reduces vibration, and leads to reduced insert wear and increased tool life. Also offered is the Capto-compatible internal and external turning tools available in C6 internal and external models for turning, boring, threading and grooving.
Longer tool life
The new NS9530 incorporates Tungaloy’s “PremiumTec” special surface technology that reduces micro roughness on the surface to support improved tool life. The smooth layer on the NS9530 grade insert has cut flank wear in comparison to rival products.
The GT9530 offers enhanced adhesion between the substrate and the coating layer to stabilize wear resistance and tool life while delivering a consistently high quality surface finish whereby sudden peeling or fracture are avoided.
Tiger•tec Silver Turning for steel turning applications, consisting of three new grades and four new geometries, can bring longer tool life, faster cycle times and process reliability to a wide array of applications.
The cutting tools can handle a variety of materials including unalloyed and alloy steel, cast steel, stainless ferritic and martensitic steel, as well as ductile cast iron.
Improved wear resistance
Widia Victory turning grades include 10 different grades and 14 different geometries, including five new chipbreaker designs. The inserts employ coating technologies to improve wear resistance and allow for higher speed and feed capabilities. Additional post-coat treatment provides increased cutting edge toughness to reduce the depth of cut notching and extend tool life.