Turning tools - MetalTech Report
- May 19, 2012
Deeper face grooving and turning
Iscar has expanded its Minicut line of inserts and cutting tools for deeper and wider face grooving and turning.
The expanded diameter range is 10 to 34 mm, for up to 9 mm grooving depth. The MIFR 10 inserts are screw-clamped into a long pocket of the MIFHR bars with rigid clamping, resulting in prolonged tool life and enabling high machining parameters.
An internal coolant hole is directed to the cutting edge. The new products can be used for grooving in deep holes. They offer uninterrupted chip flow on the insert rake and can also be used for rotating applications. Standard inserts are available in 2.0 to 3.0 mm widths made from IC908 grade, and special widths can be ordered on request within this range.
Better performance in OD and ID turning
Because of their high performance strength and relatively light weight, high temperature alloys are growing in applications across many manufacturing industries, notably aerospace and defense, automotive, heavy equipment, and energy.
Higher temperature strength materials, however, also mean high cutting forces when machining. Titanium, for example, exhibits high work hardening and a large strain rate, which also raises temperatures and the energy required to remove the chip. In most applications, the answer means slower speeds and feeds, since a carbide cutting tool’s strength decreases as temperatures increase.
New Beyond grades from Kennametal are delivering higher productivity for turning tough alloys, in higher speeds and feeds (faster turnaround time) and longer tool life (more parts per tool). KCU10 is specifically engineered for increased performance in OD and ID turning, grooving, plunging, undercutting, and threading. KCU25 covers threading, grooving, cutoff, and selected additional turning applications.
Both take advantage of new PVD (physical vapour deposition) coating technology, including special surface treatments that improve machining performance in high temperature materials. In many cases, speeds, feeds, or depth-of-cut, can be increased, while related wear issues like depth-of-cut notching, are reduced.
KCU10 has a dual-layer coating application, a top layer of AlSiTiN atop a second layer of AlTiN. The boundary between the two serves to help deflect micro-cracks
Designed for turning die steels and bearing steels with hardnesses of 50 HRc and above, the BN2000 provides high wear resistance and robust toughness. It boasts a newly developed CBN substrate consisting of a ceramic binder with exceptional purity. While impure binders contribute to premature chipping and cutting edge wear, the purity of the BN2000 significantly reduces tool failure.
The tool excels in both continuous to medium interrupted hardened steel finishing applications. This wide application range makes it suitable for even small bores that may require lower SFMs–speeds conventional CBN cannot match. Along with its exceptional tool life, the improved edge sharpness offers customers consistent parts with the capability of attaining surface finishes as low as 3.2 Ra.
Spectrum turning is a minimum program that provides a simplified choice of inserts designed to efficiently machine different materials at various cutting conditions.
Excellent for different small batch production, Spectrum turning grades and geometries take away the complication of having many different tools for different jobs.
So whether external or internal machining, rough turning or finishing, machining continuously or with interrupted cuts, these inserts have been designed to be as versatile as possible, yet deliver high performance output in terms of reliability, tool life and chip control.
The grades can be used for turning in steels, stainless steels, HRSA, cast irons, titanium and nonferrous materials.
Two grades are being launched: GC15, which combines high strength micro-grain cemented carbide with a thin, PVD coating that adds edge strength and wear resistance, and GC30 which has high bulk toughness with a gradient cemented carbide substrate and a highly wear and heat resistant CVD coating.
75% productivity boost in steel turning
Walter’s Valenite Tiger-tec Silver for turning is a combination of three new insert grades and four new geometries developed in parallel that can boost the productivity of steel turning applications by up to 75 per cent, claims the company.
The Tiger-tec Silver inserts also feature a new micro-edge technology that makes it possible, in some cases, to increase tool life by over 30 per cent, and a new silver flank face for easier wear detection. In addition, the insert seating surface is ground after coating to ensure optimum seating in the toolholder.
The new grades are designated WPP10S, WPP20S, and WPP30S. WPP10S offers the highest temperature resistance and hardness. It has excellent wear resistance and is suitable for processes ranging from continuous cutting to minor interrupted cuts at very high cutting speeds. WPP20S, the medium-grade, is suitable for use as a universal cutting material for processes ranging from roughing to finishing, and brings exceptional reliability to automated production. WPP30S, the toughest of the three, brings maximum reliability to the most difficult applications, such as interrupted cuts and unstable conditions.
In addition to the three grades, Tiger-tec Silver for turning includes four new geometries developed in parallel and matched to one another to ensure that the complete range of steel turning applications is supported, reducing the number of insert types a user needs.
For facing and light cuts, the FP5’s double V chip breaker provides reliable chip control during turning operations from 0.008-in. depth of cut. It has a positive, curved cutting edge to reduce the tendency to oscillate, thus allowing excellent surface finishes. Its undulating chip formers prevent chip packing in turning and facing operations.
The MP3 geometry excels at medium machining. Its cutting edge is ideal for machining forged parts such as gearwheels, ball joints, transmission shafts or cold pressed sheet components such as cover plugs or converter housings. The spherical design of the surface—the so-called “bullet design”—gives the chip greater rigidity for optimum chip breaking.
From smooth cuts to bar stock and interrupted cuts, the MP5 geometry can handle them all with its versatile and stable “basket arch” design cutting edge. In addition, its reinforced chip breaker blades ensure better chip breaking and reduced tool wear.
The RP5 geometry is designed for roughing. The strong, positive 3° chamfer reduces power requirements and its open, deep and wide chip breaker groove generates a low cutting temperature, reducing wear.