Optimized machining of nickel-based and titanium high temperature alloys
- June 14, 2018
Over the past few years, Iscar has invested in R&D to optimize the machining of nickel-based and titanium high temperature alloys, with solutions that include the creation of customized grades and implementation of high pressure coolant technologies to develop cutting tools that will handle the heat issues.
For high material removal rates, Iscar has developed ceramic grades to facilitate machining nickel-based alloys at cutting speeds of 200 – 400m/min:
IW7 - Whisker-reinforced ceramic grade, provides high hardness with excellent toughness used for roughing and semi-finishing continues operations at 8-10 times faster cutting speeds when compared with carbide grades.
IS25 - Reinforced SiAlON composite grade, excellent for machining Ni based high temperature alloys at continuous and light interrupted applications
IS35 - Reinforced SiAlON composite grade, excellent for machining Ni based high temperature alloys at light & heavy interrupted applications
A series of carbide grades was developed specifically to create tools for machining nickel-based and titanium alloys:
IC806 - A hard submicron substrate combined with a thin TiAlN PVD coating. The unique coating procedure which involves a special post coating treatment creates a thinner and smoother coating layer providing the insert with the best characteristics suitable for machining nickel-based and titanium alloys.
IC804 – Same TiAlN PVD coating on a harder submicron substrate designed especially for machining Ni based alloys used in newly designed jet engine parts that feature very high hardness (40-47 HRC).
IC20 – An uncoated carbide grade which is highly recommended for machining aluminum and titanium. IC20 provides very high performance and is mostly used for continuous cut applications.
High pressure coolant tools
Although high pressure coolant features have been in existence for a long time in the metal removal world. today high pressure coolant tools play an increasingly significant role in the machining process, facilitating enhanced productivity and chip control especially for hard to machine materials such as titanium and nickel-based alloys. Incorporating high pressure is the key to directing coolant to exactly where it is needed in order to flush the chips away from the cut.
Iscar is one of the first cutting tool producers to respond to market needs by developing and manufacturing tools for the optimal use of high pressure coolant in lowering high temperatures and regulating chip flow, including JetCut custom high-pressure coolant tools.