Based on a completely new series of carbide substrates, the new inserts provide a significant increase in tool life and support higher cutting speeds. The carbide structure has been modelled in such a way that they provide an optimum relationship between ductility and wear resistance.
To maximise the scope of the new grades, Mapal has engineered the new ISO insert lines to correspond with existing 75º face-mill cutters, as well as Mapal’s 90º tangential shoulder-milling tools with a tight pitch designation for high feed machining. Furthermore, the new inserts can also be allocated to 45º and 88 º shoulder-milling tools having alternately mounted tangential indexable inserts that enhance the economic benefits of the new grades. For higher levels of cost-effectiveness, radial eight-edged inserts can be allocated to Mapal’s 45 º face mill cutters with a cutting depth of up to 10 mm.
Flexibility to work with the numerous toolholder geometries is supported by availability of sintered tangential inserts with four, six or eight cutting edges that are suitable for everything from heavy duty rough machining through to semi-finishing operations.
The insert series includes three PVD-coated carbides and two CVD-coated grades. The PVD coating consists of an optimised TiAlCrN with very fine structuring of the layers to create an optimum relationship between ductility and hardness/wear resistance. The CVD coating is based on an MT-TiCN with an alpha-Al2O3 top coat. This layer combination offers high wear resistance and also good thermal stability.
A special post-treatment has been developed for both the PVD coating and the CVD coating to ensure an extremely smooth surface. This improves chip flow and the evacuation from the work envelope, which minimises tribo-chemical wear. With the CVD coating, the post-treatment additionally sets a selective intrinsic stress in the coating, stabilising the cutting edge or increasing the ductility of the cutting material.
The inserts support dry to wet machining and a wide range of applications and machine conditions.
