Savings, guaranteed

Every few years, tooling giant Iscar makes a major product launch. Last year was one of those occasions, with the company's president, Jacob Harpaz, travelling to various destinations around the globe to unveil the company's HIghQLine (IQ) 'Intelligent Machining' campaign, arriving in the UK in November for an event held at Birmingham's ICC venue and which saw almost 250 in attendance. It was around five years ago that the company had such a similar major multi-product launch, with its Sumo line being the main event. Of course, in between, there have been product developments, but November saw a veritable avalanche under the Intelligent Machining banner and within Iscar's new IQ line of products. There are some 1,350 new product lines across around 20 product families released as part of IQ, with additional improvements made elsewhere. Machining intelligently means machining 24 hours a day, non-stop, with zero set-up time, explains Mr Harpaz. In support of this, Iscar's IQ range delivers higher cutting speeds and feeds, while also boosting tool life – thus driving up productivity; reducing setting times; and, in the case of hard material machining, offering the possible elimination of grinding. And the promise being held out by Iscar is that the company will guarantee to reduce part costs by 15% in the first year and bring further savings year on year. How? Simple, explains Mr Harpaz, and it's not about the price of carbide tooling, because that accounts, typically, for around 3% of total costs – other inputs related to machine (26%), manpower (28%), overhead (21%) and material (22%) are much greater. "If Iscar gives you a 50% discount on your tooling for a year, will that help you compete? Or, if we give it to you free for a year, can you compete against China or Russia?" Well, no. Because since tool cost is just 3% of part cost, that doesn't get you anywhere close to 15%, is how he answers his own question. And if tool life is boosted by double, that just gives a 1.5% advantage, Mr Harpaz adds. The only way to drive down cost by a large proportion is by boosting speed and feed, without also slashing tool life - increasing productivity by 20%, in fact, to get a 15% part cost reduction. This has been achieved via new coating technology, new insert geometries, new toolholder designs supporting more free chip flow and improved insert clamping (greater rigidity), while clever toolholder design has reduced insert change times via faster, easier in situ insert changing. KEY DEVELOPMENTS Key product introductions highlighted by Mr Harpaz include Dove IQ Turn, which sees an innovative dovetail insert pocket, and corresponding insert features, combined with a clever clamping mechanism providing extremely secure and rigid insert location for heavy turning. The system employs no top clamp and can employ trigon inserts with six cutting edges, or two styles of rhombic inserts with two or four edges. (The dovetail design feature is a common theme throughout much of Iscar's new developments, incidentally.) Dove IQ Grip Line is an advanced new range of tools for deep, heavy grooving applications that have a claimed unique front locking mechanism, once again delivering unobstructed chip flow. This new design eliminates the top jaw and thus improves chip flow, eliminating toolholder jaw wear and supporting heavier duty grooving. Image: Dove IQ Grip Line Image: The dovetail detail in close-up Groove widths from 10 to 20 mm are supported (25-40 mm with a cartridge head design), with the new Dove-IQ inserts featuring a 'scalloped' pattern on its top surface, aiding improved cutting and swarf management. The inserts also feature a dovetail element, which provides a secure location. Now out of the way of swarf, the clamping screw head is no longer a weak point, either. And for wide inserts, there are three coolant jets built into the front of the tool. Penta IQ Grip is a novel design of small pentagonal insert with five cutting edges, intended for deeper and more accurate grooving and parting applications. This represents the next step on from its Penta Cut design and is now able to part off bar up to 40 mm in diameter, although grooving and side turning are also supported. It supports higher feeds than before (courtesy of a new moulded in chip breaker), features a single screw that means "almost no set-up time", while side deflection is less than 10% that of others' products, resulting in good turned surface finish. The dovetail location feature is employed again for solid, accurate positioning. Image: Penta IQ Grip Heli IQ Mill 390 milling inserts have three true 90° cutting edges and feature advanced cutting geometries, offering reduced cutting forces that result in lower power consumption. This is a development of the previous Helimill that features just two cutting edges. Due to the low cutting force design, the cutters are suitable for use on high temperature alloy, Iscar highlights. Image: Heli IQ Mill 390 Video: Heli IQ Mill 390 video Dove IQ Mill 845 Line features a milling insert having a claimed unique design boasting eight cutting edges and is applicable for a wide range of face milling applications, including 45° and roughing, plus finishing operations on a wide range of materials. Image: Dove IQ Mill 845 Line Hold IQ Lock is a new ER collet design that features strong and reliable clamping, preventing a tool from being pulled out of the holder in heavy applications. These can be used with any standard cylindrical, Weldon or whistle notch tool, from 12 to 25 mm diameter. The main element is, in fact, a key that sits in the flute of a cutter, at the top, preventing slippage and pull-out – cutters are loaded through the rear of the collet and engage the key. Image: Hold IQ Lock IQ UPGRADES, TOO In addition to these, and numerous other new product introductions (see extended online article), Iscar has upgraded several other products. For example, the company's Swisscut tooling range has been 'IQ upgraded' with the addition of an elliptical screw that is also accessible from either side of the tool – it is no longer necessary to remove the screw from the holder to change a tip, thus reducing idle time. Iscar's Picco internal turning range has also been improved to deliver 10x better cutting edge position accuracy, again reducing downtime, Mr Harpaz underlines. The Tang Grip parting line has received a boost, too, with Tang-Grip IQ now combined with Jet HP Line high pressure coolant capability for Inconel and titanium machining – the high pressure coolant breaks the chips. The upper jaw has been eliminated, meaning unlimited life for the toolholder itself. Parting up to 600 mm diameter is possible. The Tang Grip face grooving line similarly benefits from the elimination of the top jaw, thus supporting better chipflow, with the result that deeper grooves are possible. The same insert can be used for both right- and left-hand tool, as well. Image: The Tang Grip parting line The company's Cut-Grip range for sliding-head and other turning machines has been redesigned with a new side clamping mechanism, which support fast in situ tip changing to reduce set-up time and again places the screw head out of the way of swarf flow. Supporting improvements in tool management, the company revealed its new Maxi and Mini systems. And to aid more efficient insert recycling, Iscar has introduced Matrix recycle, an automated system into which scrap tips are placed and weighed continuously, sending a message to the tool supplier when collection is required. Finally, to further enhance its levels of customer support, Iscar is continuing to develop its Iscar Tool Advisor (ITA), a parametric search engine that supports tool and process selection. In addition to the online version, there are applications available for Apple iOS and Google Android operating systems. Moreover, Iscar has an offline DVD version available in 26 languages. ITA, says the company, has become the industry standard for optimising tool selection and process parameters. All its new HIghQLine tools are included in Iscar's ITA system. This latest batch of product introductions offer, a multitude of benefits, backed by many small and not so small design details, but underpinning them all is the company's guaranteed 15% part price reduction promise. A major, and clearly confident launch, indeed. Box item 1 Who and what is Iscar? Iscar is part of IMC group of companies (International Metalworking Companies), the world's second largest carbide cutting tool organisation, although Mr Harpaz likes to underscore the fact that the company only focuses on tools for metalcutting, unlike its rivals. Brands within the group are, alphabetically: CTMS; Ingersoll; Iscar; IT.TE.DI.; MasteRound; Métaldur; Microtools; Outiltec; TaeguTec; Tungaloy; Unitac Inc; UOP SpA; Wertec and Zurim Tools. IMC group employs 11,000, with some 4,500 of those located in Israel. In 2006, investor Warren Buffet's Berkshire Hathaway company took an 80% stake in family-owned IMC – it was the investment firm's first industrial stakeholding and its first non-US acquisition – with the remainder held by the Wertheimer family. As a group, IMC has grown revenues by more than 40%, compared to 2008, recovering well from the -20% hit seen from 2008 to 2009 triggered by the financial crisis. Strong growth is continuing, says Mr Harpaz, due to the fact that "50% of IMC sales are coming from unique, innovative product lines". Talking specifically about Iscar, in 1982 it was a $100 million concern; today it is a $3 billion operation. And, according to Mr Harpaz, some 40% of revenues come from products that are under five years old. R&D spend for Iscar is 5-6% of annual revenues. The method adopted by Iscar to support its innovative product development is its use of competing R&D teams. So a product is innovated by team 1, then it is handed on to team 2 to improve and then team 3, explains Mr Harpaz. "We compete against ourselves through such ongoing R&D," he explains, adding that the idea is "always to be first in the market with a new product". Extended article from here New insert grades New inserts New ISOTurn chipbreaker designs Additional new products Box item 2 New insert grades [] Sumo Tec 806 – a new S (super alloys ) grade intended for turning Inconel at low to medium cutting speeds. A tough submicron substrate, TiAlN PVD coated with special Sumo Tec surface treatment. [] Sumo Tec 807 – P (steel), M (stainless steel), K (cast iron), S and H grades for turning HRSA, austenitic stainless steel and hard steel at low to medium speeds. A tough submicron substrate, improved TiAlN PVD coated. [] Sumo Tec 808 – P, M S and H grades designed for heat-resistant alloys, austenitic stainless steel, hard alloys and carbon steel at medium to high cutting speeds. Excellent notch wear and built-up edge resistance. A tough sub-micron substrate with improved TiAlN PVD coating. [] Sumo Tec 830 – P, M K and S grades, suitable for milling stainless steels, high temperature alloys and other alloy steels. Recommended for interrupted cut and heavy operations, it has an improved PVD TiAlN coating. [] Sumo Tec 6015 - P and M grades, featuring a very hard substrate with cobalt-enriched outer layer and alpha Al2O3 coating. It is for finishing and medium turning of stainless steel at high cutting speeds. It features long tool life and excellent repeatability. [] Sumo Tec 6025 – M grades, featuring a tough substrate with MTCCVD Al2O3 coating, it is for machining stainless steel at high speeds and can run at medium speeds in unfavourable conditions. [] Sumo Tec 8350 – P, M grades having a very tough substrate with cobalt-enriched layer, combined with and improved MTCVD TiCN and alpha Al2O3 CVD coating. Excellent toughness and chipping resistance on steel for interrupted and unstable conditions. [] Sumo Tec 8150 – P and K grades that have a very hard substrate with a cobalt-enriched layer combined with an improved MTCVD TiCN and thick alpha Al2O3 CVD coating. Excellent thermal stability, resistance to chipping and plastic deformation; recommended or high speed machining of steel or slightly unstable conditions. [] Sumo Tec 8250 – P and M grades having a tough substrate with cobalt-enriched layer, combined with improved MTCVD TiCN and a thick layer of AL2O3 CVD coating. Recommended for general use machining of steel in a wide range of conditions. High toughness, resistance to chipping and plastic deformation. [] Sumo Tec 5010 – K grade. It has a hard substrate, improved MTCVD TiCN and a thick layer of alpha Al2O3 CVD coating. Excellent thermal stability and improved toughness, recommended mainly for grey cast iron at stable or slightly unstable conditions, it can also be used on nodular cast iron. [] Sumo Tec 330 – P, M and S grades that have a tough TiCN + TiN, thin PVD coating and special Sumo Tec surface treatment, suitable for milling a wide range of material at low to medium speeds and in unstable conditions. [] Sumo Tec 380 – P, M, S and H grades have a tough sub-micron substrate, TiCN PVD coating and special Sumo Tec surface treatment. Designed for machining HRSA and austenitic stainless steels at medium to high speeds and in interrupted cut or unfavourable conditions. Excellent notch wear and built-up edge resistance. High resistance to mechanical and thermal shock, so milling with coolant is fine. [] Sumo Tec 908 – P, M K, N (non-ferrous), S, H grades that have a tough sub-micron substrate, TiAlN PVD coating and which are designed for machining heat-resistant alloys, austenitic stainless steel, hard alloys and carbon steel at medium to high cutting speeds and in interrupted cut and unfavourable conditions. Notch wear and built-up edge resistance are excellent. [] Sumo Tec 907 – N grade, a diamond-coated grade for drilling carbon fibre reinforced plastic (CFRP) and titanium CFRP laminates. Box item 3 New inserts [] In many turning applications, larger inserts than are actually required are employed for the machining parameters being applied Iscar's ISOTurn small size inserts provide an economical advantage, as regards cost per cutting edge. The new inserts are available in a wide range of geometries, corner radii, chipformers and the most advanced carbide grades. Also available are small size Heliturn LD inserts in CNMX and TNMX geometries. [] A new 25° corner insert (YNMG-F3P) is for machining very narrow v-shaped grooves. [] A new insert with a unique Chatterfree geometry upgrades the HELI2000 milling line performance. The new unique Chatterfree insert can be mounted on any HM90 E90AD end mill, HM90 F90A face mill, HELIMILL shell mill or extended flute cutter. [] The HSM90S 14 tool and insert family is another evolution of the HELIALU line. The new family includes 90° end mills and face mills for milling aluminium at very high spindle speeds. The new tools, required mainly by the aerospace industry, enable modern machines to maximise metal removal rate and minimize production costs. The new HSM90S-14 tools were designed to eliminate insert radial displacement, which occurs due to high centrifugal forces at very high spindle speed. [] The Helido range has been expanded with the OXMT 0507R08-FF insert, which is designed to add the Feedmill's high feed capability to the Helido 845 and 890 milling lines, while providing a moderate feed advantage to the Helido 865 line. Feedmill tools direct cutting forces axially towards the spindle. Another innovation is the RXMT 1607N round insert, which adds profiling and corner rounding application options to the SOF45, SOE45, S890 and FF-SOF milling cutter families. [] Helido Round inserts have six 90° segments of 6 mm radii round cutting edges, this provides the ramping down capability required for profiling applications. The H606 RXCU 1206 insert is available with an AXT chip former for steel and cast iron applications or with an AXMP chip former, suitable for austenitic stainless steel and high temperature alloys. They are used on 50, 63 and 80 mm diameter face mills. Box item 4 New ISOTurn chipbreaker designs Introduced to complement grades IC8150, IC8250 and IC 8350. [] F3P – a positive rake chip breaker for finish machining of steel, offering smooth cutting and reduced cutting forces, reducing insert wear and prolonging tool life of this double-sided insert. [] M3P – a double-sided insert chip breaker for medium machining of steel. It has a reinforced edge and features positive rake for reduced cutting forces. [] R3P – a single-sided insert for roughing and having a reinforced edge and featuring positive rake for smooth cutting of steel. Box item 5 Additional tooling products [] Jet HP Line is a new line of turning toolholders that incorporate a replaceable high pressure coolant nozzle above the tool tip. Cutting speeds can be increased by up to 200% when machining titanium and heat resistant alloys, resulting in shorter machining time, while tool life increases by up to 100%, not only on titanium and heat resistant alloys, but also on stainless and alloy steels. Image: Jet HP Line Modular Grip adapters and Jet High Pressure (JHP) sees JHP integrated with CAMFIX shanks, providing modularity and high performance grooving and turning. [] The T465 FLN D…22ST is a modified family of 65° lead angle, face mills with protective seats. The 65° lead angle is a very efficient solution for the high metal removal face machining of cast iron and steel components. Using these face mills minimises burrs and edge chipping for cast iron applications. The new face mills carry tangentially clamped inserts with four cutting edges, which can be used for up to 19 mm depth of cut. Image: T465 FLN face mills The T465 LNHT 2212-DN inserts feature a high positive rake cutting angle, for a light cut and minimum power consumption. The new inserts also have a positive axial angle (right-hand. helix) for soft entry into and exit from the workpiece. The insert features a 2.5 mm flat wiper providing a high quality surface finish. In addition, inserts are available with chip splitting grooves that can greatly improve performance in rough milling operations. [] The Sumocham DCN 12xD expands the range by adding 12xD depth to diameter ratio, in a diameter range of 12 to 25.9 mm. The new DCN drills feature cylindrical shanks, which enable clamping of the drill in hydraulic toolholders (recommended) or in spring collets. All drill bodies feature helical coolant holes. Prior to using the 12xD drill, it is recommended that users drill a pre-hole by using a DCN 1.5xD drill or a centring drill. Image: Sumocham DCN Flat Sumocham drill heads expand the Sumcham range and are designed for drilling steel components (ISO P material group). Drilling with FCP inserts provides a nearly flat bottom in the hole, which is required in a variety of applications. [] The new Sumogun line for deep drilling applications is offered in a diameter range 12 to 25 mm (total length of 1,500 mm). Image: Sumogun [] The Sumo Unicham combines the advantages of the Sumocham drills with those of the Chamring, to chamfer around holes in a diameter range of 7.5 to 25.9 mm and length-to-depth ratios of 3xD and 5xD. Image: Sumo Unicham [] The Helido 800 line is expanded with the SOF45-R26 45° face mills. The new mills are designed for heavy duty machining of steel and cast iron components at a high metal removal rate. The versatile new face mills can carry either the S845 SNMU 26 square double-sided inserts, with 8 cutting edges, or the ONMU 10 octagonal double-sided inserts, with 16 cutting edges. The new family provides an extremely versatile and cost effective tool for productive milling in difficult cutting conditions. [] The new P290 - 90° shred milling tools line is based on the claimed unique P290 ACKT 1806PDR-FW and P290 ACKT 1806PDR-FWE serrated cutting edged inserts. These tools can also carry the regular P290 ACCT 1806PDR-HL straight-edged inserts for finishing cuts. The new rectangular inserts have two positive 18 mm long indexing options. When the new tools are used with the serrated edged P290 ACKT 1806PDR-FW inserts, very small chips are produced. This is the ideal solution for the machining of very deep cavities as the chips can be easily removed from the machining zone. This provides very effective chatter dampening abilities even when positioned at very long overhang positions. Image: The P290 - 90° shred milling tools First published in Machinery, January 2013