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    MILLING
    NPA 21/2018


    X_QUAD

    New Extended Flute Milling Cutters Carrying Square Inserts for Machining Titanium and High Temperature Alloys


    Highlights
    ISCAR introduces new extended milling flute cutters and inserts for machining titanium, high temperature alloys and stainless steel.



    The aerospace industry today is seeing a growing role of titanium and high temperature alloys (HTSA) in producing machine parts. In new designs, the need to reduce component weight has led to the introduction of high-strength titanium grades such as 10-2-3 or 5-5-5-3 as a real alternative to steel and stainless steel in key elements of loaded structures. The latter grades are difficult to cut; their machining by existing methods does not meet productivity requirements in this industry.
    In order to provide the necessary level of metal removal rate (MRR) and tool life that will ensure full use of modern high-efficiency machines, the industry requires new solutions from cutting tool manufacturers.

    ISCAR has developed a new family of indexable milling cutters to answer this need: XQUAD, especially designed for productive rough machining titanium alloys. The cutters are also suitable for milling HTSA and hard-to-cut stainless steel of austenitic, duplex and PH types. The new family applies to ISO S and ISO M material groups.

    XQUAD cutters are available in two types: carrying 10 or 12 mm (.394 and .472”) insert sizes.

    High performance of the new family is based on advantageous combination of all three newly developed integrants:
    - Cutter design
    - Insert geometry
    - Insert carbide grades


    Cutter Features

    SDK-10/12-C/HP Extended Flute Cutters
    • 90° extended flute shell mills carrying square inserts with 4 cutting edges.
    • Designed for rough milling operations that require extremely high depth of cut, such as machining deep shoulders, cavities, high edges and full slots.
    • Alternating rake angles are produced by different inserts mounted in the tool, which is combined with varying flute pitch to provide efficient chatter dampening, smooth progressive penetration into material and stable cutting action.
    • Cutter design ensures that one cutting point is always in contact with the material during entrance and exit. This ensures optimal and steady harmonic oscillation, reduces power consumption and maximizes tool life.
    • High material removal rates due to spacious chip gullet (flute) that enables uninterrupted chips flow.
    • Coolant channels directed to each insert cutting edge.
    • The SDK …-HP cutters have coolant nozzles for high pressure coolant supply (HPC) through the cutter body. HPC dramatically improves effectiveness of chip evacuation and temperature stability in the cutting edge, significantly increases tool life.



    Insert Features
    One-sided inserts with 4 cutting edges


    SDHW 100408-TN / SDHX 120508-PD-N
    • Reinforced flat rake face for high-load resistant cutting edge
    • Intended mainly for rough milling shoulders and slots
    • Insert geometry designed for effective milling of difficult-to-cut aerospace materials


    SDHT 100408-PDEN / SDHT 120508-PDEN
    • Positive rake face
    • Designed mainly for milling stainless steel and titanium grades that feature relatively good machinability. The inserts may be recommended also for semi-finish operations.


    SDHW 100408-TN-CS
    • Serrated cutting edge for chip-splitting action that contributes to reducing cutting force and diminishing vibration
    • Intended for rough milling when chip evacuation is difficult or low rigidity conditions (poor clamping or long overhang)


    The inserts have 2 splitting grooves on one cutting edge and 1 on the opposite side. It is recommended to mount the inserts in an alternating edge configuration on adjacent cutter flutes, to achieve the most effective chip splitting.

    Side A
    Side B
    with 1 Groove
    with 2 Groove
    New Insert Grades
    The inserts are produced from ISCAR’s more advanced coated carbide grades, which were introduced recently.

    IC882 (S20-S30) (M25-M40)IC882 (S20-S30) (M25-M40)
    A carbide grade featuring a tough submicron substrate, new PVD hard coating and a post-coating treatment.
    Designed for machining materials with poor heat conductivity of ISO S and M material groups. The grade has high resistance to thermal cracks, oxidation, chipping and wear, ensuring long tool life.

    IC5820 (S15-S25) (M20-M35)
    A carbide grade featuring a tough submicron substrate, strong new CVD hard coating and a post coating treatment.

    It is characterized by substantially improved impact strength, higher heat resistance, oxidation, notch wear and built-up edge formation resistance. These properties result in longer tool life, reliable wear and chipping resistance, enabling increasing cutting speeds and boosting MRR.
    High coolant flow rate, pin pointed cooling and HPC significantly improve the grade performance.
    Recommended primarily for milling titanium alloys.

    Applications
    • The new XQUAD tools were developed especially for manufacturers of aerospace components, to achieve extremely high metal removal rates.
    • For slot, shoulder, contour and pocket milling operations in titanium and high temperature alloys components.


    Benefits
    • High process reliability due to stable design
    • Maximum metal removal rate due to high depth of cut and maximum number of teeth
    • Reduction of machining cost
    • Reliable production for long-term process
    • Soft-cutting geometry, thanks to helical cutting edges and positive rake angle



    Cutting Speed Recommendations for XQUAD inserts SDHW 100408-TN / SDHW 100408-TN-CS / SDHX 120508-PD-N
    ** ISCAR material group in accordance with VDI 3323 standard

    Cutting Speed Recommendations for XQUAD Inserts SDHT 100408-PDEN / SDHT 120508-PDEN
    ** ISCAR material group in accordance with VDI 3323 standard


    Attached are field reports which show the advantage of using XQUAD tools

    Application: Deep shoulder milling
    Part name: Jet Engine Mount
    Material: Titanium 6Al4V cast
    Machine: Makino T1
    Coolant: Pressure 1015 bar; 26.5 GPM

     ISCAR
    Tool DesignationSDK D3.-5.0-5-HSK100*12HP
    Diameter (inch)3.00
    Number of teethZeff=5 Z=60
    Insert typeSDHX 120508-PD-N (first 4 rows)
    SDHT 120508-PDEN (others)
    GradeIC5820
    Cutting speed (SFM)180
    Depth of cut (in)5.1
    Width of cut (in).79 up to 1.4
    Feed per tooth (in/t).0035-.0052
    Table feed (in/min)3.94 - 5.90
    Tool life (min)300
    Application: Deep shoulder milling
    Part name: Upper Drag Brace
    Material: Titanium 10.2.3
    Machine: Makino T2
    Coolant: Pressure 71015 bar; 26.5 GPM

     ISCAR
    Tool DesignationSDK D3.0-2.6-05-1.25-12-C
    Diameter (inch)3.00
    Number of teethZeff=5 Z=30
    Insert typeSDHX 120508-PD-N
    GradeIC5820
    Cutting speed (SFM)115
    Depth of cut (in)1.57
    Width of cut (in)1.18
    Feed per tooth (in/t)0.047
    Tool life (min)70
     

    Material: TiAl6V4

     ISCAR
    Tool DesignationSDK D50-47-3-22-10-HP
    Diameter (inch)1.97
    Number of teethZeff=3 Z=18
    Insert typeSDHW 100408-TN
    GradeIC882
    Coolant typeInternal HPC 1000 PSI @ 100 lit/min
    Cutting speed (SFM)180
    Depth of cut (in)1.81
    Width of cut (in)Up to 1.97
    Feed per tooth (in/t)0.0028
    Table feed (in/min)2.13
    CoolantWet
    Tool life (min)45.0
    Material: AISI 316L (DIN 1.4404)

     ISCAR
    Tool DesignationSDK D2.0-1.9-3-1.00-10-C
    Diameter (inch)2.00
    Number of teethZeff=3
    Insert typeSDHT 100408-PDEN
    GradeIC882
    N (rpm)764
    Cutting speed (SFM)390
    Depth of cut (in)1.57
    Width of cut (in).47
    Feed per tooth (in/t)0.047
    Table feed (in/min)10.8
    CoolantWet
    Tool life (min)60
     



    SDK-10-C/HP
    Extended Flute Shell Mills Carrying SDHW/T 100408... Inserts
    (1) Designed with coolant nozzles for high pressure coolant
    (2) Number of flutes
    (3) Number of inserts
    (4) For adaptation see page
    (5) Item weight



    SDHW/T 100408
    Square Inserts for Machining Titanium, High Temperature Alloys and Stainless Steel
    (1) First choice for machining stainless steel
    (2) First choice for machining titanium.
    (3) Chip splitting cutting edge


    SDK-12-C/HP
    Extended Flute Shell Mills Carrying SDHT 1205... Inserts
    (1) Number of flutes
    (2) Number of inserts
    (3) Item weight



    SDHT/X 120508
    Square Inserts for Machining Titanium, High Temperature Alloys and Stainless Steel
    (1) First choice for machining stainless steel
    (2) First choice for machining titanium



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