New Profile Milling Cutters Carrying Round Ceramic Inserts
Highlights
Following growing market demands for efficient machining of difficult-to-cut high temperature superalloys and other engineering materials, ISCAR is introducing new milling cutters carrying double-sided round inserts made from ceramics.
Cutters
The new cutters are intended mostly for rough and semi-finish milling of planes and 3D surfaces at extremely high cutting speeds. The more common applications include machining faces, cavities, pockets, and shoulders. The cutters are available in shell mill configurations in 50, 63 and 80 mm diameters.
Cutter Body Features
More teeth increase productivity and higher feed rate capability
Low-wearing design due to superior toughness and high resistance to abrasive and chemical wear
Coating of the cutter body facilitates chip flow and protects against corrosion and wear
Wedge design can supply airflow directed to each cutting edge
Inserts
The economical double-sided round inserts are made from the following cutting ceramic grades:
IS25 and IS35 - SiAlON
IN22 and IN23 - “black” ceramics
IW7 - whisker reinforced ceramics
The inserts feature superior cutting-edge integrity while ensuring impressive wear-resisting properties when machining at high cutting speeds and high feed rates.
Insert Features
Durable structure
Double-sided design for high ceramics utilization
Excellent wear resistance and thermal shock resistance
High fracture toughness
Available in 3 design options according to cutting edge preparation:
honed, chamfered (T-land), and combined (chamfered and honed)
Application Notes
Main ISO groups of application: S (high temperature Ni- and Co-based superalloys),
K (cast iron) and H (hard materials). Cutters carrying inserts from the grade IN23 can be also successfully applied to productive milling steel parts (ISO P group)
Industries: the main fields of application relate to aerospace, power generation, and marine engineering
Examples of the machined parts: blades, airfoils, discs, shafts, casings, high-strength wear-resistant components
Dry coolant only. Using a wet coolant is prohibited due to its negative impact on
performance and insert tool life!
Insert tightening torque: the insert should be secured by applying tightening torque 4.8 Nm
Due to the advanced design, the new cutters feature more teeth in comparison with the same diameter tools that are provided by main competitors. This is an important advantage that represents an additional source for increasing productivity in milling difficult-to-cut materials
Machining data
The attached tables provide recommendations regarding selecting a more suitable ceramic
grade, cutting-edge-preparation type and machining data. For milling in unstable conditions,
the limit values of cutting speeds and feeds in the table data should be reduced by 20-30%.
ISCARMILL CERAMIC LINE: maximum productivity and dramatic reduction in cycle time in milling!
FRN
Face Mill for Wedge-Clamped Double-Sided Round Insert
• Radius for programing: 6.35
(1) Cutting diameter maximum (2) Number of inserts (3) For interpolation (4) For interpolation (5) Maximum ramping angle
(a) Recommended tightening torque:4.8 Nm
RNGN-Ceramic
Round Double-Sided Ceramic Inserts
(1) Insert with a dimple
Recommended ceramic grade and machining data for milling
*According to VDI 3323 standard.
Recommended range of depth of cut is 0.5-3 mm.
The attached table provides recommended machining data. For milling in unstable conditions the limit values in the table data should be reduced by 20-30%.
