The world of chip removal manufacturing is constantly changing. Modern machining tools process metal at much faster speeds and higher feeds than just a few years ago. Therefore, at ISCAR, development never stands still – 'Industrealize' is the motto. This holistic tool development concept combines innovation with Industry 4.0-inspired digitizations and leads to modern solutions for productive, high-quality, and efficient manufacturing across all industries.
In numerous factories with modern, networked machine parks, ISCAR's NEOLOGIQ tools are in use. Users machine faster, reduce their setup times, and can work around the clock seven days a week. This is made possible by innovative indexable insert (WSP) geometries and chip formers. Regardless of component size, workpiece material, or design, the right WSP can make a crucial difference in the manufacturing process and ensure high productivity.
Each industry has individual requirements that can only be met by specialized tools. Whether turning, grooving, threading, milling, or drilling – as a complete provider of machining tools, ISCAR has the right solution for every industry to process common workpieces.
Difficult-to-machine materials: Aerospace industry
In the aerospace industry, in addition to stainless steel, especially difficult-to-machine materials such as titanium or nickel-based alloys like Inconel are very common. They are used for engine housings and turbine blades, as well as in rotors of the compressor stage in jet engines, known as blisks. To efficiently process these different components, ISCAR offers users a wide range of standard tools with adapted chip formers for all machining steps.
Titanium blisks, for example, are turned, milled, drilled, grooved, and finished during the production process. For complete machining, users can rely on a combination of various representatives from ISCAR's SUMOGRIP, CUT-GRIP, and ISOTURN lines.
The SUMOGRIP turning tools are multifunctional, and users can use them for both grooving and turning. Their tangential insert seat securely clamps the cutting inserts. Since no clamping finger is required, free and unobstructed chip flow is possible. Users benefit from long tool life. Additionally, they can achieve high feeds. The CUT-GRIP line offers a versatile and extensive range of multifunctional grooving and turning tools with a large selection of precision-ground cutting inserts – also for special applications. For roughing and finishing, ISCAR's ISOTURN tools are predestined. They are available in all standard geometries, including as trigon indexable inserts with three 80-degree cutting edges for face turning and axial machining.
The major challenge in machining titanium and similar materials: High temperatures are generated that wear out the tools. ISCAR addresses this with specially tailored cutting material combinations for these materials. Additionally, the tools are equipped with internal coolant channels and jet cooling. This brings the coolant directly into the cutting zone and reduces wear on the cutting edge.
The change is noticeable: Automotive industry
In no industry is the trend towards sustainable mobility more noticeable than in the automotive industry. It is in the midst of a transformation process away from combustion engines towards electric mobility. The rapid increase in the development, manufacture, and introduction of battery-powered electric vehicles (BEVs) shows that they are not only the future but already the present. ISCAR supports companies in transitioning to products for e-mobility with clever, innovative, and efficient machining solutions for their components. Compared to combustion engines, the electric variant has far fewer moving parts.
For manufacturers, this means shorter production times and lower costs. One of the main components of an electric motor is the housing made of aluminum. To meet the requirements for weight, durability, ductility, surface quality, precision, and geometric tolerances, a special approach is required. The partially hollow shape presents an additional challenge. Low cutting forces are necessary during machining to meet the demands for surface quality and cylindricity.
Thanks to ISCAR's complete strategy, manufacturers can shift the necessary steps from costly standard processes on the lathe to an economical machining center. This results in less scrap and optimizes their ability to manufacture parts within the required tolerances. This is made possible by ISCAR's PKD tools. For face milling the separating surface on the motor housing cover, cutters with axially adjustable, tangentially PKD-coated indexable inserts (WSP) are used. The drilling of the main diameter is handled by step drills in lightweight construction for semi-finishing with axially adjustable cassettes for PKD-WSP. Additionally, a reamer with radially adjustable cassettes for PKD-WSP is used. PKD-WSP-coated reamers are also applied for the bearing seats of the motor housing.
Complex projects: Tool and mold making
Few industries impose more complex requirements on tools and solutions than tool and mold making. Like all machinists, users from this sector are always interested in more productive, reliable, and precise tools. However, the specific characteristics require special design considerations that go beyond general requirements. Workpiece materials, processed shapes, and strategies are three characteristic features and have a significant impact on cutting tools. ISCAR continuously develops its solutions for this industry and introduces new products. For example, users can completely machine a complex base plate for mold making from A to Z. This is made possible with a whole range of standard tools from ISCAR across the entire tool repertoire.
For face milling, roughing, and profile milling, WSP milling cutters from the HELIDO line are used, and for finishing, a DOVEIQMILL cutter. A MILLSHRED with Weldon shank is responsible for cavities, and a CHATTERFREE solid carbide (VHM) cutter is used for pockets. A HELISLIT is used for grooves, and the HELIIQMILL is the solution for corner milling. Users can drill holes with drills from the CHAMIQDRILL, SUMOCHAM, and CHAMRING series or spindle them with an ITSBORE. SOLID-THREAD thread milling cutters, SUMOUNICHAM fibers, MULTI-MASTER cutters with VHM interchangeable heads for chamfering, and the BAYO-T-REAM high-speed reaming system complete the tool package.
Concentrated Information
ISCAR presents its industry-specific complete solutions on the Industrealize homepage based on focus components and their exemplary processing presented clearly and sorted by industry – from automotive to wind energy, medical technology, and railways to solutions for the oil and gas industry. Users will not only learn everything about the appropriate tools but will also find further information on the workpiece material, the recommended cutting material types, useful links, and downloads.
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