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“Exotic materials are not for production jobs—these are low volume applications,” says Tom Ficker, regional sales manager for Cogsdill Tool Products, Inc., with responsibility for Canada. “The problem with precision grooving in high nickel alloys is that you beat down on the grooving insert almost from the get-go.”

The HyproJET X6 from Ceratizit is based on an improved and patented design which makes is possible to increase cutting performance, leading and lifetime.

The Logiq4Turn is a double-sided insert with four cutting edges. Intended for general turning applications, these positive rake inserts have a dovetail shape of that fits into an innovative pocket design ensuring better positioning, stability and increased tool life.

For machines that only have X-axis options, Iscar’s new innovative vertical X-axis blade combined with a new X-axis block can be mounted on all types of machine. The block and angled blade system performs parting at high feed rates of 0.5mm/revolution and also enables the parting of large diameters while applying high feed rates with no vibration. Iscar claims this enables superior productivity on all machines up to four times faster.

Milling is the application with the largest number of new products from Iscar and a key focus for the company is the area of micro-machining with the introduction of very small cutters such as the NanMill and NanFeed endmills.

When it comes to turning, Iscar has introduced new developments such as JetRTurn, a new tool holder designed to deliver coolant directly to the cutting edge of the insert. The clamp used to hold the insert also contains a channel through which coolant can be delivered. Suitable for high and standard coolant pressures, JetRTurn has three options for connecting the coolant inlets. Through the bottom of the tool, the back of the tool or through a VDI connection.

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“The geometries are not standardized, but there are ways to create space at the head of the tool to promote chip flow,” says Stewart. “Sometimes the actual grooving tooth on the cutting tool will have a chip breaker on it—this will help the chip move out and get flushed with coolant.”

Developments such as electric vehicles and powertrains in large volumes, additive manufacturing and cyber connectivity will mean significant changes in the style of machining and the materials being used. Workpieces will be produced more commonly at near net shapes for final machining and finishing.

LogiqGrip tools are designed for applications such parting off, grooving, threading and back turning. The range includes inserts such as the TangFGrip. This 3-4mm wide insert is able to perform parting at very high feed rates on conventional X-axis machines. In the case of multitask machines and turning centres, parting can be performed on the Y-axis of the machine with the new vertical 32 or 35 Y-axis TangFGrip blades at high feed rates of 0.45mm/revolution providing very high productivity.

Commenting on the new release of tools, David Jones, Iscar UK sales manager said: “The application of Logiq represents a smart, logical progression in a series of strategic moves to implement Industry 4.0 machining standards while ensuring continuity and stability.

Another addition for miniature machining is the Micro3Feed – a micro-sized insert combined with small diameter multi-toothed endmill for high feed milling. The hexagon shaped insert with three cutting edges enables substantially increased feeds for higher productivity and the positive rake angle reduces cutting forces and guarantees a reliable soft cut at high feeds.

But replaceable inserts, single edge, can still get to some small diameters. More cost effective than a solid carbide tool, they can also deliver better axial depth. That said, solid carbide tools are usually more expensive, toolholders aren’t, and there is a risk the holder might break after a dozen or so uses.

It has capabilities for many head replacements and a self-centring sharp point geometry to achieve an absolutely accurate hole size. The head runout is minimal and it remains accurately in position after replacement ensuring there is no set-up time required.

Mr Harpaz explained that Iscar’s new tools will enable machinists to perform metal cutting at a rate similar to that found in the woodworking industry: “The cutting tool can have a huge impact on productivity. Not every company can buy the latest machine tools but changing to our cutters means the tools can run at very high speeds with a minimum of downtime.”

“It has allowed the creation of advanced new tool families, enabled existing lines to be upgraded and inspired innovative product ranges that assist users in maximising equipment utilisation and optimising performance.

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Managing chip generation in tight spaces has always been a challenge, because the smaller the hole the harder it is to get the chip out. One approach is to plum or port the tool to get coolant out. There are also advanced tools, like Kennametal’s AF-GUP insert geometry for grooving and turning, that are specially designed for these challenges.

Another approach is to compress chip width, thus ensuring it doesn’t lodge in the groove and result in tool failure. Either way, when it comes to grooving small parts, the combination of slow feed rates, proper tool selection, and a strategy for chip evacuation is the best way to ensure success.

Iscar’s Slim Slit line is also claimed to be the narrowest line of indexable slitting cutters available on the market. Slim Slit inserts enable cutting grooves down to 0.6mm and also feature through tool coolant which helps chip removal.

“It would be preferable to take an indexable insert into small grooves, because it would be more economical. But you often have to go with a one piece design, using a brace tool with a carbide or carbon steel cutter brazed to it.”

As Sherlock Holmes might say finding the solution to a problem is merely a matter of logic. This theme of reasoning has now been applied by Iscar in its latest cutting tool developments.

The HyproJET X6 from Ceratizit is based on an improved and patented design which makes is possible to increase cutting performance, leading and lifetime.

“Look at the impact that a company like Amazon has had on sales and marketing,” he said. “We are moving into an era of e-commerce and distribution and inventories with vending machines. In the US, the large majority of our cutting tool sales come through our vending machine systems. Industry 4.0 is not just about cutting process data, tool monitoring and sensors – it’s also about the most efficient supply and distribution.”

Hydraulics, given their need to control pressure, create demand for inside diameter (ID) and outside diameter (OD) grooving seals and threads, as well as relief grooves. In the automotive sector, miniature grooving applications include fittings for air bags and fuel injection components.

As Sherlock Holmes might say finding the solution to a problem is merely a matter of logic. This theme of reasoning has now been applied by Iscar in its latest cutting tool developments. An extension of its IQ concept, the new Logiq range offers an array of machining solutions for applications in parting off, turning, milling and drilling. This new ‘Chess Line’ series of cutting tools is intended to be fit for the coming era of Industry 4.0 and the smart factory. At its Logiq product launch held at the ICC in Birmingham to an audience of distributors, customers, Iscar personnel and members of the press, Jacob Harpaz, Iscar’s CEO, spelled out how the digital domain will impact manufacturing. Developments such as electric vehicles and powertrains in large volumes, additive manufacturing and cyber connectivity will mean significant changes in the style of machining and the materials being used. Workpieces will be produced more commonly at near net shapes for final machining and finishing. “By 2030 there will be big changes in the automotive sector, for example,” Mr Harpaz explained. “The major OEMs are moving away from the internal combustion engine which will mean much less metal removal will be required. There will be wider use of composite materials and the introduction of 3D printing will also mean less metal removal. At Iscar we are preparing for these changes. Cutting tools will have to adapt to remove less metal but at much faster speeds and feeds.” Mr Harpaz explained that Iscar’s new tools will enable machinists to perform metal cutting at a rate similar to that found in the woodworking industry: “The cutting tool can have a huge impact on productivity. Not every company can buy the latest machine tools but changing to our cutters means the tools can run at very high speeds with a minimum of downtime.” According to Mr Harpaz, Industry 4.0’s impact will not just come through sophisticated new technology such as sensors, process monitoring and acquiring machining data, but in the integration of factories and the supply and distribution of consumables used in manufacturing and products leaving the factory. Jacob Harpaz, CEO Iscar “Look at the impact that a company like Amazon has had on sales and marketing,” he said. “We are moving into an era of e-commerce and distribution and inventories with vending machines. In the US, the large majority of our cutting tool sales come through our vending machine systems. Industry 4.0 is not just about cutting process data, tool monitoring and sensors – it’s also about the most efficient supply and distribution.” When it comes to innovation, Iscar has a long legacy of not standing still. 40% of its tools in its product lines are less than five years old. The new Logiq range reflects the company’s comprehensive portfolio of cutting tools made from numerous carbide grades, along with the cubic boron nitride (CBN), polycrystalline diamond, Cermet and ceramic tools. There are four main product areas in the new Logiq range reflecting tools designed for different applications: LogiqGrip, LogiqTurn, LogiqMill and LogiqDrill. LogiqGrip LogiqGrip tools are designed for applications such parting off, grooving, threading and back turning. The range includes inserts such as the TangFGrip. This 3-4mm wide insert is able to perform parting at very high feed rates on conventional X-axis machines. In the case of multitask machines and turning centres, parting can be performed on the Y-axis of the machine with the new vertical 32 or 35 Y-axis TangFGrip blades at high feed rates of 0.45mm/revolution providing very high productivity. For machines that only have X-axis options, Iscar’s new innovative vertical X-axis blade combined with a new X-axis block can be mounted on all types of machine. The block and angled blade system performs parting at high feed rates of 0.5mm/revolution and also enables the parting of large diameters while applying high feed rates with no vibration. Iscar claims this enables superior productivity on all machines up to four times faster. Also in this range is the Logiq5Grip – a five-pocket blade system that is designed to deliver extended tool life. The interchangeable blade is assembled on a toolholder which indexes tangential grip 2 and 3mm inserts for parting and grooving. This system also indexes what Iscar says is the world’s narrowest insert slitting and grooving blade with a 0.6mm width of cut for parting and grooving. Iscar’s Slim Slit line is also claimed to be the narrowest line of indexable slitting cutters available on the market. Slim Slit inserts enable cutting grooves down to 0.6mm and also feature through tool coolant which helps chip removal. LogiqTurn When it comes to turning, Iscar has introduced new developments such as JetRTurn, a new tool holder designed to deliver coolant directly to the cutting edge of the insert. The clamp used to hold the insert also contains a channel through which coolant can be delivered. Suitable for high and standard coolant pressures, JetRTurn has three options for connecting the coolant inlets. Through the bottom of the tool, the back of the tool or through a VDI connection. Another development for deep boring turning applications is the Whisperline boring bar. Designed to eliminate chatter and vibration, the shank of the bar has an integrated absorber for smoother machining. The bar has changeable heads for turning, threading and grooving and is available up to a length of 10xD. The Logiq4Turn is a double-sided insert with four cutting edges. Intended for general turning applications, these positive rake inserts have a dovetail shape of that fits into an innovative pocket design ensuring better positioning, stability and increased tool life. LogiqMill Milling is the application with the largest number of new products from Iscar and a key focus for the company is the area of micro-machining with the introduction of very small cutters such as the NanMill and NanFeed endmills. These endmills have a clever design which means the tiny triangular inserts are held in place by a wedge-shaped screw keeping them further away from the cutting edge and holding them securely. The NanMill has three cutting edges for 90° shoulder and deep ramp down milling down to 8mm diameter. Indexing the inserts is aided through the use of a magnetic key which helps to ensure the insert is held in place as it is mounted to the endmill. The NanFeed is a similar endmill designed for high feed milling; suitable for high ramp down angles in deep cavity milling. The tools feature through tool coolant for easy chip evacuation and a high surface finish. Another addition for miniature machining is the Micro3Feed – a micro-sized insert combined with small diameter multi-toothed endmill for high feed milling. The hexagon shaped insert with three cutting edges enables substantially increased feeds for higher productivity and the positive rake angle reduces cutting forces and guarantees a reliable soft cut at high feeds. When it comes to finish milling, Iscar has introduced the TangFin which achieves a mirror like finish by using tangential step mounted inserts which feature a long wiper to achieve a highly polished surface. The new radial and axial positioning of the inserts creates optimal chip distribution and a smooth light cut. Each insert removes a small amount of metal meaning milling is carried out with less noise and vibration. For rough milling, a new line is the Logiq8Tang, a cost-effective insert with eight cutting edges for 90° shoulder milling. The system features a large wiper and is most suitable for use with steel and cast iron, offering high feeds and durability in extreme cutting conditions. This is enabled by the firm placement of the insert due to its dovetail shape. The tangential mounting of the insert reduces forces on the insert screw, eliminating shearing breakages. LogiqDrill New additions to Iscar’s hole making tools include the SumoCham, claimed to be the world’s smallest indexable drilling head at just 4mm. This micro-sized drill head is attached by an ergonomic key for easy clamping. This drill has the same clamp size compared to solid carbide drills and features Iscar’s no set up time system. The high productivity Sumo head is suitable for all materials including steels, stainless steels, cast iron, aluminium, heat resistant alloys and hardened steels. Finally, another Logiq range development is the Logiq3Cham – a new line of drill heads and bodies with three cutting edges allowing higher feeds and higher productivity. The insert head has an innovative design which holds the head firmly in position. It has capabilities for many head replacements and a self-centring sharp point geometry to achieve an absolutely accurate hole size. The head runout is minimal and it remains accurately in position after replacement ensuring there is no set-up time required. Global growth The launch of these new products comes at a time when Iscar’s sales are thriving. Mr Harpaz revealed that in 2017-18 the company had seen double digit growth in sales, and he is optimistic about prospects in growing markets such as the automotive sector in India and China and the burgeoning revival in oil and gas. Commenting on the new release of tools, David Jones, Iscar UK sales manager said: “The application of Logiq represents a smart, logical progression in a series of strategic moves to implement Industry 4.0 machining standards while ensuring continuity and stability. “It has allowed the creation of advanced new tool families, enabled existing lines to be upgraded and inspired innovative product ranges that assist users in maximising equipment utilisation and optimising performance. “Constant communication with customers that operate in all of the world’s major metalcutting sectors, a thorough understanding of advancements in materials and an in-depth knowledge of current machine tool developments allows Iscar to stay ahead of market developments.” Iscar www.iscar.co.uk Watch Iscar talking about its latest cutting tools at MACH 2018 below. https://twitter.com/PESMEDIAcom/status/984369787081019392

“If you are cutting to small major diameters on the face, where the grooves generally aren’t that deep, the chips are not an issue,” says Drape. “But in ID grooving applications where the groove is deep into a bore, then we need to get coolant in, and also need to break down the chip so it can evacuate.”

“The cutting process produces pressure on the work piece and on the tool. Controlling the pressure during machining dictates how successful we will be [in producing an effective cutting tool]. We can control cutting pressures by controlling the width of the grooving insert; the wider the insert, the more pressure it will produce. We also grind positive rakes on the inserts to control the pressure and to act as a chip former to control the chip shape and size.”

“When things get small you have a length and diameter ratio to contend with,” says Ficker from Cogsdill.

Easily access valuable industry resources now with full access to the digital edition of Canadian Fabricating & Welding.

“The grades Iscar uses for our inserts depend on how fast the machine spindle can spin,” says Iscar Tool’s Geisel. “10,000 rpm sounds high but remember you are working with very small parts, around .100 in. in diameter. So that 10,000 rpm with a .100 in. diameter works out to be about 260 sfm…we need to design and produce the insert out of carbide grades with coatings that can run at such speeds.”

The launch of these new products comes at a time when Iscar’s sales are thriving. Mr Harpaz revealed that in 2017-18 the company had seen double digit growth in sales, and he is optimistic about prospects in growing markets such as the automotive sector in India and China and the burgeoning revival in oil and gas.

Another development for deep boring turning applications is the Whisperline boring bar. Designed to eliminate chatter and vibration, the shank of the bar has an integrated absorber for smoother machining. The bar has changeable heads for turning, threading and grooving and is available up to a length of 10xD.

When it comes to innovation, Iscar has a long legacy of not standing still. 40% of its tools in its product lines are less than five years old.

For rough milling, a new line is the Logiq8Tang, a cost-effective insert with eight cutting edges for 90° shoulder milling. The system features a large wiper and is most suitable for use with steel and cast iron, offering high feeds and durability in extreme cutting conditions. This is enabled by the firm placement of the insert due to its dovetail shape. The tangential mounting of the insert reduces forces on the insert screw, eliminating shearing breakages.

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There are four main product areas in the new Logiq range reflecting tools designed for different applications: LogiqGrip, LogiqTurn, LogiqMill and LogiqDrill.

When grooving small pieces, cutting pressure tends to be relatively high. Aside from slowing feed rates, it can also help to use high lubricity coolants that work well in tight spaces.

How best to approach grooving a small part has a lot to do with the materials involved: repeat, high volume applications tend to be with softer metals, with specialty one-offs applying to higher value applications, often with tougher alloys.

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The new Logiq range reflects the company’s comprehensive portfolio of cutting tools made from numerous carbide grades, along with the cubic boron nitride (CBN), polycrystalline diamond, Cermet and ceramic tools.

“This is a double-sided insert that works well with slow cutting forces,” says Kaufmann. “The GUP insert geometry is advanced and versatile, with excellent metal removing rates.”

Geisel concurs with John Stewart that the challenge for tooling suppliers is to make a strong, rigid cutting tool or insert.

This new ‘Chess Line’ series of cutting tools is intended to be fit for the coming era of Industry 4.0 and the smart factory. At its Logiq product launch held at the ICC in Birmingham to an audience of distributors, customers, Iscar personnel and members of the press, Jacob Harpaz, Iscar’s CEO, spelled out how the digital domain will impact manufacturing.

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“There are companies that require face grooves with major diameters as small as 0.2 mm,” says Duane Drape, national sales manager for Horn USA Inc., in Franklin, TN. “This is mostly aluminium, but I have had customer requirements to get that small with steel at 50 + Rockwell.”

The latest Iscar LogiQuick campaign has unveiled a diverse range of new cutting tools, effectively replenishing the company's portfolio.

These endmills have a clever design which means the tiny triangular inserts are held in place by a wedge-shaped screw keeping them further away from the cutting edge and holding them securely. The NanMill has three cutting edges for 90° shoulder and deep ramp down milling down to 8mm diameter.

“As a tooling manufacturer, we are being pushed to produce tooling able to groove in smaller, and smaller diameters. Our PICCO line can produce grooves in diameters from as small as 2 mm (.08 in.) and we can go smaller by special request.”

The problem with carbide is that reducing deflection increases the risk a tool will break, so it’s important to preserve the strength of the neck of the tool. Tool monitoring is also recommended, because with small cutting edges it can be hard to see or hear when a tool breaks.

As a result, Cogsdill’s tools are better suited to high production lines, an area that has seen some big changes of late. Only a few years ago, small bores were typically 4 mm, but now leading vendors are delivering off-the-shelf bore grooves to 2 mm, with specialty applications going much smaller. This has resulted in new abilities—and challenges—when it comes to grooving very small parts, as well as increased demand.

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Solid carbide grooving tools are usually L-shaped. Part of the challenge is that even the non-cutting, or “leg” part has to fit into the bore diameter. Given that the bottom of the L, or the “foot” has to be even smaller, strength becomes an issue, as does the fact that groove depth is limited. As a result, with bores of less than 2 mm in diameter the best tools are now constrained to a groove depth of around 0.2 mm.

According to Mr Harpaz, Industry 4.0’s impact will not just come through sophisticated new technology such as sensors, process monitoring and acquiring machining data, but in the integration of factories and the supply and distribution of consumables used in manufacturing and products leaving the factory.

“Slow feeds can be a good idea, depending on the material,” says Bokum Tool’s Stewart. “With smaller sizes a weaker tool neck will want to deflect, especially with carbide, and with increased distance to the groove, feed speeds need to be adjusted downward.”

If the chip created by the grooving tooth is wider than the finished groove, then you can minimize the possibility that the chip will stay in the groove. But when it comes to harder metals the challenge isn’t chip control so much as creating the chip in the first place. “At 1.5 mm you need to have a tool that is strong enough to create the chip,” says Stewart. “But from there, with a strong alloy like Inconel, it is relatively easy to control the chip. In the case of aluminium and softer materials, where the chip is continuous, it creates greater headaches because the material balls up.”

“Constant communication with customers that operate in all of the world’s major metalcutting sectors, a thorough understanding of advancements in materials and an in-depth knowledge of current machine tool developments allows Iscar to stay ahead of market developments.”

The latest Iscar LogiQuick campaign has unveiled a diverse range of new cutting tools, effectively replenishing the company's portfolio.

New additions to Iscar’s hole making tools include the SumoCham, claimed to be the world’s smallest indexable drilling head at just 4mm. This micro-sized drill head is attached by an ergonomic key for easy clamping. This drill has the same clamp size compared to solid carbide drills and features Iscar’s no set up time system. The high productivity Sumo head is suitable for all materials including steels, stainless steels, cast iron, aluminium, heat resistant alloys and hardened steels.

An extension of its IQ concept, the new Logiq range offers an array of machining solutions for applications in parting off, turning, milling and drilling.

ID grooving in particular can be an issue with small parts, says Steve Geisel, senior product manager for Iscar Tools Inc., Oakville, ON.

Indexing the inserts is aided through the use of a magnetic key which helps to ensure the insert is held in place as it is mounted to the endmill. The NanFeed is a similar endmill designed for high feed milling; suitable for high ramp down angles in deep cavity milling. The tools feature through tool coolant for easy chip evacuation and a high surface finish.

“By 2030 there will be big changes in the automotive sector, for example,” Mr Harpaz explained. “The major OEMs are moving away from the internal combustion engine which will mean much less metal removal will be required. There will be wider use of composite materials and the introduction of 3D printing will also mean less metal removal. At Iscar we are preparing for these changes. Cutting tools will have to adapt to remove less metal but at much faster speeds and feeds.”

When it comes to finish milling, Iscar has introduced the TangFin which achieves a mirror like finish by using tangential step mounted inserts which feature a long wiper to achieve a highly polished surface. The new radial and axial positioning of the inserts creates optimal chip distribution and a smooth light cut. Each insert removes a small amount of metal meaning milling is carried out with less noise and vibration.

Also in this range is the Logiq5Grip – a five-pocket blade system that is designed to deliver extended tool life. The interchangeable blade is assembled on a toolholder which indexes tangential grip 2 and 3mm inserts for parting and grooving. This system also indexes what Iscar says is the world’s narrowest insert slitting and grooving blade with a 0.6mm width of cut for parting and grooving.

“It is important to keep speeds as low as possible when you have small-sized parts,” says Igor Kaufmann, a member of Kennametal Inc.’s global team for turning tools. When grooving miniature parts, Kaufmann emphasizes that the tools still need to fit axially and apply radial force to the bore. As a result, it is hard to ensure that the tool is strong enough, which then leads not only to chatter issues but also challenges with breakage and chip evacuation.

Finally, another Logiq range development is the Logiq3Cham – a new line of drill heads and bodies with three cutting edges allowing higher feeds and higher productivity. The insert head has an innovative design which holds the head firmly in position.

“The challenge with grooving is that below 1.5 mm it is difficult to make a tool that is strong enough,” says John Stewart, VP of engineering at Bokum Tool in Madison Heights, MI. “The overall determining factor is: What does a groove look like in a hole that size? If it is proportionally very similar to a larger hole then it is theoretically possible to get very small, but it really comes down to the strength of the tool itself.”

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“You need the chips to be able to freely get out of the bore and away from the cutting action so they do not interfere with the machining process.”

MSC Industrial Supply Co. UK (MSC) is celebrating a successful season after sponsoring two local youth football teams during the 2023/2024 campaign.

A frequent issue is whether or not to go with inserts or solid carbide tools. Inserts can be indexable or have only one edge for single use. Inserts tend to be less expensive, but usually can’t get into the smallest bores, and are not as strong as solid-carbide tools.