The COVID-19 pandemic did not interrupt the innovation process, and between 2020-2021 the cutting tool specialist introduced the NeoLogiq marketing campaign comprised of advanced cutting tools and tooling solutions for modern metalworking.

Easily access valuable industry resources now with full access to the digital edition of Canadian Metalworking.

Horn’s Torus end mill is carbide grade TSCC for machining of cobalt chrome alloys. It comes with a 2- to 5-fluted design with a 30-degree helix angle. Photo courtesy of Horn.

Hundreds of British manufacturing companies opened their doors in a UK-wide open house today as part of National Manufacturing Day, giving their local communities the chance to see the highly paid careers and jobs on offer in our exciting and diverse sector.

There are several challenges that operators should be aware of when milling cobalt chrome. The material tends to be extremely abrasive, which causes the cutting tools to dull prematurely and reduces the life of the tool.

A modular tool concept is the way to reach high levels of versatility and NeoSwiss is a new tool system with quick-change heads, that follows this concept. There are different types of heads for indexable inserts. The system is suitable for turning, parting, grooving, and threading applications. Through the use of an innovative high-clamping-force mechanism, the heads are mounted on a toolholder. The mechanism provides an accurate cutting edge position each time and utilises high position repeatability. The system intended mainly for Swiss-type machines enables removing heads and replacing inserts within the tight confines of CNC machining centres.

Using the appropriate cutting tools is essential to optimizing cutting conditions for cobalt chrome. According to Cetkovic, one of the biggest cutting tool considerations should be strength of the tool design. He recommends starting with a reinforced shank diameter. Choosing a milling tool geometry with a positive break angle will reduce cutting forces and deflection, which tend to be problematic with this material.

When it comes to thermal shrink fit toolholders, the chuck thickness is a factor that limits the working space of a tool which often causes an increase in the tool overhang to reach a machined surface. To address this, Iscar’s X-Stream family of thermal shrink toolholders is a series of slim design chucks to eliminate such a restriction. The new chucks follow Iscar’s coolant jet channel technology providing direct coolant supply to the tool cutting edge.

Big Kaiser’s end mills are designed to increase productivity and meet some of the most challenging application requirements. These micro cutting tools are produced using solid carbide with a reinforced shank to maximize stability. Photo courtesy of Big Kaiser.

Beyond these characteristics, cobalt chrome is heat-treatable, not magnetic, offers good hot and cold formability, and has high coefficient of thermal expansion and very high resistance to acid, making these alloys a great fit for dental equipment, medical tech, the energy sector, chemical industries, and aerospace.

This is generally because of the low thermal conductivity of the material. Cetkovic explained that when cutting, the tool will absorb a lot of the heat. Adding coolant as the tool exits the cut can cause it too cool down quickly, which can cause the tool to fracture because of thermal shock. Machining cobalt chrome dry can help operators avoid situations like this.

Logiq-F-Grip features a new highly advanced tool family for parting solutions. The central component of the family is a robust tool block that mounts a four-pocket adapter. There are cases when the rib, a reinforcement element of the block, interferes and prevents clamping the block on typical turret positions. NeoLogic overcomes this problem by providing additional blocks with the rib placed on the alternative side of the block.

NeoDo S890 is a family of 90° indexable face mills for rough and semi-finishing operations. The mills mount durable square double-sided inserts with eight cutting edges. NeoDo S890 facilitates face and square shoulder milling while providing an additional option for milling close to shoulders where there are workpiece or workholding fixture constraints. Iscar customers have requested additional corner radii and tool diameters, therefore, this tool family has been expanded with additional pressed to size inserts with a 0.8mm corner radius and cutters in diameters 32 and 25mm including endmill design configurations.

Luminoso has a bachelor of arts from Carleton University, a bachelor of education from Ottawa University, and a graduate certificate in book, magazine, and digital publishing from Centennial College.

"Enhancing the efficiency of machining cobalt chrome can be accomplished by keeping a close eye on the tool life, for all the tools in the process, and frequently changing tools to ensure that you are cutting the material and not rubbing the material with dull tools," said Foschaar. "Most times cutting parameters are drastically reduced in this material to avoid poor tool life, but there is a fine line or small window to machine within for cobalt chrome."

"These materials also can be polished at an extremely high level, which eliminates surface areas where bacteria can form in medical devices," said Dan Doiron, milling product manager, Emuge Corp., West Boylston, Mass.

Manufacturers in the orthopedic and dental implant sectors are familiar with difficult-to-machine materials like cobalt chrome. These superalloys are known for their biocompatibility, making them a great choice for medical device manufacturing. Even the aerospace industry has taken note of the unique characteristics and high degree of hardness that cobalt chrome offers. As this material becomes more mainstream, machine shops have to adapt to meet the challenges when milling this hard-to-cut material, particularly because the cost of cobalt chrome is quite high.

"Cobalt chrome is considered a DTC [difficult-to-cut] material due to its high hardness, corrosion resistance, high melting points, and incredible strength at high temperatures," said Chris Foschaar, application and sales engineer, Horn USA Inc., Franklin, Tenn. Foschaar added that there are many variations of the material, with an average hardness of 40-50 HRC. Depending on the type of cobalt chrome, the material also can carry hard spots throughout upwards of 58-60 HRC.

The Iscar Logiq-3-Cham is also based on the concept of exchangeable carbide heads with three flutes for improved productivity and is now supplemented by new carbide heads for achieving nearly flat bottom holes. Flat bottom holes are necessary for screw head sockets, spring seats, washer ports, etc. The heads ensure drilling up to an 8-hole depth-to-diameter ratio without a pre-hole. The new design facilitates generating holes with a nearly flat bottom in a single pass. The heads are mounted on existing Logiq-3-Cham tools that significantly expand the application range of the family and reduce inventory costs.

Foschaar added that solid-carbide tools are preferred for machining cobalt chrome materials. Carbide cutting tools generally have thermal shock-resistant properties while at the same time have a high degree of bending strength and fracture toughness, making them suited for the characteristics of this material.

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Coalville, Leicestershire-based CMS Cepcor is a leading supplier of aftermarket crusher spares, manganese-steel wear liners and other equipment for the mining, aggregate production and associated industries worldwide.

Iscar’s NeoLogiq series is based on new tools that were developed with its customers’ input. The company says its clients can expect more development to assure advanced machining in the new era of metalworking.

Precision carbide cutting tool maker Iscar has released a raft of new products to address the latest trends in modern metalworking. PES finds out more. The slogan ‘Where Innovation Never Stops!’ appears on the walls of Iscar production facilities around the world and has been synonymous with the company for several decades. The COVID-19 pandemic did not interrupt the innovation process, and between 2020-2021 the cutting tool specialist introduced the NeoLogiq marketing campaign comprised of advanced cutting tools and tooling solutions for modern metalworking. The significant and accelerated changes in manufacturing such as digitisation and the shift to electric drive in the automotive industry have resulted in new demands for cutting tools. Iscar has responded with an expansion of its NeoLogiq range. According to the company, ‘Machining with No Boundaries’ is the term that sums up the NeoLogiq mindset. Holemaking advances Iscar’s Cham-IQ-Drill, the family of assembled drills that mount exchangeable carbide heads, has been upgraded with new heads in the 33-40mm diameter range These heads can be mounted on any drill with the appropriate pocket size. The main feature of the new heads is a multifunctional cutting geometry, which enables the effective drilling of a wide range of materials such as steel, stainless steel, heat-resistant special alloys, and titanium (ISO P, M, and S groups of application) assuring hole precision within IT10-IT9 accuracy grades. Iscar says its customers will benefit from using the new heads; more interchangeability means less tools to stock. A NeoSwiss turning tool carries a quick-change head with indexable insert The Iscar Logiq-3-Cham is also based on the concept of exchangeable carbide heads with three flutes for improved productivity and is now supplemented by new carbide heads for achieving nearly flat bottom holes. Flat bottom holes are necessary for screw head sockets, spring seats, washer ports, etc. The heads ensure drilling up to an 8-hole depth-to-diameter ratio without a pre-hole. The new design facilitates generating holes with a nearly flat bottom in a single pass. The heads are mounted on existing Logiq-3-Cham tools that significantly expand the application range of the family and reduce inventory costs. Longer drilling applications ModuDrill is a family of modular drills with replaceable carbide heads that carry indexable inserts and provide an alternative solution. Mounting an exchangeable extension holder on a drill body increases the drilling depth by an additional 200mm when machining holes in a diameter range of 33-40mm. In high-speed reaming, a combination of a carbide reaming head with a rolling device in one single tool results in a short operational time for achieving accurate hole diameters along with a mirror-like surface finish. Modular turning A modular tool concept is the way to reach high levels of versatility and NeoSwiss is a new tool system with quick-change heads, that follows this concept. There are different types of heads for indexable inserts. The system is suitable for turning, parting, grooving, and threading applications. Through the use of an innovative high-clamping-force mechanism, the heads are mounted on a toolholder. The mechanism provides an accurate cutting edge position each time and utilises high position repeatability. The system intended mainly for Swiss-type machines enables removing heads and replacing inserts within the tight confines of CNC machining centres. A 90-degrees NeoDo S890 face mill Locked up rigidity Iscar has also developed a new lever dual lock securing mechanism for improved clamping rigidity intended for ISO turning inserts. The new design, referred to as the Combi-D-Lock family, combines the advantages of two conventional clamping methods through the use of a lever and a top clamp. An insert is locked in two directions from the top and the bottom. This provides better stability and rigidity, and in comparison to the conventional lever improves tool life and increases productivity. Logiq-F-Grip features a new highly advanced tool family for parting solutions. The central component of the family is a robust tool block that mounts a four-pocket adapter. There are cases when the rib, a reinforcement element of the block, interferes and prevents clamping the block on typical turret positions. NeoLogic overcomes this problem by providing additional blocks with the rib placed on the alternative side of the block. The Logiq-F-Grip parting system was designed to achieve extra stability and vibration-resistant high productivity parting and grooving operations. The highly engineered system is an assembled tool block that comprises a durable holder and a high-stiffness quad blade with pockets for mounting inserts. Milling innovations NeoDo S890 is a family of 90° indexable face mills for rough and semi-finishing operations. The mills mount durable square double-sided inserts with eight cutting edges. NeoDo S890 facilitates face and square shoulder milling while providing an additional option for milling close to shoulders where there are workpiece or workholding fixture constraints. Iscar customers have requested additional corner radii and tool diameters, therefore, this tool family has been expanded with additional pressed to size inserts with a 0.8mm corner radius and cutters in diameters 32 and 25mm including endmill design configurations. A durable double-sided round insert is now available. The combination of an innovative pocket design and a special peripheral shape of the insert provides reliable insert clamping and fail-proof insert indexing. Depending on the depth of cut, there are up to six insert indexes on each side (up to 12 indexes total). When indexing, there is no need to remove the insert clamping screw. The main application of the new cutters is for rough and semi-finish milling complex surfaces, especially in die and mould, power generation, and aerospace parts. The range of solid carbide endmills has been expanded by adding new tool diameters and corner radii. A Micro 90 coolant-driven high-speed compact spindle ensures extremely high rotating velocities Toolholder upgrades Iscar SpinJet, a family of coolant-driven high-speed compact spindles for small diameter tools intended to upgrade existing machines to high-speed performance, is now supplemented with Micro 90 intended for miniature rotating tools in milling, drilling, countersinking, thread milling, engraving, chamfering and deburring operations. Micro 90, made of a solid titanium shell and assembled from just six parts, enables rotating velocities that range from 35,000 to 53,000rpm while the main machine spindle remains idle. When it comes to thermal shrink fit toolholders, the chuck thickness is a factor that limits the working space of a tool which often causes an increase in the tool overhang to reach a machined surface. To address this, Iscar’s X-Stream family of thermal shrink toolholders is a series of slim design chucks to eliminate such a restriction. The new chucks follow Iscar’s coolant jet channel technology providing direct coolant supply to the tool cutting edge. Evolving to meet demand Changes in metalworking technology place new demands on cutting tools and to meet these demands, cutting tool manufacturers develop new products to assure increased performance. In turn, The industry’s response to the products spawns new requirements. Iscar’s NeoLogiq series is based on new tools that were developed with its customers’ input. The company says its clients can expect more development to assure advanced machining in the new era of metalworking. Iscarwww.iscar.co.uk

The significant and accelerated changes in manufacturing such as digitisation and the shift to electric drive in the automotive industry have resulted in new demands for cutting tools. Iscar has responded with an expansion of its NeoLogiq range. According to the company, ‘Machining with No Boundaries’ is the term that sums up the NeoLogiq mindset.

ModuDrill is a family of modular drills with replaceable carbide heads that carry indexable inserts and provide an alternative solution. Mounting an exchangeable extension holder on a drill body increases the drilling depth by an additional 200mm when machining holes in a diameter range of 33-40mm.

"This in turn causes the next challenge, which is work hardening of the material," said Foschaar. "These challenges can be minimized by selecting the proper cutting tools for the application."

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

Emuge’s TiNox-Cut product range consists of submicron grain carbide end mills for difficult-to-cut materials, particularly aerospace materials. Photo courtesy of Emuge.

Precision carbide cutting tool maker Iscar has released a raft of new products to address the latest trends in modern metalworking. PES finds out more.

Because of this, the heat concentrates at the cutting edge of the tool," said Doiron. "This is where the geometry of the tool plays a big role in its ability to absorb that heat and chip away the material. Also, when working with cobalt chrome, establishing proper cutting parameters is vital to prevent tool failure."

A South West-based engineering team is aiming to transform the large-format additive manufacturing sector with the launch of its latest product.

"We also tend to see some variability when it comes to coolant delivery," said Cetkovic. "We’ve also seen a large number of cases where customers are dry machining these materials."

Doiron added that it’s not just the cutting tools themselves that an operator needs to consider. Having a rigid setup with the cutting tool fully inserted into the toolholder to the maximum depth is an optimal scenario. If an operator can keep the tool engaged in the holder to the correct gauge line, tool wear can be reduced, which is already a significant challenge even without overextending the tool.

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He explained that for operators or shops that haven’t come across it or are now just starting to get into it, they may find it very disappointing because of the SFM rating and tool life expectancy. However, once a shop has worked out the correct machining parameters and knows how to approach the material, it can successfully machine cobalt chrome and get the best tool performance.

The Logiq-F-Grip parting system was designed to achieve extra stability and vibration-resistant high productivity parting and grooving operations. The highly engineered system is an assembled tool block that comprises a durable holder and a high-stiffness quad blade with pockets for mounting inserts.

Iscar has also developed a new lever dual lock securing mechanism for improved clamping rigidity intended for ISO turning inserts. The new design, referred to as the Combi-D-Lock family, combines the advantages of two conventional clamping methods through the use of a lever and a top clamp. An insert is locked in two directions from the top and the bottom. This provides better stability and rigidity, and in comparison to the conventional lever improves tool life and increases productivity.

"Tools designed for nickel-based alloys or tools for hardened materials are also suitable for this material," said Foschaar. "Nose end mills or square end mills with corner radii are usually ideal for this material. It’s also important that the tools are sharp. Dead sharp tools should be avoided due to the rapid decline of the cutting edge, which will cause rubbing, and a work-hardening situation will occur."

Lindsay Luminoso, sr. editor/digital editor, contributes to both Canadian Metalworking and Canadian Fabricating & Welding. She worked as an associate editor/web editor, at Canadian Metalworking from 2014-2016 and was most recently an associate editor at Design Engineering.

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

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

Proper cooling at the cutting edge, reducing tool projections as much as possible, and using a very strong, rigid fixture setup on the machine will help deal with the challenges of milling cobalt chrome. With the high price of the material, ensuring process reliability through proper tool selection and cutting parameters is essential.

Adding to the fact that this material is difficult to mill, the hard spots also can lead to inconsistent machining results. According to Cory Cetkovic, product manager, Big Kaiser, Hoffman Estates, Ill., it is important to take note of these hard spots in the material and determine the most appropriate tool to handle a range of hardnesses within the material.

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

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

Another significant consideration is that cobalt chrome is very heat-resistant with low thermal conductivity. During cutting of standard steels, heat generally is evacuated through the chip. However, with cobalt chrome, heat does not generate into the chips.

Beyond substrate, geometry, and edge prep, adding a coating can be a big asset. Cetkovic explained that a coating can have a huge influence on chip evacuation, which is extremely important in this heat-resistant material.

Iscar’s Cham-IQ-Drill, the family of assembled drills that mount exchangeable carbide heads, has been upgraded with new heads in the 33-40mm diameter range These heads can be mounted on any drill with the appropriate pocket size. The main feature of the new heads is a multifunctional cutting geometry, which enables the effective drilling of a wide range of materials such as steel, stainless steel, heat-resistant special alloys, and titanium (ISO P, M, and S groups of application) assuring hole precision within IT10-IT9 accuracy grades. Iscar says its customers will benefit from using the new heads; more interchangeability means less tools to stock.

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"We are able to take a lot of our more common tool geometries and apply a special coating or put a radius on the edge to help them perform in some of these more difficult-to-machine materials," he added.

The slogan ‘Where Innovation Never Stops!’ appears on the walls of Iscar production facilities around the world and has been synonymous with the company for several decades.

Cetkovic added that operators need to be aware of the high work-hardening rate of this material. He suggests that a slow feed rate, although better for cutting tool life, could also result in this work hardening, so it’s important to discuss with cutting tool manufacturers the range of cutting speeds (SFM) that the tool can handle in the material. To extend tool life, he also recommends a low depth of cut.

In high-speed reaming, a combination of a carbide reaming head with a rolling device in one single tool results in a short operational time for achieving accurate hole diameters along with a mirror-like surface finish.

Changes in metalworking technology place new demands on cutting tools and to meet these demands, cutting tool manufacturers develop new products to assure increased performance. In turn, The industry’s response to the products spawns new requirements.

Iscar SpinJet, a family of coolant-driven high-speed compact spindles for small diameter tools intended to upgrade existing machines to high-speed performance, is now supplemented with Micro 90 intended for miniature rotating tools in milling, drilling, countersinking, thread milling, engraving, chamfering and deburring operations. Micro 90, made of a solid titanium shell and assembled from just six parts, enables rotating velocities that range from 35,000 to 53,000rpm while the main machine spindle remains idle.

"I think everyone who cuts this material, or at least has been in the industry, understands how difficult it is," said Doiron.

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A durable double-sided round insert is now available. The combination of an innovative pocket design and a special peripheral shape of the insert provides reliable insert clamping and fail-proof insert indexing. Depending on the depth of cut, there are up to six insert indexes on each side (up to 12 indexes total).

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

When indexing, there is no need to remove the insert clamping screw. The main application of the new cutters is for rough and semi-finish milling complex surfaces, especially in die and mould, power generation, and aerospace parts. The range of solid carbide endmills has been expanded by adding new tool diameters and corner radii.