A new double-sided design featuring two pockets in one shank offers cost-effectiveness and sustainable utilisation of the shank material. The shank, which is made of steel, includes a central through hole for internal coolant supply.

For a 17-mm-diameter WC part, machining time is 90 seconds. With a required Sa spec for this <5 nm part, the μ-LAM process yielded roughness values of 2 to 2.5 nm.

The Optimus T+1 was coupled to a 1064 nm yttrium aluminum garnet (YAG) laser via a fiber-optic cable and collimated lens. The diamond tool is optically transparent to the wavelength of the laser and fabricated to perform as a focusing lens that directs the beam precisely to the tool's cutting edge radius. This allows for only the cutting zone of the material to be heated and softened.

It is achieved by adjusting the suggested cutting data, considering factors such as machine characteristics, batch sizes, and adaptation limitations. Consequently, this empowers engineers to choose the most suitable machining parameters. By simulating drilling cycles, customers can achieve the desired commercial result.

Iscar is known for prioritising innovation, so it comes as no surprise that these new products have piqued the interest of the metalworking community, including machine shops and other cutting tool manufacturers. The innovations span across all aspects of the company's range, including turning, parting, holemaking, milling, threading, and toolholding.

A specialist designer and manufacturer of sustainable electric motors and powertrain systems has tapped into a new skills pilot to help it achieve ambitious expansion plans, fuelled by a recent £23m raise.

The Multi-Master family of tools with exchangeable cutting heads has been an Iscar flagship product for almost a quarter of a century. Despite its longevity, innovation never stops within this versatile product line. The launch of the LogiQuick campaign has introduced new developments, further expanding the application range of the popular family.

The latest Iscar LogiQuick campaign has unveiled a diverse range of new cutting tools, effectively replenishing the company's portfolio. In this article, Iscar’s senior technical manager, Andrei Petrilin explains how these new products are all focused on delivering enhanced performance, increased productivity and greater profitability.

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To demonstrate extended tool life, many Si diffractive lenses were machined using the μ-LAM process and analyzed for surface roughness and form error using a white light interferometer with a standard Gaussian 0.08 mm filter applied. Note that the part numbers correspond to the order in which they were machined—for example, part 12 would be the 12th part the tool would have machined.

Along with these new developments, the campaign also introduces additional designs that improve and expand the existing families. There is also a special emphasis on the digital component, which has become an integral part of tools for modern smart manufacturing. In fact, LogiQuick sets the direction for Iscar's strategy in the coming years.

Compared to standard diamond turning, the μ-LAM process not only produces good Si part quality with more than 3X reduction in surface roughness, but it also enables increased manufacturing productivity, more than quadrupling the number of parts that can be produced in a single shift (see Table 1).

The μ-LAM technology directly heats and thermally softens the workpiece material, in the chip deformation and generation zone, increasing the material's ductility. Improved ductility that results from reduced material hardness allows for easier chip formation, decreased brittleness, and ultimately higher material removal rates-all leading to better tool performance and increased productivity that in turn translates into lower manufacturing costs.

This review aims to explore the benefits of some recently introduced products and reveal how they can boost the profitability of machining operations. At times, a newcomer might appear insignificant. However, even a seemingly minor change is strategically directed towards enhancing cutting performance to improve cost-effectiveness. According to Iscar, this aspect is the heart, the essence of the entire product development process.

Recently, μ-LAM technology has made some groundbreaking progress in machining optical-quality tungsten carbide (WC) using a diamond-turning process. While favored in the glass molding industry, as it performs well under high temperature and high-pressure applications, WC is an extremely hard material (about 3X harder than Si) and, therefore, has never been successfully diamond-turned to an optical quality surface. The status-quo process to manufacture WC optical molds is to grind and polish them in an arduous 3–4 hour per-part process.

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

One of the new products is a series of six-flute solid carbide heads, intended for quick metal removal in roughing using the high feed milling (HFM) method (Fig. 2). These heads have ramping and slotting capabilities and are suitable for machining hard steel and cast iron (up to HRC 65).

A typical Si diffractive lens used in an IR optical system with a 50.4 mm diameter, for example, has a 0.5 fringe irregularity tolerance, surface roughness <10 nm Sa, 60-40 surface quality, no spokes, and no gray or brittle bands. The primary challenge here is achieving the 0.5 fringe (<160 nm) irregularity tolerance that can only be achieved with a well-preserved (not worn) cutting tool edge.

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EuroBLECH, the world’s largest sheetmetal working technology exhibition will take place in Hannover from 22-25 October. At the event, Yamazaki Mazak will announce the European debut of the Optiplex 3015 Ez, its latest affordable laser processing machine. This cutting-edge technology offers high-quality laser processing capabilities at a cost-effect...

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

In addition to Si, the μ-LAM process also improves productivity for other crystals and IR materials (see Table 2). μ-LAM is also an enabling technology, producing high-quality, large-diameter Si optics and all sizes of CaF2 optics compared to zero acceptable parts using conventional diamond turning alone.

Following market demands, the set of product families has been expanded using a traditional approach. For example, the Sumocham self-centring drilling heads family, which falls within the diameter range of 4 to 32.9mm, has been enriched by introducing 0.1mm diameter increment sizes in addition to the initial 0.5mm increment. The cutting geometry of these heads is optimised for drilling both steel and cast iron (ISO P and ISO K groups of application). This means that one head can replace two other types, resulting in reduced stock.

Also, NEOITA has been enhanced with a new smart AI feature, which allows users to search for and access detailed material specifications, including metallurgical composition and common uses. The search results can then be incorporated into the NEOITA material library database or the customer's personal libraries, if needed.

The Z-PRO VU series of taps from Japanese company Yamawa is especially designed for use with water-soluble cutting fluid and represents the optimum solution for tapping on high performance machining centres. Recently, the company has broadened the range of the VU series with new products and sizes.

For our analysis, the μ-LAM system was mounted on a UPL to machine a diffractive Si lens (see Fig. 1). The μ-LAM system's tool post, termed Optimus T+1, is a bolt-on system that replaces the existing tool post and takes <60 min to retrofit. The laser controls are connected to the UPL, enabling it to be controlled with an M-code command.

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To evaluate the machinability of optical-grade crystals via the μ-LAM process, machining tests were performed on a diamond-turning ultra-precision lathe (UPL) with a 15 pm positional accuracy feedback system. Such UPLs are designed for producing optical lenses, optical mold inserts and mirrors, and small precision mechanical components.

The new cutters are produced in an endmill design with a diameter range of 16-25 mm. Additionally, the Multi-Master head configuration is available within the same range, featuring an option for a pinpointed internal high-pressure coolant supply.

Another example is the Chatterfree solid carbide end mills (SCEM) family. These versatile tools are designed for machining steel, stainless steel, and hardened steel (ISO P, ISO M, and ISO H groups of application). They have been expanded with a variety of new corner radii.

Deepak Ravindra is CEO, Sai Kumar Kode is lead process engineer, and Chris Stroshine is global sales manager, all at Micro-LAM, Portage, MI; e-mail: [email protected]; www.micro-lam.com.

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

They are available in diameters ranging from 8 to 25mm. Another addition is represented by new three-flute heads specifically designed for shallow drilling operations (with a depth of up to one head diameter). The heads seamlessly combine the highly efficient cutting geometry of Logiq-3-Cham, another popular Iscar product, with the exceptional robustness of the Multi-Master concept. This combination results in a highly productive drilling tool, especially when used with materials that produce short chips.

The Z-PRO VU series of taps from Japanese company Yamawa is especially designed for use with water-soluble cutting fluid and represents the optimum solution for tapping on high performance machining centres. Recently, the company has broadened the range of the VU series with new products and sizes.

Fig1The latest Iscar LogiQuick campaign has unveiled a diverse range of new cutting tools, effectively replenishing the company's portfolio. In this article, Iscar’s senior technical manager, Andrei Petrilin explains how these new products are all focused on delivering enhanced performance, increased productivity and greater profitability.Iscar is known for prioritising innovation, so it comes as no surprise that these new products have piqued the interest of the metalworking community, including machine shops and other cutting tool manufacturers. The innovations span across all aspects of the company's range, including turning, parting, holemaking, milling, threading, and toolholding.Along with these new developments, the campaign also introduces additional designs that improve and expand the existing families. There is also a special emphasis on the digital component, which has become an integral part of tools for modern smart manufacturing. In fact, LogiQuick sets the direction for Iscar's strategy in the coming years.This review aims to explore the benefits of some recently introduced products and reveal how they can boost the profitability of machining operations. At times, a newcomer might appear insignificant. However, even a seemingly minor change is strategically directed towards enhancing cutting performance to improve cost-effectiveness. According to Iscar, this aspect is the heart, the essence of the entire product development process.Fig2Classical expansionsFollowing market demands, the set of product families has been expanded using a traditional approach. For example, the Sumocham self-centring drilling heads family, which falls within the diameter range of 4 to 32.9mm, has been enriched by introducing 0.1mm diameter increment sizes in addition to the initial 0.5mm increment. The cutting geometry of these heads is optimised for drilling both steel and cast iron (ISO P and ISO K groups of application). This means that one head can replace two other types, resulting in reduced stock.Another example is the Chatterfree solid carbide end mills (SCEM) family. These versatile tools are designed for machining steel, stainless steel, and hardened steel (ISO P, ISO M, and ISO H groups of application). They have been expanded with a variety of new corner radii.Additionally, the T-Slot family, a popular range of slot milling cutters with exchangeable solid carbide heads, has been expanded to include a new head diameter of 25mm. This upgrade lowers the minimum limit of the T-Slot head diameter range and is designed to accommodate a wider range of widths, making the heads highly efficient for milling narrow slots and grooves in various workpiece materials.New developments in thread millingIscar has expanded its family of solid carbide thread endmills by introducing new tools with an increased number of flutes (up to eight), significantly reducing machining time. A few words are worth mentioning about the new Quick-M-Thread family of milling cutters with triangular inserts (Fig. 1) in the range of indexable threading products.These incorporate a step-release design concept that substantially reduces cutting forces, minimises bending load, and improves dynamic stability, thereby enhancing productivity. The new tools, both solid and indexable, are also equipped with an internal coolant supply option, which not only increases the cooling effect and lubricity during thread milling but also contributes to better chip flow and surface finish.Fig3Multi-Master’s headline The Multi-Master family of tools with exchangeable cutting heads has been an Iscar flagship product for almost a quarter of a century. Despite its longevity, innovation never stops within this versatile product line. The launch of the LogiQuick campaign has introduced new developments, further expanding the application range of the popular family.One of the new products is a series of six-flute solid carbide heads, intended for quick metal removal in roughing using the high feed milling (HFM) method (Fig. 2). These heads have ramping and slotting capabilities and are suitable for machining hard steel and cast iron (up to HRC 65). They are available in diameters ranging from 8 to 25mm. Another addition is represented by new three-flute heads specifically designed for shallow drilling operations (with a depth of up to one head diameter). The heads seamlessly combine the highly efficient cutting geometry of Logiq-3-Cham, another popular Iscar product, with the exceptional robustness of the Multi-Master concept. This combination results in a highly productive drilling tool, especially when used with materials that produce short chips.A new double-sided design featuring two pockets in one shank offers cost-effectiveness and sustainable utilisation of the shank material. The shank, which is made of steel, includes a central through hole for internal coolant supply.A novel design for a known conceptThe concept of an ‘all-in-one’ compact 90° indexable cutter suitable for various milling operations – for example, milling square shoulders, slot or complex contours, along with drilling capabilities – is not new. Such a cutter excels in many machining applications, eliminating the need for specialised tools. However, the Quick-D-Mill (Fig. 4), a new family of these cutters, features an innovative design that undoubtedly provides additional benefits for customers. The family includes double-toothed right-hand cutters with two rectangular-shaped indexable carbide inserts. Each insert possesses a total of 4 cutting edges, and the Quick-D-Mill design enables the insert to be used for both central and peripheral cutting.Fig4This optimises insert utilisation, reduces the frequency of insert replacements, and lowers costs. The insert pocket's robust design incorporates a dovetail clamping mechanism, enhancing process reliability. While the cutter is characterised by one effective tooth during drilling, it features two effective teeth during milling, offering a significant functional advantage.The new cutters are produced in an endmill design with a diameter range of 16-25 mm. Additionally, the Multi-Master head configuration is available within the same range, featuring an option for a pinpointed internal high-pressure coolant supply.Elevating the well-known to a higher level by infusing it with new qualities is a phrase that Iscar says, summarises the essence of the Quick-D-Mill family. AI power for NEOITAThe NEOITA Iscar Tool Adviser, a ‘hybrid expert’ that suggests optimal tooling solutions for specific machining applications, has improved its online features. In terms of drilling processes, the recently introduced editing and comparison functions make it easier to challenge the NEOITA. It is achieved by adjusting the suggested cutting data, considering factors such as machine characteristics, batch sizes, and adaptation limitations. Consequently, this empowers engineers to choose the most suitable machining parameters. By simulating drilling cycles, customers can achieve the desired commercial result.Also, NEOITA has been enhanced with a new smart AI feature, which allows users to search for and access detailed material specifications, including metallurgical composition and common uses. The search results can then be incorporated into the NEOITA material library database or the customer's personal libraries, if needed.Iscarwww.iscar.co.uk

Optical-grade Si is typically used as a lens for IR imaging systems. Previously, Ge was a favored material, as it is typically easier (softer) to machine. However, there are several advantages of Si over Ge, such as lighter weight, lower cost for the bulk material, and better thermal stability and mechanical properties-primarily higher hardness.

Although the increased hardness in Si is preferred to minimize part failure during service, it also makes it much more difficult to machine. The hardness and abrasiveness of Si causes the diamond tool to rapidly wear, yielding poor part quality and high form errors. The μ-LAM process has shown significant benefits in machining Si and other optical crystals, as it temporarily reduces the workpiece material's hardness, resulting in significantly less tool wear.

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

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Iscar has expanded its family of solid carbide thread endmills by introducing new tools with an increased number of flutes (up to eight), significantly reducing machining time. A few words are worth mentioning about the new Quick-M-Thread family of milling cutters with triangular inserts (Fig. 1) in the range of indexable threading products.

A wide range of materials, including metals and alloys, ceramics, glasses, semiconductors, and composites, are manufactured to meet service requirements to a given geometry, accuracy, finish, and surface integrity. Metals and alloys in general are easier to machine because of their high fracture toughness, low hardness, non-directional bonding, low porosity, large strain to fracture, and high impact energy. On the other hand, non-metals such as ceramics, semiconductors, optical crystals, and many infrared (IR) optical materials are characterized by covalent or ionic bonding, limited slip systems for plastic deformation, high hardness, and low fracture toughness, making them more challenging to machine.

After optimizing such machining parameters as the depth of cut, cross feed, cutting speed, and laser power, several Si lenses were fabricated and evaluated for their surface finish (roughness), surface aesthetics (spokes, brittle bands), form accuracy or irregularity tolerance, tool life (based on the number of parts fabricated), and productivity (pushing the machining parameters to enhance production).

These incorporate a step-release design concept that substantially reduces cutting forces, minimises bending load, and improves dynamic stability, thereby enhancing productivity. The new tools, both solid and indexable, are also equipped with an internal coolant supply option, which not only increases the cooling effect and lubricity during thread milling but also contributes to better chip flow and surface finish.

Elevating the well-known to a higher level by infusing it with new qualities is a phrase that Iscar says, summarises the essence of the Quick-D-Mill family.

The NEOITA Iscar Tool Adviser, a ‘hybrid expert’ that suggests optimal tooling solutions for specific machining applications, has improved its online features. In terms of drilling processes, the recently introduced editing and comparison functions make it easier to challenge the NEOITA.

With a less-than-eight-month payback, the μ-LAM system is proving its worth for many IR optical materials and crystals, with productivity improvements up to 500%, machine efficiency increases up to 200%, and improved part quality. μ-LAM processes are also being developed for ultrahard materials such as silicon carbide (SiC), sapphire, spinel, glass, and some selected metals used in the optics and aerospace industries.

A new technology called micro-laser-assisted machining (μ-LAM) is gaining traction for machining optical crystals and IR materials including silicon (Si), calcium fluoride (CaF2), zinc selenide (ZnSe), germanium (Ge), and zinc sulfide (ZnS). As evidenced by a materials study undertaken at Micro-LAM, the value proposition for μ-LAM technology includes extended tool life, increased productivity, and improved part quality during the manufacture of optical crystals and IR optics.

This optimises insert utilisation, reduces the frequency of insert replacements, and lowers costs. The insert pocket's robust design incorporates a dovetail clamping mechanism, enhancing process reliability. While the cutter is characterised by one effective tooth during drilling, it features two effective teeth during milling, offering a significant functional advantage.

However, the Quick-D-Mill (Fig. 4), a new family of these cutters, features an innovative design that undoubtedly provides additional benefits for customers. The family includes double-toothed right-hand cutters with two rectangular-shaped indexable carbide inserts. Each insert possesses a total of 4 cutting edges, and the Quick-D-Mill design enables the insert to be used for both central and peripheral cutting.

Image

The concept of an ‘all-in-one’ compact 90° indexable cutter suitable for various milling operations – for example, milling square shoulders, slot or complex contours, along with drilling capabilities – is not new. Such a cutter excels in many machining applications, eliminating the need for specialised tools.

Image

Additionally, the T-Slot family, a popular range of slot milling cutters with exchangeable solid carbide heads, has been expanded to include a new head diameter of 25mm. This upgrade lowers the minimum limit of the T-Slot head diameter range and is designed to accommodate a wider range of widths, making the heads highly efficient for milling narrow slots and grooves in various workpiece materials.