Nano-range surface finish on laser machining PCBN material - cnc lathe round insert surface finish

In total 16 vises are mounted on a 4th modified axis in a 3-axis machine. Thanks to the use of the compact vise SCHUNK KSC mini, the workpieces can be processed in one set up which results in a strong decline of run through time.

Iscar strives to work closely with customers, not only to develop new technologies that meet emerging needs, but also to maximise the value of investments in modern machinery by increasing equipment utilisation and optimising performance. Iscar’s IQ STARTUP tools and inserts are well-suited for the new generation of machining centers, enabling high feeds and speeds for highly productive machining operations. These tools are a part of Iscar’s commitment to the ongoing success of its customers.

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Failure analysis as it relates to cutting tools is an often-overlooked path to improving a machining process. Of course, eventually all cutting tools will fail, but failure analysis will help to optimize the output of the operation. Failure analysis works by checking the condition of the insert at a predetermined number of pieces. The condition of the insert would be analyzed at these checkpoints. The condition of the insert would be compared to typical failure modes, a diagnosis would be determined and adjustments would be made to maximize productivity. All too often a machine operator will bring a fractured insert to the tool crib and request more inserts. Once the insert has fractured, there are no clues as to the reason for the failure.Often in North America, tool life is simply measured by the amount of cut time, the number of parts or the distance the tool travelled while removing material. The determinant to indicate when the tool has reached its life expectancy is often the load on the spindle, the surface finish on the part or in some cases catastrophic failure. This is unfortunate, as the performance of the tool could be greatly enhanced with the proper diagnosis and alterations.In Japan, it is common to set predetermined checkpoints to inspect the insert. This is helpful, because one can see what is happening to the insert and make adjustments to optimize the tool’s output. Once the other failure modes have been corrected, measuring flank wear can then be the determinant of tool life.As mentioned earlier all inserts will wear out. However the ideal wear pattern is flank wear. By checking the insert at predetermined intervals, it is possible to see how the insert is wearing. There are many different types of wear patterns classified in failure analysis. Ultimately these failure modes – flank wear, notch wear, crater wear, plastic deformation, built up edge, thermal cracking, chipping and edge fracture – are symptoms of a shortened tool life. If the symptoms are recognized early, adjustments may be made to reach the desired outcome of flank wear.Some of the symptoms of tool wear are:

• Dove IQ Turn: An innovative dovetail pocket combined with a lever clamping mechanism provides very firm and rigid insert clamping for heavy turning. • Dove IQ Grip: This line of tools has a unique frontal locking mechanism designed for deep heavy grooving applications with unobstructed chip flow. • Penta IQ Grip: This remarkable design of small pentagonal inserts with five cutting edges is intended for deeper and more accurate grooving and parting applications. • Heli IQ Mill 390: Milling inserts with three cutting edges and advanced cutting geometries function with reduced cutting forces and lower power consumption. This is an economical advantage vs. inserts with two edges. • Dove IQ Mill: Milling insert features a unique design with 8 cutting edges for a wide range of 45o face milling applications, roughing and finishing operations on a wide range of materials. • FlashTurn: A wide range of IsoTurn small size inserts that provide an economical advantage regarding cost per cutting edge. They are available in a wide range of geometries, corner radii, chipformers and the most advanced carbide grades. • Deca IQ Thread: This unique geometry is a 16mm round insert with five double-sided corners that provide 10 cutting corners. The new geometry provides the most economical price per threading corner compared to three cornered laydown inserts. • Do-Grip Jet Line: The coolant stream of the JHP (high-pressure) tools is directed precisely between the insert rake face and the flowing chip. This results in superb chip evacuation which provides extended tool life. • Cham IQ Drill 700: Features a unique design, utilising the carbide flexibility for self-locking, eliminating the need for clamping accessories. Extremely accurate and provides high cylindricity due to an advanced self-centering edge geometry. • SumoCham IQ: Expanded SumoCham drilling head options, featuring a revolutionary drilling head geometry that features concave cutting edges which substantially enhance the self-centering capability of the drill. No pilot hole is necessary. • Sumo Unicham: Drills without a flange, for adjustable protrusion lengths and chamfering operations by using the standard ChamRing modular chamfering drill holders. • SumoGun: Based on the SUMOCHAM insert geometry, for deep drilling applications of a diameter range of 10 to 25.9mm (total length of up to 800mm). SumoGun enables replacement of the drilling head inside the machine – no need to remove the drill for head indexing. • OneTap: A new family of taps that feature an optimised cutting geometry for universal use on all types of materials. • Tang-Grip IQ: Single-ended parting inserts with an unbeatable clamping method featuring a flat blade, thus eliminating chip obstruction. • Swisscut Innoval: Upgraded SwissCut line with new inserts that feature an innovative oval-shaped hole. The new clamping design uses a special screw that can be accessed and operated from both tool sides, preventing the risk of falling parts. • MillShred P290: The ideal solution for machining very high shoulders. The tools and wavy edged inserts reduce chatter and enable optimal machining for a large variety of materials. • Helido 690 Line: New family of tools for 90°milling. The H690 features a triangular insert with six helical right-hand cutting edges. The helical design provides extremely high durability and very stable performance. • SPINJET: Coolant-driven HSM spindles 20 000, 30 000 and 40 000 rpm for small diameter tools.

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In today’s economy with tight resources, lean operations and challenging demands, manufacturers need more support from their supply partners. The new innovative tool families, under the IQ Startup campaign, assist the user to increase profitability by employing leading-edge engineering solutions. These new Iscar tools will enable manufacturers to continue to improve their efficiency in metalworking by using modern machining strategies.

It is useful to observe the visible signs on the insert. This illuminates common failure modes, and helps to correct those failure modes that lead to under-performing cutting tools. The desired outcome is standard flank wear on the insert.Flank WearFlank wear is normal. All inserts will eventually wear out. The best situation is to have the insert wear through flank wear.  However, premature flank wear is not desired. The ideal situation is when it is possible to extend the life of the insert before flank wear causes failure, thus minimizing cycle time.The cause of flank wear is generally abrasive wear caused by the cutting speed, the hardness of the part, or a hard skin on the material being removed. Flank wear occurs when abrasion erodes the coating and eventually the substrate. The ideal flank wear is an even progression, making the process predictable.Some remedies to reduce flank wear are to select a grade that has more wear resistance. As a quick fix, one could simply slow the cutting speed, thereby increasing tool life but sacrificing cycle time. Of course, the best solution is to keep cycle time as short as possible. The long-term solution is to select a better grade.Notch WearNotch wear appears as a notch on the insert, generally at the depth of cut level. It is an oxidation at the depth of cut. This oxidation is caused by high temperatures and the presence of air. Tungsten and cobalt, the main ingredients in carbide inserts, form weak oxide films during oxidation.To remedy notch wear, select a more wear resistant grade. Generally inserts coated with Al2O3 which can help prevent oxidation of the substrate. As a quick fix one could increase the lead angle on the tool. This would ease the insert into the material and would also provide “chip thinning”. Another remedy would be to vary the depth of cut. In this way, the insert is not always cutting at the same depth of cut point. A variation of that method would be to make your first pass a taper and your next path a straight cut which would produce a constantly changing depth of cut.Crater WearCrater wear appears as a diffusion between the insert and the workpiece material. It occurs when enough thermal energy is created to enable the exchange of atoms across the tool-workpiece interface. The amount of diffusion depends on the chemical affinity between the two. For instance, tungsten and steel have a high chemical affinity. Effective remedies include using a lower cutting speed, or choosing a grade with more wear resistance. For instance, an Al2O3 coating helps to prevent diffusion and reduces crater wear.If you begin to lose chip control, check for crater wear because excessive types of this wear tend to change the edge geometry of the insert. Plastic DeformationCompression and heat, combined with high feeds and hard work materials, cause deformation of the insert edge. As edge deformation increases from the pressure, temperatures continue to rise, contributing to further deformation.Look for the edge to lose sharpness and bulge out when this happens.A quick fix is to reduce the speed or feed rate. But for long-term productivity, a more wear-resistant grade is key. Built-up edgeA built-up edge is when the workpiece material gets welded to the cutting edge. This usually occurs when cutting temperatures are too low. Additional chip flow is needed to avoid it. The remedies to this are to increase the cutting speed, and select a more positive insert geometry. Another remedy would be to increase the coolant flow to add lubricity. In the case of aluminum, use a polished insert to increase lubricity. In gummy steels, use a smooth, slippery coating.Thermal CrackingThermal Cracking is caused by abrupt temperature changes. A quick remedy is to turn the coolant off completely, or by drenching the tool in coolant to stabilize the temperature. Using a tougher, more wear-resistant grade is also an effective solution. When doing interrupted cutting, always run without coolant. ChippingChipping occurs when the insert edge breaks rather than wears. The fatigue associated with chipping is generally caused by temperature and force fluctuations. It usually means that the application is too demanding for the selected insert.To remedy this, it is necessary to select an insert with a stronger cutting edge. Also, try a tougher, more shock-resistant grade of carbideEdge FractureEdge fracture happens as a result of the other wear types. Remedy check all the cutting data and setup to consider what it might be. Once the edge fractures, the reason is unknown. Ideally, you want to check the insert before a fracture occurs to determine why such an incident might happen. The likely remedies for this are to reduce the feed rate, reduce the cutting speed, or select a tougher grade.John Mitchell, MBA, is the General Manager of Tungaloy Canada.

The new tools focus on increased productivity with smart insert locking mechanisms, which, therefore, create a more stable machining process. Iscar has responded to the new market demands that resulted from the trend toward high-speed machining and mill-turn machining centers, with upgrades in both tools and insert geometries, leading to less machine downtime and less labour.

At the Iscar stand, which will emphasise the theme ‘Machining Intelligently’, leading-edge tools will be displayed. These tools help customers adapt to high-speed and high-feed machining, minimum quantity lubrication (MQL) and other modern machining strategies. Iscar continues to expand its existing array of products, which have established many benchmarks in the global metalworking industry.

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