aerospace industry l engineering
diameter range for the exchangeable endmill heads to 32 mm (1.25").
brought a new powerful instrument to aid in
tool design: 3D computer modeling of chip
formation. ISCAR's R&D team actively uses
modeling to find optimal cutting geometries and form the rake face of indexable inserts and exchangeable heads.
The F3S chipformer for the most popular
ISO inserts, such as CNMG, WNMG and
SNMG, was designed specifically for finish
turning high temperature nickel-based alloys
and exotic materials (Fig. 2). It ensures a smooth and easy cut with notable chip breaking
results. The remarkable working capability
of the designed cutting geometry is a direct
result of chip flow modeling.
In hole making, applying modeling to the
design process significantly contributed to
creating a chip splitting geometry of
SUMOCHAM exchangeable carbide heads
for drilling holes with depth up to 12-hole diameters in hard-to-cut austenitic and duplex
Aerospace products can vary immensely
in material, dimensions, shape , complexity, and more. To make such a diverse range of products, the product manufacturer
needs dozens of machine tools and technological processes. Not every standard
cutting tool is optimal for performing certain machining operations with maximum
productivity and, consequently, the aerospace industry is a leading consumer of customized tools.
A customer producing titanium parts
might be interested in solutions comprising indexable shell mills and arbors from
the standard line; while another customer
producing similar parts might prefer special milling cutters with an integral body, for
direct mounting in a machine spindle.
ISCAR developed the MULTI-MASTER
and SUMOCHAM families of rotating tools with exchangeable heads and different
body configurations to ensure various tool
assembly options that simplify customization and decrease the need for costly tailormade products.
A further example of simplified customization can be found in ISCAR's recentlylaunched modular drills for multi-spindle
and Swiss-type machines. The drills combine the SUMOCHAM design with a
FLEXFIT threaded connection (Fig. 3). Multi-spindle and Swiss-type machines typically have a limited space for tooling, which
means that the tools in operation need to
be as short as possible to avoid collisions
and facilitate easy set up. A wide range of
FLEXFIT threaded adaptors and flatted
shanks has been designed precisely to fit
the drills and maximally shorten an overhang.
Responding to demands from the aerospace sector, the company also expanded
the MULTI-MASTER family by introducing
a new thread connection to increase the
Although machining aluminum might appear to be an extremely simple process,
effective cutting of aluminum actually represents a whole field of technology with
its own laws and challenges.
The need to increase productivity and
boost metal removal rates for milling
aluminum workpieces, especially large
parts of aerospace structural components, has led machine tool builders to
develop milling machines with a powerful main drive - up to 150 kW with high spindle speeds of up to
33000 rpm. To meet this demand,
ISCAR has expanded its family of 90°
indexable milling cutters by introducing new tools carrying large-size inserts that enable up to 22 mm (.870")
depth of cut (Fig. 4). The tools have been designed to eliminate insert radial
displacement, which might occur due
to high centrifugal forces during very
high rotational speed. This concept facilitates reliable milling in a rotational
speed range of up to 31000 rpm.
In hole making, the company developed new inserts for drilling aluminum
with indexable drills from the DRTWIST drilling tool range. The inserts
are peripherally ground and feature
sharp cutting edges and polished rake
face for light cut, preventing adhesion.
ISCAR's cutting tool program for the
aerospace sector is based on several
principles: the complex needs of this
industry, taking into consideration
trends in metalworking, and the drive
to strengthen partnerships with tool
consumers. ISCAR believes that such a
tri-pronged approach ensures the successful realization of innovative ideas
for efficient machining of the difficultto-cut materials that characterize this
challenging and dynamic field.