1) Near-net-shaped (NNS) forgings and additive layer manufacturing (ALM) are getting more popular in automotive, lowering metal-removal needs. How is Iscar keeping up?
Traditional machining can involve numerous processes to get to the finished product stage. With NNS and ALM only semi-finishing and/or finishing may be needed in turning these components. Historically, larger inserts were needed for heavy or rough turning. Those may no longer be needed.
Iscar has developed our new FLASHTURN turning line just for this reason. The tools are smaller inserts that handle up to 80% of the depths of cut as their larger cousins. More economical, they often cost 25% less than traditional inserts.
2) How is Iscar increasing tool life for automotive manufacturers?
One major issue in turning is coolant delivery. You need to be very precise as to where the coolant is being placed in the cutting zone. Iscar’s JETCUT tooling line delivers high pressure coolant and reduces the need for cumbersome lines and hoses that can get in the way of the turning process. Pinpoint accuracy of JETCUT systems improve tool life and chip control, even at low pressures.
3) What other improvements has Iscar made to help with chip control in turning?
Chip control is very important in automotive because so many processes are unattended. Long, stringy chips interfere with the ever-growing use of robotics, so Iscar has developed many new chip formers for carbide inserts and cermet grades.
We have a couple of new chip formers that are assigned to the ISO P, or steel material group, designated M3P and F3P for the medium and finishing depths of cut. We also have these available for the ISO M, or stainless-steel material group, which are designated M3M and F3M. These new chip formers can replace two to three of the previous chip formers, reducing costly inventory.
4) Does Iscar offer turning products for hardened materials?
Iscar has a very wide range of cubic boron nitride (CBN) turning inserts. CBN offers less-complex machine setups, shorter cycle times, ease of programing versus dressing grinding wheels, and disposal of chips rather than grinding swarf.
Numerous grades and geometries offer continuous and interrupted hard part turning (HPT). Multi-cornered CBN products can make HPT even more economical. Chip formers with our CBN inserts include HM for medium depths of cut and HF for finishing.
5) What other Iscar innovations could be advantageous in automotive manufacturing?
Iscar’s new LOGIQ4TURN could be a game changer. The standard, widely used CCMT insert geometry offers stability in turning where part size is small and depths of cut are not large. Although the LOGIQ4TURN insert CXMG 4 size can take a 0.200" per side depth of cut, it is double sided and has four cutting edges versus two for the CCMT.
Tool holders have the high-pressure coolant, JETCUT, option. The LOGIQ4TURN also uses dovetail pocketing geometry, making it a superior performer with economic advantages due to longer tool life, higher feed rates, and shorter cycle times.