DOVEIQMILL IQ845 is characterized by the precise "dovetail" profile of the insert's pocket.
The chips that were produced illustrate the effectiveness of the advanced new milling cutter. The classic small-size, twisted conical chip spirals act as an indicator of smooth and stable cutting.
The machining of flat surfaces with the use of face mills is a familiar metalcutting process throughout the world. Indexable face mills with 45 - 65° cutting edge angles are the most common cutting tools used for this everyday operation. The widespread use of these tools has resulted in the current availability of a plethora of face mill design variations from a wide range of manufacturers.
"Recently, groundbreaking work by ISCAR's pioneering R&D team has resulted in the launch of ISCAR's DOVEIQMILL IQ845. Rather than being regarded as a further step in the continuing evolution of indexable face mill technology, ISCAR is describing its advanced new range as a 'quantum leap forward'," said a company spokesperson.
The indexable face mill design brief given to ISCAR's R&D team was a demanding one:
- Create a durable and robust tool
- Design a long lasting economical insert
- Enable users to achieve class-leading surface finish characteristics.
"Following an extended design and development period and exhaustive machining trials, each of the demanding design challenges were accomplished. ISCAR's revolutionary DOVEIQMILL IQ845 is characterized by the precise 'dovetail' profile of the insert's pocket. This ultra-secure arrangement is a major factor in the advanced tools' success," said the spokesperson.
The system's inserts are double-sided and have eight cutting edges (four on each side). The inserts' top and bottom surfaces feature complex geometries that ensure a positive rake and result in improved chip formation. These surfaces rotate relative to each other around the central axis of the central hole.
The inserts' side surfaces consist of alternating faces with different angles of inclination. The use of superior cutting geometry and relatively wide wiper widths enables high-quality surface finish results to be achieved throughout milling operations.
"Soft and stable cutting, and smooth entry and exit of the milling tool into the machined material, depends on cutting edge inclination. Although, in the case of the indexable cutters carrying negative or 'dovetail' profile inserts, ensuring a positive inclination is a very difficult design task. To overcome this problem ISCAR's R&D team have succeeded in finding an ingenious solution. It is thought that DOVEIQMILL IQ845 is the first indexable milling tool with double-sided inserts that features a significantly positive cutting edge inclination (more than 20°) to provide a very smooth and easy cut," said the spokesperson.
The below user example illustrates the successful application of ISCAR face mill IQ845 FSY D80-08-27-R07 (80 mm dia., eight teeth) to machine low-alloy steel with a hardness value of HRC 38 - 40.
Cutting data
- Cutting speed 180 m/min
- Feed 0.2 mm/tooth
- Depth of cut 3.5 mm
- Width of cut 40 mm.
Result
The surface roughness value achieved was Ra0.5 (formerly - Ra1.6.).
The introduction of the advanced ISCAR face mill substantially improved the overall process. It allowed previously used separate rough and finish milling operations to be combined in to a single, efficient operation. Cycle times were slashed and production costs were significantly reduced.
In the above example, the chips that were produced illustrates the effectiveness of the advanced new milling cutter, the classic small-size, twisted conical chip spirals act as a perfect indicator of smooth and stable cutting.
For more information contact:
ISCAR Metals, Inc.
300 Westway Place
Arlington, TX 76018
817-258-3200
info@iscarmetals.com
www.iscarmetals.com