Indexable cutting tools continue to evolve from roughing to finishing and are available in smaller diameter tools. The most obvious benefit of indexable inserts is their ability to exponentially increase the number of effective cutting edges without the extreme effort typically required for solid carbide round tools.
However, to achieve good chip control, indexable inserts must be selected with special attention to workpiece material type and application size, shape, geometry and grade, coating and nose radius. Here’s how products from leading suppliers are designed to meet customer requirements for optimal metal cutting using interchangeable cutting tools.
Sandvik Coromant has launched the new CoroTurn Y-axis turning method, designed to machine complex shapes and cavities with one tool. Benefits include reduced cycle times, improved part surfaces and more consistent machining. The new turning method is based on two exchangeable cutting tools: the new CoroTurn Prime variant, suitable for shafts, flanges and undercut parts; CoroPlex YT twin tool with CoroTurn TR and CoroTurn 107 profile inserts with rail interface. Round inserts for processing parts. with pockets and cavities.
The development of Y-axis turning follows Sandvik Coromant’s success with its innovative PrimeTurning technology, non-linear turning and interpolation turning, for which two indexable inserts were developed: CoroTurn with three 35° cutting angles. Prime A type cutter designed for light machining and finishing. and finishing. Analysis: CoroTurn Prime B has double-sided negative inserts and four cutting edges for finishing and roughing.
“These advances, combined with the advanced capabilities of modern machines and CAM software, are paving the way for new approaches to Y-axis turning,” says Staffan Lundström, product manager at Sandvik Coromant Turning. “With the tools and techniques now available, we look forward to exploring the opportunities this approach can provide for our clients.”
CoroTurn YT Y-axis turning is a simultaneous three-axis turning method that interpolates the axis of the milling spindle. The new tool can also be used in “static mode” and features a locking spindle for flexible 2-axis turning with fast insert indexing. This method is suitable for all materials and requires a multitasking machine with an option that allows interpolation of the milling spindle axis during turning. All operations are performed with one tool, including roughing, finishing, longitudinal turning, trimming and profiling.
Y axis turning, as the name suggests, uses the Y axis. All three axes are used simultaneously during machining. The tool rotates around its center. The insert is placed in the YZ plane and the axis of the milling spindle is interpolated during the turning process. This makes it possible to process complex shapes with one tool.
Sandvik Coromant says the benefits of Y-axis turning include the ability to machine multiple parts with one tool without changing tools, reduced cycle times and minimizing the risk of blending spots or irregularities between adjacent machined surfaces. The Wiper insert can be held perpendicular to the surface to create a Wiper effect even on conical surfaces. The main cutting forces are directed to the machine spindle, which increases stability and reduces the risk of vibration. A constant entering angle significantly improves chip control and avoids chip jamming.
PrimeTurning toolpath programming is supported by CAM partners and is used to create optimized NC code for faster turning. PrimeTurning is recommended for high-volume production or parts that require frequent set-ups and tool changes on the machine, including turning centers, vertical lathes and machining centers. For turning cylindrical parts, it is best suited for turning short, compact parts and thin parts using a tailstock. For internal turning, a diameter of more than 40 mm and an overhang of up to 8-10 XD are best suited. Combining Y-axis turning with nonlinear turning, or PrimeTurning, can further improve productivity, suppliers say.
Ingersoll Cutting Tools in Rockford, Illinois, offers customized, heavy-duty precision machining solutions for aerospace, railroad, oil and gas, and automotive transmission applications. This includes products designed for use with the latest CNC machines as well as legacy equipment.
According to suppliers, the benefits of using replaceable tools (versus solid ones) include:
Flexibility in choice of alloy and geometry. Replaceable inserts are available in a variety of tip sizes, geometries and alloys to suit the same cavity.
Higher performance. The indexable inserts feature improved edge geometry for durability and higher chip load.
Indexable machines are traditionally used in most roughing operations. However, according to Ingersoll, improvements in precision and manufacturing methods are also increasingly opening up applications in finishing applications.
In addition, replaceable inserts facilitate the use of cubic boron nitride (CBN) and polycrystalline diamond (PCD) inserts, eliminating the need for solid-brazed tools.
Ingersoll’s indexable insert design trends include smaller indexable tools: single-body end mills as small as 0.250 in. (6.4 mm) and triple-flush end mills with indexable inserts as small as 0.375 in. (9.5 mm). Advances include reinforced edges for aggressive roughing, better adhesion coatings and high-feed geometries across many milling and turning product lines. For all deep hole drill series, the new IN2055 grade will replace the current IN2005. IN2055 is reported to extend tool life by up to four times when machining steel, stainless steel and high temperature alloys.
Ingersoll says new indexable tool models, such as high-feed cutters and barrel cutters, can provide higher productivity and quality because the machines can operate at higher speeds and table feeds. Ingersoll’s SFeedUp product combines advanced features focused on high speed and high feed. “Many of the new machines have higher speeds and lower torque, so we expect the trend of high feed machining with lighter Ap (depth of cut) or Ae (lead) to continue,” said Mike Dicken, milling product manager .
Advances in the development of interchangeable tooling have improved productivity and part quality. Some high feed insert geometries are interchangeable with standard insert geometries in the same holder. Dicken claims that a smaller helix angle allows higher feed rates to be achieved by exploiting the principle of chip thinning.
DeepTrio indexable gun drills for machining centers, lathes and gun drills replace brazed carbide-tipped gun drills. “DeepTrio indexable insert gun drills provide up to six times the productivity and reduce downtime associated with tool changes,” said John Lundholm, product manager for DeepTrio and drills at Ingersoll. “When it comes time to change the soldering gun drill bit, the machine shuts down for an extended period of time. DeepTrio inserts have three cutting edges, so indexing an insert takes only a few seconds instead of an hour. Another advantage is that DeepTrio drill bits use those The same guides and support bushings are used in brazed drill presses, so there is no need to change machine parts,” he notes.
Successful indexable insert machining begins with a rigid connection to the tool holder, whether on a new or old turning, milling, drilling or reaming machine. But advanced machines may have an advantage, according to Kennametal Inc. from Latrobe, Pennsylvania. New modern machining centers use system tools, such as the modular KM system, which allows tools to be easily changed and preset before the machine in less time. Car is not working.
In general, the new vehicles are more maneuverable and have higher speed capabilities. System tools, which serve as the link between the cutting edge and the machine, are key to high productivity and results. For example, Kennametal says the KM coupling, designed for vertical lathes, lathes and machining centers, can safely perform virtually any operation without sacrificing productivity.
KM’s modular tooling provides greater flexibility, allowing customers to customize the machine to suit their needs. Great speed, rigidity and maneuverability are attractive to multi-job shops, allowing them to maximize their return on investment. Another additional feature of the KM system is the KM4X100 or KM4X63 coupling. This connection is designed for heavy-duty applications using replaceable and durable tools. Kennametal says that whenever higher bending moments or longer distances are required, the KM4X100/63 is the best connection.
Advances in tool change design have improved the performance of traditional and modern machine tools. New geometries, alloys, and physical and chemical vapor phase coatings (PVD and CVD) are introduced that require improved chip control, higher edge strength, and increased heat and wear resistance to meet the demands of challenging materials applications. These include Mitral Valve (MV) geometry for steel machining, High-PIMS grade KCS10B with PVD coating for high temperature turning of alloys, grade KCK20B for milling and KENGold KCP25C CVD coating for steel machining. Trademark. According to Kennametal, all of this reduces the risk of equipment failure, increases productivity and reduces equipment downtime, thereby increasing overall productivity.
The company said that with the advancement of digitalization and Industry 4.0, as technology advances, a lot of work has been done on machine control using RFID, smart tools and robots to improve tools and improve machine performance. .
Matt Hasto, Application Engineer at Big Daishowa Inc. in Hoffman Estates, Illinois, says indexable insert cutting tools offer significant advantages over standard carbide circular tools, depending on the application. He mentioned the company’s newest grades ACT 200 and ACT 300, as well as new PVD coatings for chamfering, backturning, end milling and face milling.
“PVD coatings are different from standard coatings,” Hasto says. “It is a multi-layer nanoscale titanium aluminum nitride coating that is impregnated with carbide to improve wear resistance, extend tool life and increase productivity.”
Big Daishowa chamfering tools are available in several different types to optimize performance for a specific application. Small tools with multiple inserts allow contour chamfering with optimal feed rates. Other cutters have large chamfering inserts that allow you to chamfer the inside diameter of a wide range of hole diameters.
According to the company, replaceable centering tools provide reliable tool performance at the cost-effectiveness of a replaceable tool, requiring only the cutting tip to be replaced. For example, a C-type center cutter can do face milling, back chamfering and chamfering, making it a versatile tool.
The latest enhancements to Big Daishowa’s Ultra High Feed Chamfer Cutter now include four C-Cutter Mini inserts (instead of two) and a much smaller diameter, allowing for higher spindle speeds. Hasto says increasing the number of cutting edges can significantly increase feed rates, resulting in shorter cutting times and cost savings.
“The C-Cutter Mini is used in a wide range of applications, primarily chamfering and face milling, with extremely high efficiency and accuracy,” says Hasto. “Back chamfering can be easily accomplished with a single blade by going through a threaded hole and chamfering or countersinking a hole from the back of the workpiece.”
The C-Cutter Mini has a sharp cutting edge that reduces blade drag and provides smoother routing. The coating is wear-resistant, which increases the number of times the plate can be cycled before it needs to be installed on a new edge, according to the supplier.
The Big Daishowa also features a single insert type that can be offset, dropped through a hole, and centered to create features, a centerable tool for small rake chamfers, and a universal tool that can change angles from 5° to 85° depending on the application.
Whether you’re end milling, pilot drilling, helical milling or square shoulder milling, Big Daishowa offers high-precision end mills for smooth, quiet milling. Interchangeable cutters provide sharp cutting edges in both the radial and axial directions, helping to ensure smooth, quiet end milling. The BIG-PLUS dual contact design provides greater accuracy and rigidity in precision applications. All models also feature a modular design with optional inserts including CKB connections for long-distance or heavy-duty applications.
“Standard R-Cutters use inserts that provide a sharp cutting edge and deburr the edge of the part, resulting in a superior surface finish on the workpiece,” says Hasto. “This tool creates a radial chamfer on the workpiece and is used for both back and front cutting. Finishing cutters are designed for high-volume machining and allow four cutting edges per insert. This means the use can be reversed.” before needing replacement. Four-position inserts for ultra-fine finishing, saving significant time and money compared to fixed tools.
”Our BF (back countersink) is typically used on workpieces that need to be bored to create a countersink without the operator having to waste time turning the workpiece or fixture. The BF tool is capable of being offset as it passes through the hole, centering and creating a countersink, and then offset again to exit the hole. The BF-Cutter is designed for backturning closed holes for M6 – M30 or 1/4 – 1 1/8 inch (6.35 – 28.6 mm) bolt holes and is ideal for all types of steel. ( Ideal for use in stainless steel, cast iron and aluminum, among others, the latest blade grades allow for careful selection based on material and conditions for optimal surface quality and service life,” said Hasto.
Post time: Sep-11-2023