2. © Iscar Seminar 2001 1 Applications Cutting Tools Machining Conditions Conditions

3. © Iscar Seminar 2001 2 Inserts Grades for Turning/Grooving Carbon Steel Alloy Steel Cast Steel Stainless Steel High Temp. Alloys Nonferrous Materials Cast Iron Nodular & Gray IC9025 IC354 IC508 IC908 IC907 Hardness Toughness Material IC328 IC908 IC928 IC907 IC07 IC08 IC20 IC28 IC428 IC418

4. © Iscar Seminar 2001 GRIP Inserts with Positive Rake for Machining High Temp. Alloys Submicron Grade for Exotic Materials PVD Coating of TiAlN GIPA 3-6

5. © Iscar Seminar 2001 4 Titanium - Ti6Al4V F45KT-D80-27-R07 OFCR 07T3AEN IC328 40 (132 sfm) 50 x 4.6 mm (2”x.18”) 0.14 mm/t (5.5 inch/t) 50 min.006”/z -> 10  inch.008”/z -> 11  inch.012”/z -> 12  inch High Surface Quality with Positive Insert OFCR 07T3AEN Ground insert with sharp cutting edge Super positive geometry Polished rake face, decreases friction Excellent surface finish, low forces and soft cut Material Tool Insert Speed m / min Width & Depth Feed Vs. Surf. Fin. Tool Life Aluminum - Al 2024 F45KT-D80-27-R07 OFCR 07T3AEN IC28 (2475 sfm) 750 (2475 sfm) (2”x.04”) 50 x 1 mm (2”x.04”) 0.15mm/t ->0.27  m 0.20mm/t ->0.28  m 0.30mm/t ->0.30  m 0.30  m

6. © Iscar Seminar 2001 Machining of Housing Bearings (P & W) Example of machining bearing housing with GRIP tools Inconel 718

7. © Iscar Seminar 2001 6 Profiling of Low Pressure Turbine Rotors with CUT-GRIP Material: Inconel 718 Diameter: 850mm Width: 130mm Remark: All shown operations are done after rough turning with ISO tools

8. © Iscar Seminar 2001 7 Rough Profiling of Low Pressure Turbine Rotors with CUT-GRIP Tool: GHFUR 32-8-6486 Insert: GIMY 808 IC908 Vc: 35m/min f : 0.18mm/rev

9. © Iscar Seminar 2001 8 Finishing (Step 1): Profiling of Low Pressure Turbine Rotors with CUT-GRIP Tool: GHDPR 32-3-6841 Insert: GIPY 315 IC907 Vc: 35m/min f : 0.15mm/rev

10. © Iscar Seminar 2001 9 Turning & Sampling of Titanium Rotor Disc Ø600 173 2 3 1 Workpiece: Disc, Ti6Al4V Customer: Israel OperationToolVc m/min f mm/rev ap mm Drilling Turning Roughing Turning Finishing Competitor Ø38 CNMG 643 IC20 26 40 0.08 0.25 0.15 38 6 Max 40 1 2 3 1 Max CNMG 643 IC20

11. © Iscar Seminar 2001 10 Turning & Sampling of Titanium Rotor Disc Ø600 173 4 5 Workpiece: Disc, Ti6Al4V Customer: Israel OperationToolVc m/min f mm/rev ap mm Grooving Face Grooving GFN 5M IC20 40 0.1 5 40 4 5 4 GFN 4M IC20 Sampling - Ring Extraction

12. © Iscar Seminar 2001 11 Hard Grooving of Complicated Slots in Hardened Landing Gear Parts (IAI Israel) Finishing by Hard Turning Replacing Grinding Workpiece: Alloy Steel 56-58 HRc Insert: CUT-GRIP GIFM 2.00 IB50, Modified Tool: GMDL Vc: 30 m/min f: 0.0125 mm/rev View A A

13. © Iscar Seminar 2001 12 Groove Turn of Landing Gear with Cut-Grip Workpiece: Landing Gear 300M Insert: CUT-GRIP GDMY 840 IC908 Machining Conditions: Finishing: ap: 1.0 mm f: 0.08 mm/rev Replacing: ISO DNMG with very short tool life Ø193 R38, R10, Ø193, Ø188.4 R38 R10 Ø188.4

14. © Iscar Seminar 2001 13 Extended-Length Endmills with Steel or Carbide Shanks for Machining Engine Rotors Shank: DIN 69871 HELIBALL Inserts Max Length: 500 mm Max Length: 250 mm D: 32 mm

15. © Iscar Seminar 2001 14 Finite Element Analysis of Ball Nose Endmills Max stress

16. © Iscar Seminar 2001 15 High-Performance Cutting of Aircraft Wings (Honeycomb) 1: Facing 2: Shouldering 3: Slotting 4: Ramp Down    4231

17. © Iscar Seminar 2001 16 High Speed Machining of Aluminum Wings (AIRBUS & Boeing & Subcontractors ) Holders: HM90-EAL-D… Inserts: HM 90 APCR 1605… 0.4  R  6.0 mm

18. © Iscar Seminar 2001 17 Testing of Milling Cutters at Very High Speeds for the Evaluation of Speed Limit High Speed Machining (Darmstadt, Germany)

19. © Iscar Seminar 2001 18 Balancing of Cutter for HSM of Aluminum (Darmstadt, Germany) Recommended machining speed is n  38750 RPM with a dynamically balanced tool A B C In n  5,000 RPM a vibration amplitude of up to 200  m In 10,000  n  5,000 the maximum observed amplitude was below 100  m Maximum rotation of 80,000 RPM before damage occurred. Rotation Speed n 0100200300400500600700800900 10001100 sec 1300 10000 20000 30000 40000 50000 60000 70000 80000 RPM 100000 Vibration Amplitude a (  m) Rotation Speed (n) Time t 1400 0 100 200 300 400 500 600 700 Vibration Amplitude a A B C mm

20. © Iscar Seminar 2001 19 Recommended Maximum Rotation Speed as a Function of Tool Diameter Nr. of Insert Tool with ØD = 25 mm with one insert only 5000 10000 20000 30000 40000 02532405063 1222/33 0 ØD Tool Diameter Maximum Revolution n RPM z

21. © Iscar Seminar 2001 20 Machining of Turbine Blades Tailor-made slotting cutters Tailor-made tangential cutters Blade material: Ti6Al4V Blade technology: Israel Inserts: QPCT 1004 IC328 Insert: Tailor-made IC328

22. © Iscar Seminar 2001 21 High Speed Machining of Stinger (Wing Beams) Tool: ETS-D4.4-1.0-R17 Tailor-made Radial insert adjustment Fine sensitivity (10  m)

23. © Iscar Seminar 2001 22 High Speed Machining of Stinger (Wing Beams) Tool: ETS-D4.4-1.0-R17 Tailor-made Axial insert adjustment Fine sensitivity (10  m) Clamping screw Adjustable screw

24. © Iscar Seminar 2001 23 Milling of Guiding Rails for Wings in Hardened Steel The previous process of soft machining, hardening and finishing is replaced by roughing (1 & 2) and finishing (3) in hardened stage The IC900 with TiAIN is excellent for hardened steel Better results with coolant (no high-pressure air available) Tool life T = 2 parts Total machining time is only 90 minutes. 1 3 2 3 3 A A B 280 1

25. © Iscar Seminar 2001 24 Milling of Guiding Rails for Wings in Hardened Steel 1 3 2 3 3 A A B 280 1 224 25 20 A-AB-B Operation Endmills Vc fz Vf ap ae m/min mm/z mm/min mm mm External Roughing 2. Roughing of Slot 3. Finishing, Ext. & Slot ERF160A32-4 W16 IC900 ERF120A28-4W12 IC900 EC160-B32-4C16-R2-IC900 73 70 0.05 0.035 0.05 275 2.60 280 15 9 20-25 11 12 0.4 Workpiece: Alloy steel 300M Hardness: 55 ±2HRc Machining Data

26. © Iscar Seminar 2001 25 Machining of Hydraulic Connecting Elements Workpiece Material: Titanium Alloy (Cast) Tools: HELIMILL, HELIQUAD, HELIBALL Finished Product Blanks

27. © Iscar Seminar 2001 26 Machining of Hydraulic Connecting Elements Vc m/min ISCAR Comp. 35 15 fz mm/z 0.10 z 9 10 t min 9 10 ap mm 3.5-6 Roughing / Finishing ISCAR RoughingFinishing Tool: Insert: F90A-D125-40-KB6 ADKT150564R-HM IC28 AUR 9 (HSS) TICN coated ISCAR Tool: Insert: F90A-D125-40-RB6 ADKT150564R-HM IC28 7700 VR12-40 RPEX1204 MOE-701 Competitor Facing both sides

28. © Iscar Seminar 2001 27 Machining of Hydraulic Connecting Elements Roughing / Finishing ISCAR CompetitorSlotting Competitor Profiling Tool: Insert: SPK-D40-42-W32-10 SPMT 1004 08 TR HQ IC328 40 AUR 9 (HSS) TICN Coated 7700 VR12-40 RPEX1204 MOE-701 Tool: Insert: Vcm/min ISCAR Competitor 35 19 fzmm/z 0.08 z 3535Vc 35 19fz 0.12 z 3535 vc 35 15 fz 0.12 z 3535

29. © Iscar Seminar 2001 28 Machining of Hydraulic Connecting Elements Rouging / Finishing ISCAR Competitor Roughing Competitor Finishing Tool: Insert: F90A-D125-40-KB6 ADKT150564R-HM IC28 AUR 9 (HHS) TICN couted 7700 VR12-40 RPEX1204 MOE-701 ISCAR Profiling Profiling Competitor Tool: Insert: CM D20-A-W20 CR- D200-QF IC328 CMD25-A-W25 CRF-D250-QF IC328 Ø20 P26315-R10-WTL71 Competitor Ø25 P26315-R125-WTL71 vc m/min ISCAR Competitor 41 fz mm/z 0.32 0.20z 2121 ap mm 8888 ae 5-25 vc m/min 60 fz mm/z 0.06 0.073z 2121 ap mm O.5 0.5 ae mm 0.5

30. © Iscar Seminar 2001 29 Always look ahead...

31. © Iscar Seminar 2001 30