Tungaloy Corporation is now adding threading inserts with sharp cutting edges to its TetraMini-Cut insert series, which allows undercutting and finishing a flange wall.

Complemented by the new PVD grade, SH725, TetraMini-Cut’s new threading insert features sharp cutting edges, making it perfect for cutting fine pitch threads at a high cutting speed. The cutting edge is offset to one side of the insert, allowing threading all the way to the flange wall.

The threading inserts of the TetraMiniCut series are ground-finished and perfected for when high accuracy and quality are required in a threading operation. The innovative insert pocket shelters unused cutting edges from chip damages, assuring the full usage of all four cutting edges.

Tungaloy’s unique clamping system secures insert rigidity and guarantees accurate repeatability.

 Main features:

• Incorporates sharp cutting edges perfect for fine pitch threads on small diameter screws.
• Capable of threading to a flange wall.
• Economical four-cornered insert
• Powerful clamping system for rigid insert clamping.
• Innovative insert pocket that protects unused corners from chip damage, assuring utilization of all four cutting edges.

• Insert: 2 items

Tungaloy Corporation is pleased to announce an expansion of the AH8000 series for heat-resistant alloy turning, which has been one of the most popular turning tools in the market since its release. This expansion adds a new positive insert line to the product family.

The new PVD grade, the AH8000 series, was engineered specifically for turning heat-resistant alloys. Using the world’s first nano-multi-layered AlTiN coating with high Al content, the new grade reduces notch wear, crater wear, and built-up edge in machining heat-resistant alloys. The two grades include AH8015, the first choice grade for well-balanced wear and fracture resistance; and AH8005, the grade with high hardness for strong wear resistance. These two grades are treated with PremiumTec: Tungaloy’s special surface treatment technology, which adds a highly polished cutting surface for extra stability and longer tool life.

With this new addition of a positive insert line, the AH8000 series can now cover a wider application range in heat-resistant alloy turning, and in combination with the existing negative insert line, provide customers with a drastic increase in productivity.

Main features:

• The AH8000 series features nano-multi-layered AlTiN coating with high Al content and provides incredible wear and fracture resistance in heat-resistant alloy turning.
• PS, PSS, and PSF chipbreakers are available for positive inserts as well as All-round chipbreaker to complement.

Stainless steel is a vitally important material for many industries around the world. Even though it was created more than 100 years ago, use of the material has increased significantly since the turn of the 21^st century.

Ricky Payling, application specialist at Dormer Pramet, outlines the growth of stainless steel, how the cutting tool industry has evolved to machine the material, as well as providing a summary of some of its most common grades.

According to the International Stainless Steel Forum (ISSF) the global demand for stainless steel products has nearly doubled in the last 20 years, and continues to grow five per cent each year.

In 2014, almost 42 million metric tons of stainless steel was produced worldwide – a 70 per cent increase from 2005 (24 million metric tons). This growth is predominantly achieved by an increase in China, where production has grown from a 13 per cent share of global output in 2005 to more than 52 per cent in 2014.

This rapid development is not only to meet worldwide demand, but also to support increased use within China, where stainless steel is consumed in household metal products, building materials and machinery.

Stainless steels’ anti-corrosive qualities make it perfect for use in a huge range of environments and components, such as aerospace, general engineering, consumer, oil and gas, medical and marine industries.

Its versatility is reflected by the fact that there are more than 150 different grades. Common stainless steels include ferritic, martensitic, austenitic, super-austenitic and duplex. More details of which are covered below.

The main alloying element is Chromium, which forms an ultra-thin oxide film on the surface. As a general rule, resistance to corrosion and oxidation increases in line with Chromium content. Other alloying elements, such as Nickel and Molybdenum, can be added to change the structure, increase corrosion resistance and improve strength.

This increase in production and consumption has coincided with advancements and new developments within the cutting tool industry. Due to the difficult process of machining stainless steel, manufacturers have invested a huge amount of time and resources in finding new ways to try to combat the numerous application challenges.

Recent introductions include changes to the cutting tool design, new geometries, improved coolant and developing stronger coatings to improve performance and tool life.

Drills with thin margins for example, reduces the contact with the hole surface, minimising friction between the cylindrical land and the hole walls, decreasing work hardening and temperatures generated.

Positive point geometries ensure excellent chip breaking and evacuation, while a specially designed web combines the benefits of maximum rigidity with space for efficient chip removal, reducing machine downtime.

Coatings and coolant
Significant heat is generated during machining of stainless steel, resulting in plastic deformation and severe crater wear. Therefore, a generous flow of cutting fluid removes heat from the cutting edge, helps chip breaking and improves dimensional stability of the component.

When using flood coolant, it is important to ensure a plentiful supply as any period of coolant starvation can cause temperature fluctuations. This can cause thermal cracking, resulting in reduced tool life. Cutting tools with through coolant also provide an instant reduction in temperature and supports chip evacuation.

Meanwhile, a Titanium Aluminium Nitride (TiAlN) coating is ideally suited for machining stainless steel as it holds its hardness at higher temperatures due to a layer of aluminium oxide, helping to transfer the heat away from the cutting tool.

The high strength of stainless steels combined with their high ductility makes chip breaking more difficult. This increases the risk of vibration, which can affect surface finish quality and reduce the service life of the tool or insert.

To address this, always make sure tooling and work pieces are stable and well clamped. Always keep tool overhang to a minimum, especially when drilling or internal turning. To help reduce vibration, use sharp tools or inserts with a small nose or corner radius.

Ferritic & Martensitic
The machinability of ferritic and martensitic stainless steels shows a resemblance to that of ISO P: Steel. Normal chromium content is 12-18 per cent, with only small additions of other alloying elements.

Ferritic materials are used in shafts for pumps, steam and water turbines, nuts, bolts, hot water heaters, and in the pulp and food processing industries. Martensitic steels can be hardened and are, as a result, used for edges in cutlery steel, razor blades and surgical instruments.

Machinability of ferritic and matensitic stainless steels is good and very similar to low alloyed steels.

Austenitic & Super-Austenitic
Austenitic stainless steels are the most commonly used ISO M material, accounting for 70 per cent of all stainless steel machined. This is due primarily to their very good resistance to corrosion.

The most common composition is 18 per cent chromium and 8 per cent nickel. Steel with greater corrosion resistance is created by adding two to three per cent molybdenum, often called “acid-proof steel” or type 316.  Super-austenitic stainless steels have a nickel content of more than 20 per cent.

Austenitic and super-austenitic stainless steels are used where good resistance against corrosion is required. Typical industry sectors include the chemical, pulp and food processing industries. It is also used in aircraft exhaust manifolds.

Austenite stainless steel produces tough, long, continuous chips that are difficult to break. It is prone to work hardening during machining, producing hard surfaces and chips which lead to notch wear. It also creates adhesion and produces built-up edge, resulting in poor surface finish and reducing tool life.

To minimize this, avoid using tools with worn edges which could accelerate tool wear and cause breakage. Make regular checks for signs of wear and change tools or inserts regularly. Also, try to avoid any dwells or pauses in the cutting process as this will cause heat build-up and increase work hardening.

A high rake angle reduces heat generated during milling, minimising work hardening.

Duplex
Adding nickel to a ferritic chromium based steel will form a mixed base structure containing both ferrite and austenite. This is known as a duplex stainless steel.

Duplex materials have a high tensile strength and maintain very high corrosion resistance.  Super-duplex and hyper-duplex indicate higher content of alloying elements and even higher corrosion resistance.

Chromium content between 18-24 per cent and nickel content between 4-7 per cent are common in duplex steels, producing a ferritic share of 25-80 per cent.

Duplex stainless steels are used in the chemical, food, construction, medical, cellulose and paper making industries, and in processes that include acids or chlorine. They are often used in equipment related to off-shore oil and gas applications.

Machinability of Duplex is generally poor due to high yield point and high tensile strength. Higher content of ferrite – above 60 per cent – improves machinability.

Dormer Pramet has developed a comprehensive assortment of indexable and rotary cutting tools to support machining of stainless steel.

Its solid carbide drill for applications up to 8xD has been specifically developed to overcome problems typically associated with deep-hole drilling of stainless steel. Created within the Dormer product portfolio, the R459 broadens the existing MP-X range which already consists of 3xD and 5xD solid carbide multi-material drills.

Meanwhile, a versatile range of OEHT octagonal inserts for cutting depths 4 – 10 mm, alongside REHT (round) and XEHT (wiper) inserts, is suitable for stainless steel.

By utilising eight cutting edges – the highest number available for positive inserts – the new range provides an economical offer for customers, while the wiper insert option boosts feed rate capabilities and surface finish quality.

Courtesy: Dormer Pramet
 

Seco has expanded the roughing and semi-finishing performance capabilities of its Secomax CS100 sialon ceramic grade by adding inserts with T-style edge preparation to the line. Featuring a free-cutting, extremely sharp geometry, the new inserts bring stability and performance longevity to the machining of nickel-based superalloys in unstable conditions.

Well suited for turning applications that require tight tolerances and low cutting forces, the T-style

(chamfered) CS100 inserts are available in 20-degree chamfers that range from 0.05 mm to 0.1 mm in width. The sharp, negative reinforced cutting edges on these inserts help absorb some of the high cutting force and pressure that would otherwise be placed on the machine setups and workpieces.

As a result, these inserts eliminate the risk of workpiece deformation, especially in thin-walled components, as well as reduce excessive vibrations that shorten tool life and negatively impact surface finish. The characteristics of the T-style inserts also complement the existing S-style (chamfered and honed) CS100 products designed to handle high cutting forces in rigid, stable machining conditions.

Well suited for turning applications that require tight tolerances and low cutting forces, the T-style (chamfered) CS100 inserts are available in 20-degree chamfers that range from 0.05 mm to 0.1 mm in width. The sharp, negative reinforced cutting edges on these inserts help absorb some of the high cutting force and pressure that would otherwise be placed on the machine setups and workpieces.

As a result, these inserts eliminate the risk of workpiece deformation, especially in thin-walled components, as well as reduce excessive vibrations that shorten tool life and negatively impact surface finish. The characteristics of the T-style inserts also complement the existing S-style (chamfered and honed) CS100 products designed to handle high cutting forces in rigid, stable machining conditions.

Collectively, the T-style and S-style inserts in the CS100 line have high abrasion resistance and superior toughness that extends tool life and allows for high cutting speeds when processing challenging materials such as Inconel, MAR, RENE and Waspaloy. In other words, manufacturers, especially those in aerospace and power generation, using these inserts benefit from high productivity, consistent quality and a low cost per part.

Furthermore, Seco has added new ceramic insert holders to its comprehensive product portfolio. Available in standard shaft and Seco-Capto styles, these holders have special pocket designs and clamping systems that easily accommodate the different thicknesses and missing centre-mounting holes that are common with these types of inserts.

Tungaloy Corporation is pleased to introduce AH8000 series of new PVD grades and chipbreakers for turning heat-resistant alloys.

The new PVD grades feature astonishing resistance to both wear and fracture due to the world’s first nano-multi-layered AlTiN coating with high Al content and dramatically reduce notch wear, crater wear, and built-up edge in machining heat-resistant alloys. The two AH8000 grades include AH8015, the first choice grade with well-balanced wear and fracture resistance; AH8005, the high hardness grade with excellent wear resistance. These two new grades are treated with PremiumTec, Tungaloy’s special surface technology that adds highly polished cutting surface for extra stability and long tool life.

The new chipbreakers, HRF and HRM, cover a wide range of applications from finish to medium cut. The HRF chipbreaker for finish provides low cutting force due to the large rake angle and inclination on the cutting edge, delivering excellent chip control particularly in machining in the low depth-of-cut range. The HRM chipbreaker for finish to medium cut features the protrusion on the rake surface. This protrusion minimizes the swarf from contacting the rake surface and dramatically decreases built-up edge.

These new grades and chipbreakers of the AH8000 series offer outstanding cutting performance in various turning operations from finish to medium cut of heat-resistant alloys, resulting in remarkable increase in customer productivity.

Main features:

Nano-multi-layered AlTiN coating with high Al content, the world’s first technology, on the PVD grades helps provide incredible wear and fracture resistance.

• The HRF and HRM chipbreakers cover a wide range of turning applications from finish to medium cut of heat-resistant alloys.

• 86 items in total

Following market demand, ISCAR is introducing a new family of FEEDMILL tools that carry square single-sided inserts with
4 cutting edges, designed for reducing cutting forces when used on low power machines or long overhang applications.

The new FFQ4 D…-12 shell mill cutters are available in 40, 50, 63, 80 and 100 mm diameters, designed for roughing operations in the Die & Mold industry, general engineering and the aerospace industry.

FFQ4 SOMT 12516 Insert Features

• Single-sided square insert with 4 cutting edges
• Available with two types of cutting geometries for optimal machining of different materials: 
FFQ4 SOMT 12516T for steel, ferritic and martensitic stainless steel, cast iron and hardened steel
FFQ4 SOMT 12516HP for austenitic stainless steel and high temperature alloys
• Produced from ISCAR’s latest SUMOTEC carbide grades that ensure high productivity

FFQ4 D…-12 Tool Features 


• 9 ̊ cutting edge angle
• Positive axial rake angle
• Ramping down capability
• 1 mm radius for programming
• Internal coolant holes directed to each cutting edge
• Cutter body with a special protective polished coating for uninterrupted chip flow and 
protection from corrosion and wear

Advantages 


• Covers a wide range of applications including slotting, pocketing, helical interpolation, plunging and surface sculpturing
• Suitable for machining various workpiece materials
• An optimal solution for high-efficiency roughing operations
• Excellent chip flow
• An economical solution

ISCAR has recently introduced the DECAIQTHREAD line of external threading tools carrying inserts with 10 threading corners. The new system has been enthusiastically received in the market.

In order to accelerate the product penetration, ISCAR has prepared two promotional kits that can be very attractive for both large and small manufactures.

Each kit contains 5 inserts featuring the most popular ISO profile pitch sizes and one square shank tool. One kit with a 20 mm square shank tool, the other with a 25 mm square shank tool.

ISCAR is expanding the TNF single-ended inserts for face grooving with a tangentially oriented pocket by adding 5 and 6 mm width inserts.

The TANG-GRIP Face Line includes single- and double-ended blades and inserts in 3, 4 and new 5 and 6 mm widths in the most advanced IC808 SUMO TEC grade.
The TNF inserts are available in two chipformer configurations:

TNF-P-IQ – for machining steel
TNF-M-IQ – for machining stainless steel and high temperature alloys

The blades are in a standard size, which fit ISCAR’s standard blocks.

FACE-GRIP System Features

• Very rigid clamping in a tangentially oriented pocket
• The face grooving penetration diameter range of TNF 5 and 6 mm inserts is 45 to 700 mm
• Enables machining at very high feed rates and interrupted cuts, providing excellent surface finish
• Offers a free, unobstructed chip flow since there is no upper jaw as in the other clamping systems 
(very important in deep grooving applications)
• The combination of tangential clamping and free chip flow results in very high reliability, 
improved tool and pocket life
• Provides a solution to the problem of inserts being pulled out during retraction
• The same insert can be used for both right- and left-hand tools
• Provides excellent performance on a wide range of materials and cutting conditions
• The tools are equipped with a user-friendly clamping and extraction device

Seco has expanded its range of insert geometries for the turning of challenging materials, such as hardened steels and superalloys. The new geometries are available in the TH1000 PVD-coated grade and TH1500 Duratomic^®CVD-coated grade. Combining a Seco-Capto machine-side interface with rigid P-lever-clamping, the new holders accommodate larger inserts for heavy-duty applications, particularly in ductile materials.

Both the TH1000 and TH1500 offerings have been significantly expanded with new inserts shapes, chipbreakers and nose radius sizes. The addition contains optimal solutions for a range of applications in the aerospace, energy and automotive industry segments.

TH1000 inserts offer a TiSiN-TiAlN nanolaminate PVD-coated grade ideal for finishing operations or interrupted cuts in hardened steels from 50 to 62 HRC. The grade also excels in long, continuous finishing and semi-finishing operations in superalloys, such as Inconel 718, Waspaloy and Nimonic C263. The grade allows for faster cutting speeds in these applications and joins Seco’s carbide grades TS2000 and CP200 and CBN grade CBN170 to form a complete finishing package for superalloys.

TH1500 incorporates Seco’s unique Duratomic coating technology, which manipulates oxygen and aluminium at the atomic level to optimise the coating’s properties. The grade offers excellent performance in hardened steel applications with high cutting data, as well as continuous cuts in materials from 40 to 55 HRC. TH1500 also achieves superior finish turning of grey and ductile cast irons, making it an excellent complement to Seco’s TK1001 and TK2001 grades within that application area.

To support heavy-duty roughing operations in superalloys and long-chipping steels, Seco has introduced versions of its Seco-Capto P-lever holders that accommodate large CN and SN inserts. The Seco-Capto interface sizes range from C5 to C10 and insert sizes range from CN..16/SN..19 to CN..25/SN..25. The P-lever clamping system leaves the area above the insert free for maximum chip flow and unhindered chip evacuation. Additionally, Seco-Capto P-lever holders feature a new nozzle design, ensuring coolant pressure capabilities of up to 70 bar, for efficient heat removal from the cutting zone.

A completely new range of cutters and inserts for economical face milling of stainless steel form part of a launch of products by Pramet.

The versatile range includes OEHT octagonal inserts for cutting depths 4 – 10 mm, alongside REHT (round) and XEHT (wiper) inserts.

By utilising eight cutting edges – the highest number available for positive inserts – the new range provides an economical offer for customers, while the wiper insert option boosts feed rate capabilities and surface finish quality.

Pramet’s new double positive 45° milling cutter, S45OE, is available in diameters up to 200mm and supports internal coolant delivery.

Its versatile design allows the same cutter body to be used with both the octagonal inserts for face milling and the round inserts for face and copy milling applications.

Suitable for use even on machines with limited power, the combination of new inserts and cutter offer high metal removal rates with low cutting force. The risk of chatter is also reduced – an important consideration when machining valuable components.

Karel Tiefenbach, indexable milling product manager at Dormer Pramet, said: “Our latest package of products for stainless steel offers additional economical and versatile options for the customer. The cutters design features positive axial and radial face angles, promoting a good cutting action and directing chips away from the work-piece. Our S45OE range offers a wider selection of diameters and enhances our line of cutters with double positive geometry. This is especially beneficial when the work-piece is fragile, the fixture is unstable or the component material has the tendency to work harden – a common issue when machining stainless steel.”

For use with the OEHT inserts, three new positive geometries – MF, MM and M – have been introduced for various cutting conditions.

The MF is a sharp and highly positive geometry for finishing applications in stainless steel, mild carbon steel and non-ferrous metals. MM is a sharp and positive geometry for machining stainless steel in medium cutting conditions.

The M is a positive geometry with stabiliser – suitable for difficult cutting conditions in materials such as carbon steels and harder stainless steel.

The new geometries offer reduced cutting forces and increased durability for machining with or without coolant.