Technology Adding an edge to traditional inserts boosts productivity

Editor: Eric Culp

Israeli cutting tool manufacturer Iscar has unveiled a line of inserts that advance its well-proven technology with the axiom “more is better”.

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The tools not only offer improved structure and rigidity, they also provide lower costs per cutting edge, Iscar says
The tools not only offer improved structure and rigidity, they also provide lower costs per cutting edge, Iscar says
(Source: Iscar)

According to Iscar, the invention of Helimill in the 1990’s – said to be the first indexable sintered carbide insert with a helical cutting edge – elevated the company’s reputation as a producer of milling tools. The helical cutting edge, produced by the intersection of a helical relief surface and a rake face with a complex shape, ensures positive and constant rake angles along the whole edge.

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This provided practical benefits, the company noted: smooth cutting action, advantageous chip formation, lower cutting forces and power consumption, better tool life and more. As a result, the helical cutting edge significantly increased productivity and improved tool performance. Almost every indexable milling tool, especially cutters intended for machining 90° shoulders, relies on the helical cutting edge as a basic design principle, it noted.

Two edges good, three edges better

Today, Helimill milling cutters feature a broad spectrum of insert geometries and sizes. Such a variety is said to ensure success of the original cutters in practically all shoulder milling operations. They machine all types of engineering materials and the accuracy of machined surface and its roughness have been good enough. But the company said it has improved the technology with the Heliqmill 390 line – a further development of inserts with helical cutting edges.

The classical insert and its derivatives have two cutting edges. The new line offers a triangular insert with three cutting edges. Interestingly, the length of the cutting edge of an insert with three edges is the same as for an insert with two, the company explained, noting that the new inserts are available with 10 and 15 mm cutting edge lengths.

Geometry provides increased stability, precision

Furthermore, the three-edged insert has a stronger structure and its clamping into the pocket features high rigidity, Iscar said. The advanced cutting geometry of the insert results in a precise 90° shoulder and a wiper flat provides excellent surface finish, according to the supplier, which added that the Heliqmill 390 tools have exhibited impressive ramping-down abilities.

The new tools are intended for machining shoulders, slots and planes. In addition, Iscar pointed out that they can be a good choice in milling surfaces, ramping-down or helical interpolation such as pockets or cavities. The tools are available as endmills with shanks and face mills with a central bore.

The best of both worlds for the optimum result

The line incorporates all the advantages of Helimill, the company said, along with all the added advantages of an extra cutting edge, a more robust design, improved reliability and added accuracy, which provide increased performance. The result is milling of true 90° in combination with an improved cost per cutting edge since the inserts cost they same as their dual-edged HM90 precursors.

The inserts are produced from the company’s Sumo Tec carbide grades, which is said to contribute significantly to their ability to increase productivity.