As Sherlock Holmes might say finding the solution to a problem is merely a matter of logic. This theme of reasoning has now been applied by Iscar in its latest cutting tool developments.
An extension of its IQ concept, the new Logiq range offers an array of machining solutions for applications in parting off, turning, milling and drilling.
This new ‘Chess Line’ series of cutting tools is intended to be fit for the coming era of Industry 4.0 and the smart factory. At its Logiq product launch held at the ICC in Birmingham to an audience of distributors, customers, Iscar personnel and members of the press, Jacob Harpaz, Iscar’s CEO, spelled out how the digital domain will impact manufacturing.
Developments such as electric vehicles and powertrains in large volumes, additive manufacturing and cyber connectivity will mean significant changes in the style of machining and the materials being used. Workpieces will be produced more commonly at near net shapes for final machining and finishing.
“By 2030 there will be big changes in the automotive sector, for example,” Mr Harpaz explained. “The major OEMs are moving away from the internal combustion engine which will mean much less metal removal will be required. There will be wider use of composite materials and the introduction of 3D printing will also mean less metal removal. At Iscar we are preparing for these changes. Cutting tools will have to adapt to remove less metal but at much faster speeds and feeds.”
Mr Harpaz explained that Iscar’s new tools will enable machinists to perform metal cutting at a rate similar to that found in the woodworking industry: “The cutting tool can have a huge impact on productivity. Not every company can buy the latest machine tools but changing to our cutters means the tools can run at very high speeds with a minimum of downtime.”
According to Mr Harpaz, Industry 4.0’s impact will not just come through sophisticated new technology such as sensors, process monitoring and acquiring machining data, but in the integration of factories and the supply and distribution of consumables used in manufacturing and products leaving the factory.
“Look at the impact that a company like Amazon has had on sales and marketing,” he said. “We are moving into an era of e-commerce and distribution and inventories with vending machines. In the US, the large majority of our cutting tool sales come through our vending machine systems. Industry 4.0 is not just about cutting process data, tool monitoring and sensors – it’s also about the most efficient supply and distribution.”
When it comes to innovation, Iscar has a long legacy of not standing still. 40% of its tools in its product lines are less than five years old.
The new Logiq range reflects the company’s comprehensive portfolio of cutting tools made from numerous carbide grades, along with the cubic boron nitride (CBN), polycrystalline diamond, Cermet and ceramic tools.
There are four main product areas in the new Logiq range reflecting tools designed for different applications: LogiqGrip, LogiqTurn, LogiqMill and LogiqDrill.
LogiqGrip
LogiqGrip tools are designed for applications such parting off, grooving, threading and back turning. The range includes inserts such as the TangFGrip. This 3-4mm wide insert is able to perform parting at very high feed rates on conventional X-axis machines. In the case of multitask machines and turning centres, parting can be performed on the Y-axis of the machine with the new vertical 32 or 35 Y-axis TangFGrip blades at high feed rates of 0.45mm/revolution providing very high productivity.
For machines that only have X-axis options, Iscar’s new innovative vertical X-axis blade combined with a new X-axis block can be mounted on all types of machine. The block and angled blade system performs parting at high feed rates of 0.5mm/revolution and also enables the parting of large diameters while applying high feed rates with no vibration. Iscar claims this enables superior productivity on all machines up to four times faster.
Also in this range is the Logiq5Grip – a five-pocket blade system that is designed to deliver extended tool life. The interchangeable blade is assembled on a toolholder which indexes tangential grip 2 and 3mm inserts for parting and grooving. This system also indexes what Iscar says is the world’s narrowest insert slitting and grooving blade with a 0.6mm width of cut for parting and grooving.
Iscar’s Slim Slit line is also claimed to be the narrowest line of indexable slitting cutters available on the market. Slim Slit inserts enable cutting grooves down to 0.6mm and also feature through tool coolant which helps chip removal.
LogiqTurn
When it comes to turning, Iscar has introduced new developments such as JetRTurn, a new tool holder designed to deliver coolant directly to the cutting edge of the insert. The clamp used to hold the insert also contains a channel through which coolant can be delivered. Suitable for high and standard coolant pressures, JetRTurn has three options for connecting the coolant inlets. Through the bottom of the tool, the back of the tool or through a VDI connection.
Another development for deep boring turning applications is the Whisperline boring bar. Designed to eliminate chatter and vibration, the shank of the bar has an integrated absorber for smoother machining. The bar has changeable heads for turning, threading and grooving and is available up to a length of 10xD.
The Logiq4Turn is a double-sided insert with four cutting edges. Intended for general turning applications, these positive rake inserts have a dovetail shape of that fits into an innovative pocket design ensuring better positioning, stability and increased tool life.
LogiqMill
Milling is the application with the largest number of new products from Iscar and a key focus for the company is the area of micro-machining with the introduction of very small cutters such as the NanMill and NanFeed endmills.
These endmills have a clever design which means the tiny triangular inserts are held in place by a wedge-shaped screw keeping them further away from the cutting edge and holding them securely. The NanMill has three cutting edges for 90° shoulder and deep ramp down milling down to 8mm diameter.
Indexing the inserts is aided through the use of a magnetic key which helps to ensure the insert is held in place as it is mounted to the endmill. The NanFeed is a similar endmill designed for high feed milling; suitable for high ramp down angles in deep cavity milling. The tools feature through tool coolant for easy chip evacuation and a high surface finish.
Another addition for miniature machining is the Micro3Feed – a micro-sized insert combined with small diameter multi-toothed endmill for high feed milling. The hexagon shaped insert with three cutting edges enables substantially increased feeds for higher productivity and the positive rake angle reduces cutting forces and guarantees a reliable soft cut at high feeds.
When it comes to finish milling, Iscar has introduced the TangFin which achieves a mirror like finish by using tangential step mounted inserts which feature a long wiper to achieve a highly polished surface. The new radial and axial positioning of the inserts creates optimal chip distribution and a smooth light cut. Each insert removes a small amount of metal meaning milling is carried out with less noise and vibration.
For rough milling, a new line is the Logiq8Tang, a cost-effective insert with eight cutting edges for 90° shoulder milling. The system features a large wiper and is most suitable for use with steel and cast iron, offering high feeds and durability in extreme cutting conditions. This is enabled by the firm placement of the insert due to its dovetail shape. The tangential mounting of the insert reduces forces on the insert screw, eliminating shearing breakages.
LogiqDrill
New additions to Iscar’s hole making tools include the SumoCham, claimed to be the world’s smallest indexable drilling head at just 4mm. This micro-sized drill head is attached by an ergonomic key for easy clamping. This drill has the same clamp size compared to solid carbide drills and features Iscar’s no set up time system. The high productivity Sumo head is suitable for all materials including steels, stainless steels, cast iron, aluminium, heat resistant alloys and hardened steels.
Finally, another Logiq range development is the Logiq3Cham – a new line of drill heads and bodies with three cutting edges allowing higher feeds and higher productivity. The insert head has an innovative design which holds the head firmly in position.
It has capabilities for many head replacements and a self-centring sharp point geometry to achieve an absolutely accurate hole size. The head runout is minimal and it remains accurately in position after replacement ensuring there is no set-up time required.
Global growth
The launch of these new products comes at a time when Iscar’s sales are thriving. Mr Harpaz revealed that in 2017-18 the company had seen double digit growth in sales, and he is optimistic about prospects in growing markets such as the automotive sector in India and China and the burgeoning revival in oil and gas.
Commenting on the new release of tools, David Jones, Iscar UK sales manager said: “The application of Logiq represents a smart, logical progression in a series of strategic moves to implement Industry 4.0 machining standards while ensuring continuity and stability.
“It has allowed the creation of advanced new tool families, enabled existing lines to be upgraded and inspired innovative product ranges that assist users in maximising equipment utilisation and optimising performance.
“Constant communication with customers that operate in all of the world’s major metalcutting sectors, a thorough understanding of advancements in materials and an in-depth knowledge of current machine tool developments allows Iscar to stay ahead of market developments.”
Iscar www.iscar.co.uk
Watch Iscar talking about its latest cutting tools at MACH 2018 below.
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