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Cutting Diamond
                                                                                                                                  In manufacturing parts from composites, drilling
                                                                                                                                  is widely regarded as the major cutting operation.
                                                                                                                                  Improving capabilities of drilling tools has had a direct
                                                                                                                                  impact on the effectiveness of machining composites
                                                                                                                                  and composite stacks.
                                                                                                                                  Most recently, ISCAR introduced a series of new
                                                                                                                                  solid drills, in the diameter range of 3.3-12 mm
                                                                                                                                  (.130-.500"), which are specially designed for
                                                                                                                                  composites. The common feature of these tools is
                                                                                                                                  the use of polycrystalline diamond (PCD) or diamond
                                                                                                                                  coating to ensure high abrasion wear resistance. There
                                                                                                                                  are several types of these new drills; one of them is
                                                                                                                                  based on using a PCD nib as a central point of a drill,
                                                                                                                                  and another type has a diamond wafer. Both drill types
                                                                                                                                  offer a large area for multiple regrinding.
                                                                                                                                  The third type of drills are solid carbide tools with a
                                                                                                                                  diamond-coated cutting area. Their wavy cutting edge
                                                                                                                                  facilitates reducing burr formation, specifically when
                                                                                                                                  drilling carbon fiber reinforced plastics (CFRP) and
                                                                                                                                  CFRP-Aluminum stacks.













        Exotic for Exotic: advantageous ceramics               ceramics. The mills are intended mostly for rough
        Cemented carbide is still the main cutting material for   and semi-finish machining of planes and 3D surfaces
        machining. Introducing carbide tools revolutionized    at extremely high cutting speeds. The economical
        the metalworking industry ensuring a significant       double-sided insert design provides high ceramics
        growth of productivity due to sharply increased cutting  utilization. The inserts are made from several ceramic
        speeds. However, despite this, even today cutting      grades such as "black" ceramics, whisker reinforced
        speeds for difficult-to-machine Ni- and Co-based       ceramics and SiAlON (a type of silicon-nitride-based
        high-temperature superalloys (HTSA) are low: typically   ceramics). Applying the new mills is directed on
        within the range of 25-50 m/min (80-160 sfm). How      maximizing metal removal rate (MRR) and dramatic
        do we expand the speed boundaries?                     reduction in cycle time.

        Exotic ceramic materials have already found            One more example of successful usage of cutting
        themselves as cutting materials. Using exotic ceramic   ceramics is another of ISCAR's latest products: a
        material ensures a totally different level of cutting   family of solid endmills from SiAlON. The endmills
        speeds. For example, machining the superalloys by      were designed specifically for productive rough
        ceramic tools, the cutting speed 1000 m/min (3300      machining Ni-based superalloys such as various
        sfm) is completely real. Therefore, ceramic tools      grades of Inconel, Incoloy, Haynes, etc. in the
        become more and more common in machining HTSA.         aerospace industry. In comparison with typical solid
        Recently, ISCAR developed a family of indexable        carbide endmills, SiAlON endmills allow an increase in
        shell mills carrying double-sided inserts made from    cutting speed of up to 50 times!





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        36    MACHINING     IN  TELLIGENTLY                                                                                                                                                                                        ISCAR    37
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