Milling

Question	Answer
Which families are included in ISCAR’s indexable milling line?	The indexable milling line consists of cutters intended for the main types of milling operations: milling right shoulders, milling open faces, milling edges (edging) and deep shoulders, milling 3-D surfaces (profile milling), milling slots and grooves, milling chamfers, etc. Separate families of cutters have been developed to handle fast feed milling (a specific machining technique).
The logos of various ISCAR’s indexable milling families start with the wording “HELI” (a derivative from “helix”), and phrases such as “helical cutting edge” and “helical milling” are often emphasized as benefits in technical information. Why?	In the early 1990’s, ISCAR introduced the HELIMILL – a family of milling tools carrying indexable inserts with a helical cutting edge. The highly effective edge was generated by the intersection of the shaped insert top (rake) face and the helical insert side (relief) surface. The design of the HELIMILL tools formed a constant positive rake and a constant relief along all cutting lengths. This feature immediately caused a significant reduction in power consumption and ensured a smooth cut. The HELIMILL heralded a new design approach that is considered today as the acknowledged format in indexable milling, and positioned the shaped surfaces of an insert into the forefront. The wording “HELI” reflects the helical cutting edge as a significant factor in the advancement of these indexable milling families.
Does ISCAR provide indexable milling cutters for machining aluminum?	Yes. ISCAR has developed an entire comprehensive range of indexable milling cutters, designed specifically for the efficient machining of aluminum. Each family of these high-quality cutters features integral or lightweight body designs, unique principles of carbide insert clamping, structures with adjustable cartridges, various ground and polished inserts with different corner radii and, most popular in aluminum machining, inserts with polycrystalline diamond (PCD) tips. The vast majority of the cutters have inner channels for coolant supply through the body. The ISCAR HELIALU line of indexable milling tools enables efficient high speed machining (HSM) of aluminum, ensuring powerful metal removal rates (MRR).
The term “high positive” is often used when speaking about indexable milling cutters. What does it mean?	Generally, this term relates to rake angles of an indexable milling cutter. Advances in powder metallurgy have resulted in the production of helical-cutting-edge inserts with a rake face that is “aggressively” inclined with respect to the insert cutting edge. This causes a significant increase in the positive rake angles (normal and axial) of a cutter carrying the inserts. The definition “high positive” emphasizes this feature.  Note: This definition reflects the current state of the art.  As the production of tools with cemented carbide inserts does not deplete its own resources, we may assume that the “high positive" of today will be considered as “normal” tomorrow.
Cemented carbide is a main cutting material for indexable inserts. ISCAR provides a rich variety of carbide grades. Where can I find basic information about the properties of a grade, recommended cutting speeds and application range?	ISCAR offers a range of electronic and printed catalogues to reference guides that contain this information and specify the structure of a grade (substrate type, coating), the application range in accordance with ISO standards and the range of cutting speeds. Contact ISCAR representatives in your region for details and assistance.
Do the indexable milling cutters have internal channels for coolant supply?	Most of the indexable milling cutters introduced recently feature an inner channel for coolant supply to each insert directly through the cutter body.
There are face shell mills that do not have these channels. If an internal coolant supply is necessary, how I can modify the mills?	In most cases, this modification is not needed. Instead, ISCAR proposes clamping screws with adjustable nozzles to provide a simple solution to the problem. The screws not only secure the shell mills on arbors but provide effective coolant supply directly in the cutting zone and improve chip evacuation. A nozzle, the movable part of the screw, allows easy adjustment of coolant supply depending on the depth of a mill countersink depth, insert sizes or application needs.
How I can guarantee applying correct torque for tightening clamping screws that secure inserts in the milling cutters?	In indexable milling lines, ISCAR provides two types of torque keys: with adjustable and fixed torque value. The first type allows the user to set torque within an available range, while the second type features a fixed torque value that is already preset. Information about which torque is necessary for tightening screws, which secure the inserts, can be found in catalogues, technical guides and leaflets. In addition, this data is now printed on the milling cutter body as a mark detail.
What is better for control productivity – varying the feed or the depth of cut within acceptable limits?	It should be noted that the question has no unambiguous answer and depends on several factors. However, in general, under the same MRR, increasing the feed coupled with reduced depth of cut is more favorable than the opposite combination (lesser feed with deeper cut) because it normally results in greater tool life.
How can I find a more efficient indexable milling cutter for my applications?	If you know the application parameters, ITA (ISCAR Tool Advisor), a computer-aided search engine, can be a very effective tool. This software is free and it may be installed even on your smartphone. If your question relates to more broad issues and considerations about selecting a suitable family of cutters, we have specific recommendations regarding priorities – please contact our representatives for assistance.