Slitting Brochure Inch

 

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Slitting Brochure Inch

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Engineered for MaxiMuM Slotting and grooving Performance Inch Version W W W. I S C A R . C O M

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ISCAR’s Complete Machining Solutions Catalogs Now on Your Tablet User-Friendly App Online Interface Updates Web Viewer at ISCAR’s Website GrooveTurn Tools SolidCarbide & MM Endmills Milling Tools Hole Making Tools Turning & Threading Tools Tooling Systems New Products Catalog w w w. i s c a r. c o m

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f or d ing re mov ee mu ro e gin i d G nc En ax an rma M ting erfo t P Slo MULTI-MASTER...................................................................................... 12 T-SLOT..................................................................................................... 36 CHAMSLIT............................................................................................... 40 MINI-TANGSLOT.................................................................................... 46 TANGSLOT.............................................................................................. 55 ISCARMILL.............................................................................................. 60 HELISLOT................................................................................................ 66 TANGMILL............................................................................................... 74 TANGSLIT................................................................................................ 81 SELF-GRIP.............................................................................................. 88 CUT-GRIP................................................................................................ 96 1

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Application Range MM TS - pages 18-19 .028-.375 ø .303-1.00 MM GRIT - pages 20-21 .030-.394 ø .618-1.091 MM TS-DG - Double-Groove Heads for Tube Sheets of Heat Exchangers - page 22 2 ISCAR

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f or d ing re mov ee mu ro e gin i d G nc En ax an rma M ting erfo t P Slo Application Range MM GRIT...45A 45° Chamfering Heads - page 22 ø .697, .854 MM TRD- Milling Heads for 55° and 60° Partial Profile Thread Milling - page 23 MT ...- MM- Milling Heads for Internal ISO Metric Thread, UN Thread Profile and 55° BSW Thread Profile - pages 24-25 ?.?-?? 3

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Application Range SD-SP - page 38 .078-.250 ø 1.238 TRIB - pages 42-44 .047-.256 ø 1.268-3.000 ETS T-Slot - pages 52-53, 63, 68 .125- .620 ø .78- 2.48 4 ISCAR

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f or d ing re mov ee mu ro e gin i d G nc En ax an rma M ting erfo t P Slo Application Range FDN - pages 55, 68, 70, 75 .281-1.00 ø 3.0-10.0 SDN - pages 54, 56, 69, 71, 75 .125-1.0 ø 3.0-10.0 SSB...R/L- page 77 ap .551 ø 3.0-6.0 5

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Application Range GM/SGSF/SGSA / TGSF - pages 82, 88, 93, 95 TGSF .063-.157 SGSA .118-.157 ø 1.97-6.299 Tmax .4-1.550 ø 1.25-4.92 Tmax .22-1.00 GM-DG .118-.157 SGSF .055-.256 ø 3.94-7.87 Tmax 1.14-2.32 ø 1.26-9.87 Tmax .27-3.34 6 ISCAR

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f or d ing re mov ee mu ro e gin i d G nc En ax an rma M ting erfo t P Slo Milling Slots and Grooves Reference Guide This catalog and user guide relates to tools for machining slots, grooves, slitting and cut-off operations with the use of indexable rotating tools. ISCAR offers a wide choice of slotting cutters with various cutting geometries, configurations and dimensions designed for various applications. This catalog was prepared to help planners working with manufacturing processes, operators wishing to improve tool performance and managers searching for a more productive machining methodology. Other milling tools data can be found in ISCAR printed and online catalogs. The included user guide is based on the knowledge and experience of ISCAR engineers, application specialists from our worldwide branches and our customer’s feedback. Slitting Cutting-off Milling Slots/Grooves T-Slot Slotting Operations and Tools The word “slotting”, commonly known as “slot milling”, is widespread in shoptalk. Actually, slotting is a partial case of planing or shaping – a machining process where a single-point cutting tool moves linearly and piston wise, and a workpiece is fixed or moves only linearly. In classical slotting machines the tool moves vertically. As it seems from its description, slotting machines or slotters were designed first of all for producing slots of various shapes. Modern CNC machine tools pushed the slotters into the background. However, the lowcost and reliable slotters remain popular in small shops dealing with small batch production. Generally speaking, milling tools of different types – side milling cutters, endmills, extended flute (long-edge) milling cutters and even face mills – are suitable for machining slots and grooves (Fig. ). Generally two and four flute solid endmills and slot drills are used for machining slots for keyways. They have at least one center cutting tooth for plunging into the cut. However, endmills or slot drills are designed for general purpose applications and do not mill long slots very efficiently. On the other hand, side slot milling (or slotting) cutters (Fig. ) with teeth on face and periphery, were designed especially for machining slots and grooves. The slotting cutters simultaneously mill three surfaces: bottom and two sidewalls. This is the reason why slotting cutters are often called side and face milling cutters. If a full side cutter (Fig. ) generates the full profile of a slot from solid, a half side cutter (Fig. ), which has only one cutting face, is suitable for machining one of the slot sidewalls or milling shoulders. In addition, the saw-type slotting cutters of narrow width are used mainly for cutting-off. 7

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Cutter Adaptations Disk Type Flange Type Shank Type Interchangeable Heads Slotting cutters differ in their adaptation (mounting methods). They feature either arbor hole or shank-type configurations, or alternatively, interchangeable heads for modularly assembled tools (Fig. ). In case of mounting on an arbor, disk or flange type cutters are used. Disk-style cutters are an effective means for gang-tool assemblies for simultaneously machining several slots. Accuracy Customers searching for a productive alternative to slotting cutters with brazed carbide tips, sometimes wonder why the modern indexable tools are less accurate in comparison with the brazed ones. Practically the brazed cutters are one-piece products; their final shape is obtained by grinding, which ensures high accuracy. In indexable milling cutters, replaceable inserts are mounted in pockets. The accumulated tolerances arising from insert and pocket manufacturing result in a lower accuracy. Note: Solid carbide large diameter cutters are very expensive when compared with indexable insert tools. Indexable tools offer grade and geometry variety. The flange-type design features an expanded length of central bore. It transmits torque via face-mounted driving keys, providing reliable cutting even under heavy loads. In milling, depth of cut is usually measured along the axis of a cutter, axially (“axial is depth of cut”, “ap”), while width of cut – radially, in the direction perpendicular to the axis (“radial depth of cut”, “ae”). This generally accepted approach may sometimes lead to confusion in the case of the slotting cutters. The depth of cut here is equal to the width of cutter teeth and it defines the width of a milled slot. The radial depth of cut (the width of cut) reflects the slot depth. Therefore, having to deal with slotting cutters using the terms “axial depth of cut” and “radial depth of cut” seems more correct as it prevents possible misunderstanding. Depth and Width of Cut ae ap The slotting cutters can be indexable (carrying replaceable carbide inserts), solid or with brazed carbide tips. The latter were very popular in the past, but they are less common nowadays due to low productivity. The solid carbide slotting cutters provide high machining accuracy, however, they are manufactured in a relatively limited range of diameters. The majority of modern slotting cutters are highly-efficient indexable tools. Generally, they are less accurate than solid carbide cutters, although indexable cutters with adjustable cartridges carrying inserts can provide precise solutions. In addition, there are slotting cutters with interchangeable milling heads made from solid carbide. These cutters combine the advantages of solid carbide tools (high accuracy) and indexable tools (replaceability of cutting elements). However, they are still limited by diameter and generated slot widths. Narrow Slot The term “narrow slot” generally defines a deep slot of small width. A more rigorous but empirical rule considers a “narrow slot” to be the slot with a width less than .197” and a depth of at least 2.5 times the width. 8 ISCAR

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f or d ing re mov ee mu ro e gin i d G nc En ax an rma M ting erfo t P Slo The average chip thickness is an important parameter in milling. In machining slots and grooves with the use of side and face milling cutters, the average chip thickness hm reflects interplay between a nominal cutter diameter D and a radial depth of cut ae during operation. For practical calculations the average chip thickness can be found from the following equation: hm≈fz×√(ae/D). For example, if a 1.250” diameter cutter machines Average Chip Thickness a .276” depth slot in one pass, while the feed is .006 ITP, the average chip thickness will be approximately .006×√.276/1.25=.0028 inch. The average chip thickness indicates tooth loading and therefore allows correctly defining the feed using the conversion calculation. Generally in milling slots and grooves, the average chip thickness is .0012-.0060”. Table 1 contains more detailed data regarding the average chip thickness and the corresponding feed. Table 1 - Actual Average Chip Thickness (hm) as a Function of ae/D and Feed per Tooth (fz) hm (inch) .0012 ae/D .03 .05 .10 .15 .20 .25 .30 .35 .40 .50 .007 .005 .004 .003 .003 .002 .002 .002 .002 .002 .009 .007 .005 .004 .004 .003 .003 .003 .002 .002 .011 .009 .006 .005 .004 .004 .004 .003 .003 .003 .013 .010 .007 .006 .005 .005 .004 .004 .004 .003 .016 .012 .009 .007 .006 .006 .005 .005 .004 .004 .018 .014 .010 .008 .007 .006 .006 .005 .005 .004 .020 .016 .011 .009 .008 .007 .006 .006 .006 .005 .022 .017 .012 .010 .009 .008 .007 .007 .006 .006 .025 .019 .014 .011 .010 .009 .008 .007 .007 .006 .027 .021 .015 .012 .010 .009 .009 .008 .007 .007 .030 .023 .016 .013 .011 .010 .009 .009 .008 .007 .031 .024 .017 .014 .012 .011 .010 .009 .009 .008 .033 .026 .019 .015 .013 .012 .011 .010 .009 .008 .0016 .0020 .0024 .0028 .0031 .0035 .0039 .0043 .0047 .0051 .0055 .0059 fz (IPT) The orange highlight shows the field of values that are more common in milling slot and grooves 9

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Designation of Slotting Cutters The designation of ISCAR slotting cutters indicates the type of the cutter: ETS – a cutter with shank, FDN – a full slot cutter with a flange for arbor adaptation, SSB – a half side disk slotting cutter with central bore, etc. ETS FDN SSB SDN FSB FST Cutter Types for Right- and Left-Hand, Top and Bottom Milling FDN...-R Full Side Flange Type Right-Hand Spindle Rotation FSB...-R Half Side Bottom Flange Type Right-Hand Spindle Rotation SSB...-R Half Side Top Disk Type SDN Full Side Disk Type SDN Full Side Disk Type Left-Hand Spindle Rotation SSB...-L Half Side Bottom Disk Type Right-Hand Spindle Rotation SSB...-R Half Side Bottom Disk Type Left-Hand Spindle Rotation SSB...-L Half Side Top Disk Type Right-Hand Spindle Rotation FST...-R Half Side Top Flange Type Right-Hand Spindle Rotation Cutters with cartridges can be assembled according to required configuration. Left-Hand Spindle Rotation Right-Hand Spindle Rotation 10 ISCAR

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f or d ing re mov ee mu ro e gin i d G nc En ax an rma M ting erfo t P Slo Tools with Tangentially Clamped Inserts Machining Heat Resistant Alloys The main component of cutting forces acting on a tool during machining is the tangential force. It defines power consumption. In a cutter with tangentially clamped inserts, the tangential force acts against the largest cross-section of an insert that improves the insert strength and allows for increasing cutting data. A cutter design based on tangential clamping can be a good solution for better productivity for machining shallow cuts, short chips, etc. Since the largest cross-section of a tangentially clamped insert is from the back side of the insert cutting edge, such an insert is sometimes called an “on-edge” insert. Heat-resistant alloys, such as Inconel, emit a lot of heat during machining. Therefore, when machining deep and narrow grooves, short and unpredictable tool life might be obtained. In these cases it is recommended to machine at no deeper than 25% of the diameter of the cutter per pass. When using circular interpolation to perform groove milling, feed rates are decreased when cutting IDs and increased when cutting ODs. For an internal groove in a hole, the programmed feed rate is often that of the feed rate at the center of the hole. The feed rate calculated at the periphery is different and the result is often an excessive feed rate for the cutter. The feed rate, then, should be decreased to allow for the difference. For external grooves, it is just the opposite. Again, the feed rate calculated at the periphery is different but the result is often too low of a feed rate for the cutter. The feed rate should be increased to allow for the difference. It is recommended to enter the groove in a 45° to 180° angle to reach the maximum DOC. A radial entry of the milling cutter causes a long contact angle, which leads to vibration. Slotting cutters generally require a reduced chip load compared to a relative slitting cutter. ISCAR slitting cutters produce a narrower chip than that which is produced with a single wide insert, enhancing chip evacuation. The cutting edge is orientated at a 70° to 60°, so it deflects the chip from the slot surface to avoid scratching damage. The angle actually draws the chip away from the slot wall. Number of Effective Teeth The number of effective teeth is an important parameter of a slotting cutter. If the axial depth of cut is large enough, it engages two adjacent teeth (in some special cases even more) and the chip produced during cutting is divided between them. This fact should be taken into account for defining the feed, in order to prevent overloading: the number of teeth used for calculating the feed per revolution and the feed speed is half the total number of teeth (three times less in the aforementioned special cases). The correct calculations are extremely important for milling T-slots, where difficult chip evacuation limits tool performance and increases tool loading. Always set feed according to the number of effective teeth of a tool, as noted in ISCAR catalogs and other technical sources. As the depth of the groove increases, cutter diameter should be larger. At least one tooth should be engaged at all times when groove milling, to keep the spindle under load. If periodically the spindle is not under load, spindle whip can occur, damage it and cause tool failure. Therefore, in case of shallow grooves, it would be better to have a fine-pitch cutter and thus the cutter will be always under load. 11

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Sl n ot M gin tin ax ee Pe g a im red rfo nd f rm G um o r an ro ce ov in g E Typical Applications T-Slot Bottom Deburring Circular Groove Straight Groove Bottom Circular Groove Internal Circular Groove

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f or d ing re mov ee mu ro e gin i d G nc En ax an rma M ting erfo t P Slo MULTI-MASTER is a family of modular tools with shanks and interchangeable cutting heads for a variety of machining applications and milling slots and grooves. The MULTI-MASTER design approach is based upon a unique thread profile system (T-thread), which is accurately located by means of a short precise taper and face contact. A MULTI-MASTER solid carbide slot milling head is disk-shaped with a conical spigot and threaded back-end connection. This screws into a shank with a corresponding internal thread and conical taper, resulting in a secure connection through elastic MM GRIT... (except MM GRIT 28...) deformation of the taper and face contact between the insert flange and shank face.This method of coupling ensures strong and rigid clamping of the head. The MULTI-MASTER tools meet the requirements of high accuracy because the head geometry is finished by precise grinding and the connection guarantees concentricity within very close limits. The tools are simple to operate as they are screwed onto the shank and locked by a key. 1 2 3 4 1 MM TS... MM GRIT 28... 2 3 4 The MULTI-MASTER family with its large variety of heads, shanks and extensions provides a wide variety of small diameter slot milling cutter configurations. The basic concept is, a shank that can carry different heads and a head can be mounted on different shanks. The tool versatility diminishes the need for special tools. As is in the case of solid carbide or brazed cutters, re-sharpening of tools is no longer required, because a worn-out cutting head is simply replaced. MM GRIT MM TS W r Tmax There are two kinds of MULTI-MASTER heads intended for milling slot and grooves: MM GRIT and MM TS. The MM GRIT heads were originally designed for machining internal and external grooves for various O-rings and retaining rings in accordance with international standards - DIN 471 or ANSI B27.7M. The heads feature two types of cutting geometry. The first is the general-duty K-type, which is the first choice for milling steel and cast iron. The second is the P-type, which is recommended for milling soft and gummy materials. The heads of both types are secured in a shank with the use of special clamping keys. The majority of the MM GRIT heads have a straight tooth design with three or four teeth. MM TS heads with six teeth are produced with staggered inclined teeth with larger widths of cut and higher tooth density when compared with MM GRIT heads of similar diameters. In order to improve chip evacuation, increase cutting stability and reduce power consumption, MM TS heads with wide teeth are available with chip splitting grooves. In addition, MM TS heads feature a TORX shaped recess on the head face for clamping the head with the use of a TORX key. An exception is the MM GRIT 28… head. It combines specific elements of both head kinds (for instance six staggered teeth and a TORX recess commonly resembling the MM TS heads). 13

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