At the Right Angle
In milling applications, 90° cutters are perhaps the most common tools. These versatile tools are used for milling square shoulders, slots, face operations bound by shoulders, edges, pockets, and cavities. It is apparent that 90° cutters prevail in the product range of tool manufacturers. With so many options available to us, It isn’t an easy job to decide which cutter is the right for us.
In selecting 90° milling cutter, there are several factors to be examined such as the material to be machined, the removal of stock, required accuracy, surface finish, stability, and the characteristics of the machine tool in use. All of these factors are important for choosing a cutter to use in the production processes. For example, solid mills provide ultimate maching accuracy while indexable tools enable machining under heavy loads and provides additional cost-effectiveness per cutting edge. Also, there are various shapes available in 90° cutters such as rectangular and square. The shape of the insert determines the number of cutting edges on the insert and affects its features. For example, a parallelogram-shaped inserts provides an optimally harmonious combination of the cutting-edge length, varied corner radii, ramping-down capabilities, and additional parameters of the cutting geometry and insert strength. However, the major disadvantage of this shape is that the number of cutting edges is limited to two in a traditional design configuration. Although the double-sided reversible insert concept seems to be the simple way to increase the number of edges on this insert, there is a limitation on the effect on the relief angle and the increase in the axial rake of a milling cutter after the inserts are assembled on the tool body. Overall, there are many factors when it comes to choosing inserts in milling operations. Moreover, many solutions come with limitations. Is it possible to find a cutter that is cost-effective, durable, versatile and can be used in various industries with the ability to cut deep without repeated milling?
To better satisfy requirements of manufacturers and overcome limitations of 90° inserts, ISCAR has arranged a NEOLOGIQ campaign and encouraged ISCAR’s product development and design engineers to invent the new NEODO S890 milling cutter designed for rough, semi-finishing, face and square shoulder milling operations primarily for steel and cast iron. The tool utilizes a strong-structured double-sided insert. The insert features a square profile and is specially shaped by ISCAR’s unique pressing technology. This provides 8 helical right-hand cutting edges, 4 from the top and 4 from the bottom. When mounted on the cutter, the insert guarantees positive radial and negative axial tool rake angles, which promise smooth cutting and reduced power consumption for milling under diverse machining conditions and interrupted cuts. A dovetail profile of the insert pocket enables very rigid clamping that substantially increases cutter stiffness. The insert has a built-in wiper flat to improve surface finish. The advantages of our design and technologies have resulted in effective and economical solutions for face milling, particularly for machining close to shoulders where work holding constraints exist.
NEODO S890 is considered as one of ISCAR’s proudest innovations due to its versatility and ability to overcome the limitations of 90° milling cutters. Our product will allow manufacturers to find “the right and better” 90° cutter that can offer an excellent solution.
