New Cutting Tools for Cast Iron Machining

"Kyocera Precision Tools, Inc. unveiled its new MFK indexable milling cutter for cast iron, a milling system that will allow machinists to reduce costs and improve their milling operations through the use of double-sided, 10-edge negative inserts," said a company spokesperson.

Automotive engines, construction equipment and machine tools require metal components in complex shapes that are commonly created by casting molten metal in specialized molds. Castings taken from these molds require difficult finish machining. Many workpieces are challenging to hold securely during the machining process because their complex shapes limit clamping rigidity. Insufficient clamping rigidity causes vibration and chattering due to the cutting forces of the machining process. In addition, cast iron workpieces are susceptible to a phenomenon known as "breakout," in which the edge of the workpiece chips away rather than being cut cleanly. Cutting tool inserts that can improve machining quality by reducing the cutting forces and preventing chipping are therefore in great demand.

Kyocera's new MFK cast iron milling cutter utilizes a newly developed double-sided insert with 10 cutting edges. Although negative inserts offer cost benefits because cutting edges can be formed on both sides of the insert, they tend to increase cutting resistance, causing a decrease in sharpness or an increase in chattering. To address this challenge, Kyocera has developed uniquely shaped inserts using its proprietary molding technology, which reduces both cutting resistance and chattering. The inserts also improve machining quality through a double-edge structure in which two cutting edges are provided for the insert corners, said the spokesperson.

New Product Features:

• Double-sided, 10-corner negative inserts
• Proprietary edge shape reduces cutting resistance. The newly developed negative inserts utilize two lead angles per corner. Using molding technology developed by Kyocera, a large axial rake angle is provided on cutting edges, reducing cutting resistance and facilitating smoother machining. Increasing the lead angle also reduces cutting resistance in an axial direction of the workpiece, vibration and chattering.
• Double-edged structure helps prevent inserts from fracturing and breakout. A proprietary double-edged structure using two main cutting edges is utilized on each corner to cushion initial shock at the moment of workpiece contact - the onset of cutting. This helps prevent inserts from fracturing and breakout, helping to stabilize the machining process and improve finish quality.
• Newly developed CVD material for cast-iron milling offers long tool life and stable machining. Kyocera has added the new CA420M Chemical Vapor Deposition coating (CVD) material for cast iron milling to its insert grade lineup. CA420M is comprised of a newly developed, high-toughness base substrate with a new CVD coating developed using proprietary crystal-control and film-formation technologies. The Chemical Vapor Deposition coating method allows multiple layers of different materials, resulting in thicker film.
• Accommodates a wide range of cast-iron machining conditions, from roughing to finishing. Kyocera's extensive lineup of milling cutters, insert shapes and grades provide a combination to cover a wide range of conditions, from cast iron roughing to finishing.

For more information contact:

Kyocera Precision Tools, Inc.

102 Industrial Park Road

Hendersonville, NC 28792

800-823-7284

cuttingtools@kyocera.com

www.kyoceraprecisiontools.com