Highlights

Following the steady increase in the processing of nickel-based high temperature superalloys (HTSA), such as various grades of Inconel, Incoloy, Haynes etc. in the aerospace industry, and the demand to decrease production costs (CPU), ISCAR is introducing new solid ceramic endmills. The new endmills can also be successfully applied to productive roughing of cast iron and graphite.
The new tools enable increasing the cutting speed by up to 50 times when compared to carbide tools, thereby drastically saving machining hours and reducing production costs.

Features

• There are 2 configurations:
    E3 - with 3 flutes for shouldering applications
    E7 - with 7 flutes, feed mill style for rough applications
• The endmills are produced from two ceramic grades:  IS6, designed specifically for machining HTSA  IS35, intended for cutting mainly cast iron and graphite
• Reduction in process times on nickel-based superalloys such as Inconel, as well as cast iron and graphite
• Available in 6 to 20 mm diameters
• Relieved neck diameter behind the effective cutting edge for machining next to shoulders
• Recommended cutting speed up to 1000 m/min
• Average tool life on superalloys is 15-25 minutes

Note: The current sintering process produces tools with a slight color difference.
The color difference has no influence on tool performance whatsoever.

User Guide

• Ceramic tools behave differently than carbide tools. In most cases, the end of a tool life is determined by the acceptable level of burrs and not by wear size
• Only air coolant should be used
• Use with the same types of toolholders as carbide EMs (shrink,collet etc )

EC-E3/E7-CE (ceramic)
3 and 7 Flute Solid Ceramic Endmills with Relieved Necks for Machining Superalloys, Cast Iron and Graphite • Recommended cutting speed on high temperature nickel-based superalloys: 250-1000 m/min
• Maximum width of cut for the 3 flute cutters is 0.1xDC
• Maximum width of cut for the 7 flute cutters is DC
(1) Programming radius
(2) Number of flutes
(3) Maximum ramping angle

P	M	K	N(K)	S(M)	H(P/K)
		+	+	+

+ recommended

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TEST REPORT - Rough Profiling
Part name: Mixer
Operation: Profile mill
Material: Inconel 718
Machine: DMG 80eVo HMC
Target: Productivity improvement

	Competitor	ISCAR Current Grade
Tool	STR540-0.500-D3-R090.0-Z5	EC-E7 12-02C12R1.5N83CE
Grade	ALCRN	IS6
Diameter (mm)	12.7	12
Cutting speed (m/min)	33	610
Rotating speed (rpm)	827	16,189
Feed per tooth (mm/t)	0.03	0.03
Depth of cut (mm)	1	0.5
Table feed (mm/min)	128	3,454
Parts per tool	1	3
Cutting time (Hrs)	14.3	1.1
Machince cost per part (USD)	139.6	14.3
	Carbide Endmill - Low cutting speed - Only 5 Flutes - Short tool life	CERAMIC Endmill √ High productivity – 7 Flutes √ Economical solution (CPU) √ Extremely fast √ High repeatability

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TEST REPORT - Rough milling
Part name: Engine part
Material: Inconel 718 (AMS 5663)
Machine: DAHLIH 1020 BA
Target: Process improvement

	Competitor	ISCAR Current Grade
Holder	Collet Holder	Hydraulic Holder
Spindle Taper	BT40	BT40
Tool Diameter (mm)	25	12(Ceramic master)
Insert/Tool	JDMT 09T302 VP15TF	EC-E7 12-02C12R1.5N83CE
Grade	VP15TF	IS6
Z (Flutes)	2	7
Vc(m/min)/ RPM	62/800	301/8000
DOC (mm)	0.3	0.3
Feed per tooth (mm/t)	0.25	0.03
Table feed (mm/min)	400	1680
WOC (ae)	12mm (0.5D)	8mm (0.7d)
MRR (cm³/min)	1.44	4.03
Spindle Load		9%
Cycle time	28 Minutes	15 Minutes
Coolant	Wet	Dry (Air for chip evacuation)
	Carbide Insert - Low cutting speed - Short tool life - Only 2 Flutes - Insert for High Feed Cutting	CERAMIC Endmill √ High productivity – 7 Flutes √ Economical solution (CPU) √ Extremely fast repeatable feed √ High repeatability

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