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New series of cutting materials for the milling of cast iron grades

New series of cutting materials for the milling of cast iron grades

Added to MTDCNC by MAPAL on 05 July 2017

The extensive MAPAL portfolio of ISO tools for milling operations has now been extended with the addition of a new range of cast iron insert grades that cover the bandwidth from GJL and GJV to GJS.

The new inserts provide a significant increase in tool life and a consequent result of improved cost-effectiveness. Moreover, the new product line facilitates higher cutting speeds that will maximise productivity. The insert series is based on a completely new series of carbide substrates. The structures of the carbides have been modelled in such a way that they provide an optimum relationship between ductility and wear resistance.

To maximise the scope of the new grades, MAPAL has engineered the new ISO insert lines to correspond with existing 75 degree face mill cutters as well as MAPAL's renowned 90 degree tangential shoulder milling tools with a tight pitch designation for high feed machining. Furthermore, the new inserts can also be allocated to 45 and 88 degree shoulder milling tools with alternately mounted tangential indexable inserts that enhance the economic benefits of the new grades.  For unprecedented levels of cost effectiveness, radial eight edged inserts can be allocated to MAPAL's 45 degree face mill cutters with an astounding cutting depth of up to 10mm. 

The flexibility to work with the numerous tool holder geometries is afforded by the availability of sintered tangential inserts with four, six or eight cutting edges that are suitable for everything from heavy duty rough machining through to semi-finishing operations.

The insert series includes three PVD-coated carbides and two CVD-coated grades. The PVD coating consists of an optimised TiAlCrN with very fine structuring of the layers to create an optimum relationship between ductility and hardness/wear resistance. The CVD coating is based on an MT-TiCN with an alpha-Al2O3 top coat. This layer combination offers high wear resistance and also good thermal stability.

A special post-treatment has been developed for both the PVD coating and the CVD coating to ensure an extremely smooth surface. This improves chip flow and the evacuation from the work envelope, which minimises tribo-chemical wear. With the CVD coating, the post-treatment additionally sets a selective intrinsic stress in the coating, stabilising the cutting edge or increasing the ductility of the cutting material.

The optimum cutting material for the milling of cast iron grades is therefore available for everything from dry to wet machining and for a very wide range of applications and machine conditions. So, if you want to benefit from a three-fold tool life improvement whilst generating higher cutting speeds and feeds - its time to look at the MAPAL cast iron milling series.

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