ISCAR
430
TEXT
USER GUIDE
GROOVE-TURN
JETCUT Tools High-Pressure (up to 340 bar)
The high-pressure coolant feature has been in existence
for a long time in the metal removal world, taking a bigger
role in today’s machining. ISCAR was one of the first
cutting tools companies to respond to market needs by
designing and producing tools for ultra-high and high-
pressure coolant flow. High-pressure coolant was initially
implemented mainly for difficult-to-machine materials
such as Titanium, Inconel and other heat resistant alloys.
Later it was found that tool life, productivity and chip
control can be improved when machining stainless and
alloyed steel. JETCUT tools are essential and important
in the aviation, aerospace and medical industries.
How does it work?
The stream velocity of the coolant emitted from the pump
increases as the coolant holes become smaller. When it
emerges out of the tool through the nozzle, the velocity
is very high, exerting considerable force on the chips,
lowering their temperature and protecting the cutting edge
from thermal shock. High temperature alloys produce a
very high temperature as they are being cut. By effectively
removing the heat, the chips become less ductile and thus
easier to break. Shorter chips are easily managed, they
do not tangle around the workpiece or machine parts, so
there is no need to stop the process frequently. Usually in
conventional cooling the chip prevents the coolant from
reaching the insert rake face in the cutting zone. The
coolant stream of the JETCUT tools is directed precisely
between the insert rake face and the flowing chip. This
results in longer tool life and a much more reliable process.
The coolant channels of the JETCUT tools
feature outlets very close to the cutting edges,
thus gaining the following advantages:
• Shorter machining time – the cutting speed
may be increased by up to 200% when
machining Titanium & heat resistant alloys
• Longer tool life – tool life increases by up to
100% not only on Titanium and heat resistant
alloys, but also on stainless and alloy steels
• Improved chip control – even on the most ductile and
problematic materials, small chips can be obtained
• Very effective cooling down of the cutting edge,
which reduces sensitivity to heat fluctuations
• Safer and more stable process
JETCUT tools provide advantageous performance also when
conventional pressure is applied.
General Information
Pressure Ranges
Up to 30 bar – Low pressure (LP) may provide some
improvement in tool life. Usually will not have an effect on
chip control. 30 – 120 bar – High-pressure (HP) the most
commonly used pressure range used with JETCUT tools.
Increase in tool life, increase in cutting speeds, improved
chip control. 120 – 400 bar – Ultra high-pressure (UHP)
requires special tool design in order to take advantage
of the extra pressure. Minor increase in tool life compared
to HP range. Ultra high-pressure coolant is usually
implemented for machining Titanium and heat resistant
alloys when there is a need for very small chips and higher
machining rates.
Since 2000, ISCAR has provided hundreds of
special tools featuring ultra high-pressure coolant
capability for various customers and applications.
Pressure vs. Flow
Each JETCUT tool is designed to work at a certain flow
rate, depending on the pressure. The flow rates are listed
in the catalog pages for each tool. The user should verify
that the pump can supply the required flow in order to
achieve the optimal results. The pump data sheet will
usually list the maximum flow rate for each pressure range.
Chips & Pressure
The coolant flow will start to break the chips at a
certain pressure, depending on the specific tool and
the workpiece material. If the chips are not breaking,
the pressure should be increased until chip control
is achieved. Above this pressure, as it is increased
the chips become smaller and smaller. It is possible
to control the size of the chips by modifying the
pressure in order to achieve the desired chip size.
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