KYOCERA Introduces New Industrial Cutting Tools for Cast Iron Machining

Kyocera MFK milling tools reduce costs, improve quality in machining workpieces of complex-shaped cast iron

02 February 2015

Kyoto/Neuss – Kyocera Corporation today launched 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.

NameCast iron milling cutter (MFK)
ModelsToolholders: 24 models
(custom designs available separately)
Inserts: Offered in 4 chipbreakers and 3 grades
Recommended work materialGray and ductile cast irons
Production facilityShiga Yohkaichi Plant (toolholders)
Kagoshima Sendai Plant (inserts)


Development Background

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.

New Product Outline

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.

Kyocera’s MFK milling cutters offer improved quality and better cost performance in machining cast iron, with higher productivity in conditions ranging from roughing to finishing.

New Product Features

Double-sided, 10-corner negative inserts provide quality and cost benefits

1.1 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.

1.2 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.

2. Newly developed CVD material for cast-iron milling offers long tool life and stable machining

Kyocera has added the new CA420M 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. Improved abrasion resistance, essential in machining cast iron, will allow CA420M to deliver better cost performance, longer tool life and a more stable machining process.

3. Accommodates a wide range of cast-iron machining conditions, from roughing to finishing

Kyocera’s extensive lineup of milling cutters, insert shapes, and grades ensures an ideal combination to cover a wide range of conditions, from cast iron roughing to finishing. The MFK family of products is comprehensively designed to help improve customer productivity.

*The Chemical Vapor Deposition coating method allows multiple layers of different materials, resulting in thicker film.

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