In recent years, additive manufacturing (AM), commonly known as 3D printing, has emerged as a transformative
force across various industries, including metalworking. This technology, characterized by its
layer-by-layer material addition process, contrasts with traditional subtractive manufacturing methods and
has introduced a new paradigm in the design and production of metalworking tools. ISCAR's additive
manufacturing is affecting the evolution of metalworking tools, highlighting the benefits, challenges, and
future potential of this innovative approach to assure customers receive tools to increase productivity and
metalworking efficiency.
The aluminum wheels industry is experiencing rapid and sustained growth, driven by the constant demand for
new vehicles across global markets. Consumers increasingly prefer stylish, lightweight, and high-performance
wheels, which has led manufacturers to expand production capacity and adopt more efficient manufacturing
processes. This market expansion, however, comes with intense competition, as manufacturers must balance the
demands for cost efficiency with the need to deliver superior quality. The price of an aluminum wheel is
influenced not only by raw material costs but also by the machining technology and production methods
employed in its manufacture.
Aluminum wheel manufacturers operate in a fast-paced production environment where precision, surface
quality, and cycle times significantly affect profitability. They must meet the automotive industry’s
stringent dimensional and aesthetic standards while ensuring that production remains efficient and
cost-effective. This requires tools and systems that can accommodate high cutting speeds, withstand heavy
cutting forces, maintain consistent performance, and deliver a flawless finish that enhances the wheel’s
appearance (Fig.1). These challenges are compounded by the trend toward mass customization, where different
wheel designs, sizes, and finishes must be produced with minimal downtime and setup changes.
ISCAR addresses these industry needs by providing advanced, cost-effective machining solutions specifically
developed for aluminum wheel production (Fig.2). The company’s tool systems are engineered to optimize
productivity, extend tool life, and consistently produce superior surface quality in demanding machining
operations. ISCAR’s solutions cover the full range of wheel manufacturing processes, including outer
diameter and inner diameter machining, facing, undercutting, and the drilling of valves, lugs, and center
holes.
Among ISCAR’s leading technologies is the DTF Quick Change Toolholder system, designed for speed, stability,
and accuracy in high-volume production (Fig.3). This system is particularly well-suited for automatic
machining stations, where stable tool life is essential. Its user-friendly design allows the operator to
clamp or release tool heads using a single screw, drastically reducing changeover time. The system’s
dovetail face contact provides maximum rigidity and stability, ensuring precise machining under both axial
and radial forces. DTF tools are compatible with ISCAR’s GRIP and ISO insert families and are suitable for
use with emulsion and Minimum Quantity Lubrication (MQL) systems. This makes them a favored choice among
aluminum wheel manufacturers seeking to improve efficiency without compromising performance.
Maintaining the correct temperature during aluminum machining is crucial for achieving the high surface
quality required in wheel production. ISCAR’s DTF tooling integrates a targeted coolant supply that delivers
coolant directly to the cutting edge, reducing heat buildup, improving chip evacuation, and prolonging tool
life. This precision cooling approach supports both productivity and product quality.
In applications requiring the highest possible cutting performance, ISCAR recommends Polycrystalline Diamond
(PCD) inserts. Designed for stability under high cutting conditions, PCD inserts are available in multiple
geometries, including ISO 35° rhombic shapes and full-radius designs, with or without chipbreakers. These
inserts can be used for roughing, semi-finishing, and finishing (Fig.4). Special bright-facing PCD inserts
are also available to prevent surface porosity and burr formation after painting, ensuring that wheels meet
the strict visual standards expected by both automakers and consumers.
For cost efficiency, ISCAR offers the VNGU ISO 35° rhombic insert, which features four cutting edges, a 7°
positive flank, and a very positive rake angle. Its sharp, polished cutting edge is engineered for aluminum
wheel machining, delivering improved chip control under high-pressure coolant, an extended tool life, and
excellent finish—all while lowering per-part costs (Fig.5).
ISCAR also provides a complete range of drilling solutions tailored to the specific needs of aluminum wheel
manufacturers. These drills are designed for the precision machining of center holes, lug holes, valve
holes, and back chamfering. They are available in solid carbide, indexable insert, and PCD-tipped designs,
offering flexibility across varying production requirements.
To ensure peak performance across different aluminum machining conditions, ISCAR’s cutting tool grades are
formulated for specific applications. These include IC20, an uncoated carbide grade for medium to high
cutting speeds; IC04, a hard submicron carbide for titanium, high-temperature alloys, and aluminum; and
IC07, another hard submicron carbide suitable for similar applications at medium to high speeds. The ID5
grade features a PCD brazed tip for very high cutting speeds, while IC1520 is DLC-coated to extend tool life
during medium to high-speed aluminum machining.
In addition, ISCAR places special emphasis on the quality of the cutting edge of the inserts. Most of
ISCAR’s aluminum machining inserts are precision-ground to be extremely sharp, with positive edge geometries
specifically designed to prevent material buildup on the cutting edge. Since aluminum is known to be a
highly adhesive material during machining, these features ensure a clean, smooth, and uninterrupted cutting
process. These are unique grinding profiles developed by ISCAR, providing a significant advantage in
achieving high-quality, stable machining results.
Furthermore, ISCAR’s aluminum inserts are supplied with a polished top surface, which plays a critical role
in facilitating smooth chip flow and preventing chip adhesion. This polished finish reduces friction between
the chip and the insert surface, helping to evacuate chips more efficiently and maintain a clean cutting
zone. This contributes to a softer, cleaner cut and minimizes the risk of built-up edge formation, an
essential factor when machining sticky materials like aluminum.
As vehicle design trends evolve, the demand on aluminum wheel manufacturers will continue to rise. Faster
production cycles, tighter tolerances, and flawless finishes are now industry norms. ISCAR’s integrated
approach combining high cutting speeds, precision coolant delivery, rigid toolholding solutions, and
advanced insert technologies gives manufacturers the competitive edge they need. By equipping production
lines with ISCAR’s specialized tooling systems, aluminum wheel producers can achieve higher productivity,
reduced downtime, extended tool life, and consistently superior results, securing their position in a
rapidly expanding and increasingly demanding global market.
