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Wind power industry

Wind power industry
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Wind power industry

Product catalog summary

Global Network and Support

ISCAR maintains a worldwide presence with subsidiaries and agents in 52 industrial countries, including regional offices near customer production sites. Many subsidiaries have training centers to educate metalworking personnel on advanced machining techniques. Manufacturing facilities are distributed across Europe, the Americas, and Asia.

Wind Turbine Components Overview

Wind turbines comprise four main assemblies: rotor (blades and hub), nacelle (housing generators and gearboxes), tower, and balance of system components. Rotor blades capture wind energy with adjustable pitch mechanisms. Towers can reach heights up to 160 meters, supporting blades up to 130 meters in diameter. Wind power is a fast-growing renewable energy source with environmental benefits.

ISCAR's Commitment to Wind Power Manufacturing

ISCAR develops advanced cutting tools and machining methods to improve productivity and competitiveness in manufacturing wind turbine components.

Machining Solutions for Wind Turbine Components

  • Rotor Blade: Slotting cutters (Ø80-250 mm) for rough milling; high-speed face mills (Ø63-125 mm) for finishing aluminum and carbon fiber; SUMOCHAM drills (Ø8-25.9 mm and Ø12-80 mm) with twisted coolant channels for efficient chip evacuation.
  • Blade Adapter: HELIDO face milling tools (Ø16-315 mm and Ø63-315 mm) for 90° milling; SUMOCHAM drills similar to rotor blade ranges.
  • Blade Bearing: Gear gashing slotting cutters (Ø300-420 mm) for gear teeth roughing and finishing; twisted coolant drills (Ø12-80 mm); external rough turning tools; CBN and ceramic inserts for hard turning up to 65 HRc.
  • Rotor Hub: Tangential geometry tools for shouldering, chamfering, rough pocketing (Ø8-125 mm); solid carbide thread mills (Ø4-20 mm); face milling with square/octagonal inserts (Ø40-200 mm); helical interpolation rough boring (Ø20-80 mm); fine boring with ITSBORE system up to Ø2.1 m.
  • Axle Pin (Gearless): Heavy-duty rough and finishing external turning tools; SUMOCHAM drills; made from alloy steel connecting rotor hub and annular generator without gears.
  • Main Shaft: Heavy-duty rough turning tools; finishing tools with tangential inserts; deep drilling via BTA double and single tube systems (Ø18.41-168.99 mm and Ø14.51-245.99 mm); groove-turn tools for superior surface quality; face milling (Ø16-315 mm and Ø63-315 mm); solid carbide thread mills; SUMOCHAM drills; forged hardened steel material.
  • Main Bearing Housing: SUMOCHAM drills (Ø8-25.9 mm); solid carbide thread mills (Ø4-20 mm); chamfering tools with interchangeable heads (Ø6-25 mm).

Key Technologies and Features

  • SUMOCHAM Clamping System: Enhances productivity and increases insert indexing.
  • Twisted Coolant Channels: Improve chip evacuation and drill torsion resistance.
  • HELIDO Milling Tools: 90° milling with helical cutting edges for efficient metal removal.
  • Material Compatibility: Tools designed for aluminum, carbon fiber, bearing steel, hardened steels up to 65 HRc, and other materials.

Machining Tools and Ranges Overview

  • Drilling Tools: Deep drilling (Ø25-65 mm) for milling centers and lathes; standard drilling (Ø12-80 mm) with twisted coolant channels; tower flange drilling (Ø8-25.9 mm) using SUMOCHAM system.
  • Milling Tools: Face milling (Ø16-315 mm and Ø40-200 mm) including HELIDO tools; roughing by helical interpolation (Ø20-80 mm); gear milling with hob indexable cutters (Ø180-450 mm) and special form cutters (Ø210-500 mm); extended flute counter bore milling (Ø16-125 mm).
  • Boring Tools: Fine boring up to Ø1.1 m with aluminum twin cutter heads; rough boring (Ø18-200 mm) with modular insert holders; fine boring (Ø18-500 mm); bearing rolling inner boring for heavy-duty applications.
  • Turning Tools: External rough turning with large inserts; CBN and ceramic hard turning finishing for materials 40-65 HRc; tangentially clamped inserts for high feeds and depths of cut.

Gearbox and Planetary Carrier Components

Planetary gear systems convert low-speed, high-torque rotor rotation to high-speed rotation for generators. The planetary carrier, made of nodular cast iron, is machined using face milling cutters with multiple cutting corners and gear gashing slotting cutters for gear teeth.

Yaw System and Tower Components

  • Yaw System: Orients rotor to wind; made from alloy or bearing steel; machined with gear gashing slotting cutters and drills.
  • Tower Flange: Connects tower sections; made from rolled steel; machined with SUMOCHAM drills; towers range from 50 to over 125 meters tall.

Material Compatibility and Cutting Parameters

Tools support ISO material groups: P (steel), M (stainless steel), K (cast iron), N (non-ferrous metals), S (superalloys), and H (hardened materials). Specialized inserts enable hard turning and finishing at defined hardness levels.

ISCAR 3Productivity Program

  • Focuses on tooling innovation, technical training, and process optimization.
  • Reduces quality control rejects and tool inventory.
  • Improves chip volume capacity and provides cost/efficiency data via CTMS tool management.
  • Includes production audits, new process layouts, tooling cost and ROI proposals, and 24/7 technical support.
  • Aims to optimize production capacity, accelerate delivery, and shorten ROI, especially with composite materials reducing chip volume.

Global Contact and Support

ISCAR headquarters is in Israel, with subsidiaries and offices worldwide providing local technical assistance and supply chain support. The document lists detailed contact information for regional offices across Europe, Americas, Asia, and Africa.

Critical Information Summary

  • Tool diameters range from Ø1.1 mm to Ø1.1 meter for boring.
  • Specialized inserts and geometries enable fast metal removal, high feed rates, and precision finishing.
  • Broad material compatibility including hardened steels and superalloys.
  • Innovative clamping systems like SUMOCHAM enhance productivity and insert indexing.
  • 3Productivity program integrates tooling innovation with training and process optimization to boost manufacturing competitiveness.

Additional Notes

ISCAR reserves the right to modify products without prior notice to ensure continuous improvement.

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Catalog excerpts

Wind power industry-4

Marketing Support Marketing Support & Production Center Right Choice A Global Metalworking Company In a world of different languages and different mentalities, it is important to have a fully equipped, knowledgeable local supplier to meet your needs. ISCAR knows this. We have subsidiary offices and agents located in 52 major industrial countries. In some of the larger countries, regional offices have been opened to bring ISCAR personnel and facilities as close as possible to customer production sites. Many of our subsidiaries have fully equipped training centers. These centers are dedicated to...

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Wind power industry-5

ISCAR has global manufacturing facilities in each of the following countries: In Europe South Korea United States Spain Switzerland Turkey Hungary Slovenia

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Wind power industry-6

Wind Turbine Components Major Components Modern wind turbines employ four major component assemblies - the rotor, nacelle, tower, and balance of system. The rotor includes blades which are used to harness wind energy and convert it into mechanical energy and a hub to support the blades. In addition, most wind turbines have a pitch mechanism to rotate and change the angle of the blades, based on the wind speed and the desired rotating speed. The nacelle is the structure that contains, encloses and supports the components that convert mechanical energy into elecricity. These components include...

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Wind power industry-7

Rotor blade Pitch system Main bearing housing Main shaft

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Wind power industry-8

Rotor Blade Milling - Slotting (Roughing) 1 Slotting cutters with tangentially mounted inserts for precision shallow grooving and slotting applications. Semi-standard PCD tipped inserts on request. Face Milling (Finishing) 2 High speed dynamic balanceable face mills for machining aluminum casting and carbon fiber materials, with interchangeable PCD brazed cartridges.

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Wind power industry-9

Modern commercial-sized turbines are typically three-bladed designs. These are manufactured from fiberglass reinforced polyester with epoxy resin binder. New materials such as carbon fiber are being introduced, which provide the high strength-to-weight ratio needed for modern wind turbine blades. The length of a typical turbine blade can reach 60 meters long, installed in 5 MW machines! SUMOCHAM comprises a revolutionary clamping system that enables improved productivity output rates, while enabling more insert indexes. These drills are designed with twisted coolant channels, allowing a strong...

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Wind power industry-10

Blade Adapter Face Milling 1 HELIDO is a family of tools for 90° milling. The HELIDO H490 ANKX rectangular inserts have 4 helical right-hand cutting edges. 16 economical cutting corners for Fast Metal Removal. Fine pitch 45° face mills are designed for high table speed.

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Wind power industry-11

The rotation platform of the blade pitch system is made of cast iron. ISCAR has all the right technological solutions for the production of blade adapters. SUMOCHAM comprises a revolutionary clamping system that enables improved productivity output rates, while enabling more insert indexes. 3 These drills are designed with twisted coolant channels, allowing a strong body with excellent resistance to torsion and very efficient chip evacuation.

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Wind power industry-12

Blade Bearing Gear Gashing Slotting for Roughing and Finishing Operations 1 Range: Ø300 - 420 mm (Ø11.81 - 16.53”) Gear slotting cutters with tangentially mounted inserts are excellent for rough and finishing a variety of teeth profile modules. These drills are designed with twisted coolant channels, allowing a strong body with excellent resistance to torsion and very efficient chip evacuation. External Rough Turning A line of external and internal tools, as well as large-sized inserts for heavy duty applications.

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Wind power industry-13

Adjusts the angle of the blades by rotating a bearing at the root of each blade. The blade bearing enables to control power and slow the rotor. Made of bearing steel. Inner Boring of Bearing Roll A line of external and internal tools, as well as large-sized inserts for the heavy duty applications. Ceramics - Hard Turning Finishing Operation CBN - Hard Turning Finishing Operation

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Wind power industry-14

4 cutting corners, tangential geometry for Fast Metal Removal at very high material removal rates. A family of tools with shanks that have unique interchangeable heads for a variety of milling applications including ball nose, straight shoulder, slitting and slotting applications. 2 P M K N S H Trigon double-sided insert with 6 edges combines HELIDO’s strength and FEEDMILL’s special geometry to facilitate milling at very high feeds.

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Wind power industry-15

The hub is made of a cast iron case. It generally connects the three blade rotational assembly to a linear low speed shaft, which connects to the turbine’s gearbox. Most modern turbine hubs contain a pitch system to adjust the angle of the blades by rotation of a bearing at the root of each blade, to control power and slow the rotor as required. Mill Threading Range: Ø4 - 20 mm (Ø.157 - .787”) Solid carbide thread mills for the production of small internal threads. The thread mills feature a short 3-tooth cutting zone with 3 flutes and a released neck between the cutting zone and the shank. SUMOCHAM...

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Wind power industry-16

Rotor Hub Face Milling 7 1 S845 SNMU 1305... - square double-sided inserts with 8 cutting edges, or ONMU 0505... octagonal, double-sided inserts with 16 cutting edges. Enable highly efficient milling. Helical Interpolation Rough Boring 8 2 4 cutting corners, tangential geometry for Fast Metal Removal. These drills are designed with twisted coolant channels, which allow for a strong drill body with excellent resistance to torsion and very efficient chip evacuation.

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Wind power industry-17

The hub is made of a cast iron case. It generally connects the three blade rotational assembly to a linear low speed shaft, which connects to the turbine’s gearbox. Most modern turbine hubs contain a pitch system to adjust the angle of the blades by rotation of a bearing at the root of each blade, to control power and slow the rotor as required. Enables internal thread milling and external qualitative precision threads on CNC machines by using a helical interpolation CNC program. MILLTHREAD thread milling cutters are available in addition to solid carbide thread milling cutters with indexable...

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All ISCAR Tools catalogs and technical brochures

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  2. SWISS-CUT

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  3. CUT-GRIP

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  4. TANG-GRIP IQ

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  5. FLASHTURN

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  6. ISCAR INdustry

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  7. catalog 2015

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  8. JET HP Line

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  9. Heat Exchanger

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  10. Milling systems

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  11. TANG-GRIP

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  12. FLASH-TURN

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  13. IQ New Products

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  14. GrooveTurn

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Archived catalogs

  1. THREADING

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  2. MILLING

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  3. Combicham

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.