PD1005 / PD1010. DLC-Coated Inserts for Non-Ferrous Metals Welding and chipping resistant coated grades specialized for machining non-ferrous metals
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1 DLC-Coated Inserts for Non-Ferrous Metals Welding and chipping resistant coated grades specialized for machining non-ferrous metals Advanced DLC-Coated Grades Maximized resistance to welding and wear of coating enables quality machining at high speeds Improved chipping resistance due to specialized grades for each workpiece
2 For continuous cutting of aluminum and copper Interrupted machining of forged aluminum alloy, AlSi (< 8%) Advanced DLC-Coated Inserts for Non-Ferrous Metals such as Aluminum and Copper Non-ferrous metals such as aluminum and copper have relatively low melting points, causing heavy welding on the tool edges during machining. The dulled cutting edges bring about poor resulting in unstable tool life. To provide our customers with a satisfactory grade solution for non-ferrous metal machining, KORLOY has developed DLC (Diamond-Like Carbon) coated grades. is a grade for workpieces made of aluminum or copper, and for continuous cutting. The latest DLC coating with maximized wear and welding resistance enables high speed machining for those materials, delivering excellent surface finish in continuous cutting of general non-ferrous metals. is a grade for workpieces made of forged aluminum or AlSi alloy, and for interrupted cutting. The combination of the chipping-resistant substrate and DLC coating greatly improves toughness, providing stable and long tool life in interrupted cutting or when machining nonferrous metals of high hardness. Advanced DLC coating Maximized resistance to wear and welding Advantages Chipping resistant substrate Stable tool life at high interruptions and for non-ferrous metals of high hardness Dedicated grades specialized for non-ferrous metals 02 KORLOY TECH-NEWS
3 Problems When Machining Non-Ferrous Metals 1. Build-up edges 2. Unexpected chipping Development of New PD Series DLC coating Diamond-Like Carbon Amorphous carbon coating with physical properties similar to those of diamonds High hardness and lubrication ideal for nonferrous metal machining with a high probability of build-up edge occurring Rough coating surface General DLC Hardness of coating : 3000 HV Friction coefficient : < 0.25 General DLC coating Ultra-hard H-DLC coating Smooth coating surface Excellent resistance to wear and welding H-DLC Hardness of coating : 6500 HV Friction coefficient : < 0.15 Hard DLC coating Chipping resistant substrate Improved chipping resistance Optimized proportion of WC particles and Co binders for each workpiece material provides improved resistance to chipping and wear. The ultrafine structure which has been made uniform attains stable machinability at all corners. Workpiece AlZn5.5MgCu Cutting conditions vc (m/min) = 1,000 fz (mm/t) = 0.2 ap (mm) = 1.0 ae (mm) = 70, dry Development Effects 1. Improved resistance to welding and chipping 2. Extended tool life Tools XEKT19M508FR-MA PAXCM5100HR-A 60% Average tool life (%) Milling applications of forged aluminum (facing at medium to high speeds) 120% 100% Uncoated carbide Uncoated carbide 03
4 Applicable Products Depth of cut, ap (mm) AK AR Cutting type Turning AK Name AR Feed rate, fn (mm/rev) Pro-X Mill Alpha Mill Future Mill (FMA, FMP) Milling Guideline for Grades Application PD1000 Series Recommended grades by Si content (%) for aluminum alloy Higher speed and feed availability compared to uncoated grades Expanded application range for workpieces of higher Si content Stable and long tool life Cutting speed, vc (m/min) Continuous cutting General cutting Interrupted cutting ND Series (Diamond-coated grades) H01 H Si content (%) Recommended Cutting Conditions Cutting type Turning Milling Workpiece Application C / B Soft, non-ferrous (Si < 4%) Hard, non-ferrous (Si < 8%) Soft, non-ferrous (Si < 4%) Hard, non-ferrous (Si < 8%) Soft, non-ferrous (Si < 4%) Hard, non-ferrous (Si < 8%) Medium cutting Medium to rough cutting General cutting AK AR MA Grade Recommended cutting conditions Turning: fn (mm/rev) vc (m/min) ap (mm) Milling: fz (mm/t) KORLOY TECH-NEWS
![Cutting Performance 38 min [ ] 38 min [ Uncoated carbide ] Performance evaluation of with AK (Turning) Workpiece Cutting conditions Tools Aluminum alloy (AlZn5.5MgCu) Chip removal rate (Q) = 8.](/docs-images/94/121726557/images/5-0.jpg "0 cm 3 /min vc (m/min) = 400 550 500 fn (mm/rev) = 0.2 [] 450 59 min. machined ap (mm) = 1.")
![machined Qtot = 304 Cutting time (min) 11 min [ ] 11 min [ Uncoated carbide ] Performance evaluation of with Pro-X Mill (Milling) Workpiece Cutting conditions Tools Copper (C1020) vc (m/min) = 2000](/docs-images/94/121726557/images/5-2.jpg "fz (mm/t) = 0.1 ap (mm) = 1.")
5 Cutting Performance 38 min [ ] 38 min [ Uncoated carbide ] Performance evaluation of with AK (Turning) Workpiece Cutting conditions Tools Aluminum alloy (AlZn5.5MgCu) Chip removal rate (Q) = 8.0 cm 3 /min vc (m/min) = fn (mm/rev) = 0.2 [] min. machined ap (mm) = Qtot = outside diameter turning, dry Insert : VCGT AK () 200 Holder : SVJCL2525-M % increased cutting volume compared to uncoated grades Chip removal volume ( ) [Uncoated carbide] 38 min. machined Qtot = 304 Cutting time (min) 11 min [ ] 11 min [ Uncoated carbide ] Performance evaluation of with Pro-X Mill (Milling) Workpiece Cutting conditions Tools Copper (C1020) vc (m/min) = 2000 fz (mm/t) = 0.1 ap (mm) = 1.0 ae (mm) = 70, wet Insert : XEKT19M508FR-MA () Holder : PAXCM5100HR-A % more cutting volume compared to uncoated grades Chip removal volume ( ) Chip removal rate (Q) = 44.6 cm 3 /min [] 25 min. machined Qtot = 1133 [Uncoated carbide] 11 min. machined Qtot = Cutting time (min) 71 min 71 min Performance evaluation of with Alpha Mill (Milling) [ ] DLC grade Workpiece Cutting conditions Tools Aluminum alloy (AlMg1SiCu) vc (m/min) = 800 fz (mm/t) = 0.1 ap (mm) = 3.0 ae (mm) = 20, dry Insert : APMT1604PDFR-MA () Holder : AMC3100HS Chip removal rate (Q) = 15.3 cm 3 /min [] 118 min. machined Qtot = Cutting time (min) Chip removal volume ( ) 71 min. machined Qtot = min Performance evaluation of with Pro-X Mill (Milling) [ ] 24 min Workpiece Cutting conditions Tools Aluminum casting alloy vc (m/min) = 200 fz (mm/t) = 0.2 ap (mm) = 2.0 ae (mm) = 50, wet Insert : XEKT19M508FR-MA () Holder : PAXCM5100HR-A Chip removal volume ( ) Chip removal rate (Q) = 12.7 cm 3 /min [] 47 min. machined Qtot = min. machined Qtot = Cutting time (min) 05
6 Application Examples Truck's clutch housing Workpiece luminum die casting alloy, Al-Si8Cu3 (Fe) (Si 8%) Cutting conditions vc (m/min) = 400, fn (mm/rev) = , ap (mm) = , wet Tool Insert : CNMG HA () Holder : PCLNR2525-M12 Competitor 30ea/corner 80ea/corner 166% more 166% more machined workpieces compared to the competitor Automotive aluminum wheel Workpiece Aluminum forged alloy, Al-Si7Mg (Fe) (Si 7%) Cutting conditions vc (m/min) = , fn (mm/rev) = , ap (mm) = , wet Tool Insert : VCGT AR () Holder : S40T-XVXCR-22-DG Competitor 330ea/corner 450ea/corner 36% more 36% more machined workpieces compared to the competitor Automotive differential carrier Workpiece Aluminum forged alloy, Al-Si7Mg (Fe) (Si 7%) Cutting conditions vc (m/min) = 740, fz (mm/t) = 0.15, ap (mm) = , wet Tool Insert : XEKT19M504FR-MA () Holder : PAXS5032HR-A Competitor 480ea/corner 900ea/corner 188% more 188% more machined workpieces compared to the competitor 06 KORLOY TECH-NEWS
7 Available Stock (Turning) Grade Dimensions (mm) Cutting conditions Chip breaker Designation I d t r d1 Feed rate, Depth of cut, fn (mm/rev) ap (mm) Figure AK CCGT AK T302-AK T304-AK AK DCGT AK T302-AK T304-AK T308-AK VCGT AK AK AK AK : Stock item Available Stock (Milling) Grade Dimensions (mm) Cutter Designation I I2 I1 d t r d1 a Figure Pro-X Mill Alpha Mill XEKT 19M504FR-MA M508FR-MA M512FR-MA M516FR-MA M520FR-MA M530FR-MA M532FR-MA M540FR-MA M550FR-MA APMT 1604PDFR-MA SEET 14M4AGFN-MA FMA SDET R-MA FMP : Stock item 07
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