MK / RK Chip Breaker. Turning Solution for Cast Iron NC6315. MK Chip Breaker. RK Chip Breaker

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Cleopatra Hicks
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MK / Chip Breaker MK Chip Breaker (For medium )

solution for cast iron under high speed, high

Chipping Resistance CVD coated inserts with

Breaker (For rough ) Solutions for Most Common

wear on rake and flank surfaces of insert,

medium ) Chip Breaker (For rough ) Increased

1 MK / Chip Breaker MK Chip Breaker (For medium ) Turning Solution for Cast Iron Advanced turning solution for cast iron under high speed, high feed, and interrupted conditions Higher Wear and Chipping Resistance CVD coated inserts with increased resistance to wear and chipping Chip Breaker (For rough ) Solutions for Most Common Issues in Cast Iron Machining Preventing excessive wear on rake and flank surfaces of insert, chipping and burr creation MK Chip Breaker (For medium ) Chip Breaker (For rough ) Increased Productivity chipping resistance Increased wear resistance Increased High quality surface finish

MK Chip Breaker Chip Breaker For medium For rough For ductile cast iron and gray cast iron components for automobiles and machinery CVD Coated Grade for High Efficiency and Quality Turning

Ductile cast iron is commonly used in automobile and machinery components which require high resistance to heat and corrosion.

and magnesium(mg) easily causing built-up edges between the tool and chips.

In contrast, gray cast iron is an acicular carbide readily chips and causing less built-up edges than ductile cast iron.

$It secures stable antifracture capability even with highly interrupted cast iron materials and with severe vibrations, making good use of the combination of a universal grade and new CVD coated$ $chip breaker features wide lands and supporting area that provide excellent toughness and fracture resistance under high force such as high depth of cuts or high interruption.$

2 MK Chip Breaker Chip Breaker For medium For rough For ductile cast iron and gray cast iron components for automobiles and machinery CVD Coated Grade for High Efficiency and Quality Turning Application of Cast Iron Cast iron refers to ferrous metal that contains more than 2% of carbon and can be sorted into ductile cast iron and gray cast iron. Ductile cast iron is commonly used in automobile and machinery components which require high resistance to heat and corrosion. Ductile cast iron is known for damage on edge due to chipping on the rake and flank surface of an insert, or welding, more frequently than gray cast iron, it s spheroidal carbide contains silicon(si) and magnesium(mg) easily causing built-up edges between the tool and chips. Moreover it is prone to age hardening, the hardness of a cast iron workpiece increases at room temperature, or unstable tool life according to seasons. In contrast, gray cast iron is an acicular carbide readily chips and causing less built-up edges than ductile cast iron. is a K15 grade with largely enhanced resistance to chipping and wear in high feed and highly interrupted machining of ductile cast iron and gray cast iron. It secures stable antifracture capability even with highly interrupted cast iron materials and with severe vibrations, making good use of the combination of a universal grade and new CVD coated layers. MK chip breaker improves performance and reduces load during cast iron machining, leading to higher wear resistance and quality surface finish at high speed and continuous. A wide supporting area was designed for solving unexpected tool breakage and edge chipping due to vibrations during machining, improving stability. chip breaker features wide lands and supporting area that provide excellent toughness and fracture resistance under high force such as high depth of cuts or high interruption. Its land was engineered to optimize edge toughness and performance, and achieve stable tool life and higher chipping resistance for high feed applications. The combination of MK / chip breakers and answers your needs for higher productivity and high quality results. Minimized quality deviation Stable tool life Optimized blade design Improved surface finish Advantages Good combination of a grade and chip breakers Extended tool life and enhanced performance Wide availability to various cast iron components Universal use responding to workpiece change 02 KORLOY TECH-NEWS

CVD Coated Grade K Common Problems When Machining

Excessive flank wear Built-up Excessive flank wear

layers 1 An alumina layer with better surface

$anti-fracture 3 A functional substrate with$ optimized combination of hardness and toughness

exceptional performance Higher productivity

ductile / gray cast iron at high speed over vc =

built-up edges Augmented tool life stability and

Improved resistance to wear and flaking Stronger

3 CVD Coated Grade K Common Problems When Machining Cast Iron 1. Rake surface wear and built-up edge 2. Excessive flank wear Built-up Excessive flank wear Rake surface wear Development of the New coating layers 1 An alumina layer with better surface finish and increased resistance to wear and welding 2 A titanium layer with stronger anti-fracture 3 A functional substrate with optimized combination of hardness and toughness Optimized CVD coated layers Extended life and exceptional performance Higher productivity Excellent wear resistance in highly interrupted of ductile / gray cast iron at high speed over vc = 350m/min Upgraded alumina coating layer Minimizes built-up edges Augmented tool life stability and wear resistance Development Effect 1. Improved resistance to wear and flaking Stronger flaking resistance Stronger resistance to rake surface 2. Enhanced wear resistance Nomal wear on the flank 03

MK Chip Breaker (for medium ) K Ideally suited for continuous of ductile cast iron and gray cast iron Angle lands provide upgraded surface finish MK Chip Breaker

supporting area Higher clamping stability Prevents chipping at vibrations during operation [ Code system of chip breakers ] M K [ Workpiece material ] P: Steel

ap(mm) 7.0 6.0 5.0 4.0 3.0 2.0 1.0 Recommended Cutting Range MK 0.0 0.1 0.2 0.3 0.4 0.5 0.

4 MK Chip Breaker (for medium ) K Ideally suited for continuous of ductile cast iron and gray cast iron Angle lands provide upgraded surface finish MK Chip Breaker Features Angle land Sharper performance thanks to applied angle lands Maximized wear resistance in continuous High quality results in surface finish Wide supporting area Higher clamping stability Prevents chipping at vibrations during operation [ Code system of chip breakers ] M K [ Workpiece material ] P: Steel M: Stainless steel K : Cast iron [ Application range ] M: Medium R: Roughing Continuous General Interrupted Application Range MK MK Medium Roughing Depth of cut, ap(mm) Recommended Cutting Range MK Feed, fn(mm/rev) Recommended Cutting Conditions Recommended Cutting Conditions Application For medium Chip breaker Depth of cut, ap(mm) Feed, fn(mm/rev) Min. Recommended Max. Min. Recommended Max. MK KORLOY TECH-NEWS

Chip Breaker (for roughing) K Ideally suited for high speed / high feed of ductile cast

Chip Breaker Features Flat land Upgraded toughness and chipping resistance thanks to

or interrupted Optimized land width for high feed machining Wide supporting area Higher

chip breakers ] R K [ Workpiece material ] P: Steel M: Stainless steel K : Cast iron [

Range MK MK Medium Roughing Depth of cut, ap(mm) 7.0 6.0 5.0 4.0 3.0 2.0 1.

6 Feed, fn(mm/rev) Recommended Cutting Conditions Recommended Cutting Conditions

5 Chip Breaker (for roughing) K Ideally suited for high speed / high feed of ductile cast iron and gray cast iron Flat lands provide upgraded toughness and chipping resistance Chip Breaker Features Flat land Upgraded toughness and chipping resistance thanks to flat lands applied Stable machining availability under high loads at high depth of cuts or interrupted Optimized land width for high feed machining Wide supporting area Higher clamping stability Prevents chipping at vibrations during operation [ Code system of chip breakers ] R K [ Workpiece material ] P: Steel M: Stainless steel K : Cast iron [ Application range ] M: Medium R: Roughing Continuous General Interrupted Application Range MK MK Medium Roughing Depth of cut, ap(mm) Recommended Cutting Range MK Feed, fn(mm/rev) Recommended Cutting Conditions Recommended Cutting Conditions Application Chip breaker Depth of cut, ap(mm) Feed, fn(mm/rev) Min. Recommended Max. Min. Recommended Max. For roughing

Cutting Performance Impact resistance test Built-up edges easily occur when machining ductile cast iron in high

welding Exceptional chipping resistance Workpiece Cutting conditions Cutting time Tools 500-7(ISO), Ø90 (Triangular tube)

35, ap(mm) = 2, wet 15 passes with results of normal rake surface wear and good chipping resistance Insert CNMG120408- ()

stability and wear resistance [ Existing Product ] () [ () ] 130% increased chipping resistance Existing product No.

cast iron MK chip breaker with angle lands applied Reduces load and built-up edge Workpiece Cutting conditions Cutting

6 Cutting Performance Impact resistance test Built-up edges easily occur when machining ductile cast iron in high interruption Vulnerable to flaking of rake surface coatings An alumina coating applied to improve resistance to wear and welding Exceptional chipping resistance Workpiece Cutting conditions Cutting time Tools 500-7(ISO), Ø90 (Triangular tube) Ø30 machining vc(m/min) = 380, fn(mm/rev) = 0.35, ap(mm) = 2, wet 15 passes with results of normal rake surface wear and good chipping resistance Insert CNMG () Holder DCLNR2525-M12 A functional substrate with optimized combination of hardness and toughness Augmented tool life stability and wear resistance [ Existing Product ] () [ () ] 130% increased chipping resistance Existing product No. of Pass [ chipping ] Flank wear, edge peeling by chips and fine chipping occur in continuous of ductile cast iron MK chip breaker with angle lands applied Reduces load and built-up edge Workpiece Cutting conditions Cutting time Tools Wear resistance test 500-7(ISO), Ø90 (Spherical tube) Ø30 machining vc(m/min) = 400, fn(mm/rev) = 0.35, ap(mm) = 2.5, wet 30 passes with results of normal wear on rake / flank surface Insert CNMG MK () Holder DCLNR2525-M12 Coating layers with exceptional welding resistance Reduced edge peeling and fine chipping [ Existing Product ] [ MK() ] MK() 125% increased flank wear resistance Existing product No. of Pass KORLOY TECH-NEWS

: The first recommended grade for general Continuous General Interrupted Application Range Medium Roughing High hardness / High speed Cutting speed, vc(m/min) 600 500 400 300 200 100 Recommended

AC415K Comparison of Turning Chip Breakers for Cast Iron (Negative Type) MK : The first recommended chip breaker for general : A chip breaker for high feed and highly interrupted Application Medium

7 : The first recommended grade for general Continuous General Interrupted Application Range Medium Roughing High hardness / High speed Cutting speed, vc(m/min) Recommended Cutting Range Continuous General Interrupted Feed, fn(mm/rev) High toughness / High interruption Grade Comparison ISO KORLOY A B C D E F G K15 TT7015 GC3225 CA4515 CA315 UC5115 MC5015 TK2001 WKK20S AC415K Comparison of Turning Chip Breakers for Cast Iron (Negative Type) MK : The first recommended chip breaker for general : A chip breaker for high feed and highly interrupted Application Medium to finishing Roughing KORLOY A B C D E F G MK MT KM, KF KG, KQ MK, LK M5 NM5 UZ RT, KT KR KH MR7 -MA GZ Comparison of Turning Chip Breakers for Cast Iron (Positive Type) Application Medium to finishing Roughing KORLOY A B C D E F G MP MT KM GK, HQ MK F2 PM5 MU C25 - KR All round -MW - -MW -MW 07

8 Recommended Cutting Conditions This table refers to recommended conditions for maximizing tool life and productivity in medium and/or rough with (K15). It is advised to utilize this information depending on your working environment. GCD (Ductile cast iron) Workpiece (ISO) Tensile strength (N/mm²) Hardness (HB) Recommended speed, vc(m/min) Min. Recommended Max ~ ~ ~ ~ ~ GC (Gray cast iron) Recommended Cutting Conditions Application For medium Chip breaker Depth of cut, ap(mm) Feed, fn(mm/rev) Min. Recommended Max. Min. Recommended Max. MK For roughing KORLOY TECH-NEWS

Application Examples Brake disk Workpiece Cutting conditions Tools () Gray cast iron (250) vc(m/min) = 550, n(rpm) = 547, fn(mm/rev) = 0.

case mission Workpiece Cutting conditions Tools MK() Ductile cast iron (500-7) vc(m/min) = 250, n(rpm) = 800, fn(mm/rev) = 0.25, ap(mm) = 1.

Ductile cast iron (500-7) vc(m/min) = 400, n(rpm) = 398, fn(mm/rev) = 0.

9 Application Examples Brake disk Workpiece Cutting conditions Tools () Gray cast iron (250) vc(m/min) = 550, n(rpm) = 547, fn(mm/rev) = 0.3, ap(mm) = 3, wet Insert CNMG () Holder DCLNR % 30ea/edge more 24ea/edge 25% longer tool life compared to the competitor Diff. case mission Workpiece Cutting conditions Tools MK() Ductile cast iron (500-7) vc(m/min) = 250, n(rpm) = 800, fn(mm/rev) = 0.25, ap(mm) = 1.5, wet Insert CNMG MK () Holder DCLNR % 100ea/edge more 70ea/edge 30% longer tool life compared to the competitor Fly wheel Workpiece Cutting conditions Tools Ductile cast iron (500-7) vc(m/min) = 400, n(rpm) = 398, fn(mm/rev) = 0.3, ap(mm) = 2, wet Insert CNMA () Holder DCLNR % 35ea/edge more 30ea/edge 16% longer tool life compared to the competitor Knuckle Workpiece Cutting conditions Tools MK() Ductile cast iron (500-7) vc(m/min) = 200, n(rpm) = 1100, fn(mm/rev) = 0.25, ap(mm) = 2, wet Insert DNMG MK () Holder DDJLNR % 110ea/edge more 90ea/edge 22% longer tool life compared to the competitor 09

10 Available Stock [Negative] Coated Dimensions (mm) Cutting conditions (mm) Type Designation I d t r d₁ Depth of cut, ap(mm) Feed, fn(mm/rev) Figure V type T type S type D type C type CNMG MK ~ ~ MK ~ ~ MK ~ ~ ~ ~ ~ ~ ~ ~0.63 CNMA ~ ~ ~ ~ ~ ~0.70 DNMG MK ~ ~ MK ~ ~ MK ~ ~ ~ ~ ~ ~0.53 DNMA ~ ~ ~ ~0.65 SNMG MK ~ ~ MK ~ ~ ~ ~ ~ ~ ~ ~0.53 SNMA ~ ~ ~ ~ ~ ~0.80 TNMG MK ~ ~ MK ~ ~ MK ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~0.63 TNMA ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~0.55 VNMG MK ~ ~ MK ~ ~ MK ~ ~0.50 : Managed stock 10 KORLOY TECH-NEWS

11 Available Stock [Negative] (mm) Coated Dimensions (mm) Cutting conditions Type Designation I d t r d₁ Depth of cut, ap(mm) Feed, fn(mm/rev) Figure W type WNMG MK ~ ~ MK ~ ~ MK ~ ~ ~ ~ ~ ~ ~ ~0.60 WNMA ~ ~ ~ ~ ~ ~0.70 Available Stock [Positive] (mm) Coated Dimensions (mm) Cutting conditions Type Designation I d t r d₁ Depth of cut, ap(mm) Feed, fn(mm/rev) Figure V type T type S type D type C type CCMT MP ~ ~ MP ~ ~ T304-MP ~ ~ T308-MP ~ ~ MP ~ ~ MP ~ ~ C ~ ~ T304-C ~ ~ T308-C ~ ~ C ~ ~ C ~ ~0.36 DCMT 11T304-MP ~ ~ T308-MP ~ ~ T304-C ~ ~ T308-C ~ ~0.30 SCMT 09T304-MP ~ ~ T308-MP ~ ~ MP ~ ~ T304-C ~ ~ T308-C ~ ~ C ~ ~0.38 TCMT 16T304-MP ~ ~ T308-MP ~ ~ T304-C ~ ~ T308-C ~ ~0.30 VCMT MP ~ ~ MP ~ ~0.25 : Managed stock 11

12 Holystar B/D, 1350, Nambusunhwan-ro, Geumcheon-gu, Seoul, 08536, Korea Tel : Fax : , Web : export@korloy.com 620 Maple Avenue, Torrance, CA 90503, USA Tel : Toll Free : Fax : sales@korloy.us Plot NO.415, Sector 8, IMT Manesar, Gurgaon , Haryana, INDIA Tel : Fax : sales.kip@korloy.com Gablonzer Str , Oberursel, Germany Tel : Fax : sales@korloyeurope.com Av. Aruana 280, conj.12, WLC, Alphaville, Barueri, CEP , SP, Brasil Tel : vendas@korloy.com TN54-EM-01 /

MP / LP Chip Breaker. Turning Insert for Machining Automobile Components. MP (Negative) MP (Positive) LP (Negative)

MP / LP Chip Breaker. Turning Insert for Machining Automobile Components. MP (Negative) MP (Positive) LP (Negative) MP (Negative) For medium cutting MP (Positive) For medium cutting Turning Insert for Machining Automobile Components Complete turning solution to increase productivity at a wide range of cutting speed,