Insert Series for Turning Application of Hard-to-cut Materials

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1 / / Insert Series for Turning Application of Hard-to-cut Materials VP2 Chip Breaker (For medium to finishing) Chip Breaker (For finishing) A Solution for Machining Hard-to-cut Materials PC8100 Series Exclusive grades for turning application of heat resistant alloy and stainless steel VP3 Chip Breaker (For medium ) / Exclusive grades for machining titanium alloy VP Series Chip Breaker Higher productivity and stable machining due to excellent chip evacuation at high temperature VP2 VP3

Insert Series for Turning Application of Hard-to-cut Materials High Performance PVD Coated Turning Insert for Hard-to-cut Materials such

) causes high force and temperature on edges when being operated resulting from its properties of high strength at high temperature and

In addition, it accompanies chipping, breakage or notch wear in accordance with depth of cut due to thermal shock and work hardening.

PC8100 Series (VP2 chip breaker) PC8100 Series (VP3 chip breaker) For medium to finishing For medium, and are PVD turning grades for Heat

(S05) is a grade used for finishing heat resistant alloy and stainless steel with its characteristics of wear resistance in continuous

(S10) is an universal grade used for medium to finish of heat resistant alloy and stainless steel with its characteristics of wear

(S15) is an universal grade used for finish, medium and roughing of heat resistant alloy and stainless steel with its characteristics of

2 Insert Series for Turning Application of Hard-to-cut Materials High Performance PVD Coated Turning Insert for Hard-to-cut Materials such as Heat Resistant Alloy and Stainless Steel PC8100 Series ( chip breaker) For finishing (Continuous ) Heat resistant alloy(inconel, etc.) causes high force and temperature on edges when being operated resulting from its properties of high strength at high temperature and low heat conductivity. Therefore, velocity should be decreased as tools go worn out. In addition, it accompanies chipping, breakage or notch wear in accordance with depth of cut due to thermal shock and work hardening. Thus, it is so important to select the most proper chip beaker and grade depending on your velocity and length and the other factors. PC8100 Series (VP2 chip breaker) PC8100 Series (VP3 chip breaker) For medium to finishing For medium, and are PVD turning grades for Heat resistant alloy. (S05) is a grade used for finishing heat resistant alloy and stainless steel with its characteristics of wear resistance in continuous operation at high speed and high temperature. (S10) is an universal grade used for medium to finish of heat resistant alloy and stainless steel with its characteristics of wear resistance and chipping resistance in continuous operation at mid to high speed and high temperature. (S15) is an universal grade used for finish, medium and roughing of heat resistant alloy and stainless steel with its characteristics of wear resistance and chipping resistance in various machining conditions. Stable tool life Higher productivity Advantages Longer tool life and high removal rate Difficult conditions possible and shortened time Perfect harmony between grades and chip breakers Increased tool life Various operation range such as finishing and roughing Proper to machine heat resistant alloy and stainless steel Responsive to a wide range of hard-to-cut materials 02 KORLOY TECH-NEWS

50 th Anniversary Troubles when Machining Hard-to-cut Materials 1.

$Chipping / fracture Hard-to-cut materials(inconel, etc.$ This results in concentrated heat on edges and thus rapid wear at a

In addition, thermal impact and work hardening cause involve

Development of PC8100 Series It prevents wear at a high temperature

stability between corners and improve chipping and wear resistance

Soft coating surface [ PC8100 Series ] Improved lubrication Rough

technology (Pictures of coating layer heat-treated at 900 C)

3 50 th Anniversary Troubles when Machining Hard-to-cut Materials 1. Severe wear 2. Chipping / fracture Hard-to-cut materials(inconel, etc.) feature high hardness and low heat conductivity. This results in concentrated heat on edges and thus rapid wear at a high temperature over 800. In addition, thermal impact and work hardening cause involve chipping or breakage according to the depth of cut. Development of PC8100 Series It prevents wear at a high temperature to apply excellent surface roughness and coating with oxidation resistance and high hardness. It improves wear resistance to equalize submicron matrix, secure stability between corners and improve chipping and wear resistance Coating surface treatment technology (Pictures of coating layer) Soft coating surface [ PC8100 Series ] Improved lubrication Rough coating surface [ Conventional coating ] Oxidation resistant coating technology (Pictures of coating layer heat-treated at 900 C) Improved oxidation resistance Oxidized layer is prevented. [ PC8100 Series ] Oxidized layer easily happens [ Competitor ] Development Effect 1. Increased wear resistance 2. Reduced chipping / fracture Reduced wear Reduced chipping [ ] [ Competitor S05 ] [ ] [ Competitor S15 ] / / 03

Insert Series for Turning Application of Hard-to-cut Materials / ( chip breaker) For finishing (Continuous ) Carbide Insert Exclusive for Turning Application of Titanium Alloy Titanium

actions. Its characteristics of low heat conductivity and high work hardening trigger notch wear, while the low elasticity is blamed for elastic recovery and bending of workpieces.

Therefore, it is important to select the best combination of exclusive grade and chip breaker for machining titanium alloy.

return increases tool life. (S05) is a grade used for finishing titanium alloy with its characteristics of a sharp edge in continuous operation at high speed.

On top of that, we recommend a PVD coated universal grade, in interrupted machining or roughing of titanium alloy.

4 Insert Series for Turning Application of Hard-to-cut Materials / ( chip breaker) For finishing (Continuous ) Carbide Insert Exclusive for Turning Application of Titanium Alloy Titanium alloy is highly responsive to chemicals and built-up edges on blades frequently happen during operation, which in result causes rapid increase of loads or unnecessary overlapped actions. Its characteristics of low heat conductivity and high work hardening trigger notch wear, while the low elasticity is blamed for elastic recovery and bending of workpieces. This is why chipping on edges or breakage occurs on tools during operation. Therefore, it is important to select the best combination of exclusive grade and chip breaker for machining titanium alloy. / (VP2 chip breaker) For medium to finishing and are specially designed for titanium alloy operation with its special surface treatment to prevent built-up edges and breakage, which in return increases tool life. (S05) is a grade used for finishing titanium alloy with its characteristics of a sharp edge in continuous operation at high speed. / (VP3 chip breaker) For medium (S15) is a grade highly recommended for medium to finishing of titanium alloy in various machining conditions. On top of that, we recommend a PVD coated universal grade, in interrupted machining or roughing of titanium alloy. / - Exclusive Grade for Machining Titanium Alloy Cemented carbide substrate applied Special surface treatment / sharp edge Excellent chipping & wear resistance Excellent welding & wear resistance Troubles when Machining Titanium and Development Effect Titanium alloy features high hardness and low heat conductivity. This results in concentrated heat on edges and thus rapid wear and flaking derived from built-up edge. Excellent welding & wear resistance Competitor A Competitor B 04 KORLOY TECH-NEWS

5 50 th Anniversary Features of VP Chip Breakers Advanced technology enables sharp edges and minimized heat. (For finishing-continuous ) Cutting edges designed in high-positive Reduced contact area between rake surface and chip minimizes heat and improved tool life. Recommended conditions = 0.05~0.2, = 0.1~1.5 VP2 (For medium to finishing) Cutting edges designed in high-positive / Side rake angle applied Stable chip control improves machinability when ball machining at variable depth of cut. Recommended conditions = 0.1~0.4, = 0.5~4.5 VP3 (For medium ) Cutting edges designed in high-positive / Wide land applied Improved stability at interrupted when toughness is required. Stable chip control and machinability at high depth of cut. Recommended conditions = = 0.1~0.45, = 0.5~5.0 Chip Breaker Line-up [ Heat resistant alloy and stainless steel ] Negative Positive Continuous VP2 VP3 MP Continuous VL MP General VP2 VP3 MP General VL MP Interrupted VP2 VP3 MP Interrupted VL MP Finishing (~1.0mm) Medium to finishing (~1.5mm) Chip Breaker Line-up [ Titanium alloy ] Negative Medium (~3.0mm) Roughing (~5.0mm) Finishing (~1.0mm) Medium to finishing (~1.5mm) Positive Medium (~2.5mm) Continuous VP2 VP3 Continuous VL General VP2 VP3 General VL Interrupted VP2 VP3 Interrupted MP Finishing (~1.0mm) Medium to finishing (~1.5mm) Medium (~3.0mm) Finishing (~1.0mm) Medium to finishing (~1.5mm) * Detailed recommended depth of cut per designation and insert shape differ according to nose R. Please see page 11~15p. / / 05

Insert Series for Turning Application of Hard-to-cut Materials Performance Test surface roughness performance test Inconel718 vc(m/min) = 60, = 0.1, = 0.

High precision and high quality machining 10 μm [ KORLOY ] [ Competitor ] VP2 tool life test X5CrNi18-9 / X5CrNiMo17-12-2 vc(m/min) = 200~120, = 0.25, = 1.

Wear on rake surface prevented [ KORLOY (After 300 passes) ] [ Competitor (After 300 passes) ] VP3 tool life test Inconel718 vc(m/min) = 60, = 0.2, = 2.

6 Insert Series for Turning Application of Hard-to-cut Materials Performance Test surface roughness performance test Inconel718 vc(m/min) = 60, = 0.1, = 0.2, wet Insert CNGG () Holder DCLNR2525-M12 chip breaker enables high precision and high quality machining. High precision and high quality machining 10 μm [ KORLOY ] [ Competitor ] VP2 tool life test X5CrNi18-9 / X5CrNiMo vc(m/min) = 200~120, = 0.25, = 1.5, dry Insert CNMG VP2 () Holder DCLNR2525-M12 VP2 chip breaker prevents wear on rake surface of insert with excellent chip control when machining HRSA. Wear on rake surface prevented [ KORLOY (After 300 passes) ] [ Competitor (After 300 passes) ] VP3 tool life test Inconel718 vc(m/min) = 60, = 0.2, = 2.0, wet Insert CNMG VP3 () Holder DCLNR2525-M12 VP3 chip breaker prevents notch wear with sharp edges and wide land. CNMG VP3 Reduced notch wear CNMG [ KORLOY (After 10 passes) ] [ Competitor (After 7 passes) ] 06 KORLOY TECH-NEWS

50 th Anniversary Performance Test tool life test Inconel718 vc(m/min) = 50, = 0.

5, wet Insert CNMG120408-VP3 () Holder PCLNR2525-M12 [ Machining type ] Chip

75cm 3 /min 24% longer tool life 34min machining Qtot=126cm 3 42min machining

A(S05) 34min 90 70 50 Competitor B(S05) 34min 10 20 30 40 50 Cutting time (min)

25cm 3 /min 43% longer tool life 6min machining Qtot=70cm 3 5min machining

7 50 th Anniversary Performance Test tool life test Inconel718 vc(m/min) = 50, = 0.15, = 0.5, wet Insert CNMG VP3 () Holder PCLNR2525-M12 [ Machining type ] Chip removal rate(cm 3 ) Chip removal rate(q) = 3.75cm 3 /min 24% longer tool life 34min machining Qtot=126cm 3 42min machining Qtot=157cm 3 34min machining Qtot=126cm 3 (VP3) 42min Reduced wear Competitor A(S05) 34min Competitor B(S05) 34min Cutting time (min) (VP3) Competitor A(S05) Competitor B(S05) tool life test Inconel718 vc(m/min) = 50, = 0.15, = 1.5, wet Insert CNMG VP3 () Holder PCLNR2525-M12 [ Machining type ] Chip removal rate(cm 3 ) Chip removal rate(q) = 11.25cm 3 /min 43% longer tool life 6min machining Qtot=70cm 3 5min machining Qtot=60cm 3 9min machining Qtot=100cm 3 (VP3) 9min Reduced chipping Competitor(S15) 6min 40 Conventional grade 5min Cutting time (min) (VP3) Conventional grade Competitor (S15) / / 07

Insert Series for Turning Application of Hard-to-cut Materials

type ] Chip removal rate(cm 3 ) 400 350 300 250 200 150 Chip

machining Qtot=184cm 3 67min machining Qtot=335cm 3 () Reduced

machining Qtot=80cm 3 Competitor (C/B for medium ) 34min 10 30

tool life test Ti-6Al-4V vc(m/min) = 80, = 0.2, = 2.

type ] Chip removal rate(cm 3 ) 110 100 90 80 70 60 50 Chip

25cm 3 /min 43% longer tool life 6min machining Qtot=70cm 3 5min

8 Insert Series for Turning Application of Hard-to-cut Materials Performance Test tool life test Ti-6A-4V vc(m/min) = 100, = 0.1, = 0.5, wet Insert CNMG () Holder PCLNR2525-M12 [ Machining type ] Chip removal rate(cm 3 ) Chip removal rate(q) = 5cm 3 /min 82% longer tool life 34min machining Qtot=184cm 3 67min machining Qtot=335cm 3 () Reduced wear (VP3) 67min Reduced built-up edge 16min min machining Qtot=80cm 3 Competitor (C/B for medium ) 34min Cutting time (min) () (VP3) Competitor (C/B for medium ) tool life test Ti-6Al-4V vc(m/min) = 80, = 0.2, = 2.0, wet Insert CNMG VP3 () Holder PCLNR2525-M12 [ Machining type ] Chip removal rate(cm 3 ) Chip removal rate(q) = 11.25cm 3 /min 43% longer tool life 6min machining Qtot=70cm 3 5min machining Qtot=60cm 3 9min machining Qtot=100cm 3 (VP3) Competitor A 9min Reduced wear and built-up edge 6min 40 Competitor B 5min Cutting time (min) (VP3) Competitor A Competitor B 08 KORLOY TECH-NEWS

50 th Anniversary Application Example Pipe ring Competitor Inconel718, H RC 46, Ø300 vc(m/min) = 30, = 0.2, = 1.

Competitor X2CrNiMo17-12-2, H RC 22, Ø30 vc(m/min) = 80, = 0.2, = 7.

Competitor Ti-6Al-4V, H RC 50, Ø200 vc(m/min) = 60, = 0.2, = 0.

9 50 th Anniversary Application Example Pipe ring Competitor Inconel718, H RC 46, Ø300 vc(m/min) = 30, = 0.2, = 1.0, wet Insert CNMG VP3 () 2ea/corner 4ea/corner 100% longer 100% longer tool life per corner Parts for general machine Competitor X2CrNiMo , H RC 22, Ø30 vc(m/min) = 80, = 0.2, = 7.0, wet Insert CNMG VP3 () 3ea/corner 6ea/corner 100% longer 100% longer tool life per corner Parts for Industrial machine Competitor Ti-6Al-4V, H RC 50, Ø200 vc(m/min) = 60, = 0.2, = 0.8, wet Insert CNMG VP2 () 8ea/corner 12ea/corner 50% longer 50% longer tool life per corner Parts for Industrial machine Competitor Ti-6Al-4V, H RC 47, Ø50~Ø70 vc(m/min) = 50, = 0.15, = 2.0, wet Insert CNMG VP3 () 15ea/corner 13ea/corner 15% longer 15% longer tool life per corner / / 09

Insert Series for Turning Application of Hard-to-cut Materials Grade Line-up S Heat resistant alloy S Titanium alloy M Stainless steel Cutting speed, vc(m/min) 80 60 40 20 Cutting speed, vc(m/min)

Comparison [ Heat resistant alloy / STS ] ISO KORLOY Competitor A Competitor B Competitor C Competitor D Competitor E Competitor F Competitor G S05 S05F MP9005 VP05RT IC808 PR1305 S10 GC1105 0RT

WSM30 Turning Grade Comparison [ Titanium alloy ] ISO KORLOY Competitor A Competitor B Competitor C Competitor D Competitor E Competitor F Competitor G S05 - - - - - - - S15 H13A MT9015 IC20 - TT5080

10 Insert Series for Turning Application of Hard-to-cut Materials Grade Line-up S Heat resistant alloy S Titanium alloy M Stainless steel Cutting speed, vc(m/min) Cutting speed, vc(m/min) Cutting speed, vc(m/min) PC9030 PC5400 Continuous General Interrupted Continuous General Interrupted Continuous General Interrupted,,, Turning Grade Comparison [ Heat resistant alloy / STS ] ISO KORLOY Competitor A Competitor B Competitor C Competitor D Competitor E Competitor F Competitor G S05 S05F MP9005 VP05RT IC808 PR1305 S10 GC1105 0RT IC907 PR1310 TT5080 TS2000 WSM10 S15 GC1115 MP S25 GC1125 GC2025 5TF VP20MF IC908 PR1125 PR1325 TT9030 TT9080 CP500 TS2500 WSM20 S35 PC5400 GC2035 MP7035 IC328 PR660 TT8020 TT8080 TM4000 F40M WSM30 Turning Grade Comparison [ Titanium alloy ] ISO KORLOY Competitor A Competitor B Competitor C Competitor D Competitor E Competitor F Competitor G S S15 H13A MT9015 IC20 - TT5080 THR WS10 S25 GC1125 RT9015 IC908 PR1125 PR1325 TT9030 TT9080 CP500 TS2500 WSM20 Turning Grade Comparison [ HRSA ( Heat resistant alloy / Titanium alloy ) ] ISO KORLOY Competitor A Competitor B Competitor C Competitor D Competitor E Competitor F Competitor G R (Roughing) M (Medium ) L (Medium to finishing) F (Finishing) MP SMR RS, GJ TF MS ET MR4 NRT, NRS VP3 SM MS VL MU EM MR3 NMS VP2 NGP MJ PP TK ML MF1 NMT SF LS, FJ SF MQ EA M1 NFT 10 KORLOY TECH-NEWS

11 50 th Anniversary Available Stock [ Negative_ ] PVD Coated Non Coated CNMG M ~ ~ M ~ ~ 0.20 DNMG M ~ ~ M ~ ~ M ~ ~ M ~ ~ 0.20 Available Stock [ Negative_VP2 ] PVD Coated Non Coated CNMG VP2 M ~ ~ VP2 M ~ ~ 0.40 DNMG VP2 M ~ ~ VP2 M ~ ~ VP2 M ~ ~ VP2 M ~ ~ 0.40 SNMG VP2 M ~ ~ VP2 M ~ ~ VP2 M ~ ~ 0.50 TNMG VP2 M ~ ~ VP2 M ~ ~ VP2 M ~ ~ VP2 M ~ ~ VP2 M ~ ~ 0.45 WNMG VP2 M ~ ~ VP2 M ~ ~ VP2 M ~ ~ 0.40 / / 11

12 Insert Series for Turning Application of Hard-to-cut Materials Available Stock [ Negative_VP3 ] PVD Coated Non Coated CNGG VP3 G ~ ~ VP3 G ~ ~ VP3 G ~ ~ 0.50 CNMG VP3 M 0.10 ~ ~ VP3 M 0.50 ~ ~ VP3 M 0.50 ~ ~ 0.50 DNGG VP3 G ~ ~ VP3 G ~ ~ VP3 G ~ ~ VP3 G ~ ~ VP3 G ~ ~ VP3 G ~ ~ 0.50 DNMG VP3 M 0.10 ~ ~ VP3 M 0.50 ~ ~ VP3 M 0.50 ~ ~ VP3 M 0.10 ~ ~ VP3 M 0.50 ~ ~ VP3 M 0.50 ~ ~ 0.50 SNGG VP3 G ~ ~ VP3 G ~ ~ VP3 G ~ ~ 0.50 SNMG VP3 M 0.10 ~ ~ VP3 M 1.00 ~ ~ VP3 M 1.00 ~ ~ 0.50 TNGG VP3 G ~ ~ VP3 G ~ ~ 0.45 TNMG VP3 M 0.10 ~ ~ VP3 M 0.50 ~ ~ 0.45 VNGG VP3 G ~ ~ VP3 G ~ ~ KORLOY TECH-NEWS

13 50 th Anniversary Available Stock [ Negative_VP3 ] PVD Coated Non Coated VNMG VP3 M 0.10 ~ ~ VP3 M 0.50 ~ ~ 0.45 WNMG VP3 M 0.50 ~ ~ VP3 M 0.50 ~ ~ VP3 M 0.10 ~ ~ 0.30 Available Stock [ Negative_MP ] PVD Coated Non Coated CNMG MP M ~ ~ MP M ~ ~ MP M ~ ~ 0.50 DNMG MP M ~ ~ MP M ~ ~ MP M ~ ~ MP M ~ ~ MP M ~ ~ MP M ~ ~ 0.50 SNMG MP M ~ ~ MP M ~ ~ 0.45 TNMG MP M ~ ~ MP M ~ ~ MP M ~ ~ 0.50 VNMG MP M ~ ~ MP M ~ ~ 0.45 WNMG MP M ~ ~ MP M ~ ~ MP M ~ ~ 0.50 / / 13

14 Insert Series for Turning Application of Hard-to-cut Materials Available Stock [ Positive_ ] PVD Coated Non Coated CCGT G ~ ~ G ~ ~ G ~ ~ T301- G ~ ~ T302- G ~ ~ T304- G ~ ~ 1.50 DCGT G ~ ~ G ~ ~ G ~ ~ T301- G ~ ~ T302- G ~ ~ T304- G ~ ~ 1.50 VCGT G ~ ~ G ~ ~ G ~ ~ 1.20 VPGT G ~ ~ G ~ ~ G ~ ~ 1.20 Available Stock [ Positive_VL ] PVD Coated Non Coated CCMT VL M ~ ~ T304-VL M 0.10 ~ ~ T308-VL M 0.10 ~ ~ 0.15 DCMT VL M ~ ~ VL M 0.08 ~ ~ T302-VL M ~ ~ T304-VL M ~ ~ T308-VL M 0.10 ~ ~ 0.15 SCMT 09T304-VL M ~ ~ T308-VL M ~ ~ 0.15 TCMT 16T304-VL M ~ ~ T308-VL M ~ ~ 0.20 TPMT VL M ~ ~ KORLOY TECH-NEWS

15 50 th Anniversary Available Stock [ Positive_VL ] PVD Coated Non Coated VBMT VL M ~ ~ VL M ~ ~ VL M ~ ~ 0.25 VCMT VL M ~ ~ VL M ~ ~ 0.20 Available Stock [ Positive_MP ] PVD Coated Non Coated CCMT MP M ~ ~ MP M ~ ~ T302-MP M ~ ~ T304-MP M ~ ~ T308-MP M ~ ~ 0.30 DCMT MP M ~ ~ MP M ~ ~ MP M ~ ~ T302-MP M ~ ~ T304-MP M ~ ~ T308-MP M ~ ~ 0.30 SCMT 09T304-MP M ~ ~ T308-MP M ~ ~ MP M ~ ~ 0.35 TCMT MP M ~ ~ MP M ~ 1.t ~ MP M ~ ~ T304-MP M ~ ~ T308-MP M ~ ~ T312-MP M ~ ~ 0.40 TPMT MP M ~ ~ VBMT MP M ~ ~ MP M ~ ~ MP M ~ ~ 0.35 VCMT MP M ~ ~ MP M ~ ~ MP M ~ ~ 0.33 / / 15

Head Office Holystar B/D, 1350, Nambusunhwan-ro, Geumcheon-gu, Seoul, 08536, Korea Tel : +82-2-522-3181 Fax : +82-2-522-3184 Web : www. korloy.com E-mail : export@korloy.

16 Head Office Holystar B/D, 1350, Nambusunhwan-ro, Geumcheon-gu, Seoul, 08536, Korea Tel : Fax : Web : www. korloy.com export@korloy.com Cheongju Factory 55, Sandan-ro, Heungdeok-gu, Cheongju-si, Chungcheongbuk-do, 28589, Korea Tel : Fax : Jincheon Factory 54, Gwanghyewonsandan 2-gil, Gwanghyewon-myeon, Jincheon-gun, Chungcheongbuk-do, 27807, Korea Tel : Fax : R & D Institute Cheongju 55, Sandan-ro, Heungdeok-gu, Cheongju-si, Chungcheongbuk-do, 28589, Korea Tel : Fax : R & D Institute Seoul Holystar B/D, 1350, Nambusunhwan-ro, Geumcheon-gu, Seoul, 08536, Korea Tel : Fax : Maple Avenue, Torrance, CA 90503, USA Tel : Toll Free : Fax : sales@korloy.us Gablonzer Str , Oberursel, Germany Tel : Fax : sales@korloyeurope.com Plot NO.415, Sector 8, IMT Manesar, Gurgaon , Haryana, INDIA Tel : Fax : sales.kip@korloy.com Av. Aruana 280, conj.12, WLC, Alphaville, Barueri, CEP , SP, Brasil Tel : vendas@korloy.com Ground Dongjing Road 56 District Free Trade Zone. Qingdao, China Tel : Fax : kycpjh@korloy.com TN07-EM-01

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