PC2005 / PC2010 / PC2015 Insert Series for Finishing High ......

Laser Mill SeriesNew Laser Mill series for high hardness steel and for universal purpose covering all the die steel

▣ PC2005 / PC2010 / PC2015 Outstanding increase of wear resistance through optimized grade per workpiece

▣ KF / KH Chip Breaker Increased strength and design of cutting edges through optimized blade geometries per workpiece

Insert Series forFinishing High Hardness Steel

PC2005 / PC2010 / PC2015

KHChip Breaker(For high hardness steel)

KFChip Breaker(For mild steel)


02 KORLOY TECH-NEWS

PC2005 Tool steel or high hardness steel after heat treatment has very high hardness that causes severe wear on relief surface of cutting edges during cutting actions, as well as chipping due to heavy cutting loads. In order to prevent these problems, we progressively improved wear resistance and chipping resistance of the substrate by applying ultra fine raw materials to PC2005.

PC2010 In cutting conditions when cutting fluid is applied, thermal cracks occur on tool’s surface due to repetitive thermal impact. To avoid thermal cracks, we applied a heat shield coating to PC2010. In addition, it was optimized for wet machining of pre hardened steel by using ultra fine raw materials and high binder on substrate and thus increasing stability.

PC2015 When machining carbon steel and mild steel, wear that looks like bites on tool’s relief surface is caused by viscosity between tools and workpieces. PC2015 guarantees excellent tool life and machining stability with its characteristics of the high toughness substrate and the welding resistant coating with low reactivity to workpieces.

PC2005 For high hardness steel and press die steel

PC2010 For pre hardened steel and plastic die steel

PC2015 For carbon steeland cast iron

Laser Mill Line-up optimized for machining die and mold of which material is high hardness steel, tool steel, pre hardened steel, etc.

Perfect harmony between grades and chip breakers Increased tool life and prevention against unexpected breakage

Available for all kinds of workpieces including high hardness steel, tool steel, pre hardened steel, carbon steel, cast iron, etc.

Increase wear resistance and breakage prevention Possible to various cutting conditionsAdvantages

50th Anniversary

03Laser Mill Series

Wear comparison

Super high hardness substrate and coating

High hardness substrate prevents chipping and wear on relief surface.

PC2005 (For high hardness workpiece and press die steel) P

Super high hardness substrate and coating improve wear resistance dramatically.

Excellentwear

resistance

Ultra fine WC Coating hardness : 53GPa

[ Competitor ][ PC2005 ]

Chip removal rate(Q) = 0.097638in3/min

Chip

rem

oval

rate

(in3 )

Cutting time(min)20 40 8060 100 120 140

14.457

128.1498

109.8427

91.5356

73.2285

54.9213

36.6142

18.3071

PC2005 Competitor A Competitor B

108min machiningQtot=105.937in3



Competitor B 87min

PC2005-KH 108min

Competitor A 22min

[ Machining type ]

Performance TestPC2005 tool life test

Workpiece Cutting conditions Tools

High hardness heat-treated steel [ D2(AISI), heat-treated HRC60 ]vc(sfm) = 459, fz(ipt) = 0.006, ap(inch) = 0.047, ae(inch) = 0.047, dryInsert LBH0500-KH (PC2005)


04 KORLOY TECH-NEWS

Wear comparison

Result of heat conductivity

Excellentwear

resistance

Super high hardness coating with heat shield

Uncoated carbide

Temperature (℃)20 36 50 70 85 101 117 133 150 186 250

Competitor (TiAlN) PC2010

Competitor A 2.1h

Competitor B 18.4h

PC2010-KH 18.4h

[ Competitor ][ PC2010 ]

PC2010 (For pre hardened steel and plastic die steel) P

Ultra fine WC and high contents cobalt were applied to the substrate to expand application range to high hardness steel and pre hardened steel.


Chip

rem

oval

rate

(in3 )

Cutting time(h)2 3 ··· 18 19

36.6142

30.511872

24.4095

18.3071

···

3.6614

3.0511

2.441

2.1h machiningQtot=3.295in3


PC2010 Competitor A Competitor B

[ Machining type ]



Pre hardened steel [ P20+Ni(AISI) ]vc(sfm) = 906, fz(ipt) = 0.006, ap(inch) = 0.012, ae(inch) = 0.047, dryInsert LBH0500-KH (PC2010)

Heat shield coating was applied to prevent thermal crack. Ultra fine WC was combined with high contents cobalt to be optimized for machining pre hardened steel.

50th Anniversary

05Laser Mill Series

Competitor A 1.3h

PC2015 13.3h

High toughness substrate and coating layer less responsive to workpiece applied. Excellent tool life due to minimized wear and flaking

CompetitorPC2015Normalwear

None built-up edge or flaking Built-up edge and flaking occur

PC2015 (Exclusive for Laser Mill for machining cast iron and carbon steel) P

High toughness substrate based grade for general cutting of cast iron and HRSA with the use of lubricative coating layer.



Carbon steel [ 1045(AISI) ]vc(sfm) = 820, fz(ipt) = 0.014, ap(inch) = 0.012, ae(inch) = 0.012, dryInsert LBH0500 (PC2015)

[ Machining type ]

Chip

rem

oval

rate

(in3 )

Cutting time(h)1 2 ··· 13 14

25.6299

25.0197

24.4095

23.7992

···

2.4409

1.8307

1.2204

PC2015 Competitor A





06 KORLOY TECH-NEWS

Features of KF / KH Chip Breaker■ KF : Exclusive chip breaker for stable machining of carbon steel with its characteristics of

high wear resistance at center part and improved blade design.■ KH : Stronger insert with the combination of rake angle and relief angle that are ideal for

machining high hardness workpiece.

Type Shape comparison

Standard(For general

cutting)

■ Proper to general cutting■ Insert shape for uniform performance

치즐부

SECTION A-A

Exclusive for carbon steel with higher wear resistance at center and improved blade design→ Stable machining

possible

■ Smaller chisel improves wear resistance at center for machining carbon steel.■ Improved cutting edge design by higher rake angle(α̊ )■ Longer tool life and better cutting performance with the use of excellent blade design

SECTION A-A

KF(For carbon

steel)

Perfect combination between center shape and rake / relief angle for machining high hardness workpiece→ Stronger insert

■ Center shaper proper for machining high hardness workpiece and uniformed tool life at center part ■ Improved cutting edge design by higher rake angle(α̊ )■ Lower relief angle(ß°) increases strength of cutting edges than universal inserts.

SECTION A-A

KH(For high hardness

steel)

50th Anniversary

07Laser Mill Series

Application Guideline per Workpiece

Inte

rrupt

ed c

uttin

g

Carbon steelP

Tool steelP

Heat-treated steelP

Pre hardened steelP

Cast ironK

Workpiece hardness (HRC)20 30 40 50 60

PC2015-KF

PC2010-KH

PC2005-KH

• PC2005-KH : Ideal for machining heat-treated steel and high hardness steel with its characteristics of excellent wear resistance and the harmony between improved blade design and strong chip breaker.

• PC2010-KH : Ideal for machining pre hardened steel with its characteristics of the harmony between excellent thermal shock resistance and strong cutting edges.

• PC2015-KF : Ideal for machining carbon steel with its characteristics of the harmony between excellent welding resistance and strong cutting edges/chip breakers.

Recommended grade and chip breaker

Recommended Cutting Conditions

When the overhang is over 3D, adjust the feed and cutting speed down as the following table.

WorkpieceGrade Chip

breaker

Recommended cutting conditions

ISO Material HB(HRC) vc(sfm) fz(ipt) ap(inch) ae(inch)

KGray cast iron GC250 180(8)

PC2015PC2010PC2005

KF427~689 0.008

~ 0.020 0.003D 0.003DDuctile cast iron GCD600 250(24)

P

Carbon steel S20C~S50C 150 558~820 0.008~ 0.020 0.003D 0.003D

Alloy steel SCM21~SCM5H 270(28)

PC2010PC2015PC210F

KH

427~689 0.004~ 0.012 0.003D 0.003D

Prehardened

steel

KP4M 300(32)

328~525 0.004~ 0.012 0.020D 0.020D

NIMAX 370(40)

CENA1 370(40)

NAK80 400(43)

STAVAX 510(52)

High speed tool steel

SKH51~ SKH59 550(55)

PC2005PC2010 KH

262~427 0.004~ 0.080 0.012D 0.012D

Alloy tool steel

STD61(Hot forged)

630(60) 230~394 0.004~ 0.080 0.020D 0.020D

STD11(Cold forged)

Overhang vc(sfm) fz(ipt)

Under 3D 100% 100%

3D ~ 5D 70% 70%

5D ~ 8D 60% 60%

8D ~ 10D 50% 50%


08 KORLOY TECH-NEWS

Application Example

Automobile press mold [ D2(AISI), hot forged steel ]

30% longer cutting time per corner than competitor’s

PC2005Competitor

6.5hour/corner

5hour/corner

30%longer

Cutting conditions Tools

vc(sfm) = 1237, fz(ipt) = 0.020, ap(inch) = 0.020, ae(inch) = 0.012, dryInsert LBH1000-KH (PC2005) Holder LBEA100551S-S100C

Automobile press mold [ P20+Ni(AISI) ]


PC2010Competitor

10hour/corner

8hour/corner

25%longer


vc(sfm) = 656, fz(ipt) = 0.004, ap(inch) = 0.004~0.020, ae(inch) = 0.004~0.020, wetInsert LBH0625-KH (PC2010) Holder LBEA062394S-S063C

CV Joint [ 1053(AISI), forged steel ]


PC2015Competitor

300ea/corner

200ea/corner

50%longer


vc(sfm) = 656, fz(ipt) = 0.010, ap(inch) = 0.020~0.079, ae(inch) = 0.004~0.039, dryInsert LBH1000-KF (PC2015) Holder LBEA100551S-S100C

50th Anniversary

09Laser Mill Series

Insert

Shape DesignationStock Dimension(inch)

Fig.PC2005 PC2010 PC2015 l d t r

LBH 0312-KF - - - 9/32 5/16 3/32 5/32

0375-KF - - - 21/64 3/8 7/64 3/16

0500-KF - - - 13/32 1/2 1/8 1/4

0625-KF - - - 15/32 5/8 5/32 5/16

0750-KF - - - 37/64 3/4 13/64 3/8

1000-KF - - - 47/64 1 15/64 1/2

1250-KF - - - 59/64 1 1/4 9/32 5/8

LBH 0312-KH - - - 9/32 5/16 3/32 5/32

0375-KH - - - 21/64 3/8 7/64 3/16

0500-KH - - - 13/32 1/2 1/8 1/4

0625-KH - - - 15/32 5/8 5/32 5/16

0750-KH - - - 37/64 3/4 13/64 3/8

1000-KH - - - 47/64 1 15/64 1/2

1250-KH - - - 59/64 1 1/4 9/32 5/8

20160410TN08-EI-01

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PC2005 / PC2010 / PC2015 Insert Series for Finishing High ......

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