Kennametal has introduced a new range of PCD round tools for aluminium machining that delivers up to 10-times greater productivity than carbide tooling. The new line of drills, reamers and end mills provides ‘exceptional tool life and wear resistance even in very abrasive aluminium alloys’ and are available with very short lead times.
Michael Hacker, Kennametal’s product manager, said: “Our new PCD round tools line enables our customers to machine aluminium significantly faster, for greater productivity on the shopfloor. In drilling and reaming operations, these tools consistently perform at cutting speeds of up to 900m/min, while milling operations can be performed at 6,000m/min — far higher than non-PCD tooling.
With through-tool coolant capabilities and an MQL-ready interface, these PCD round tools are ideal for both rough and finish machining. Moreover, extremely sharp cutting edges and low-friction rake surfaces eliminate concerns over built-up edge. Low friction machining also produces superior surfaces in finishing operations, such as reaming, where a surface roughness of Ra 0.1–0.8µm is achievable — far superior to conventional carbide tooling.
Kennametal says PCD grade KD1410 provides extended tool life and is particularly beneficial in the high-silicon-content aluminiums used to make automotive parts like engine blocks and cylinder heads.
The line of PCD end mills feature: diameters from 6 to 50mm; cutting depths up to 50mm; centre-cutting, roughing, and finishing geometries; and various rake angles. The PCD drills feature: diameters from 6 to 20mm in 0.5mm increments; drilling depths up to 5xD; and both inch and metric sizes. The PCD reamers feature: diameters from 6 to 20mm in 1mm increments; and both through- and blind-hole versions. For larger diameters (up to 42mm), a PCD modular reaming system with KST coupling is available.
Mr Hacker concluded: “Many of these PCD round tools can also be requested as custom solutions to fit specific customer needs while still maintaining short lead times. Kennametal is leveraging its decades of experience with PCD tooling in the automotive industry to make this technology readily available to any manufacturer looking for a cost-competitive and highly productive solution for aluminium machining.”