For Small Parts Machining Aluminum Alloy Machining Solutions

For Small PartsMachiningAluminum AlloyMachining SolutionsFor Small Parts MachiningAluminum AlloyMachining SolutionsSolutions to Improve Productivity in Aluminum Alloy MachiningMolded PCDAPD ChipbreakerMolded PCDImproved Chip ControlY-axis ToolholderAGT Chipbreakerfor KTKF holders

For Small Parts MachiningAluminum Alloy Machining SolutionsPCD Chipbreaker for Finishing, Multifunctional PCD Chipbreaker for Grooving and Traversingwith Good Chip Control, and Y-axis Toolholders for Excellent Aluminum Machining ResultsSuperior Chip Control Improves Machining Quality and ProductivityMolded PCD APD ChipbreakerAPD Chipbreaker shows good chip control from small to large D.O.C.APD ChipbreakerCompetitor A(with molded chipbreaker)Improved ChipControlBeautiful SurfaceFinishHigh Performance Across a Variety of Machining ApplicationsMolded PCD AGT Chipbreaker for KTKF holdersUnique chipbreaker design provides excellent chip controlImproved ChipControlMultifunctionalPCD Chipbreakerfor Grooving andTraversingNew Toolholders Maintain Stable MachiningImproved Chip ControlY-axis ToolholderExcellent Chip Evacuation with Y-axis Tuning Prevents Chip EntanglementControls ChipEvacuation1

Molded PCD ChipbreakerAPD ChipbreakerImproved ChipControlBeautiful SurfaceFinishSuperior Chip Control when Machining AluminumGood Chip Control Improves ProductivityChip clogging causes machining downtimeChallengesReduced part quality with cloudy finishLong chips cause these problemsChip clogging reduces surface finish qualityNewly developed molded chipbreaker designImproved chip control increases productivitySOLUTIONHead ADC12-1Cutting Conditions : n 2700min , Vc 850 m/min, ap 0.5 mm, f 0.10 mm/revCCMT09T304APD KPD001ø1001APD ChipbreakerStabilizing chip conditionsCompetitor B (without chipbreaker)10 mmChip cloggingChips are evacuated smoothlyNo chip clogging and long chips10 mm(User evaluation)2

2Newly Designed Molded Chipbreaker Controls ChipsChipbreaker FeaturesDot for large D.O.C.Controls chips with stepDot for medium D.O.C.Controls chips with side of dotLand for small D.O.C.Good Control of thin chipsFront edge dotsStable chip control with a dot thatprotrudes to the cornerChipbreaker Mapap (mm)1.51.0APDChipbreaker0.50.000.10.20.3f (mm/rev)Chip Control Comparison (Internal evaluation)APD chipbreaker showed stable machining of less than 1 mm D.O.C. under various cutting conditions.Excellent chip control from small D.O.C. to large D.O.C.APD Chipbreaker (KPD001)Competitor A Molded Chipbreaker (PCD)0.500.50ap (mm)1.00ap (mm)1.000.250.250.100.10Good Chip Control0.100.150.200.10f (mm/rev)0.15f (mm/rev)Cutting Conditions : Vc 500 m/min, ap 0.1 - 1.0 mm, f 0.10 - 0.20 mm/rev, Continuous external turning , Wet, Workpiece : A505230.20

3Excellent Surface FinishAPD Chipbreaker with sharp edge showed better surface finish comparedto competitorAPD Chipbreaker (Indicated by red line on the right pic)Competitor CSurface Finish Comparison (Internal evaluation)APD Chipbreaker (KPD001)Competitor D Molded Chipbreaker (PCD)GoodTearing and mm-4μm0.1mmCutting Conditions : Vc 450 m/min, ap 0.25 mm, f 0.10 mm/rev, Continuous external turning , Wet, Workpiece : ADC12Standard Stock DescriptionShapeDimensions Description80 CCMTSRE09T302APD09T304APDDCMTS11T304APDICS11 RE9.5253.974.417 55 D1RELEKPD001D1ICLE60 No. of Cuttingedge7 APDIC: Standard StockRecommended Cutting ConditionsWorkpiecePCD KPD001Aluminum AlloyBrassNotes300 1,500Vc : m/minap(mm) 1.0fz(mm/t)0.05 0.20Vc : m/min300 1,500ap(mm) 1.0fz(mm/t)0.05 0.204Wet

Molded PCD Chipbreaker for KTKF holdersAGT ChipbreakerImproved ChipControlMultifunctionalPCD Chipbreakerfor Grooving andTraversingImproved Chip Control for Various Aluminum AlloyMachining Applications1Stable Machining for a Wide Range of ApplicationsChip control and surface finish comparison with grooving and traversingChip Control Comparison (Grooving)TKF-AGTSurface Finish Comparison (Traversing)TKF-AGTCompetitor ECutting Conditions : Vc 250 m/min, ap 2.0 mm, Wet Workpiece : A6061Competitor ECutting Conditions : Vc 250 m/min, ap 0.5 mm, Wet Workpiece : A6061AGT Chipbreaker showed better chip control when grooving compared to competitor.It also showed superior surface finish with less scratching when traversing.2Unique Chipbreaker Provides Excellent Chip ControlDotsTraversingReduces chip clogging by adjusting thewidth of the chipbreaker to the D.O.C.Dots around cutting edge for small D.O.C.GroovingStable machining with three chipbreakerdotsSloped cutting edgeReduces chattering with low cutting force designGood surface finish with excellent chipevacuation5

Standard Stock DescriptionShapeDescriptionDimensions (mm)RE W1SS1 0 0.05TKF12R 200-AGT2.04.80.1250-AGT2.54.80.1D1LEAnglePSIRRNo. of CuttingKPD001edge3.08.78.35.04.20 13.08.78.35.04.20 1LESS1RE CW 0.03W1D1RE CDXCW CDX 0 0.05: Standard StockRecommended Cutting ConditionsChipbreaker minum Alloy0.03 0.150.03 0.20ap (mm)200 500Vc : m/minfz(mm/t)43TKF-AS2TKF-NB100 350Vc : m/min1Brassfz(mm/t)0.03 0.150.03 0.20PCD inserts are for traversing and grooving applications.When using in cut-off machining, maximum cut-off diameter is ø8.Set the feed rate less than 0.08mm/rev.Cutting with coolant is recommended.00.050.100.150.20f (mm/rev)Case StudiesSpool ValveA6061TKF-AGTn 6,500 min-1ap 2.0 mm (Grooving), 0.15 mm / 2.0 mm (Traversing)f 0.1 mm / rev, Wetø15Traversing (ap 0.15mm)Traversing (ap 2.0mm)GroovingGood chip control without chip cloggingConventional A10Chip ControlImprovedTraversing (ap 0.15mm)Chip clogging occurred6Traversing (ap 2.0mm)Grooving(User evaluation)

Improved Chip ControlY-axis ToolholderNew Special Shape Toolholder for Small PartsMachining1Controls ChipEvacuationControlled Chip Evacuation for Stable MachiningKTKFMachining in the Y-axis directionX-axisY-axisChips fall downwardThe Y-axis machining direction allows the chips to fall down andaway from the workpiece, improving chip evacuation.2KTKF Grooving and Cut-Off System and External Turning HoldersKTKFExternal TurningBack Turning, Threading and Cut-offFront turningKTKFR1216JX-12-Y : Shank 1216 TypeKTKFR1616JX-12-Y : Shank 1616 TypeApplicable inserts : TKF12R SDJCR1212JX-11FF-Y : Shank 1212 TypeSDJCR1616JX-11FF-Y : Shank 1616 Type11T3 Applicable inserts : DCFor more details, see Kyocera Y-axis Toolholder catalog.The information contained in this brochure is current as of June 2020.Duplication or reproduction of any part of this brochure without approval is prohibited.CP461 CAT/16.2T2005DNT 2020 KYOCERA Corporation

TKF-AGT Conventional A Chip Control Improved S1 S CW RE RE CDX D1 LE 0.03 W1 f (mm/rev) 0.05 0.10 0.15 0.20 3 4 5 2 1 ap (mm) TKF-AGT TKF-NB TKF-AS 0 Chipbreaker Map PCD inserts are for traversing and grooving applications. When using in cut-off machining, maximum cut-off diameter is ø8. Set the feed rate less than 0.08mm/rev. Cutting with .