PD1005 / PD1010

DLC-Coated Inserts for Non-Ferrous Metals

Welding and chipping resistant coated grades specialized
for machining non-ferrous metals

▣ Advanced DLC-Coated Grades

Maximized resistance to welding and wear of coating enables
quality machining at high speeds

▣ PD1005 / PD1010
Improved chipping resistance due to specialized grades
for each workpiece
 Advanced DLC-Coated Inserts for Non-Ferrous Metals
such as Aluminum and Copper
PD1005 / PD1010
Non-ferrous metals such as aluminum and copper have relatively low melting points, causing
heavy welding on the tool edges during machining. The dulled cutting edges bring about poor
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resulting in unstable tool life.
PD1005 For continuous
cutting of aluminum To provide our customers with a satisfactory grade solution for non-ferrous metal machining,
and copper KORLOY has developed DLC (Diamond-Like Carbon) coated grades.

PD1005 is a grade for workpieces made of aluminum or copper, and for continuous cutting.
The latest DLC coating with maximized wear and welding resistance enables high speed
machining for those materials, delivering excellent surface finish in continuous cutting of
general non-ferrous metals.

PD1010 Interrupted machining

of forged aluminum PD1010 is a grade for workpieces made of forged aluminum or AlSi alloy, and for interrupted
alloy, AlSi (< 8%) cutting. The combination of the chipping-resistant substrate and DLC coating greatly improves
toughness, providing stable and long tool life in interrupted cutting or when machining non-
ferrous metals of high hardness.

■ Advanced DLC coating ■ Chipping resistant substrate

→ Maximized resistance to → Stable tool life at high
wear and welding interruptions and for
Advantages non-ferrous metals of
high hardness

■ Dedicated grades specialized for

non-ferrous metals

02 KORLOY TECH-NEWS
 Problems When Machining Non-Ferrous Metals
1. Build-up edges 2. Unexpected chipping

Development of New PD Series

Exce
resistanllent
DLC coating Ultra-hard H-DLC coating wear ance to
weldingd
•Diamond-Like Carbon General DLC H-DLC
•Amorphous carbon coating • Hardness of coating : 3000 HV • Hardness of coating : 6500 HV
with physical properties • Friction coefficient : < 0.25 • Friction coefficient : < 0.15
similar to those of diamonds
•High hardness and
lubrication ideal for non-
ferrous metal machining
with a high probability of
build-up edge occurring
Rough coating surface General DLC coating Smooth coating surface Hard DLC coating

Improve
Chipping resistant substrate chippingd
resistan
ce
• Optimized proportion of WC particles and
d
Co binders for each workpiece material
provides improved resistance to chipping
and wear.
• The ultrafine structure which has been
made uniform attains stable machinability
at all corners.

Development Effects

■Workpiece 1. Improved resistance to welding and chipping 2. Extended tool life

AlZn5.5MgCu
＊Milling applications of forged aluminum
Average tool life (%)

■Cutting conditions (facing at medium to high speeds)

vc (m/min) = 1,000
fz (mm/t) = 0.2 120%
ap (mm) = 1.0
ae (mm) = 70, dry PD1010 100%
■Tools
XEKT19M508FR-MA
PAXCM5100HR-A 60%

Uncoated carbide

Uncoated carbide PD1010 &RPSHWLWRU·V

PD1005 / PD1010 03
 Applicable Products
Cutting type Name
Depth of cut, ap (mm)

5.0

4.0 AR
AK AK AR
3.0

2.0
Turning
1.0

0
0.1 0.2 0.3 0.4 0.5
Feed rate, fn (mm/rev)

Pro-X Mill Alpha Mill Future Mill

(FMA, FMP)

Milling

Guideline for Grades Application

PD1000 Series Recommended grades by Si content (%) for aluminum alloy
•Higher speed and feed
Cutting speed, vc (m/min)

availability compared to Continuous cutting General cutting Interrupted cutting

uncoated grades
•Expanded application range 2000
for workpieces of higher Si PD1005 ND Series
(Diamond-coated grades)
content
1500
•Stable and long tool life
PD1010
1000
H01
H05
500

0 Si content (%)
1 3 5 7 9

Recommended Cutting Conditions

Recommended cutting conditions
Cutting
Workpiece Application C / B Grade Turning: fn (mm/rev)
type vc (m/min) ap (mm)
Milling: fz (mm/t)
Soft, non-ferrous
(Si < 4%) Medium PD1005 200 - 350 - 500 0.03 - 0.2 - 0.4 0.1 - 2.0 - 4.0
WRÀQLVK AK
Hard, non-ferrous cutting
Turning

(Si < 8%)

PD1010 150 - 275 - 400 0.03 - 0.2 - 0.4 0.1 - 2.0 - 4.0
Soft, non-ferrous
(Si < 4%) Medium PD1005 200 - 350 - 500 0.05 - 0.25 - 0.5 0.5 - 2.2 - 4.0
to rough AR
Hard, non-ferrous cutting
(Si < 8%)
PD1010 150 - 275 - 400 0.05 - 0.25 - 0.5 0.5 - 2.2 - 4.0
Soft, non-ferrous
PD1005 300 - 1150 - 2000 0.10 - 0.25 - 0.4 0.5 - 8.0 - 16.0
Milling

(Si < 4%) General

MA
Hard, non-ferrous cutting
(Si < 8%)
PD1010 200 - 850 - 1500 0.10 - 0.25 - 0.4 0.5 - 8.0 - 16.0

04 KORLOY TECH-NEWS
 Cutting Performance
38 min
n Performance evaluation of PD1005 with AK (Turning)
P

■ Workpiece Aluminum alloy (AlZn5.5MgCu) Chip removal rate (Q) = 8.0 cm3/min

Chip removal volume (㎤)

■ Cutting vc (m/min) = 400 550
[ PD1005 ] conditions fn (mm/rev) = 0.2 500 [PD1005]
450 59 min. machined
38 min ap (mm) = 1.0 400 Qtot = 472 ㎤
350
outside diameter turning, dry 300 [Uncoated carbide]
250 38 min. machined
■ Tools Insert : VCGT160404-AK (PD1005) 200 Qtot = 304㎤

Holder : SVJCL2525-M16 10 20 30 40 50 60 70
Cutting time (min)
[ Uncoated carbide ]

55% increased cutting volume compared to uncoated grades

11 min Performance evaluation of PD1005 with Pro-X Mill (Milling)

■ Workpiece Copper (C1020) Chip removal rate (Q) = 44.6 cm3/min

Chip removal volume (㎤)

■ Cutting vc (m/min) = 2000 1300 [PD1005]
[ PD1005 ] conditions fz (mm/t) = 0.1
1150 25 min. machined
1000 Qtot = 1133 ㎤

11 min ap (mm) = 1.0 850

700
[Uncoated carbide]
ae (mm) = 70, wet 550
11 min. machined
400 Qtot = 504 ㎤
■ Tools Insert : XEKT19M508FR-MA (PD1005) 250

Holder : PAXCM5100HR-A 5 10 15 20 25 30 35
Cutting time (min)
[ Uncoated carbide ]
125% more cutting volume compared to uncoated grades

71 min 71 min Performance evaluation of PD1010 with Alpha Mill (Milling)

Pe
■ Workpiece Aluminum alloy (AlMg1SiCu) Chip removal rate (Q) = 15.3 cm3/min
Chip removal volume (㎤)

■ Cutting vc (m/min) = 800 2000

conditions 1800 [PD1010]
fz (mm/t) = 0.1 1600 118 min. machined
Qtot = 1800 ㎤
ap (mm) = 3.0 1400
1200
>&RPSHWLWRU·V'/&JUDGH@
ae (mm) = 20, dry 1000
800 71 min. machined
Qtot = 1081㎤
■ Tools Insert : APMT1604PDFR-MA (PD1010) 600

Holder : AMC3100HS 55 70 85 100 115 130 145

[ PD1010 ] [ &RPSHWLWRU·V Cutting time (min)
DLC grade ]
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ZRUNSLHFHFRPSDUHGWRWKHFRPSHWLWRU·V'/&JUDGH

24 min Performance evaluation of PD1010 with Pro-X Mill (Milling)

■ Workpiece Aluminum casting alloy Chip removal rate (Q) = 12.7 cm3/min
Chip removal volume (㎤)

■ Cutting vc (m/min) = 200 650

[ PD1010 ] conditions 600 [PD1010]
fz (mm/t) = 0.2 550 47 min. machined
Qtot = 598 ㎤
ap (mm) = 2.0 500
24 min 450 >&RPSHWLWRU·V'/&JUDGH@
ae (mm) = 50, wet 400 24 min. machined
350 Qtot = 300 ㎤
■ Tools Insert : XEKT19M508FR-MA (PD1010) 300

Holder : PAXCM5100HR-A 20 25 30 35 40 45 50
Cutting time (min)
>&RPSHWLWRU·V'/&JUDGH@
LQFUHDVHGFXWWLQJYROXPHFRPSDUHGWRWKHFRPSHWLWRU·V'/&JUDGH

PD1005 / PD1010 05
 Application Examples
Truck's clutch housing

■ Workpiece Aluminum die casting alloy, Al-Si8Cu3 (Fe) (Si 8%)

■ Cutting conditions vc (m/min) = 400, fn (mm/rev) = 0.25-0.3, ap (mm) = 1.0-1.5, wet
■ Tool Insert : CNMG120408-HA (PD1005) Holder : PCLNR2525-M12

PD1005 80ea/corner 166%

Competitor 30ea/corner more

166% more machined workpieces compared to the competitor

Automotive aluminum wheel

■ Workpiece Aluminum forged alloy, Al-Si7Mg (Fe) (Si 7%)

■ Cutting conditions vc (m/min) = 260-337, fn (mm/rev) = 0.6-0.7, ap (mm) = 2.0-3.0, wet
■ Tool Insert : VCGT220530-AR (PD1010) Holder : S40T-XVXCR-22-DG

PD1010 450ea/corner 36%

Competitor 330ea/corner more

36% more machined workpieces compared to the competitor

Automotive differential carrier

■ Workpiece Aluminum forged alloy, Al-Si7Mg (Fe) (Si 7%)

■ Cutting conditions vc (m/min) = 740, fz (mm/t) = 0.15, ap (mm) = 1.0-1.5, wet
■ Tool Insert : XEKT19M504FR-MA (PD1010) Holder : PAXS5032HR-A

PD1010 900ea/corner 188%

Competitor 480ea/corner more

188% more machined workpieces compared to the competitor

06 KORLOY TECH-NEWS
 Available Stock (Turning)
Grade Dimensions (mm) Cutting conditions
Chip

PD1005
PD1010
Designation Feed rate, Depth of cut, Figure
breaker I d t r d1
fn (mm/rev) ap (mm)

CCGT 060204-AK - ƀ 6.0 6.35 2.38 0.4 2.8 0.02-0.15 0.10-3.00

09T302-AK - ƀ 9.4 9.525 3.97 0.2 4.4 0.02-0.20 0.05-3.00
09T304-AK - ƀ 9.2 9.525 3.97 0.4 4.4 0.02-0.30 0.10-5.00
120404-AK - ƀ 12.4 12.7 4.76 0.4 5.5 0.03-0.50 0.10-5.00
DCGT 070204-AK - ƀ 7.3 6.35 2.38 0.4 2.8 0.02-0.30 0.10-4.00

AK 11T302-AK - ƀ 11.4 9.525 3.97 0.2 4.4 0.02-0.30 0.05-4.00

11T304-AK - ƀ 11.2 9.525 3.97 0.4 4.4 0.03-0.50 0.10-5.00
11T308-AK - ƀ 10.8 9.525 3.97 0.8 4.4 0.03-0.50 0.10-5.00
VCGT 110302-AK - ƀ 10.5 6.35 3.18 0.2 2.8 0.02-0.20 0.05-3.00
110304-AK - ƀ 10.0 6.35 3.18 0.4 2.8 0.02-0.25 0.10-4.00
160404-AK - ƀ 15.6 9.525 4.76 0.4 4.4 0.03-0.40 0.10-5.00
160408-AK - ƀ 14.0 9.525 4.76 0.8 4.4 0.03-0.50 0.10-5.00
●: Stock item

Available Stock (Milling)

Grade Dimensions (mm)
PD1005
PD1010

Cutter Designation Figure

I I2 I1 d t r d1 a

XEKT 19M504FR-MA - ƀ 18 16.4 1.4 - 5 0.4 4.4 -

19M508FR-MA - ƀ 18 16.4 1.0 - 5 0.8 4.4 -
19M512FR-MA - ƀ 18 16.4 0.6 - 5 1.2 4.4 -
19M516FR-MA - ƀ 17.5 16.4 0.5 - 5 1.6 4.4 -
Pro-X
19M520FR-MA - ƀ 17.5 16.4 0.5 - 5 2.0 4.4 -
Mill
19M530FR-MA - ƀ 17 16.4 0.7 - 5 3.0 4.4 -
19M532FR-MA - ƀ 17 16.4 0.5 - 5 3.2 4.4 -
19M540FR-MA - ƀ 16.5 16.4 0.5 - 5 4.0 4.4 -
19M550FR-MA - ƀ 16 16.4 0.4 - 5 5.0 4.4 -
APMT 1604PDFR-MA - ƀ 16.4 - - 9.41 5.76 0.8 4.5 -

Alpha
Mill

SEET 14M4AGFN-MA - ƀ - - - 14.0 4.0 - 4.4 2.64

FMA

SDET 130504R-MA - ƀ - - - 13.5 5.56 0.4 5.56 2.2

FMP

●: Stock item

PD1005 / PD1010 07
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TN68-EM-01 / 20181020