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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)
Insert Series forFinishing High Hardness 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
87min machiningQtot=84.762in3
22min machiningQtot=21.175in3
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)
Insert Series forFinishing High Hardness Steel
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 removal rate(Q) = 0.05248in3/min
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
18.4h machiningQtot=29.6575in3
PC2010 Competitor A Competitor B
[ Machining type ]
Performance TestPC2010 tool life test
Workpiece Cutting conditions Tools
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.
Performance TestPC2015 tool life test
Workpiece Cutting conditions Tools
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
1.3h machiningQtot=2.1968in3
13.3h machiningQtot=24.4095in3
Chip removal rate(Q) = 0.027461in3/min
Insert Series forFinishing High Hardness Steel
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%
Insert Series forFinishing High Hardness Steel
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) ]
25% longer cutting time per corner than competitor’s
PC2010Competitor
10hour/corner
8hour/corner
25%longer
Cutting conditions Tools
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 ]
50% longer cutting time per corner than competitor’s
PC2015Competitor
300ea/corner
200ea/corner
50%longer
Cutting conditions Tools
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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