“Our new PCD round tools line enables our customers to machine aluminum significantly faster, for greater productivity on the shop floor,” says Michael Hacker, Product Manager, Kennametal. “In drilling and reaming operations, these tools consistently perform at cutting speeds of up to 900 m/min (3,000 SFM). Milling operations can be performed at an incredible 6.000 m/min (20,000 SFM)—far higher than non-PCD tooling.”

Long tool life, high productivity gains
With through-the-tool coolant capabilities and an MQL-ready interface, these PCD round tools are ideal for both rough and finish machining.

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. Surface roughness of Ra 0,1–0,8 μm (0.0025–0.02 μ-in) is achievable – far superior to conventional carbide tooling.

PCD grade KD1410 assures extended tool life and is particularly beneficial in the high silicon content aluminum used to make automotive parts like engine blocks or cylinder heads.

The offering at a glance
The line of PCD end mills features:
-6 to 50 mm diameter tools
-Cutting depths up to 50 mm
-Center-cutting, roughing, and finishing geometries
-Various rake angles.

The PCD drill offering features:
-6 to 20 mm diameter in 0.5 mm increments
-Up to 5 x D
-Inch and metric sizes

The PCD reaming portfolio offers:
-6 to 20 millimeter in diameter in 1 mm increments
-Through and blind hole versions
-For larger diameters up to 42 mm, the PCD modular reaming system with KST coupling is available.

“Many of these PCD round tools can also be requested as custom solutions to fit specific customer needs while still maintaining short lead times,” says Hacker. “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 aluminum machining.”