Optimized design of inserts for maximum drilling efficiency

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1 KORLOY Indexable new generation drill KING DRILL Optimized design of s for maximum drilling efficiency Excellent cutting performance and chip control due to the optimized geometry and chip breaker of both s, central & peripheral 2 different s, optimized for the central and peripheral locations in order to maximize cutting tool life

2 Quality, performance, value - Guaranteed! Code system of holder K 5D A KING, KORLOY A : Inch Type No mark : MM Type 1000 : Drill diameter Ø0 Three decimal place marked Aspect ratio(l/d) 2D, 2.5D, 3D, 3.5D, 4D, 4.5D, 5D 125 : Shank diameter Ø, Ø, Ø, Ø Two decimal place marked 09 : Inscribed circle of 05, 06, 07, 09, 11, 13, 15, 18 Shank shape No code : Flange Shank, Weldone HP(Standard) : Flange Shank, Weldon, NPT Tap F1 : Flange Shank, Whistle Notch F2 : Flange Shank, Without Side Lock S : Straight Shank, Weldone S1 : Straight Shank, Whistle Notch S2 : Straight Shank, Without Side Lock M0, M1, M2, M3 : MT0, MT1, MT2, MT3 H63, H100 : HSK63, HSK100 B30, B40, B50 : BT30, BT40, BT50 Features of Insert Optimized design of s for maximum drilling efficiency - Excellent cutting performance and chip control due to the optimized geometry and chip breaker of both s, central & peripheral - Different s, optimized for the central and peripheral locations in order to maximize cutting tool life Chip breaker PD LD Features - Universal - At medium speed and medium feed Insert Peripheral Central Peripheral - Superior chip control for machining mild steel and stainless steel - Light cutting(at low ~ medium speed and low feed) Central Shape Grades for workpiece : P : P, M, K, S PC6510 : K : P, M, K, S PC5335 : P, M PC5335 : P, M 02_ KORLOY TECH-NEWS

3 Features of Drill 3 coolant hole system The center coolant hole system helps prevent wear on the chip pocket of the central and improves chip control The optimized shape of the flute increases the rigidity of the drill body and improves chip evacuation Machining performance Tool life comparison KING DRILL has the best tool life. No. of hole Holes/94.5ft 230 Holes/67.9ft More than 2 times longer tool life KING DRILL 320 Holes (94.5ft) Normal wear Holes/41.3ft Competitor A 230 Holes (67.9ft) Chipping on cutting edge 0 KING-DRILL Competitor A Competitor B Workpiece AISI4140 Cutting conditions vc (sfm) = 492, fn (ipr) = Depth of drilling : 3.15 inches (pass though), wet Tools Insert : SPMT PD (), XOMT PD () Holder : K5DA HP-07 Competitor B 140 Holes (41.3ft) Wear and chjipping on cutting edge Surface roughness Superior surface roughness of KING DRILL Surface roughness Ra() times superior surface roughness KING DRILL Competitor A Competitor B KING DRILL Competitor A Competitor B Workpiece AISI4140 Cutting conditions vc (sfm) = 492, fn (ipr) = , Depth of drilling : inches (pass though), wet Tools Insert : SPMT PD(), XOMT PD () Holder : K5DA HP-05 KING DRILL _03

4 Quality, performance, value - Guaranteed! Precision of machining Hole diameter(inch) Competitor A Competitor B KING DRILL More than 2 times longer tool life Beginning of hole Middle of hole End of hole Beginning Middle End KING DRILL Workpiece AISI4140 Cutting conditions vc (sfm) = 492, fn (ipr) = Depth of drilling : 19.7 ft (pass though), wet Tools Insert : SPMT PD (), XOMT PD () Holder : K5DA HP-05 Regular hole diameters at the beginning, middle and end of hole Competitor A Hole diameter : beginning<middle<end Competitor B Bigger hole diameter at the end of hole The diameters of beginning, middle, and end of hole are regular after drilling with KING DRILL Chip evacuation KING DRILL Stable chip control Workpiece AISI1045 Competitor A Thin and long chips are coiled around the holder Competitor B Folded chips under certain cutting condition Poorchip evacuation Cutting conditions vc (sfm) = 295~590, fn (ipr) = ~0.0047, t (inch)=3.5, Through coolant system, pass through Tools Insert : SPMT07T208-PD (), XOMT07T205-PD () Holder : K5DA HP-07 Application examples [Workpiece] KING DRILL Competitor ea ea 150% longer tool life Superior surface finish and chip evacuation KING DRILL : 180ea, Competitor's : 120ea 150% longer tool life EA Workpiece Track link bush Cutting conditions vc (sfm) = 394, fn (ipr) = Through coolant system Tools Insert : SPMT07T208-PD (), XOMT07T205-PD () Holder : K5DA HP-07 Machine Drilling machine 04_ KORLOY TECH-NEWS

5 Example of longer tool life KING DRILL Competitor A Competitor B Holes Holes Holes 184% longer tool life Tool life Superior chip evacuation and surface finish 184% longer tool life comparing to competitor A 117% longer tool life comparing to competitor B [Workpiece] Workpiece Hydraulic oil pump (AISI4140) Cutting conditions vc (sfm) = 449 fn (ipr) = ap (inch) = 2.3 (not pass though) through coolant system Tools Insert : SPMT PD () XOMT PD () Holder : K5DA HP-09 Machine : KV45 Example of improved productivity KING DRILL Competitor vf(inch/min)=7.8 vf(inch/min)= % improved productivity Tool life [Workpiece] KING DRILL : 95 Holes, Competitor : 70 Holes, 135% longer tool life 135% improved productivity Workpiece Track link bush (AISI4130) Cutting conditions Competitor s vc (sfm) = 459, fn (ipr) = Korloy s vc (sfm) = 459, fn (ipr) = Tools Insert SPMT PD () XOMT PD () Holder K3DA Machine MCT Example of improved productivity and tool life. KING DRILL Competitor 150 Holes 220 Holes 145% longer tool life [Workpiece] Tool life Workpiece Track link (AISI4140) Cutting conditions Competitor s vc (sfm) =154, fn (ipr) = , Through coolant system Korloy s vc (sfm) = 360, fn (ipr) = , Through coolant system Tools Insert : SPMT PD (), XOMT PD () Holder : K3DA Machine MCT Chips from KING DRILL Chips from competitor's KING DRILL has 145% longer tool life and 200% improved productivity Good surface finish, improved chip control and less chattering KING DRILL _05

6 Quality, performance, value - Guaranteed! KING DRILL- for through coolant system with a lathe Drill with through coolant system for general lathe and CNC lathe without through coolant system Through coolant system with drill holder, plug, oil-hole hose and oil-hole pump NPT Tap in the plug is combined to NPT Tap connected to oil hose. Available to use the drill without a plug in milling machine Holder + Plug Oil pump Clamping oil hose to the bottom of plug and connect the oil pump to the holder (inch) Designation Diameter Shank Dia. M x p Plug K DA ~ HP- K DA ~ HP- K DA ~ HP- K DA ~ HP- Ø0.484 ~ Ø0.625 Ø0.687 ~ Ø0.875 Ø0.937 ~ Ø1.375 Ø1.437 ~ Ø2.375 Ø Ø Ø Ø M14 x 1.5 M18 x 2.0 M22 x 2.0 M33 x 3.0 PLG14PT18 PLG18PT18 PLG22PT14 PLG33PT38 Plug Plug is assembled Plug Type M x p NPT Tap A PLG14PT18 PLG18PT18 PLG22PT14 PLG33PT38 M14 x 1.5 M18 x 2.0 M22 x 2.0 M33 x 3.0 1/8 1/8 1/4 3/8 5/8 7/8 1 1/8 11/8 06_ KORLOY TECH-NEWS

7 Recommended cutting conditions (inch) Workpiece Grade vc Feed (aspect ratio = 2D, 3D, 4D) Fn (ipr) depending on drill Dia. P ISO Carbon steel Alloy steel Workpiece Hardness(HD) sfm 0.47~ ~ ~ ~ ~ Central LD PC (197~591) Low carbon 80~180 Peripheral ~ ~ ~ ~ ~ steel PD 623(427~820) High carbon 180~280 PD Peripheral 459(262~656) ~ ~ ~ ~ ~ LD PC (197~591) ~ ~ ~ ~ ~ Low alloy 140~260 Peripheral steel PD 492(295~656) ~ ~ ~ ~ ~ Low pre - hardened Low alloy stee Central Central Central 200~400 PD 328(164~492) ~0.004 Peripheral Central 50~260 PD 328(164~525) ~0.007 Peripheral 0.002~ ~ ~ ~ ~ ~ ~ ~ High prehardenedsteel Central 220~450 PD Peripheral 230(98~394) ~ ~ ~ ~ ~ M Stainless steel Austenite series Ferrite series Martensite series ~275 LD PD LD PD Central Peripheral Central Peripheral PC5335 PC ~ ~ ~ ~ ~ (131~492) ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ (197~525) ~ ~ ~ ~ ~ K Cast iron Central Gray cast iron 150~230 PD 623(492~820) ~ ~ ~ ~ ~ Peripheral PC6510 Central Ductile cast iron 150~230 PD 492(328~656) ~ ~ ~ ~ ~ PC6510 Peripheral S Heat resisting alloy Ni-heat resisting alloy Ti-heat resisting alloy High hardened steel 130~ ~400 over400 PD PD PD 164(98~328) ~ ~ ~ ~ ~ (98~295) ~ ~ ~ ~ ~ (66~262) ~ ~ ~ ~ ~ UIn case of 5D, reduce 30~40% of cutting condition from the above UIn interrupted machining part, reduce 30~50% of feed from the above machining around interrupted part KING DRILL _07

8 Quality, performance, value - Guaranteed! Required machine power The graphs below show the cutting force required in drilling Machining with the KING DRILL and a machine with high rigidity and power Workpiece AISI4140 (240HB) Cutting conditions vc (sfm) = 328 Through coolant system Required machine power(kw) fn (ipr) = fn (ipr) = fn (ipr) = Drill diameter (inch) Thrust(N) fn (ipr) = fn (ipr) = fn (ipr) = Drill diameter (inch) Torque() fn (ipr) = fn (ipr) = fn (ipr) = Drill diameter (inch) 08_ KORLOY TECH-NEWS

9 Cutting oil quantity Cutting oil quantity(l/ min) Recommended cutting oil quantity Min. cutting oil quantity Drill diameter(inch) Workpiece AISI4140 (240HB) Cutting conditions vc (sfm) = 328, Through coolant system Recommended pressure of coolant : 5kg/cm 2 above The data of the graph above could be changed depending on workpiece and cutting condition Drill tolerance and hole tolerance (inch) Drill diameter Ø0.484 ~ Ø1.125Ø1.812~ Ø1.187 ~Ø1.750 Ø D~3D Drill tolerance ( ØD) Hole tolerance 0 ~ ~ ~ ~ ~ ~ D~5D Drill tolerance ( ØD) Hole tolerance 0 ~ ~ ~ ~ ~ ~ The actual hole tolerance of KING DRILL is as shown in the chart above The length of drill, kind of workpiece, machine stability, and cutting condition could affect the hole tolerance KING DRILL _09

10 Quality, performance, value - Guaranteed! The shape of the bottom of blind hole Drill diameter(inch) Peripheral Central a Ø0.484~Ø0.531 SPMT PD XOMT PD 0.4 Ø0.562~Ø0.625 SPMT PD XOMT PD 0.4 Ø0.687~Ø0 SPMT PD XOMT PD 0.5 Ø0.812~Ø0.875 SPMT07T208-PD XOMT07T205-PD 0.5 Ø0.937~Ø1.125 SPMT PD XOMT PD 0.7 Ø1.187~Ø1.375 SPMT11T308-PD XOMT11T306-PD 0.8 Ø1.437~Ø1.687 SPMT PD XOMT PD 1.0 Ø1.750~Ø2.000 SPMT15M510-PD XOMT15M508-PD 1.1 Ø2.062~Ø2.375 SPMT PD XOMT PD 1.2 KING DRILL drills with two s, central and peripheral Refer to the above chart for remaining curve of blind hole bottom 10_ KORLOY TECH-NEWS

11 How to clamp KING DRILL to side lock arbor Bolt 2 Bolt 1 Side lock Plunge side 1 2 Stick the arbor to the plunge side. Clamp the bolt 2 Clamp the bolt Recommendation to use side lock arbor for KING DRILL 1. Insert the part of side lock of drill to the same direction of clamping the bolt to the arbor 2. Push the plunge side of drill into the arbor 3. Clamp the bolt 1 first 4. Next, clamp the bolt 2 Notice for setting the drill in the lathe Set the peripheral parallel to the X axis. (based on the side lock) If the machined core is 0.02Inch after machining 0.2Inch, that is the proper setting * Please make sure that the location of the side lock could be different depending on manufacturers of machine KING DRILL _11

12 Quality, performance, value - Guaranteed! Machining required attention Workpiece Machining Machining irregular face Possible chipping and fracture of the Reduce normal feed 25% Machining convex side Possible initial contact with central Reduce feed 50% until both s are engaged Machining concave side Reduce feed 50% until both s are engaged Boring Reduce feed 50% from normal conditions Ramping Reduce feed 50% from normal conditions Machining cross holes Reduce feed 50% in the overlapped section Machining overlapped holes Reduce feed 50% from normal conditions Machining overlapped panels Possible chipping and fracture of Reduce normal feed 25% 12_ KORLOY TECH-NEWS

13 Solutions for machining failure Failure Detail Solution Different diameters of one machined hole Enlarging or reducing hole diameter Chattering Poor chip evacuation Poor surface finish Short tool life of Different diameters of one machined hole The end of hole Diameter is bigger Enlarging or reducing hole diameter Vibration while machining Long chip Short chip Scratch on the machined side Too much wear or chipping on Use more coolant and check the coolant evacuation Change the drill to one with small aspect ratio Change the cutting condition for better chip control Milling Use more coolant Check the coolant evacuation Turning Check the center of drill and workpiece Rotate the drill to 180 Set the overhang of drill short Reduce the cutting speed and feed Stable clamping Check the torque of machine Mild steel/sts speed up, feed down Alloy steel/carbon steel speed up, feed up Speed down, feed down, pressure of coolant up Set the cutting condition for better chip control Feed down or speed up Increase the coolant flow and check the coolant evacuation Set the overhang of drill short and more stable clampin Check the cutting condition Use more coolant and check the coolant evacuation Set the overhang of drill short and more stable clamping Change the grade Insert and parts Diameter of drill Peripheral Central Screw Wernch Ø0.484~Ø0.531 Ø0.562~Ø0.625 Ø0.687~Ø0 Ø0.812~Ø0.875 Ø0.937~Ø1.125 Ø1.187~Ø1.375 Ø1.437~Ø1.687 Ø1.750~Ø2.000 Ø2.062~Ø2.375 SPMT PD SPMT PD SPMT PD SPMT07T208-PD SPMT PD SPMT11T308-PD SPMT PD SPMT15M510-PD SPMT PD XOMT PD XOMT PD XOMT PD XOMT07T205-PD XOMT PD XOMT11T306-PD XOMT PD XOMT15M508-PD XOMT PD FTNA0204 FTNA0204 FTKA02206S FTKA02565 FTKA0307 FTKA03508 FTKA0410 FTNC04511 FTNA0511 TW06P TW06P TW07P TW07S TW09S TW15S TW15S TW20S TW Torque(Nm) In clamping, clean the tip seat and apply the CASMOLY1000 on screw Make sure to use Korloy s screw and ranch only KING DRILL _13

14 Quality, performance, value - Guaranteed! Special drill order form ( V Mark V in the box) Coolant type Though coolant system No oil hole Side coolant system (CNC lathe) Hole type Blind hole Thru hole Types of shank (Flat Type) (Weldon Type) (Whistle Notch Type) Location of side lock Parallel to peripheral (standard) 90 angle to peripheral Note currently using tool : current cutting conditions - RPM or vc (sfm): - vf (inch/min) or fn (ipr) - depth of cut (inch) standard of measuring tool life : currently using machine - Machining center - General lathe - CNC lathe 150 angle to peripheral 180 angle to peripheral 14_ KORLOY TECH-NEWS

15 Insert Central (inch) Drill diameter Designation Grade I t r d1 Ø0.484~Ø0.531 Ø0.562~Ø0.625 Ø0.687~Ø0 Ø0.812~Ø0.875 Ø0.937~Ø1.125 Ø1.187~Ø1.375 Ø1.437~Ø1.687 Ø1.750~Ø2.000 Ø2.062~Ø2.375 SPMT PD PD PD 07T208-PD PD 11T308-PD PD 15M510-PD PD Peripheral (inch) Drill diameter Designation Grade I d t r d1 Ø0.484~Ø0.531 Ø0.562~Ø0.625 Ø0.687~Ø0 Ø0.812~Ø0.875 Ø0.937~Ø1.125 Ø1.187~Ø1.375 Ø1.437~Ø1.687 Ø1.750~Ø2.000 Ø2.062~Ø2.375 XOMT PD PD PD 07T205-PD PD 11T306-PD PD 15M508-PD PD KING DRILL _15

16 Quality, performance, value - Guaranteed! KING DRILL-2D DesignatonØDØd1Ød2l1l2 L Insert Screw (inch) Wrech K2DA A HP-04 A HP-04 A HP-04 A HP-05 A HP-05 A HP-06 A HP-06 A HP-07 A HP-07 A HP-09 A HP-09 A HP-09 A HP-09 A HP-09 A HP-11 A HP-11 A HP-11 A HP-11 A HP-13 A HP-13 A HP-13 A HP-13 A HP-13 A HP-15 A HP-15 A HP-15 A HP-15 A HP-15 A HP-18 A HP-18 A HP-18 A HP-18 A HP-18 A HP /64 1/2 17/32 9/16 5/8 11/16 3/4 13/16 7/8 15/ /32 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1 7/16 1 1/2 1 9/16 1 5/8 1 11/16 1 3/4 1 13/16 1 7/8 1 15/ /16 2 1/8 2 3/16 2 1/4 2 5/16 2 3/ SPMT XOMT SPMT XOMT SPMT XOMT SPMT07T208- XOMT07T205- SPMT XOMT SPMT11T308- XOMT11T306- SPMT XOMT SPMT15M510- XOMT15M508- SPMT XOMT FTNA0204 TW06P FTNA0204 TW06P FTKA02565 TW07P FTKA02565 TW07S FTKA0307 TW09S FTKA03508 TW15S FTKA03508 TW15S FTNC04511 TW20S FTNA0511 TW _ KORLOY TECH-NEWS

17 KING DRILL _17 KING DRILL-3D (inch) A HP-04 A HP-04 A HP-04 A HP-05 A HP-05 A HP-06 A HP-06 A HP-07 A HP-07 A HP-09 A HP-09 A HP-09 A HP-09 A HP-09 A HP-11 A HP-11 A HP-11 A HP-11 A HP-13 A HP-13 A HP-13 A HP-13 A HP-13 A HP-15 A HP-15 A HP-15 A HP-15 A HP-15 A HP-18 A HP-18 A HP-18 A HP-18 A HP-18 A HP /64 1/2 17/32 9/16 5/8 11/16 3/4 13/16 7/8 15/ /32 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1 7/16 1 1/2 1 9/16 1 5/8 1 11/16 1 3/4 1 13/16 1 7/8 1 15/ /16 2 1/8 2 3/16 2 1/4 2 5/16 2 3/ SPMT XOMT SPMT XOMT SPMT XOMT SPMT07T208- XOMT07T205- SPMT XOMT SPMT11T308- XOMT11T306- SPMT XOMT SPMT15M510- XOMT15M508- SPMT XOMT FTNA0204 TW06P FTNA0204 TW06P FTKA02565 TW07S FTKA02565 TW07S FTKA0307 TW09S FTKA03508 TW15S FTKA03508 TW15S FTNC04511 TW20S FTNA0511 TW20S K3DA DesignatonØDØd1Ød2l1l2 L Insert Screw Wrech

18 Quality, performance, value - Guaranteed! 18_ KORLOY TECH-NEWS KING DRILL-4D (inch) A HP-04 A HP-04 A HP-04 A HP-05 A HP-05 A HP-06 A HP-06 A HP-07 A HP-07 A HP-09 A HP-09 A HP-09 A HP-09 A HP-09 A HP-11 A HP-11 A HP-11 A HP-11 A HP-13 A HP-13 A HP-13 A HP-13 A HP-13 A HP-15 A HP-15 A HP-15 A HP-15 A HP-15 A HP-18 A HP-18 A HP-18 A HP-18 A HP-18 A HP /64 1/2 17/32 9/16 5/8 11/16 3/4 13/16 7/8 15/ /32 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1 7/16 1 1/2 1 9/16 1 5/8 1 11/16 1 3/4 1 13/16 1 7/8 1 15/ /16 2 1/8 2 3/16 2 1/4 2 5/16 2 3/ SPMT XOMT SPMT XOMT SPMT XOMT SPMT07T208- XOMT07T205- SPMT XOMT SPMT11T308- XOMT11T306- SPMT XOMT SPMT15M510- XOMT15M508- SPMT XOMT FTNA0204 TW06P FTNA0204 TW06P FTKA02565 TW07S FTKA02565 TW07S FTKA0307 TW09S FTKA03508 TW15S FTKA03508 TW15S FTNC04511 TW20S FTNC04511 TW20S K4DA DesignatonØDØd1Ød2l1l2 L Insert Screw Wrech

19 KING DRILL _19 KING DRILL-5D (inch) A HP-04 A HP-04 A HP-04 A HP-05 A HP-05 A HP-06 A HP-06 A HP-07 A HP-07 A HP-09 A HP-09 A HP-09 A HP-09 A HP-09 A HP-11 A HP-11 A HP-11 A HP-11 A HP-13 A HP-13 A HP-13 A HP-13 A HP-13 A HP-15 A HP-15 A HP-15 A HP-15 A HP-15 A HP-18 A HP-18 A HP-18 A HP-18 A HP-18 A HP /64 1/2 17/32 9/16 5/8 11/16 3/4 13/16 7/8 15/ /32 1 1/16 1 1/8 1 3/16 1 1/4 1 5/16 1 3/8 1 7/16 1 1/2 1 9/16 1 5/8 1 11/16 1 3/4 1 13/16 1 7/8 1 15/ /16 2 1/8 2 3/16 2 1/4 2 5/16 2 3/ SPMT XOMT SPMT XOMT SPMT XOMT SPMT07T208- XOMT07T205- SPMT XOMT SPMT11T308- XOMT11T306- SPMT XOMT SPMT15M510- XOMT15M508- SPMT XOMT FTNA0204 TW06P FTNA0204 TW06P FTKA02565 TW07S FTKA02565 TW07S FTKA0307 TW09S FTKA03508 TW15S FTKA03508 TW15S FTNC04511 TW20S FTNC04511 TW20S K5DA DesignatonØDØd1Ød2l1l2 L Insert Screw Wrech

20 KORLOY Europe KORLOY China (Factory Qingdao) KORLOY Inc. KORLOY America KORLOY India KORLOY Brasil Head Office Holystar B/D, 1350, Nambusunhwan-ro, Geumcheon-gu, Seoul, , Korea Tel : Fax : , Web : export@korloy.com Cheongju Factory 55, Sandan-ro, Heungdeok-gu, Cheongju-si, Chungcheongbuk-do, , Korea Tel : Fax : Jincheon Factory 54, Gwanghyewonsandan 2-gil, Gwanghyewon-myeon, Jincheon-gun, Chungcheongbuk-do, , Korea Tel : Fax : R & D Institute 55, Sandan-ro, Heungdeok-gu, Cheongju-si, Chungcheongbuk-do, , Korea Tel : Fax : Heinrich-Lanz-Allee 12, Frankfurt am Main, Germany Tel : Fax : sales@korloyeurope.com Ground Floor, Property No. 217, Udyog Vihar Phase 4, Gurgaon , Haryana, INDIA Tel : Fax : sales.kip@korloy.com Av. Aruana 280, conj.12, WLC, Alphaville, Barueri, CEP , SP, Brasil Tel : vendas@korloy.com Ground Dongjing Road 56 District Free Trade Zone. Qingdao, China Tel : Fax : kimyc@korloy.com 620 Maple Avenue, Torrance, CA 90503, USA Tel : Toll Free : Fax : sales@korloy.us Seoul Headquarter KORLOY Engineering Center Cheongju Research & Development Jincheon Factory Office Jincheon Factory TN07-EI-01

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