top solid piercing drill cone tpdc - korloy.us news/2016technews_tpdc.pdf · top solid piercing...

TPDCCone Shaped HeadIndexable Drill

Top solid Piercing Drill Cone

▣ High Precision

High precision drilling available to the level of carbide solid drill

▣ High Feed

High feed machining available through stable chip evacuation with optimized cutting edge & helical oil hole

02 03KORLOY TECH-NEWS TPDC

TPDC 50th Anniversary

As for existing indexable drills for general purpose, there was problem with low productivity and poor machining precision due to chip shape and poor chip evacuation when machining tough material such as mild steel and forged steel.

In order to solve this problem, blade design and coolant hole system has upgraded to make it possible to get good chip geometry and stable chip flow in any material of workpieces. As a result, productivity has been improved than that of previous indexable drills for general purpose, with availability in high speed and high feed machining.

On top of that, the One step clamp system applied to TPDC for easy and quick tool change. This clamping design allows to change inserts while the holder is attached on the machine in a shortened setting time.Better stability and sustainability are now possible with this system.

TPDC inserts guarantee excellent anti chipping and wear resistance by ultra fine substrate and multi layer coating.Not only that, special surface treatment on the holders improves durability and chip flow.

TPDC 3D / 5D / 8D

Insert

Improved productivity through excellent chip control and stable chip flow

Cone Shaped Head Indexable Drill

[ Holder ]

[ Insert ]

Code System

- -

Top solid Piercing Drill

-TPD

Top solid Piercing Drill

TPD

Flute length (inch)

2953 : 2.953”

2953

Insert typeC : Cone type

C

A : Inch typeNo code : Metric

type

A

A : Inch typeNo code : Metric

type

A

Drill dia.0591 : Ø0.591”

0591

Insert typeC : Cone type

C

Aspect ratio(L/D)3D, 5D, 8D

5D

Drill dia.0591 : Ø0.591”

0591

Shank dia.075 : Ø0.75”

075

One step clamp system Rigidity and stability

Easy to change inserts Shortened setting time

Material technology Excellent anti chipping & wear resistance

Optimized blade design Excellent chip control

Helical shaped coolant hole system Better chip evacuation

Advantages

Machining areaP : Steel, UniversalM : Stainless steelK : Cast iron

P

N : AluminiumC : Carbon fiber

Reinforced plastic



Better chip flow

Flute polishing

Good durability

Surface treatment

Low cutting load and good machinability

High helix angle

Chip flow improved

Helical shaped coolant hole system

Improved chip control and wear resistance

Optimal blade design

Excellent centering and penetration

Overlap thinning

Clamping design - One step clamp system Increased stability - Clamping system allowing to change inserts while the holder is attached on the machine Shortened setting time

Optimized blade design - Excellent chip control Possibility to use for various types of workpieces

Helical shaped coolant hole system - Wide chip pocket area secured Better lubrication + chip flow improved

Material technology - Ultra fine substrate + Multi layer coating applied Excellent anti chipping & wear resistance

Features of TPDC

Clamping area : Easy and fast tool change

Anti-rotating area : Performs as a stopper

Clamping and anti-rotating area make an acute angle to prevent insert rotation while machining

One Step Clamp System Easy and quick tool change with good repeatability

Features of Clamping System

Clamping area

Anti-rotating area

Sustainability testDurability test

14121086420

Run

-out

(㎛)

No. of clampings1time 30time 60time 90time 120time 150time

After clamping 150 times,the drill run-out remains

After using 40 inserts, the setting run-out remains below 15㎛

Workpiece Cutting conditions

Tools

AISI4140(HRC22)Dill dia.(inch) = Ø0.591vc(sfm) = 259.3fn(ipr) = 0.01ap(inch) = 2.362wetInsertHolder

TPD0591CAPTPDCA5D-0591075-2953

ExcellentSustaina-

bility



Cutting Performance

[ TPDC ]

[ Competitor ]

Edge in good shape

[ TPDC ]

[ Competitor ]

Excellent wear resistance

[ TPDC ]

[ Competitor ]• Long chip due to wear of cutting edge

• Poor chip control

Edge in good shape

Lubricative multi layer coating prevents chipping on cutting edges.

Alloy steel (AISI4140, HRC22)

TPDCCompetitor

2.268inch(640Hole)

2.079inch(586Hole)

1.1 timesmore

Workpiece Cutting conditions Tools

Part of machineDrill dia.(mm) = Ø0.748, vc(sfm) = 328.1, fn(ipr) = 0.012, ap(inch) = 3.543, wetInsert TPD0758CAP (PC5335) Holder TPDCA5D-0748100-3740

Optimized blade design secures better chip flow and chip geometry.

Carbon steel (A633 Gr.E, HRC20)

TPDCCompetitor

0.681inch(192Hole)

0.335inch(94Hole)

2 timesmore


Part of welding machineDrill dia.(mm) = Ø0.748, vc(sfm) = 328.1, fn(ipr) = 0.008, ap(inch) = 3.543, wetInsert TPD0758CAP (PC5335) Holder TPDCA5D-0748100-3740

Lubricative multi layer coating enhances wear resistance.

Carbon steel (AISI1045, HRC19)

TPDCCompetitor

1.205inch(382Hole)

0.803inch(255Hole)

1.5 timesmore



Lubricative multi layer coating enhances wear resistance.

Carbon steel (AISI1045, HRC40)

TPDCCompetitor

0.394inch(153Hole)

0.335inch(130Hole)

Ø940

1.2 timesmore





Recommended Cutting Condition

Cutting Performance

In case of 8D, reduce the cutting condition 40~50% lower than above after machining the beginning of hole(1.5D). In case of interrupted machining, reduce the feed to 0.0039~0.0059 (inch) arround the interrupted part.

Workpiecefn(Depth of cut = 3D, 5D)

iprØ0.472~Ø0.629ISO Workpiece HB Ø0.630~Ø0.786

vc

sfmGrade

P

80~120

180~280

140~260

200~400

50~260

220~450

PC5335

PC5335

PC5335

PC5335

PC5335

PC5335

360(262-459)

328(230-426)

360(262-459)

246(164-328)

230(164-295)

197(131-262)

0.0060-0.0118

0.0060-0.0118

0.0070-0.0138

0.0070-0.0138

0.0070-0.0138

0.0070-0.0138

0.0079-0.0138

0.0079-0.0138

0.0090-0.0150

0.0090-0.0150

0.0079-0.0138

0.0079-0.0138

Low carbon steel

High carbon steel

Low alloy steel

Low pre-hardened steel

High alloy steel

High pre-hardened steel

Carbon steel

Alloy steel

Chip control

[ TPDC ] [ Competitor ]

Optimized blade design secures better chip geometry.

Chips in good shapeLongchips


Tools

A633 Gr.E(HRC20)Drill dia.(inch) = Ø0.748vc(sfm) = 295.3fn(ipr) = 0.01ap(inch) = 3.543wetInsertHolder

TPD0758CAP (PC5335)TPDCA5D-0748100-3740

Cutting load1861551239362310

674.7562.3449.8337.4224.9112.5

0

Torq

ue (in

.lbf)

Thru

st (lb

f)

Cutting time(min) Cutting time(min)[ Torque ] [ Thrust ]

TPDCCompetitor

TPDCCompetitor

High helix angle and helix shaped coolant hole system lower cutting loads and improve uniformity.


Tools

AISI1045(HRC19)Drill dia.(inch) = Ø0.591vc(sfm) = 295.3fn(ipr) = 0.0098ap(inch) = 2.362wetInsertHolder

TPD0591CAP (PC5335)TPDCA5D-0591075-2953

Surface roughness

[ Competitor ] [ Competitor ]

1.331.5

1.3

1.1

0.9

0.7

0.5

Ra

(㎛)

[ TPDC ]

[ TPDC ]

0.56


Tools


TPD0758CAP (PC5335)TPDCA5D-0748100-3740

Machining precision

[ TPDC ] [ Competitor ]

[ Roundness ]

X

Y

X

Y

7㎛ 24㎛

Optimized blade designand overlap thinning improve precision.


Tools


TPD0591CAP (PC5335)TPDCA5D-0591075-2953

TPDC

0.59230.59190.59150.59110.59070.5904

Hole

Dia.

(inch

)

LocationBeginning Middle End

Competitor



How to Make Good Insert Clamping

Coolant Tip

Precautions When Setting

Precautions When Drilling

50

40

30

20

10

0

20

15

10

5

0Coola

nt vo

lume

(ℓ/m

m)

Coola

nt p

ress

ure

(Bar

)Drill dia.(Ø inch) Drill dia.(Ø inch)

0.197 0.394 0.591 0.787 0.984 1.181 0.197 0.394 0.591 0.787 0.984 1.181

Recommended Recommended

MinimumMinimum

The data of the graph could be changed depending on workpiece and cutting condition.

Follow this picture when setting to make the best condition of TPDC.

① Clean the mounting seat with air or cloth.② Put an insert on the

holder.③ A part of wrench and

B part of insert must be parallel to each other before clamp the insert. Turn the wrench clockwise to finish clamping.

Peripheral vibration under 0.0008inch

[ Setting of the horizontal equipment ] [ Setting of the vertical equipment ]

Max. 0.0008inch

1. A slope inclined more than 6° is not allowed.

2. When entering, reduce the feed to 30~50%.

1. Space between panels affects chip evacuation problem.

2. Do not make space between panels.

Not allowed Not allowed

Ramping Machining overlapped panels Plunging Boring

Clamped state


AISI4140(HRC22)vc(sfm) = 328.1, wet



W

h7

Insert

Recommended Torque per Wrench

※ Oder made items available

Designation Drill dia.(ØD) Torque(in.lbf)

TPDC-W12

TPDC-W13

TPDC-W14

TPDC-W15

TPDC-W16

TPDC-W17

TPDC-W18

TPDC-W19

22.1

22.1

22.1

22.1

22.1

31.0

31.0

31.0

0.472~0.511

0.512~0.550

0.551~0.590

0.591~0.629

0.630~0.668

0.669~0.708

0.709~0.747

0.748~0.786

(inch)

(inch)

Designation Drill dia.(ØD) W Grade Holder Wrench

TPD0472CAP 0.472~0.491

0.448

PC5335 TPDCA(3,5,8)D-0472063-(1417,2362,3780)

TPDC-W12

0492CAP 0.492~0.511 PC5335 TPDCA(3,5,8)D-0492063-(1496,2480,3937)

0512CAP 0.512~0.531

0.484

PC5335 TPDCA(3,5,8)D-0512063-(1535,2559,4094)

TPDC-W13

0532CAP 0.532~0.550 PC5335 TPDCA(3,5,8)D-0532063-(1614,2677,4252)

0551CAP 0.551~0.570

0.528

PC5335 TPDCA(3,5,8)D-0551063-(1654,2756,4409)

TPDC-W14

0571CAP 0.571~0.590 PC5335 TPDCA(3,5,8)D-0571063-(1732,2874,4567)

0591CAP 0.591~0.629 0.563 PC5335 TPDCA(3,5,8)D-0591075-(1772,2953,4724) TPDC-W15





TPDC

(mm)

※ The shank is based on DIN6535 and ISO9677.

Designation ØD Ød Ød1 ℓ1 ℓ2 L Insert Fig.

TPDCA 3D-0472063-1417 0.472~0.491 0.625 0.787 1.417 1.890 3.898 TPD0472CA-0491CA 13D-0492063-1496 0.492~0.511 0.625 0.787 1.496 1.890 3.976 TPD0492CA-0511CA 13D-0512063-1535 0.512~0.531 0.625 0.787 1.535 1.890 4.055 TPD0512CA-0531CA 13D-0532063-1614 0.532~0.550 0.625 0.787 1.614 1.890 4.134 TPD0532CA-0550CA 13D-0551063-1654 0.551~0.570 0.625 0.787 1.654 1.890 4.173 TPD0551CA-0570CA 13D-0571063-1732 0.571~0.590 0.625 0.787 1.732 1.890 4.213 TPD0571CA-0590CA 13D-0591075-1772 0.591~0.629 0.750 0.984 1.772 1.969 4.449 TPD0591CA-0629CA 23D-0630075-1890 0.630~0.668 0.750 0.984 1.890 1.969 4.606 TPD0630CA-0668CA 23D-0669075-2008 0.669~0.708 0.750 0.984 2.008 1.969 4.724 TPD0669CA-0708CA 23D-0709100-2126 0.709~0.747 1.000 1.299 2.126 2.205 5.197 TPD0709CA-0747CA 23D-0748100-2244 0.748~0.786 1.000 1.299 2.244 2.205 5.315 TPD0748CA-0786CA 25D-0472063-2362 0.472~0.491 0.625 0.787 2.362 1.890 4.843 TPD0472CA-0491CA 15D-0492063-2480 0.492~0.511 0.625 0.787 2.480 1.890 4.961 TPD0492CA-0511CA 15D-0512063-2559 0.512~0.531 0.625 0.787 2.559 1.890 5.079 TPD0512CA-0531CA 15D-0532063-2677 0.532~0.550 0.625 0.787 2.677 1.890 5.197 TPD0532CA-0550CA 15D-0551063-2756 0.551~0.570 0.625 0.787 2.756 1.890 5.276 TPD0551CA-0570CA 15D-0571063-2874 0.571~0.590 0.625 0.787 2.874 1.890 5.354 TPD0571CA-0590CA 15D-0591075-2953 0.591~0.629 0.750 0.984 2.953 1.969 5.630 TPD0591CA-0629CA 25D-0630075-3150 0.630~0.668 0.750 0.984 3.150 1.969 5.866 TPD0630CA-0668CA 25D-0669075-3346 0.669~0.708 0.750 0.984 3.346 1.969 6.063 TPD0669CA-0708CA 25D-0709100-3543 0.709~0.747 1.000 1.299 3.543 2.205 6.614 TPD0709CA-0747CA 25D-0748100-3740 0.748~0.786 1.000 1.299 3.740 2.205 6.811 TPD0748CA-0786CA 28D-0472063-3780 0.472~0.491 0.625 0.787 3.780 1.890 6.260 TPD0472CA-0491CA 18D-0492063-3937 0.492~0.511 0.625 0.787 3.937 1.890 6.417 TPD0492CA-0511CA 18D-0512063-4094 0.512~0.531 0.625 0.787 4.094 1.890 6.614 TPD0512CA-0531CA 18D-0532063-4252 0.532~0.550 0.625 0.787 4.252 1.890 6.811 TPD0532CA-0550CA 18D-0551063-4409 0.551~0.570 0.625 0.787 4.409 1.890 6.929 TPD0551CA-0570CA 18D-0571063-4567 0.571~0.590 0.625 0.787 4.567 1.890 7.087 TPD0571CA-0590CA 18D-0591075-4724 0.591~0.629 0.750 0.984 4.724 1.969 7.402 TPD0591CA-0629CA 28D-0630075-5039 0.630~0.668 0.750 0.984 5.039 1.969 7.756 TPD0630CA-0668CA 28D-0669075-5354 0.669~0.708 0.750 0.984 5.354 1.969 8.071 TPD0669CA-0708CA 28D-0709100-5669 0.709~0.747 1.000 1.299 5.669 2.205 8.740 TPD0709CA-0747CA 28D-0748100-5984 0.748~0.786 1.000 1.299 5.984 2.205 9.055 TPD0748CA-0786CA 2

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20160410TN03-EI-01

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TPDC 3D / 5D / 8D

Fig. 1 Fig. 2

(Flute length)

h6h7

(Flute length)

h6h7

top solid piercing drill cone tpdc - korloy.us news/2016technews_tpdc.pdf · top solid piercing...

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