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Kennametal says its PCD round tools for aluminum machining deliver up to 10 times higher productivity than carbide tooling. The new line of drills, reamers and end mills provides enhanced tool life and wear resistance even in abrasive aluminum alloys and is available with very short lead times.

“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 at 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 6,000 m/min (20,000 SFM) – far higher than non-PCD tooling.”

Kennametal also says the PCD round tools’ through-the-tool coolant capabilities and MQL-ready interface make them useful for both rough and finish machining. It continues by saying the tools’ sharp cutting edges and low-friction rake surfaces reduce the chance of built-up edge, while low-friction machining enhances surfaces in finishing operations like reaming. The company also says its PCD round tools can achieve surface roughness of Ra 0.1–0.8 μm (0.0025–0.02 μin) – smoother than with conventional carbide tooling – and perform well with high-silicon-content aluminum such as that used in the automobile industry.

Kennametal’s line of PCD end mills features 6 to 50 mm-diameter tools; cutting depths up to 50 mm; various rake angles; and center-cutting, roughing and finishing geometries. Its PCD drill offering features 6 to 20 mm-diameter tools in 0.5 mm increments, body lengths up to five times the diameter body lengths and inch and metric sizes. The company’s PCD reaming portfolio offers 6 to 20 mm-diameter tools in 1 mm increments, through and blind-hole versions of tools and a PCD modular reaming system with KST coupling for larger diameters up to 42 mm.