PCD round tools for aluminum

PCD round tools for aluminum

December 2, 2020

Kennametal Inc.


Kennametal has introduced a new line of PCD round tools for aluminum machining that delivers up to 10x higher productivity than carbide tooling. The new line of drills, reamers, and end mills provides exceptional tool life and wear resistance even in very abrasive aluminum alloys and are available with very short lead times.

A broad selection of PCD end mills in diameters up to 50mm are available as standard.

“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 900m/min (3,000sfm). Milling operations can be performed at an incredible 6,000m/min (20,000sfm) – far higher than non-PCD tooling.”

With through-the-tool coolant capabilities and an MQL-ready interface, these PCD round tools are for 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 to 0.8μm (0.0025 to 0.02μ-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 PCD round tool line includes a range of holemaking and hole finishing options, including modular reaming heads up to 42mm in diameter.

PCD end mill features:

  • 6mm to 50mm diameter
  • Cutting depths up to 50mm
  • Center-cutting, roughing, finishing geometries
  • Various rake angles

PCD drill features:

  • 6mm to 20mm diameter in 0.5mm increments
  • Up to 5xD
  • Inch, metric sizes

PCD reaming portfolio:

  • 6mm to 20mm diameter in 1mm increments
  • Through, blind hole versions
  • For diameters up to 42mm, 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.”