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Gabriel Sanchez
Gabriel Sanchez

APKX 1505 PDER-M 8026: A Comparison of Different Chipbreaker Geometries and Coatings


APKX 1505 PDER-M 8026: A High-Performance Milling Insert for General Machining




If you are looking for a high-performance milling insert that can handle general machining of steel and cast iron, you might want to check out APKX 1505 PDER-M 8026. This is a single-sided milling insert with an 85 parallelogram shape, a 0.8mm corner radius, an R geometry with rounded cutting edges and facet, and an 8026 PVD coated fine grained WC-Co carbide grade. In this article, we will explore the features and benefits of this milling insert, its applications and materials, and how it compares to other milling inserts in the market.


Features and Benefits of APKX 1505 PDER-M 802 Features and Benefits of APKX 1505 PDER-M 8026




APKX 1505 PDER-M 8026 is a milling insert that has several features and benefits that make it suitable for general machining of steel and cast iron. Let's take a look at some of them in more detail.




apkx 1505 pder-m 8026



Single-sided milling insert with 85 parallelogram shape




The shape and size of the milling insert affect the depth of cut, indexing accuracy, and stability of the milling operation. APKX 1505 PDER-M 8026 has an 85 parallelogram shape, which means that it has four cutting edges that are parallel to each other and form an angle of 85 with the insert base. This shape allows for a large depth of cut, up to 10mm, which is ideal for medium to rough machining. The shape also ensures a high indexing accuracy, as the insert can be easily aligned with the holder and the workpiece. Moreover, the shape provides a high stability, as the insert has a large contact area with the holder and a low center of gravity.


Another feature of APKX 1505 PDER-M 8026 is that it is a single-sided milling insert, which means that it has only one usable cutting edge per side. This may seem like a disadvantage compared to double-sided inserts, which have two usable cutting edges per side, but it actually has some benefits. For one thing, single-sided inserts are cheaper than double-sided ones, as they require less material and processing. For another thing, single-sided inserts have a higher clearance angle than double-sided ones, which reduces the risk of rubbing and friction between the insert and the workpiece. This improves the surface finish and tool life of the insert.


0.8mm corner radius and R geometry with rounded cutting edges and facet




The corner radius and geometry of the milling insert affect the surface finish, chip formation, and tool life of the milling operation. APKX 1505 PDER-M 8026 has a 0.8mm corner radius, which is the smallest among the APKX inserts. This corner radius provides a sharp cutting edge that can produce a smooth surface finish on the workpiece. The corner radius also reduces the stress concentration on the insert edge, which prolongs the tool life.


The geometry of APKX 1505 PDER-M 8026 is R geometry, which means that it has rounded cutting edges and a facet on each side. The rounded cutting edges reduce the cutting forces and vibrations during milling, which improves the stability and accuracy of the operation. The rounded cutting edges also enhance the chip formation and evacuation, as they create small and uniform chips that can be easily removed from the cutting zone. The facet on each side of the insert provides a positive rake angle, which reduces the power consumption and heat generation during milling. The facet also protects the cutting edge from chipping and cracking, which extends the tool life.


8026 PVD coated fine grained WC-Co carbide grade




The coating and substrate of the milling insert affect the wear resistance, heat resistance, and toughness of the milling operation. APKX 1505 PDER-M 8026 has an 8026 PVD coated fine grained WC-Co carbide grade, which is one of the most advanced grades in the market. The coating is a thin layer of titanium nitride (TiN) that is applied on the substrate by physical vapor deposition (PVD) process. The coating provides a high wear resistance and heat resistance to the insert, as it prevents abrasive wear, adhesive wear, and thermal cracking. The coating also enhances the lubricity and anti-welding properties of the insert, as it reduces friction and sticking between the insert and the workpiece.


The substrate is a fine grained tungsten carbide-cobalt (WC-Co) alloy that is made by powder metallurgy process. The substrate provides a high toughness and strength to the insert, as it resists impact load, shock load, and deformation. The substrate also provides a high hardness and stiffness to the insert, as it resists plastic deformation and elastic deformation. The fine grained structure of the substrate ensures a uniform distribution of cobalt binder and carbide particles, which improves the homogeneity and reliability of the insert.


The ISO-grade range of APKX 1505 PDER-M 8026 is P15-P30 for steel machining and K15-K30 for cast iron machining. This means that it can handle medium to rough machining conditions with moderate to high cutting speeds and feeds for both steel and cast iron materials. The ISO-grade system is an international standard that classifies milling inserts according to their material suitability, application range, and performance level.


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APKX 1505 PDER-M 8026 is a versatile milling insert that can handle general machining of steel and cast iron materials. Let's see how it performs in different applications and materials.


General machining of steel and cast iron




Steel and cast iron are two of the most common materials used in various industries, such as automotive, aerospace, energy, construction, and manufacturing. They have different characteristics and challenges that require suitable milling inserts to achieve high performance. Steel is a metal alloy that consists mainly of iron and carbon, with varying amounts of other elements. Steel can have different properties depending on its composition, such as hardness, strength, ductility, toughness, and corrosion resistance. Cast iron is a metal alloy that consists mainly of iron and carbon, with a higher carbon content than steel. Cast iron can have different types depending on its microstructure, such as gray cast iron, ductile cast iron, white cast iron, and malleable cast iron. Cast iron can have different properties depending on its type, such as hardness, brittleness, wear resistance, and thermal conductivity.


Some of the challenges of machining steel and cast iron are:



  • High cutting temperatures and pressures that can cause thermal and mechanical wear on the insert



  • High hardness and strength that can cause abrasive wear and chipping on the insert



  • Low ductility and toughness that can cause brittle fracture and cracking on the insert



  • Poor chip formation and evacuation that can cause built-up edge, chip jamming, and chip recutting on the insert



  • Poor surface finish and dimensional accuracy that can affect the quality and functionality of the workpiece



APKX 1505 PDER-M 8026 can overcome these challenges and achieve high performance in general machining of steel and cast iron by:



  • Providing a high wear resistance and heat resistance with its 8026 PVD coated fine grained WC-Co carbide grade



Providing


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