We recently assisted a customer in optimizing their machining process for SKD11 mold steel components using high-performance ceramic inserts. Here’s an overview of the application and the improved solution we provided.
Workpiece: Rolling Mill
Material: SKD11
Hardness: 59–62 HRC
- Insert Model: RCGX090700P20015 PT600M
- Monthly Consumption: 30–50 pcs
Machining Parameters:
- Cutting Speed: 150 m/min
- Feed: 0.2 mm
- Depth of Cut: 0.15–0.25 mm
- Coolant: Required
Properties of SKD11 Mold Steel
SKD11 is a high-carbon, high-chromium tool steel known for its exceptional performance in demanding applications. Key characteristics include:
- High Hardness: Reaches HRC 58–60, offering superior wear resistance.
- High Strength: Excellent tensile and compressive strength, suitable for heavy-duty operations.
- Good Toughness: Resists cracking and chipping even under high stress.
- Corrosion Resistance: withstands exposure to certain chemicals and harsh environments.
Why Ceramic Inserts Are Ideal for Machining SKD11
Ceramic inserts provide significant advantages in processing high-hardness materials like SKD11:
1. Exceptional Hardness & Wear Resistance
With a hardness of 91–95 HRA, ceramic inserts far outperform carbide tools. They offer up to 5x longer tool life, making them ideal for high-wear applications like mold steel machining.
2. Superior High-Temperature Performance
Ceramic inserts maintain high hardness (80 HRA) even at temperatures exceeding 1200°C. This allows for cutting speeds 2–5x higher than carbide, drastically reducing machining time.
3. Excellent Chemical Stability
Low affinity to metals reduces adhesion and diffusion, minimizing built-up edge and improving surface finish.
4. Low Friction Coefficient
Reduces cutting forces and tool wear, enabling smoother finishes and often making grinding unnecessary.
5. Broad Applicability
Suitable for both cold-work (e.g., Cr12MoV, D2) and hot-work (e.g., H13) mold steels, especially in roughing and finishing of high-hardness, high-toughness materials.
Conclusion
By implementing ceramic inserts, we helped our customer achieve longer tool life, higher cutting speeds, and improved surface quality in machining SKD11 rolling mill components. This optimization resulted in reduced downtime and lower overall processing costs.
If you are machining high-hardness materials like SKD11, our ceramic inserts may offer the performance upgrade you need. Contact us for a customized solution.
