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Introduction to KennametalIntroduction to Kennametal
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Kennametal, Inc.Kennametal, Inc.
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Kennametal’s missionis to be our customers’ first choicefirst choice
worldwide for cutting tools,tooling systems, supplies,
and technical servicesin the metalworking, mining,
and highway-construction industries.
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How?How?
by providing technical leadership
by providing innovative solutions
by reducing costs
by understanding and exceeding
customer needs
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R
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Kennametal World Headquarters Kennametal World Headquarters located just a few miles from the located just a few miles from the original site established in 1938original site established in 1938with 14 employees.with 14 employees.
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Kennametal Global LocationsKennametal Global Locations
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Industries ServedIndustries Served
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Automotive / Light TruckAutomotive / Light Truck
engine blocks
cylinder heads
brakes, drums, rotors
wheels
more
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Aerospace
airframesairframes
turbine bladesturbine blades
rotor assembliesrotor assemblies
moremore
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Heavy EquipmentHeavy Equipment
crankshafts
transmissions
railroad wheels
drive-linecomponents…more
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MedicalMedical
hip-replacement joints
knee-replacement joints
…more
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Oil / Gas / EnergyOil / Gas / Energy
pumps
valves
seals
…more
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Kennametal web page http://www.kennametal.com
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National Center for Defense Manufacturing and Machining Mission Statement
The NCDMM will deliver state of the art manufacturing solutions to ensure the quality, affordability, maintainability, and rapid deployment of existing and yet-to-be developed defense systems. Collaboration among Government, Industrial, and Academic organizations will enhance key development efforts. Disciplined training & implementation methodologies will ensure the rapid deployment of best practices to key stakeholders.
Affordable Manufacturing Methods
Proven Solutions
Advanced Technology
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Center Model & Alliance PartnersCenter Model & Alliance Partners
Industry Stakeholders
Cutting Tool Providers
Universities
Machine Tool Builders
CenterGovernment Labs
Raw Material ProvidersTechnology Enablers
EXTRUDEHONE
THIRD WAVE SYSTEMS
Alliance Partners
Timken
Alcoa Inc.
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Productivity Improvement Productivity Improvement
Example:Example: Aircraft Engine MountAircraft Engine Mount
Material: Inconel 718
Conventional Machining Method– HSS or Carbide Tooling
– 1.0 cubic inch - metal removal rate
– ~45 hours to rough machine (1st oper.)
System Solution– Ceramic Milling Technology
– 20 cubic inch - metal removal rate
– <13 hours to rough machine (1st oper.)
– 32 hours reduction in machine timeMachine time NOW available for additional work
Cost Savings - $1.5M
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Contact Information:Contact Information:1. K.Govindarajan
DGM, Product Management & Tech. Servicese
email. [email protected]
2. S. M. Kulkarni
Manager, Advance Business Group
Tel: 080-28394321
email. [email protected]
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Engineered Technologies
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Some New TechnologiesSome New Technologies….….that are becoming commonplace in progressive
manufacturers….
Tuned Tooling...Stability Lobes & Preferred Speed Selection... Electromagnetic Balancing...Heat ShrinkHigh Velocity Machining...
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Tuned Tooling...Tuned Tooling...
10 x 1
Steel
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Tuned Tooling...Tuned Tooling...
Tunable Components
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Tuned Tooling...Tuned Tooling...
Enables 10:1 L to D precision boring...
Forward mounted “Tuner Package”
Precision Boring Head
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Electromagnetic BalancingElectromagnetic Balancing
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Results…..Results…..
Spindle Housing Vibration During Electromagnetic Toolholder Balancing
0
0.5
1
1.5
2
2.5
3
5000 7500 10000 12500 15000
Spindle Speed (rpm)
Dis
plac
emen
t (m
icro
ns)
Initial ConditionAfter Active Balancing
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System easily retrofitable in less System easily retrofitable in less than 1 hour...than 1 hour...
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Heat Shrink Systems
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Heat
Heat
Shrink fit Technology
Body O.D.
Body I.D.
Tool Shank
Heat
Heat
Heat
Heat
ClearanceZone
Expansion
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Possibilities………….
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High Velocity Machining ???
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The Importance of Engineering the Whole Package……
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Finite Element Modeling & AnalysisFinite Element Modeling & Analysis
Cutter Body Analysis
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Predicted vs. Actual ResultsPredicted vs. Actual Results12”(305mm) Body Diameter
Predicted Speed at Failure ~ 60,000 RPM
Actual Speed at Failure - 55,000 RPM
Equivalent Surface Footage - 173,000 SFM* (52730 m/min)
*Mach 2.6 (or 2.6 times speed of sound)
Resultant “Safe Spin” RPM - 25,000
Equivalent Surface Footage - 78,500 SFM (23926 m/min)
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Why do we need to know the limits???
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Before….
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After….
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Prediction vs. PracticePrediction vs. Practice
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In SummaryIn Summary
•Metalcutting is a Violent Process of High Forces & High Heat…
All cutting tools play a major role in the metalcutting manufacturing process…
Utilize this week’s information to increase your metalcutting productivity!!!
