Introduction to Kennametal

Kennametal, Inc.

Kennametals mission is to be our customers first choice worldwide for cutting tools, tooling systems, supplies, and technical services in the metalworking, mining, and highway-construction industries.

How?
by providing technical leadership by providing innovative solutions by reducing costs by understanding and exceeding customer needs
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Kennametal World Headquarters located just a few miles from the original site established in 1938 with 14 employees.

Kennametal Global Locations

Industries Served

Automotive / Light Truck

engine blocks cylinder heads brakes, drums, rotors wheels more

Aerospace
airframes turbine blades rotor assemblies more

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Heavy Equipment
crankshafts transmissions railroad wheels drive-line components more

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Medical
hip-replacement joints knee-replacement joints more

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Oil / 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.

Proven Solutions

Advanced Technology

Affordable Manufacturing Methods

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Center Model & Alliance Partners

Industry Stakeholders Cutting Tool Providers Government Labs Machine Tool Builders Universities

Center
Technology Enablers

Raw Material Providers

Alliance Partners

EXTRUDEHONE
Timken THIRD WAVE SYSTEMS

Alcoa Inc. 18

Productivity Improvement
Example: Aircraft 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 time
Machine time NOW available for additional work

Cost Savings - $1.5M

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Contact Information:
1. K.Govindarajan
DGM, Product Management & Tech. Servicese email. govindarajan.k@kennametal.com 2. S. M. Kulkarni Manager, Advance Business Group Tel: 080-28394321 email. Sanjay.kulkarni@kennametal.com

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Engineered Technologies

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Some New Technologies. Technologies

.that are becoming commonplace in progressive manufacturers. Tuned Tooling... Stability Lobes & Preferred Speed Selection... Electromagnetic Balancing... Heat Shrink High Velocity Machining...

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Tuned Tooling...

10 x 1

Steel

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Tuned Tooling...

Tunable Components

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Tuned Tooling...
Forward mounted Tuner Package Enables 10:1 L to D precision boring...

Precision Boring Head

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Electromagnetic Balancing

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Results..
Spindle Housing Vibration During Electromagnetic Toolholder Balancing
Displacement (microns)

3 2.5 2 1.5 1 0.5 0 5000

Initial Condition After Active Balancing

7500

10000

12500

15000

Spindle Speed (rpm)

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System easily retrofitable in less than 1 hour...

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Heat Shrink Systems

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Shrink fit Technology

eat H

Expansion
Heat Tool Shank

t He a
Body O.D.

Heat Clearance Zone Heat

Heat

Body I.D.

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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 & Analysis

Cutter Body Analysis

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Predicted vs. Actual Results

12(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. Practice

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In 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 weeks information to increase your metalcutting productivity!!!

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