Kennametal
First-generation design (9.5 kg) on the left, and latest tool design variants (less than 8 kg) on the right for hassle-free tool changing.
First-generation design (9.5 kg) on the left, and latest tool design variants (less than 8 kg) on the right for hassle-free tool changing.
First-generation design (9.5 kg) on the left, and latest tool design variants (less than 8 kg) on the right for hassle-free tool changing.
First-generation design (9.5 kg) on the left, and latest tool design variants (less than 8 kg) on the right for hassle-free tool changing.
First-generation design (9.5 kg) on the left, and latest tool design variants (less than 8 kg) on the right for hassle-free tool changing.

3DP Boring Tool Saves Set-Up, Machining Time

March 3, 2022
Lightweight, complex tool is capable of machining three large diameters in one operation, achieving speed, accuracy, and high-quality surfaces for EV component manufacturers.

KENNAMETAL introduced a 3D-printed stator bore tool for machining aluminum engine housings for electric vehicles. This latest version of the tool features a newly designed arm structure, a larger center tube made of carbon fiber, and a further weight reduction of greater than 20 percent over the original design. The complex tool is capable of machining three large diameters in just one operation, saving set-up time and machining time for automotive component manufacturers and delivering the highest accuracy and surface qualities.

“As our automotive customers expand their offerings of hybrid and electric vehicles, we continue to respond to their need for lighter-weight tooling solutions. By leveraging advanced manufacturing techniques like 3D printing, we’ve reduced weight a further 20 percent over the first-generation tool, while improving chip control and increasing tool rigidity—innovations that help our customers machine faster and more efficiently,” said product manager Ingo Grillenberger.

Machining three diameters in one operation, the stator bore tool ensures alignment and concentricity of machined surfaces while reducing cycle time significantly. The lightweight, 3D-printed combination tool enables a faster tool change and spin-up even on less powerful machines. The surface specifications and component tolerances are achieved without constraints.

Hassle-free chip removal is ensured by means of airfoil shaped arms that feature through-tool cooling featured to ensure precise and powerful coolant supply to the cutting edges and guide pads. This would be difficult or impossible to economically produce with traditional manufacturing, but 3D printing enables us to realize even such complex internal features. Additionally, the Kennametal RIQ reaming system features easy diameter adjustment and a trouble-free setup of new inserts.

Learn more at www.kennametal.com

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