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Taking ER Farther

Taking ER Farther

Kennametal has announced an expansion of the turret adapted clamping units (TACU): ERready driven units in conjunction with a line of solid ER collets which are threaded to accept screwon milling cutters.

Taking ER Farther

Turning a CNC lathe machine into a milling machine by providing access of any small diameter screw-on milling cutter to ER driven units.

“Together the new TACU ER units and the solid ER collets are a great marriage of technology. Available in sizes ER25 through ER40 with thread sizes ranging from M08 through M16, this innovation provides machining center-like capabilities to your live tool lathe. These new products provide the flexibility to use standard ER collets with solid end mills, or the new solid ER collets together with screw-on indexable milling cutters”, said Ronald West, Manager, Tooling Systems.

Sealed for through-the-tool coolant and there is a one-millimeter standoff for additional clearance on larger end mills with a precision-ground locating boss for minimal runout. It’s a very compact design, reducing the chance of interference on smaller machines. Compared to a standard springstyle ER collet, they’re very rigid, so you can take heavier cuts.

The TACU offering can be used on seven leading brands of CNC lathes, both VDI and boltmounted turrets (BMT) with a variety of static and driven blocks. TACU’s are equipped for internal and external coolant, with up to 12,000 RPM possible on specified driven tools. “This addition greatly increases the capabilities of our TACU offering”, said West.

 

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Kennametal Makes Hard Turning More Cost-Effective

Kennametal Makes Hard Turning More Cost-Effective

Kennametal introduces it latest innovation in hard turning-KBH10B and KBH20B PcBN grades, double-sided inserts for materials up to 65 HRC.

The new grades are specially designed to deliver higher productivity and longer tool life when turning tool steels and other hardened materials.

“Kennametal’s new KBH10B and KBH20B grade inserts are an excellent choice for high-volume production of hardened gears, shafts, bearings, housings, and other drivetrain components, where tooling cost per part is an important metric”, said Robert Keilmann, Product Manager, Turning.

Polycrystalline cubic boron nitride (PcBN) mini-tipped inserts have long been recognised as a great option for reducing part cost when turning hardened steel components. Kennametal’s new grades of PcBN inserts improve upon that value proposition by delivering increased productivity with a lower cost per part. Features include:

-Patented ceramic binder structure and TiN/TiAlN/TiN coating that provides extreme wear resistance even at elevated cutting speeds.
-A gold PVD coating makes it easy to identify when an insert needs indexing, while the numbered corners assure that a machine operator won’t inadvertently switch to a used edge.
-Two edge preparations in a “trumpet” style hone for heavier and interrupted cuts, and a light hone for continuous turning. Both are free-cutting, further extending tool life and generating surface finishes down to 0.2 Ra.
-The PcBN mini-tips are offered in four insert shapes—three rhomboidal and one triangular—which means up to six cutting edges per insert.

 

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Kennametal KOR 5: The King Of Roughing

Kennametal KOR 5: The King Of Roughing

Kennametal has released the KOR 5 solid carbide end mill—its latest innovation in high-velocity aluminum roughing. Designed for maximum productivity in aerospace machining, with this five-flute end mill table feed rates increase up to 66 percent compared to commonly used three-flute tools—redefining productivity for aircraft manufacturers and their suppliers.

KOR 5 is aimed at removing large amounts of metal and getting it away from the work zone as quickly as possible:

-Tapered core, variable pitch design, and 35 deg helix – eliminates chatter and tool deflection
-Coolant through the tool – flushes chips away while reducing heat.
-Unique chip splitter pattern – designed to break up long chips, eliminating re-cutting, but still contributes to high surface qualities.

The tool has the potential to become the new standard for machines utilising CAD/CAM tool paths.
KOR 5 has more active contact points versus a 2-fluted or 3-fluted end mill because it is a 5-fluted end mill, which creates improved stability and eliminates chatter on even the heaviest cuts.
Applying the tool with low radial engagement, but high depth of cut results in much higher metal removal rates than traditional methods.

And to assure predictable, no pull-out performance at maximum feed rates, the KOR 5 is available with Safe-Lock shanks.

“Slotting, deep pocketing, dynamic milling—whatever your aluminum application, KOR 5 can do it faster”, said Thilo Mueller, Manager for Solid Carbide End Milling.

 

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Kennametal Launches 3D Printing Business Unit

Kennametal Launches 3D Printing Business Unit

Kennametal Incorporated has formed a 3D printing materials and production business unit, Kennametal Additive Manufacturing, as part of its Infrastructure segment. The new business unit, which is already shipping production parts to customers, combines the Company’s longstanding expertise in materials science and wear-resistant solutions with additive manufacturing capabilities to supply high-performance metal additive powders and fully finished 3D printed parts for wear, erosion, corrosion, and high temperature applications.

“Kennametal Additive Manufacturing combines our recognised expertise in wear materials, such as tungsten carbide and Kennametal Stellite, with the advantages of 3D printing—design flexibility, shorter development cycles and reduced lead times,” said Ron Port, Vice President, Kennametal Inc. and President, Infrastructure Business Segment. “We are focused on high-growth potential additive solutions, and this new business unit is advancing both what we make and how we make it, so we can produce better parts, faster and more efficiently, for our customers.”

Kennametal has been leveraging 3D printing materials and processes within its existing businesses for some time to manufacture prototype components and cutting tools. The new Kennametal Additive Manufacturing business builds on these capabilities to offer comprehensive 3D printing solutions, from raw material to finished part. The Company’s gas atomisation powder production capabilities supply cobalt, nickel, and iron powders optimised for specific additive manufacturing processes. At its research and development, pilot production and prototyping center in Latrobe, Pennsylvania, the business utilises laser powder bed and binder jet printing technologies, combined with post-print processing capabilities, including sintering, hot isostatic pressing and machining, to produce fully finished components.

The business unit is led by Sherri McCleary, Director, Additive Manufacturing Business, who brings 30 years of materials science and business development expertise to the role. Kennametal Additive Manufacturing has already shipped its first production parts to customers in the oil and gas and power industries. These high-performance wear components include parts printed with powders specifically designed and optimised for 3D printing, including Kennametal KAC89 tungsten carbide and Stellite 6 AM, a wear resistant cobalt-chrome alloy.

 

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Kennametal Releases HARVI I TE Four-Flute Solid Carbide End Mill

Kennametal Releases HARVI I TE Four-Flute Solid Carbide End Mill

Kennametal announced the latest addition to its best-selling HARVI line of high-performance solid end milling tools, the HARVI I TE four-flute solid carbide end mill. With a radical new design, the HARVI I TE delivers outstanding performance in a broad range of materials, including steel, stainless steel, high-temperature alloys and cast iron –with tool life to match. And thanks to significantly reduced cutting forces, this game-changing tool can be used on any machining center or mill-turn center in the shop.

“The HARVI I TE consistently outperformed competing four-flute end mills in both wet and dry machining tests on a variety of materials and applications, with unprecedented tool life in many cases,” said Bernd Fiedler, Manager, Solid End Milling.

“It performs exceptionally well on heavy roughing and finishing cuts alike – from deep cavities and full width slots to shoulder and dynamic milling.”

Kennametal engineers designed the HARVI I TE to address four key problems that plague more than 90 percent of all milling applications: chip evacuation, tool deflection, corner stability, and breakage due to radial cutting forces. The result is a tool that’s durable and versatile enough to tackle the lion’s share of milling applications.

Consider chip evacuation. The HARVI I TE has an innovative flute design that helps curl and break chips into manageable pieces, while a series of chip gashes within the flute lift those chips up and away from the workpiece. Both serve to promote coolant flow, eliminate chip re-cutting, and improve tool life. A twisted end face and unique gashing further promote chip evacuation but are also responsible for the HARVI I TE’s awesome ramping and plunging capabilities.

Tool deflection is reduced thanks to the tool’s parabolic core, as well as an eccentric, faceted relief along the entire flute length that significantly lowers cutting friction. This relief also increases edge strength, making the tool a versatile solution.

Together with a variable helix angle and asymmetric flutes it dampens vibration before it can negatively affect machining operations.

“The HARVI I TE improves process stability, surface quality and chip evacuation,” said Fiedler. “Most importantly, it maintains these benefits even at increased feeds, speeds, and depths of cut – delivering maximum metal removal, tool life and productivity.”

 

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3D Printing The Future Of E-Mobility Tools

3D Printing The Future Of E-Mobility Tools

Leveraging proven Kennametal technologies. High precision RIQ reaming inserts, and KM4X adaptor for highest possible rigidity.

Kennametal has developed a 3D printed stator bore tool specifically designed to meet growing customer demand for lighter weight tooling solutions used to machine components for hybrid and electric vehicles.
E-mobility components are typically machined on smaller, low horsepower CNC machining centers that require lighter weight tooling solutions. Kennametal’s 3D printed stator bore tool weighs half that of the conventionally manufactured version, while still meeting accuracy, roundness, and surface finish requirements for aluminum motor body boring.

“The main bore, that houses the stator of an electric motor measures approximately 250 mm in diameter (9.84″) and approximately 400 mm (15.74″) in length, with a smaller bearing bore at the bottom,” said Harald Bruetting, Manager, Program Engineering. “When manufactured using conventional means, a reamer for this type of application would weigh more than 25 kilograms (55 lb.), far too heavy for the existing machine tool or for an operator working with the tool.”

Bruetting and Kennametal’s Solution Engineering Group turned to the company’s in-house additive manufacturing capabilities to 3D-print a strong but lightweight indexable tool, equipped with proven Kennametal technologies including fine adjustable RIQ reaming inserts for high precision finishing and a KM4X adaptor for maximum rigidity. The tool also features internal 3D printed cooling channels that help maximise productivity and tool life.

“By using metal powder bed 3D-printing together with finite element analysis software, we were able to design and build a tool that brought the moment of inertia very close to the spindle face, increasing its rigidity while meeting the customer’s weight restrictions,” said Werner Penkert, Manager, Future Solutions. “It is an excellent example of how Kennametal is using advanced manufacturing technology to help meet our customer’s unique challenges.”

Two versions of the tool were built, one with a carbon-fiber tube, the other using a 3D-printed metal tube. The results were impressive. The tool with the 3D printed tube weighed in at 10.7 kg (23.6 lb.) and the carbon fiber version at 9.5 kg (20.9 lb.), less than half of their conventional counterparts.

 

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Kennametal Unveils Restructuring Plans, Plant Closures

Kennametal Unveils Restructuring Plans, Plant Closures

Kennametal Inc. recently unveiled several restructuring actions that would facilitate a simplified and leaner structure, while further positioning the company for long-term profitable growth. As part of its ongoing simplification/modernisation initiative, Kennametal is optimising its operations globally, including footprint rationalisation, by closing its manufacturing facilities in Essen and Lichtenau as well as its distribution centre in Neunkirchen, all in Germany. Additionally, the company announced its decision to close its manufacturing facility in Irwin, Pennsylvania, USA.

“The proposed measures are difficult but necessary to achieve structural improvements, further improve operational efficiency and continue to drive value for shareholders,” said President and CEO Christopher Rossi. “We recognise the effect on our employees and will work closely with their representatives to support them throughout this transition.”

These restructuring actions advance the company toward the fiscal 2021 financial targets announced at its most recent Investor Day. They are also part of the previously announced goal of reducing plants through simplification/modernisation, with additional plants currently under evaluation.

Under the proposed measures, the company would consolidate its Essen and Lichtenau operations, including both Kennametal and WIDIA branded products, into other lower-cost Kennametal Industrial facilities. The Irwin operations would be consolidated primarily into the newly modernised Infrastructure plant in Rogers, Arkansas.

Kennametal also proposed plans to outsource the distribution operations in its Neunkirchen and Essenfacilities to a third-party logistics specialist.

The closure plans are contingent on the negotiations with the relevant employee representatives.

The company will continue to maintain a strong presence in Germany, including planned modernisation investments in other Kennametal locations in the country.

The proposed restructurings are expected to be executed over the next two years. Facility closures in fiscal 2020 are part of the current restructuring action, which in total are expected to deliver estimated annualised savings of $35–$40 million and $55–$65 million in pre-tax charges.

Fiscal 2021 closures would result in further structural cost reductions with estimated annualised savings of $25–$30 million. Most of these savings will be achieved in fiscal 2021 with full run rate savings being realised in fiscal 2022. The company is expected to incur pre-tax charges of $60–$75 million through fiscal 2020 and 2021 for this restructuring. These charges are primarily cash with the majority being spent in fiscal 2021.

 

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Kennametal Receives Indirect Procurement Supplier Award From Honda

Kennametal Receives Indirect Procurement Supplier Award From Honda

Kennametal Inc. was recently awarded a 2019 Indirect Procurement Supplier Award for Performance Excellence by Honda. The award places Kennametal amongst an elite group of 22 honoured suppliers that provide indirect products and services to Honda’s manufacturing plants in North America, including Honda’s corporate functions across the region. The awards were presented at the annual Honda Indirect Procurement Supplier Conference held at the Bridgewater Banquet and Conference Centre in Powell, Ohio.

Award-winning suppliers were selected for achievements in the categories of Special Recognition, Outstanding Value and Performance Excellence, as well as the Supplier of the Year. These outstanding honourees were selected from the more than 2,200 suppliers that provide equipment, products and services to Honda manufacturing plants and corporate functions across North America.

“Our suppliers and business partners make us a stronger company, helping us realise innovation and advancement, by delivering the benefits the marketplace has to offer,” said Monica Oliverio, department manager of the North American Indirect Procurement Department at Honda of America Mfg Inc. “This complimentary and valued relationship is an important part of our mutual success.”

 

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Kennametal Inks Beta Machine Partnership With ExOne

Kennametal Inks Beta Machine Partnership With ExOne

The ExOne Company has signed an initial X1 25PRO beta machine partnership with Kennametal Inc., a global provider of material science, tooling and wear-resistant solutions.

Unveiled at the RAPID + TCT event in Detroit, Michigan last week, the X1 25PRO is capable of printing metal, ceramic, and other advanced material parts directly. X1 25PRO can print standard industry powders utilised in MIM (metal injection moulding) and other PM (powdered metal) processes.

During the beta period, ExOne and Kennametal will have an opportunity to evaluate the new X1 25PRO machine and trial test new materials and processes. A multiple machine customer, Kennametal is on the cutting edge of binder jetting technology adoption for additive manufacturing.

“We see binder jetting technology as a key enabler for our differentiated, high-performance wear materials, such as tungsten carbide and Kennametal Stellite alloys,” said Sherri McCleary, director, Business Development Additive, Kennametal. “Kennametal is uniquely qualified to supply these additive materials and components, and we’re pleased to collaborate with ExOne on cutting-edge technology with the potential to help us advance from prototyping to serial production.”

“Working with innovative, global companies like Kennametal is another important step towards integrating industrial 3D printing into existing and new production lines. We are excited to bring Kennametal on as a beta user and look forward to beginning the testing programme,” said ExOne CEO John Hartner.

 

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Kennametal Reports 10th Consecutive Quarter Of YoY EPS Growth

Kennametal Reports 10th Consecutive Quarter Of YoY EPS Growth

Kennametal Incorporated has posted sales of US$597 million for the fiscal 2019 third quarter ended March 31, 2019, down by two percent from US$608 million compared with the same period in the previous year. Earnings per share (EPS) was $0.82, up from $0.61 in the prior year quarter, and adjusted EPS of $0.77, compared with $0.70 in the prior year quarter—the company’s 10th consecutive quarter of EPS growth.

“We delivered organic sales growth in every business segment, on increasingly tougher comparables, and end markets remained generally positive except for automotive,” said Chris Rossi, president and CEO. “Earnings improved, and our adjusted EBITDA margin for the quarter increased notably year-over-year which is in-line with the fiscal 2021 targets outlined at our most recent Investor Day. We are seeing the increasing benefits from simplification/modernisation in our financial results. Moving forward, we expect the associated restructuring efforts to further reduce structural costs while maintaining customer commitments.”

Kennametal has also detailed the next phase of restructuring associated with simplification /modernisation. These actions are expected to reduce structural costs and are currently estimated to achieve US$35-US$40 million of annualised savings by the end of fiscal 2020. The company is expected to incur pre-tax charges of $55-$65 million through fiscal 2019 and 2020 for these restructuring activities.

Operating income was US$82 million, or 13.7 percent margin, compared to US$81 million, or 13.3 percent margin, in the prior year quarter. Adjusted operating income was US$85 million, or 14.3 percent margin, compared to US$83 million, or 13.6 percent margin, in the prior year quarter.

Net cash flow provided by operating activities was US$157 million compared to US$158 million in the prior year period. Free operating cash flow (FOCF) was US$15 million compared to US$54 million in the prior year period. The change in FOCF was driven primarily by higher working capital and greater net capital expenditures due in part to simplification/modernisation initiatives, partially offset by increased cash flow from operations before changes in certain other assets and liabilities.

Segment Results

Industrial sales was US$319 million, down by four percent from US$333 million year-over-year. Operating income was US$57 million, or 18 percent margin, compared to US$50 million, or 15.1 percent margin, in the prior year quarter. Adjusted operating income was $58 million, or 18.3 percent margin, compared to US$51 million, or 15.4 percent margin, in the prior year quarter.

Widia sales reached US$51 million, down by two percent from US$52 million year-over-year. Operating income was break-even, compared to US$1 million, or 2.4 percent margin, in the prior year quarter. Adjusted operating income was US$1 million, or 1.3 percent margin, compared to US$1 million, or 2.4 percent margin, in the prior year quarter.

Infrastructure sales was US$228 million, up by two percent from US$223 million year-over-year. Operating income was US$25 million, or 11 percent margin, compared to $30 million, or 13.5 percent margin, in the prior year quarter. Adjusted operating income was $27 million, or 11.7 percent margin, compared to $31 million, or 13.8 percent margin, in the prior year quarter.

 

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