AM is key to Kennametal’s award-winning stator bore tool

March 3, 2022

Kennametal’s award-winning AM  stator bore tool weighs 7.3 kg
Kennametal’s award-winning AM stator bore tool weighs 7.3 kg (Courtesy Kennametal)

Kennametal Inc., Pittsburgh, Pennsylvania, USA, has introduced a next-generation additively manufactured stator bore tool, weighing 7.3 kg, for the machining of aluminium engine housings for electric vehicles. The newly redesigned tool recently won MM MaschinenMarkt’s Best of Industry Award in the Production and Manufacturing category, based on votes by readers and industry experts.

This version of the tool features a newly designed arm structure, and a larger centre tube made of carbon fibre. Capable of machining three diameters in one operation, the stator bore tool is said to ensure the alignment and concentricity of the machined surfaces whilst reducing the cycle time. The tool enables a faster tool change and spin-up even on less powerful machines. The surface specifications and component tolerances are achieved without constraints.

Complex internal and external features, enabled by Additive Manufacturing, include the airfoil shaped arms with through coolant and RIQ reaming technology (Courtesy Kennametal)

Hassle-free chip removal is said to be ensured by means of airfoil-shaped arms that enable 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 AM has enabled Kennametal to realise complex internal features. Additionally, the the company’s RIQ reaming system features easy diameter adjustment and a trouble-free setup of new inserts.

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

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