China3D printingNet October 11, Pennsylvania-based tool and industrial material supplier Kennametal has developed3D printingStator hole tools to respond to the growing needs of automotive customers.
This tool is specifically designed for machining parts on hybrid and electric vehicles, and is specially developed for electric vehicle manufacturers looking for lightweight tools. Electric vehicle parts are usually processed on smaller, low-horsepower CNC machining centers, which require lighter weight tooling solutions compared to standard automotive practices.
Kennametal use3D printingCreated two stator boring tools, which are the fixed part of the rotating equipment on the processing system, and the weight of both is less than half of the traditionally manufactured similar tools. The main hole containing the motor stator has a diameter of about 250 mm (9.84 inches), a length of about 400 mm (15.74 inches), and a smaller bearing hole at the bottom. Supervisor Harald Bruetting explained.
“When manufactured using traditional methods, this type of reamer weighs more than 25 kilograms (55 pounds), which is too heavy for existing machine tools or the work of operators.”
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Stator hole” alt=”equipped with RIQ reamer and KM4X adapter
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Stator hole” />
Equipped with RIQ reamer and KM4X adapter3D printingStator hole. The picture comes from Kennametal.
KennametalAnd additive manufacturing
Kennametal was founded in 1938 and is headquartered in Pittsburgh, dedicated to the development of various metal mold products and materials. For example, the company provides blades, disks, skins, fuel control systems and landing gear products for the aerospace industry. It also developed many lathes and fixtures for the machining industry, and provided tools for customers in the automotive industry.
The company’s3D printingThe division is called Kennametal Additive Manufacturing, which provides metal powders, optimization and prototyping, and mass production services for additively manufactured parts.Parts use Kennametal’s internal adhesive jet and laser powder bed3D printingTechnical production.Inside3D printingMachine includes leading industrial3D printingMachine supplier ExOne’s X1 25PRO metal adhesive spray system. Kennametal, along with Swedish engineering group Sandvik, was appointed by ExOne in May 20193D printingBeta tester of the machine.
use3D printingDevelopment of lightweight automotive tools
In order to meet the needs of electric vehicle customers for the stator holes of lightweight CNC machine tools, the solution engineering team of Bruetting and Kennametal referred to it as an additive manufacturing solution.Use metal powder bed3D printingTwo iterations of the tool were manufactured.The first equipped carbon fiber tube weighs 9.5 kg (20.9 lb), and the other equipped3D printingThe metal pipe weighs 10.7 kg (23.6 lb). Both meet the lightweight requirements of the tool, and the weight is less than half of the standard stator hole, which is 25 kg.
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Stator hole” alt=”with carbon fiber tube
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Stator hole” />
With carbon fiber tube3D printingStator hole. The picture comes from Kennametal.
These tools are also designed with Kennametal’s technology to meet the accuracy, roundness, strength and surface finish requirements of the standard stator hole settings. The company equipped it with RIQ reaming inserts for high-precision finishing, and equipped it with a KM4X spindle adapter for maximum rigidity.Both tools also have internal3D printingThe cooling channel is designed to help increase its productivity and service life.
China3D printingNet Comments: By combining metal powder bed3D printingUsed together with finite element analysis software, we are able to design and manufacture a tool that makes the moment of inertia very close to the end face of the spindle, which improves its rigidity while meeting the customer’s weight limit.KennametalA good example of how to use advanced manufacturing technology to help meet customers’ unique challenges.
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