CNC Software, LLC, developers of Mastercam, the world’s leading CAD/CAM software, has collaborated with Kennametal, a global technology leader and provider of metal cutting tools and solutions, to provide customers with the ability to access tooling data for Kennametal brand drills and solid carbide end mills directly in the Mastercam tool library on their Tech Exchange.

Mastercam developers worked closely with Kennametal to enable users to import data on their most versatile and high-performance cutting tools, including GOdrill and Kenna Universal solid carbide drills and a selection of HARVI and KOR end mills directly into Mastercam. The integration allows Mastercam customers to save significant time searching for desired tools and building tool assemblies.

Kennametal tool libraries on Mastercam’s Tech Exchange website
“We are excited to offer these high-performance drills and endmills from Kennametal in a native Mastercam tool library format and make it available to our user base of over 300,000,” said Stas Mylek, Partnership Program Manager, CNC Software, LLC. “The collaborative effort between both companies provides Mastercam users easy and integrated access to the latest cutting tools from Kennametal,” Mylek continued.

Mastercam’s Maintained users can download the cutting tool libraries from the Mastercam Tech Exchange portal on their website. The native Mastercam tool database is fully compatible with Mastercam 2022 and the latest Mastercam 2023 release.

“The integration of our tooling data within Mastercam’s library digitizes Kennametal innovation and productivity, making it easier for customers to identify tooling requirements, build machining strategies, and ultimately purchase our tools,” said Eddie McBarnet, Vice President Marketing, Kennametal. “Our digital tooling data, in combination with the powerful Mastercam software, will enable hundreds of thousands of customers to quickly find solutions to their toughest machining challenges and be more productive and efficient using Kennametal tooling.”

DUO-LOCK modular end mills fit a wide variety of toolholders and adapters, including the KM4X platform

Back in 2014, Kennametal announced a technology partnership with Haimer for the development of a modular cutting tooling system. Since that time, the company has been busy developing, testing, and building inventory of DUO-LOCK, which promised even then to be “the most rigid and most precise interface in the marketplace.”

Today it’s even better. According to Thilo Mueller, manager of solid carbide end milling at Kennametal, DUO-LOCK is the only modular endmill solution able to compete at solid carbide levels, and outperforms its nearest modular competitor by more than two to one. That means full-width slotting at depths up to 1 x cutter diameter, and side milling up to 50 percent radial engagement at 1.5 x the diameter deep, even in stainless steel, titanium, and other high-temp aerospace alloys.

Mueller says he’s excited about the tool’s robust machining qualities, but is equally enthusiastic about its broad initial product offering. “We have over 400 line items coming in the first wave, with many more coming early next year,” he says. “These include the most popular size end mills in both inch and metric, as well as a broad array of adapters, integral shank holders, and extensions.”

Many of those extensions are equipped with HAIMER’s Safe-Lock technology, a secure clamping mechanism that eliminates concerns over tool pullout and creep in high-performance milling applications. HSK, CAT, BT, and comparable spindle tapers are also available.
One of the things that makes DUO-LOCK unique is its intelligent thread design. Using FEA-based design tools, Kennametal has optimized the connection to eliminate any possibility of tool failure even at elevated loads. The result, says Mueller, is that DUO-LOCK handles 25 percent more torque than its closest competitor, permitting higher feedrates and axial depths of cut, especially in long reach conditions.

The cutting geometry is likewise unique, and uses an upgraded HARVI front end with an asymmetrical flute design. This breaks up cutting harmonics, reduces chatter, and provides 20 percent or greater chip load per tooth compared to the solid carbide versions. The HARVI II 5 flute cutters also received an upgrade: a variable helix known for its full slotting capabilities in titanium. The eccentric relief behind the cutting edge with HARVI III is also a proven performer in titanium and other heat resistant alloys, and is sure to satisfy the needs of customers looking for larger modular versions as well. Multiple carbide grades are also available, including Kennametal’s proprietary Beyond grades KCSM15 and KCPM15, making DUO-LOCK a go-to solution for everything from heavy roughing to semi-finishing. “Because of the very small amount of tool runout, some of our customers are even seeing success in fine finishing applications,” says Mueller.

Assembly is easy: clean the DUO-LOCK insert and coupling, thread it by hand onto the adapter (use gloves, the edges are sharp!), and torque it down. That’s it. Since DUO-LOCK operates at far higher cutting parameters than its competition, the torque values are likewise much greater, an indicator to customers familiar with such tooling that DUO-LOCK is a different species within the modular machining world. DUO-LOCK’s double-cone locating surface provides Z-axis coupling repeatability of 10 µm (.0004 in.) or better, and tool to tool repeatability in the 50µm (.002 in.) range, eliminating the need for offline presetting or tool touch-off in the machine. And the additional contact surface at the base of the tool assures radial runout at the coupling below 5 µm (.0002 in.), improving run out at the cutting edge tremendously, similar to the 2nd contact area enjoyed by KM or KM4X customers. And when the cutter’s dull, simply load it into a Kennametal Blue Box and ship it to one of the company’s reconditioning facilities around the world.

The result is a rigid, highly accurate tooling solution that offers greatly reduced setup time and simplified tool changeover, cutting performance equal to solid carbide, and the stiffness to remove more metal in less time than competing modular systems. “We are understandably proud of the DUO-LOCK design,” says Mueller. “It’s an ideal solution for a wide variety of applications.”

If you’re ready to replace your solid carbide endmills with a competitively priced alternative, reduce setup time and improve accuracy, and remove large amounts of metal very, very quickly, hold on tight: Kennametal’s taking chipmaking to the next level.

A wide variety of KM tooling for multitasking machines, machining centers, and mill-turn lathes is readily available, improving productivity in any machining application

Multitasking and mill-turn centers were once considered high-end specialty machines, found only in shops with the financial resources and production volumes needed to justify such an investment. Not anymore. Turning centers with live tool stations are becoming increasingly popular with machine shops of all sizes. These machines offer the ability to cost effectively machine parts in a single operation.

With capability comes complexity, however, and the need to maximize the output of such a machine tool investment through reduced setup time is ever present. Kennametal Inc., Latrobe, PA has been meeting these needs for decades with state-of-the-art cutting tool and toolholder solutions such as its KM (Kennametal Modular) quick-change tooling, and has recently announced a substantial expansion of that offering, one that promises to make driven tool setup fast and accurate.

“The partnership between Kennametal and EWS Tool Technologies is aimed at maximizing our customers’ productivity by providing the best tooling solution and support for their CNC lathes,” says Jay Verellen, Director of Global Product Management, Tooling Systems. “The KM quick change connection is one of the most comprehensive in the industry. Together with EWS’ global leadership in driven tooling and static tool blocks, we will provide a standard range ready to tool up many major brands of CNC turning centers with this incredible system.”

EWS was founded in 1960 as a manufacturer of laboratory equipment and hydraulic components in Köngen, Germany. The company soon expanded into machine tool accessories and today offers more than 15,000 driven and 25,000 static toolholders in its product lineup. EWS’ corporate philosophy of placing customers’ needs first, along with dedication to its employees, customer service levels, and high quality products, makes its slogan “Precision meets Motion” much more than just a catchphrase.

It’s more than a large selection of the highest quality lathe tooling, though. Anyone who’s owned or operated a live-tool lathe knows the importance of service after the sale. Metal becomes fatigued, bearings eventually fail, operators make mistakes. Sending live tools and tool blocks overseas for reconditioning is a costly, time-consuming affair, one that shop owners can ill afford. “You don’t have to wait two weeks for a worn tool to arrive in Germany,” says Bahti Hanedar, Chief Financial Officer at Command Tooling Systems, a wholly-owned subsidiary of EWS. “For those in the US, the tools are serviced here using original OEM parts, by factory trained personnel. EWS also has manufacturing locations in Korea, China, and Russia, so no matter where your shop is located, service is never more than a day away. At EWS, global presence is more than a logo.”

Quick response applies to custom tooling as well. There’s no need to worry about time zones to get a rush quote on a non-standard gage length toolholder, or a 45-degree angle head able to spin at 15,000 rpm. Says Hanedar, “We have the capability for quick turnaround of custom solutions in the US and elsewhere, and are making significant engineering and service investments at all locations.”

“For our customers we are making it really easy, one call into our service centers and we’ll take care of everything else,” comments Verellen.

Kennametal’s Mill 16 has a wedge-style clamping system, numbered pockets and inserts, and an open pocket design to increase chip flow in heavy roughing Iron is the most abundant element on earth by mass. For over twenty-five centuries it’s been used to plow fields, build bridges, cook food, and wage war. Without iron, the Industrial Revolution would have gone nowhere, we would have no trains, automobiles, or machine tools today, and mankind would still be an agrarian society. It is quite simply the most important metal in history

There’s a newcomer to this metal family, though, one that’s making manufacturers take notice. As automakers strive for increasingly fuel efficient and environmentally friendly vehicles, they’re turning away from traditional iron favorites such as gray and ductile iron (GCI and DCI) to compacted graphite iron, or CGI. Also known as vermiculate graphite iron, CGI’s mechanical attributes meet or exceed its counterparts, sometimes drastically so.

Unfortunately, CGI is also more difficult to machine, requiring cutting tools both tough and wear-resistant. And because of the continuing call for cost-effective machining solutions across all manufacturing industries, these tools must also offer a low cost per part and predictable tool life. For face milling applications, that tool is Mill 16 “Compared to cast iron, CGI has lower weight and greater strength, and is ideal for components that are exposed to both thermal and mechanical stresses like engine blocks
and heads for cars and trucks, exhaust manifolds, and brake parts,” says Senior Global Product Manager for Indexable Milling, Marcelo Campos. “As with other cast irons, however, it is quite abrasive, and somewhat gummy to machine. We developed Mill 16 as a best in class face mill not only for CGI, but for all types of cast iron, which remains a popular choice for gear boxes, housings, pump bodies, and other components used in the automotive, agricultural, and heavy equipment sectors.”

Campos outlines Mill 16’s unique strengths as follows:
– The Mill 16 has a fine-pitch and medium pitch cutter body equipped with an innovative single-screw, wedge-style clamping system. This reduces time spent in the tool crib setting the tool and assures rigid, no-fail tool placement. Each pocket on the cutter body is numbered, as are each of the insert’s cutting edges, assuring maximum accuracy and ease of use when indexing to a new cutting edge.

– The heart of the Mill 16 is an octagonal, double-sided insert with 16 effective cutting edges, providing the lowest tooling cost per part possible. The face of each cutting edge contains an aggressive chip-breaker for positive cutting action and increased chip flow. The wedge clamp on either side of the insert’s top face is likewise chamfered to improve chip evacuation.

–  Mill 16 is available in cutter diameters ranging from 2 in. to 10 in. (50 mm to 250 mm). Kennametal has rated the maximum axial depth of cut (Ap1) at 5.5 mm (0.216 in.), although depths to 9 mm (0.35 in.) or greater are achievable, an important consideration where casting variation is a concern. Due to the cutter’s low cutting forces, up to 100% radial cutter engagement is possible. All cutters have internal coolant supply capability.

–  The carbide is new as well. Kennametal’s grade KCK20 is a PVD AlTiN/AlTiCrN multilayer coating bonded to a wear resistant substrate which provides an average tool life of 30% greater than comparable TiAlN-coated grades.

–  A wide assortment of insert edge preps, geometries, corner radii, as well as a number of complementary grades assure the Mill 16 is a top performer in a variety of machining conditions, from heavy roughing to semi-finishing and, because of the insert’s integrated wiper facet, fine finishing to Ra 3.2 μm or better.

Customer field tests have shown consistent and positive results. During a dry machining operation on a ductile cast iron plate using Mill 16, feed rates were increased by 41% and tool life doubled tool. A gray iron transmission case was machined at a feed rate of 0.39 mm per tooth (0.015 in.) and cutting speed of 208 m/min (682 ft/min), leading to reduced spindle loads compared to the legacy tool and slightly improved tool life. Metal removal rate and tool life on a water pump housing was more than doubled by switching to Mill 16. There are more examples. Campos says he’s worked extensively with automakers and their suppliers, and in all cases the Mill 16 outperformed his competitor’s cutting tools.

“We have cutting force dynamometers. We take videos. We run head to head tool life tests. For us to stand up and say we get 20% better tool life or 50% more metal removal than our next competitor, you can be certain it’s true. We at Kennametal are very excited about the Mill 16, and what it can do for our customers machining CGI and other types of cast iron.”

A wide variety of KM tooling for multitasking machines, machining centers, and mill-turn lathes is readily available, improving productivity in any machining application Multitasking and mill-turn centers were once considered high-end specialty machines, found only in shops with the financial resources and production volumes needed to justify such an investment. Not anymore. Turning centers with live tool stations are becoming increasingly popular with machine shops of all sizes. These machines offer the ability to cost effectively machine parts in a single operation.

With capability comes complexity, however, and the need to maximize the output of such a machine tool investment through reduced setup time is ever present. Kennametal Inc., Latrobe, PA has been meeting these needs for decades with state-of-the-art cutting tool and toolholder solutions such as its KM (Kennametal Modular) quick-change tooling, and has recently announced a substantial expansion of that offering, one that promises to make driven tool setup fast and accurate.

The partnership between Kennametal and EWS Tool Technologies is aimed at maximizing our customers´ productivity by providing the best tooling solution and support for their CNC lathes,says Jay Verellen, Director of Global Product Management, Tooling Systems. The KM quick change connection is one of the most comprehensive in the industry. Together with EWS´ global leadership in driven tooling and static tool blocks, we will provide a standard range ready to tool up many major brands of CNC turning centers with this incredible system.

EWS was founded in 1960 as a manufacturer of laboratory equipment and hydraulic components in Köngen, Germany. The company soon expanded into machine tool accessories and today offers more than 15,000 driven and 25,000 static toolholders in its product lineup. EWS´ corporate philosophy of placing customers´ needs first, along with dedication to its employees, customer service levels, and high quality products, makes its slogan »Precision meets Motion» much more than just a catchphrase.

It´s more than a large selection of the highest quality lathe tooling, though. Anyone who´s owned or operated a live-tool lathe knows the importance of service after the sale. Metal becomes fatigued, bearings eventually fail, operators make mistakes. Sending live tools and tool blocks overseas for reconditioning is a costly, time-consuming affair, one that shop owners can ill afford. »You don’t have to wait two weeks for a worn tool to arrive in Germany, says Bahti Hanedar, Chief Financial Officer at Command Tooling Systems, a wholly-owned subsidiary of EWS. For those in the US, the tools are serviced here using original OEM parts, by factory trained personnel. EWS also has manufacturing locations in Korea, China, and Russia, so no matter where your shop is located, service is never more than a day away. At EWS, global presence is more than a logo.

Quick response applies to custom tooling as well. There´s no need to worry about time zones to get a rush quote on a non-standard gage length toolholder, or a 45-degree angle head able to spin at 15,000 rpm. Says Hanedar, We have the capability for quick turnaround of custom solutions in the US and elsewhere, and are making significant engineering and service investments at all locations.

For our customers we are making it really easy, one call into our service centers and we´ll take care of everything else, comments Verellen. Making a good thing better: the partnership between Kennametal and EWS promises to expand the company´s already extensive offering of KM tooling

Anyone who´s replaced a head gasket on an internal combustion engine knows a smooth, flat surface on both cylinder head and block is needed for proper operation. No one understands this better than automakers, who strive for predictable, controlled surface finishes and high production output, together with maximum tool life and the lowest tooling cost per machined component.

Many machinists might think, »What´s the big deal? Aluminum is one of the easiest materials around.» And while that is certainly true of the ubiquitous 6061-T6, nothing could be further from the truth when it comes to the aluminum alloys used in automotive applications. Grades 319 and 390, for example, are readily cast into the complex shapes needed for engine blocks, pistons, heads, pulleys, and similar parts, but due to their high silicon content—easily 20 to 30 times that of 6061—they´re like cutting sand.

Fortunately for those charged with machining these abrasive metals, there´s a better alternative than carbide cutting tools, one that produces mirror finishes and produces tens of thousands of parts per edge.

»Finishes of 2 to 3 μm Ra are easily obtainable, as is tool life between indexing of 40,000 engine blocks, cylinder heads, and other automotive components,» says Tim Marshall, Senior Global Product Manager for Indexable Milling at Kennametal. »This new face milling platform uses a fine-pitch aluminum body with wedge-style clamps and adjustable pockets. A variety of polycrystalline diamond (PCD) inserts are available, from mini-tips for light finishing cuts to full face wipers, standard cartridge inserts, and 1/2 in. (12.7 mm) axial cutters for heavy roughing and shoulder cutting.»

He´s talking about the KBDM PCD face milling system from Kennametal. Designed for high-volume machining, the KBDM is stocked in standard sizes of 2.5 – 8.0 in. (63 – 200 mm), although Marshall is quick to point out the company´s custom solution capabilities. »We can offer cutters up to 21.5 in. (550 mm) in diameter. This allows customers to machine very large components in a single pass. We also have options for integral shank bodies, HSK mounting, left hand cutter rotation, as well as special edge preps and nose radii.»

There´s more to the KBDM than a robust body design, however. Since automakers often create their own proprietary aluminum alloys, Kennametal has developed two PCD grades to complement it: KD1400 uses small diamond grains and offers excellent chipping resistance and good wear attributes, while KD1425 uses large diamond grains, giving it excellent abrasion resistance and thermal stability but only slightly lower performance where chipping is a concern. Both are capable of very high cutting parameters—depending on the alloy and setup rigidity, Kennametal recommends an initial cutting speed of 3280 ft/min (1000 m/min) and feedrates of .004 in. per tooth (0.01 mm), although substantially higher values are possible.

»A major machine builder conducted cutting tests for us against several competitive solutions,» Marshall says. »Using a 24-tooth, 6.0 in. (150 mm) diameter face mill at 80% radial engagement and 0.04 in. axial DOC (1 mm), we ran at a feedrate of 0.006 in. IPT (0.15 mm) and 9600 ft/min surface speed (2926 m/min). This comes out to 6112 rpm, with a table feed of 880 IPM (22,350 mm). It was really moving. Even so, the KBDM produced a 14.7 Ra surface finish, several points better than the other cutting tools.»

Marshall recommends presetting the KBDM offline using an optical or video style presetter. A small amount of lubricant should be applied to the adjustment and locking screws, and also the wedge side of the pocket. Turn the axial adjustment screw until the insert is 0.0004 – 0.0006 in. (0.010 – 0.015 mm) below the final set height, tighten the locking screws to 31 in/lb. (3.5 Nm)—don´t overtighten—then adjust each insert to its final height position. If using a wiper insert, set it 0.0006 – 0.0008 in. (0.015 – 0.020 mm) higher than the rest.

»It´s simple to set up,» Marshall says. »You can easily get everything within a couple microns. That’s one of the keys to successful face milling, not only for proper balance at high spindle speeds but also for achieving the desired surface finish—when you’re finishing a deck face on a block or head, both are critical.»

Adjusting the KBDM is a straightforward process—use an optical presetting device whenever possible, and DON´T OVERTIGHTEN!

KBDM PCD inserts are available in a variety of sizes. Here, a mini-tip suitable for finishing cuts is shown.

KBDM cutters are stocked in standard sizes of 2.5 – 8.0 in. (63 – 200 mm), although specials up to 21.5 in. (550 mm) in diameter are possible.

DUO-LOCK modular end mills fit a wide variety of toolholders and adapters, including the KM4X platform Back in 2014, Kennametal announced a technology partnership with Haimer for the development of a modular cutting tooling system. Since that time, the company has been busy developing, testing, and building inventory of DUO-LOCK, which promised even then to be “the most rigid and most precise interface in the marketplace.”

Today it’s even better. According to Thilo Mueller, manager of solid carbide end milling at Kennametal, DUO-LOCK is the only modular endmill solution able to compete at solid carbide levels, and outperforms its nearest modular competitor by more than two to one. That means full-width slotting at depths up to 1 x cutter diameter, and side milling up to 50 percent radial engagement at 1.5 x the diameter deep, even in stainless steel, titanium, and other high-temp aerospace alloys.

Mueller says he’s excited about the tool’s robust machining qualities, but is equally enthusiastic about its broad initial product offering. “We have over 400 line items coming in the first wave, with many more coming early next year,” he says. “These include the most popular size end mills in both inch and metric, as well as a broad array of adapters, integral shank holders, and extensions.”

Many of those extensions are equipped with HAIMER’s Safe-Lock technology, a secure clamping mechanism that eliminates concerns over tool pullout and creep in high-performance milling applications. HSK, CAT, BT, and comparable spindle tapers are also available.

One of the things that makes DUO-LOCK unique is its intelligent thread design. Using FEA-based design tools, Kennametal has optimized the connection to eliminate any possibility of tool failure even at elevated loads. The result, says Mueller, is that DUO-LOCK handles 25 percent more torque than its closest competitor, permitting higher feedrates and axial depths of cut, especially in long reach conditions.

The cutting geometry is likewise unique, and uses an upgraded HARVI front end with an asymmetrical flute design. This breaks up cutting harmonics, reduces chatter, and provides 20 percent or greater chip load per tooth compared to the solid carbide versions. The HARVI II 5 flute cutters also received an upgrade: a variable helix known for its full slotting capabilities in titanium. The eccentric relief behind the cutting edge with HARVI III is also a proven performer in titanium and other heat resistant alloys, and is sure to satisfy the needs of customers looking for larger modular versions as well. Multiple carbide grades are also available, including Kennametal’s proprietary Beyond grades KCSM15 and KCPM15, making DUO-LOCK a go-to solution for everything from heavy roughing to semi-finishing. “Because of the very small amount of tool runout, some of our customers are even seeing success in fine finishing applications,” says Mueller.

Assembly is easy: clean the DUO-LOCK insert and coupling, thread it by hand onto the adapter (use gloves, the edges are sharp!), and torque it down. That’s it. Since DUO-LOCK operates at far higher cutting parameters than its competition, the torque values are likewise much greater, an indicator to customers familiar with such tooling that DUO-LOCK is a different species within the modular machining world. DUO-LOCK’s double-cone locating surface provides Z-axis coupling repeatability of 10 µm (.0004 in.) or better, and tool to tool repeatability in the 50µm (.002 in.) range, eliminating the need for offline presetting or tool touch-off in the machine. And the additional contact surface at the base of the tool assures radial runout at the coupling below 5 µm (.0002 in.), improving run out at the cutting edge tremendously, similar to the 2nd contact area enjoyed by KM or KM4X customers. And when the cutter’s dull, simply load it into a Kennametal Blue Box and ship it to one of the company’s reconditioning facilities around the world.

The result is a rigid, highly accurate tooling solution that offers greatly reduced setup time and simplified tool changeover, cutting performance equal to solid carbide, and the stiffness to remove more metal in less time than competing modular systems. “We are understandably proud of the DUO-LOCK design,” says Mueller. “It’s an ideal solution for a wide variety of applications.”

If you’re ready to replace your solid carbide endmills with a competitively priced alternative, reduce setup time and improve accuracy, and remove large amounts of metal very, very quickly, hold on tight: Kennametal’s taking chipmaking to the next level.

With a unique insert geometry and extremely accurate pocket positioning, the Mill 4-11 offers the free cutting action of a single-sided insert at the low cost per edge of a double-sided. The Mill 4-11 is also available in a variety of mounting options, with cutter diameters ranging from 16 mm (0.625 in.) to 80 mm (3.000 in.) The issue with many square shoulder indexable milling cutters is the stair-step effect they leave on workpiece walls.

Two years ago, Kennametal introduced a double-sided 90º milling platform that eliminates this issue while providing manufacturers a cost-effective machining solution to boot. The Mill 4 Series of indexable shoulder mills is now a proven performer, offering high metal removal rates, excellent tool life, and surface finish that frequently eliminates semi-finishing operations—and in some cases, can even be used as a finishing cutter, reducing reliance on expensive solid carbide end mills.

Kennametal is expanding its game-changing Mill 4 family with a new cutting tool, the Mill 4-11. Designed for smaller machining centers, the Mill 4-11 accommodates 40-taper CAT and BT, HSK50, and similarly-sized spindles. Due to its free-cutting capabilities, it is ideal for successful metal removal in less-than-rigid setups and on light-duty machine tools, multitaskers and live-tool lathes.

Tim Marshall, Senior Global Product Manager for Indexable Milling, says the Mill 4-11 enjoys the same strong insert design as its larger cousin, the Mill 4-15, but is 24 % shorter and 34% narrower. With an 11 mm (0.433 in.) maximum cut length, this addresses the needs of those job shops and manufacturers producing smaller parts and part features while still offering high metal removal rates and excellent tool life.

“What’s unique about it is the step down,” says Marshall. “Because of the insert design and precision, there’s very little mismatch between passes—for example, using a 63 mm diameter tool (2.48 in.) and our SGE geometry, we were able to achieve less than 8µm (0.00003 in.) deviation between successive 6 mm (0.236 in.) deep passes. One of our largest automotive customers completely eliminated a finishing operation on a steel alloy housing because of it, saving them many thousands of dollars annually.”

Scott Etling agrees. The Director of Global Product Management for Indexable Milling, he says the Mill 4-11 platform offers a full complement of grades and geometries. “KCPM40 is our go-to grade for most steel applications and our newest KCSM40 is our first choice in aerospace and medical machining. Of course we have cast iron and aluminum grades, and a variety of edge preps and corner radii up to 1.6 mm (0.062 in.) as well. We’re very proud of this new offering.”

The Mill 4-11 is also easy to use. Each insert is securely locked in place with a single M3 screw, and marked with a series of dimples to indicate geometry and insert style. Marshall recommends customers keep the tool clean and the screws lubricated with a small amount of grease, and says it’s a good idea to mount all of the inserts with the dimples or markings facing the same direction. “This improves accuracy during indexing, no matter whose cutting tools you’re using.”

The cutter has uneven pocket spacing designed to break up machine harmonics and reduce chatter. Because of its complex insert geometry and positive placement in the pocket, it has an effective radial rake angle between 1° to 11°, depending on the cutter diameter, and an axial rake angle of 3°, this despite the Mill 4-11’s double-sided design.

When taking cuts up to approximately 6.5 mm (0.255 in.) axial engagement, the cutter is essentially “stepless”, although Marshall says cuts up to 11 mm deep (0.433 in.) are possible while still maintaining square, smooth walls. Best of all, it removes material quickly. “We’ve performed extensive testing,” Marshall says. “Time and again we beat the competition, in some cases by 35% greater metal removal rates and 40% or longer tool life. It’s quite simply a great addition to our portfolio.”
The Mill 4-11’s has a complex, double-sided geometry that provides low cutting forces for light duty machine tools and less-than-rigid setups, and one of the lowest tooling costs per part in the industry

Quick-change modular tooling is a clear way to increase productivity, shorten setup time, and generally improve the bottom line for job shops and large manufacturers alike. The KM system from Kennametal Corp., Latrobe, PA has been a top performer in this area for over three decades, and is known throughout the industry for its high clamping strength and consistent accuracy in both spindle-mounted and static tooling applications.The bending moment of KM4X is substantially higher than any tooling interface available on the market today, superior even to Kennametal´s own KM design

So when aerospace giant Boeing came to Kennametal with a request for a heavy-duty spindle connection capable of outperforming traditional CAT and BT-style adapters, tooling engineers turned to this robust and well-established platform as a starting point. The result was a 100 mm spindle connection with four ball tracks instead of two and up to 40 percent greater clamping force than comparably-sized KM tooling.

That was 15 years ago. KM continues to thrive, and was adopted in 2008 by the International Organization for Standardization (ISO) as ISO standard 26622. The original Boeing-inspired design has been renamed as well, and marketed for the past several years as KM4X100, a spindle platform popular with machine builders such as Fives Group, Mitsui Seiki, Stama, and others, as well as those machine shops looking for superior rigidity in demanding machining conditions.

That popularity is about to grow. Kennametal has announced the KM4X tooling family has gained a 63 mm sibling, one aimed at a broader machine tool platform and therefore greater availability to the machining community.

Just as we did with Boeing, we challenged ourselves to make a great solution even better, says Bill Redman, Kennametal Global Product Manager, Tooling Systems. The clamping strength, bending stiffness, and RPM capabilities of the KM4X63 are dramatically higher than virtually any other connection out there.

Redman and others on the product management and engineering team aren’t done. They recently approached a number of machine builders to ask for opinions on the initial KM4X product offering. Based on that feedback, Kennametal continues to expand the portfolio—the KM4X lineup now includes shrink fit toolholders, HydroForce hydraulic chucks, TG and ER collet chucks, and a variety of other spindle tooling, clamping units, and modular adapters, with more on the way.

By the end of 2016, we’re going to add roughly 30 new line items, most of which will be extensions in the 80 to 200 mm range, and centerline turning tools to support mill-turn applications, says Redman. We’ve found that, because of KM4X’s extreme rigidity, we can greatly increase gage lengths. This means our customers can reach much farther without having to buy a special tool, something that´s especially important with 5-axis machining—they can basically add on whatever extension length is needed and off they go, in both static or rotating applications. We’re pretty excited about that.

One example of this is a 674 mm gage length (26.54 in.) KM4X boring bar that will be displayed on an Integrex i-400 in the Mazak booth at this year’s IMTS. KM4X63 has a maximum bending moment of 2,100 Nm (1548 ft. lb.) and, depending on the machine, clamping force of 36 to 58 Kn (8093 to 13038 lb.), he says. It’s the strongest connection available in this size range, period.

It’s also faster. Redman says KM4X63 comes out of the box capable to 38,000 rpm, which is higher than HSK-A and dramatically faster than competing brands of spindle tooling.

For those shops on the fence about spindle tooling and quick-change, Redman offers the following advice. »There´s nothing worse than going into a shop that just bought a $500,000 machining center or lathe and then discovers they should have opted for a different tooling platform. We as tooling providers have an obligation to educate customers, and get them thinking about what they´re trying to accomplish—whether they need high spindle speeds for an aluminum or die-mold application, or greater low-end torque for titanium and HRSA machining. The majority of tooling systems out there can accommodate one of these things, but not both. We feel KM4X provides a competitive advantage no matter what you’re cutting..

KM and KM4X work on stationary applications as well, as in this centerline turning tool holder for multi-tasking machines and mill-turn lathes.

Due to its inherently balanced design, KM4X63 achieves out of the box spindle speeds 30% greater than HSK, and nearly twice that of comparably-sized polygon-style toolholders.

Anatomy of the KM4X clamping mechanism: four ball tracks instead of two. On the system size 63, this provides 50% greater clamping force over PSC, and 150% higher clamping force than HSK63.

Most shops evaluate new cutting tools in an effort to reduce machining time, increase tool life, or improve part quality, and sometimes all three. Stellar Precision Components Ltd., a Tier II aerospace supplier in Jeanette, Pennsylvania, did it for an entirely different reason. “We’d just taken an order for some Inconel parts,” says production manager Edward Frieze. “None of us were really worried at that point about tool life or making a profit on the job—our only concern then was how the heck could we get them shipped in eight weeks.”

Opening Doors
Four decades earlier, Mike Vucish Sr. was working for a manufacturer of naval nuclear components when he saw an opportunity to go into business for himself. He bought some equipment, invited a few students from the technical school where he taught shop class at night, and opened the doors of Stellar Precision in 1978. He continued to work at his day job until his fledgling company was firmly established, but in the meantime brought some family members on board to help out.

“We started out doing a lot of overload work from other larger shops in the area, but that evolved into direct support of several nuclear programs because of my father’s experience in this area,” says daughter Lori Albright, now owner and president of Stellar Precision. “We’ve since become a key supplier to a number of prime aerospace and defense contractors including Boeing, Lockheed, and Raytheon, as well as various nuclear and medical customers, and have over 70 employees and sales revenues of nearly ten million dollars US.”

Stellar prides itself on continual updates to its equipment list, and has an eclectic mix of CNC machine tools from Haas Automation and Okuma, although that balance is steadily tipping in Haas’ favor as the shop’s older machines go into retirement. Albright says not only is the Haas equipment less expensive than its foreign-built competition, but that “Made in America” resonates with many of Stellar’s customers. “This approach also lets us replace our equipment on a more regular basis, which in turn keeps us current on technology.”

Key equipment includes an Okuma LB-45 lathe able to turn 36 in. diameter parts up to 120 in. long (91 mm x 305 cm), and a Haas VF-11 5-axis machining center with 10 ft. of X-axis travel (305 cm) and a table load capacity 4000 lb. (1814 kg). Stellar also has several wire EDMs, a dozen or so 3, 4, and 5-axis machining centers and mill-turn lathes, and offers value-added services such as non-destructive testing, welding, heat treating, and Teflon coating.

Not Too Tough
Stellar is used to meeting demanding requirements. Recent projects include components for RAM Block II anti-ship missiles, the CCtCap crew transport vehicle, 155mm Long Range Land Attack Projectile (LRLAP) advanced gun system, rocket motor cases for the Atlas Five launch vehicle, and others. Their newest project, however, would be one to test the mettle of machinists and management alike.

Frieze explains that Stellar had just received a purchase order for a handful of Inconel 625 prototypes. The raw material blanks for the job measured 18 in. square x 3 in. thick (457 x 457 x 76 mm), and weighed nearly 300 lb. each (134 kg). The project team suffered little indigestion over the tough material’s poor machinability; Stellar routinely cuts Inconel and other nickel-based superalloys, as well as tungsten, maraging steels, 60 Rc 4340 (300M), and tool steel.

Nor was tolerance an issue. Frieze points to one recent titanium part that called out a 0.005 in. (0.127 mm) profile tolerance over its 12 in. length (304 mm), the equivalent of holding “a couple tenths” in parts that cost over $5000 apiece before machining. Meeting the relatively wide open tolerances on the Inconel part was not a concern.

The problem was one of raw material removal: when finished, the Inconel plates weighed in at a svelte 30 lb. (13.6 kg), 90-percent lighter than their starting weight. Frieze knew there weren’t enough hours in the day to remove that much material using conventional carbide tooling, not if he were to meet the deadline. He needed a better solution.

Seminar Payoff
Earlier that year, Frieze and several of his coworkers had attended a learning event sponsored by a local chapter of the National Tooling and Machining Association (NTMA), and hosted at the Kennametal technical center in the nearby town of Latrobe. There he met product manager Matthieu Guillon, who introduced him to a cutting tool that Frieze was initially skeptical of. “It looked and felt like a plastic toy end mill,” he laughs.

That tool was Kennametal’s series of 4 and 6-flute high performance full ceramic end mills. Constructed of SiAlON KYS40 grade ceramic and designed specifically for roughing in nickel-based high-temperature alloys, these end mills often out-produce carbide by up to 20 times. Says Guillon, “We recommend a starting speed of 825 SFM up to 3300 SFM (250 to 1000 m/min) and feedrates starting at around 0.001 IPT (0.03 mm) depending on the tool diameter and other conditions. Despite the far higher cutting speeds, we have some customers who have reported 2 to 3 times greater tool life than carbide.”

Stellar didn’t have any immediate use for the ceramic tools, but after making some quick feed and speed calculations, Frieze knew they would be an effective solution given the right application. Several months later, that application arrived with the Inconel plates. He called Guillon to say he might have a good use for those ceramic cutters they were talking about, and wondered how soon he could get some.

Skeptic to the Last
Frieze remained skeptical. He’d tried indexable ceramic cutting tools on both milling and turning jobs in the past and had mediocre results. In this case, however, he was willing to try anything if it meant meeting the customer’s deadline. When Guillon arrived a few days later with the ceramic end mills, Frieze followed Kennametal’s feed and speed recommendations to the letter, crossed his fingers, and pushed cycle start.

“We weren’t certain what would happen so started out with a block of test material,” he says. “You don’t use cutting fluid with ceramic—only an air blast—and everyone in the shop was crowded around the machine saying, ‘Wow, look at that!’ There was fire shooting everywhere. It was something we’d never seen before. But within the first hour, we knew it was going to work.”

“The tools aren’t inexpensive,” he says. “At one point, Lori had around $20,000 worth of end mills sitting in her office and we were starting to question the investment. But once you calculated in the machine costs and reduced cycle time, we figured it was three to four times more cost-effective to go this route. Each end mill gave us one half hour of cut time, at which time we replaced it whether it was worn or not. The process was so predictable we were able to run lights out. It was a drastic savings.”

Enjoying the Heat
Best of all, Stellar delivered the parts on time with zero scrap, and is now quoting a second, even larger order. Owner Lori Albright was quite pleased with the outcome. “This type of situation is the nature of our business. We have to react to our customers’ needs and employ the best technology available to do so. That’s one of the reasons why Kennametal is so welcome here. We work together as a team to solve challenges.”

Looking forward, Albright anticipates continued growth. Having expanded Stellar’s existing facility six times, she figures it might be time to put up an entirely new building on nearby property. She also looks forward to bringing additional young people to the machining trade. “We have apprenticeship programs with several of the area schools, one of which my father used to teach at,” she says. “I find that it’s often our younger people that drive our innovation. It’s too easy to keep doing things the old way and not invest in tooling and equipment, or pursue new technology. The days of high volume, round-the-clock fender clip manufacturing are gone, and it’s only by continually improving their manufacturing processes that companies can succeed and grow. For us, Kennametal is part of that success.”