3D Printing Processes

Kennametal develops 3D printed stator bore tool to CNC the future of e-mobility

New tool meets accuracy, roundness, and surface finish requirements.

Stay up to date with everything that is happening in the wonderful world of AM via our LinkedIn community.

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.

3D printed stator bore tool
Leveraging proven Kennametal technologies. High precision RIQ reaming inserts, and KM4X adaptor for highest possible rigidity.

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 at Kennametal. “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 maximize 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.

 

Research 2021
Ceramic AM Market Opportunities and Trends

This market study from 3dpbm Research provides an in-depth analysis and forecast of the ceramic additive ma...

Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based 3dpbm. Today the company publishes the leading news and insights websites 3D Printing Media Network and Replicatore, as well as 3D Printing Business Directory, the largest global directory of companies in the additive manufacturing industry.

Related Articles

Back to top button

We use cookies to give you the best online experience. By agreeing you accept the use of cookies in accordance with our cookie policy.

Privacy Settings saved!
Privacy Settings

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. Control your personal Cookie Services here.

These cookies are necessary for the website to function and cannot be switched off in our systems.

In order to use this website we use the following technically required cookies
  • PHPSESSID
  • wordpress_test_cookie
  • wordpress_logged_in_
  • wordpress_sec

Decline all Services
Accept all Services

STAY AHEAD

OF THE CURVE

Join industry leaders and receive the latest insights on what really matters in AM!

This information will never be shared with 3rd parties

I’ve read and accept the privacy policy.*

WELCOME ON BOARD!