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November 2011

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ATI Stellram Launches New 1B Turning Geometry
BIG Kaiser Introduces Premium ER Collet Chuck System
New RHINO-FEED Heavy-Feed Cutters and Inserts from Dapra
Dorian Offers CNMG and CCMT Recycle Milling Cutters
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Grinding Technology Specializes in Round Carbide Tooling
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HT Series Quick-Change Tool Adapter System from Heimatec
Helical Introduces HXF End Mills
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Kaiser Tool Company Introduces FORM-A-GROOVE Tooling
New KM4X Spindle Connection from Kennametal
KOMA Precision Offers SmartChange Live Tools with Interchangeable Adapters
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Riten Releases Extra-Light Live Centers
Sandvik Coromant Introduces Quick Change Clamping Units
SCHUNK Releases TENDO E Compact
Seco Introduces Double Octomill R220.48 Facemilling Cutter
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Star SU Offers Balinite Alcrona Pro
Sumitomo Introduces Coated Carbide Turning Grade AC420K
Pinzbohr High Precision Modular Boring Tools from Techniks
MST Rite Angle Attachments Now Available from Tecnara
Tungaloy Offers Stream Jet Mini Coolant Through Boring Bars
Walter USA Announces New Grade to its Walter Valenite Indexable Milling Lineup
WIDIA Introduces New VariDrill
ATI Stellram Launches New 1B Turning Geometry
BIG Kaiser Introduces Premium ER Collet Chuck System
New RHINO-FEED Heavy-Feed Cutters and Inserts from Dapra
Dorian Offers CNMG and CCMT Recycle Milling Cutters
New Emuge Tap Features Innovative Chip-Breaking Technology
EXSYS Tool Offers EXSYS/EPPINGER Adjustable Tool Holding System
Genswiss Offers New Coolant Thru Tool Holders
Gleason Announces Faster Deliveries on Coarse Pitch Hobs
Greenleaf Introduces WG-700
Grinding Technology Specializes in Round Carbide Tooling
Haimer Introduces New Power Cooler
HT Series Quick-Change Tool Adapter System from Heimatec
Helical Introduces HXF End Mills
ISCAR Introduces SUMOMILL Family of Endmills
Kaiser Tool Company Introduces FORM-A-GROOVE Tooling
New KM4X Spindle Connection from Kennametal
KOMA Precision Offers SmartChange Live Tools with Interchangeable Adapters
LOVEJOY Tool Company Offers Precision Cutting Tools
MAPAL Offers High Torque Chuck
Velocity Products Offers New Line of Driven Tooling for Okuma Lathes
OSG Offers HY-PRO CARB 3D and 5D Coolant-Through Drills
Parlec Offers Centering Camera Option for Presetting of Lathe Tools
Rego-Fix Introduces PG6 powRgrip for Tight Machining Areas
Riten Releases Extra-Light Live Centers
Sandvik Coromant Introduces Quick Change Clamping Units
SCHUNK Releases TENDO E Compact
Seco Introduces Double Octomill R220.48 Facemilling Cutter
SST Offers New MST Slimline Curve Shrink-Fit Tool-Holder System
Star SU Offers Balinite Alcrona Pro
Sumitomo Introduces Coated Carbide Turning Grade AC420K
Pinzbohr High Precision Modular Boring Tools from Techniks
MST Rite Angle Attachments Now Available from Tecnara
Tungaloy Offers Stream Jet Mini Coolant Through Boring Bars
Walter USA Announces New Grade to its Walter Valenite Indexable Milling Lineup
WIDIA Introduces New VariDrill
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New KM4X Spindle Connection from Kennametal



When machining tough materials like titanium, there is a need for a spindle connection that makes the best use of available power. Machinists are challenged to maximize metal removal rates to achieve production efficiencies yet face low cutting speeds and considerably higher cutting forces. In response, machine tool builders have improved stiffness and damping on spindles and machine structures over the years to minimize undesirable vibrations that deteriorate part quality and tool life. Although all these advances add to greater productivity, the weakest point has often been the spindle connection itself.

"Kennametal's response to this traditionally weak point has been the KM quick-change system, recognized by the International Organization for Standardization (ISO) as an ISO standard - ISO 26622," said a company spokesperson. "Now Kennametal is introducing its next-generation spindle connection, KM4X."

Some systems may be able to transmit considerable amount of torque, but cutting forces also generate bending moments that will exceed the interface's limits before torque limits are exceeded. The combination of the KM4X system's high clamping force and controlled interference levels lead to a robust connection, extremely high stiffness and restrained bending moment for greatly improved performance in titanium machining.

KM4X engineering results in three times the bending moment resistant capacity compared to other tool systems. This means shops can use their high-performance machining centers to increase speeds and feeds in difficult machining applications, thus gaining the full potential from the machine tool.

Moreover, the ability to retrofit KM4X to an existing machine tool offers the added advantage of increasing throughput without having to invest in expensive additional capital equipment.

The tool-spindle interface must withstand high loads and yet maintain its rigidity. In most cases it will determine how much material can be removed on a given operation until tool deflection is too high or the onset of chatter is reached.

Several different types of spindle connection have been developed or optimized over the last few decades. Due to a good cost/benefit position, the 7/24 ISO taper became one of the most popular systems in the market. Used successfully in many applications, limitations in its accuracy and speed prevent it from growing further.

The advent of face contact represented a major step forward over the standard 7/24 taper. The combination of face contact with 7/24 solid taper provides higher accuracy in the Z-axis, but also presents some disadvantages, namely the loss in stiffness at higher speeds or high side loads. Most of these tools in the market are solid, and the spindles have relatively low clamping force. Connection stiffness is limited, as radial interference needs to be kept to a minimum. Required tolerances to achieve consistent face contact are thus very tight, leading to high manufacturing costs.

"In the early 80's, Kennametal introduced the KV system, which was a shortened version of CV tooling with a three-ball mechanism acting on a conical surface of a bore," said a company spokesperson. "Later versions were designed and sold with face contact. In 1985, Kennametal and Krupp WIDIA initiated a joint program to develop a universal quick-change system, now known as KM and recently standardized as ISO 26622. The polygonal taper-face connection known as PSC, now also standardized as ISO 26623, and the early 90's HSK system started being employed on machines in Europe and later became DIN 69893, then ISO 121."

When machining tough materials like titanium, cutting speeds are relatively low due to thermal effects on cutting tools. In response, machine tool builders have improved stiffness and damping on spindles and machine structures over the years. Spindles have been designed with abundant torque at low rotational speeds.

The spindle connection must provide torque and limited bending capacity compatible with machine-tool specifications and the requirements for higher productivity. It becomes obvious in end-milling applications, where projection lengths are typically greater, the limiting factor is the spindle interface's bending capacity. As an example, an indexable helical cutter with 250mm (9.84 in.) projection from spindle face, 80 mm (3.15 in.) in diameter generates 4,620 Nm (3,407.5 ft-lbs) of bending moment and less than 900 Nm (663.8 ft. lbs.) of torque.

The most critical parameters of a taper-face spindle connection are the clamping force and radial interference. Maximizing clamping force and selecting appropriate values of interference can further improve connection rigidity.

For more information contact:

Kennametal Inc.

P.O. Box 231

1600 Technology Way

Latrobe, PA 15650

800-466-7738

www.kennametal.com

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