Expert: Katie Myers – Global Product Manager, Solid End Milling.
Q: What challenges are aerospace manufacturers facing the most?
A: This industry is always evolving, so staying current with machining technologies and strategies in response to complex and changing needs is a major challenge. More specifically, aero manufacturers need reliable, precision tools for working with notoriously tough materials, intricate designs and tight tolerances.
Q: Beyond precision and performance reliability requirements, material evolution in aerospace applications is a prominent factor. How is Kennametal collaborating with customers to stay ahead of the evolving material machining challenges?
A: Kennametal is always putting its customers first. We have a really engaged sales team, and we are always working jointly with customers to develop tools for emerging materials together. We have metal cutting labs globally where we test our tools on specific customer parts or materials to ensure customers have the best possible machining solutions when they put our tools into production.
Q: What makes Kennametal’s offering a cut above the rest?
A: We offer an expansive standard, high-performance lineup of tools, including the high-performance HARVI™ end mill lineup, which is used and recommended by industry giant Lockheed Martin. But Kennametal also creates custom solutions by fusing a century of engineering expertise and an advanced know-how in additive manufacturing.
Whether the need is custom, standard or a combination, customers can count on our full-service offering with new project engineering, process optimisation, global application support, supply chain optimisation, and machining strategy and programming support. Our support goes nose to tail.
Q: Tell us more about how Kennametal innovates with engineering and design?
A: We’re always experimenting at our global labs. Our solutions include super innovative and protective coating technologies, like KCS10B inserts that increase tool life and process reliability while making wear easier to spot. We also manipulate flute design to improve versatility, because the more projects you can use a tool on, the more money you’re saving. For example, the latest addition to the HARVI platform, HARVI IV, was engineered with a unique 8-flute design for better versatility and higher metal removal and feed rates than 7- or 9-flute designs can offer. In that same powerhouse solid carbide end mill lineup is HARVI II TE—featuring 5 flutes designed for the most aggressive cutting parameters. We also find the KenTIP™ FS modular drill to be a shop staple because it can handle more applications than any other modular system. We put carbide where it matters on this one—with inserts that cover and protect the entire front of the drill.
Q: The HARVI range is renowned for its performance and material removal rates. Where do you anticipate the next aerospace technology breakthroughs to come from?
A: Likely in the composite materials space because its demand is growing at the fastest rate of all materials used with cutting tools. This is primarily due to lightweighting in the aerospace industry and composite materials offering more strength at a lighter weight than traditional metals. With each composite having a different makeup depending on use, like adding copper mesh layers for lightning strike protection, the need for tooling that can even further adapt to these often-complex layers absolutely exists for aerospace manufacturers.
Q: What new tools from Kennametal should aero manufacturers know about?
A: We are really committed to simplifying machining abrasive composite materials. For example, with the recent launch of the ROCO™ Router platform, we’re delivering more versatility for increased applications like trimming/side milling, helical milling, pocketing, slotting and ramping with the addition of the KCC05A grade, which offers enhanced tool life thanks to a thicker, remarkably consistent diamond fill coating. This is the newest router in composites and a game-changer for shops dealing with splintering, delamination and other poor surface finishes.
Q: How is Kennametal impacting the industry?
A: Whether we’re cutting costs for tier 1 suppliers with nearly 100% improvements in tool life or developing solutions for major industry leaders like Pratt & Whitney and Héroux Devtek, there’s a reason they turn to us to improve their efficiency and for critical, innovative solutions. We’re trusted because we show up, listen, test and don’t sleep until we solve our customers’ toughest challenges.
