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techview


Mark Huston VP, Global Engineered Solutions


Custom Tools, Process Solutions “K


nowing what to measure and how to measure it makes a complicated world less so.” These words from “Freakonomics” pertaining to economics pertain equally well to a discussion on custom tooling. In a production scenario, the right solution is neither custom nor standard tooling, but often comprises the right mix of both, backed by process knowledge and experience. The most productive solution reduces cost per part and opens up existing capacity. It makes a complicated manufac- turing world less so. Improving productivity means addressing a number of things: cycle-time reduction, setup reduction, and improved throughput (higher metal-removal rate, longer tool life, or both). Bundling engineered solutions through collaborative planning with a customer often yields such scenarios as a combination of standard tools, custom tools, logistics sup- port, improved tool management, and more. Often, collaborative engineered solutions are undergone with machine tool builders for much the same reasons, to support part programs or processing needs for the machine tool builder’s client base. Whether directly for manufacturing customers or for technology providers, enhanced knowledge is a valuable benefi t, leading to enhanced productivity for the customer, further tooling innovations from the tooling developer, and the opportunity to share that knowledge to the benefi t of all.


Everything starts with collaborative planning. One cus-


tomer’s story proves this point. An international supplier to the aerospace industry began with a heads-up test among tooling companies for machining alloys such as 6Al4V tita- nium and “triple nickel three” (5553). Many times, the initial needs are predicated by the workpiece geometry. Our collab- orative planning process, however, goes deeper, starting with a discovery phase, entailing a site visit, project and process review, and current-state analysis. This is followed by such details as: Determine customer tooling preferences, budget and timeline; develop a “hybrid” manufacturing process plan; select cutting tools and holders; resolve outstanding “concept” cutting tool engineering issues; quote durable and perishable tooling; present solution to customer; and revise


Dave Cope


Manager, Technical Engineered Programs Americas, Kennametal Inc. Latrobe, PA


and requote based on customer feedback Following the quote is engineering and building, followed


by runoff and production ramp up. Support is provided at the customer and/or machine tool builder site, followed by optimizing tooling performance and operating parameters. Custom tooling support for this customer included end mills and indexable end milling cutters, but even more im- portant was a follow-up presentation at a university in their headquarters city on material solutions in development.


As companies lose expertise to attrition and retirement, making collaborative engineering and building a database of proven solutions is vital.


Whether process plans and custom tools are developed for a single part program or for the ongoing needs of an entire plant, one common theme that emerges is making the most of the customer’s resources, both in capital equipment and human capital. Many companies continue to lose internal expertise to attrition and retirement, making collaborative engineering and building a database of proven solutions even more vital to ongoing success. Kennametal has gone further, taking not only its cata- log (tens of thousands of tools), but 75+ years of process knowledge (how they best work) and turning it into a powerful cloud-enabled digital knowledge stream called NOVO. Re- sponding to user input, NOVO defi nes machining sequences through an advisor, selects and ranks the best tools, builds assemblies, downloads CAD graphic models for simulations and process planning, and obtains application parameters in minutes. NOVO also provides process technical and applica- tion data, including speed and feed recommendations, inven- tory availability, and even the ability to confi gure custom radii, lengths, or toolholder requirements. Whether custom or standard, the most productive solu-


tion reduces cost per part and opens up existing capacity. Capturing process knowledge ensures this becomes the new starting point for continued innovation.


49 — Aerospace & Defense Manufacturing 2015


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