FEATURE TOOLS & TOOLING
Developing cutting tools using metal 3D printing
Renishaw’s metal additive
manufacturing system uses laser powder bed fusion technology in an inert argon atmosphere. An extremely thin bed of metal powder is laid down and areas that will form the component are melted using a high performance ytterbium fibre laser and then solidified on cooling. This process is repeated with layers of metal powder, typically between 20 and 60 μm thick, until the part is finished. The thinner the layers, the better the accuracy and surface quality of the finished part.
THE RESULT The first of the projects handled jointly between Komet and Renishaw was the development of a new range of PCD (Poly-Crystalline Diamond) screw-in milling cutters. The main bodies of the cutters are manufactured on a Renishaw metal additive system, with multiple bodies produced during each cycle of the machine, and then fitted with PCD blades and screwed onto their tool holders. The use of the Renishaw technology to
K
omet Group is using Renishaw metal additive manufacturing technology to
produce new ranges of cutting tools. As well as allowing special cutters to be produced more quickly, the use of additive manufacturing enables more complex shapes to be generated, both for the external shape of the tooling and for the internal cooling channels.
THE CHALLENGE Germany’s Komet Group is one of the world’s leading suppliers of precision cutting tools. Dr. Reinhard Durst, research and development manager for hard metal tools at Komet Group, has been investigating the potential of additive manufacturing for tooling production and the equipment available on the market for several years. Durst has been working with Renishaw
for the last year. The transfer of knowledge and know-how is inherent throughout Renishaw’s new and growing network of Additive Manufacturing Solutions Centres. Before buying the machine outright, customers can lease the latest equipment at a Solutions Centre and work independently on their projects. As a result, potential customers can familiarise themselves with additive manufacturing technology, with expert help on-hand, and discover how it might meet their specific requirements. “We are aiming for a win-win
situation,” explains Ralph Mayer, the manager responsible for additive manufacturing services at Renishaw. “With our support, the customer shortens their learning curve and reduces the number of potential mistakes to a
18 SEPTEMBER 2017 | FACTORY EQUIPMENT
minimum. We only raise the question of purchasing a system when the customer is clear that it will provide added value for them. At the same time, we gather valuable information about the needs of the industry, which we can use to develop our machines and technology further. “Parts produced with additive
manufacturing can reach up to 99.9 per cent consistent structure, just like rolled or cast metal components,” says Mayer. “However, the correct strategy must be applied for every component. Our skill is analysing the technical challenges of our customers’ components and working with them to find the most effective solution.”
Above: Dr. Reinhard Durst, research and development manager for hard metal tools at Komet Group
Below: A screw-in cutter
manufacture the tools allows geometries to be produced that would be almost impossible by conventional means. “Thanks to the additive process we
have been able to place many more PCD blades on each tool,” explains Durst. “We have changed the arrangement of the blades and achieved a substantially greater axis angle. Compared to conventional milled tools, we have greatly shortened the grooves. These changes mean that the tool is a lot more productive for the user.” For example, with a 32mm screw-in
head, the number of grooves and blades has been increased from six to 10, achieving a feed rate that can be up to 50 per cent higher. In addition, the ability to optimise the paths of the coolant channels ensures that each cutting edge is supplied precisely with coolant through a separate channel, while the external design of the bodies helps to ensure that chips are removed reliably from the face of the tool. “The ability to freely design the internal
and external tool geometry alone means that excluding this additive process from our future plans would be inconceivable,” continues Durst. “It gives us the ability to increase tool performance and productivity to an extent that it creates considerable added value for customers. “Renishaw has contributed a wealth of
knowledge to help us find the parameters that are needed to produce a good tool. The new design freedom and the cooperation with Renishaw is helping us to develop even more tool solutions.”
Renishaw
www.renishaw.com/komet
/ FACTORYEQUIPMENT
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