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7/30/2019 A 08 01792 Wind Energy En
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SuStainable SolutionSManuacturing and Farming Wind Energy or a New Generation
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Your componentS machinedin record time
With the right tool and the right know-how,
your speed, accuracy, and output can be
improved tremendously. As your trusted partner
or optimized production, Kennametal oers an
unprecedented commitment to research and
development excellence, leading to highly
innovative ways to enhance your productivity.
Certication to ISO 9001, QS 9000 TES, and
VDA 6.4 guarantees the highest possible
quality standards.
environmental SuStainabilitY
At Kennametal, we are deeply committed to designing
and manuacturing environmentally responsible
products that deliver high perormance and proven
value. With decades o experience in tooling and
manuacturing, the synergies o superior engineering,
leading technology, and customized solutions oer
customers some o the most eective opportunities
or sustainable manuacturing in the industry. Our
comprehensive range o products, local support,
and excellent customer service make Kennametal
your complete supplier o sustainable wind turbine
generator manuacturing solutions.
Wind energyKennametal leads the way with innovation, engineering,
and service in standard and custom tooling.
Wind Energy >> WIND INDUSTRIES >> 02/03
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ToWer SegmenTSWind turbine manuacturers throughout the world ace
business challenges every day and seek solutions or more
capacity, higher productivity, and better quality. When it
comes to tower segments, manuacturers need to produce
high-quality chamer welds with components spaced and
aligned perectly. Furthermore, capacity constraints require
dramatic reductions in manual operations and routineprocessing times. Thats where Kennametal can assist.
Kennametal KSEM and KSEM PLUS modular drills have
set new standards in the manuacturing o components
including tower segments, pitch bearings, hubs, housings,
and rames. KSEM drills double the metal removal rate
compared with older tools. In less than 30 seconds, you
can drill a 39mm hole to 175mm DOC (112" x 678") deep
into 42CrMo4 steel. With the KSEM and KSEM PLUS drills,
youll add hundreds o hours to your machine capacity
each year.
7/30/2019 A 08 01792 Wind Energy En
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drillinG
KSem pluS
Double the metal removal rate.Replaces conventional indexable
drilling operations.Modular design or easiest handling and setup.Diameter range o 32mm to 70mm (112" to 234").
millinG o weldinG chamerS
weldinG millinG cutterImprove cycle time to machine 16m (5212 t)
rom 120 minutes to 25 minutes.Minimum inventory, maximum variety.75 possible variations using only
2 styles o inserts.Vc = 160 m/min (525 sm)
V = 700mm/min (2,297 sm)
visit www.kennametal.comand exploreKennametaltools and custom solutions.
CLICKAND SEE
Wind Energy >> TOWER SEGMENTS >> 04/05
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roTor HUBUsing conventional tooling, the giant cast iron rotor hub
can consume more than 20 hours o processing time.
But with highly productive tooling solutions rom
Kennametal, you can be assured the shortest cutting
times with the maximum lexibility to perorm
multiple operations without tool changes.
For rough milling o aces and bores with helical
interpolation, Kennametal milling cutters and inserts
oer progressive eed rates o 612 m/min (2040 t/min).
Each minute o reduced cycle time will improve
throughput, osetting the cost o additional capacity.
In addition to rotor hubs, Kennametals advanced technology
can be applied to a variety o components, including nodular
or grey cast iron housings, gearboxes, planet carriers, and
rames. Other advanced tools such as Kennametal KSEM,
KSEM Plus, and HTS drills and HSS taps should be used
on rotor hubs or maximum eciency.
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90 interpolation millinG
ix perectOne cutter or all 90 interpolation milling
operations requiring minimum tool changes.Remarkable cutter design with proven
perormance.Excellent tool lie with lowest carbide cost
by using up to 8 eective cutting edges.Wiper inserts available or ne nishing.Reduction o cycle time by advanced
cutting parameters.Vc = 200250 m/min (650820 t/min)
V = 6 m/min (20 t/min)
ace and interpolation millinG
dodeKa
Universal 45 lead cutter or all ace and rough
interpolation operations.Positive rakes enable high-eed rates at given
spindle power.
Inserts with big corner radius recommended (e.g., R 4,3)
or better surace nish.Lowest possible insert cost with long tool lie and 12
cutting edges per insert.Broad insert range with strong cutting edge as well as wiper
Reduction o cycle time by advanced cutting parameters.Vc = 200250 m/min (650820 t/min)
V = 211 m/min (636 t/min)
Wind Energy >> ROTOR HUB >> 06/07
Longer tool life is a hallmark
of sustainable production.
Kennametal utilizes sub-micron grain
sized grades of tungsten carbide to
provide the maximum wear life whencompacting abrasive materials.
DID youKNow
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These remarkably long components range rom 1360 m
(40200 t). In addition to material handling constraints,
rotor blades require 5 to 6 hours o machining time with
changeover requirements up to 2 hours.
Kennametals legendary experience in high-speed machining
or the aerospace industry has driven the development o
drills or the wind turbine blades made rom composite
bers. Kennametal DFT and DFS drills are equipped
with polycrystalline diamond inserts or high cutting
speeds and long tool lie.
roTor BladeS
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holemaKinG
drill ix dt & dS
with pcd inSertSImproved cycle times by piloting and drilling
on a single operation.PCD-tipped carbide inserts or long tool lie.High-speed cutting.In-stock system with standard tooling to
replace custom gun-drill applications.
Kennametal provides product
solutions that withstand harsh
wear, impact, and corrosive
environments to prolong tool life and
reduce costs. We offer custom-madepreformed, semi-finished, and finished
products to meet your needs.
DID youKNow
Wind Energy >> ROTOR BLADES >> 08/09
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HoUSingContemporary wind turbines have much larger housings and
gearbox components to accommodate ever-increasing power
generation capacity. These larger, more sophisticated cast
iron designs require high-precision machining, especially
in boring operations. A 5mW turbine, or example, requires
a 3m diameter bore hole with an H7 tolerance.
To achieve this accuracy, Kennametal bridge tools with
standard Romicron neboring units are your rst choice.
The tools are made rom high-strength aluminum and
allow or both coarse and ne adjustment. For ne
adjustment, the Romicron units are unsurpassed in
precision, reliability, adjustment speed, and operator
riendliness. The number o measuring cycles and
re-adjustments is minimal. Using a reerence cut,
the nal diameter can be easily and reliably set
within microns inside the machine.
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tappinG
Gun and Spiral lute tapM36x4 HSG 5FL 15 spiral fute tap
with TIN+CRC/C coating.Broad range o standard and custom
design capabilities.Proprietary coating technology or steel,
cast iron, and non-errous materials.Vc = 5060 m/min (160200 t/min)
borinG
Km63tS tunable barSDesigned or large length-to-diameter boring
applications.Provides 23x the dynamic stiness over
competing products.Reduce tooling inventory by utilizing ISO
standard KM Quick-Change connection.Pre-tuned, enables nite adjustments.
ineborinG
romicron
bridGe toolUp to 4m (12 t) in diameter.Through coarse adjustment, one tool or dierent diameters.High-strength aluminum body, balanced by design.Standard Romicron cartridges or reliable, indexable
adjustment by micron.Carbide inserts with high-positive geometry and sharp
cutting edges or highest precision and tool lie.Vc = 200250 m/min (650820 t/min)
=0,120,15 mm/rev in GGG40
Wind Energy >> HOUSING >> 10/11
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BearingS and gearS
For the pitch drives o rotor blades and nacelle, large
compact bearings with internal or external gears are
needed. Producing these components requires turning,
holemaking, and gear milling. With Beyond turning
grades, KSEM PLUS drills, and internal and external
gear milling or roughing and nishing, ensure the
minimum cycle time and cost without sacricing
superior quality.
Rely on Kennametals milling portolio or rough and nish
gear milling o one- or multi-start indexable hobs and 6mm
module and 40mm module gears. Proven carbide grades,
together with up to 8 indexes per insert, enable the lowest
tooling cost. Our innovative cutter designs enable advanced
cutting, even under less-than-stable conditions.Kennametal
gear specialists are available to help you determine the
optimum tool and process.
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millinG
Gear GaSherMost productive tool or external gears with lower number o teeth and or
internal gears.Module 6mm to 40mm, roughing and nishing cutters.Lowest cost per piece rom inserts with multiple (up to 8) cutting edges.Positive insert geometries reduce cutting orces.Roughing: VC = 140 m/min (450 t/min) and V = 480mm/min in 42CrMo4.Finishing: VC = 180 m/min (600 t/min) and V = 2.750mm/min in 42CrMo4.
hobbinG
Gear hobMost productive tool or external gears
with higher number o teeth.Module 6mm to 40mm (14" to 112")
as one- and two-start hobs.
Simple, modular design; operator-riendlyinsert change.Positive insert geometries available
to reduce cutting orces.VC = 120 to 160 m/min (397 to 525 t/min),
= 4mm (16") per gear revolution
in 18CrNiMo.
Wind Energy >> BEARINGS and GEARS >> 12/13
visit www.kennametal.comand exploreKennametaltools and custom solutions.
CLICKAND SEE
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main SHaFT
In a wind turbine, the main shat is one o the components
with the highest loads. Machining a shat consumes more
than 5 hours o processing time to transorm cast steel
material to a high-precision component with stringent
surace requirements.
Kennametal provides industry-leading turning technology
to meet this need. The new Beyond platorm is designed
to increase metal removal rates and to extend tool lie,
up to 2x, in the alloy steels used in the wind industry.
The surace technology o the new Beyond turning grades
combine with substrate design, multi-layer coatings, and
chip-breakers to deliver higher productivity, longer tool
lie, and better operating conditions.
Forged 34CrNiMo6CV or 42CrMo4 steel is machined
on large lathes with Kennametal heavy duty toolholders.
The back end ts all current adaptation systems on
the market today.
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holemaKinG
htS drillProven modular platorm up to 450mm (1734")
diameter and up to 3m (10 t) in length.Excellent centering and chip evacuation.Cartridges and inserts available or drilling or sinking
operations.Low power consumption.Diameter 270mm x 1.5mm (1058" to 60") in 55 minVc = 80 m/min (260 t/min), = 0.21/ rev
turninG
heavY-dutY turninG toolSWK or other back end to t heavy duty lathes.Roughing, acing, grooving, and copying toolholders
and inserts.Wide range o standard inserts in new Beyond grades.
Roughing: Vc = 5070 m/min (160225 t/min);
= 0.8 . 1.5mm (0.0300.060")Finishing: Vc = 5070 m/min (160226 t/min);
= 0.40.6mm (0.016-0.025")
turninG
beYond
inSertSNew Beyond turning grades increase tool lie up to 100%.30% to 300% more productive 85% o the time.Proprietary post-coat treatment and multi-layer coatings.Applicable across a wide range o cutting conditions
in slow- to high-speed machining.
Wind Energy >> MAIN SHAFT >> 14/15
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Successul project engineering requires planning,
teamwork, and disciplined execution. Through our
extensive experience in developing and implementing
new project engineering strategies, Kennametal
has pioneered a proven methodology to help you
manuacture new products and bring them to market
quickly. Service deliverables are careully outlined
and jointly agreed upon beore the project begins.
We ormally evaluate progress and results with you
throughout the project according to our award-winning
stage-gate management systems.
Kennametal can provide your engineering teams
and machine tool builders with process engineering
support, advanced metalcutting technologies, and
project management expertise to help you achieve your
sustainability goals. With our best-in-class processes,
youll experience accelerated time-to-market, lower
overall costs, and reduced risks to implement new
technologies.
SUSTainaBle
engineeringKennametal leads the way with innovation, engineering,
and service in standard and custom tooling.
A Proven Methodology and Partnership.
7/30/2019 A 08 01792 Wind Energy En
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execution
Manuacturing.
Procurement.
Project Management.
Assembly.
Pre-setting.
Balancing.
Inspection.
Shipping.
Training.
Run-o Support.
acceptance
Review perormance versus contract.
Customer decision gate: Formal acceptance.
production ramp-upaSSiStance
Support program launch schedule through
assistance in spare part and consumable
procurement planning and urther
process optimization.
diScoverY and propoSaldevelopment
Review project needs with customer and/or
machine tool builder.
Customer decision gate: Request proposal.
propoSal preSentation
Discuss how Kennametal can be o service.
Customer decision gate: Approve proposal.
build project plan
Clariy technical and commercial aspects
o projects.
Develop engineering and project schedule.
Customer decision gate: Approve drawings.
project plan approval
Present drawings and conirm order.
Customer decision gate: Approve project plan
and deliverables.
Kennametal has more than 700 highly trained
and innovative research scientists and
development engineers. They are creating new
advanced materials or demanding applications
and are designing proprietary components that
deliver superior perormance or our customers.
DID youKNow
Wind Energy >> SUSTAINABLE ENGINEERING >> 16/17
7/30/2019 A 08 01792 Wind Energy En
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Our Kennametal CompleteTM
Program leverages advanced servicesand a network o strategic alliance partners to address your
overall manuacturing productivity and signifcantly improve
your proftability.
proceSS optimizationK pss o Ss
:
Tool selection, application, standardization,and design.
Workholding and standardization to reduceinventory.
Operation consolidation to maximize value.Lean principles to minimize waste.Process sequencing to create low.
carbide recYclinGlgss m S
Its easy or your company to be environmentally
conscious and theres an added incentive:
It is proitable. Through our Carbide Recycling
Program, Kennametal will purchase your
used carbide (tooling credits available dependingon region).
new projectenGineerinGusg i c
c ag
Kennnametals New Project Engineering Services
have supported the successul launch o
hundreds o new manuacturing lines worldwide
in the automotive, aerospace, heavy equipment,
general engineering, rerigeration equipment,
railroad equipment, and marine sectors.
o - ss :
Lean process development.Custom tooling.Cost assessments.Scheduling, monitoring, and procurement.
KennameTal CompleTe
SupplY chain ServiceSwy s y s K Sy c
Ss?
s rss Our proven expertise means
we can help you to identiy needs, provide
solutions, and achieve measurable results
quickly and cost eectively.
ds p e We have
implemented hundreds o customized supply
chain programs with major manuacturers
worldwide, achieving impressive eiciency gains,
cost reductions, and other related beneits.
educationt K Kg c ss
y s y
ss y gg y ss :
Comprehensive engineering courses.Industry- and application-speciic courses.Customized onsite programs and sel-pacede-learning.
tool reconditioninGKennametal Reconditioning Services help you
optimize the value o your metalcutting tools
throughout their service lives by giving them
like-new perormance characteristics
in rapid turnaround time so the tools you
need are always on-hand.
comprehenSive ServiceproGramThrough the Kennametal Complete
Comprehensive Services Program, we
build partnerships that ocus on delivering
year-over-year productivity improvements
through integration into your engineering
and production processes via:Continuous on-site optimization.Concurrent new product/project engineering.In-plant logistics.
7/30/2019 A 08 01792 Wind Energy En
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CompleTe ComponenT
SolUTionS
Wind Energy >> Kennametal COMPLETE >> 18/19
operation product hub
houSinG
Gearbox
GeneratorhouSinG
GearS
mainShaft
tower
mainframe
bearinGrinG
blade tYpical diameter ranGe
or wind applicationS
(mm/inch)
millinG Dodeka KSHR X X X X X X 125250 410"
millinG FixPerect 90 IC15 X X X X X 125250 410"
millinG KSSM 45/ KSSM 90 IC12 X X X X X 125315 412"
millinG KSRM RCGT20 X X X X 125250 410"
millinG KMS PDHX X X 100 4"
millinG KSSM Helical X X X 80100 34"
millinG Brazed Helical X X X 80100 34"
millinG Proile Mill X X X 100200 48"
millinG Chamer Mill X 160315 612"
millinG Gear Gasher X 160700 627.5"
millinG Gear Hob X X M640
holemaKinG HTS X X X X X 200450 7.87517.750"
holemaKinG KSEM Plus X X X X X X X X 3270 1.2501.750"
holemaKinG KSEM X X X X X 45270 1.75010.625"
holemaKinG KenTip X X X X X 4070 1.5001.750"
holemaKinG DFT/ DFS PCD X 12.573 0.5002.875"
tappinG HSG Taps X X X X X X M3080 1.1253.000"
ineborinG ModBORE X X X X X 1683 0.6253.250"
ineborinG Romicron Bridge Tool X X X X X M16M42 0.6251.625"
turninG Heavy Duty Tools X X 150655 525"
turninG TTS Boring Bar X 4004000 15.750157.500"
turninG Beyond X X
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.k.
e hqs
Kennametal Europe GmbH
Rheingoldstrasse 50
CH 8212 Neuhausen am Rheinall
Switzerland
Phone: (41).52.6750.100
E-Mail: [email protected]
w c hqs
Kennametal Inc.
1600 Technology Way
Latrobe, PA USA 15650
Phone: 800.446.7738 (United States and Canada)
E-Mail: [email protected]
as-pf hqs
Kennametal Pte. Ltd
No.11 Gul Link Jurong
Singapore 629381
Phone: (65).6.2659222
E-Mail: [email protected]
i hqs
Kennametal India Limited
8/9th Mile, Tumkur RoadBangalore - 560 073
Phone: +91 (80) 2839 4321
E-mail: [email protected]