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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.

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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.

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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

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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.

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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)


as-pf hqs

Kennametal Pte. Ltd

No.11 Gul Link Jurong

Singapore 629381

Phone: (65).6.2659222


i hqs

Kennametal India Limited

8/9th Mile, Tumkur RoadBangalore - 560 073

Phone: +91 (80) 2839 4321

E-mail: [email protected]

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