b'Printing cutting tools is appropriate when an application is suitable.By Alan RichterI t might seem counterintuitive to build up something to tear down another object, but toolmakers are using additive manufacturing tech-nology to 3D-print cutting tools. However, the objective is not to eliminate conventional production of cutting tools but rather to print ones that would be impossible or cost-prohibitive to create another way for targeted applications.We dont just print tools be-cause we have the capability to do Kennametalit, said Ingo Grillenberger, product manager for Pittsburgh-based Ken-nametal Inc. Rather, were strategi-cally leveraging the unique benefits of 3D printing where it makes sense fromacustomerstandpointin order to solve specific challenges.Going Electric This 3D-printed stator bore tool has a carbon-One cutting tool that the com- fiber body that weighs 7.3 kg (16.1 lbs.).pany found suitable for 3D printing some of the components is the RIQ stator bore tool for finishing three diameters of an aluminum elec- flowing smoothly through cornerspossible without compromising the tric vehicle engine housing in oneand bends. tools performance and durability, operation. You cannot manufacture thatGrillenberger said.According to Kennametal, by ma- inthetraditionalwaybecauseThelightweight,3D-printed chining three diameters in one op- there are too many corners, Gril- combination tool reportedly en-eration, the tool ensures the align- lenberger said. You would haveables a fast tool change and ro-ment and concentricity of the ma- to drill too many angles.Here, 3Dtation even on low-horsepower chined surfaces while significantlyprinting is areal problem-solver. machines.reducing setup and cycle times. He said the tool manufacturerYou can accelerate anddecel-Some of the features on this toolused finite element analysis and cal- erate light tools faster than heavy are simply not possible to manufac- culation methods to design the tooltools, Grillenberger said. Its also ture with traditional manufacturingand prints it with laser powder bedmore energy-efficient to speed up methods, Grillenberger said. melting. and slow down lighter tools than He said one specific feature isThe latest version of the statorheavier ones, and machine com-the coolant channels through thebore tool is about 20% lighter thanponents, such as bearings, are less tools airfoil-shaped arms, enablingthe first-generation one and weighsstressed when running lighter tools. coolant to be applied at the exact7.3 kg (16.1 lbs.). Part manufacturers must also ac-position and angle required afterWe reduced weight as much ascount for a tools tilting moment 18DECEMBER 2022Additive.indd 18 11/15/22 12:20 PM'