Condition Analyzer – Innovative Process Data Analysis
After years of research, metallurgist Philipp M. McKenna succeeded in 1938 in producing a tungsten-titanium carbide alloy that would give cutting tools greater durability while increasing cutting speeds. Based on this patented development, he founded Kennametal. In the decades that followed, the company became a globally active tool manufacturer and solutions provider with around 9,000 employees today.
„In the age of digitization, it was important for us to exhaust all digital possibilities right from the start. With the DMG MORI CONDITION ANALYZER, we have found exactly the right solution for this.”
Andreas Lieber, Staff Engineer Global Machining Technology at Kennametal
„The DMG MORI CONDITION ANALYZER provides us with the best comparison options with regard to our data collection and analysis and helps us with our new product development, which ultimately benefits our customers.“
Jochen Groß, Senior Engineer Global Machining Technology at Kennametal
The portfolio includes products for metalcutting as well as for the infrastructure sector, which includes mining and oil & gas, for example. In Fuerth, one of the global Technology Centers was established, where experienced specialists continuously develop the standard product range as well as customerspecific tool solutions. The focus is on cutting tools, which the team there subjects to all the necessary tests on a DMU 80 P duoBLOCK dating from 2012 and a DMU 85 monoBLOCK installed in 2020. Also on board the newer machine is the CONDITION ANALYZER, which sustainably optimizes testing of the prototypes.
Over 1,730 patents for optimum machining results
“Transform how everyday life is built.” With this vision, Kennametal develops tools that indeed literally shape everyday products – in the automotive, aerospace, and energy sectors, to name just three examples. “For us, it's all about producing innovative tools that are as wear-resistant as possible for the most demanding machining applications,” Andreas Lieber, Staff Engineer Global Machining Technology , explains. This, he says, requires continuous development of tool materials, countless tests of prototypes and, last but not least, the inquiring mind of the company's founder. This is also reflected in the 1,730 active patents held by Kennametal. Over 140 new patents have been granted in the past year.
CONDITION ANALYZER for optimizing the cutting properties of new tools
On one hand, the Technology Center in Fuerth works on innovations for the standard product range. These include tools for the Kennametal and Widia brands. On the other hand, the focus is on individual tool solutions for customers. “In both cases, we want to set new standards in metal cutting," Jochen Groß says, Senior Engineer Global Machining Technology. Machining tools are a decisive factor in optimizing productivity and quality in production, he adds. In standardized trials, Kennametal tests these tools in its Test & Demonstration Center to analyze and further improve their properties under specific application conditions. “To do this, we measure relevant data that we can access during machining, for example power consumption or spindle utilization,” Jochen Groß explains. “Nowadays, we analyze these with the Condition Analyzer from DMG MORI."
DMU 85 monoBLOCK: Highly stable for tests up to 20,000 rpm
For testing the tools, Kennametal in Fuerth uses the DMU 80 P duoBLOCK and the DMU 85 monoBLOCK. “The crucial factor for us is the stability of the machines, so that we can carry out very dynamic machining at high speeds – the monoBLOCK machine has a speedMASTER spindle with 20,000 rpm – without hesitation,” says Andreas Lieber, explaining the purchase in view of the wide range of applications. “The standardized workpieces are made of every conceivable material – from aluminum to titanium,” Jochen Groß adds. But the size of the working area is also important, he says, given the length and diameter of some tools.
High data density and quality thanks to DMG MORI CONDITION ANALYZER
The investment in the DMU 85 monoBLOCK was made with an eye to future requirements, as Andreas Lieber recalls: “In the age of Industry 4.0, we wanted to consider all digital aspects in this project from the very beginning.” That is why DMG MORI's CONDITION ANALYZER took on a central role, he says. Under manufacturing conditions, the software analyzes and visualizes the machine condition in real time on a component-by-component basis in order to avoid downtime. It supports preventive maintenance and improves workpiece quality by analyzing and optimizing NC processes.
“The fact that the CONDITION ANALYZER collects so much data and evaluates it in a user-friendly manner naturally also helps us when testing tools,” Andreas Lieber comments. Specifically, Kennametal analyzes the power consumption curve and the performance data of the feed drives, from which the forces acting can be calculated. The CONDITION ANALYZER also measures the spindle temperature, which will be used to improve tools in the future. According to Jochen Groß, the added value compared to older machines lies in the large amount of data and its quality: “The CONDITION ANALYZER measures up to 20 data points per second and enables informative, high-resolution graphs.” For example, he says, a load increase can be displayed during the short period of tool entry into the workpiece prior to full diameter engagement.
CONDITION ANALYZER for increasing competitiveness
The use of the CONDITION ANALYZER in this research environment was preceded by intensive cooperation with DMG MORI. Andreas Lieber is more than satisfied: “In the Technology Center, we have different requirements for a manufacturing solution than in production. Therefore, the Condition Analyzer had to be adapted to these conditions again and again.” The final result impressed him and the entire project team – it offers Kennametal a better comparison and an easier exchange of data and experiences. “This investment in digitization will benefit customers through improved quality, product performance and innovation and will bring added value,” says Jochen Groß.
Kennametal Shared Services GmbH
Wehlauer Str. 73
90766 Fürth, Deutschland
www.kennametal.com