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The ongoing effort to increase fuel efficiency, tactical mobility, and payload capacity design in the aerospace industry has driven engineers to find ways to design components utilising lightweight materials such as composites, aluminium, and plastics. In most structural and assembly joints using lightweight materials, the parent material needs to be reinforced through the use of a wire insert, moulded/potted insert or ultrasonic insert. However, in challenging applications where significant loads cannot be supported by the aforementioned inserts, engineers and designers may consider lightweight and heavy-duty key threaded inserts. For many years, key threaded inserts, made from stainless steel and A286 have been used with either a standard thread or prevailing torque. Still, many applications utilising these key inserts fall short of addressing the locking limitations and potential for vibration-induced thread loosening that is inherent in the standard 60° thread form. The prevailing torque thread, on the other hand, may have complications with bolt rundown and/or thread reusability. Fortunately, advances in fastener insert technology help protect against fastener loosening or failure, while offering additional benefits of reducing assembly time, maintenance costs, and even overall weight. The Spiralock Key insert represents yet another company innovation that combines the Spiralock self-locking threads with a conventional key insert fastener. The Spiralock thread form offered by Stanley Engineered Fastening allows for superior locking performance when compared to standard threads and prevailing torque threads. Spiralock design featuring a 30° wedge ramp at the root of the female thread creates a continuous spiral line contact along the entire length of the thread engagement, eliminating radial clearances and spreading the clamp force more evenly over all engaged threads. Other benefits of Spiralock include reduction of galling between screw and fastener and extended reusability for exceptional product longevity. Applications include aircraft engines, avionics, radar instrumentation panels and communications. www.stanleyengineeredfastening.com

The ongoing effort to increase fuel efficiency, tactical mobility, and payload capacity design in the aerospace industry has driven engineers to find ways to design components utilising lightweight materials such as composites, aluminium, and plastics. In most structural and assembly joints using lightweight materials, the parent material needs to be reinforced through the use of a wire insert, moulded/potted insert or ultrasonic insert.

Rotating cutting tool used to enlarge a drilled hole to size. Normally removes only a small amount of stock. The workpiece supports the multiple-edge cutting tool. Also for contouring an existing hole.

Enlarging a hole that already has been drilled or cored. Generally, it is an operation of truing the previously drilled hole with a single-point, lathe-type tool. Boring is essentially internal turning, in that usually a single-point cutting tool forms the internal shape. Some tools are available with two cutting edges to balance cutting forces.

Babcock International Group (Babcock), the defence company, has been awarded a two-year contract extension by the UK Ministry of Defence (MOD) to continue to provide technical support services across the UK armed forces.

In celebration of World Space Week, Space-Comm Expo has announced visitor registration is now officially live and open for the London ExCeL, event, running 11-12 March 2025.

“The main bore that houses the stator of an electric motor measures approximately 250 mm (9.84") in diameter and approximately 400 mm (15.74") in length with a smaller bearing bore at the bottom,” explained Harald Bruetting, manager of program engineering at Kennametal. “When manufactured using conventional means, a reamer for this type of application would weigh more than 25 kg (55 lbs.), far too heavy for the existing machine tool or for an operator working with the tool.”

Bruetting and Kennametal’s Solutions Engineering Group turned to the company’s in-house additive manufacturing capabilities to print a strong yet lightweight indexable-insert tool equipped with Kennametal technologies, such as fine-adjustable RIQ reaming inserts for precise finishing and the KM4X adapter for enhanced rigidity. The tool also features 3D-printed coolant channels, which help boost productivity and extend tool life.

Although Kennametal developed the tool to machine stator bores, alternative applications are conceivable wherever there are big bores and large depths, such as the bores in transmission cases.

Machinists can realize ease of handling and energy efficiencies when producing components for e-mobility applications with Latrobe, Pennsylvania-based Kennametal Inc.’s 3D-printed, lightweight stator bore tool. It is for machining the stator bore of hybrid and electric engine housings.

Spiralock design featuring a 30° wedge ramp at the root of the female thread creates a continuous spiral line contact along the entire length of the thread engagement, eliminating radial clearances and spreading the clamp force more evenly over all engaged threads. Other benefits of Spiralock include reduction of galling between screw and fastener and extended reusability for exceptional product longevity.

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Fortunately, advances in fastener insert technology help protect against fastener loosening or failure, while offering additional benefits of reducing assembly time, maintenance costs, and even overall weight.

Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.

“By using metal powder bed 3D printing together with finite element analysis software, we were able to design and build a tool that brought the tilting moment very close to the spindle face, increasing its rigidity while meeting the customer’s weight restrictions,” said Werner Penkert, manager of Kennametal’s Future Solutions.

Still, many applications utilising these key inserts fall short of addressing the locking limitations and potential for vibration-induced thread loosening that is inherent in the standard 60° thread form. The prevailing torque thread, on the other hand, may have complications with bolt rundown and/or thread reusability.

The tool’s reduced weight is significant because the resulting lower tilting moment makes it easier for machinists to maneuver the tool, and the resulting lower moment of inertia reduces not only wear on machine components but energy consumption.

The Spiralock Key insert represents yet another company innovation that combines the Spiralock self-locking threads with a conventional key insert fastener. The Spiralock thread form offered by Stanley Engineered Fastening allows for superior locking performance when compared to standard threads and prevailing torque threads.

E-mobility components typically are machined on small, low-horsepower CNC machine tools that require lightweight cutting tools. Kennametal’s 3D-printed stator bore tool weighs about half that of the conventionally manufactured version while still meeting requirements for accuracy, roundness and surface finish when boring aluminum.

“In the housing itself, all components of the engine, such as stator, rotor and bearings, are fitted in,” said Ingo Grillenberger, technical program manager of e-mobility for Fürth, Germany-based Kennametal GmbH’s Solutions Engineering Group. “For the final performance and efficiency of the electric engine, it is very important that all these components are aligned perfectly and they are concentric.”

Two versions of the tool were built: one with a carbon fiber tube and the other using a 3D-printed metal tube. The tool with the 3D-printed tube weighs 10.7 kg (23.6 lbs.), and the carbon fiber version weighs 9.5 kg (20.9 lbs.).

However, in challenging applications where significant loads cannot be supported by the aforementioned inserts, engineers and designers may consider lightweight and heavy-duty key threaded inserts. For many years, key threaded inserts, made from stainless steel and A286 have been used with either a standard thread or prevailing torque.

The Boeing X-37B spaceplane is to begin executing a series of novel manoeuvres, called aerobraking, to change its orbit around Earth, the US Space Force has announced.

Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.