A-12-02809 KMT ToolingSystems2013 Sectionm Technical

KEN_TOOLINGSYSTEMS11_M000_M001.
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Technical Information
The Correct Spindle Connection and Application Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M2
Shank Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M3–M6
Spindle Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M8–M19
KM4X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M9–M11
KM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M12–M13
HSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M14–M15
7/24 Face Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M16–M17
7/24 ISO Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M18–M19
Clamping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20–M35
KM Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M20–M21
KM Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M22–M29
KM-LOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M30–M31
KM-LOC II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M32–M33
KM Rapid/Rapid Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M34
KM Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M35
KM ATC Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M36
KM XMZ Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M37
KM Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M38–M51
KM Tooling Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M52–M61
KM Micro/KM Mini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M62–M72
Clamping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M62–M69
Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M70–M72
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M74–M77
Shrink Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M78–M81
SAFE-LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M82
Hydraulic Chucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M84–M87
HPMC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M88–M89
Tunable Tooling System (TTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M90–M91
Tunable Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M92
Tunable Boring Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M93–M95
Screw-On Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M96
Through-Coolant Shell Mill Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M97
Collet Chuck Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M98–M99
Collets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M100–M103
Gripping Strength Comparison Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M104–M105
www.kennametal.com M1
KEN_TOOLINGSYSTEMS11_M002_M003.qxp:WIDIA 11:46 AM Page M2
Spindle Connection
The Correct Spindle Connection

and Application Guide
The Spindle Connection
Several different types of spindle connection have been developed or In 1985, WIDIA™ (Krupp WIDIA) and Kennametal initiated a joint
optimized over the last few decades. The 7/24 ISO taper became one of program to further develop the concept of taper and face contact
the most popular systems in the market. It has been successfully used in interface and a universal quick-change system — now known as
many applications, but its accuracy and high-speed limitations prevent it KM™ and recently standardized as ISO 26622. The KM system has
from growing further due to only having one surface of contact around a very strong design, utilizing three surfaces of contact, the ﬂange face,
the gage diameter/uppermost cone. The recent combination of face and lower as well as upper ring of contact of the cone. The polygonal
contact with 7/24 solid taper provides higher accuracy in the Z-axis taper-face connection, known as PSC, is now also standardized as
direction, but this also presents some disadvantages, namely the loss in ISO 26623, and in the early 1990s, the HSK system started being
stiffness at higher speeds or high side loads. Most of these tools on the employed on machines in Europe and later became DIN 69893 and
market are solid and the spindles have relatively low clamping force. later ISO 12164 with two rings of contact. KM4X™ is the next generation
of KM targeted at heavy-duty machining due to the combination of high
interference and high clamping forces.
KM4X
KM
HSK
PSC
7/24 Taper
Face Contact
7/24 ISO Taper
M2 www.kennametal.com
Shank Controls
Taper Speciﬁcations
KM Micro™ and KM™ Mini
D D2 B1 L2 L5
12,0 10,0 4,2 6,7 13,0
KM12
.427 .394 .167 .264 .512
16,0 10,0 4,2 6,7 13,0
KM1612
.630 .394 .167 .264 .512
16,0 12,0 4,9 7,11 14,3
KM16
.630 .472 .193 .280 .562
20,0 12,0 4,9 7,1 14,3
KM2016
.787 .472 .193 .280 .562
20,0 16,0 6,6 10,0 18,0
KM20
.787 .630 .260 .394 .709
25,0 16,0 6,6 10,0 18,0
KM2520
.984 .630 .260 .394 .709
25,0 20,0 8,0 10,0 20,0
KM25
.984 .787 .314 .394 .787
32,0 20,0 8,0 10,0 20,0
KM3225
1.260 .787 .314 .394 .787
KM™ — ISO 26622-1
D D2 D3 D4 D5 L5 L2 L3 L4 B1
32,0 24,0 29,0 36,45 3,5 20,0 8,0 4,9 10,0 9,0
KM32TS
1.260 .945 1.142 1.435 0.138 0.787 1.102 0.193 0.394 0.354
40,0 30,0 37,0 44,45 3,5 25,0 11,0 5,89 12,0 10,1
KM40TS
1.575 1.181 1.457 1.750 0.138 0.984 0.433 0.232 0.472 0.398
50,0 40,0 42,7 59,4 7,0 32,0 12,0 8,9 16,0 14,1
KM50TS
1.969 1.575 1.681 2.339 0.276 1.260 0.472 0.350 .0630 0.555
63,0 50,0 55,7 72,4 7,0 40,0 18,0 9,9 18,0 16,1
KM63TS
2.480 1.969 2.193 2.850 0.276 1.575 0.709 0.390 0.709 0.634
80,0 64,0 72,7 89,4 7,0 45,0 18,5 11,0 22,0 20,1
KM80TS
3.150 2.520 2.862 3.520 .0276 1.772 0.728 0.433 0.866 0.791
NOTE: Valid for all KM styles including XMZ and ATC.
KM4X™
D D2 D3 D4 D5 D10 (max) F2 (min) L2 L3 L4 L5

63,0 48,0 55,0 72,2 7,0 53,0 42,0 6,3 18,0 26,0 32,0
KM4X63
2.480 1.890 2.165 2.843 .276 2.087 1.654 .248 .709 1.024 1.260
100,0 75,0 92,0 109,7 7,0 85,0 45,0 10,0 20,0 29,0 50,0
KM4X100
3.937 2.953 3.622 4.319 .276 3.346 1.772 .394 .787 1.142 1.969
NOTE: Valid for all KM styles including XMZ and ATC.
Shank Controls
Taper Specifications
HSK — DIN 69893 Part 1, Form A HSK — DIN 69893 Part 1, Form C
D1 D2 D5 D10 L1 L6 B1 F1 F2
mm mm mm mm mm mm mm mm mm D1 mm D2 mm D5 mm L1 mm L6 mm B1 mm F1 mm
(h10) (ref) (h11) (max) (-0,2) (js10) (±0,04) (-0,1) (min) (h10) (ref) (h11) (-0,2) (js10) (±0,04) (-0,1)
40A 40 30 25,50 34 20 11,42 8,05 20 35 32C 32 24 21 16 8,92 7,05 10
50A 50 38 32 42 25 14,13 10,53 26 42 40C 40 30 25,50 20 11,42 8,05 10
63A 63 48 40 53 32 18,13 12,54 26 42 50C 50 38 32 25 14,13 10,53 12,5
80A 80 60 50 67 40 22,85 16,04 26 42 63C 63 48 40 32 18,13 12,54 12,5
100A 100 75 63 85 50 28,56 20,02 29 45
HSK — DIN 69893 Part 5, Form E HSK — DIN 69893 Part 1, Form F (with Pin)
D1 D10
mm D2 mm D5 mm mm L1 mm L6 mm F1 mm F2 mm D1 mm D2 mm D5 mm L1 mm L6 mm F1 mm
(h10) (ref) (h11) (max) (-0,2) (js10) (-0,1) (min) (h10) (ref) (h11) (-0,2) (js10) (-0,1)
40E 40 30 25,5 34 20 11,42 20 35 63F (pin) 63 38 32 25 14,13 26
50E 50 38 32 42 25 14,13 26 42 80F (pin) 80 48 40 32 18,13 26
BTKV — Taper Face CVKV — Taper Face
D1 D6 L1 F3 A G D1 D6 D8 L1 F2 F3 A G
40 44,45 63,00 65,40 27,00 1,00 M16 40 44,45 63,05 44,45 68,25 35,00 19,05 1,00 5/8-11
(1.750) (2.480) (2.575) (1.063) (.039) thread (1.750) (2.500) (1.750) (2.687) (1.375) (.750) (.039) thread
50 69,85 100,00 101,80 38,00 1,50 M24 50 69,85 98,41 69,85 101,60 35,00 35,00 1,50 1-8
(2.750) (3.937) (4.008) (1.496) (.059) thread (2.750) (3.875) (2.750) (4.000) (1.375) (1.375) (.059) thread
Shank Controls
Taper Specifications
BT — JIS B6339 CAT (CV) — ANSI B5.50
D1 D6 L1 F3 A G D1 D6 D8 L1 F2 F3 A G
30 31,75 46,00 48,40 22,00 2,00 M12 30 31,75 46,02 31,75 47,63 35,00 19,05 3,18 1/2-13
(1.250) (1.811) (1.906) (.866) (.079) thread (1.250) (1.812) (1.250) (1.875) (1.375) (.750) (.125) thread
35 38,10 53,00 56,50 24,00 2,00 M12 40 44,45 63,05 44,45 68,25 35,00 19,05 3,18 5/8-11
(1.500) (2.087) (2.224) (.945) (.079) thread (1.750) (2.500) (1.750) (2.687) (1.375) (.750) (.125) thread
40 44,45 63,00 65,40 27,00 2,00 M16 45 57,15 82,50 57,15 82,55 35,00 19,05 3,18 3/4-10
(1.750) (2.480) (2.575) (1.063) (.079) thread (2.250) (3.250) (2.250) (3.250) (1.375) (.750) (.125) thread
45 57,15 85,00 82,80 33,00 3,00 M20 50 69,85 98,41 69,85 101,60 35,00 19,05 3,18 1-8
(2.250) (3.346) (3.260) (1.299) (.118) thread (2.750) (3.875) (2.750) (4.000) (1.375) (.750) (.125) thread
50 69,85 100,00 101,80 38,00 3,00 M24 60 107,95 139,70 107,95 161,93 38,10 19,05 3,18 1 1/-7
(2.750) (3.937) (4.008) (1.496) (.118) thread (4.250) (5.500) (4.250) (6.375) (1.500) (.750) (.125) thread
DV — DIN 69871 Form B — Flange Coolant Entry Ports
section AA
D8 F2 F4
D1 D6 max L1 min F3 A G D ±0.004
30 31,75 49,95 45,00 47,65 35,00 19,05 3,20 M12 30 4,00 21,00
(1.250) (1.967) (1.772) (1.876) (1.378) (.750) (.126) thread (.157) (.827)
40 44,45 63,00 50,00 68,25 35,00 19,05 3,20 M16 40 4,00 27,00
(1.750) (2.480) (1.969) (2.687) (1.378) (.750) (.126) thread (.157) (1.063)
45 57,15 82,00 63,00 82,55 35,00 19,05 3,20 M20 45 5,00 35,00
(2.250) (3.228) (2.480) (3.250) (1.378) (.750) (.126) thread (.197) (1.378)
50 69,85 97,45 80,00 101,60 35,00 19,05 3,20 M24 50 6,00 42,00
(2.750) (3.827) (3.150) (4.000) (1.378) (.750) (.126) thread (.236) (1.654)
QC — ERICKSON™ Quick Change R8 — Bridgeport
D8 F2
D1 D6 max L1 min F3 A G D1 D2 L1 L2 L3 S1 G
30 31,75 46,03 35,05 68,33 19,81 10,69 1,96 1/2" - 13 R8 .469 1.241 4.000 .938 2.750 .157 7/16-20 UNF - 2B
(1.250) (1.812) (1.380) (2.690) (.780) (.421) (.077) UNC - 2B
40 44,45 63,50 50,80 93,73 20,83 9,88 1,93 5/8" - 11
(1.750) (2.500) (2.000) (3.690) (.820) (.389) (.076) UNC - 2B
50 69,85 88,90 73,66 127,00 30,73 15,09 3,58 1" - 8

(2.750) (3.500) (2.900) (5.000) (1.210) (.594) (.141) UNC - 2B
Shank Controls
Shank Specifications
VDI — DIN 69880
D1 D2 D3 L1 L2 L3 L4 L5 L6 H2 R1
30,00 14,00 68,00 55,00 29,70 40,00 2,00 7,00 20,00 27,00 25,00
30
1.181 0.551 2.677 2.165 1.169 1.575 0.079 0.276 0.787 1.063 0.984
40,00 14,00 83,00 63,00 29,70 40,00 3,00 7,00 20,00 36,00 32,00
40
1.575 0.551 3.268 2.480 1.169 1.575 0.118 0.276 0.787 1.417 1.260
50,00 16,00 98,00 78,00 35,70 48,00 3,00 8,00 24,00 45,00 37,00
50
1.969 0.630 3.858 3.071 1.406 1.890 0.118 0.315 0.945 1.772 1.457
60,00 16,00 123,00 94,00 43,70 56,00 4,00 10,00 28,00 55,00 48,00
60
2.362 0.630 4.843 3.701 1.720 2.205 0.157 0.394 1.102 2.165 1.890
KM4X
The Latest Innovation in Spindle Interface Technology!
Dramatically increase your metal removal rates when machining
high-temperature alloys!
• Run jobs at significantly faster feeds and speeds than is achievable with other spindle interfaces.
• Unique use of clamping force and interference level increases clamping capability 2 to 3 times.
• You experience lower cost of ownership, increased throughput, and superior results.
Load-Deflection chart
0.20
7/24 Taper — Size 50
0.18
0.16 with Face Contact
deflection (m) @ 150mm
0.14
0.12
0.10 KM4X100
0.08
HSK125A
0.06
0.04 KM4X125
0.02
HSK100A
0.00
0 600 1200 1800 2400 3000 3600 4200 4800 5400 6000
bending moment (Nm)
To learn more, scan here.

For instructions on how to scan, please see page xxxiii.
Visit www.kennametal.com or contact your local Authorized Kennametal Distributor.
www.kennametal.com
Spindle Connections
The Importance of a Strong Connection

Many component materials are switching to lighter, high-strength materials, Our response to this traditionally weak point has been the proven KM™ system,
like titanium, to increase fuel efficiency. To save time and money, machinists are and now we are introducing the next generation KM4X™. The combination of the
challenged to maximize metal removal rates at low cutting speeds and KM4X’s high clamping force and interference level lead to a robust connection
considerably higher cutting forces. Machine tool builders must also provide and extremely high stiffness and bending load capacity for unmatched
greater stiffness and damping in their spindles to minimize undesirable vibrations performance in titanium machining.
that deteriorate tool life and part quality.
Though these advances contribute to greater productivity, the weakest point is
often the spindle connection itself, which needs high torque and must overcome
high-bending applications.
Current Spindle Connections

To fulfill the increasing demand for high productivity, an important element to The advent of face contact represented a major step over the standard 7/24
consider is the tool/spindle connection. This interface must be able to withstand taper. Combining face contact with a 7/24 solid taper provides higher accuracy.
high loads and maintain rigidity throughout the machining process. In most cases, However, this also presents some disadvantages. Loss of stiffness at higher
the connection determines how much material can be removed on a given speeds or high side loads are some of the major flaws apparent in this system.
operation until high tool deflection or chatter result. Most of these tools are solid, and the spindles have relatively low clamping force.
High-performance machining is accomplished using high feeds and depths of cut. This results in limited connection stiffness, as radial interference needs to be
Because of advances in cutting tools, there is a need for spindle connections that minimal. The required tolerances to achieve consistent face contact are thus
utilize available power. very tight, leading to high manufacturing costs.
Several different types of spindle connections were developed and/or optimized
over the last few decades. Due to its strong cost/benefit position, the 7/24 ISO
taper became one of the most popular systems on the market. It has been
successfully used in many applications, but its accuracy and high-speed
limitations prevent it from becoming a more advanced and productive system.
Choosing What’s Right

With more materials that are tougher to machine and require considerably higher The KM spindle connections greatly outperform the conventional 7/24 steep
cutting forces from the machine tool, choosing the spindle interface wisely to taper and its face taper contact derivatives HSK and PSC systems. KM4X
maximize cutting edge performance is key to success. is the best large, heavy-duty spindle connection for rigidity because it has
superb balance between bending and torsion capabilities from the machine tool.
7/24 ISO Taper 7/24 Taper Face Contact HSK KMTS (ISO) KM4X
• One surface contact. • Two surface contact. • Two surface contact. • Three surface contact. • Three surface contact.
• Relatively low stiffness. • Higher static and • Higher axial and • Superior static and • Superior static and
• Possible runout due dynamic stiffness. radial accuracy. dynamic stiffness. dynamic stiffness.
to taper fitment. • Higher axial and • Less mass — faster quick • Static and rotating • Static and rotating
• Low axial accuracy. radial accuracy. change and higher speeds. applications. applications.
• Rigid system. • Higher stiffness than • Higher speed. • Highest maximum speed.
7/24 tapers. • Higher stiffness than HSK • ISO (HSK) Gripper.
and 7/24 tapers.
KM4X™ Spindle Connection
KM4X™ — The Next Generation Spindle Connection System

As a global tooling supplier and a true customer support partner, we recognize
the need to offer tooling products for all spindle interfaces and make available
solutions to provide the best cutting edges to gain maximum productivity at the
spindle system connection.
KM4X is the latest version of the KM™ spindle interface targeted at heavy-duty
machining operations and is a top choice for machining large, structural
tough-to-machine materials like titanium for the aerospace industry.
The Latest Innovation in Spindle Interface Technology

• KM4X offers the most rigid connection able to withstand extremely high
bending due to a combination of high interference and high clamping forces.
• KM4X provides 3x more bending capacity than comparable face
contact systems.
• KM is the only connection that maintains stiffness at elevated rotational speeds
and is suitable for a range of applications from low speeds with high torque
to very high spindle speeds with low torque.
• KM4X maintains a better balance between bending and torsion capabilities.
• The ability to retrofit KM4X to an existing machine tool offers the added
advantage of increasing throughput.
• Heavy-duty, rigid configuration with evenly distributed clamping force.
• Simple design enables front-loaded spindle configuration.
• Balanced-by-design for high spindle speed capacity.
KM4X three-surface contact for improved stability and accuracy.

Optimized clamping force distribution and interference fit provides higher stiffness.
Why Bending Load Capacity Is Important

When machining tough materials like titanium, cutting speeds are relatively low
due to thermal effects on cutting tools. Over the years, machine tool builders
responded to this issue by improving stiffness and damping on spindles and SK-F (7/24 Taper with Face Contact)
machine structures. Spindles have been designed with abundant torque
at low rotational speeds. Nevertheless, the spindle connection has remained SK (7/24 Taper)
the weak link in the system.
HSK
The spindle connection must provide torque and bending load capacity PSC
compatible with the machine tool specifications and the requirements for higher
productivity. It becomes obvious that in end-milling applications where the TS (KM)
projection lengths are typically greater, the limiting factor is the bending load
torque
capacity of the spindle interface. KM4X
The lines on the chart to the right represent the load capacity of HSK, PSC,
and KM4X. The shaded areas represent the typical requirements for heavy-duty
applications in various machining processes. KM4X is the only system that can
deliver the torque and bending capacity required for achieving high-performance
machining. Some systems may be able to transmit a considerable amounts of
torque, but the cutting forces also generate bending moments that exceed the
interface’s limits before torque limits are exceeded.
bending moment
Drilling Turning Deep Boring
Face Milling End Milling
IMPORTANT
Information shown on the following charts was developed exclusively for use with KM tooling in static conditions. Do not use for any other tooling
system because the results will not apply. To account for cutting force fluctuations in dynamic conditions, a reduction of 20–30% should be applied
to the loads shown in charts.
Chart shows load-deflection comparison of steep taper with and without face contact — HSK and KM4X.
0.20
0.18
0.16
deflection (m) @ 150mm
0.14
0.12
0.10
0.08 150mm
0.06
F
0.04
0.02 deflection
0.00
0 600 1200 1800 2400 3000 3600 4200 4800 5400 6000
bending moment (Nm)
7/24 Taper — Size 50 7/24 Taper — Size 50 7/24 Taper — Size 60 HSK100A
with Face Contact
KM4X100 HSK125A KM4X125
Maximum Tangential Load for KM4X100
400
350
300
15kN
250 18kN
F
(mm) 200
25kN
150 35kN
45kN
100
67kN
50
0
0 50 100 150 200 250 300 350 400 450
L1 (mm)
The KM4X system is the best large, heavy-duty connection. A weak connection can fail to deliver the desired cutting edge performance.
KM4X superior rigidity equals maximum productivity.
IMPORTANT
KM™ Spindle Connection
The KM Coupling Rigidity

The KM Quick Change Clamping System is the first step in achieving maximum All KM tooling is designed around a short 10:1 tapered shank. Extensive
machine output. Please refer to the Kennametal Machine Utilization Strategy for testing of many different lengths, angles, and interference levels provided
more information on how we can help you increase your machine throughput. the optimum combination of dimensions with regard to maximum stiffness.
The KM joint achieves rigidity and stiffness by combining unique design The taper is self-centering, promoting easy tool loading in both manual
elements in both the shank of the tool and the clamping mechanism. The KM and automatic applications.
joint was developed as a system and takes full advantage of both the tool
shank and the mechanism to obtain maximum benefits from the space utilized. The three-zone contact and the ball track clamping mechanism produces
a coupling that closely approaches the ultimate rigidity of a solid piece.
Face and Taper Contact Clamping Mechanism

The KM clamping mechanism is housed inside of the taper shank, which
Three Surface Contact contains two angled holes that function as ball tracks. A cylindrical ball
canister fits inside of the taper shank, where wedge shaped forms on a central
lock rod force two hardened steel balls outward. The steel balls interact with
the angled holes in the tapered shank to produce clamping force. The
combination of the angle in the taper shank, the angle of the canister holes,
and the lock rod angle produce a measured mechanical advantage that varies
between 3.5:1–7:1. The standard manual side activation mechanism has a
mechanical advantage of 3.5:1 and fits into the system size diameter.
KM tooling is designed to have simultaneous taper and face contact. Previous

efforts to achieve this were concentrated on steep taper applications. However,
due to the relatively large angle of the taper, extremely tight tolerances are
required on the gage diameters of both the tool and receptacle. The KM taper
was designed to avoid these tight tolerances by selecting shallower taper
angles that enable elastic deformation of both the taper shank and receptacle
during clamping. It also permits larger interference levels* to be used while still
achieving taper and face contact during clamping. These interference levels,
when combined with the proper clamping force, provide superior static and
dynamic stiffness. The system’s interference capability enables the use of lower
tolerance levels for gage diameters.
The taper and face contact feature provides a radial and axial repeatability of Locking Sequence
±2,5 μm (±.0001") for a specific cutting unit in a specific clamping unit. When
more than one unit is utilized, the manufacturing and component tolerances of The clamping sequence starts by inserting the cutting unit into the female
each must be considered. Pre-gaging cutting units before they are used taper of the clamping unit. The cutting unit first makes contact at a standoff
enables the deviations of each tool tip location to be recorded. These deviations from the face of approximately 0,25mm (.010"). The cutting unit advances
can be compensated for by the machine tool control offsets. Checking for until the gage face makes contact with the clamping unit face, where a small
deviations prior to use means the first part manufactured will be a good part. amount of elastic deformation takes place at the front of the female taper as
*The difference between the gage diameters of the receptacle and the taper shank. locking force is applied. The final amount of torque applied enables the tail of
the cutting unit to clamp securely between the steel balls and the clamping
unit inside diameter.
KM™ Spindle Connection
Sealed Coolant
Sealed through-the-tool coolant is offered on all standard KM tooling and

clamping units. The coolant is sealed using O-rings in both the cutting units and
clamping units. This feature ensures that coolant is directed as close as possible
to the cutting edge while preventing contaminants from entering the clamping
mechanism. Standard Viton® O-rings are utilized on KM.
Fail-Safe Tool Orientation

A unique feature of KM clamping is the ability to ensure that the KM cutting unit
can only be installed in one orientation. The direction of this orientation feature
can be changed within the clamping unit. To allow greater flexibility, standard KM
clamping units are shipped without this feature installed. For more details on this
feature, refer to the KM operating instructions section.
Metric Slotted Pins:
• KM32TS — 2,5mm x 4mm Long
• KM40TS — 3mm x 6mm Long
orientation notch orientation pin
• KM63XMZ — 5mm x 10mm Long
• KM80ATC — 5mm x 10mm Long
Accuracy and Repeatability
Accuracy and repeatability of the coupling are shown in the table below.
Accuracy is measured over a gage insert in different cutting units changed accuracy repeatability
in and out of a clamping unit. Accuracy will decrease with inserts of varying 0,13mm 0,0025mm
axial (+/- .005") (+/- .0001")
tolerances and nose radii. Station-to-station accuracy on a turret requires
that all clamping units be set in the same position on the machine tool radial 0,13mm 0,0025mm
(+/- .005") (+/- .0001")
mechanically or that variations are recorded as offsets in the machine control.
Repeatability is measured over the nose radius of a cutting unit through many cutting 0,4mm 0,025mm
edge height (+/- .016") (+/- .001")
cycles of changing the cutting unit in and out of a clamping unit.
Summary
KM coupling offers a very rigid joint with a high degree of repeatability while
maintaining a compact envelope. This permits a high degree of versatility
without sacrificing cutting performance.
HSK Spindle Connection
HSK Quick-Reference Identification
HSK hollow-stub taper shanks are a widely used DIN standard for machine tools.
HSK tools have a simultaneous 1:10 taper, which generates two surface contact
areas: face and taper. Compared with traditional steep-taper shanks, HSK shanks
are shorter, hollow, and clamp from the inside. They also incorporate drive keys
that engage milled key-slots in machine spindles and offer higher static and
dynamic stiffness than standard steep taper tooling.
HSK tooling includes seven toolholder shank forms: A, B, C, D, E, F, and T. Various
machine-spindle receivers are available for each. However, the choice of form
depends on application requirements such as torque and spindle speed.
HSK-A HSK-B
for general-machining service greater flange support than form A
for heavier work
Form A Form B
Form A for automatic tool change is the most common shank, typically used on Form B is also for automatic tool change. It is similar in appearance to form A
new machining centers and for general service. Form A has a drive slot in the but dimensionally different. Form B provides greater flange support for heavy
small end of the tapered shank and features coolant through the center, using a machining, even though its taper shank size is smaller than form A. This style of
coolant tube thread mount inside the shank cavity. In many applications, wrench shanks have drive slots in the flange and drive keys in the taper. Coolant for form
access holes are provided through the taper as an option for manual clamping B is fed through ports in the flange. Mounting holes for an electronic chip are also
and automatic tool change shanks. Form A shanks have mounting holes for an a feature of form B.
electronic chip.
For form B there are seven different shank sizes from 40–160mm
There are eight different sizes of form A ranging from 32–160mm (1.575–6.299") flange diameter.
(1.260–6.299") flange diameter.
HSK-C HSK-D
similar to form A but for manual tool similar to form B but for manual tool
change applications change applications
Forms C and D
Forms C and D for manual tool changes are variations of forms A and B, but the There are six different shank sizes for form C ranging from 32–100mm
gripper groove and chip holes are eliminated. These two forms always have their (1.260–3.937") flange diameter. Form D has five different shank sizes from
access holes through the taper for manual clamping. These manual forms are 40–100mm (1.575–3.937") flange diameter.
typically used on transfer lines and non-rotating applications for NC lathes.
(continued)
HSK Spindle Connection
HSK Quick-Reference Identification (continued)
HSK-E
balanced-by-design for higher speeds
HSK-F HSK-T
balanced-by-design with greater flange
support for higher speeds
Forms E and F Form T

Forms E and F with automatic tool change are also variations of forms A and B. Form T shanks are similar to form A, but with tighter key ways for turning.
These forms are intended for high-speed machining. Design features, such as This gives form T improved repeatability over form A. These shanks have new
drive slots, the orientation notch, and chip holes, have been removed to help centerline technology for variance and high productivity. They are also available
eliminate imbalance. As a result, these forms are driven by the locking taper and in a wide range of standard toolholders.
are suitable only for light machining applications such as high-speed metalcutting
and woodworking machines.
Form E offers five different shank sizes ranging from 25–63mm (.984–2.480")
flange diameter. There are three shank sizes for form F from 50–80mm
(1.969–3.150") diameter on the flange.
HSK Primary Offering
flange diameter D
forms D2 D4 LS L2 L7
A and T form B form C form D form E form F mm mm mm mm mm
- - - - 25 - 19 14 13 2,5 6
32 40 32 40 32 - 24 17 16 3,2 8
40 50 40 50 40 50 30 21 20 4 8
50 63 50 63 50 63 38 26 25 5 10
63 80 63 80 63 80 48 34 32 6,3 10
80 100 80 100 - - 60 42 40 8 12,5
100 125 100 - - - 75 53 50 10 12,5
125 160 - - - - 95 67 63 12,5 16
160 - - - - - 120 85 80 16 16
Kennametal primary offering Secondary styles available upon request
7/24 Taper Face Contact Spindle Connection
7/24 Taper Face Contact V-Flange — Tooling to Fit the BIG-PLUS™ Spindle
The 7/24 Taper Face Contact Spindle Interface, is being found on machining Capable of being utilized in a variety of machining applications ranging from
centers and multitasking machines. The basic principle of this system takes the low-speed, heavy milling applications to high speeds greater than 20,000 RPM.
standard 7/24 steep-taper tool and adds material to the back face of the The systems accuracy, repeatability, and stability should be equal or greater
toolholder flange as well as to the front face of the spindle. This is controlled so to the performance of current equivalent Taper Face tooling on the market
that the two parts have both face and taper contact when locked into position. in all applications.
The distinctive features of the system are the lead-in chamfers on the drive slots
and ground back V-flange. The surface contact creates a system with higher
static and dynamic stiffness compared to a regular 7/24 taper and increased
axial and radial accuracy.
Technology
With the Taper Face System, toolholders are axially supported on the taper and
flange face, which brings about higher rigidity and precision than a conventional
7/24 toolholder. The system utilizes elastic deformation of the machine spindle
to achieve simultaneous fitting of both the taper and flange face. Although the
tapers are fit prior to clamping the mechanism, the faces are not yet secured
because of a small amount of clearance between them. When the toolholder
is pulled in by the drawbar mechanism, the machine spindle expands by elastic
deformation and the faces are fit, completing the simultaneous fit between both
taper and face. This synchronized fit prevents additional axial displacement of
the taper providing high accuracy and superior surface finish in operations such
as face milling, compared to the industry standard 7/24 V-flange.
Taper face tool’s axial position is maintained

even at high rotational speed.
Offering
Kennametal supports both the CAT (CV) ANSI B5.50 and BT JIS B6339
versions in 40 and 50 taper sizes:
• Two surface contact.
• Higher static and dynamic stiffness.
• Higher axial and radial accuracy.
• Rigid system.
• CVKV40 • BTKV40
• CVKV50 • BTKV50
7/24 Taper Face Contact Spindle Connection
Clamping Mechanism
In some cases, standard 7/24 steep-taper tooling can be used in a face contact Similar to all interfaces with face contact, special care should be taken regarding
7/24 taper spindle. However, the combination does not offer the same stability or the cleanliness of the mating faces as high contact pressures are present.
advantages of face contact. As a caution, some spindles have a safety switch that Adequate filtration systems for coolant must be used.
shuts the spindle down if face contact is not achieved. In these cases, tools will
need taper face contact for the spindle to operate.
Locking Principle
toolholder being loaded just before clamping totally clamped
taper contact and face locked taper and face contact
clearance 0,020mm (.0008")
7/24 ISO Taper Spindle Connection
Steep Taper V-Flange
Steep taper Form B coolant
Taper Size
Taper size should be chosen with realistic considerations. When selecting cutting
parameters, keep in mind that a machine with a 30 taper spindle will not achieve
the same heavy cuts or use cutters as large those on a 50 taper machine.
Pull-Back System Form B Coolant

When troubleshooting a problem, assume that the toolholder is at fault is not Spindles are now running at higher rates — quickly burning seals, making it
the correct course of action. The spring pack, drawbar, gripper, and retention difficult to seal coolant as it passes through the drawbar. One option is to direct
knob are major components for the successful operation of a machine tool the coolant around the spindle bearings and enter through the spindle face
because wear or breakage of these parts is a major concern. and toolholder flange.
• Spring pack — Can become weak or out of adjustment. This can cause
chatter during a milling operation, which causes damage to the adapter taper,
spindle taper, cutter, or workpiece.
• Gripper fingers — If worn, they may not grip the retention knob correctly,
enabling the adapter to move, resulting in chatter and damage to the adapter.
• Retention knob — A worn or incorrect retention knob will not enable proper
gripping for pull back on the taper. This is a very serious safety hazard due to
the movement of the adapter. Using an improper knob may result in a lack of
any detectable gripping force.
7/24 ISO Taper Spindle Connection
coolant through coolant through

flange form B blocked flange form B
Form AD Form B
coolant stop coolant through spindle coolant stop coolant through spindle
screw option form AD screw option form AD blocked
Kennametal™ toolholders are positioned in the AD coolant form with Form B toolholders can be converted back through the drawbar form AD by
self-sealing, nylon-coated screws. The coolant screws are designed to simply threading the coolant stop screw and stopping below the flange coolant
completely seal the tool and prevent coolant leakage under pressures entry hole. Changing coolant form can be achieved many times before it is
up to 1500 psi. However, if form B coolant is desired, the coolant stop necessary to replace the coolant stop screw.
screws must be backed out into the form B position.
All form B capable tooling is supplied with a label designating the required
screw components for each steep taper size and information necessary for
selecting a wrench to adjust the coolant stop screws.
IMPORTANT
When choosing a desired coolant form, the correct retention knob should
be used in conjunction with the coolant form applied.
Form AD Form B
(through-coolant hole) (no hole through or half hole)
KM™ Clamping Systems
Manual Clamping System

Characteristics
• KM Manual Quick Change tooling is the most economical way to reduce
downtime for setup and tool change and is an important first step toward
further automation. The machine tool builder or the customer can easily
install KM Manual Quick Change tooling.
• All KM manual clamping units require approximately three turns of the
activation screw and a specified amount of torque to lock the cutting tool.
• The KM Manual Quick Change clamping mechanism is rigid and compact,
with an easily accessible activation screw. The high mechanical advantage
of the ball track makes it simple to apply the required locking force.
• All KM Manual Quick Change clamping units accept external and internal
cutting tools. Right- or left-hand tooling can be used interchangeably, and
• The KM Manual Quick Change clamping mechanism can adapt to a wide
cutting tools can be inverted if required. KM Manual Quick Change clamping
variety of machine tool mounting configurations including flange mounts,
units support through-the-tool coolant.
square, round, and VDI shanks.
KM-LOC™ Clamping System

KM-LOC is an evolutionary step from the conventional KM manual clamping
system, the KM-LOC device employs a cam and a pre-loaded disk spring pack
to provide positive, stop-to-stop locking and unlocking in only 140º of movement.
The spring pack supplies the correct clamping force while the cam permits quick
and easy clamping/unclamping in less than one turn, and without using a torque
wrench. The KM-LOC clamping device is compact to adapt to a wide variety of
machine tool mounting configurations, including flange mounts, square, round,
and VDI shanks. The new KM-LOC clamping device offers all the features and
benefits of our industry-proven modular KM Quick Change Tooling System and
reduces the time required for manual tool changes.
KM-LOC II™ Clamping System

The KM-LOC II clamping device is the latest addition to the Kennametal KM
modular quick-change tooling family. An evolutionary step from the conventional
KM manual clamping system, the KM-LOC II employs a cam and a preloaded disc
spring pack to provide positive, stop-to-stop locking and unlocking in only 145°
of movement.
The spring pack supplies the correct clamping force without using a torque
wrench, while the cam permits quick and easy clamping/unclamping in less than
one half of a turn. The KM-LOC II clamping device is compact to adapt to a wide
variety of machine tool mounting configurations including flange mounts, square,
round, and VDI shanks.
The KM-LOC II is capable of handling through-the-tool coolant pressure of The latest KM-LOC II clamping device offers all of the features and benefits of our
100 bar (1500 psi), and the design permits lubrication of internal components industry-proven modular KM Quick Change Tooling System and reduces the time
without disassembly. The design also enables the external installation of an required for manual tool changes.
orientation screw that restricts the cutting tool to a single orientation.
KM™ Clamping Systems
Rapid Clamping System

Characteristics
KM Rapid is a compact quick-change clamping system providing outstanding
repeatability while, at the same time, allowing fast manual locking and unlocking.
KM cutting units are locked and unlocked with only a 115º turn of the actuation
cam with no torque wrench required for clamping and unclamping. A stop pin
limits the angle of rotation, and actuation is available from the side only.
The KM Rapid, with internal through-the-tool coolant capabilities, is best used
in stationary applications on turning centers in high-volume production.
KM Rapid permits the external installation of an orientation screw to restrict
KM Rapid offers two main standard styles:
the clamping unit to accept the cutting unit in only one orientation.
• Flange mount holders, fastening with four socket head cap screws and an
additional orientation pin, can be used on turrets axially or radially.
• VDI shank tool holders, according to DIN 69880, in axial and right-angle styles
for I.D. and O.D. turning applications.
Rapid Plus Clamping System

Characteristics
The KM Rapid Plus clamping system provides approximately 20% more locating
face force versus the KM Rapid. It is designed for retrofitting in dedicated
applications enabling cutting units to be locked and unlocked with only a 180º
turn of the actuation cam. Actuation is available from the top only.
The Rapid Plus cartridge design allows use in smaller but slightly longer
receivers, such as Multifix™ and Parat™ adapters.
Automatic Clamping System • Spring-Pack Activated
Characteristics
Automatic KM clamping systems enable tools to be locked or unlocked with
the push of a button by the machine operator or changed automatically by the
machine tool. These units also allow tools to be changed quickly and provide
a high level of automation at a moderate cost.
Operation
The pull on the lock rod for the automatic KM clamping unit is provided by disc
springs that are an integral part of the clamping unit. Release is accomplished by
pushing on the back of the clamping unit with a hydraulic cylinder mounted on
the turret assembly. Many machine tool builders design and build the turrets for
their machines to be equipped with the KM Automatic Clamping Units.
KM™ Manual Clamping System
KM™ Manual Clamping Units

KM Manual clamping units require a torque wrench to operate. Using the proper When a KM head is unlocked, the head will bump-off. KM’s 10:1 taper is self-
torque wrench value is critical. Tighter is not better because over tightening can locking, and therefore, requires a mechanical release. This is accomplished within
cause damage. the design of the KM System and does not require operator intervention.
The specific operating torque of the KM manual clamping units is listed After the head has been released, you will need to turn the torque screw another
on each unit. 3/4–1-1/2 turns. This rotation will feel free of resistance. When the free turning
motion stops, the head can be pulled from the clamping unit. Do not turn the
The KM connection must be kept clean and free from nicks and burrs. torque screw further, as damage can occur to the lockrod and/or bump-off pin.
KM plugs are available to ensure cleanliness when a cutting unit is not
engaged in the clamping unit.
KM Manual Clamping System • Single-Pin Design
1
6
8
5
8 3 4
7 6
KM Manual Clamping Components • Functional Definitions

1. Clamping Unit Body 5. Lockrod
• Primary component of the clamping unit assembly, • Dual function:
less additional hardware. a. Acts as a wedge when advanced between locking balls,
causing them to move outward in the ball canister and pushing
2. Canister Pin the locking balls into the ball tracks of the cutting unit (not shown).
• Secures ball canister to clamping unit body. b. Acts as a wedge when retracted using a raised, tapered key to
force the bump-off pin against the cutting unit (not shown).
3. Pin Canister
• Main component of KM clamping mechanism holds and locates 6. Locking Balls (2)
the locking balls and bump-off pin. • Precision, chrome alloy-steel hardened balls used to transmit
pull-back force to the cutting unit.
4. Torque Screw
• Rotation moves the lockrod: 7. Bump-Off Pin
a. Clockwise rotation advances lockrod, securing • Dual function:
cutting unit (not shown). a. Releases cutting unit from the clamping mechanism.
b. Counterclockwise rotation retracts lockrod, releasing b. Prevents lockrod from rotating.
cutting unit (not shown).
8. Bump-Off Pin Retention Screws (2)
• Secures bump-off pin in ball canister.
KM™ Manual Clamping System • Four-Pin Design
1
7
6
2
9 5
4
9
3
7
8

1. Clamping Unit Body 6. Lockrod
• Primary component of the clamping unit assembly, • Dual function:
less additional hardware. a. Acts as a wedge when advanced between locking balls,
causing them to move outward in the ball canister and pushing
2. Canister Screw the locking balls into the ball tracks of the cutting unit (not shown).
• Secures screw canister to clamping unit body. b. Acts as a wedge when retracted using a raised, tapered key to
force the bump-off pin against the cutting unit (not shown).
3. Screw Canister
• Main component of KM clamping mechanism holds and locates 7. Locking Balls (2)
the locking balls and bump-off pin. • Precision, chrome alloy-steel hardened balls used to transmit
pull-back force to the cutting unit.
4. Canister Pins (4)
• Prevents canister from rotating. 8. Bump-Off Pin
• Dual function:
5. Torque Screw a. Releases cutting unit from the clamping mechanism.
• Rotation moves the lockrod: b. Prevents lockrod from rotating.
a. Clockwise rotation advances lockrod, securing
cutting unit (not shown). 9. Bump-Off Pin Retention Screws (2)
b. Counterclockwise rotation retracts lockrod, releasing • Secures bump-off pin in ball canister.
cutting unit (not shown).
KM Manual Clamping Operating Instructions (KM32–KM80)

Locking
Before inserting the KM cutting unit into the clamping mechanism (Figure 1), Figure 1
clean the contact face and taper.
KM Manual clamping units require a torque wrench for proper operation. Turning
the torque screw clockwise locks the cutting unit in position. For maximum safety,
tighten the torque screw to the specified torque. Using a torque wrench ensures
that the proper clamping forces are exerted.
Contact Face
Taper Clockwise
for Locking
KM Manual Clamping System • Operating Torque
KM torque torque actuation

size (ft. lbs.) (Nm) drive size
KM32 7–9 10–12 5mm
KM40 9–12 12–16 6mm CAUTION
KM50 20–25 27–34 10mm Over tightening can cause damage to the clamping mechanism.
KM63 35–40 47–54 12mm
KM80 58–63 79–85 14mm
Operating Position
With the balls locked in position, and the face and self-locking taper Figure 2
fully engaged, the cutting unit and clamping unit are rigidly secured
together (Figure 2).
Unlocking
Rotate the torque screw counterclockwise until initial resistance is felt. In this Figure 3
position, the locking balls are free of the cutting unit, but the taper interference is
still holding the KM unit in the clamping unit. At this point, the bump-off pin is in
position to free the cutting unit from the interference fit.
Continue to rotate the torque screw slowly until the cutting unit is no longer
making face contact (Figure 3) and is released from the taper. The torque screw
will stop rotating and more resistance will be felt. Do not turn the torque screw
any further.
Counterclockwise
for Unlocking
CAUTION
Continuing to rotate the torque screw may damage
the clamping components.
KM Manual Repair Package Components (KM32–KM80)
4 6
KM Manual Repair Package Components • Functional Definitions

1. Torque Screw KM Manual Repair Packages
2. Lockrod
3. Locking Balls (2x) catalog 3S order 3L order
number number number
4. Bump-Off Pin
KM32-PKG 3S or 3L 1023697 1023698
5. O-Ring
KM40-PKG 3S or 3L 1023699 1023700
6. Bump-Off Pin Retention Screws (2x)
KM50-PKG 3S or 3L 1023726 1023725
KM63-PKG 3S or 3L 1013701 1013702
Operator Maintenance:
All KM Clamping Units showing damage must be replaced or rebuilt. KM80-PKG 3S or 3L. 1144980 1023701
Burrs and nicks should be removed by stoning and/or polishing.
• Use KM Plugs to protect clamping units when not in use.
• Use KM spindle wipers to clean clamping units.
KM™ Manual Clamping Unit • Disassembly Procedures
1. Remove the two socket-head cap screws that retain the bump-off pin Tools Required
(see Frame 1).
• Hex wrenches.
2. Grip the exposed end of the bump-off pin with pliers and pull straight out. • Pliers.
Some resistance may be felt due to the O-ring seal around the bump-off pin • Kennametal recommends and uses GLEITMO™ 805.
(see Frame 2). • Clean towels or shop rags.
3. Using the appropriate metric hex wrench, remove the torque screw. • Solvent or degreaser that does not leave residue (used to clean inside the taper
The lockrod should come out with the torque screw. Separate the torque and canister). Should the unit become contaminated, you can use a degreasing
screw from the lockrod, remembering the lockrod has left-hand threads agent or something similar to clean the surfaces.
(see Frame 3 on next page).
4. Remove the locking balls from within the canister. Grease can cause them
to stick inside. Pushing the balls one at a time towards the center of the
canister then turning the clamping unit upside down and tapping it against
your palm will usually dislodge them. If you must hit the clamping unit harder,
be certain you do not damage the gage or locking face of the unit. A small
magnetic screwdriver also works well (see Frame 4 on next page).
5. Normally, no further disassembly should be attempted. If the clamping unit
body or canister has been damaged, it should be replaced with a new unit.
You can also contact your Kennametal Sales office for instructions on how
to send the unit to a Kennametal Repair facility.
CAUTION
KM hex DO NOT USE silicone cleaner or WD-40™-type lubricants.

size size
KM32 2mm
KM40 2,5mm
KM50 3mm order
lubricant number size
KM63 5mm GLEITMO 805 grease 1567575 500g cartridge
KM80 5mm GLEITMO 805 grease 1567577 1000g tin
Frame 1 Frame 2
(continued)
KM™ Manual Clamping Unit • Disassembly Procedures (continued)
6. Clean locking balls, torque screw, lockrod, and bump-off pin of all 7. Inspect inside the KM taper for damage and/or contamination. Clean the taper
grease and inspect for wear, burrs, or obvious damage. If rebuilding the and canister with solvent. Allow the unit to dry before reassembling. Inspect the
unit with a repair parts package, we recommend using all new components torque screw threads in the body for damage.
contained in the kit. If you are not using the repair package, but are retiming
or adjusting the unit, inspect the external threads on the torque screw and 8. If the unit is equipped for through-coolant capability, you may want to verify
lockrod, the locking ball contact surfaces on the lockrod, and the mating that the coolant passages are clear. Clean if required.
surfaces between the lockrod and bump-off pin. Discard any components
of questionable condition and replace with new ones. Note the condition
of the raised taper key on the lockrod as you will need this later.
KM torque screw
size hex size
KM32 5mm
KM40 6mm
KM50 10mm
KM63 12mm
KM80 14mm
Frame 3 Frame 4
KM™ Manual Clamping Unit • Assembly/Timing Procedures
1. Place a small amount of GLEITMO™ 805 grease into the canister where the Tools Required
locking balls make contact, paying particular attention to the inner top surface
• Hex wrenches.
of the locking ball bores.
• Pliers.
2. Lightly coat both locking balls with grease. Insert the balls, one at a time, • Kennametal recommends and uses GLEITMO™ 805.
into the canister’s central bore until it bottoms, then move the ball outward • Clean towels or shop rags.
into the locking ball bores, not the torque screw hole (see Frame 5).
3. Lightly coat the threads of the lockrod and torque screw with grease and
thread them together finger tight (left-hand threads). The torque screw and
lockrod must remain tightly together during the reassembly procedure and
rotated as one piece throughout (see Frame 6).
4. Make sure the balls are pushed radially into the bores. Using the metric
Allen or T-handle wrench, thread the torque screw lockrod assembly into
the body until it makes soft contact with the balls. Be certain the torque
screw and lockrod rotate together by looking down into the canister as
you thread them. If the lockrod and torque screw become unthreaded,
you should remove them, re-tighten, and start Step 4 again.
5. Look into the canister through the bump-off pin bore and note the raised
key on the lockrod. Position the key facing outward through the bump-off
pin bore, centering it in the bore by backing out the torque screw only
enough to properly align the key.
6. Place a KM cutting unit into the clamping unit. If cutting unit does not CAUTION
drop into place, go to Step 7. If the cutting unit drops into place, remove DO NOT USE silicone cleaner or WD-40™-type lubricants.
it, push the balls radially back out into the ball bores, and turn the torque
screw/lockrod assembly inward a full turn (360°). Repeat Step 6 as
many times as necessary until the unit does not drop into the taper.
order
GLEITMO 805 grease 1567575 500g cartridge
GLEITMO 805 grease 1567577 1000g tin
KM torque screw
size hex size
KM32 5mm
KM40 6mm
KM50 10mm
KM63 12mm
KM80 14mm
Frame 5 Frame 6
(continued)
KM™ Manual Clamping Unit • Assembly/Timing Procedures (continued)
7. Thread the torque screw/lockrod assembly outward one full turn (360°), 11. Reinstall the socket-head cap screws that retain the bump-off pin
making sure the raised key faces outward. Place a KM cutting unit into (see Frame 8). Check for proper operation of the unit by pushing down
the clamping unit. It should drop into the taper easily. If it does not, on the end of the bump-off pin with your finger while tightening and
repeat Step 7. loosening the torque screw through its full travel. You should feel the
bump-off pin move in and out as the direction of the torque screw changes.
8. Insert the bump-off pin without its O-ring into the bore, being certain the
angled surface of the bump-off pin will ride on the angled surface of the 12. As a final check, rotate the torque screw outward until it stops. Install a
lockrod (see Frame 7). KM cutting unit and tighten the torque screw to the proper torque required
for locking. Ensure that there is no air gap between the locking faces of
9. When the bump-off pin is properly seated, its largest diameter should the cutting unit and the clamping unit. Loosen the torque screw. Initially,
be below the end of the canister — it should not rotate. The pin is resistance will be felt while loosening the screw, and again when bumping
rotationally restrained by the lockrod key, in the bump-off pin keyway. off the tool from the taper. Only use light force to loosen the screw after
10. If all is correct, remove the bump-off pin, install its O-ring, lightly coat with the tool has been bumped off. Do not force the torque screw loose after
grease paying particular attention to the slot, and reinstall into the bore. tool bump-off or damage may result. Remove the cutting unit and install
protective plastic or steel plug.
KM hex
size size
KM32 2mm
KM40 2,5mm
KM50 3mm
KM63 5mm
KM80 5mm
Frame 7 Frame 8
KM-LOC™ Clamping Units
Operating Instructions
All KM-LOC Clamping Units utilize disk springs to develop the correct clamping activation cam
force. This clamping system does not require a torque wrench to achieve proper
clamping force. The KM-LOC System provides consistent clamping forces
designed to last 50,000 cycles.
KM-LOC Locking Sequence

Always ensure that the KM cutting unit and clamping unit are free of dirt and
contaminants. When installing the cutting head into the clamping unit, note
the key relations of the male and female tapers. The flange face will have
about 1mm (.040") standoff from the gage face before lock up. If the amount
of standoff is greater than this, the unit is either error proofed or the tapers
are contaminated. Rotate the head 180° for correct, free-state standoff.
Next, insert a wrench with the properly sized metric bit into the cam socket.
Rotating the cam socket clockwise 140° (where it will stop) locks the head orientation notch
into the clamping unit. The dimples on both the cam and clamping unit body error proofing
are aligned when a positive stop is reached.
KM-LOC Unlocking Sequence KM-LOC Activation Drive Size

Remove chips or foreign material from around the cutting unit flange and KM drive
clamping body. Insert the metric bit into the cam and rotate counterclockwise to system size size
unlock the unit. During this procedure, the lockrod will make contact with the KM32 6mm
inside of the cutting unit (this could feel like a positive stop), continue the KM40 8mm
counterclockwise turn until the head moves apart from the gage face. KM50 10mm
When unlocked, a KM head will bump off. The KM System utilizes a 10:1 KM63 10mm
self-locking taper that requires a mechanical release.
(continued)
KM-LOC™ Clamping Units (continued)
The KM-LOC
Under normal use, the KM-LOC unit is designed to last 50,000 cycles.
The KM-LOC units are greased at the factory during assembly. To keep the
unit functioning properly, it should be periodically greased and, if operating
under normal conditions, done regularly every six months.
How to Grease the KM-LOC

Remove the M6 sealing screw from the front face of the lockrod and thread the
grease fitting into the tapped hole. A grease fitting is in the spare parts package
included with every KM-LOC clamping unit.
Approximate grease amounts are as follows:
KM32™ ..............0.2–0.3 fl. oz
KM40™ ..............0.3–0.4 fl. oz.
KM50™ ..............0.5–0.6 fl .oz.
KM63™ ..............0.5–0.6 fl. oz.
Kennametal uses and recommends GLEITMO™ 805, a white,
high-performance grease paste. order
KM-LOC™ Mounting Wedges • Tightening Torque
catalog wedge screw

number hex size ft. lbs. Nm
KM32CLSR/L2050K 4mm 10–14 14–18
KM32CLSR/L1250B 4mm 10–14 14–18
KM32CLSR/L1250C 4mm 10–14 14–18
KM32CLSR/L1650C 4mm 10–14 14–18
NOTE: Use a hex bit socket.
KM-LOC II Clamping Units
activation cam
The KM-LOC II clamping system employs a cam and a pre-loaded disk spring
pack to provide positive, stop-to-stop locking/unlocking in only 145º of
movement. This clamping system does not require a torque wrench to achieve
proper clamping force. The KM-LOC II clamping system provides consistent
clamping forces designed to last 50,000 cycles.
KM-LOC II Locking Sequence

Always ensure that the KM cutting unit and clamping unit are free of dirt and
contaminants. When installing the cutting head into the clamping unit, note
the key relations of the male and female tapers. The flange face will have
about 1mm (.040") standoff from the gage face before lock up. If the amount
of standoff is greater than this, the unit is either error proofed or the tapers
are contaminated. Rotate the head 180° for correct, free-state standoff.
orientation notch
Next, insert a wrench with the properly sized metric bit into the cam socket.
error proofing
Rotating the cam socket clockwise 145° (where it will stop) locks the head
into the clamping unit. The dimples on both the cam and clamping unit body
are aligned when a positive stop is reached.
KM-LOC II Unlocking Sequence KM-LOC II Activation Drive Size

Remove chips or foreign material from around the cutting unit flange and KM drive
clamping body. Insert the metric bit into the cam and rotate counterclockwise to system size size
unlock the unit. During this procedure, the lockrod will make contact with the KM32 6mm
inside of the cutting unit (this could feel like a positive stop), continue the KM40 8mm
counterclockwise turn until the head moves apart from the gage face. KM50 10mm
When unlocked, a KM head will bump off. The KM System utilizes a 10:1 KM63 10mm
self-locking taper that requires a mechanical release.
(continued)
KM-LOC II Clamping Units (continued)
The KM-LOC II
Under normal use, the KM-LOC II unit is designed to last 50,000 cycles.
The KM-LOC II units are greased at the factory during assembly. To keep the
unit functioning properly, it should be periodically greased and, if operating
under normal conditions, done regularly every six months.
How to Grease the KM-LOC II
Remove the standard M4 socket-set screw from the bottom of the cam hex,
and thread the grease assembly into the tapped hole. An assembled grease fitting
and adapter are in the spare parts package included with every clamping unit.
Approximate grease amounts are as follows:
KM32™ ..............0.2–0.3 fl. oz
KM40™ ..............0.3–0.4 fl. oz.
KM50™ ..............0.5–0.6 fl .oz.
KM63™ ..............0.5–0.6 fl. oz.
Kennametal uses and recommends GLEITMO™ 805, a white,
high-performance grease paste.
order
KM-LOC II Mounting Wedges • Tightening Torque
catalog wedge screw

number hex size ft. lbs. Nm
KM40 CL2SR/L 1260B 6 30–34 41–46
KM40 CL2SR/L 1660C 7 43–47 58–64
KM40 CL2SR/L 1660D 7 43–47 58–64
KM40 CL2SR/L 2060D 7 43–47 58–64
KM40 CL2SR/L 2560M 7 43–47 58–64
KM40 CL2SR/L 3260P 7 43–47 58–64
KM50 CL2SR/L 1675D 7 43–47 58–64
KM50 CL2SR/L 2075D 8 58–62 79–84
KM50 CL2SR/L 2575M 7 43–47 58–64
KM50 CL2SR/L 2575P 7 43–47 58–64
KM63 CL2SR/L 2090E 8 58–62 79–84
KM63 CL2SR/L 3290P 8 58–62 79–84
NOTE: Use a six-point socket.
KM™ Rapid Clamping System
KM Rapid Clamping Units
Operating Instructions KM Rapid Locking Sequence

The KM Rapid clamping system is a compact quick-change tooling system that At the “unlock” position, which is marked on the housing, the cutting unit can be
does not require a torque wrench to achieve proper clamping force. The KM removed or fitted in the clamping unit. By moving the cam clockwise, the locking
Rapid clamping unit spring pack supplies the correct clamping force while the balls are pushed outwards and the face stand-off gets closed. Moving the cam
cam permits quick and easy locking/unlocking of the KM cutting unit. further pushes the locking balls further outward and generates clamping force
at the locating face. The handling force moves past the maximum position, then
slightly back, to reach the “lock” position.
KM Rapid Unlocking Sequence

To unlock the cutting unit, turn the cam counterclockwise. In this position, the
locking balls are free of the cutting unit, but the taper interference is still holding
the KM cutting unit in the clamping unit. By turning the cam further to overcome
the interference, the cutting unit will be released and can be removed. In any
case, do not try to push too hard against the unlocking point because it will
result in damage to the locating pin and the cam.
The entire locking and unlocking sequence takes a few seconds.
KM Rapid Plus Clamping Units

Operating Instructions KM Rapid Plus Locking Sequence

The KM Rapid Plus clamping system is a compact cartridge quick-change tooling At the “unlock” position, the cutting head can be removed or fitted in the
system that does not require a torque wrench to achieve proper clamping force. clamping unit. By moving the eccentric shaft clockwise, the axial lockrod is
The KM Rapid Plus clamping unit spring pack supplies the correct clamping force moving, the clamping balls are pushed outward, and the face stand-off is closed.
while the cam permits quick and easy locking/unlocking of the KM cutting unit. Moving the eccentric shaft further pushes the locking ball over the axial lockrod
further outward and generates clamping force at the locating face. The handling
force moves past the maximum position, then slightly back, to reach the “lock”
position. Do not move the cam further at this position.
KM Rapid Plus Unlocking Sequence

To unlock the cutting unit, turn the eccentric shaft counterclockwise. In this
position, the locking balls are free of the clamping unit, but the taper interfence
is still holding the cutting unit in the clamping unit. By turning the eccentric shaft
further to overcome the interference, the cutting head will be released and can
be removed.
The entire locking and unlocking sequence takes a few seconds.
™
KM Automatic Clamping System
Automatic Clamping System

The KM automatic clamping system uses a disk spring package to supply force
to the lock rod — driving the locking balls and providing clamping force to the
cutting unit. The mechanical advantage of the clamping mechanism is designed
specifically for a given spring force to supply proper clamping force. Once the
cutting unit is clamped in the KM automatic clamping unit, it is securely held
in place until released by applying force to the end of the spring end cap.
In most cases, this is accomplished using a hydraulic cylinder. KM automatic
clamping units contain sealed coolant ports as well as a system for distributing
air through the unit.
Air serves two functions: (1) air is used to clean the taper and face area during
tool change; (2) it is also used to detect improper tool change. Air is routed to
the intersection of the taper and the face. If the faces of the cutting unit and the
clamping unit do not totally seal after a tool change, air will continue to escape
and can be used to detect a tool change fault. KM automatic clamping units are
available in several configurations for application on a wide variety of machines.
KM™ ATC Configurations
KM-TS™ • Kennametal Modular Tool Changing Summary of Benefits
Automatic tool changer configuration
KM-TS is engineered to provide machine tool builders the capability to design a • A proven spindle interface for Daewoo®, Nakamura-Tome™, Takisawa™,
machine around a very rigid and proven system while maintaining full and many other builders.
automation. It is the ultimate in flexible tooling systems and is equipped with • Full compatibility with KM63™ and Kennametal UT63™ tools and adapters.
four holes in the V-groove. • Use with manual and fully automatic tool changing on lathes and modern
The next generation of multifunction mill-turn machines demand flexible and mill/turn machines.
high-tech tooling systems. Previously, the V-groove in the KM system permitted • Precision-ground tool taper and locating face.
automatic tool changing but without the capability for tool identification chips. • Optimal coolant supplied directly onto the cutting point, guaranteeing
the highest-level of performance (see chart below).
Tool Changing Location Features
• For dry machining, the coolant hole can be easily closed with a screw.
• Two horizontally opposed holes in the V-groove for the tool changer
and storage in the tool magazine. Within these two holes are
counterbored holes that can be used for tool orientation.
• Two vertically oriented holes in the V-groove for tool identification
chip and balancing.
Additional New Features

• A standard hardness of 50–54 HRC makes the tool durable enough
to withstand the forces generated during high-speed tool changes

and enables long-term use.
• Optimal toughness from the taper to the insert pocket seat ensures
maximum protection against wear at all contact points and the highest
stability under high cutting loads.
• The KM-TS tools have a silver, satin-finished surface that provides order
durability and long-lasting appearance. number description
1975161 M5 Coolant Nozzle
O-ring
KM catalog order
size number number
KM32TS OR00614070V90 1850414
KM40TS OR00739070V90 1179959
KM50TS OR00987103V90 1284041
KM63TS OR01234139V90 1608616
KM80TS OR01734139V90 1586813
KM™ XMZ Configurations
KM63XMZ™ KM63XMZ Tool Orientation Specification
Left-Hand Orientation
For turning clockwise toward the main spindle.
Catalog Number: KM63XMZMCLNLF12Y
Automatic tool changer configuration orientation notch
KM63XMZ has been engineered to work specifically on Mazak® INTEGREX®

Mark IV Series of Integrex machines. The Mazak INTEGREX combines a
high-powered turning center and a full-function machining center to produce
parts in a single setup. KM63XMZ is an integral part of the success and
ingenuity of these machines.
A standard hardness of 50–54 HRC enables long-term use and durability
to withstand the forces generated during high-speed tool changes. KM63XMZ
standard material provides optimal toughness from the taper to the insert
pocket seat. This ensures maximum protection against wear at all contact
points and the highest stability under high cutting loads. The tools have a silver,
satin-finished surface that provides a durable and long-lasting appearance.
Conventional machine tools require multiple setups, extra manpower for part
handling, in-process inventory, larger floor space, and increased tooling and
workholding expenses.
• KM63XMZ will help reduce your overall manufacturing cost with Right-Hand Orientation
multitask piece part processing. For turning counterclockwise toward the main spindle.
• KM63XMZ will optimize your machining operations — however Catalog Number: KM63XMZMCLNR12Y
challenging your particular application!
• The world’s most economical, rigid, and accurate modular
quick-change tooling!
• Dramatically reduce your machine downtime and increase productivity!
• Large product selection for your machining needs!
• Special design tools available for unique applications!
• A proven tooling system for multitasking machines like the orientation notch
Mazak INTEGREX Machine Tool System!
O-ring
KM catalog order
size number number
KM63XMZ OR01237103V90 1979353
KM™ Application Data
Operating Conditions
The KM tooling joint is an extremely rigid and stable system that is specifically Chart 1 F and L1 Dimensions (mm) vs. Tangential Loads (N)
for KM32TS
designed to supply consistent results. As with any mechanical coupling, KM has 120
limits that, if exceeded, could result in mechanical damage to the joint and/or its
components. To help you stay within these limits, Kennametal has established 100
maximum safe tangential loads for each system size. These loads are described
1700
as a certain amount of force at the standard “F” and “L1” dimensions for each 80
2000
given system size. 2400
F 60
2700
(mm)
3400
40 4000
4700
5400
20
0
0 20 40 60 80 100 120 140
L1 (mm)
Example
IMPORTANT
Example of Calculation:
Where: P = rated tangential load Given: The KM integral shank boring bar, ordering code
KM40TS S32G-MCLNR12
K = empirical coefficient depending on
KM system size and the units of measure Dimensions: L1 = 90mm (3.543")
F = 22mm (0.866")
KM32™ K=190200 Required: What is maximum permissible tangential load?
KM40™ K=383600
KM50™ K=887400
KM63™ K=1718000
KM80™ K=3085800
K 383600
P= P= = 5095 N
(0.8 L1) 2 + F 2 (0.8 x 90) 2 + 222
(continued)
Operating Conditions (continued)
IMPORTANT
The following example illustrates how to use Charts 1, 3, 5, 7, and 9
Given: KM40™ integral shank boring bar, ordering code KM40TS-S32G-MCLNR12
Dimensions: KM40 integral shank boring bar, ordering code KM40TS-S32G-MCLNR12 — L1 = 90mm, F = 22mm
Required: What is maximum permissible tangential load?
Solution: To determine the tangential load:

a) Determine the correct chart to use. (This is a KM40 tool, so use Chart 3).
b) Find the intersection point of the two lines that correspond to the dimensions
L1 = 90mm, F = 22mm. These two lines intersect just above the 6670 N (1500 lbs) curve.
c) The permissible tangential load is the approximate load at the point of intersection.
The point of intersection is at approximately 6890 N (1550 lbs).
As you can see from the calculation, the actual value is 6790 N (1528 lbs). Small variations are to be expected from reading the approximate location on the chart
but should be inconsequential.
Safe cutting conditions are achieved when the actual tangential load that They are recommended when using standard CNMG and TNMG insert
is being put on the KM tooling does not exceed the maximum permissible geometries to machine plain carbon steels (AISI 1000 series), most alloy
tangential force. To help you determine the approximate value of your steels (AISI 4000 series), and some tool and stainless steels (H11, 316).
actual tangential force, Charts 2, 4, 6, and 8 have been developed
(pages K26–K35). They show the relationship between depth of cut
and feed rate at various tangential forces.
The following example illustrates how to use Charts 2, 4, 6, 8, and 10
Given: KM40 integral shank boring bar, ordering code KM40TS-S32G-MCLNR12

feed rate: 0.016 IPR
depth of cut: .200" (doc)
Required: What is approximate tangential force?
Solution: To determine the tangential force:

a) Determine the correct chart to use. (This is a KM40 tool, so use Chart 4).
b) Find the intersection point of the two lines that correspond to the 0.016 IPR
feed rate and the .200" doc.
c) The approximate tangential force is the force at the point of intersection.
The point of intersection is at approximately 4450 N (1000 lbs).
Please remember that these are approximate values and should be used These charts were designed to determine conditions within the limits of
only as a reference. If there is any doubt whether these charts are the various KM tooling system sizes. However, in actual cutting conditions,
accurate enough, the actual cutting force should be calculated. there are many other limitations, such as insert strength or excessive
overhangs, that may limit the cutting forces to values far lower than
those represented in the charts.
Operating Conditions • KM32TS™ • Metric
IMPORTANT
Chart 1 F and L1 Dimensions (mm) vs. Tangential Loads (N)

for KM32TS
120
100
1700
80
2000
60 2400
F 2700
(mm)
3400
40 4000
4700
5400
20
0
0 20 40 60 80 100 120 140
L1 (mm)
Chart 2 Depth of Cut (mm) and Feed Rate (mm/rev) vs. Tangential Forces (N)
for KM32TS
9,00
7,50
6,25
5400
4700
5,00 4000
3400
doc 2700
(mm) 3,75 2400
2000
1700
2,50
1,25
0
0 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00
feed rate (mm/rev)
Operating Conditions • KM32TS™ • Inch
IMPORTANT
Chart 1 F and L1 Dimensions (inch) vs. Tangential Loads (lbs)

for KM32TS
4.8
4.0
400
3.2
500
2.4 550
F 600
(inch)
750
1.6 900
1050
1200
0.8
0
0 1.0 2.0 3.0 4.0 5.0 5.5
L1 (inch)
Chart 2 Depth of Cut (inch) and Feed Rate (IPR) vs. Tangential Forces (lbs)
for KM32TS
0.35
0.30
0.25
1200
1050
0.20 900
750
doc 600
(inch) 0.15 550
500
400
0.10
0.05
0
0 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040
feed rate (IPR)
IMPORTANT

for KM40TS
140
120
100
80 3000
3400
F 4000
(mm) 60
5000
6000
40 7000
8000
9000
20
0
0 20 40 60 80 100 120 140 160
L1 (mm)
for KM40TS
11,50
10,00
9,00 9000
8000
7,50 7000
6000
5000
6,25
4000
doc
(mm) 5,00 3400
3000
3,75
2,50
1,25
0
0 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00
feed rate (mm/rev)
IMPORTANT

for KM40TS
5.5
4.8
4.0 700
750
3.2
900
F
(inch) 2.4 1100
1350
1600
1.6
1800
2000
0.8
0
0 1.0 2.0 3.0 4.0 5.0 6.0
L1 (inch)
for KM40TS
0.45
0.40
0.35
2000
1800
0.30 1600
1350
0.25 1100
doc 900
(inch) 0.20
750
700
0.15
0.10
0.05
0
0 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040
feed rate (ipr)
IMPORTANT

for KM50TS
250
200
150 4000
F 5000
(mm) 100 6000
7000
8400
50 10000
13400
16800
0
0 30 60 90 120 150 180 210 240 270
L1 (mm)
for KM50TS
15,00
12,50
16800
13400
10,00
10000
8400
doc 7,50 7000
(mm) 6000
5000
4000
5,00
2,50
0
0 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10 1,20 1,25
feed rate (mm/rev)
IMPORTANT

for KM50TS
10.0
8.0
900
6.0
1200
F
(inch) 1400
4.0 1600
1900
2300
2.0 3000
3800
0
0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
L1 (inch)
for KM50TS
0.60
0.50 3800
3000
0.40
2300
1900
doc 0.30 1600
1400
(inch) 1200
900
0.20
0.10
0
0 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040 0.045 0.050
feed rate (IPR)
Operating Conditions • KM63TS™ and KM63XMZ™ • Metric
IMPORTANT

for KM63TS and KM63XMZ
400
350
300
250 5000
F 200
6700
(mm)
150 8400
10000
100 13400
16700
50 20000
26700
0
0 40 80 120 160 200 240 280 320 360 400 440
L1 (mm)
20,00
17,50
26700
15,00
20000
12,50 16700
13400
doc 10,00
10000
(mm) 8400
7,50 6700
5000
5,00
2,50
0
0 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 1,10 1,20 1,30 1,40 1,50
feed rate (mm/rev)
Operating Conditions • KM63TS™ and KM63XMZ™ • Inch
IMPORTANT

16.0
14.0
12.0
10.0
F 8.0 1200
(inch)
6.0 1500
1900
4.0 2300
3000
3800
2.0 4500
6000
0
0 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12.0 13.5 15.0 16.5
L1 (inch)
0.80
0.70
6000
0.60
4500
0.50 3800
3000
doc 0.40
(inch) 2300
1900
0.30 1500
1200
0.20
0.10
0
0 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040 0.045 0.050 0.055 0.060
feed rate (IPR)
Operating Conditions • KM80TS™ and KM80ATC™ • Metric
IMPORTANT

for KM80TS and KM80ATC
400
350
300
250
9000
F 200
(mm) 11500
150
15000
100 19000
23000
27000
50
30000
38000
0
0 40 80 120 160 200 240 280 320 360 400 440
L1 (mm)
30
27
24
21
18
38000
doc 15
30000
(mm) 27000
12 23000
19000
9 15000
11500
6
9000
3
0
0 0,25 0,50 0,75 1,00 1,25 1,50 1,75 2,00 2,25 2,50
feed rate (mm/rev)
Operating Conditions • KM80TS™ and KM80ATC™ • Inch
IMPORTANT

16.0
14.0
12.0
10.0
2000
F 8.0
(inch)
2700
6.0
3400
4.0 4000
5100
2.0 5900
6800
8500
0
0 1.5 3.0 4.5 6.0 7.5 9.0 10.5 12.0 13.5 15.0 16.5
L1 (inch)
1.20
1.00
0.90
0.80
0.70
8500
doc 0.60 6800
(inch) 5900
0.50 5100
4000
0.35 3400
2700
0.25 2000
0.15
0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10
feed rate (ipr)
VDI Application Guide
Clockwise Spindle Rotation
VDI Clamp Wedge • Top VDI Clamp Wedge • Bottom
RCM RCM1 LCM LCM1
left-hand KM units and bars left-hand KM units and bars

Counterclockwise Spindle Rotation
VDI Clamp Wedge • Top VDI Clamp Wedge • Bottom
RCM RCM1 LCM LCM1
right-hand KM units and bars right-hand KM units and bars
Mounting Details • NCM Square Shank Conversion
KM Toolholder Replacement — Square Shank Toolholder — Style MCLNL shown
Toolholder Replacements • Metric

KM square shank
replacement unit equivalent B* B H L1 F F2
KM32-NCM4040 20 x 20 20 40 40 45 22 23
KM32-NCM5040 25 x 25 25 40 50 45 22 23
KM40-NCM5044 25 x 25 25 44 50 40 27 23
KM40-NCM6444 32 x 32 32 44 64 40 27 23
KM50-NCM6454 32 x 32 32 54 64 50 35 28
*For MCLNR/L holders.
Toolholder Replacements • Inch

KM square shank
replacement unit equivalent B* B H L1 F F2
KM32-NCM2425 3/4 x 3/4 3/4 1.562 1.500 1.378 0.866 0.884
KM32-NCM3225 1x1 1 1.562 2.000 1.378 0.866 0.884
KM40-NCM3228 1x1 1 1.750 2.000 1.575 1.063 0.937
KM40-NCM4028 1-1/4 x 1-1/4 1-1/4 1.750 2.500 1.575 1.063 0.937
KM50-NCM4034 1-1/4 x 1-1/4 1-1/4 2.125 2.500 1.969 1.378 1.122
*For MCLNR/L holders.
NOTE: F equals the dimension from the centerline of the KM cutting unit over the nose radius of the gage insert.
F2 equals the dimension from the back of the clamping unit to the centerline of the KM cutting unit (see column F2 above).
The offset is identical with most KM cutting units, except for positive lead angle units and neutral units.
KM™ Tooling Mounting Dimensions
KM Manual NCM-F Flanges
o-ring
max thru hole

min coolant supply
KM
size D1 D2 D3 D4 D5 D6 F L1 L2 L3 L4 L5 L6 L7 L8 L9 B G W1 W2 O-ring
32,02 30,30 24,00 43,00 4,00 6,370/ 18,01 26,37 25,20 0,50 21,50 17,61 12,33 11,18 11,00 11,51 11,00
6,348
KM32 M6 70º 35º OR00987103V75
1.261 1.193 0.945 1.693 0.157 .2508/ 0.709 1.038 0.992 0.020 0.847 0.693 0.486 0.440 0.433 0.453 0.433
.2499
40,02 35,51 29,01 54,00 5,00 6,370/ 22,00 31,88 30,61 0,80 27,00 22,12 15,49 11,18 18,01 12,75 12,70
6,348
KM40 M8 70º 35º OR01174103V75
1.575 1.398 1.142 2.126 0.197 .2508/ 0.866 1.255 1.205 0.031 1.063 0.871 0.610 0.440 0.709 0.502 0.500
.2499
50,03 42,80 37,01 67,01 6,50 7,958/ 27,51 39,88 38,61 1,00 33,50 27,44 19,22 12,70 18,01 18,24 17,50
7,935
KM50 M10 70º 35º OR1487103V75
1.970 1.685 1.457 2.638 0.256 .3133/ 1.083 1.570 1.070 0.039 1.319 1.080 0.757 0.500 0.709 0.718 0.689
.3124
63,03 53,90 48,01 81,99 8,00 14,079/ 35,99 46,89 45,62 1,50 41,00 31,70 25,99 19,99 35,00 23,50 21,49
14,054
KM63 M12 78º42' 39º21' OR01925103V75
2.481 2.122 1.890 3.228 0.315 .5543/ 1.417 1.846 1.796 0.059 1.614 1.248 1.023 0.787 1.378 0.925 0.846
.5533
80,03 66,60 60,00 105,00 9,00 16,079/ 45,00 58,39 57,12 1,50 52,50 41,61 32,01 25,00 50,00 23,50 23,00
16,054
KM80 M16 75º8' 37º34' OR02425103V75
3.151 2.622 2.362 4.134 0.354 .6330/ 1.772 2.300 2.249 0.059 2.067 1.638 1.260 0.984 1.969 0.925 0.906
.6320
NOTE: Contact Kennametal for the latest dimensional data.
™
KM Tooling Mounting Dimensions
KM LOC-II™ CL2NS/T-EF Flanges • KM Manual NCM-EF Flanges
o-ring
max thru hole

min coolant supply
KM
size D1 D2 D3 D4 D5 D6 F L1 L2 L3 L4 L5 L6 L7 L8 G W1 W2 O-ring
32,02 30,30 24,00 43,00 4,00 6,370/6,348 18,01 13,87 12,70 0,50 21,50 17,61 12,33 11,18 11,00
KM32 M6 70º 35º OR00987103V75
1.261 1.193 0.945 1.693 0.157 .2508/.2499 0.709 0.546 0.500 0.020 0.847 0.693 0.486 0.440 0.433
40,02 35,51 29,01 54,00 5,00 6,370/6,348 22,00 16,89 15,62 0,80 27,00 22,12 15,49 11,18 18,01
KM40 M8 70º 35º OR01174103V75
1.575 1.398 1.142 2.126 0.197 .2508/.2499 0.866 0.665 0.615 0.031 1.063 0.871 0.610 0.440 0.709
50,03 42,80 37,01 67,01 6,50 7,958/7,935 27,51 21,87 20,60 1,00 33,50 27,44 19,22 12,70 18,01
KM50 M10 70º 35º OR1487103V75
1.97 1.685 1.457 2.638 0.256 .3133/.3124 1.083 0.861 0.811 0.039 1.319 1.080 0.757 0.500 0.709
63,03 53,90 48,01 81,99 8,00 14,079/14,054 35,99 21,87 20,60 1,50 41,00 31,70 25,99 19,99 30,00
KM63 M12 78º42' 39º21' OR01925103V75
2.481 2.122 1.890 3.228 0.315 .5543/.5533 1.417 0.861 0.811 0.059 1.614 1.248 1.023 0.787 1.181
80,03 66,60 60,00 105,00 9,00 16,079/16,054 45,00 26,89 25,62 1,50 52,50 41,61 32,01 25,00 50,00
KM80 M16 75º8' 37º34' OR02425103V75
3.151 2.622 2.362 4.134 0.354 .6330/.6320 1.772 1.059 1.009 0.059 2.067 1.638 1.260 0.984 1.969
KM Rapid RNS-EF
KM
size D4 D5 H11 D6 L3 L4 L5 L6 L7 L8 L9 min G
KM40 40 10 5 16 21,7 27 13 12 15 44 M8
KM50 50 12 6,5 20 28,7 35 16 14 20 46 M10
KM63 63 14 8 26 31,7 41 20 16 24 52 M12
NOTE: Chart values shown are metric.
™
KM Rapid Plus RPNT-F
KM screw
size D D2 D3 D4 D5 D6 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 G1 G2 DIN-ISO 7380
KM40 40 30 6 13.5 17.2 5 16 21 24 12 46 80 15 20.5 34.5 25.5 12.5 M8 M6 M6x6
KM50 50 40 6 18.5 22.2 8 20 25.5 29.2 12 59 105 25 26 43.8 33.5 16.5 M10 M8 M8x10
KM63 63 45 10 24.5 28.5 8 26 31.7 38.5 20 18 120 30 35 58.5 41.3 19.5 M12 M8 M8x10
NOTE: Chart values shown are metric.
KM-LOC™ CLNS/T-EF
D5
coolant
supply
o-rings
KM
size D1 D2 D3 D4 L1 L2 L3 L4 L5 L6 L7 L8 B G H W1 W2 O-ring
32,00 30,00 43,00 6,35 30,00 10,00 11,30 16,15 17,6 12,30 19,50 11,50 40,00
KM32 M6 60,00 70º 35º OR00145070V75
1.260 1.181 1.693 0.250 1.181 0.394 0.445 0.646 0.693 0.484 0.768 0.453 1.575
40,00 36,00 54,00 6,35 44,00 12,00 14,18 19,56 22,10 15,50 22,50 11,50 48,00
KM40 M8 70,00 70º 35º OR00176070V75
1.575 1.417 2.126 0.250 1.732 0.472 0,558 0,770 0.870 0.610 0.886 0.453 1.890
50,00 47,00 67,00 7,95 49,00 14,00 18,25 23,90 27,40 19,20 25,50 13,00 58,00
KM50 M10 85,00 70º 35º OR00208070V75
1.969 1.850 2.638 0.313 1.929 0.551 0.719 0.941 1.079 0.756 1.004 0.512 2.283
™
KM LOC-II™ CL2NS/T-BC Boring Cartridge
VIEW A
top access
cam location
o-ring
VIEW A
side access
cam location
VIEW B
optional customer coolant
port access area 360º
to coolant port
VIEW A VIEW B access area
KM
size D1 D2 D3 D4 D5 D6 D7 F F1 H H1 L1 L2
47,04 44,54 60,00 6,36 10,80 15,00 5,50 50,00 25,00 80,00 40,00 90,00 78,50
KM40
1.852 1.754 2.362 0.250 0.425 0.591 0.217 1.969 0.984 3.150 1.575 3.543 3.091
58,29 54,10 74,00 7,94 10,80 18,00 6,50 64,00 32,00 96,00 48,00 100,00 88,00
KM50
2.295 2.130 2.913 0.313 0.425 0.709 0.256 2.520 1.260 3.780 1.890 3.937 3.465
74,04 69,92 94,00 14,04 12,80 20,00 6,50 78,00 39,00 122,00 61,00 115,00 100,80
KM63
2.915 2.753 3.701 0.553 0.504 0.787 0.256 3.071 1.535 4.803 2.402 4.528 1.535
KM
size L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 G W1 W2 O-ring
32,75 30,00 25,98 15,00 20,00 16,00 65,50 3,75 2,00 18,10
KM40 M10 60 30 OR00614070V90
1.289 1.181 1.023 0.591 0.787 0.630 2.579 0.148 0.079 0.713
38,00 37,00 32,04 18,50 21,00 16,00 75,75 5,30 6,75 24,25
KM50 M12 60 30 OR00614070V90
1.496 1.457 1.261 0.728 0.827 0.630 2.982 0.209 0.266 0.955
47,20 47,00 40,70 23,50 20,00 16,00 87,50 6,45 5,00 26,00
KM63 M16 60 30 OR00739070V90
1.858 1.850 1.602 0.925 0.787 0.630 3.445 0.254 0.197 1.024
KM RACA and NAC
min
D4 D5
coolant air
supply supply
KM
size D1 D2 D3 D4 D5 D6 D7 L1 L2 L3 L4
52,00 51,60 10,08 5,00 5,00 47,08 85,00 9,00 72,00 85,00 24,00
KM32
2.047 2.032 0.397 0.196 0.196 1.853 3.346 0.354 2.835 3.346 0.945
62,00 61,70 10,08 7,70 7,70 55,08 100,00 10,00 78,50 95,00 30,00
KM40
2.441 2.421 0.397 0.303 0.303 2.168 3.937 0.394 3.091 3.74 1.181
72,00 71,70 12,08 8,00 8,00 65,08 120,00 10,00 97,00 115,00 34,00
KM50
2.835 2.815 0.475 0.315 0.315 2.562 4.724 0.394 3.819 4.528 1.339
85,00 84,60 16,08 9,50 9,50 75,08 140,00 12,00 124,50 145,00 35,35
KM63
3.346 3.327 0.633 0.374 0.374 2.956 5.512 0.472 4.902 5.709 1.392
KM
size L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 G
11,50 32,00 32,00 27,50 34,00 24,00 32,00 27,50 70,00 38,00 14.50 M8-1,25x20
KM32 (.79) deep
0.453 1.260 1.260 1.083 1.339 0.945 0.945 1.083 2.756 1.496 0.571
15,00 37,00 39,50 33,00 40,00 26,50 39,50 34,00 84,00 46,00 22.00 M10-1,5x25
KM40 (.98) deep
0.591 1.457 1.555 1.299 1.575 1.043 1.043 1.339 3.307 1.811 0.866
16,50 45,00 46,00 42,00 48,00 34,00 46,00 42,00 102,00 54,00 22.00 M12-1,75x25
KM50 (.98) deep
0.650 1.772 1.811 1.654 1.890 1.339 1.339 1.654 4.016 2.126 0.866
18,80 51,70 55,00 46,00 55,00 42,15 55,00 47,00 117,00 65,00 24.00 M16-2,0x30
KM63 (1.18) deep
0.740 2.035 2.165 1.811 2.165 1.659 1.659 1.850 4.606 2.559 0.945
™
KM RACA and
NACA Spring-Pack Cylinder
turret disk cylinder (F)
force required
for tool release
cylinder retracted
cylinder extended
L2
L3 min
L1 min
KM
size L1 L2 L3
85,00 76,50 3,00
KM32
3.346 3.012 0.118
95,00 83,20 3,00
KM40
3.740 3.276 0.118
115,00 103,00 3,00
KM50
4.528 4.055 0.118
145,00 131,00 3,00
KM63
5.709 5.157 0.118
NCA Spring-Pack Mounting Details
coolant
air supply supply
left-hand
mounting
coolant
supply
air supply
locator pin holes
KM
size D1 D2 D3 D4 D5 L1 L2 L3 L4 L5 L6 L7 G
51,00 50,50 8,00 3,20 3,20 36,00 10,50 27,50 19,50 6,00 44,00 9,00 M8-1,25x20
KM32-NCA-DS31 (.79) deep
2.008 1.988 0.315 0.126 0.126 1.417 0.413 1.083 0.768 0.236 1.732 0.354
62,00 61,50 12,00 4,50 4,50 45,00 13,00 34,01 24,00 9,00 53,01 11,00 M10-1,5x20
2.441 2.421 0.472 0.177 0.177 1.772 0.512 1.339 0.945 0.354 2.087 0.433
78,00 71,50 15,00 5,50 5,50 56,00 16,00 42,00 28,00 6,00 74,00 12,00 M12-1,75x30
KM50-NCA-DS50 (1.18) deep
3.071 2.815 0.591 0.217 0.217 2.205 0.630 1.654 1.102 0.236 2.913 0.472
KM32 NCA
coolant inlet air inlet
left-hand
mounting
coolant inlet
air inlet
KM
size D1 D2 D3 D4 D5 L1 L2 L3 L4 L5 L6 L7 L8 G
51,00 50,80 6,04 5,00 5,00 29,37 10,69 23,93 20,09 20,00 65,00 11,20 32,25 M8-1,25x15
2.008 2.000 0.238 0.197 0.197 1.156 0.421 0.942 0.791 0.787 2.559 0.441 1.270
™
XGL – Static
L2
min depth
for piston bore
hydraulic D5
inlet coolant
supply
D2
D6
air
supply
KM
size D1 D2 D3 D4 D5 D6 D7 G L1 L2 L3 L4 L7 L8 W1 W2 W3 W4
92,177 92,177 107,00 12,045 6,35 6,35 18,00 81,95 53,525 14,00 30,00 32,00
KM80 M10 M12 70º 35º 17"30' 17"30'
3.629 3.629 4.213 .4742 0.25 0.25 0.709 3.226 2.107 0.551 1.181 1.26
KM Micro™/KM™ Mini Manual Clamping System
The KM Micro/KM Mini Coupling Taper Shank

The rigidity and stiffness of the patented KM Micro/KM Mini joint is achieved All KM Micro/KM Mini tooling is designed around a short 10:1 tapered
through a combination of unique design elements incorporated in both the shank. Extensive testing of many different lengths and angles proves
shank of the tool and the clamping mechanism. The KM Micro/KM Mini joint this combination provides the maximum stiffness and input forces
was developed as a system and takes full advantage of both the tool shank and required for locking/unlocking. The taper is self-centering to promote
the mechanism to obtain maximum benefit from the space utilized. easy tool loading and unloading.
Face and Taper Contact Clamping Mechanism

The mechanism design consists of two components: the torque screw and the
wedge nut. This simple, yet highly effective clamping mechanism allows the
user to lock and unlock the cutting unit by simply using a preset torque
Three Surface Contact wrench. This KM Micro/KM Mini clamping mechanism fits inside the taper
shank of the KM Micro/KM Mini cutting unit and utilizes a coincidental cone
design that maximizes the contact area between the clamping mechanism
and the cutting unit. As a result, the cutting unit and clamping mechanism are
on a shared axis and provide accurate axial and radial repeatability of
±.00008" (± 2 micron) for a specific cutting unit in a specific clamping unit.
When more than one cutting unit is used, the accuracy of each cutting unit
must be considered. Pre-gaging (when changing tools) measures the
deviations of each tool from the nominal. These deviations can then be
compensated for by the machine tool control offsets.

KM Micro/KM Mini tooling is designed to have simultaneous taper and face
contact. Two alternate methods provide metal-to-metal contact. One method is
to manufacture both halves of the coupling holding very close tolerances. The
other is to design a small amount of elastic deformation into the assembly. With
KM Micro/KM Mini tooling, elastic deformation takes the form of expansion of
the female taper (on the clamping unit) as the larger male taper (on the cutting
unit) is pulled back during lockup.
Our testing proved that an optimum combination of pull-back force and elastic
deformation (rather than a close tolerance) provides greater static and dynamic
stiffness and achieves a metal-to-metal fit.
™ ™
KM Micro /KM Mini Manual Clamping System
Locking Sequence Installation

The clamping sequence starts with the insertion of the cutting unit into the When initially clamping the KM Micro/KM Mini shank in a machine tool slot, it
female taper of the clamping unit. The cutting unit first makes contact at a is recommended to have a cutting unit in the shank.
stand-off from the gage face of approximately .010" (0,25mm). The torque
screw is then activated by a preset torque wrench at a right angle to the
centerline of the cutting tool, located behind the gage face of the clamping
unit. A small amount of elastic deformation takes place at the front of the
female taper as the locking force is applied. As the torque screw is further
tightened to the preset torque of 25–30 ft. lbs. (34–40 Nm), (4-1/4 turns),
the cutting unit advances until the gage face makes contact with the
face of the clamping unit. The final amount of torque applied allows the Lubrication
tail of the cutting unit to spread to clamp securely between the clamping
mechanism and the clamping unit inside diameter. Once the proper Using the appropriate wrench, back out the torque screw against the positive
operational torque is achieved, continuing to rotate the torque screw stop and generously apply grease to the threads and conical surface of the
may damage the clamping components. component hardware. Also, apply grease to the female taper surface. This
should be done periodically. Recommended grease: GLEITMO™ 805.
order
CAUTION
DO NOT USE silicone cleaner or WD-40™-type lubricants.
Summary
The KM Micro/KM Mini coupling offers a very rigid joint with a high degree of
repeatability while maintaining a very compact envelope. This permits a high
degree of versatility without sacrificing cutting performance.
KM Micro/KM Mini Clamping Operating Instructions (KM12–KM25)

Locking
Before inserting the KM Micro and KM Mini unit into the clamping mechanism Figure 1
(Figure 1), clean the contact face and taper. KM Micro and KM Mini manual
clamping units require a torque wrench for proper operation. Turning the torque
screw clockwise locks the cutting unit in position. For maximum safety, tighten
the torque screw to the specified torque. Using a torque wrench ensures that the
proper clamping forces are exerted.
Taper Contact Face

Clockwise
for Locking
KM Micro/KM Mini Manual Clamping System • Operating Torque
KM torque torque actuation

size (ft. lbs.) (Nm) drive size
KM12 5–6 7–8 25IP
KM1612 5–6 7–8 25IP
KM16 7–8 10–11 27IP
KM2016 7–8 10–11 27IP
KM20 14–16 19–22 5mm CAUTION
KM2520 14–16 19–22 5mm Over tightening can cause damage to the clamping mechanism.
KM25 25–30 34–40 6mm
KM3225 25–30 34–40 6mm
Operating Position
With the torque screw and nut to the proper torque, coincidental cones locked Figure 2
in position, and the face and self-locking taper fully engaged, the cutting unit
and clamping unit are rigidly secured together (Figure 2).
Unlocking
Rotate the torque screw counterclockwise until initial resistance is felt. In this Figure 3
position, the locking cones are free of the cutting unit, but the taper interference
is still holding the KM™ unit in the clamping unit. At this point, the bump-off angle
is in position to free the cutting unit from the interference fit.
Continue to rotate the torque screw slowly until the cutting unit is no longer
making face contact (Figure 3) and is released from the taper. The torque screw
will stop rotating and more resistance will be felt. Do not turn the torque screw
any further.
Counterclockwise
for Unlocking
CAUTION
Continuing to rotate the torque screw may damage
the clamping components.
™ ™
KM Micro/KM Mini Center Height Adjustment Feature for Flange Clamping Units
KM Micro flange mounts can adjust insert center height via a cam pin to be
purchased separately. To do this:
1. Remove the locating pin that is installed in the flange mount clamping unit.
2. Install the adjusting cam in the toolblock-locating pin hole.
3. Install the flange mount clamping unit to the toolblock, ensuring the cam
portion of the adjusting pin locates within the slot on the back side of
the flange.
4. To adjust, simply access the hex through the locating pin hole of the flange
unit and rotate to set center height with mounting screws loose.
5. Tighten the mounting bolts to the required torque for the specific bolt size.
Adjusting Cam
KM order catalog
size number number
12 1925860 MICROCAM12
Mounting Screws (4x)
16, 25, 3225 1851803 MICROCAM16
What is KM1612/KM2016/KM2520/KM3225 for ID Machining?
The KM1612/KM2016/KM2520/KM3225 is the ID endworking tooling
product line to complement the KM12/KM16/KM20/KM25 OD turning
tooling product line.
• Products are through-coolant capable.
• External tapers are the same as KM12/KM16/KM20/KM25.
Round shank clamping units
Major difference is center height location of the insert.
H1
KM12/KM16/KM20/KM25 KM1612/KM2016/KM2520/KM3225
Square shank cutting units Centerline cutting units
Insert is above centerline Insert is on centerline
KM Micro/KM Mini Manual Clamping Repair Package Components
Square Shank
3
2

1. Torque Screw KM Micro/KM Mini Manual Clamping Repair Packages
• Rotation moves the locking cones.

Clockwise rotation secures cutting unit. KM catalog order
Counterclockwise rotation releases cutting unit.
size number number
KM12 KM12NAPKG 3953388
• Provides bump-off angle.
2. Wedge Nut
• Contains anti-rotation feature.
3. Containment Screw
• Provides unlocking positive stop.
• Provides anchor for wedge nut anti-rotation feature.
Operator Maintenance
All KM Micro/KM Mini clamping units showing damage must be replaced or rebuilt.
• Use KM Micro/KM Mini Plugs to protect clamping units when they are not in
use.
For KM Micro Plugs, see page A117.
For KM Mini Plugs, see page A186.
™ ™
KM Micro/KM Mini Manual Clamping Repair Package Components
Round Shank
Flange Mount
1 2
3 2

1. Torque Screw KM Micro/KM Mini Manual Clamping Repair Packages
• Rotation moves the locking cones.
Clockwise rotation secures cutting unit. KM catalog order
Counterclockwise rotation releases cutting unit.
size number number
KM12
• Provides bump-off angle. KM12NRPKG 1925858
KM1612
KM16
2. Wedge Nut KM16NRPKG 1851801
• Contains anti-rotation feature. KM2016
KM20
KM2520NRPKG 3645148
3. Containment Pin KM2520
• Provides unlocking positive stop. KM25 KM25NAPKG 2386037
• Provides anchor for wedge nut anti-rotation feature. KM3225 KM3225NRPKG 2656552
Operator Maintenance:
All KM Micro/KM Mini Clamping Units showing damage must be replaced or
rebuilt.
• Use KM Micro/KM Mini Plugs to protect clamping units when they are
not in use.
For KM Micro Plugs, see page A117.
For KM Mini Plugs, see page A186.
KM Micro/KM Mini • Assembly/Disassembly Instructions
1. Apply GLEITMO™ 805 grease generously to threads, cones on torque screw Tools Required
and nut, and bump-off area (behind threads) of the torque screw. Also, apply
• Hex wrenches.
grease generously to the female taper on the shank.
• Pliers.
2. Screw the torque screw and the nut together. • Kennametal recommends and uses GLEITMO™ 805.
3. Insert the torque screw and nut into the shank (as one unit) as shown • Clean towels or shop rags.
in (Frame 1). • Solvent or degreaser that does not leave residue (used to clean inside the taper
and canister). Should the unit become contaminated, you can use a degreasing
4. Install the containment screw as shown (Frame 2). agent or something similar to clean the surfaces.
5. When initially clamping the KM Micro shank in a machine tool slot, it is
recommended that a cutting unit be in the shank.
6. Disassembly is the reverse of assembly procedure.
CAUTION
DO NOT USE silicone cleaner or WD-40™-type lubricants.
order
Frame 1
Torque Screw
Nut
(continued)
™ ™
KM Micro/KM Mini • Assembly/Disassembly Instructions (continued)
Maintenance Schedule
Disassemble the shanks once a month and re-apply new grease. Grease should
also be applied 1 or 2 times per week to the torquw screw, nut, and both tapers
(internal and external) in the release position without the need to disassemble.
Before re-applying grease, shop air should be used to blow out oil coolant.
If contamination of the grease is evident, then the old grease should be
immediately removed and the shank cleaned. Then new grease should be
re-applied acording to procedure.
NOTE: Apply grease with a coarse bristle brush to prevent shedding of bristles.
KM hex
size size
KM12 2,5mm
KM16 3mm
KM20 4mm
KM25 5mm
Frame 2
Containment Screw
KM Micro™/KM™ Mini Mounting Dimensions
KM Micro/KM Mini NCM-SF

KM
size D1 D3 G L1 L4 L5 L6 L7 L8 L9 P
KM12 10,025/ 4,064/ M3 5,0 8,25 8,00 5,13 6 8 10,0 22
10,050 4,077
KM16 14,025/ 5,055 M4 6,5 10,75 10,25 6,00 10 12 15,0 28

14,050 5,075
KM20 18,025/ 5,055/ M5 8,0 13,00 12,25 7,75 10 12 15,0 34

18,050 5,075
KM25 24,025/ 5,055/ M6 8,5 15,75 14,50 10,50 10 15 18,0 40

24,050 5,075
KM Micro /KM™ Mini Mounting Dimensions
™
KM Micro/KM Mini NCM-SF with Coolant
KM
size D1 D3 D4 G L1 L4 L5 L6 L7 L8 L9 P
KM1612 17,025/ 4,060/ 6 - 12 M4 6 11,00 9,75 6,75 6 12 18 27,5
17,050 4,080
KM2016 20,025/ 5,055/ 6 - 16 M5 8 13,25 12,00 8,00 7 13 18 34,0

20,050 5,075
KM2520 26,025/ 5,055/ 6 - 22 24.5 8 16,15 14,50 10,00 10 12 18 39,0

26,050 5,075
KM Micro™/KM™ Mini Mounting Dimensions
KM Mini NCM-SF with Coolant
D4
(2X) coolant
KM
size D1 D3 D4 G L1 L3 L4 L5 L6 L7 L8 L9 L10 P
KM3225 24,025/ 5,106/ 3 M6 8,5 14,7 9,5 17 13 10 15 18 16,5 45
24,050 5,126
KM Micro ™
Quick Change
Tooling System
A smaller, more compact version of the internationally renowned KM™ system.
• Quick-change cutter heads reduce indexing and set-up times by 66%.

• Specially designed for use with automatic and smaller universal lathes.
• Unique flange attachment system increases machine tool capacity.
• KM Micro square shank adapters can be installed quickly and easily in existing tool block adapters.
Experience the advantages at your Authorized Kennametal Distributor or at www.kennametal.com.
www.kennametal.com
Balancing
Balancing
Kennametal offers a range of balanced and balanced-by-design
toolholders capable of extending spindle and tool life and improving
part quality at higher machining speeds.
Definitions for Balance
Standard Toolholder Balanceable

A toolholder that may contain uncorrected features (unbalanced drive slots, A toolholder with a built-in mechanism that can adjust to correct any
notches, locking screws, etc.). Standard toolholders have no compensating unbalance inaccuracies incurred during normal manufacturing. The fully
features added to correct balance, used in basic, low-speed applications. assembled tool (toolholder and cutting tool) can be balanced as a system
using a balancing device.
Balanced-by-Design Balanced
A toolholder designed with compensating features to correct any unbalance A toolholder has been balanced to predetermined specification after manufacture
caused by uneven drive slots, notches, locking screws, etc. The balanced by checking the balance condition with a balancing device. This may be followed
toolholder is capable of being used in high-speed applications. Small, residual by physically removing material from the toolholder, such as holes and/or slots.
unbalance may result due to normal manufacturing tolerances within the shank
standards.
When machining at higher speeds, responsible machining practices must Forces caused by unbalance increase with the rotational speed squared.
be observed. Unbalance is caused by uneven mass distribution in the tool Excessive unbalance can cause premature wear to the tool and spindle bearing,
or toolholder. Potential sources of unbalance are movable parts (adjustable which can adversely affect surface finish and accuracy.
cartridges, set screws, spindle spring pack, and clamping mechanisms),
manufacturing tolerances, and design.
(continued)
Balancing
Balancing (continued)
The balance quality is usually specified by the balance grade G, according
to IS0 1940-1 and ANSI S2.19 standards.
The balance quality grade (G) was derived from practical experience, which
is expressed in millimeters per second (mm/s) and ranges from 0,16–4000.
For rotating tooling and general machinery parts, it is usually specified to be
G 2.5 or G 6.3. A lower number designates better balance quality.
The permissible residual unbalance can be calculated by the following equation:
9549 x G x M
U per = n
Where: Example:
U per = permissible unbalance, expressed in gram millimeters (gmm) Rotor mass = 2 kg
G= desired balance grade n= 10,000 RPM
M= rotor mass in kilograms (kg) Desired balancing grade = G 6.3
n= operating speed in rotations per minute (RPM)

U per = 9549 x 6.3 x 2 = 12 gmm
10,000
The same value can be obtained from the chart on the following page. It gives
the permissible specific unbalance in gram millimeters (gmm) as a function of the
rotational speed and the balance quality (G). For the example above, at 10,000
RPM and for grade G 6.3, the maximum residual unbalance would be 6 gmm/kg.
The toolholder assembly (including the tool) has a mass equal to 2 kg, the
permissible unbalance is [(6 gmm/kg) x 2 kg], which equals 12 gmm.
(continued)
Balancing
20
permissible specific unbalance (gmm/kg)
15
G1
G 2.5
10 G 6.3
0
5000 10000 15000 20000 25000 30000
surface finish (Ra) vs. feed rate
From the approach described in ISO 1940-1, the requirements for maximum Comparing the cutting forces can provide a reference for the balancing
residual unbalance become very strict as speed increases. For example, a G 2.5 requirements. Generally, finishing operations generate lower cutting forces and
balancing grade can become unpractical at 25,000 RPM for a tool with a mass require a better balance quality. Though rotating components should always be
of 1 kg. The chart shows that the maximum residual unbalance would be 1 gmm, balanced, in most cases it is sufficient to keep the unbalance forces to 5–10%
which could be very time consuming to be achieved or even beyond the accuracy of the cutting forces.
of the balancing machine.
(continued)
Balancing
The permissible residual unbalance can be calculated by the following equation:
F = U x (n/9,549)2 (Newtons)
Where:
U = unbalance in gram millimeters (gmm)
N = rotational speed (RPM)
In this particular case, the unbalanced induced force would be Good balancing quality does not necessarily guarantee safe operation
F = 1 x (25,000/9,549)2 = 6,9 N. The cutting forces generated at higher speeds. Other variables (spindle connection, type of operation,
are likely to be orders of magnitude greater than that. cutting parameters, machine stiffness, bearing condition, etc.) should
always be considered.
Unbalance can be corrected by material removal (drilling, milling, grinding), For a given unbalance, the following formula can be used to determine
material addition (set screws), and material redistribution (balancing rings the hole depth (L) necessary to correct for the unbalance*:
or set screws).
* Formula for steel components only.
L= D- D2 - U x 1300/d2
2
Where:
U = unbalance (gmm)
D = diameter of placement (mm)
d = hole diameter (flat bottom) (mm)
L = hole depth (mm)
Shrink Fit
Shrink Fit
HEAT
toolholder body O.D.
cutting tool shank
HEAT HEAT
clearance zone
toolholder I.D.
HEAT
The Concept Shrink Fit Tooling Advantages:

• Low runout — cutting tools are gripped 360° along the entire length of the
Heat shrinking is not a new process in the machine tool industry. However, cutting tool shank for an evenly distributed clamping force.
the concept was only recently implemented as a quick-change toolholding
mechanism for clamping cylindrical cutting tools for high-speed machining
applications. • Clamping forces are greater than collets or hydraulic chucks.
The Shrink Fit process begins by applying a quick and precise heat to the
• During testing, tool material properties break down and shear before
holding end of a toolholder. This causes the internal bore, which is slightly
slippage occurs.
smaller than the shank of a cutting tool, to expand, allowing a tool to be
inserted. As the toolholder cools, the bore shrinks to create 360° of uniform
pressure along the entire length of the bore, resulting in an evenly distributed • Slim and short toolholder profile designs are achievable because no moving
clamping force that mechanical toolholding cannot beat. parts are used.
Due to the design, flatted-style, Weldon®, and Whistle Notch™ cutting tool
shanks can employ Shrink Fit technology. To gain full benefits of the • Well suited for high-speed operations because their symmetry provides the
technology, fully cylindrical tool shanks are recommended. As long as the best possible balance.
heating processes are kept within the elastic range of the toolholder material,
this clamping operation can be repeated for several thousand cycles. • Sealing stop screws are not required — designed interference between the
cutting tool and toolholder forms a seal that enables coolant to flow only
through designated passages.
These advantages enable Shrink Fit technology to work at greater speeds and
feeds, produce better finishes, deliver increased tool and spindle life, and
generate more productivity.
Shrink Fit
Heat-Activating Systems
Shorter cycle time, less cooling downtime, localized heating, and integrated
cooling systems are essential for a safe and simple heating system. Shrink Fit HEAT
heating systems include induction, hot-air, and open-flame methods, with
induction being the easiest and fastest of these systems.
HEAT
Toolholders
• Slim design.
• Balanced.
• Flatted-style, Weldon®, and Whistle Notch™ shanks can be gripped. Optimal

results are obtained with smooth, cylindrical shank cutting tools — without
flats and/or notches.
• Avoid using carbide tools with polished shanks. This will reduce
torque values by 60%.
HT (High Torque) Shrink Fit Toolholders

HT Shrink Fit holders have a high interference level that offers 30–50% greater
torque than competitive systems. This line is only to be used with carbide tools ®
because of their low thermal expansion coefficient. These toolholders require

a machine with at least 10 kW of power to apply heat quick enough to avoid
heating the tool.
GP (General Purpose) Shrink Fit Toolholders Ideal Surface Quality

GP toolholders enable the use of all materials and extensions because • Metric (ISO standard) Ra ≥0,8 μm surface finish.
they have lower interference levels. Operators should use this style if not
generating high cutting forces. • Inch (industry standard) Ra ≥32 μin surface finish.
(continued)
Shrink Fit
Shrink Fit (continued)
Straight shank toolholder extensions are a great complement to the Shrink Fit
system. Use caution and do not overheat Slim Line products. Overheating can
cause warping or other permanent damage. Toolholder life drastically reduces
if activating heat is not properly controlled.
Cutting Tool Requirements
metric (ISO standard)
cutting tool shank diameters tolerance

3mm 2,997 3,000 0.000/-0.003
h4
4mm 3,996 4,000 0.000/-0.004
5mm 4,995 5,000 h5 0.000/-0.005
6mm 5,992 6,000 0.000/-0.008
8mm 7,991 8,000 0.000/-0.009
10mm 9,991 10,000 0.000/-0.009
12mm 11,989 12,000 0.000/-0.011
14mm 13,989 14,000 0.000/-0.011
16mm 15,989 16,000 0.000/-0.011
h6
18mm 17,989 18,000 0.000/-0.011
20mm 19,987 20,000 0.000/-0.013

25mm 24,987 25,000 0.000/-0.013
32mm 31,984 32,000 0.000/-0.016
40mm 39,984 40,000 0.000/-0.016
50mm 49,984 50,000 0.000/-0.003
inch (industry standard)
cutting
cuttingtool
toolshank
shank diameters
diameters tolerance
tolerance
1/8 .1249 .1247 -0.0001/-0.0003
3/16 .1874 .1872 -0.0001/-0.0003
1/4 .2499 .2496 -0.0001/-0.0004
5/16 .3124 .3121 -0.0001/-0.0004
3/8 .3749 .3746 -0.0001/-0.0004
7/16 .4375 .4371 0.0000/-0.0004
1/2 .5000 .4996 0.0000/-0.0004
9/16 .5625 .5621 0.0000/-0.0004
5/8 .6250 .6246 0.0000/-0.0004
11/16 .6875 .6871 0.0000/-0.0004
3/4 .7500 .7495 0.0000/-0.0005
7/8 .8750 .8745 0.0000/-0.0005
1 1.0000 .9995 0.0000/-0.0005
1-1/4 1.2500 1.2495 0.0000/-0.0005
1-1/2 1.5000 1.4995 0.0000/-0.0005
2 2.0000 1.9995 0.0000/-0.0005
Shrink Fit
Axial Adjustment Gages
Cutting tool length adjustment is performed using a special axial adjusting gage
(b) before shrinking the cutting tool into the toolholder. This gage (b) is placed
on the toolholder (a) along with the cutting tool (c). The length difference of the
setting gage (l2) is calculated into the required tool assembly length. The whole c
assembly can then be placed into a length presetter for adjustment. Rotating
the gage moves the axial stop screw and presets the assembled tool to the
required length. After removing the gage, the cutting tool can then be shrunk b
into the toolholder.
a
I2
SAFE-LOCK™
SAFE-LOCK™
SAFE-LOCK™ is a pull-out protection system for high-performance By locking the cutting tool in the holder, this pull-out security ensures
machining, in particular for heavy-duty cutting. This is achieved by helical optimum process reliability in conjuction with shrink fit runout accuracies
grooves that are ground into the tool shank. These, together with the and rigidity for longer tool life and maintains higher productivity and part
respective pin drivers in a shrink fit holder, prevent the tool from being accuracies for our customers.
pulled out, even during extreme machining conditions.
SAFE-LOCK™ feature in the chuck

SAFE-LOCK™ Spiral
grooves ground in cutting
tool shank
High-Performance
Milling Chucks
• Heavy- and fine-milling capabilities.
• Prebalanced G6.3 @ 20,000 RPM — six threaded M6 holes to accept set screws for fine balancing.
• Heavy milling — tighten locknut until O-ring on back face of locknut just touches the flange
on the chuck body to achieve runout .0004" 3 x D1.
• Fine milling — tighten as above, then back the locknut off 1/8–1/4 turn to achieve runout .0002" 3 x D1.
• Sub-zero heat treatment for material stability.
• Through-the-toolholder coolant capability using stop screw as sealing device.
• 3/8" axial adjustment stop screw.
Experience the advantages at your Authorized Kennametal Distributor or at www.kennametal.com.
www.kennametal.com
Hydraulic Chucks
Standard Styles
Kennametal hydraulic chucks provide optimum performance for clamping full- A safety stop prevents chuck damage caused by over-tightening either with or
cylindrical straight shanks, such as solid carbide drills and end mills. Activation without the cutting tool in place. Another unique feature is the special spiral wiper
of the chuck is achieved by turning the piston screw, which pressurizes the groove in the chuck’s clamping bore that securely grips oily tool shanks. All
hydraulic fluid and exerts force on a thin-walled membrane along the length of Kennametal hydraulic chucks utilize a range of sealed, cutting-tool-reducing
the clamping bore. This highly concentric clamping force not only holds the tool sleeves to maximize chuck versatility. Reducing sleeves can also be used for
shank more securely, but also produces a dampening effect that reduces converting bores from inch to metric and vice versa.
vibration and helps eliminate microcracking on cutting edges.
Slim Line Standard/HP Line

Slim Line hydraulic chucks have a sophisticated shape for universal application Our proven Standard Line hydraulic chucks have an external adjustment screw
and maximum precision. After the chucking process, safety is guaranteed if a for radial alteration up to 3/8" of the cutting-tool length. This feature
minimum clamping force or a transmittable torque (determined according to eliminates the need to remove the cutting tool or retention knob to make fine
the clamping diameter) is reached. This is achieved through the clamping adjustments. Standard Line chucks are prebalanced and can also be used with
screw operation and the stroke of the clamping piston that force the hydraulic SEFAS™ chamfering rings. Please see the toolholder sections of this catalog for
oil into the thin-walled expansion chamber with high pressure. information regarding balancing quality.
Trend Line Basic Line

New Trend Line hydraulic chucks offer maximum precision at an attractive Basic Line hydraulic chucks have a high-quality runout specification of
price. This system provides the same accuracy specifications as the Standard .0001. These chucks are balanced-by-design for speeds up to 10,000 RPM.
Line except with an axial back-up screw through the chuck bore to achieve the Like the Trend Line, Basic Line chucks utilize an axial back-up screw
3/8" radial adjustment of the cutting tool length. SEFAS chamfering rings also through the chuck bore to achieve a 3/8" radial adjustment. Larger body
can be used with our Trend Line chucks. diameters give this chuck a higher torque transmission (grip) of 220 ft. lbs.
Please note that the standard SEFAS chamfering ring cannot be used in this
chuck design.

Hydraulic Chucks
General Design
Function Effect
Tightening the piston clamping screw exerts force on the pressure piston, which The hydraulic clamping system has a dampening effect. Vibration in a
presses the hydraulic fluid, exerting force on the thin-walled expansion sleeve. mechanical clamping system can cause microcracking on insert cutting edges.
This pressure causes the sleeve to compress around the tool shank, creating a This is prevented by the hydraulic expansion chuck and results in higher
highly concentric clamping force. production quality and up to 4x better tool life.
Accuracy
The accuracy shown is based on a round shank (no flats) with h6 tolerance
and no reducing sleeve.
set screw for tool

length adjustment
piston clamping screw expansion chamber
clamping bore
pressure piston tool length
adjustment sleeve hydraulic medium
Features
• Turning the external set screw adjusts axial tool length. There is no need • High-performance balanced chucks can be converted to balanceable chucks
to remove the cutting tool or coolant supply unit for standard designs. by adding a set of Kennametal balance rings that compensate for cutter
imbalance and optimize performance.
• Maintained contact with the tool-length adjusting sleeve ensures that the
tool is safely held. 10mm of adjustment is provided. • Wiper grooves inside the bore safely grip oily shanks, sealing the bore
to eliminate contamination from chips, dirt, or coolant.
• A sealed bore and a large hole through the tool-length adjusting screw
enable maximum coolant to flow through coolant-fed cutting tools. • SEFAS™ chamfering rings can be added to chucks, reducing the need for step
drills and secondary chamfering operations.
• A uniquely designed piston clamping screw prevents damage from
overtightening and accidentally actuating the hydraulic mechanism • A wide assortment of reducer sleeves are available to increase the application
without a tool in the chuck. range of hydraulic chucks. When using a bushing, the runout could be up to
twice as high as the example shown.
(continued)
Hydraulic Chucks
General Design (continued)
Application
Hydraulic expansion chucks work best when clamping these style shanks:
• Shanks to DIN-6535 — forms HA, HB, and HE.
• Shanks to DIN-1835 — forms A and B (with shank tolerance h6 and Ra
minimum of 0,3 μm).
• Forms HA and A — plain cylindrical shank, 6–32mm diameter.
0,003mm
• Forms HB and B — Whistle Notch™ shank, 6–20mm maximum diameter. (.0001")
• Form HE — Whistle Notch shank, 6–20mm maximum diameter.
(Kennametal suggests the use of a reducer collet).
D h6
• Inch straight shanks:
1/4–5/8" (.0004 under nominal diameter maximum).
3/4–1-1/4" (.0005 under nominal diameter maximum).
2.5 x D
max 50mm
(2")
Slim Line Design
Weldon® shanks with a maximum diameter of 20mm (3/4") can be

gripped without reducer collets. However, Kennametal recommends using
reducer collets for all flatted shanks. Highest accuracy is obtained
with plain, cylindrical shanks.
0,006mm
(.0002")
D h6
2.5 x D
max 50mm
(2")
Using a sleeve gives higher grip torque:

Formula: sleeve bore x chuck torque = assembled torque
chuck bore
Example: 12mm (sleeve bore) x 220 Nm = 132 Nm
20mm (chuck bore)
While chart shows for a 12mm Hydraulic Chuck = 70 Nm approx.
2x grip advantage
Hydraulic Chucks
Setting Up New Hydraulic Chucks
Length adjustment for: Length adjustment for:

Standard/HP Line and Slim/Standard Line Trend Line, Basic Line, and Slim/Trend Line
clamping screw released

clamping screw released
max 10mm (3/8")

max 10mm (3/8")
limit stop for tool-length adjustment
limit stop for tool-length adjustment
1. Remove all grease from the hydraulic chuck before using. 4. Always tighten the clamping screw with a hex wrench as far as the limit stop
by hand tightening. Never try to adjust the stop pin when the hydraulic chuck
2. Insert the cutting tool into the clamping bore as far as the is in the clamped position.
stop pin/stop screw will allow.
5. The tool is now clamped and ready for use.
3. Adjust the cutting tool length with a hex wrench.
Maintenance
Kennametal hydraulic chucks are maintenance-free and deliver long service life.
It is important that the clamping function be checked with a test pin on a regular
basis. Any dirt in the bore can be removed with a nylon cleaning brush.
• The clamping function can be tested quickly and easily using the test pin.
• Insert the test pin into the clamping bore as far as the stop pin/stop
screw allow. turn screw clockwise
to a full stop
• Tighten the clamping screw with a hex wrench as far as the limit stop
testing bar
by hand tightening.
• The chuck is functioning correctly if the test pin cannot be moved by normal
hand pressure.
IMPORTANT
Reducing sleeves are available; see page J4. Never tamper with the oil-loading orifice (sealed with a cap) as this could
destroy the clamping ability of the hydraulic chuck and require it to be sent
to Kennametal for service.
In the event of small tool crashes or misuse of the chuck, please contact
Cleaning brushes are available; see page L15. your local Kennametal Service and Repair Department to have your
Kennametal hydraulic chuck serviced or repaired by qualified Kennametal
service technicians.
Test pins are available; see page L14.
HPMC System
The HPMC (High-Performance Milling Chuck) System
Application
The HPMC System is ideal for holding round shank cutting tools and extensions
on various applications because it offers greater versatility. This makes it an
excellent choice for end mills, reamers, indexable cutters, drills, straight shank
extensions, and boring systems. The HPMC System, with its powerful gripping
torque, provides the maximum performance for tough roughing and high metal
removal applications, as well as delivering first-rate accuracy for finishing
applications — all with the same chuck.
These toolholders are through-coolant capable with the use of supplied
backup screws. Threaded holes in the chucks accept set screws for fine
balancing, and reducing sleeves allow the same holder to be converted for
smaller gripping sizes.
Design
The HPMC System is comprised of an inner chuck body, a needle roller bearing
assembly, and a thick-walled outer locknut. The inner chuck body, with radial and
axial grooves at the inside bore, acts as a master collet by compressing around Cutter
the cutting tool, exerting a very strong grip. The chuck bore is compressed by
roller bearings as they track up a taper of approximately 4°. The roller bearings
are held in a retainer (four per window to maximize contact) at an angle slightly
skewed from that of the chuck taper angle. The locknut bearing retainer’s wall
thickness is greater than that of the chuck body nose. Therefore, as the locknut
is rotated clockwise, the roller bearings track in a helical movement, gradually
climbing the shallow taper.

There are no threads in the HPMC System. As the two tapers are forced together,
To get the maximum accuracy out of the HPMC System, tighten the locknut to
a tremendously high, uniform force is created. This squeezes the chuck body
the face stop and then back off half a turn. As this is done, be sure the O-ring
inward, conforming it to the cutting tool shank. Radial grooves assist the internal
on the back face of the locknut stays in contact with the chuck face.
diameter by evenly collapsing inward, which improves gripping torque, accuracy,
and prevents fretting. Force continues to be applied until the locknut’s back face Stop screws are included with all HPMC Systems for length adjustment or
bottoms out on the chuck’s body face. This is the maximum gripping torque coolant feed. These screws are designed with a cone face and reversible
position. Oil residue left on cutting tool shanks can cause slippage, but axial flat face and an O-ring for coolant sealing options.
grooves minimize this by draining contaminants.
HPMC Systems are subjected to sub-zero treatment to stabilize the material
Shallow contact angles produce a self-locking effect, so the chuck will not and prevent pitting on the bearing contact surface. This helps to ensure long,
release during operation. Because of this strong grip, no torque wrench is worry-free tool life.
required. Also, the high gripping force of the HPMC enhances its ability to
transmit energy to the machine tool, so vibration, deflection, and runout are
minimized. The cutting tool shank offers an advantage over collet chucks
because there is no axial drawback as the locknut is tightened.
A single toolholder provides 5–10% more gripping torque for heavy milling,
and the same chuck is versatile enough to do finishing work, too.
(continued)
HPMC System
The HPMC (High-Performance Milling Chuck) System (continued)
Cutting Tool Requirements Maintenance Operations

The outside diameter of the cutting tool shank and the inside diameter of Greasing the needle bearing is the only required maintenance. Follow the
the HPMC System must be wiped with a clean dry cloth before assembly. procedure below to ensure maintenance is properly performed:
Any contamination will increase runout and reduce gripping force.
1. Tighten the locknut clockwise to obtain clearance from the retaining ring.
Carefully monitor the cutting tools used in these chucks so they do not exceed
h6 (nominal to -.0005") on the shank diameter. Use tools as close to nominal 2. Remove the retaining ring from the chuck.
as possible. Cutting tool shank roundness should be within 0,003mm (.0001"). 3. Unlock the locknut counterclockwise, and lift the nut assembly
Undersized tools cause excessive stress and may cause chuck failure. from the chuck.
Optimal chuck performance is attained when the cutting tool shank is round, 4. Wipe off old grease from the milling chuck and all other components.
without flats. Cutting tools with small flats may be held, but they will increase
runout. Whistle and flatted cutting tool shanks are recommended in conjunction 5. Recoat the needle bearings in the locknut liberally with a quality,
with reducing sleeves. For best performance, keep shank flats to a minimum. water-resistant grease.
The minimum length of engagement is 2x the diameter of the cutting tool 6. Regrease the outside diameter of the milling chuck where the locknut
shank. Short holding length may cause the tool and/or chuck to break. This is housed.
could dislodge the cutting tool and result in serious injury to the operator.
7. Reinstall the locknut on the milling chuck body and tighten to gain
The milling chuck should never be tightened without a cutting tool inside clearance for reinserting the retaining ring.
the bore. High gripping forces will cause permanent deformation to the
inside diameter. 8. Tighten and loosen the locknut several times. Recheck the retaining ring
for correct fitting.
9. Wipe away any excess grease.
Please contact the Kennametal Service and Repair Department to
have your Kennametal products serviced or repaired by qualified
Kennametal service technicians.
Setting the Accuracy of the Milling Chuck
Heavy Milling Finish Cut

• Tighten the locknut all the way down with a milling chuck wrench until the • Back the locknut off 1/8–1/4 of a turn from above position.
O-ring on the locknut just touches the flange of the milling chuck body • Best accuracy — 5 μm (.0002") at 3x diameter up to 50mm (2").
(O-ring should not be compressed).
• Accuracy 10–20 μm (.0004–.0008") at 3x diameter up to 50mm (2").
face contact can distraught chuck

O-ring just touching flange
X and damage bearings
O-ring backed off 1/8–1/4 from touching flange O-ring touching face of chuck
CAUTION
DO NOT over tighten the milling chuck without a tool shank inserted. This may cause serious damage to the milling chuck or loss of performance.
Tunable Tooling System (TTS)
Overview
When machining with extended length setups, undesirable regenerative vibrations The problem with these solutions is that they do not allow high metal removal
(chatter) can arise, causing poor surface finish, dimensional control issues, and rates to be maintained. To uphold high rates, the dynamic stiffness of the system
tool breakage. To avoid chatter, machine operators are generally forced to reduce must be increased. Dynamic stiffness is proportional to the product of static
cutting parameters, which decreases metal removal rates and diminishes stiffness and damping ratio. Static stiffness can be increased through using
productivity. shorter setups or larger toolholder diameters. Materials with a higher modulus
of elasticity can also increase static stiffness.
Cutting force fluctuates when chip thickness varies. This is caused by waves left
on the workpiece from the previous pass. These waves may create chatter when The Kennametal Tunable Tooling System (TTS) provides a means for maximizing
the cutting tool and workpiece interact. Continued chatter can further produce the dynamic stiffness of boring bars and milling adapters by suppressing
variation in cutting force, leading to more vibration. If not addressed, the vibrations with a passive dynamic absorber. TTS is designed with an internal mass
amplitude of vibration may eventually reach levels that cause the tool that vibrates close to the natural frequency of the most dominant vibration mode
to bounce out of the workpiece or even result in catastrophic failure. in the system. The motion of the internal mass will dissipate energy and prevent
chatter. The overall result depends on a machine’s dynamic characteristics*
This problem can be approached in many different ways. Chatter can be avoided and the rigidity of the connection between tool and machine tool. Manufacturing
by drastically reducing cutting speeds to increase process damping (friction tolerances, preload, and wear may change the dynamic response of a machine
between flank face and workpiece), which dissipates energy to reduce vibrations. and adversely affect overall results.
Another approach utilizes milling cutters that have inserts with differential
spacing. This minimizes the regenerative effect by creating a disturbance on the
wave pattern left on the workpiece. However, this approach provides limited *Machines from same builder and model are not dynamically identical.
success as chip loads are no longer evenly distributed over the cutting edges and
may require the feed rate to be restricted. Also, because the spacing is not even,
the surface quality could be negatively affected.
While passive dampening improves the dynamic stiffness of an extended reach

tool, the damping mechanism will not perform the same with every machine.
Not only does the natural frequency of the tool affect its dynamic stiffness,
frequencies inherent to the machine do as well. Because machine tools have
their own dynamic signature, a tool that is tuned on one machine may not be
tuned on another. Unlike other products on the market that are pretuned,
Kennametal tunable boring bars and milling adapters are tunable. They allow
users to adjust the passive damper, optimally tuning the tool for a specific
machine or setup. This enables extended reach tooling to be retuned to match
a machine’s dynamic signature, even as it changes over time. A key benefit
of Kennametal’s tunable boring bars and milling adapters is that they can be
optimally tuned for any given setup. While Kennametal standard tunable
products come pretuned from the factory, it may be beneficial to further
optimize them once installed.
(continued)
Tunable Tooling System (TTS) (continued)
With the Kennametal TTS System, longer L:D ratio toolholders can be used for
Surface Finish (Ra) vs. Feed Rate
larger DOC, better surface finishes, and longer tool life. When TTS is applied to
45
milling adapters, using greater insert density on milling cutters or increasing
ADOC or WOC enables higher MRR. Better surface finishes and tool life can also 40
surface finish Ra (uin)

be expected from these adjustments.
35
30
The benefits of using Kennametal’s Tunable Systems go beyond increased metal
removal rates. In metalcutting tests, a good correlation between dynamic stiffness 25
and vibration levels were measured at the spindle. Vibrations can not only cause
premature tool life, but also limit spindle bearing life. Preventing vibration from 20
propagating through the machine promotes longer life for spindle-related
components and maintains machine accuracy over time. 15
40 50 60 70 80 90
feed (IPM)
Kennametal Competitor
Surface finish measurements comparing a pretuned milling

adapter from a competitor and a Kennametal’s optimally tuned adapter
on the spindle. An increase of up to 50% in feed rate for similar
surface finish values can be noticed.
Dynamic Stiffness
Figure 1 shows the relative dynamic stiffness of a tunable boring bar as a function Normalized Dynamic Stiffness
of adjusting screw tightness — loose to tightened (left to right). 1.20
1.00
The chart shows that for the given bar, optimal tuning occurs at about 70%
0.80
or when the relative performance equals 1.
0.60
It is also important to note that performance decreases more severely when the 0.40
tool is over-tuned, compared to when it is under-tuned. For this reason, it is best

0.20
to slightly under-tune the system.
0.00
0 1 2 3 4 5 6 7 8 9
number of turns
Fig. 1
Dynamic Stiffness of Damped Milling Adapters
1.20
dynamic stiffness (normalized)
1.00
1.00
0.75
0.80
0.60
0.53
0.34
0.40 0.32
0.25
0.20
0.00
machine A machine B
Competitor Kennametal Standard

(pre-tuned) (tunable) Toolholder
Tunable Milling
Tunable Milling Adapters

The Kennametal Tuned Tooling System offers a full line of tunable milling adapters
capable of performing at maximum output without the hindrance of vibration.
Tunable milling adapters are through-coolant capable, and, because the internal
damper can be adjusted to alleviate chatter, they provide optimum surface finish
and longer tool life.
General Guidelines for Milling with Extended Reach Adapters
1. Loosen both clamping screws.

2. Turn the adjusting screw in the positive direction until it becomes snug. The adjusting screw becomes snug when it locks the tuner mass.
3. Turn the screw one complete turn in the negative direction and take a test cut.
4. Repeat Step 3 until good surface finish is achieved. You may need to use small increments to find an optimal position.
5. Back the adjusting screw off a 1/4–1/2 turn in the negative direction.
6. Tighten both clamping screws and take a test cut to confirm desired results.
1. 2. 3.
4. 5. 6.
*The TTS Milling Adapters will need to be re-tuned if the milling cutter is replaced with another with different mass.
Tunable Boring Bars
Tunable Boring Bars

The Kennametal complete portfolio of Tunable Boring Bars helps prevent chatter
and other problems associated with an internal dampening package designed
for deep-hole boring applications.
Advantages
Optimal Rigidity Machining without Chatter or Vibration
Eliminates vibration to improve surface Less noise exposure and improved results.
quality and tolerance.
Increased Productivity Tunable Damping Mechanism

Larger depth of cut and better chip removal To account for different vibration behavior,
by up to 10:1 (steel) and 15:1 (carbide) bars can be tuned on the machine, and
length-to-diameter ratio. tools can be adjusted.
Relative Stability
10
TTS Tool — area of optimum application
6
4 Standard Tool — area of optimum application
4 5 6 7 8 9 10 11 12
TTS Tool: Standard Tool: Standard Tool L/D=4 TTS Tool L/D=7
max DOC with a benefit max DOC on Increased stability allows for
of more than 500% stable conditions greater depth of cut
Note: This chart illustrates how KM™ Tunable Boring Bars proivde greater stability than standard toolholders, even in larger tool length-to-diameter ratios.
Increased stablilty enables greater depth of cut.
Tunable Boring Bars
General Guidelines for Boring with Extended Reach Bars

1. Select the largest boring bar diameter possible. Larger diameter bars 6. Make sure the insert is in the correct center position.
are stiffer and more stable. Remember to leave enough space for
chip evacuation. 7. By choosing a small corner radius you can reduce forces on the workpiece.
2. While larger diameters are more stable, the diameter may also be too large, 8. Use cutting heads with a negative back-rake angle that is as small
preventing proper chip evacuation, affecting surface finish, or damaging as possible.
the bar. Ensure the bar diameter is not so large that it will interfere with 9. Using inserts with a positive chip former is preferred.
chip evacuation.
10. Change inserts when any flank wear is detected because radial back forces
3. Keep the overhang length of the tunable boring bar as short as possible. will increase in proportion to wear.
For Tunable Boring Bars, select the shortest bar possible.
4. Balance machining parameters to prevent the occurrence of uncontrolled
vibrations and resonance.
5. The tool setting angle should be as close as possible to 90°.
Selecting the Correct Bar

Kennametal offers TTS Boring Bars with KM™ back-ends or straight shanks, The L:D ratios of Tunable Boring Bars are fixed, where straight shank tunable bar
KM front-ends, or bolt-on head connections, and they are available in L:D ratios are not. When using straight shank bars, the overhang length should be
either steel or carbide. kept as small as possible.
To find the appropriate boring bar, first consider that the length-to-diameter ratio Please note that only standard pretuned straight shank tunable bars are
(L:D) should always be kept as small as possible. The smaller the L:D ratio, the pretuned at the factory for 10:1 L:D. If the straight shank bar is mounted
greater the stiffness and stability of the bar. with less than 10:1 L:D, it may be necessary to retune the bar. This is
discussed in more detail in the “Tuning the Bar” section.
Holding Method
The holding method is as critical to performance as selecting and tuning
the boring bar. The connection between the boring bar and the machine should Most Stable
be as rigid as possible. Rigid connections enable the tuner mass to function
more effectively. The minimum holding length of the bar should be 2.5x the
diameter of the bar.
Various connection methods are shown below and listed from most stable
to least stable:
Face and Taper Contact with Interference Fit
Example: KM Tunable Boring Bar clamped with short overhang
KM clamping unit on turret
Split Sleeve/Full Cylindrical Contact

Example: Straight Shank Tunable Boring Bar with split sleeve
Screw Clamping
Least Stable
Example: Straight Shank Tunable Boring Bar with screw clamping on bar flat
Tunable Boring Bars
Tuning the Bar

Standard tunable boring bars are pretuned at our factory. Though they may Several factors influence the required adjusting screw setting
work right out of the box on some machines, for others, they may chatter because on tunable boring bars, including:
of differences in dynamic response. Chatter can be eliminated by optimally tuning
the boring bar for a given setup, and the key benefit of our tunable boring bars • Overhang and L:D ratio.
is that they can be adjusted for any application. Therefore, corrections can be • Depth of cut.
made to put the tool in tune with your machine, optimizing dynamic stiffness • Overall dynamics and rigidity of the machine.
and negating chatter.
When retuning, it is best to slightly under-tune the bar. For this reason, the tuning
process focuses on identifying the adjusting screw setting where chatter starts,
and then backing off the screw by a 1/2 turn in the negative direction.
Retuning a Tunable Boring Bar

1. Loosen both clamping screws.
2. Turn the adjusting screw in the positive direction until it becomes snug. The adjusting screw becomes snug when it locks the tuner mass.
3. Turn the screw one complete turn in the negative direction and take a test cut.
4. Repeat Step 3 until chatter is eliminated.
5. (A) Once chatter is eliminated, note that it starts between the current screw setting and one turn in the positive direction. Make 1/4 turn adjustments within
this range, taking test cuts for each setting, until you can identify the adjusting screw setting that causes chatter to start. (B) Once the adjusting screw setting
that causes chatter is determined, back the adjusting screw off a 1/2 turn in the negative direction.
6. Tighten both clamping screws and take a test cut to confirm desired results.
1. 2. 3.
4. 5. 6.
Screw-On Adapters
Screw-On Adapters
The universal design of Kennametal Screw-On Milling Cutter Adapters enables old
and new tool styles to be used interchangeably yet maintain a rigid connection.
All adapters offer superior runout accuracy, high metal removal rates, and
through-coolant capability. Screw-On Milling Cutter Adapters can be used with
Kennametal’s wide range of best-in-class inserts to guarantee excellent cutting
results, performance, and productivity.
Screw-On products can also be used with a variety of machining applications
ranging from low-speed milling applications to rates greater than 20,000 RPM,
with the added feature of coolant directed to the cutting edge. The system’s
accuracy, repeatability, and stability should be equal or greater to the
performance of any similar systems on the market today in all applications.
Features, Functions, and Benefits

F
• All adapters have through-coolant capability.
• All products are stock standard products. E
• High accuracy — low runout.
• Stable system for helix, pocket milling, contour cutting, and ramping.
• KM™, HSK, and steep taper prebalanced to G6.3 at 16,000 RPM.
• Extensions and reducers are designed with through-coolant prevision.
• The fine-tuned Screw-On indexable end mill cutters and the KM/ERICKSON™ A
toolholders together with a wide range of best-in-class inserts ensure C D B
excellence in cutting results, performance, and productivity.
A. Ground pilot and face for high rigidity and accuracy.

B. Extended shanks have slow taper for added rigidity.

C. Thread locking system.
D. Through coolant on all adapters.
E. Designed for long reach.
F. Balanced.
Applying Screw-On Adapters
Heavy-Metal Adapters Extensions with Weldon® Shank

• Devibration extensions with heavy metal (Densimet D176).
™
• Screw-On type extension with Weldon shank, as per DIN 1835-B.
• Internal threads with accurate mating surface for best possible concentric • Shank manufactured as per DIN 1835-B, internal-coolant capability.
and axial runout with the extended tools.
• Through-coolant capability.
Reducers Extensions
• Adapter uses Screw-On tools with smaller size. • Adapter uses Screw-On tools with larger thread size.
• Through-coolant capability. • Through-coolant capability.
• Mating surface helps generate accurate concentric and axial runout. • Mating surface helps generate accurate
concentric and axial runout.

Through-Coolant Shell Mill Adapters
Tightening Torque Milling Head
Connecting Tightening Mounting key size

thread size torque (mm)
M10 40 Nm 15
M12 60 Nm 17
M16 80 Nm 24
Through-Coolant Shell Mill Adapters
Shell mill adapters with high-pressure and high-volume through-coolant capability

are now available as standard offerings. Their unique design enables maximum
coolant flow to be channeled directly to a tool’s cutting edge.
These latest shell mill adapters with through coolant are ideal for holding
indexable milling cutters. Together, the toolholder and cutter ensure excellence
in tool life, surface quality, and productivity. With this combination, high-pressure
or high-volume coolant can dramatically improve surface finishes, reduce tool
wear, decrease cutting force, and control chip shape and evacuation. This
makes through-coolant shell mill adapters perfect for machining hardened
steels and other difficult-to-cut materials like titanium.
Options Coolant Flow Options
• Extended lengths available in standard stocked offering. • Through holes in the face of the pilot.
• Drive keys upgraded to high-strength material, allowing • Through the center.
for high-torque capability.
• Adapters are set for form AD coolant and can be converted
to form B flange coolant using adjusting screws.
• No extra components necessary to buy for standard tools.
Collet Chuck Styles
Collet Chuck Styles
TG Collet Chucks
Primarily for gripping straight shanks, TG collet chucks are the ERICKSON™
industry standard. These chucks offer flexibility for drilling, milling, and tapping
applications and are also capable of gripping Whistle Notch™ cutters. TG collet
chucks should be used for medium to light operations.
TG collet chucks have a range of dedicated milling and tap collets available. • Clamping range of 0,3mm (.016").
Balanceable locknuts are offered for operating at relatively high speeds. • Good rigidity and gripping power of 3:1.
Sealing/coolant locknuts and bonded collets are also available for chucks • Good concentricity.
utilizing through coolant.
ER Collet Chucks
As the DIN 6499 industry standard, ER collet chucks are designed to grip straight
shanks. They are flexible for drilling, light milling, and tapping applications. ER
collet chucks are used for medium to light applications at medium speeds.
Dedicated tap collets are available for this style collet chuck. For ER collet chucks
• Wide clamping range of 1mm (.040").

using through coolant, sealing and coolant locknuts are available.
• Fair rigidity and gripping power of 2:1.
• Good concentricity.
(continued)
Collet Chuck Styles
Collet Chuck Styles (continued)
DA Collet Chucks
DA collet chucks are an ERICKSON™ industry standard. They are intended for Milling and tap collet styles dedicated to the DA style are available. These chucks
gripping straight shanks, but the DA style also has the ability to grip drill margins. can also make use of bonded collets when employing through coolant. DA collet
This eliminates center drilling by shortening the drill. DA collet chucks also offer chucks can utilize three styles of locknuts.
flexibility for drilling, milling, and tapping.
• Clamping range of 0,8mm (.031").
• Fair rigidity and gripping power of 1:1.
• Concentricity >0,025mm (.001").
DA — 01 Series
Extended Nose Style
Long nosepiece bearing and compensating locknut delivery offer
proper axial position and prevent twisting. This style is ideal when
extreme accuracy is required.
DA — 04 Series
Close Center Style
Designed at the minimum safe outside diameter to solve close center problems.
This style should be used where reach and close proximity of workpiece problems
are encountered.
DA — 08 Series
Stub Nose Style
This DA style has a compensating nose ring with the locknut that allows collets to
find their own axial position and prevent twisting. They should be used when
better rigidity is required.
Collets
TG • Tremendous Grip
• Provides Tremendous Grip and accuracy for all drilling applications.
• 0,4mm [1/64" (.016")] range of collapse.
• Grips on back taper and margin of drill for maximum feed rates and more accurate holes.
• Manufactured to DIN 6499 Class 2 accuracy.
TGC • Tremendous Grip Coolant

• Rubber-filled slots seal collet for coolant-fed tool applications.
• Suitable for coolant pressure up to 100 bar (1500 psi).
• Unique design features permit easy entry into nosepiece.
• Available from stock in all popular sizes.
• Fits all standard TG-style collet chucks.
• 0,13mm (.005") range collapse.
• Design enables flutes of drills to enter collet, unlike competitive designs.
TGHP • Tremendous Grip High Precision

• Twice as accurate as standard TG- and ER-style collets.
• Can be used in all standard TG-style collet chucks.
• 0,25mm (.010") range of collapse.
TGCHP • Tremendous Grip Coolant High Precision

• Unique design features permit easy entry into nosepiece.

TGNP • Tremendous Grip Non-Pullout, Weldon® Style

• Positive retention and drive provided by drive wedge in collet.
• Eliminates inaccuracy created by solid end mill holders.
TGST • Tremendous Grip Single-Angle Tap Collet

• Designed to grip the tap on the shank and square.
TGSTC • Tremendous Grip Single-Angle Tap Collet, Coolant Style

• Designed to grip the tap on the shank and square.
Collets
ER • Single Angle
• Provides good grip and accuracy for all drilling applications.
• Wide clamping range.
• Available in both inch and metric bores.
• 1mm (.040") range of collapse.
ERTC • Single-Angle Tap Collet

• Designed to grip taps on shank and square to eliminate slippage.
• Fits all standard ER-style collet chucks.
ERTCT • Single-Angle Tap Collet with Axial Compensation

• Designed to grip taps on shank and square to eliminate slippage.
• Tension only, cost-effective solution for machines that require axial compensation for tapping.
• Fits all standard ER-style collet chucks.
DA • Double-Angle
• 0,8mm [1/32" (.031")] range of collapse.
DAC • Double-Angle Coolant
• Rubber-filled slots seal coolant-fed tool applications.
• Fits all standard DA-style collet chucks.
DANP • Double-Angle Non-Pullout — Weldon® Style

• Designed to grip end mills with Weldon-style shanks.
• Positive retention and drive provided by drive wedge in collet.
• Eliminates inaccuracy created by solid end mill adapters.
• Fits all standard DA-style collet chucks.
Collets
TG Collet Series
The TG collet series is the first choice when high precision, gripping torque, and The taper’s slow angle produces a sticking action, so collets must be snapped
versatility are required. These single-angle collet chucks grip at approximately into the locknut before assembling the locknut onto the chuck. Follow the
3:1 for grip torque versus tightening torque without a stop screw. procedure on page M103 for assembly/disassembly instructions.
Standard Collet
• 0,40mm (.016") maximum collapse.
Bonded Seal Collet

• 0,13mm (.005") maximum collapse.
• 100 bar (1,500 psi) coolant pressure.
DA Collet Series
DA-style collet chucks have a grip of approximately 1:1 tightening torque

versus grip torque.
ER Collet Series
The ER collet series is an international standard style used for many
applications. Collets from this series are ideal for boring, milling, reaming,
tapping, and grinding.
ER collets are manufactured from alloy steel and hardened for long life.
They offer a grip of approximately 2:1 tightening torque versus grip torque.
See page M103 for assembly/disassembly instructions.
Collets
TG and ER Collet Assembly/Disassembly Instructions
• First, place the locknut with nose ring over collet nose. Apply force on the • To remove the collet from the locknut, hold the nut firmly in one hand and
locknut until it snaps into place. The nose ring is now seated into the collet apply a bending action on the collet with the other hand until the collet snaps
undercut and should turn freely. free from the nose ring.
NOTE
Inserting the cutting tool less than 2/3 the gripping length into the collet can permanently damage the collet. The full length of the gripping bore needs to be
maintained to achieve maximum accuracy and safety. Collet accuracies are based on size-for-size conditions. Using the collapsible range can influence the
accuracy and gripping powers. Never try to stretch collets by clamping oversized cutting tools.
ER-Style Collet TG-Style Collet
Maximum Runout Error

L = 50mm (1.969")
D = 18–28mm (.71–1.02")
L = 50mm (1.969")
D = 10–18mm (.39–.71")
L = 25mm (.984")
D = 6–10mm (.24–.39")
L = 16mm (.630")
D = 3–6mm (.12–.24")
L = 10mm (.394")
D = 1,6–3mm (.06–.12")
L = 6mm (.236")
D = 1–1,6mm (.04–.06")
0,008mm 0,010mm 0,015mm 0,020mm

(.0003") (.0004") (.0006") (.0008")
TGHP (precision) = TG (standard) =
DIN 6499 Class 1 ER — DIN 6499 Class 2
Gripping Strength Comparison Chart
Gripping Strength Comparison Chart • Metric
ER collet chuck TG collet chuck standard Slim Line

based on ER40 based on TG100 hydraulic hydraulic
mm Nm mm Nm mm Nm mm Nm
3 — 3 — 3 — 3 —
4 — 4 — 4 — 4 —
5 — 5 — 5 — 5 —
6 38 6 — 6 12 6 26
8 52 8 115 8 30 8 50
10 70 10 144 10 40 10 80
12 103 12 300 12 70 12 115
14 108 14 312 14 100 14 160
16 118 16 325 16 135 16 200
18 156 18 339 18 180 18 250
20 206 20 384 20 220 20 230
25 255 25 536 25 500 25 —
32 — 32 569 32 700 32 —
40 — 40 — 40 — 40 —
50 — 50 — 50 — 50 —
Gripping Strength Comparison Chart • Inch

ER collet chuck TG collet chuck standard Slim Line

based on ER40 based on TG100 hydraulic hydraulic
in ft. lbs. in ft. lbs. in ft. lbs. in ft. lbs.

1/8 — 1/8 — 1/8 — 1/8 —
3/16 — 3/16 — 3/16 — 3/16 —
1/4 28 1/4 — 1/4 9 1/4 19.2
5/16 38 5/16 85 5/16 22 5/16 —
3/8 52 3/8 106 3/8 30 3/8 59
7/16 — 7/16 — 7/16 — 7/16 —
1/2 76 1/2 221 1/2 55 1/2 89
9/16 80 9/16 230 9/16 74 9/16 —
5/8 87 5/8 240 5/8 100 5/8 148
11/16 115 11/16 250 11/16 129 11/16 —
3/4 152 3/4 283 3/4 148 3/4 155
7/8 — 7/8 — 7/8 — 7/8 —
1 188 1 395 1 369 1 —
1 1/4 — 1 1/4 420 1 1/4 516 1 1/4 —
1 1/2 — 1 1/2 — 1 1/2 — 1 1/2 —
2 — 2 — 2 — 2 —
NOTE: Torque values in in. lbs.
Minimum values calculated for maximum bore size and minimum shank size.
Maximum values calculated for minimum bore size and maximum shank size.
Gripping Strength Comparison Chart
Gripping Strength Comparison Chart • Metric

Shrink Fit
milling
chuck standard (Nm) high torque (Nm)
mm Nm min max min max
3 — 3.3 11 — —
4 — 5.2 16 — —
5 — 6.8 20 — —
6 — 19 116 — —
8 — 26 176 — —
10 — 91 312 — —
12 — 132 445 269 582
14 — 169 546 346 723
16 — 253 587 444 779
18 — 304 865 540 1101
20 1127 412 1049 654 1292
25 1666 901 1896 1233 2227
32 2347 1033 2079 1338 2384
40 — 1907 3482 2432 4007
50 — 2651 4465 3029 4843
Gripping Strength Comparison Chart • Inch

Shrink Fit
milling
chuck standard (ft. lbs.) high torque (ft. lbs.)
in ft. lbs. min max min max

1/8 — 3.2 13 — —
3/16 — 4.6 19 — —
1/4 — 13 86 — —
5/16 — 18 117 — —
3/8 — 53 196 — —
7/16 — 65 269 — —
1/2 — 111 340 225 455
9/16 — 160 410 285 535
5/8 — 172 442 307 576
11/16 — 262 648 427 814
3/4 831 336 797 509 970
7/8 — 363 791 524 951
1 1229 674 1382 939 1647
1 1/4 1731 784 1445 1115 1775
1 1/2 — 1132 1818 1389 2075
2 — 1942 3049 2357 3465
NOTE: Torque values in in. lbs.
Minimum values calculated for maximum bore size and minimum shank size.
Maximum values calculated for minimum bore size and maximum shank size.

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KEN_TOOLINGSYSTEMS11_M000_M001.

qxp:WIDIA 11:46 AM Page L2

The Correct Spindle Connection

7/24 ISO Taper

D D2 D3 D4 D5 D10 (max) F2 (min) L2 L3 L4 L5

BTKV — Taper Face CVKV — Taper Face

BT — JIS B6339 CAT (CV) — ANSI B5.50

DV — DIN 69871 Form B — Flange Coolant Entry Ports

QC — ERICKSON™ Quick Change R8 — Bridgeport

50 69,85 88,90 73,66 127,00 30,73 15,09 3,58 1" - 8

To learn more, scan here.

Visit www.kennametal.com or contact your local Authorized Kennametal Distributor.

The Importance of a Strong Connection

Current Spindle Connections

Choosing What’s Right

KM4X™ — The Next Generation Spindle Connection System

The Latest Innovation in Spindle Interface Technology

KM4X three-surface contact for improved stability and accuracy.

Why Bending Load Capacity Is Important

Drilling Turning Deep Boring

Face Milling End Milling

Maximum Tangential Load for KM4X100

The KM Coupling Rigidity

Face and Taper Contact Clamping Mechanism

KM tooling is designed to have simultaneous taper and face contact. Previous

Sealed through-the-tool coolant is offered on all standard KM tooling and

Fail-Safe Tool Orientation

HSK Quick-Reference Identification

HSK Quick-Reference Identification (continued)

Forms E and F Form T

Kennametal primary offering Secondary styles available upon request

Taper face tool’s axial position is maintained

Steep Taper V-Flange

Steep taper Form B coolant

Pull-Back System Form B Coolant

coolant through coolant through

Manual Clamping System

KM-LOC™ Clamping System

reduces the time required for manual tool changes.

KM-LOC II™ Clamping System

Rapid Clamping System

Rapid Plus Clamping System

KM™ Manual Clamping Units

KM Manual Clamping System • Single-Pin Design

KM Manual Clamping Components • Functional Definitions

KM™ Manual Clamping System • Four-Pin Design

KM Manual Clamping Components • Functional Definitions

KM Manual Clamping Operating Instructions (KM32–KM80)

KM Manual Clamping System • Operating Torque

KM torque torque actuation

KM Manual Repair Package Components (KM32–KM80)

KM Manual Repair Package Components • Functional Definitions

KM™ Manual Clamping Unit • Disassembly Procedures

KM hex DO NOT USE silicone cleaner or WD-40™-type lubricants.

KM™ Manual Clamping Unit • Disassembly Procedures (continued)

KM™ Manual Clamping Unit • Assembly/Timing Procedures

KM™ Manual Clamping Unit • Assembly/Timing Procedures (continued)

KM-LOC™ Clamping Units

KM-LOC Locking Sequence