A new, modular system for reaming large diameter holes will be on show for the first time at MACH on the Horn Stand 340 in Hall 20. The DR-large reamers have exchangeable heads with multiple solid carbide inserts, resulting in high cutting values, short cycle times and low costs. The insert seat has been designed for micron precision changeovers and tool setting is unnecessary when exchanging the head.
The system is suitable for bore diameters from 140 to 200.2mm. Six cutter heads cover the range of diameters in 10mm increments, with two sizes fitting on each size reamer shank. Modular construction and an ABS-compatible interface mean the tool can be extended to any length.
Also new at MACH will be Horn’s products for circular interpolation milling of holes down to 8mm diameter. The triple-edged 304 system offers a versatile, productive solution for internal groove, thread and profile milling. The insert has a cutting diameter of 7.7mm.
The inserts are available in widths of 0.5, 1, 1.5 and 2mm. For milling circlip grooves, Horn offers the system with cutting widths of 0.8, 0.9, 1.1 and 1.3mm. To enable the milling of chamfers, angles of 45, 30 and 15 degrees are available. Regarding substrates, Horn uses coated grade EG55 for general steel machining and IG35 for superalloys.
Horn will also explain the importance of two new high-performance coatings, the IG6 and SG3. Despite being less than 0.005mm thick, such coatings can extend service life by a factor of 10 or more. IG6 is a copper-coloured AlTiSiN coating for steels in groups P and M with Horn’s S224 and S229 grooving systems. In conjunction with an adapted carbide substrate, the coating allows faster material removal rates. Horn’s SG3 coating is designed for machining titanium alloys and superalloys as well as hard turning and grooving.
Also making a debut will be Horn’s expanded DS range of solid carbide end mills with a new geometry for HPC milling of high strength steels. It excels in dynamic roughing as well as in standard roughing cycles. Different helix angles create an irregular tooth pitch, making the operation smooth. The end mills are available in diameters from 2 to 16mm with four or five flutes.
The optimised face geometry reduces the cutting pressure during linear or circular ramping. Improved chip spaces ensure optimal process reliability during chip formation and removal. Smooth operation means that high surface quality can be achieved during side milling. HPC milling of high strength steels at fast metal removal rates places significant demands on the tools and the new carbide substrates and tool coating make this process feasible. Horn relies on the ES3P grade, again with a HiPIMS coating.
