During high-performance reaming of through-holes or deep blind holes, standard solutions often reach their technical limits. Long-chipping materials and those that are difficult to cut make it necessary to modify the tool system as well as the internal coolant supply. Accordingly, Horn Cutting Tools will announce the availability of bespoke, additively manufactured coolant discs that can be screwed on to the tool shank to ensure reliable chip control.
It results in extended tool life due to the direct, targeted cooling and, above all, reliable chip removal. Additive manufacturing enables the coolant outlets to be freely designed so the form of the outlets prevents chips from entering. Furthermore, the cross-section and exit angle of the cooling channel can be adapted to suit the specific machining task and the material to be processed. Due to the polished and coated flutes, the tool shank facilitates removal of chips from the machining zone. Th
e combination of the shank, the solid carbide reaming inserts and 3D-printed coolant discs demonstrates Horn’s expertise in machining of drilled holes and reaffirms the company’s status as a problem solver and technology leader.
Horn is extending its 406 tangential milling cutter system to include an insert with wiper geometry for finishing. The new insert has been developed in response to demand from Horn’s customers, reflecting the fact that surface finish requirements are constantly increasing. The new geometry produces very high surface quality, even at elevated feed rates, resulting in shorter machining times. Moreover, the geometry makes it possible to reduce the need for subsequent grinding processes. The single-edged finishing insert is used in the 406 system’s 90-degree shoulder mills. Only one insert with wiper geometry is required in the tool body; the remainder may be standard 406 system indexable inserts.
The wide finishing insert is available in grade AS4B for the workpiece material groups P and M, and in grade AS46 for workpiece material group K. Horn will show its expanded range of monocrystalline diamond (MCD) tipped, ball nose end mills for brilliant-finish machining of non-ferrous materials. The new, larger diameter variants reduce machining time, ensure tight tolerances and produce finishes in the nanometre range. The expanded portfolio of end mills is available from stock in diameters of 6 mm, 8 mm, 10 mm, 12 mm and 16 mm.
All variants are single-edged, feature an internal coolant supply and have a solid carbide shank for vibration-free machining. The range of applications for brilliant-finish milling is huge. In the tool and mould making industry, the method saves on polishing of freeform surfaces while also increasing quality in terms of precision, contour accuracy, flatness and surface finish. MCD tools are therefore used where the surface quality of the mould needs to be matched by the finish of the parts being produced, such as PET blow moulds and chocolate moulds as well as applications in the medical technology sector. In addition, Horn offers MCD solutions for brilliant-finish turning. To allow users to reduce cycle times and cut production costs during series production on turning and mill-turn centres, Horn has introduced customised carbide form inserts for machining diameters from 16 mm upwards, as will be explained on the stand where representative products will be displayed. Based on its 117 tool system, the patented insert seat guarantees high concentricity and minimal axial runout as well as high repeatability of insert exchange to within microns.
Precision-ground cutting edges deliver high accuracy and surface quality. Financial savings are gained, as the option to exchange the insert leads to lower tool costs and reduced machine downtime. The internal coolant supply to both cutting edges via the round shank cools the contact zone and carries chips away efficiently.
Horn offers the tools in profile widths of 16 mm, 20 mm and 26 mm. Special profiles can be precision ground to suit a diverse range of applications, maximum profile depth being 17 mm. The insert coating is selected for each application and is available for material groups P, M, K and N. Round shanks with diameters of 16 mm, 20 mm and 25 mm in the A and E designs are standard. All variants have an internal coolant supply. Visitors to the Horn stand will learn that new toolholder variants are available for the company’s S100 system to enable parting off on turning centres that have feed movement in the Y-axis. The method enables effective parting and grooving using high cutting parameters, resulting in short machining times. Furthermore, due to the extra stability of the system, there is the option to part off large diameters with a compact toolholder and to use narrow groove widths.
High moments of force occur when parting off workpieces of larger diameter, but the space available in a machine often does not allow tools of large cross section to be used. With the new design of toolholder, the cutting forces are diverted to the main cross section of the insert. It results in increased rigidity of the system as a whole for any given toolholder, enabling higher feed rates to be used.
Horn offers two holder variants for the parting off process. For the 842 and 845 modular grooving system, there is a cartridge with cutting widths of 3 mm and 4 mm. There is also a reinforced grooving blade in identical widths. Both variants are equipped with an internal coolant supply via the clamp and through the support. Maximum groove depth is 60 mm. In addition, the S100 system provides an option for direct cooling through the cutting insert.