Horn MACH 2020 preview information

1. Printed coolant attachments for reamers

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. The 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.

2. Milling system gains wiper geometry insert

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.

3. Extended end mill range for brilliant-finish machining

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.

4. Custom carbide form tools for 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.

5. Efficient parting off and grooving along the Y-axis

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.

6. New IG35 coating has high heat resistance

The new IG35 insert coating to be launched at the show allows Horn to offer high performance and long tool life when machining stainless steels, titanium alloys and superalloys. In combination with the 3V and FY geometries, the aluminium titanium silicon nitride coating prevents the formation of built-up edges due to the low coefficient of friction. Due to HiPIMS technology, the coating delivers smoothness and high heat resistance. Furthermore, the coating is free from defects such as inclusions or faults at the cutting edge.

Horn adapts the coating system, the chipbreaker geometries and the micro-geometries to applications such as internal and external grooving, longitudinal turning, circular interpolation milling and solid carbide milling. The user can achieve higher cutting parameters, enabling shorter cycle times, which in turn has a positive impact on unit production costs. Use of the new coating also leads to higher surface quality.

The IG35 coating is available for the S100, S101, S224, S229, and S274 grooving systems as well as for the circular interpolation milling and solid carbide milling systems.

7. New insert clamping system for grooving and boring

Horn will promote a new style toolholder for its Supermini type 105 grooving and boring tools. With the novel design, clamping of the carbide insert uses a tensioning wedge on the face rather than the circumference of the tool, as was previously the case. It enables the insert to be held in place with more force, which in turn makes the entire system more rigid.

Additionally, the new clamping design results in a higher level of repeatability when changing the insert and allows better use to be made of the space available for mounting it. This is a significant advantage when working with Swiss-type lathes, as it enables users to change the insert without removing the toolholder.

The Horn Supermini tool system is suitable for boring holes from 0.2 to 8 mm in diameter. With over 1,500 varieties available as standard, there is a solution to suit every user. In addition to boring, the system is designed for grooving, chamfering, threading, broaching and other machining operations. The cutting geometries and the substrates can both be adapted to the materials being machined.

8. New tool for skiving larger gears

The skiving method for producing large gear modules on rigid turn-milling and mill-turning centres offers the benefit of shorter machining times, especially for internal teeth. Based on its experience with manufacturing small, solid carbide tools for gear skiving, Horn is now applying its expertise to the machining of larger modules.

The manufacturer’s latest tool system, which will be on the stand at MACH 2020, utilises S117 single-edge inserts whose patented seat and threaded connection ensure precise positioning and clamping for high rigidity and repeatability of exchange. A ground chipbreaker enables effective swarf removal from the machining zone, all cutting edges being cooled directly by an internal coolant supply.

At the outset, Horn discusses each tool design with the user and offers recommendations for the process before a gear skiving tool is specially designed and manufactured for the application, the feasibility of which is verified on an individual basis prior to implementation.

The tool manufacturer’s portfolio comprises a wide range of products for machining various gear tooth geometries from module 0.5 to module 30. Whether this involves gear teeth for spur gears, shaft/hub connections, worm shafts, bevel gears, pinions or customised profiles, all can be manufactured cost-effectively using milling or broaching tools, while the skiving tool range is further testament to Horn’s gear tooth manufacturing expertise.

9. Supermini HP and new holder variants

New also from Horn will be HP geometry for its Supermini system. The multi-functional tool is suitable for a range of applications including drilling, boring, face turning and skimming. The new geometry enables higher cutting data and the wiper geometry produces high surface qualities, even at elevated feed rates. When boring, an accurate 90-degree shoulder is achieved at the base of blind holes.

In addition to turning operations, the system is suitable for drilling into solid material in diameters ranging from 3 to 7 mm. The performance data of the tool cannot compete with normal drills, but there is often a lack of locations for cutters in a machine. The Supermini HP offers the option of immediately boring an inner contour after drilling, without needing to change the tool. With the single-edged version, various bore diameters can be produced using a single tool.

Horn provides tools with and without a chipbreaker for optimum chip control. For turning, the variant with a chipbreaker is recommended. The non-chipbreaker version is best for drilling. The EG35 coating allows versatile machining of both normal and stainless steels and the slightly twisted flute removes chips from the machining zone efficiently.

10. Tangential milling system for high accuracy and surface quality

Horn is continually developing its M610 tangential milling system. In addition to the side milling cutter, the range has been extended to include a 90-degree shoulder mill and new carbide grades. The patented tool system, which will be on show at MACH 2020, ensures a soft cut with positive radial and axial rake angles.

The precision-ground, indexable inserts have six cutting edges, giving low cost per edge as well as high accuracy and surface quality. The additional flank chamfer ensures a stable wedge angle and smooth milling. Horn provides the inserts with substrates AS46, IG35 and NE2B in right and left hand versions and with corner radii of 0.4 mm or 0.8 mm for machining different materials. Maximum depth of cut is 9.9 mm.

Cutters are available in the following diameters: 50 mm (5 inserts), 63 mm (6 inserts), 80 mm (8 inserts), 100 mm (10 inserts) and 125 mm (12 inserts). A special surface treatment protects the tool body against abrasive chips.