HORN Mastering Processes: Swiss Turning and Micromachining

 

Mastering Processes: Solutions for Micromachining and Swiss-type Turning

Outer diameters of 0.1 mm (0.004″), recesses of 0.5 mm (0.020″) and feed rates of 5 µm (0.0002″) – welcome to the world of micromachining! Screws for hearing aids, balance weights for automatic wristwatches or micro-turned parts for medical assemblies: Manufacturing such parts requires know-how, precise machines and special tools. With cutting depths of down to 0.01 mm (0.0004″), users place very high demands on the tools used. They include shiny surfaces and high dimensional accuracy of the components through the use of low cutting force. HORN has developed suitable solutions with the μ-Finish system for micromachining as well as with other tool systems and manufacturing processes for Swiss-type lathes.

The demands on the tools for micromachining with Swiss-type lathes are high. Due to the sometimes very small cutting depths, the tool edges must be very sharp in order to keep the cutting force as low as possible. However, the ground cutting edges are susceptible to microchipping. Even limited chipping in the range of a few µm at the cutting edge has a negative effect on the surface of the machined workpiece. Furthermore, the surface quality of the rake face plays an important role. To counteract built-up edges, the rake face must have good sliding properties. For this reason, it is finely ground or polished.

Changeover Accuracy of 2.5 µm

Clamping of the inserts is another important point in tool design. When machining turned parts of small diameter, the centre height of the tool must be precisely measured. Even slight deviations in centre height have a negative effect on the quality of the workpiece when machining the smallest diameters. In the best case, the machine operator should be able to turn the insert without having to readjust the centre height. With the μ-Finish system, HORN offers a changeover accuracy of +/- 0.0025 mm (0.0001″) when indexing a double-edged insert. This is made possible by the precise peripheral grinding of the insert in conjunction with the stable insert seat. In addition, the contact surfaces of the square shank toolholder are also ground, which has an effect on the holistic precision of the HORN system.

The grinding of a sharp, flawless tool cutting edge requires a lot of know-how. Grinding wheels with the finest grits, special new grinding techniques and a microscope with 400x magnification are necessary to ensure that the tool performs as required. In the process, every batch of the μ-Finish system produced is subject to 100 per cent inspection. Important quality assurance criteria are the tightly toleranced high surface quality of the rake and flank surfaces, the centre height and, in particular, the sharpness of the cutting edge. There must be no visually recognisable irregularities on the cutting edge with the µ-Finish system.

HORN presents itself as a holistic supplier of tools for all Swiss-type machining operations. The extensive insert portfolio can be easily adapted to the requirements of different processes in sliding-headstock turning. Close partnerships have been established with the companies Graf Werkzeugsysteme, Boehlerit and W&F Werkzeugtechnik to provide solutions for the interfaces between the cutting insert and the machine, including for ISO tools.

Broad Knowledge

Horn’s know-how does not only apply to cutting tools. The tool manufacturer also supports its customers and partners with knowledge of the correct application data and the development of new tool systems and manufacturing processes for sliding-headstock operations. This includes, for example, competence in driven tools, tool holders for backworking and entire tool solutions.

WANGEN: Hygenic Progressive Cavity Pump

 

Hygienic conveying and dosing applications in the Food & Beverage, Pharmaceutical and Cosmetics industry

The WANGEN MX progressing cavity pump precisely fulfills the demanding requirements of the food, pharma and cosmetics industries. State-of-the-art design features allow excellent ease of cleaning and maintenance. The pump is available with all common certifications.  And thanks to its great pressure stability, the MX can also be used in many ways in the chemical, paint and paper industries, among others.

Design Features:

  • Modular design
  • Quick to disassemble, e.g. due to clamp locks
  • Robust cardan joint with hygienic joint liner
  • EvenWall® stators with even elastomer wall thickness
  • Solid bearing housing with generous sealing space

Benefits:

  • 10 bar per pressure stage thanks to EvenWall® technology
  • Compact dimensions with high pressures
  • Gentle product delivery
  • Quick and easy cleaning, CIP and SIP capable
  • Low dead space, hygienic design
  • Easy to service

Please contact us for more information on WANGEN Pumps for any of  your requirements in the Food & Beverage, Pharmaceutical and Cosmetics Industries.

 

HORN Mastering Processes: High Feed Milling

 

 

Tool Systems manufactured by Paul Horn GmbH offer users the ability to design machining processes for high productivity and cost efficiency. Especially in tool and mould making, high feed milling can be used economically and productively. High performance milling is not only defined by high infeeds, but in high feed milling also by small infeeds coupled with high traverse speed of the cutter.

 Machining applications have changed and challenges have become more complex and demanding. Shorter product life cycles and reduced development times dictate that several different components must be produced on one machine in shorter cycle times. For the tool manufacturer, this requires designing tool systems for the different applications. It means, for example, that a tool may not only be used for corner milling, but should also have the optional ability to plunge cut. Another aspect is modern machine dynamics. The acceleration and deceleration of the axes as well as their synchronisation have been significantly optimised. For relatively new technologies such as trochoidal and high feed milling, tool systems must be able to withstand the high dynamic loads.

Low Infeed – High Metal Removal Rate

A few years ago, Horn introduced a system for high feed milling – DAH cutters for face milling. Due to the load being in the axial direction, the tool and spindle mainly experience compressive force and the shear forces are relatively low. Due to their low tendency to vibrate, the tools are able to withstand the high loads typically generated by a feed per tooth of fz  = 1 mm at cutting depths ap up to 1.2 mm. The large radius on the main cutting edge of the three-edged inserts creates a soft cut, ensuring an even distribution of the cutting forces and long tool life. On the inside, a small cutting edge radius ensures trouble-free and fast plunging. A primary and secondary clearance angle leads to a stable wedge angle and very good cutting edge stability. Due to significantly higher feed rates compared with conventional milling, metal removal rate in high feed milling is significantly increased, despite the lower infeed depths.

 

 

KNOLL Systems for Chip Processing

The treatment of chips has many advantages: they are dry and separated by type, so disposal costs are low. Depending on the material, it may even be possible to sell the chips. A system for chip treatment includes different components depending on the requirements: conveyor and collection devices, magnetic separator technology, filter and volume-reducing briquetting presses. Containers or chip silos are also required. The components can be linked to one another and operated completely automatically.

  • Central Chip Processing with by a lift-tip device, chip breaker, conveyor to chip centrifuge, discharge via scraper belt conveyor to containers via a swivel chute. Fluid Centrifuge for cleaning of the separated oil.

Areas of application

The chip processing system is suitable for both semi-automatic and fully automatic processing of metal chips. Chips are transported from the processing machines by automatic conveyor systems or by operating personnel with trolleys/containers. The system is used in virtually all production areas of the machining industry. Different materials (e.g. aluminium, steel or cast iron) can be processed by means of separate systems.

Properties

  • Chip drying is essential to ensuring safe transportation on public routes
  • Volume reduction reduces storage and transportation costs
  • Recovery of chips and cooling lubricant protects the environment and reduces costs

Possible main components

  • Lifting/tilting device
  • Chip reducer
  • Chip centrifuge
  • Chip conveyor
  • Separating channels
  • Magnetic separator technology
  • Briquetting press
  • Cooling-lubricant filter and collecting container
  • Control technology and cabling
  • Container filling
  • Chip silo

 

 

HORN: New Coating RC2 / RC4

New Horn coating RC2 / RC4

With the new RC2 and RC4 coatings, Paul Horn GmbH is exhibiting new developments in the field of high-performance tool coatings. The high toughness and hardness allow the machining of steels at high cutting speeds and lead to a significant increase in tool life. The high temperature resistance enables productive use in dry machining as well as with minimum quantity lubrication. Numerous tool systems are available from stock with the new HiPIMS coating. In-house coating enables fast delivery times even for special tools.

Horn is constantly investing in new and modern technologies. In 2015, the company CemeCon delivered the world’s first of three HiPIMS systems to Horn. The High Power Impulse Magnetron Sputtering technology brings specific advantages and new possibilities in the coating of precision tools. It enables the build-up of dense, compact coatings that are very hard and tough. The coatings have a homogeneous structure and uniform coating thickness even if the tool geometry is complex. Research and development of new and existing coatings and technologies is a central component of success. Horn employs a team of engineers who work exclusively on this subject. Since in-house coating started, research and development projects have been carried out in cooperation with equipment manufacturers.