Horn Milling System 406 with Wiper Geometry

Milling System 406 with Wiper Geometry                     

Paul Horn GmbH has extended the 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 quality requirements are constantly increasing. The new geometry produces very high surface qualities, even at high 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.

Please contact us for more information.

 

KNOLL AerosolMaster® System with ATS Technology

KNOLL Maschinenbau, Bad Saulgau, has replaced its Minimum Quantity Lubrication system ControLube with the AerosolMaster®system, which is based on ATS technology (aerosol dry lubrication). The system can be supplemented by cryogenic cooling technology. This has come about by the KNOLL acquisition of Rother Technologie GmbH & Co. KG, Bad Urach, including all of its patents, retroactive to July 1, 2019.

For five years, KNOLL Maschinenbau, one of the leading suppliers of conveyor and filtration systems for chips and cooling lubricants in metal processing, has been offering an alternative to wet-cooling lubrication. Managing Director Matthias Knoll is certain that “There are production areas where the future clearly belongs to minimum quantity or dry lubrication.”

Matthias Knoll is sticking to his opinion, even though the company is now discontinuing its previous MQL product – the high pressure ControLube system: “Because of its lubricating results, ControLube is a very good system that produces a particularly fine aerosol. Its disadvantage: It requires a lance through the spindle, which many machine tool manufacturers can not implement. With AerosolMaster®, we have now found an alternative lubrication system that achieves a comparably fine aerosol but is much easier to implement in the machine.”

Rother Technologie. Managing Director Reiner Rother explains: “We were looking for a partner or successor to whom it would make sense to hand over our MQL know-how, which has been acquired over nearly 25 years, and who will continue our products in the long term. KNOLL Maschinenbau, with its experience in the MQL business and its worldwide sales and service structures, was a desirable candidate for us. ”

At EMO, Reiner Rother further described the features of the AerosolMaster® : “Even without a lance in the spindle, we can perfectly lubricate the tool cutting edge and prevent heat from machining.” The technology behind it: The fine aerosol (droplet size 0.1 μm to 0.4 μm) is produced in a pressure vessel via a special venturi nozzle and patented control and regulation technology. Like the usual cooling lubricants, the aerosol is guided along a single channel, for example, through the internal cooling channels of the tool to the cutting edge.

In addition to the high aerosol quality, which has been repeatedly verified at Knoll, Matthias Knoll was particularly impressed by the simple installation: “Not only conventional MQL systems can be converted to the AerosolMaster®. Without much difficulty, it is even possible to convert many wet-cooled machines.”

With the acquisition of Rother, KNOLL has yet another trump card up its sleeve: The AerosolMaster® can be combined with the cryolub® cryogenic cooling technology – also patented by Rother – for example, into the AerosolMaster® 4000 cryolub®. By using liquid CO2, the cutting contact zone can then be cooled down to -78 °C. This is particularly advantageous in the case of heavy-duty machining of titanium and other materials that have a low thermal conductivity. Reiner Rother summarizes this in figures: “With the ‘normal’ AerosolMaster®, we can achieve a productivity increase of 30 to 70 percent; with the cryo system, the increase is even greater, between 70 and 200 percent.”

 

EMO 2019: New Coating IG35 from Horn

New Coating IG35 with High Heat Resistance

The new IG35 insert coating 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. Thanks to HiPIMS coating technology, the coating exhibits very smooth properties and high heat resistance. Furthermore, the tool coating is free from defects such as inclusions or other coating 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 a shorter cycle time, which in turn has a positive impact on unit production costs. The use of the new coating also leads to higher surface qualities.

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.

Please contact us for any information you need on the new coating.

 

 

EMO 2019: New Parting Off Solutions along the Y Axis

Efficient Grooving using High Cutting Parameters

Paul Horn GmbH is offering new tool holder variants for the S100 system for parting off with the feed movement along the Y axis on turning/milling centres. This method enables a very effective grooving process with high cutting parameters, resulting in shorter machining times. Furthermore, there is the option to part off large diameters with a compact grooving tool holder as well as to part off with narrower groove widths.

Large moments of force occur, particularly when parting off workpieces of larger diameter. The space available in a machine often does not allow tools of large cross section to be used. With the new arrangement of the insert in the tool holder, the cutting forces are diverted to the main cross section of the grooving tool. This results in increased rigidity of the system as a whole for a given cross section of the grooving tool holder and allows higher feed rates to be used. The force in the longitudinal direction of the tool means narrower holders can achieve the same system rigidity. In modern generations of turning and milling centres, parting off with the new grooving tools causes the cutting force to be diverted in the direction of the spindle, meaning higher rigidity of the overall.

Horn is offering 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 (0.118″) and 4 mm (0.157″). There is also a reinforced grooving blade, also with widths of 3 mm (0.118″) and 4 mm (0.157″). Both variants are equipped with an internal coolant supply via the clamp and through the support. In addition, the S100 system provides an option for direct cooling through the cutting insert. The maximum groove depth (Tmax) is 60 mm (2.362″). The tried-and-tested grooving insert of the S100 system is used, which is available in various substrates and geometries.

Please contact us for any information you may need on these solutions.

 

EMO Preview: New Insert Clamping System for Horn Supermini

Paul Horn GmBH at EMO 2019
Hall 5 Booth A54

Horn has developed a new tool holder for its Supermini type 105 grooving and boring tools. In the new design, the process for clamping the carbide insert uses a tensioning wedge on the face rather than the circumference of the tool, as was previously the case. This enables the insert to be held in place with more force, which makes the entire system more rigid. Additionally, the new clamping design results in a higher level of repeatability when changing inserts and allows for better use of the space available for mounting it due to the face clamping concept. This is a significant advantage when working with Swiss-type lathes, as it enables users to change the insert without removing the tool holder.

The Horn Supermini tool system is able to bore holes from 0.2 mm 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.