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.
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.
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.
- 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
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.
KNOLL’s LubiCool®-S high-pressure unit is designed for mobile use with machine tools in machining processes, particularly automatic lathes with a fixed/sliding headstock. The unit is used to clean the cooling lubricant and to supply the machine with high pressure coolant.
The potential application areas include
- Challenging machining processes
- Machining operations involving difficult materials (e.g. high-alloy steels, titanium, copper, bronze
- Situations where space for installation is particularly limited
- Initial equipment and retrofitting
For more Product Information: KNOLL LubiCool®-S High Pressure System
New DX8 CrossOver® vise to bring the same benchmark DX-series vise features to the 8-inch vise platform
The Kurt DX8 CrossOver® vise is the newest and largest vise in the DX CrossOver® vise family. We’ve combined the best features of the Kurt D810 and Kurt 3800V vises into a single vise with state-of-the-art features that set a new standard in precision flatness, parallelism and repeatability.
DX8 CrossOver features new body design
The premium, one-piece body design, now standard on all our general-purpose vises was designed using Finite Element Analysis and has 30% Less horizontal (push back) deflection than previous DX models. Less vise-body deflection means more stability than a bolt-on design allows and a lifetime of dimensional precision. It’s the same design we’ve used successfully on 3600V and 3800V models for years.
The DX8 CrossOver® vise features the same bed height and keyway to the stationary jaw face as the D810 and a redesigned nut with lighter weight, a new brush seal design and a larger, stronger bearing pack that’s more durable than previous vise designs.