Turning with form tools allows customers to benefit from economic advantages in series production. Horn offers customised carbide form inserts based on the 117 tool system for machining diameters from 16 mm upwards on turning and mill-turn centres. The patented, precision insert seat of the 117 system guarantees high concentricity and minimal axial runout as well as high repeatability of insert exchange to within microns. The precision-ground cutting edges achieve a high level of accuracy and surface quality. Financial savings are achieved due to the possibility of re-tipping, 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 the chips away efficiently.
Horn offers the tools in profile widths (w) of 16 mm, 20 mm and 26 mm. Special profiles are precision ground to suit the application. The maximum profile depth is tmax = 17 mm. The maximum profile width is w = 26 mm. The insert coating is specially selected for each application and is available for material groups P, M, K and N. The round shanks are available as standard with diameters of 16 mm, 20 mm and 25 mm in the A and E designs. All variants have an internal coolant supply.
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.
The High Requirements of Milling Fibre-Reinforced Plastics
The Machining Task
The machining of CFRPs (carbon fibre reinforced plastics) places high requirements on the tools used, their geometries and coatings. Due to the abrasiveness of carbon fibres in relation to the cutting material, standard tools very rapidly become blunt and the end of tool life is reached after only a few parts. To be able to cut carbon fibres that are laid in a matrix form, increased performance at the cutting edge is required. This statement applies above all if the carbon fibre content is more than 60 %. On milling the peripheral contour on a 21 mm thick structural part for a sports car, the customer had a clear requirement to double the tool life from the previous 10 parts to 20.
The challenge is to keep the milling tool sharp and therefore to prevent delamination at the part edges produced. In this way expensive, manual re-work is saved. At the same time, the issue is to reduce the machining time and to realise long tool lives.
The Mapal Solution
The eight cutting edge, diamond coated solid carbide end milling cutter OptiMill-Composite-Speed has a high performance geometry with a serration. This serration makes possible improved chip removal and therefore an extremely high volume of chips in one machining step. As a result the machining is undertaken using only one tool in one step and the roughing step necessary previously is saved. With twice the feed and three times the material removal rate the tool life is increased fourfold and the quality requirements in relation to surface roughness reliably achieved. As a result the customer’s expectation in relation to tool life were exceeded by a further 20 parts.
The MAPAL Effect
- Four times the tool life reduces the tool costs
- Doubled feed halves the machining time
- Only 1 machining step
Complete machining of a Cyclo-Palloid Gear with HORN Tooling:
Horn has developed highly efficient gear machining processes for the Gear Industry. We showcase here an example of machining a Cyclo-Palloid Gear with a HORN tooling solution. The wide profile is opened with a custom multi-row M279 milling cutter, then the flanks are alternately roughed. The root diameter is machined with a DS cutter, the flanks are finished with a DGVZ tool and the sharp edges are chamfered with a DS cutter.
We showcase below another example of Gear Cutting with Horn Tools, from the machining of the Cyclo-Palloid Gear Teeth to the machining of External and Internal Splines by Broaching and Power Skiving.
Click here for the full range of Horn Milling Solutions.
Please contact us for any information you would like to have on any of the products showcased in this video.
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