HORN: PTO Shaft Milling

Horn is expanding its tool portfolio for gear cutting to include types for milling PTO shafts. Manufacturers are increasingly focusing on the complete machining of drive shafts. Horn has standardised its own tool range for this purpose, which demonstrates high milling performance. The double-edged carbide insert S274 is used. The programme includes tools for PTO shaft sizes 1 3/8″ and 1 3/4″. The portfolio also includes special milling cutters for restricted shaft clearances. The M274 tool holders are equipped with an internal coolant supply for targeted cooling. The carriers have a diameter of 63 mm (2.48″) and 10 teeth.

Tractor attachments such as a mower or loader wagon do not have their own drive. To operate them, the mechanical drive energy of the tractor must be transferred to the attachment. This is done via the power take-off or PTO shaft. This drive, which can usually be switched on and off, is available at a secondary output of the tractor transmission. The energy can be utilised directly via a PTO shaft. A profiled shaft stub, which protrudes from the gearbox, is connected to the PTO shaft of the attachment by means of splined or involute gears. For operation, the user attaches the PTO shaft to the stub shaft in an axial direction. Rotationally symmetrical locks are used to secure the connection, which can be released easily and without tools.

HILZINGER-THUM: Mirror Polishing

We are pleased to offer tool brushes from Hilzinger-Thum, Germany  for the mechanical treatment of surfaces made of metal, wood, plastic or paint.  With these tool brushes burrs are broken, edges rounded and surfaces ground and polished. The results are workpieces with defined radii, as well as satanized, ground or polished to perfection surfaces.

Mirror Polishing

Hilzinger-Thum polishing tools use 100% cotton fabric for almost all applications. These fabrics are woven according to our technical specifications especially for Hilzinger-Thum. In order to meet every customer’s requirement in the best possible way, we have a wide range of fabrics: from very soft and open to very hard, heavy and extremely dense.

Our ventilated or spirally sewn polishing buffs are made of 45°-cut, highly abrasion-resistant cotton fabrics. For full leave polishing buffs, we use full and half leaves of new fabric. Stitched coloured cotton buffs are hardly used today any more. Still, we can offer them if required, mainly for manual processes. They are made of new fabric waste from the textile production such as shirting, Neubunt or inlett.

We adjust the hardness of our buffs by using different amounts of material in different geometries. In addition, the dimensions are always selected according to customer specifications. For example, we produce very soft polishing tools for customer parts made of soft materials or with a curved geometry, but also very hard polishing tools that are normally used for flat or even parts.

For high gloss polishing of sensitive and soft surfaces we offer flannel fabrics of very soft, roughened and open weave cloth.

HORN: High Performance in Stainless Steels

Horn has developed a new, solid carbide milling cutter range especially for machining stainless steels. The tools are for milling stainless materials in the food, chemical and pharmaceutical industries as well as the precision engineering and watchmaking industries. In addition, due to their geometry and good chip breaking, the milling tools are suitable for machining numerous other materials. Due to the precise combination of the substrate, the macro and micro geometry as well as the IG3 coating, the milling system exhibits high performance and long tool life. The coating in particular offers high temperature resistance for machining steels alloyed with chromium, nickel and molybdenum.

Horn offers the solid carbide milling tools from stock in two types. The DSHPR variant is suitable as both a finishing and a roughing tool. The geometry is also adapted for trochoidal machining and plunging. The DSR type, with its very sharp cutting edge geometry and short design, is suitable for very small parts and unstable clamping conditions, such as in the medical and watchmaking industries. In the DSHPR line, all tools are available with four teeth and in diameters from 2 mm (0.079″) to 20 mm (0.787″). Horn offers the DSR variant with three teeth in diameters from 1 mm (0.039″) to 10 mm (0.394″).

 

Cool Clean: CO2 Machine Tool Cooling Solution

Dry machining is essentially machining without the use of any cutting fluid or coolant. Dry machining is typically reserved for certain applications, and it may never completely replace the use of cutting fluids, but is becoming increasingly popular due to:

  • Operator Safety – Reducing fumes and splashing coolant
  • “Dry” may work better for certain metals (Ex. composites, plastics)
  • Eliminates messy work environments

Cool Clean has made significant advancements in dry machining with the ChilAire™ CO2 Machine Coolant Systems. The ChilAire™ offers the performance benefits of a liquid coolant and the environmental benefits of dry machining, all with great economics.

 

Dry Machining Features:

  • Benefits operations that must be “dry”
  • External and through tool cooling capability
  • Precision machining of plastics, PEEK, UHMW, etc.
  • Increases in tool life and tighter hole tolerances
  • Additional capability can be achieved with MQL for certain applications

The process is straightforward. CO2 spray is created through an expansion of liquid CO2 into solid CO2 crystals, or CO2 snow, that are delivered to the machining cutting zone. When the CO2 spray hits the cutting edge, the ice-crystals melt and flash back to CO2 gas in a process called sublimation – capable of absorbing significant amounts of heat. The ChilAire™ system keeps the tool and work piece at ambient temperature, hence preventing thermal shock. Further, by controlling the temperature of the cutting zone, customers can use lower cost cutting tools on applications that typically require expensive tools such as Cubic Boron Nitride (CBN), Ceramic, Polycrystalline Diamond (PCD), etc.

Benefits of the ChilAire™ are as follows:

  • Clean Operator Work Environment
  • No Splashing Coolant
  • Cutting Tool Does Not Experience Thermal Shock
  • Improved Economics
  • No Secondary Cleaning

HORN: Superfinishing of Bores with Supermini System

At EMO 2023 in Hannover, Horn is presenting an innovative extension for the Supermini system in the field of ultra-fine machining. The precision tool manufacturer has added a variant with a precision-ground rake face to the Supermini system especially for ultra-fine machining of bores. Due to precision grinding of the cutting edge, it is free from notches when magnified approximately 200 times. The tool system can be used from an inside diameter of 0.3 mm (0.012″). The sharp insert geometry enables process reliability even with very small infeed and cutting feed rates. The specially developed coating is suitable for stainless steels, non-ferrous metals and other metallic materials.

The insert of the Supermini Type 105 system requires only one tool holder for well over 1,000 insert variants. This applies equally to left-hand and right-hand versions. The carbide inserts are available in coated and uncoated versions in different grades for every application including hard machining up to 66 HRC. The patented droplet shape of the cross-section has a vibration-damping effect and delivers excellent repeatability when changing the insert. Internal coolant supply to the insert increases tool life, enhances cutting performance and improves chip removal. Horn offers the tools with elements for face clamping. This allows, for example, the insert to be changed easily without having to remove the holder from the machine.

History Horn Supermini:

In 1989, HORN launched the technically superior Supermini system at the world’s largest metalworking trade show, EMO in Hannover, Germany. After considerable technical development, it was possible to successfully manufacture precision internal grooving tools for bores down to 5 mm (0.197″) in diameter. The Supermini system was born and over time became one of Horn’s most successful products. In addition, the Supermini system was the first precision tool to benefit from Horn’s own in-house coatings.