HORN: Milling Systems

Horn Milling Systems

Presenting a demo of Milling Solutions from Horn.   The demo showcases a variety of different HORN milling cutters – the tangential milling system 409, high feed milling system DAHM, milling system DS and milling system DG.


HORN: DAH High Feed Milling System


High Chip Volume with High-Feed Milling

Paul Horn GmbH is pleased to present a new development for high-feed milling. The DAH82 and DAH84 systems from Horn represent a new generation of products for this milling process. The precision-sintered insert has eight usable cutting edges, resulting in a low cost per edge and a high level of cost-effectiveness. Despite the negative mounting position, the positive cutting geometry ensures a smooth and soft cut combined with good chip removal. Horn offers the inserts in the substrate SA4B, which is suitable for universal use in various materials. The large radius on the main cutting edge of the indexable insert results in a soft cut, ensures even distribution of the cutting forces and, in turn, extends the tool life. The maximum cutting depths supported are ap = 1.0 mm (0.039″) (DAH82) and ap = 1.5 mm (0.059″) (DAH84).

The DAH82 variant is available as an end mill and screw-in milling cutter in the following diameters: 20 mm (0.787″) (z = 2), 25 mm (0.984″) (z = 3), 32 mm (1.260″) (z = 4), 35 mm (1.378″) (z = 4) and 40 mm (1.575″) (z = 5). As an arbour milling cutter, it is available in diameters of 40 mm (1.575″) (z = 5), 42 mm (1.654″) (z = 5) and 50 mm (1.969″) (z = 6). For diameters in excess of 50 mm (1.969″), the larger DAH84 indexable insert is used. This can be supplied as an arbour milling cutter in the following standard diameters: 50 mm (1.969″) (z = 4), 52 mm (2.047″) (z = 4), 63 mm (2.480″) (z = 5), 66 mm (2.598″) (z = 5), 80 mm (3.150″) (z = 6), 85 mm (3.346″) (z = 6), 100 mm (3.937″) (z = 7) and 125 mm (4.921″) (z = 8). All tool bodies receive a special surface treatment, which results in high strength and hardness, thereby providing long-term protection against abrasive wear from chips.

Please contact us for more information on the Horn DAH High Feed Milling solutions.



Helical Lap Tooling for Aerospace

Applications requiring ultra-precise roundness, concentricity, and cylindricity are well suited for Helical Expanding Cast Iron Laps. Holding tolerances on diameter size and cylindricity to the sub-micron level is routinely achieved. Tools can be made as small as .043 inch (1 mm) up to 6 inches (150 mm) in diameter and as long as 14 inches (355 mm). Tools can be used for a wide range of materials including nonmetallic, non-ferrous, and ceramics.

Helical Lap Company provides tools for precision I.D. and O.D. finishing for major commercial aircraft and defense industry part suppliers.  The extensive industry knowledge at Helical Lap supports the demanding requirements for overhaul and repair of components for helicopter and fixed wing aircraft. Helical Lap tools are in use worldwide by commercial airlines, military, OEMs, major MRO repair facilities and sub-contract vendors for lapping a number of high technology components. The following is a list of typical aircraft components which utilize our tools:

  • Landing Gear
  • Fuel Supply Controls
  • Turbine Shafts
  • Servo Controls
  • Helicopter Rotor Components

Please contact us for further information on solutions from Helical Lap.  We can help you choose the right products and provide guidance on the best techniques for your application.


HORN: DS System for Titanium & Titanium Alloys

Efficient machining of Titanium

Horn has optimized its DS milling system to enable productive, cost-effective machining of titanium and titanium alloys. The optimizations are made possible by the newly developed substrate IG3I.  By combining the novel carbide grade with a new coating, Horn has been able to increase tool life significantly.

The new substrate demonstrates homogeneous wear.  A sharp micro-geometry on the cutting edges, positive rake angles, large clearance angles and polished flutes prevent strain hardening of the workpiece and built-up edges on the rake faces when machining titanium. Variable helix angles and different tooth pitches ensure a quiet, low-vibration milling process. Despite the sharp cutting edges, the new coating demonstrates very high layer adhesion, thus ensuring good cutting edge stability.  Thanks to its high temperature resistance, the coating serves as a heat shield and reduces the amount of heat transferred to the carbide.

In future, the IG3I substrate will replace the previous substrate TSTK, which is already known on the market for its high performance. The end mills are available in diameters from 2 mm to 20 mm as standard, with four or five flutes. The effective length is two or three times the diameter. DS titanium milling cutters were developed based on the tried-and-tested solid carbide milling cutters in the DS system, which for years have been used to machine soft and hardened steels, chromium-nickel steels and super alloys as well as copper, aluminium, plastics and fiber-reinforced plastics.