Category: Cutting Tools

HORN: Efficient Processing of Modern Materials

The alloying of lead in metallic materials has a positive effect on the machining process. Due to the EU’s REACH and ROHS regulations, the time of these easy-to-machine materials is coming to an end in many applications. However, reliable machining must still be possible in the future. With its broad tool portfolio, Paul Horn GmbH has a suitable solution for almost every application.

The main problem when machining lead-free alloys, be it brass or free-cutting steel, is the lack of reliable chip breaking. But what exactly is the effect of the alloy component lead, which is toxic to humans? During machining, the soft metal creates predetermined breaking points in the alloy, as lead forms small nests or inclusions in the alloy structure. These ensure good chip breaking and low cutting forces during machining. Furthermore, the heavy metal acts like a lubricating film, which has a positive effect on tool wear.

The changeover was initially a challenge. The good cutting properties of the lead-alloyed materials were lost. In addition, the wear on the cutting edge increased significantly. This was remedied by grooving and longitudinal turning with chip-breaking geometries from the steel sector and special laser-cut geometries. Extensive investigations show that chip-breaking geometries for steels with medium strength in particular work very well with lead-free materials.

During internal boring, adapted geometries also ensure reliable chip breaking. One of the biggest challenges in internal machining is long chips. These often occur during bore machining. They wrap around the tool, clog bores or, in the worst case, lead to tool breakage. Previously, specially lasered or ground chip form geometries were used for this purpose. However, this was associated with a corresponding cost factor for the cutting insert. With the new Type 105 Supermini and the Type Mini with I geometry, Horn has succeeded in developing universal boring tools with sintered chip form geometry. The tools offer high process reliability in use thanks to good chip control. The cutting edge geometry extends far into the corner radius of the insert. This ensures chip control even with small infeeds. The geometry can be used universally for different material groups and is suitable for internal, face, copy and reverse turning.

Please contact us for more information on the efficient machining of modern materials.

 

HORN: Supermini System with HSK Interface

Horn is expanding the Supermini tool system with new holder variants. The holder range is specifically aimed at use in modern mill-turn centers. The tool manufacturer is thus reducing the number of interfaces between the insert and spindle compared to conventional chucks. This enables greater precision and higher process reliability. Horn offers the holder system with various machine interfaces, including: HSK-T63, HSK-E40 for Willemin-Macodel, HSK-A40 for Bumotec and HSK-T40 for all other multitasking machines. In all versions, the Supermini insert is located and removed using a face clamping and lifting system. Clamping is achieved not via the lateral surface of the tool, but via a wedge on the end face. This raises the force with which the insert is held, resulting in high rigidity of the overall system.

Boring, profile turning, internal grooving, threading, chamfering, axial grooving, drilling and slotting. The Supermini tool system can be adapted and used for numerous machining operations. The solid carbide insert is for machining bores from 0.2 mm to approximately 10 mm in diameter. Horn developed the tool blank as a teardrop shape, enabling precise contact surfaces in the tool holder. Furthermore, the shape prevents the insert from twisting, leading to a consistently precise tool center height. With long tool overhangs, it reduces deflection and minimizes vibration during the turning process. Depending on the application and the diameter to be machined, Horn offers the insert in three different sizes (types 105, 109 and 110). All variants allow for internal coolant supply directly to the cutting zone. The Horn tool portfolio contains approximately 2,500 different standard variants of the Supermini. In addition, Horn has solved users’ problems with countless customized solutions.

HORN: New Chip Breaker for the 274 Tool System

Superior Chip Control during Grooving and Parting off

Paul Horn GmbH has introduced a new chip breaker geometry for the 274 tool system especially for grooving and parting off on sliding-head lathes. The sintered chip breaker geometry 1A optimizes chip control during turning, ensuring a high level of process reliability. The universal geometry is suitable for machining various materials. The indexable insert with two cutting edges is available in three cutting widths of 1 mm, 1.5 mm or 2 mm. Maximum grooving depth is between 3 and 6 mm. The insert is available in TH35 and IG35 grades. An extensive range of holders is available for adaptation to different types of lathe.

When machining turned parts of small diameter, the centre height of the tool must be precise. Even small deviations in the centre height have a negative effect on the quality of the workpiece when machining very small parts. Ideally, the machine operator should be able to index the insert without having to readjust the centre height. With System 274, Horn offers excellent repeatability of less than 0.02 mm when turning the double-edged insert. This is made possible by precise peripheral grinding of the insert in conjunction with the stable insert seat.

HORN: New System for Grooving and Parting Off

S234 – this is the name of the newly developed parting system that Horn has developed especially for large grooving depths. The double-edged system enables a maximum depth of cut of 33 mm (1.300″). This means that diameters up to 65 mm (2.560″) can be parted off reliably and economically. The combination of high grooving depths, rigid clamping, high-performance chip breaker geometry and internal cooling makes the system extremely attractive in terms of price/performance ratio.

The inserts are available in cutting widths of 2 mm (0.079”) and 3 mm (0.118″). The corner radii are 0.2 mm (0.008″) and 0.3 mm (0.012”) respectively. The sintered EN geometry ensures reliable chip removal. Depending on the material to be machined, the inserts are available in AS45 and IG65 grades. Square shank holders in sizes 20 mm x 20 mm (0.787 x 0.787″) and 25 mm x 25 mm (0.984 x 0.984″) ensure stable clamping. Horn also offers reinforced grooving blades and tool holders for the modular parting and grooving system. All types are equipped with internal coolant supply.

Please contact us for more information on the new Grooving and Parting Off solutions from Horn.

JBO : SHARK Thread Milling Cutters

Long Tool Life, Short Processing Time and Excellent Surface Quality – three advantages of solid carbide thread milling cutters from Johs. Boss GmbH & Co. KG Präzisionswerkzeugfabrik, Germany.  Available in a wide range of Thread Milling Cutters, Drill Thread Milling Cutters and Indexable Thread Milling Cutters including specials.

The SHARK high-performance Thread Milling Cutters from JBO offer precise thread machining – complemented by the G-thread range within the GFT series (solid carbide three-profile thread milling cutters).

General Advantages of Thread Milling

  1. Threads to different tolerance classes can be produced with same cutter
  2. Tool breakage does not necessarily entail scrapping of the workpiece
  3. Less power needed for cutting internal threads
  4. Short machining times due to high cutting speeds
  5. Excellent thread surface finish
  6. Short chips, hence no chip problems
  7. Right and left hand threads can be produced in blind or through holes by the same cutter
  8. Low cutting forces enable threads to be cut in thin wall workpieces
  9. Cutting speeds and feeds can be matched individually to workpiece material
  10. No change of cutter spindle direction of rotation required
  11. No special tapping chucks required, standard chucks suffice
  12. Threads can be cut to exact depth
  13. Threads can be cut down to near bottom of blind holes
  14. Start of thread accurately determined by NC programme

Please contact us to analyze your machining process and work out an optimized solution.