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Horn at AMB 2018!

 

HORN was on display at AMB 2018 with a three-storey stand (Hall 1, Stand 1J18) presenting a host of innovations and product enhancements. The key highlights of JET-Whirling with Internal Cooling, Speed-Forming and Polygon Turning were presented at the AMB.

Other major features of the stand was the opportunity to present professional and expert advice on the HORN product portfolio, and the chance to exchange ideas on the latest topics and trends.

Please visit Horn for more info on the latest products released at AMB 2018

 

 

 

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MAPAL: Machining of Valve Seat and Valve Guide

Modern precision tool provides more production capacity with lower costs at the same time on the machining of Valve Seat and Valve Guide

Machining Task
The machining of the valve seat and valve guide is one of the primary cost drivers during the machining of cylinder heads. Exact angles at the sealing chamfers on the valve seat rings and close tolerances on the concentricity between valve seat and valve guide must be met. In addition to the high geometric requirements, the increasing requirements on the high-temperature stability of the valve seat rings mean that in general very hard and difficult to machine sintered materials are used.

Challenge
The tool concept that meets these requirements while reducing costs at the same time must make use of the most suitable cutting material and have corresponding precision. Cutting material and insert geometry are responsible for the tool life and make a significant contribution to the costs per workpiece. However, the overall design of the tool is also important.

Our Solution

The solution for these tasks is a MAPAL tool with indexable blades and guide pads. It guarantees a qualitatively flawless result due to the high precision of the inserts, the insert seats and the connection in relation to the valve guide. The HX inserts for machining the chamfers on the valve seat ring are of a hexagonal shape and have six cutting edges. Due to a clever arrangement, these inserts can even be used several times for the different chamfers. The precision insert seat in which the HX inserts are mounted makes it possible to change the inserts without any setting process, as all the angles match exactly.

Conversely, all the tools previously used for this machining task require to some extent time-consuming setting work on an insert change. Also it was normally necessary to set the radial run-out on the replacement of the valve guide reamers mounted in the base tool. In the new MAPAL concept the tool for machining the valve guide is now connected using the proven HFS connection. The tool is changed with a radial run-out accuracy of < 5 µm by simply screwing in or unscrewing. This very stable connection also makes it possible to increase the feed rate.

MAPAL Effect
The comparison of the conventional system with the MAPAL solution produces a very clear result. The much higher feed rate and the related cycle time reduction result in a significant improvement in the production capacity, or even in less investment in machinery for new projects. As no setting work is required and it is only necessary to change inserts and tools, there are also significant savings in the area of the non-productive times. However the most important effect on the costs per workpiece is the inserts for machining the valve seat rings. Due to the stable mounting, the right PcBN grade and the ideal cutting edge geometry, the tool lives are increased by five to ten times compared to other systems.

Cycle time reduction due to much higher feed rate
Setting no longer necessary
Five to ten times higher tool lives

 

 

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Horn Thread Cutting Tools from M1 to M2.5

DCG thread milling cutters for M1 to M2.5

Thread Production in hard-to-cut materials

Horn presents new developments in the DCG thread milling system. Suitable for producing threads from M1 to M2.5 (metric ISO threads DIN 13–20), the tools extend the possible applications of the DCG series for the reliable milling of threads. They have extremely sharp cutting edges and are suitable for universal use thanks to their coating. The solid carbide milling cutters are available as standard up to a thread length of 2 x D. They demonstrate their special capabilities and efficiency when machining steels, stainless steels, cast iron, non-ferrous metals and in particular hard-to-cut materials used in the medical technology sector, for example.

DCG solid carbide milling cutters have been proving themselves in the production of threads sized from M3 to M12 for many years. As the single-row milling cutters can be used for different pitches, a high degree of flexibility is guaranteed.

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Tooling Solutions for Gear Skiving

For the high-productivity manufacturing of internal gear teeth, splines and other internal profiles, HORN is introducing tools for gear skiving. This machining method has a number of advantages:

  • Considerably shorter processing times in comparison to gear tooth broaching
  • Can be used on optimised milling centres
  • No undercut necessary at the end of the gear tooth
  • Turning and gear cutting possible in a single clamping

Depending on the number of gear teeth and the size of the module, a number of different tool interfaces is used. Each tool is designed specifically for the intended application and adapted for the material. Gear skiving tools are therefore used for medium and large batch sizes. On the tooth flanks, typical surfaces are created which differ from the flanks created by broaching. Depending on the geometry of the component, gear skiving may also be a useful alternative to hobbing or broaching for external gear teeth as well.