Category: Cutting Tools

HORN: Expertise in Pipe and Sleeve Machining

 

Paul Horn GmbH has succeeded in winning over the world’s leading manufacturers of machine tools for pipe and sleeve production, as well as end users, through the continuous development of customer-focused tool solutions. The tool manufacturer is able create cost-effective machining solutions for use in API- and GOST-compliant as well as premium joint applications. With a focus on user-friendliness, the tools are designed to deliver a productive edge over other solutions in the areas of handling, service life and cost per threaded connection. Horn’s own in-house product management department, which is actively engaged in the development and continuous optimisation of productive machining concepts for OCTG, designs and delivers both standard and customer-specific tools.

Horn’s product portfolio, which is designed to meet users’ productivity requirements, can offer the right package of tools for all machines. The tool systems are available with standard machine interfaces including VDI, polygonal shank and round shank holders as well as solutions that are flange-mounted on turrets. The tools are adapted to the degree of automation in the system – from manual loading all the way through to fully automated production – and are designed provide a solution that can be relied upon to meet the requirements. Both the screw clamp and the ground chip formers of the S117 and 315 systems, together with the carefully matched tool holders, make it possible to manage chip removal during sleeve and pipe end machining processes. There are no expensive parts such as chip breakers or shims to install, allowing customers to make significant savings when procuring tools. The two systems demonstrate highly precise interchangeability and use substrates and coatings for the inserts that are tailored to machining conditions, resulting in significant improvements in both cutting performance and tool life. The precise interchangeability provided by the precision insert seats reduces the number of tool adjustments that are needed after changing inserts.

In thread cutting in API- and GOST-compliant applications, the S117’s numerous teeth enable the number of cuts to be minimised. The 315 system has three usable cutting edges, leading to significant cost optimisation. It is an ideal choice for premium joints that permit no more than one to three teeth per cutting edge. The tool carrier is designed to work in perfect harmony with the insert, increasing the stability of the tool system. This means a lower tendency towards vibration, something that in turn improves surface quality, precision and tool life.

In applications involving pipes with profiles that comply with ANSI/API-5L, Horn offers tool solutions for pipe end finish machining in line with customers’ requirements. The milling heads can be used to machine pipe ends with a wall thickness of up to 50 mm. Integrated rollers compensate for any roundness errors. The workpieces that are produced comply with API tolerance requirements.

With its M101 cut-off milling system, Horn offers a purpose-developed tool for pipe end machining after rolling and for separating sections for analysis. The tool can also be used for pipe and sleeve assembly. The S101 self-clamping inserts, featuring cutting widths of 2 mm and above, deliver highly precise interchangeability, accurate cuts and short machining times.

Horn’s extensive scope of manufacture covers everything from producing blanks in its own carbide machining department, via the internal  grinding shop and production support all the way through to in-house-developed PVD coatings. This keeps the company’s lead-times short. Furthermore, with the Greenline system, for limited quantities Horn is able to offer delivery within one week of a drawing being approved by the customer. Not only that, but the tool manufacturer also allows users to benefit from process consultation services and acts as a solution provider, using its own in-house product management processes. Horn boasts expertise in machining a range of materials, from the easy-to-machine options of J55-K55, L80 and P110 to Q125 and all the way through to high-alloy materials like 13Cr or 28Cr.

Increasing drilling depths and more aggressive operational environments mean that CRAs (corrosion-resistant alloys) have become a focal point in pipe manufacture. Processing is a real challenge because these materials, which are used in HPHT (high pressure high temperature) fields, are so difficult to machine. The full weight of Horn’s expertise is in demand due to the formation of built-up edges resulting from the machining of these tough materials. The company’s many years of experience and in-house manufacturing capability are of real benefit here. Thanks to HiPIMS coating technology, the in-house produced coatings IG3 and HS3 exhibit smooth cutting properties and high heat resistance. The tool geometry, the substrate and the coating are adapted to meet the requirements of each application.

 

 

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.

 

 

MAPAL: Hydraulic Chucks with Axial and Radial Adjustment

Hydraulic Clamping Technology with Compensation Technology

The “compensation” chuck is perfectly suited to light clamping tasks with multi-bladed reamers. It builds on hydraulic clamping technology and the radial run-out can be set exactly using three adjustment elements. The radial run-out is corrected using a hex wrench depending on the direction of the error. The setting range is up to 10 μm. Wedges in the chuck align the tool, jamming of the tool is prevented. The system is self-locking, unintentional movement during fine machining is impossible. A fixed ring seals the alignment system. It is therefore low maintenance and not susceptible to dirt.

Radial Tool Length Adjustment

In the area of clamping tools with HSK connection, MAPAL offers hydraulic chucks with radial tool length adjustment.  With this setting method, radial run-out accuracy ≤ 3 μm can be ensured.

Technical Data

– Material 1600-1800 N/mm2 tensile strength
– Adjustment travel 10 mm
– Hardness 52 + 2 HRc
– DIN 1835 Form A, B, C, D
– Balanced tool holders
– DIN 6535 Form HA, HB, HE
– Laser inscription
– Coolant pressure max. 80 bar
– Max. spindle speed 40,000 min-1
(note spindle speed limit for connection, fine balancing recommended!)
– Optimum operating temperature range 20-50 °C;
higher temperatures on request, do not use above 80 °C
– Shanks suitable for clamping (tolerance h6) with and without reducing sleeves:
– DIN 1835 Form A, B, E
– DIN 6535 Form HA, HB, HE

Please contact us for more information on MAPAL Hydraulic Tool   Clamping Solutions.

 

HORN: Gear Teeth Deburring | AMB 2020 Technologieforum

Defined Chamfering Deburrs Gear Teeth in Seconds

Paul Horn GmbH has developed a process for precision deburring of gear teeth that represents a further advance in the world of gear production. Although gear teeth can be deburred relatively easily with brushes and discs, higher levels of precision and quality are being demanded, with the result that there is often no longer any scope for undefined chamfers at the tooth edges. So Horn has developed a technology – together with the associated production process – to enable the production of defined chamfers. It can be used, for example, to create a 45-degree chamfer on both sides of a module 1 gear wheel with 25 teeth in less than five seconds. A turn-mill centre with synchronised axes is required for this production process. However, users do not need any special workholding equipment. The solid carbide tools can be clamped in a standard collet, or in shrink-fit or hydraulic chucks.

The process is particularly suitable for machining gears in high volumes. The milling cutters are special tools and have to be individually designed for each gear tooth. Based on the application, Horn engineers will design the appropriate cutting edge geometry for the module, tip diameter and desired chamfer. Horn supplies the process data required for machining together with the cutter. Tool costs are low and quickly pay for themselves thanks to short machining times. The carbide substrate, tool coating and cutting edge geometry are all specially designed for each gear tooth material. As far as the actual machining process is concerned, the material is irrelevant. Chamfers can be milled into various steels, aluminium and plastics within seconds.

HORN: Bevel Gear Cutting Solutions | AMB 2020 Technologieforum

Cost-effective even for Small Batch Production

Paul Horn GmbH is expanding its range of gear cutting products. Horn’s new tool system for milling bevel gear teeth allows the complete machining of bevel gears on universal turn-mill centres. The system was created in cooperation with machine manufacturer INDEX and means that users no longer need any special machines to manufacture gears of this kind. It also allows all functional surfaces to be produced together with the gear teeth in one clamping. This enables high component precision, short lead-times, a very cost-efficient process and short machining times as a result of controlled machining cycles. With a universal turn-mill centre from INDEX, components with bevel gear teeth can be efficiently and flexibly manufactured, including in small quantities. This also makes the process attractive to small and medium-sized companies that would previously have bought in gears or had them manufactured externally.

For the process, Horn relies on its S276 and S279 double-edged indexable inserts, which are screwed on tangentially. This makes it possible to achieve a stable insert seat, which is particularly important during form milling. The tool does not have to be remeasured after the inserts have been turned around or changed because the inserts are precision-ground on the circumference. The milling body can be equipped to allow for different numbers of teeth and outer diameters when cutting gears. The process of developing the complete system (cycle, tool and clamping) called for a great deal of expertise on the part of both the machine manufacturer and the tool manufacturer. To implement the process, various types of INDEX machine with a “bevel gear hobbing” cycle are required. Horn offers the milling cutter bodies with the HSK-T40 and HSK-T63 interfaces. The profiles of the inserts are module-dependent and precision-ground.