Category: Horn

HORN: New Generation Ball Track Milling

New Horn KX System

New generation of Ball Nose Endmills

With the new KX system, HORN is launching a high-performance solution for the economical and reliable machining of ball bearing tracks. HORN developed the system specifically to meet the increasing demands for precision, flexibility and productivity in the production of constant velocity joints. The system covers a wide range of components and offers three sizes. Flexible machining strategies enable both soft and hard machining – from roughing and chamfering to finish milling. Customers can adapt the strategy precisely to their process requirements, ensuring a high level of cost-effectiveness.

With the KX system, HORN has considerably increased the performance of the tool system. Soft-cutting cutting heads with defined edge preparations enhance process reliability. Precise internal coolant positioning and a newly developed interface improve rigidity. Practical benchmarks confirm the performance: Users significantly increase cutting values and noticeably reduce cycle times. Depending on the component, they shorten the machining time by several seconds per workpiece and sustainably increase productivity.

Constant velocity joints are used in every car and are also known as homokinetic joints. Their purpose is to transmit uniform torque and angular speed from the drive shaft to a second shaft mounted at an angle to it. In other words, constant velocity joints transmit rotary motion uniformly to the next shaft. The joints are most widely used in vehicle construction for power transmission from the gearbox to the drive wheels. Constant velocity joints can transmit rotational movements at an angle of up to 50 degrees. In addition to fixed ball joints, sliding constant velocity joints are also used. They allow not only angular movement, but also axial movement so that power transmission is not interrupted when steering or during movement of the suspension.

At the heart of a homokinetic joint are the balls, which roll in precisely milled tracks. The ball tracks have a very tight manufacturing tolerance and a high surface finish is essential. The tight tolerances and the manufacturing quality determine how long the service life of the joints will be. The form tolerances of the parameters are to within microns.

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 Six-Edged Inserts with New Grooving Depth

Six-Edged Inserts with New Grooving Depth

With the 66T grooving system, Horn is expanding its tool portfolio in the area of six-edged indexable inserts. With six cutting edges, the insert offers an attractive price per cutting edge. The maximum grooving depth is 9.5 mm (0.374″). This is around 4 mm (0.157″) more than the sister system, 64T. Depending on the application, Horn offers inserts with two geometries and a version without geometry. The available geometries ensure reliable chip removal during machining. The IG65 carbide grade is used for machining stainless materials and difficult-to-cut materials. For general steels, Horn recommends the EG55 carbide grade for the 66T system.

The available cutting widths are 2.5 mm (0.098″) and 3 mm (0.118″). The corner radius is 0.2 mm (0.008″). The 1A geometry is suitable for pure groove turning operations, while the DL geometry is suitable for longitudinal turning in addition to grooving. The DL geometry is therefore also available with a corner radius of 0.4 mm (0.016″). The effective chip control of the chip breaking geometries ensures high surface quality on the groove flanks and the straight main cutting edge produces a cleanly finished base. Designed as neutral grooving inserts, they can be clamped in square shanks with internal cooling on both the left and the right side. Holder dimensions are 20 x 20 mm (0.787 x 0.787″) and 25 x 25 mm (0.984 x 0.984″). A clamping screw fixes the grooving insert precisely and securely in the central insert seat. Horn also offers type 220 clamping cassettes for the modular holder system.