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.

HORN: Gear Skiving Solutions

Skiving of Large Gear Modules

We present below a Gear Skiving Tool application from HORN for the machining of internal gears from module 3.  Featuring interchangeable cutting inserts, the tool system offers high rigidity of the overall system as well as high productivity due to short process times.

 

Please contact us for more information on Skiving Solutions from Horn.

 

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.

HORN: Grooving System 32T on Swiss-Type Lathes

Grooving System 32T on Swiss-Type Lathes

HORN has developed the new 32T system for use on Swiss-type lathes and for grooving and parting off on smaller fixed-head lathes. There is no need for clamping elements, which could potentially have a detrimental effect on chip flow. The head of the clamping screw does not introduce interference contours and therefore permits both grooving and parting off directly at the spindle. The precision-sintered grooving insert can be used as a neutral insert and as both a left-hand and a right-hand insert.

 

 

Please contact us for more information on the new 32T System for Swiss-type lathes.