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.