First up is a 3D-printed coolant attachment for reamers. During the high-performance reaming of through-holes or deep blind holes, standard solutions often reach their technical limits, says Horn. Long-chipping materials and those that are difficult to cut, make it necessary to modify the tool system and the internal coolant supply. Accordingly, Horn will announce the availability of bespoke, additively manufactured coolant discs that can be screwed on to the tool shank to ensure reliable chip control.
Adopting the discs results in extended tool life due to direct, targeted cooling and, above all, reliable chip removal. Additive manufacturing enables the coolant outlets to be freely designed so that the form of the outlets prevents chips from entering. Furthermore, the cross-section and exit angle of the cooling channel can be adapted to suit the specific machining task and the material to be processed. Due to the polished and coated flutes, the tool shank facilitates the effective removal of chips from the machining zone.
Elsewhere on the stand, MACH visitors will discover that Horn is extending its 406 tangential milling cutter system to include an insert with wiper geometry for finishing. The newly developed geometry produces high surface quality, even at elevated feed rates, resulting in shorter machining times, says the company. Moreover, the geometry makes it possible to reduce the need for subsequent grinding processes.
The single-edged finishing insert is used in the 406 system's 90° shoulder mills. Only one insert with wiper geometry is required in the tool body; the remainder may be standard 406 system indexable inserts. The wide finishing insert is available in grade AS4B for material groups P and M, and in grade AS46 for material group K.
Horn will also show its expanded range of monocrystalline diamond (MCD) tipped, ball-nose end mills for brilliant-finish machining of non-ferrous materials. The newly devised, larger diameter variants reduce machining time, ensure tight tolerances and produce finishes in the nanometre range.
Notably, the expanded portfolio of end mills is available from stock in diameters of 6, 8, 10, 12 and 16 mm. All variants are single-edged, feature an internal coolant supply and have a solid-carbide shank for vibration-free machining.
The range of applications for brilliant-finish milling is substantial. In the tool and mould-making industry, this method saves on the polishing of freeform surfaces, while also increasing quality in terms of precision, contour accuracy, flatness and surface finish. MCD tools are therefore used where the surface quality of the mould needs to be matched by the finish of the parts being produced, such as PET blow moulds and chocolate moulds, as well as applications in the medical technology sector. In addition, Horn offers MCD solutions for brilliant-finish turning.
A further development centres on allowing users to reduce cycle times and cut production costs during series production on turning and mill-turn centres. Here, Horn has introduced customised carbide form inserts for machining diameters from 16 mm upwards, as will be explained on the stand at MACH, where representative products will be displayed. Based on Horn’s 117 tool system, the patented insert seat guarantees high concentricity and minimal axial runout, as well as repeatability of insert exchange to within microns.
Precision-ground cutting edges deliver high accuracy and surface quality. In addition, financial savings are gained, as the option to exchange the insert leads to lower tool costs and reduced machine downtime. The internal coolant supply to both cutting edges via the round shank cools the contact zone and carries chips away efficiently.
Horn offers the tools in profile widths of 16, 20 and 26 mm. Special profiles can be precision-ground to suit a diverse range of applications; the maximum profile depth being 17 mm. The insert coating is selected for each application and is available for material groups P, M, K and N. Round shanks with diameters of 16, 20 and 25 mm, in the A and E designs, are standard. All variants have an internal coolant supply.
Visitors to the Horn stand will also learn that new tool-holder variants are available for the company's S100 system to enable parting-off on turning centres that have feed movement in the Y axis. This method enables effective parting and grooving using high cutting parameters, resulting in short machining times. Furthermore, due to the extra stability of the system, there is the option to part-off large diameters with a compact tool holder, and to use narrow groove widths.
High moments of force occur when parting-off workpieces of large diameter, but the space available in a machine often does not allow tools of large cross-section to be used. With the latest design of tool holder, the cutting forces are diverted to the main cross-section of the insert, resulting in increased rigidity of the system as a whole for any given tool holder, and enabling higher feed rates to be used.
Horn offers two holder variants for the parting-off process. For the 842 and 845 modular grooving system, there is a cartridge with cutting widths of 3 and 4 mm. There is also a reinforced grooving blade in identical widths. Both variants are equipped with an internal coolant supply via the clamp and through the support. The maximum groove depth is 60 mm. In addition, the S100 system provides an option for direct cooling through the cutting insert.
Another product in the spotlight at MACH will be the newly developed IG35 insert coating, which allows Horn to offer high performance and long tool life to users machining stainless steels, titanium alloys and super alloys. In combination with the 3V and FY geometries, the AlTiSiN coating prevents the formation of built-up edges due to the low coefficient of friction. Thanks to HiPIMS technology, the coating delivers smoothness and high heat resistance. Furthermore, the coating is free from defects such as inclusions or faults at the cutting edge.
Horn adapts the coating system, the chip-breaker geometries and the micro-geometries to applications such as internal and external grooving, longitudinal turning, circular interpolation milling, and solid-carbide milling. The user can achieve higher cutting parameters, enabling shorter cycle times, which in turn has a positive impact on unit production costs. Deployment of the IG35 coating also leads to higher surface quality.
IG35 is available for the S100, S101, S224, S229, and S274 grooving systems, as well as for the circular interpolation milling and solid-carbide milling systems.
At MACH, Horn will promote a new-style tool holder for its Supermini type 105 grooving and boring tools. With a novel design, clamping of the carbide insert uses a tensioning wedge on the face rather than the circumference of the tool, as was previously the case. This concept enables the insert to be held in place with greater force, which in turn makes the entire system more rigid.
Additionally, the latest clamping design results in a higher level of repeatability when changing the insert and allows better use to be made of the space available for mounting it. This benefit is a particularly advantageous when working with Swiss-type lathes, as it enables users to change the insert without removing the tool holder.
The Horn Supermini tool system is suitable for boring holes from 0.2 to 8 mm in diameter, and over 1,500 varieties are available as standard. In addition to boring, the system is designed for grooving, chamfering, threading, broaching and other machining operations. The cutting geometries and substrates can both be adapted to the materials being machined.
Visitors to the Horn stand will also see a new skiving method for producing large gear modules on rigid turn-milling and mill-turning centres that offers the benefit of shorter machining times, especially for internal teeth. Based on its experience with manufacturing small, solid-carbide tools for gear skiving, Horn is now applying its expertise to the machining of larger modules.
The manufacturer's latest tool system utilises S117 single-edge inserts, which feature a patented seat and threaded connection to ensure precise positioning and clamping for high rigidity and repeatability of exchange. A ground chip breaker enables effective swarf removal from the machining zone, with all cutting edges being cooled directly by an internal coolant supply.
At the outset, Horn discusses each tool design with the user and offers recommendations for the process before a gear-skiving tool is specially designed and manufactured for the application, the feasibility of which is verified on an individual basis prior to implementation.
Horn’s portfolio comprises a range of products for machining various gear tooth geometries from module 0.5 to module 30. Whether this involves gear teeth for spur gears, shaft/hub connections, worm shafts, bevel gears, pinions or customised profiles, all can be manufactured cost-effectively using milling or broaching tools, says the company.
Additionally, Horn will be showing newly developed HP geometry for its Supermini system. This multi-functional tool is suitable for a range of applications, including drilling, boring, face turning and skimming. The latest geometry enables higher cutting data, while wiper geometry produces high surface quality, even at elevated feed rates, reports the company. When boring, an accurate 90° shoulder is achieved at the base of blind holes.
In addition to turning operations, the system is suitable for drilling solid material in diameters ranging from 3 to 7 mm. The performance data of the tool cannot compete with normal drills, but there is often a lack of locations for cutters in a machine. The Supermini HP offers the option of immediately boring an inner contour after drilling, without needing to change the tool. With the single-edged version, various bore diameters can be produced using a single tool.
Horn provides tools with and without a chip breaker for optimum chip control. For turning, the variant with a chip breaker is recommended, while the non-chip-breaker version is best for drilling. The EG35 coating allows versatile machining of both normal and stainless steels, and the slightly twisted flute removes chips from the machining zone efficiently.
Last but not least, Horn has extended its M610 tangential milling system to include a 90° shoulder mill and newly developed carbide grades. The patented tool system ensures a soft cut with positive radial and axial rake angles.
Six cutting edges on the precision-ground indexable inserts give low cost per edge, as well as high accuracy and surface quality, says Horn. The additional flank chamfer ensures a stable wedge angle and smooth milling. Horn provides the inserts with substrates AS46, IG35 and NE2B in right and left-hand versions, and with corner radii of 0.4 or 0.8 mm for machining different materials. The maximum depth of cut is 9.9 mm.
Cutters are available in the following diameters: 50 mm (five inserts), 63 mm (six inserts), 80 mm (eight inserts), 100 mm (10 inserts) and 125 mm (12 inserts). A special surface treatment protects the tool body against abrasive chips.