Horn unveils lightweight face mills for aluminium

Horn has expanded its DTM lightweight milling system to include two newly developed versions. DTM.CX09 arbour milling cutters are designed as roughing tools for use in applications that involve high cutting depths and place fewer demands on surface quality, while the DTM.CX09.AL.F face mill for finishing adds an adjustable body to the existing product range. Axial run-out can be adjusted to the exact micron using a presetter.

The aluminium body of the tool holders has low mass, resulting in reduced energy consumption during acceleration and deceleration. As the weight is less than that of a steel cutter, faster spindle speed changes can be achieved. There is also less wear on the spindle at high speeds as the cutter body features a protective hard coating to prevent damage caused by chip impact.

The arbour milling cutter bodies offer diameters between 40 and 125 mm, and have from four to eight effective cutting edges. All body versions feature an internal coolant supply. The system is used for milling up to a maximum cutting speed of 5,000 m/min. Inserts are available from stock in several diamond materials and a variety of geometries, making it possible to obtain a cost-effective alternative to brazed face mills. Chip-breaker geometries reduce chip volume and increase process reliability.

Inserts are available with a PCD or CVD-D coating. PCD grade PD75 is described as a useful all-rounder for aluminium machining. Horn recommends substrate PD70 for alloys with a high silicon content. The substrate HD08 (CVD-D) is used for highly abrasive materials.

CVD-D consists of 99.9% diamond to maximise wear resistance. All material versions are available in a range of different geometries to suit the application.