Latest HORN Products
Drilling, grooving, turning and milling features and contours in sintered carbide – without pre-treatment or subsequent treatment – is not possible with standard tool concepts available on the market. For such applications, CVD-D-tipped tools offer real advantages. Their geometrically defined cutting edges are adapted to the particular machining tasks – from extremely sharp and rounded, all the way up to positive and negative chamfers.
Materials that are extremely difficult to machine can pose a significant manufacturing and financial challenge to cutting tools – particularly when it comes to small and miniature parts. To address the needs of these applications – in which tools from the Supermini product series machine holes with diameters from 0.2 mm – HORN has developed the EG3 and EG5 coatings.
The new grooving systems are designed for internal machining of bores with diameters ≥ 16 mm (system 209) and ≥ 20 mm (system 216). At retraction distances up to 50 mm, a groove depth of max. 7.5 mm can be achieved. Key elements of both systems include tool hold-ers with internal cooling and twoedged indexable inserts with cutting widths of 2 to 6 mm.
New products for the proven 25A axial grooving system with cartridge design and round shanks enhance its possible applications. Whereas the previous system with one-edged or two-edged indexable inserts achieved cutting widths of 2 to 4 mm, and a grooving depth of up to 18 mm from an external diameter of 15 mm, the further developed cartridge and round shank versions now allow for grooving diameters of 50 to 65 mm and from 65 to 80 mm with cutting widths of 3 and 4 mm.
The patented DR reaming system with its uncoated or coated reamers has been proving its worth for many years in applications involving diameters from 11.9 to 140.6 mm.
Fastest possible delivery times can be offered for these highprecision tools. Users at EMO are being informed that the most popular reamers are now available from stock: for H7 bores from 12 to 50 mm in diameter in millimetre increments and for bores from 52 to 100 mm in diameter in a further eleven sizes.
With the solid carbide tools from the DS milling cutter family, HORN is incorporating top-class products into its portfolio for machining copper, graphite, aluminium, plastics, fibrereinforced plastics, soft and hardened steels as well as titanium and superalloys. The end, torus, full radius, double radius, multi-edge and roughing cutters are available in diameters from 2 to 16 mm, and micro end mills have diameters ≥ 0.2 mm.
The solid carbide milling cutters from the DCG series have been proving themselves in the production of threads sized from M3 to M12 for many years. As the single-row milling cutters can be used for different pitches, high operational flexibility is guaranteed.
New developments for this series are being showcased at EMO.
At EMO Hannover, HORN is presenting the high-speed spindles from SFI Toodle, which have recently been added to its portfolio. With this addition, users do not just benefit from the advantages of these world-renowned spindles – in particular, they can reap the rewards of combining them with the solid carbide milling cutters from HORN's DS series. More than 600 DS milling cutters with cutting edge diameters of between 0.1 and 3 mm can be supplied with a premounted Toodle spindle within one week.
HORN will introduce a range of solid carbide drills at EMO in Hannover. Two geometry variants with diameters from 4.0 mm to 18.0 mm are available.
The tools feature the excellent standard of precision that customers have come to expect from HORN. They are produced with particular attention paid to the surface quality, the precision of the ground geometry and the cutting edge preparation.
The ZETAtec 90N arbour milling cutters, featuring diameters of 50 mm to 160 mm, are equipped with five to ten inserts, each of which has six cutting edges. The excellent standards of reliability they achieve during rough machining are thanks to their negative geometry – while the positive rake angle ensures a smooth cut.
The ETAtec 45P arbour milling cutters, featuring diameters of 50 mm to 160 mm, come equipped with between five and ten 7-edged inserts. The tools not only offer a 45° angle of attack and positive geometry, but also generate low cutting forces, all of which ensures a smooth machining process accompanied by high levels of productivity – an important user benefit, particularly in cases where less powerful machines and unstable clamping setups are being used.
HORN presents Boehlerit’s extended product portfolio for turning using tool holders with connections for internal coolant supply. The new tool holders are available with toggle clamp (ISO-P) and screw clamp (ISO-S) systems.
Boehlerit’s new tool holders with connections for internal coolant supply are available with a toggle clamp system (P) and screw clamp system (S).
At the EMO trade fair, HORN's proven DA32 milling system will be on show with diamond-tipped inserts for the first time. This feature allows the tools to achieve outstanding results during shoulder milling, face milling, plunge milling and circular milling. The highly positive geometry of the inserts ensures a particularly smooth cut.
The latest expansion of the 315 grooving system from HORN covers hard machining applications. The single-edged, CBNtipped insert ensures high rigidity in the tool. The insert seat has a large contact surface to direct the cutting pressure into the holder. Furthermore, the central clamping screw enables maximum tightening of the insert.
The new grooving blades are designed for universal use when producing small batch sizes. Six blades with cutting widths of 2.5/3 mm and 4 mm are available for these applications, with each pair of three blades measuring 26 mmand 32 mm high. Their projection length is universally adjustable.
The S64T insert with chipbreaker geometry is an evolution of the S64T insert that was unveiled at AMB 2016. In addition to the more extensive working range it offers, this precision tool with six cutting edges features a range of chipbreaker geometries and the new EG5 coating. Thanks to this coating, as well as the carbide substrate, the new insert is able to machine any kind of steel.
For the high-productivity manufacturing of internal gear teeth, splines and other internal profiles, HORN is introducing tools for gear skiving. This machining method has a number of advantages:
- Considerably shorter processing times in comparison to gear tooth broaching
- Can be used on optimised milling centres
- No undercut necessary at the end of the gear tooth
- Turning and gear cutting possible in a single clamping
HORN has developed the new DA62 milling system for corner, face and plunge milling. The system from the precision tool manufacturer uses a new precision sintered six-edged indexable insert. Both sides of the insert can be used and it has three axial and radial cutting edges on each side. The precision-ground, trigonal insert boasts a large core cross-section and maximum cutting length.
Horn tools for machining cast or forged aluminium wheels deliver high process reliability and excellent surface quality.
The tools, which are based on the tried and proven grooving and longitudinal turning system 229, are available as cutting inserts tipped with carbide and PCD. Furthermore, the portfolio is completed by the S29F system and a comprehensive range of ISO products, both of which are also available in PCD.
Crude oil is one of the most important and most widely used raw materials, particularly as a raw material in the chemical industry and as a fuel for transport and for generating energy. Due to the huge importance of crude oil, the crude oil industry is the largest in the world.
HORN is extending the 960 modular system for the 845 interface by adding new cartridges to hold the S229 insert. The double-edged insert for grooving and parting off, as well as for longitudinal and contour turning, is available ex stock with various chipbreaker geometries and substrates. The maximum grooving depth of the cartridge is 25 mm with a machining diameter of 68 mm. Groove widths between 3 mm and 6 mm are available. All grooving cartridges are fitted with an internal coolant supply. Cooling takes place via the clamping finger and support.
The S100 single cutting edge insert and the S224 double cutting edge insert from HORN are available with internal coolant supply through the insert. The targeted coolant jet acts directly on the point of cutting, thus ensuring optimum cutting conditions. The funnel-shaped nozzle creates a coolant jet which actively supports chip formation and thus reduces the chance of chip jamming. Furthermore, this type of internal cooling significantly reduces the formation of built-up edges and fractures on the cutting edge. Unlike conventional cooling methods, this system therefore achieves higher cutting parameters, which allow the tool to be used even more economically and efficiently.
HORN has developed the new DA62 milling system for corner, face and plunge milling. The system from the Tübingen-based precision tool manufacturer uses a new six-edged indexable insert. Both sides of the insert can be used and it has three axial and radial cutting edges on each side. The precision-sintered, trigonal insert boasts a large core cross-section and maximum cutting length. The design of the cutting edges produces a positive cutting geometry despite the negative insert angle.
The HORN Portfolio of solid carbide end mills of the series DS has been extended for dynamic trochoidal milling. The special construction of the geometry for trochoidal milling cycles ensures a quiet process due to the unequal division/split/and helical cutting edges.
The HORN product range includes the smallest patented quickchange reaming system in the world. The four system sizes offer diameters ranging from 7.600 mm (0.2992") to 13.100 mm (0.5157"). The system allows the reaming cutters in the machine to be changed quickly and easily with maximum repeat accuracy.
The patented tangential milling system has now been expanded into our T-slot-cutter range. The cutters are available with diameters of 25 mm (.9843”), 32 mm (1.2598”), 40 mm (1.5748”) and 50 mm (1.9685”). All the different cutters have shanks which are compliant with DIN1835-B. The design of the tools has been optimized specifically for machining T-slots. The cutter bodies are extremely stable and designed with internal radial coolant supply, for efficient cooling and optimized chip evacuation.
HORN has developed an impressive array of special tools for machining titanium materials. With their sharp cutting edges, positive cutting angle, large relief angle and polished cutting edges, these tools are designed to overcome the main problems encountered during titanium machining. The TSTK cutting material grade that HORN has developed for its solid carbide milling cutters is specifically intended for machining titanium in the aviation/aerospace and medical technology industries. As well as offering good tribological properties and high temperature resistance, this introduces minimal heat into the substrate and acts as a kind of thermal shield.
The optimum system solution for high-performance milling: HORN’s patented range of highly successful tangential milling tools that go by the name of the 406 and 409 systems are to be supplemented at every level with the introduction of new face, corner, screw-in and end mills. The face and corner mills will be available in standard diameters of 40 mm (1.5748") to 250 mm (9.8425") with a wide and narrow tooth pitch. These products will offer maximum performance for meeting the stringent requirements of machines and workpieces alike.
Our portfolio of products for boring now includes diamond-tipped tools with CVD-D and PCD cutting edges. These tools are used for boring, copying and grooving when working with sintered carbide, ceramics or abrasive plastics. They are also used for machining non-ferrous materials which are either highly abrasive due to their silicon content or have a tendency to exhibit chipping problems and form built-up edges. The chip geometry, which has been specially developed for this purpose, solves virtually all machining problems caused by uncontrolled formation of stringy swarf.
HORN’s modular die for pipe threads (patent pending), which is available in sizes of G¾ and G1 inch, is an easy swap system consisting of one basic holder and individual inserts. In the event of wear, all you have to do is replace the inserts in the basic holder, thereby eliminating the regrinding work that would normally be required.
The new narrow triple-edge- cutting insert for the 315 type grooving system features a range of chip geometries for full and partial cuts for grooving widths of less than 2 mm. The available indexable insert cutting widths of 1.1/1.3/1.5 and 2 mm in left or right-hand design support grooving depths of up to 5,5 mm.
New high-performance variants will be added to the Supermini® from HORN. With a new coating, new substrate and new microgeometry, it is setting new standards when it comes boring holes between 0.2 mm and 6.8 mm. With this product, HORN is enabling its customers to accelerate their production throughput, even with an increasing proportion of stainless, highalloy and inhomogeneous steel qualities.
The 64T six-edged grooving insert is the latest addition to the HORN grooving range. The type 64T insert is precision sintered and is currently available with a grooving width of up to 3.29 mm (0.1295") in the .00 geometric shape. As a neutral grooving insert, it can be used on either the left or the right in square shank holders with internal cooling. The holders measure 16 x 16 (0.6299" x 0.6299"), 20 x 20 (0.7874" x 0.7874") or 25 x 25 mm (0.9843" x 0.9843"). An adequately dimensioned clamping screw holds the grooving insert precisely, keeping it central in the insert seat and ensuring a high level of process reliability. The type 64T insert supports grooving depths of up to 3.5 mm (0.1378") and a maximum workpiece diameter of 65 mm (2.5591).
HORN has enhanced the cutting width and diameter of the tried-and-tested 25A axial grooving system with cartridges and round shanks. The cassettes are designed for the standard cassette interface K220 and are compatible with all applicable basic holders from HORN. Supplying internal coolant to the cutting point guarantees efficient cooling and boosts chip flow. Cartridges and boring bars were previously available from an external diameter of 15 mm, with a groove depth of up to 18 mm, and with one-edged or two-edged indexable inserts featuring cutting widths of 2 and 3 mm.
The thread whirling technology of Paul Horn GmbH with tools of type M271 having 6 or 9 cutting edges is a highly effective and economical system to produce single or multi start threads and profiles. Due to very short machining times the process of thread whirling, compared to conventional threading is much more cost effective. The newly developed modular thread whirling system, gives the customer a great variety of possible tool combinations, suitable for all of the most popular sliding head machines and whirling units on the market.
When machining components with diameters starting from 0.2 mm using cutting depths that often measure 0.01 mm, tools, tool systems and, primarily, cutting edge designs face extremely high requirements. In order to ensure precision chip removal even at the smallest depths, tool cutting edges must be incredibly sharp and free from break-outs, with exceptionally fi ne surface qualities.
The newly developed HORN turbo whirling® process optimises machining during thread whirling and increases efficiency. HORN has developed cutting tools for whirling with a new cutting division specially for machining threads with a larger allowance. To this end, individual cutting edges work as pre-cutters and machine the workpiece to the defined external diameter. In the case of nine-cutter tools, the cutting division allows the machining work to be divided so that each cutting edge is subject to equal load, meaning that individual cutting edges can achieve significantly higher service lives.
Working with Index and Schütte multi-spindle lathes in mind and partnering with Ernst Graf GmbH, HORN has developed the modular base carrier systems type 968 and 969 with interfaces of type 842 and 840. For Index multi-spindle lathes, there is the system type 968 for cassettes of the type 842. This means that all common cassettes of this type fit in the height-adjustable basic adapters.
The modular grooving system from HORN for grooving cartridges based on the systems interface 845 and 842 consists of:
- Basic toolholder for turrets with BMT / MAZ connection or VDI holder for turrets and star turrets
- Basic toolholder for millturn centres
- Matching cartridge range with different grooving widths and grooving depths
The new 262 tool system has been specially developed by HORN for cam-controlled lathes, with indexable inserts for holders with 6x6 and 8x8 mm cross-section. The hard-milled insert seat ensures excellent stability, the ground contact surfaces of the indexable inserts ensure exceptional precision and two fastening screws ensure stable clamping. The system allows the centre height, width and length to be positioned precisely. A lateral insert seat offers maximum freedom when designing the cutting edge.