2019
Wiper geometry milling insert
Horn has extended its 406 tangential milling
cutter system (below) to include an insert with
wiper geometry for nishing. The new insert has
been developed in response to demand from
Horn’s customers, re ecting the fact that surface
quality requirements are constantly increasing.
The new geometry produces very high surface
quality, even at high feed rates, resulting in
shorter machining times. Moreover, the geometry
makes it possible to reduce the need for
subsequent grinding processes.
The single-edged nishing 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 nishing insert is
available in grade AS4B for the workpiece
material groups P and M, and in grade AS46 for
workpiece material group K.
The 406 system now boasts wiper inserts
Printed coolant attachments for reaming tools
Horn offers bespoke, additively manufactured
coolant discs for customers requiring reliable chip
control during high performance reaming. When
reaming through-holes or deep blind holes,
standard solutions often reach their technical
limits. Long-chipping materials and materials that
are dif cult to cut make it necessary to modify
the tool system, as well as the internal coolant
supply. With its 3D-printed coolant disc, Horn has
developed a solution to this problem that can be
screwed on to the tool shank.
It results in extended tool life, due to the
direct, targeted cooling (right) and, above
all, reliable chip removal. Additive
manufacturing technology enables the
coolant outlets to be designed freely. 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 speci c
machining task and the material to be
processed.
The tool shank facilitates the removal of chips
from the machining zone, thanks to its polished
and coated utes. The coolant supply reduces the
channel cross-sections, resulting in an increased
coolant ow rate without any pressure loss. The
tool system can be converted for blind hole
cooling, shoulder cooling, or combined shoulder
and blind hole cooling. The combination of the
solid carbide reaming insert, the tool shank and
the 3D-printed coolant discs demonstrates
Horn’s expertise in the machining of drilled
holes and reaf rms the company’s status as
a problem solver and technology leader.
New tool for skiving larger gears
The skiving method for producing large gear
modules on rigid turn-milling and millturning
centres offers the bene t 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, whose patented seat
and threaded connection ensure precise
positioning and clamping for high rigidity of the
system as a whole and repeatability of exchange.
A ground chipbreaker enables effective swarf
removal from the machining zone, 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 veri ed on an individual
AM coolant rings aid reaming performance
basis prior to implementation.
The tool manufacturer’s portfolio comprises a
wide 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 pro les, all can be
manufactured cost-effectively with milling or
broaching tools, while the gear skiving range is
further testament to Horn’s gear tooth
manufacturing expertise.
It is a machining process that has been in use
for over a century, but has only recently been
incorporated into a wider range of applications
now that universal lathes and machining centres
have offered suf ciently accurate synchronisation
of workpiece rotation with cutting tool movement
plus the development of process-optimised
software to facilitate the complex technology.
Wiper milling insert, coolant
attachment, gear skiving
Horn Cu ing Tools
T: 01425 481880 F: 01425 481898
E: mikegreen@phorn.co.uk
W: www.phorn.co.uk
SPEAKING OF SUCCESS
Gear skiving now for larger modules
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