by Bernard Martin

Horn USA continues to push the boundaries of fine-bore machining with the latest iteration of its Supermini system—now featuring a sintered chip breaking geometry that sets a new standard for process reliability and productivity in internal turning applications.

For decades the Supermini has been one of Horn’s most versatile and successful tooling systems. The introduction of sintered chip breaking geometry is a pretty significant advancement in small boring, addressing one of the most persistent challenges in internal machining: uncontrolled chip formation.

What Makes the New Supermini Different
At the heart of this innovation is the sintered geometry built directly into the insert. Unlike traditional chip breakers that are ground or laser-cut as a secondary operation, Horn’s geometry is fully sintered into the cutting edge during manufacture.

This approach delivers several advantages:

• Reliable chip control across a wide range of materials. The geometry actively guides and shapes swarf, encouraging predictable chip breakage even during light feeds and small infeed settings.
• Reduced downtime and smoother cutting. Long, stringy chips that wrap around the tool or clog the hole are dramatically reduced, increasing uptime and reducing secondary chip-removal tasks.
• High process stability. The geometry extends well into the corner radius of the insert, providing consistent chip control across internal, face, copy and reverse turning operations.

Built for Precision and Practicality

Boring, profile turning, internal grooving, threading, chamfering, face grooving, drilling and slot broaching: The Supermini tool system can be adapted for numerous machining operations.

All types allow internal coolant supply directly to the cutting zone. The Horn tool portfolio contains around 2,500 different standard variants of the Supermini. In addition, Horn solves users' machining problems with countless customized solutions.

Chipbreakers make all the difference
One of the biggest challenges in internal machining is the generation of long chips. Depending on the material, boring often leads to stringers that wrap around the tool, clog holes or, in the worst case, lead to tool breakage. This is where chip breaking geometry can help. It guides and shapes the chip and causes it to break.

According to Horn USA : "Previously, specially lasered or ground chip breaking geometries were used for this purpose. However, this increased the cost of the inserts. With the new Supermini type 105, Horn has succeeded in developing a universal boring tool with sintered chip breaking geometry. The tool offers high process reliability due to its good chip control.

The cutting edge geometry extends far into the corner radius of the insert. This ensures chip control even with small infeed settings. The geometry can be used universally for different material groups and is suitable for internal, face, copy and back turning.

In addition to the geometry, Horn optimized the carbide blanks of the inserts to have greater rigidity and an even more stable cutting edge area. The coolant supply has also been revised. The new insert is compatible with numerous types of 105 tool holders. Horn offers the inserts as standard in three lengths (15.0 mm, 20.0 mm and 25.0 mm) and in carbide grades TH35 and IG35. The corner radius is 0.2 mm. The tool is suitable for use from a bore diameter of 6 mm. The wide range of applications for the inserts goes hand in hand with their cost-effectiveness, as the price of the new Supermini is similar to that of the standard insert without geometry."

Performance in Real-World Use
Early adopters of the new Supermini generation report significant improvements in chip behavior and process reliability. Components previously prone to entangled swarf now produce fine, manageable chips that no longer interrupt machining cycles. Tool life remains in line with conventional inserts while delivering the added benefit of reduced operator intervention.

Applications and Flexibility
Because the new sintered chip breaking geometry performs well across material groups—from steels to stainless alloys—it is suitable for a wide array of industries and part types. The universal design makes it ideal for internal boring in precision components where chip control, surface finish, and tight tolerances are critical.

Whether used in aerospace, medical, automotive, or general precision machining, the updated Horn USA  Supermini system stands out as a robust solution for challenging internal turning tasks.

The International Manufacturing Technology Show (IMTS) is just around the corner, and it's shaping up to be a can't-miss event for anyone in the manufacturing industry. F&L Technical Sales is excited to announce that several of our principals will be showcasing their cutting-edge products. Below is a sneak peek at what you can expect!

When it comes to precision and stability in boring operations, Dorian Tool stands out with their Solution Tool Anti-Vibration Boring Bars. These tools are engineered to reduce chatter and vibration, resulting in superior surface finishes and extended tool life. Don't miss the opportunity to see these high-performance tools in action at the Dorian Tool booth.

Horn USA will be introducing their new grade IG35 as well at IMTS. This latest innovation is designed to deliver exceptional performance in a wide range of materials, offering outstanding wear resistance and extended tool life. The new grade offers improved thermal properties so it really boosts productivity in stainless steel and heat resistant alloys. It allows improved edge adhesion on sharp edge geometries.

And don't forget to check out the new new Supermini type 105 sintered chip breaking geometry we talked about last month!

Mate Precision Technologies is set to unveil their advanced 52/96 workholding system, designed to provide unmatched precision and stability for your machining operations. These systems are tailored to improve setup times and ensure consistent, high-quality results, making them a must-see at IMTS.

  Horn has added a variant with a precision-ground rake face to the Supermini system especially for ultra-fine machining of bores.

As a result of precision grinding of the cutting edge, it is free from notches when magnified approximately 200 times. The tool system can be used from an inside diameter of 0.3 mm (0.012").

The sharp insert geometry enables process reliability even with very small infeed and cutting feed rates. The specially developed coating is suitable for stainless steels, non-ferrous metals and other metallic materials.

The insert of the Supermini Type 105 system requires only one tool holder for well over 1,000 insert variants. This applies equally to left-hand and right-hand versions.

The carbide inserts are available in coated and uncoated versions in different grades for every application including hard machining up to 66 HRC.

The patented droplet shape of the cross-section has a vibration-damping effect and delivers excellent repeatability when changing the insert. Internal coolant supply to the insert increases tool life, enhances cutting performance and improves chip removal.

Horn offers the tools with elements for face clamping. This allows, for example, the insert to be changed easily without having to remove the holder from the machine.

History Horn Supermini
In 1989, HORN launched the technically superior Supermini system at EMO in Hannover, Germany. After considerable technical development, it was possible to successfully manufacture precision internal grooving tools for bores down to 5 mm (0.197") in diameter.

​The Supermini system was born and over time became one of Horn's most successful products. In addition, the Supermini system was the first precision tool to benefit from Horn's own in-house coatings.

Horn USA has introduced the new DR-Large modular reaming system for use in the machining of large bores.

Dorian Tool has some very detailed technical information in their Solution Tool catalog to address deep hole boring. First we're going to list the fundamental rules of selecting the correct boring bar and then take a deeper dive into the fundamentals of troubleshooting. 

If you want more information, technical specifications and much more detailed information on troubleshooting you can download the Solution Tool catalog below.

A short history about deburring from E-Z Burr.

Burrs may be the last concern that an engineer or machinist wants to think about in designing a new part focusing on tolerances and production rate. However, the problem remains and calls for attention to develop a quality product. It was nearly a century ago that a solution was discovered and the first deburring tool went to market.

Today’s tools offer many solutions to accommodate the many varieties of applications and materials. Looking at the technical aspects of each application, material and individual customer’s goals, E-Z Burr has taken the process of deburring to the next level.

Since 1960, E-Z Burr has been providing innovative and versatile deburring solutions for customers. Over the last 5 years they have introduced and expanded their Carbide Series of deburring tools to produce successful results on hard to machine materials and higher production volumes. “From the very start, our goal has been to provide tools that are durable, dependable, easy to use and maintain, while offering our customers a fair and reasonable price,” says Bill Robinson, President of E-Z-Burr. “We are always looking for new, innovative ways to meet the needs of our customers.”