Horn USA has introduced a new range of tools specifically designed for deep axial grooving applications. These tools, including the Horn Mini 114 grooving tool system for turning and milling, which can create face grooves (axial grooves) up to 10 mm deep, are tailored for applications requiring exceptional accuracy and surface finish, especially in the production of internal grooves, seal grooves, and other complex geometries in small-diameter bores.

Key Features and Benefits

1. Expanded Groove Depth Capabilities -  The new tools offer grooving capabilities of up to 10 mm deep, which is a substantial improvement over previous standard tools in this category. This makes them ideal for demanding applications in industries such as aerospace, automotive, medical, firearms, and industrial equipment. By addressing the challenges of deep axial grooving, these tools enable machinists to achieve precise results without compromising on efficiency.
2. Enhanced Tool Geometry - The cutting geometry has been designed to optimize performance by reducing cutting forces and enhancing chip control. This allows for smoother operation and consistent chip evacuation, even under demanding conditions. The tools are engineered to deliver reliable performance and minimize wear, which really improves tool life.
3. Advanced Coating Technology - These tools feature the IG35 coating, Horn's proprietary technology designed to enhance heat resistance and reduce friction. The IG35 coating ensures consistent performance across a wide range of materials, including high-strength alloys and stainless steels, making the tools exceptionally versatile and durable.
4. Compatibility with Existing Tool Holders - The Mini 114 inserts are designed to fit directly into Horn’s existing axial tool holder systems. This eliminates the need for special tool holders, simplifying setup and reducing tooling investment while maintaining high-performance results.
5. Modular Tooling System - The tools are also compatible with Horn’s modular tooling system, providing users with added flexibility in adapting to various machining setups. This modularity reduces downtime during tool changes and supports greater operational efficiency.

As standard, Horn offers the EG55 carbide grade grooving tools in three different types from stock with cutting widths of 2 mm, 2.5 mm, and 3 mm. The minimum diameter for grooving is 14 mm, while the maximum is 34 mm to 36 mm, depending on the type.

Applications and Industries
The new deep axial grooving tools are particularly beneficial for:

• Seal Grooves - Precision machining of grooves for seals, commonly found in hydraulic and pneumatic systems.
• Internal Grooves - Creation of complex geometries inside cylindrical components.
• Specialized Applications - Machining tasks requiring exceptional depth-to-width ratio capabilities.

These tools are engineered to meet the high standards demanded by industries such as:

• Aerospace - Manufacturing components with intricate internal features.
• Medical - Precision machining of surgical instruments and implants.
• Automotive - Production of internal grooves for drivetrain and engine components.
• Firearms - Machining precision grooves in firearm components, such as barrels and receivers.
• Industrial Equipment - Manufacturing grooves for heavy-duty machinery parts.

The inclusion of industries such as firearms and industrial equipment highlights the relevance of these tools in the New England market, where precision manufacturing is critical.

Horn USA’s new tools for deep axial grooving demonstrate the company’s commitment to addressing the evolving needs of precision machining. By combining advanced geometry, superior coatings, modularity, compatibility with existing holders, and precise specifications, these tools set a new standard for performance and efficiency in challenging grooving applications.

For more information about these innovative tools and their applications contact us at F&L Technical Sales.

by Bernard Martin

With the new Supermini type 105, Horn has succeeded in developing a universal boring tool with sintered chip breaking geometry.  The cutting edge geometry extends far into the corner radius of the insert. This ensures chip control even with small in-feed settings. The geometry can be used universally for different material groups and is suitable for internal, face, copy and back turning.

Innovation is key to maintaining a competitive edge. Horn has raised the bar with the introduction of a sintered chip breaking geometry for their Supermini tool system. This latest development, which became available for shipping on June 12, 2024, is the next milestone in the history of the Supermini, a product that has been a cornerstone of Horn’s portfolio since its inception in 1989.

A Legacy of Innovation
The Horn Supermini system, launched 35 years ago, has undergone continuous development, addressing a wide array of machining challenges globally. "This will revolutionize boring," thought Paul Horn when he first examined the prototype of what would become one of the company's most successful products. Since then, the Supermini has evolved through numerous stages, each improving its versatility and performance.

The Supermini tool system is designed for a variety of machining operations, including boring, profile turning, internal grooving, threading, chamfering, face grooving, drilling, and slot broaching. It is adaptable to a range of diameters from 0.2mm to 10mm, thanks to solid carbide inserts shaped in a unique teardrop form. This innovative design ensures large, precise contact surfaces in the tool holder, enhancing the system's overall rigidity and minimizing deflection and vibration during use.

Addressing the Chipping Challenge
One of the most persistent issues in internal machining is managing long chips, which can lead to tool breakage and operational inefficiencies. Traditionally, chip breaking geometries were either lasered or ground, processes that increased production costs. The new sintered chip breaking geometry in the Supermini type 105 changes the game, offering high process reliability with superior chip control.

Markus Horn, Managing Director of Paul Horn GmbH, stated, "With a lot of hard work, we have managed to solve economically the problems of long chips when internally machining small bore diameters." The new geometry ensures effective chip control even with small in-feed settings and can be used across various material groups and machining operations, including internal, face, copy, and back turning.

Enhanced Features for Greater Performance
In addition to the advanced chip breaking geometry, Horn has optimized the carbide blanks to provide greater rigidity and a more stable cutting edge. The coolant supply system has also been improved to enhance performance. The new inserts are compatible with a wide range of type 105 tool holders, available in lengths of 15.0mm, 20.0mm, and 25.0mm, and in carbide grades TH35 and IG35. With a corner radius of 0.2mm, these tools are suitable for bores starting from a diameter of 6 mm.

The extensive Supermini portfolio includes approximately 2,500 standard variants, supplemented by countless custom solutions to meet specific user needs. Horn also offers a variety of tool holder options, including round shank, square shank, interface, and adjustable holders, with multiple clamping solutions to suit different applications and space constraints.

A Commitment to Excellence
The latest advancement in the Supermini series underscores Horn’s commitment to innovation and excellence in the field of machining technology. By addressing critical issues like chip management with cost-effective solutions, Horn continues to provide tools that enhance productivity and reliability for machinists around the world.

As the machining industry evolves, the introduction of the sintered chip breaking geometry in the Supermini type 105 reaffirms Horn's position as a pioneer in tool technology, dedicated to solving the challenges faced by its customers and setting new standards in the industry.

For more information or to test some of these new inserts contact the F&L Technical Sales team!

  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.

As a result of the design of the Supermini, clamping is not carried out via the lateral surface of the cutting insert but via a clamping wedge on the face.  This results in a greater holding force on the insert and thus high rigidity of the entire system.