Written & edited by Bernard Martin

HORN USA offers a comprehensive suite of Firearms Machining Systems designed to meet the diverse and intricate demands of the firearms industry. From handguns to rifles, from barrel rifling to magwell broaching, HORN’s solutions are engineered for efficiency, accuracy, and repeatability.

The firearms industry plays a vital role in the economy of New England and upstate New York, regions served by F&L Technical Sales. With a rich history of firearms manufacturing and a robust network of skilled labor and suppliers, our market area contributes significantly to innovation and production in the sector. HORN’s tools are uniquely positioned to support manufacturers in these areas, helping them maintain the high standards of quality and performance demanded by the industry.

HORN provides over 27,000 standard tools and countless made-to-order solutions. Its systems are tailored for complex operations like broaching, reaming, milling, and drilling across handgun and rifle components. The hallmark of HORN’s approach is its commitment to solving unique manufacturing challenges with precision-engineered tools and a focus on reducing secondary operations.

Rifle components on an AR-15 demand an equally high level of precision, and HORN's solutions rise to the occasion. For bolt carriers, System 306 thread milling system, is the go-to choice for machining serrations. This mini milling design ensures great finishes and repeatability, making it ideal for high-volume production. Paired with System DS solid carbide end mills, manufacturers can achieve exceptional results across all of the bolt carrier components.

When machining rifle bolts, System 224, a full-radius grooving system, and System 328, a mini milling system for custom profiles, shine. System 224 creates precise grooves essential for bolt functionality, while System 328 reduces setup times and ensures consistent results for custom bolt profiles. Complementing these systems is System DDS, a high-performance solid drilling solution designed for accurate and consistent hole placement in bolts.

As you already know the flash suppressors can equire some pretty intricate machining. System 328 handles form slot milling with precision, while System DS ensures taper bore features are machined to exact specifications using solid carbide end mills. For threading operations, the System DCG thread milling system, excels in creating precise barrel threads, allowing seamless attachment of flash suppressors.

The lower receiver demands tools capable of handling complex features. HORN’s System DS, a solid carbide end mill solution, is ideal for all of the milling operations. System DD, a solid drilling system, and System 306, a thread milling system, ensure precise drilling and threading, respectively. This combination of tools allows for efficient production while maintaining the highest quality standards.

For modular RIS/RAS rails on airsoft guns or Picatinny rails on AR's, System 328, a mini milling system for form milling, and System DDM, a high-performance drilling system, provide unparalleled precision. System 328 ensures compatibility with various modular accessories, while System DDM ensures reliable mounting hole placement. Together, these tools streamline rail production and improve consistency.

Lastly, the charging handle benefits from System 328, for detailed profiling, System M101, a slot milling system, for precision slot cutting, and System DS, solid carbide end mills, for overall machining. This trio ensures that the charging handle meets operational demands while maintaining durability and reliability.

A groundbreaking collaboration in the medical industry is reshaping how implants are produced. Through the ZykloMed project, funded by the Federal Ministry of Education and Research (BMBF), industry leaders INDEX, Paul Horn GmbH, Beutter Präzisions-Komponenten GmbH, and the wbk Institute for Production Engineering at the Karlsruhe Institute of Technology (KIT) have joined forces to develop innovative machining processes for creating advanced medical implants.

At the heart of this collaboration are cutting-edge methods that enable the efficient production of implants with complex, bionic designs. Using techniques like eccentric turning, polygon turning, and turn whirl milling, the team has successfully overcome the economic challenges of manufacturing implants with intricate geometries. These methods promise to revolutionize the production of orthopaedic, trauma, and dental implants.

The New Standard for Medical Implants
Modern implants are designed to meet stringent standards for strength, biocompatibility, and patient comfort. Their shapes, optimized to mimic natural bone structures, allow for better integration with the body, less invasive procedures, and easier attachment. However, these new designs have traditionally come with a steep price tag—due to their non-circular, curved surfaces and functional elements that require several manufacturing steps on different machines.

The ZykloMed project partners sought to simplify this complex process, reducing costs and increasing efficiency while maintaining the precision and quality required for medical applications. Their focus was on developing synchronized manufacturing techniques that can handle these bionic, non-round shapes without the need for constant repositioning and multiple machines.

The novel processes developed—eccentric turning, polygon turning, and turn whirl milling—all rely on synchronized rotating axes, making it possible to create non-circular and curved shapes efficiently. Each method brings unique capabilities to the table:

From Lab to Real-World Application
After rigorous testing in both laboratory and near-production environments, the ZykloMed team demonstrated that these synchronized machining processes can economically produce complex, multifunctional implants. These advancements not only make the production of new, bionically designed implants more cost-effective but also hold potential for optimizing the production of existing implant designs.

Beyond the medical industry, the processes developed through the ZykloMed project could have applications in other sectors where complex geometries and high precision are required.

A Step Forward in Medical Manufacturing
The success of the ZykloMed project marks a significant step forward in medical manufacturing. By combining cutting-edge research with practical industry applications, the project partners have paved the way for more efficient, economical production of advanced implants that meet the needs of modern healthcare. Their efforts are set to improve patient outcomes and push the boundaries of what is possible in implant design and production.

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.

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!

In a significant development that is set to redefine machining standards, Horn USA has announced the launch of its new carbide grades, IG3 and IG6. These introductions signal a major breakthrough in extending tool life in the machining of materials such as stainless steels, titanium alloys, and superalloys, offering unmatched performance and longevity thanks to their unique coating thicknesses and substrate materials.

The IG3 grade is distinguished by its 3-micron coating thickness, a feature denoted by the "3" in its name. Meanwhile, the IG35 insert, which falls under the IG3 grade, designates carbide substrate 5, a MG12 10% cobalt micrograin that Horn designed to be an optimal balance of hardness and toughness for enhanced durability. For more demanding applications, the IG6 grade steps up with a thicker, 6-micron coating, ensuring even greater efficiency and performance longevity.

A pivotal aspect of these new grades is the application of High Power Impulse Magnetron Sputtering (HIPIMS) coating technology. This advanced coating method ensures that the AlTiSiN coating adheres exceptionally well to the tool surface without necessitating hones or edge preparation. The coating adhesion remains consistent even on upsharp inserts.

This breakthrough not only extends tool life significantly but also contributes to a tougher tool capable of withstanding temperatures up to 1100 degrees Celsius and maintaining a Vickers hardness of 1820 (HV10). The AlTiSiN coating, applied using HIPIMS technology, facilitates a lower coefficient of friction and ensures that the heat generated during machining is directed to the chip instead of being absorbed by the insert substrate. This innovative approach allows for higher machining temperatures without compromising the tool's performance.

The enhancements brought by the IG35 variant are particularly noteworthy. Turning tools coated with IG35 have shown a remarkable increase in tool life compared to those using the previous TH3 grade, as evidenced by extensive testing. Although the IG3 grade matches the performance of the TH3 in milling applications in terms of tool life, the introduction of the IG6 grade with its thicker coating has significantly improved tool life in milling operations, without sacrificing the quality of the finish.

These improvements have been achieved while running the surface feet per minute (SFM) of the older TH3 grade, highlighting the substantial advancements in tool life and efficiency.  In some milling applications it was found to increase tool life beyond twice that of TH3, making it a good choice as a drop-in replacement in established processes.  Most engineers seems to feel that higher SFM rates should be able to be attained with the IG6 while still getting great tool life and finish.

The applications for the IG3 and IG6 grades are extensive, covering a wide array of machining tasks from grooving, both internal and external, to more specialized operations such as chamfering, face grooving, and thread machining. This versatility ensures that Horn USA's new carbide grades can meet the diverse needs of the machining industry, setting new benchmarks in performance, efficiency, and tool longevity.

Horn USA's commitment to pushing the boundaries of innovation is evident in the launch of the IG3 and IG6 grades. These new offerings not only cater to the evolving demands of the machining sector but also underscore Horn USA's dedication to enhancing manufacturing efficiency and tool performance.

Operating from Nashville, Tennessee, Horn USA, a subsidiary of the globally renowned Horn Group, continues to lead the way in delivering high-performance cutting tools and solutions. With a steadfast focus on innovation, quality, and customer service, Horn USA is poised to drive the machining industry forward, helping customers achieve unparalleled manufacturing success.

For more details on the IG3 and IG6 grades and other products from Horn USA, interested parties are encouraged contact F&L Technical Sales Inc. today.

  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.

Paul Horn GmbH is expanding the range of carbide grades for the DAH milling system to enable its use for machining a wider range of materials. The new grades SC6A and IG6B complement the tool system for high feed milling. The expansion gives customers the opportunity to choose grades best adapted to their machining applications. 

The SC6A grade is suitable for machining the ISO M material group, as well as ISO S materials as a secondary application. Horn has developed the IG6B grade for machining the ISO P group, while it is also suitable as a multi-purpose grade for other material groups. 

With the DAH82 and DAH84 systems, Horn introduces a new generation of tools for high feed milling. The eight usable cutting edges of the precision-sintered insert offer a competitive price per cutting edge and hence economical and efficient machining. The positive cutting edge geometry ensures a soft and quiet cut as well as good chip flow despite the negative mounting position.

Horn offers the inserts in the substrates SA4B, SC6A and IG6B, which are suitable for universal use machining various materials. The large radius of the main cutting edge of the insert produces a soft cut, ensures an even distribution of cutting forces and thus ensures long tool life.

​The maximum cutting depth is ap = 1.0 mm (DAH82) and ap = 1.5 mm (DAH84).  

​The DAH82 variant is available as an end mill and as a screw-in milling cutter in the following diameters (z denotes the number of inserts):

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.

It's that time of year for IMTS!

​Here's a preview of some of the products that are going to be featured during the International Manufacturing Technology Show September 12-17.  You can see all of these new products and talk to the manufacturers in the Tooling & Workholding Systems Pavilion in the West Building Level 3. 

Supermini Set. Horn USA is featuring the Supermini tool holder system with face clamping as a set, in response to customer requests for different tooling system heights. With this holder variant, 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. This increases repeatability when changing the insert and provides better utilization of the available space. This is a big time saver on Swiss-type lathes, as the user can change the cutting insert without removing the tool holder.

New carbide grades for system DAH8 - Horn USA is expanding its range of carbide grades for its DAH milling system to enable its use for machining a wider range of materials. The new grades SC6A and IG6B complement the tool system for high-feed milling. The SC6A grade is suitable for machining the ISO M material group, as well as ISO S materials as a secondary application. Horn has developed the IG6B grade for machining the ISO P group, while it is also suitable as a multipurpose grade for other material groups.

If you would like to learn more about any of these products or to see a demonstration, get in contact with us and we'll set up some time with you to visit your shop!

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