Change the Cutting Insert without Removing the Toolholder with the New SuperMini from Horn USA
Horn USA has introduced its proven Supermini tool holder system with face clamping as a set, thereby responding to customer requests for different tooling system heights.
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.
IMTS Preview of Products fRom Blue Photon, Dorian, Horn USA, Mate Workholding and Techniks.
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.
Blue Photon Workholding
Horn USA, Inc.
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.
Techniks Tool Group
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.
The latest DR tool offers easy handling and high-precision thanks to the proven technology of the DR system. The large number of cutting edges and high feed rates reduce cycle time and machining costs.
Modular construction and solid carbide inserts offer the user exceptional flexibility. Tool setting is not necessary when exchanging the cutter’s head as HORN offers reconditioning service for the DR-Large system.
The versatile and powerful interchangeable high-feed reamer is perfectly suited for finishing large bores from Ø140 mm (5.512”) to Ø200.2 mm (7.881”).
The modular construction of the reaming tools can be extended to any length with beta module standard components. The beta module interface is ABS-compatible. HORN offers six types of cutter heads to cover the entire range of diameters in 10 mm (.394”) increments.
All cutter heads are manufactured with internal through coolant to each cutting edge. The custom insert interface offers extreme precision and insert interchangeability within microns.
High-precision, high-feed reaming is a very economical machining process compared to the boring of tight tolerance holes.
The motivation behind DR-Large is the customer demand to replace large diameter tools with inserts brazed into a fixed position and tools that are diameter specific.
The fixed tools require delicate handling, are often heavy, require skilled users, and present logistical challenges when replacing worn tools. HORN offers a perfect solution with the DR-Large pre-calibrated exchangeable reaming head.
Horn USA recently expanded its circular milling system 304 with new thread milling inserts to perform in diameters of 8 mm (.315”).
The precision tools are available as partial and full-profile versions for the production of threads by helical interpolation. Triple-edged inserts in the 304 system already exist for groove milling, finish boring, and chamfering.
The new threading inserts spin on diameter 7.7 mm (.303”). Vibration dampening carbide shanks with integral through coolant ports make the system versatile and easy to use.
The HORN circular milling system offers users a host of process advantages. It is fast, reliable, and produces good surface finishes.
During the machining process, the tool plunges into the material either at an angle or almost horizontally and is then driven on a helical path. Threads can be manufactured at a highly reproduceable level of consistent quality.
Circular interpolation has a wide range of applications and can be more economical when strategically applied when machining steel, special steels, titanium, and alloys.
HORN’s circular milling tools are engineered for precision machining of grooves, threads, t-slots, profile milling and other circular interpolation processes.
HORN’s new high performance coatings IG6 and SG3 are a testaments to engineering expertise in tool manufacturing.
The new coatings are less than 0.005 mm (.0002”) thick and an essential part of modern tool technology. Testing has shown that the new tool coatings extend the service life of carbide tools by over one-thousand percent.
IG6 is a copper colored aluminum-titanium-silica nitride (AlSiTiN) coating designed for use in machining materials P and M with grooving inserts type S224 and S229. In conjunction with the carbide substrate, the coating allows for faster material removal rates and significantly extended wear resistance in machining materials P and M. Standard inserts are available from stock.
SG3 is designed for use in titanium and super-alloys as well as turning and grooving applications in hardened materials, up to 58 HRC. The coating can be function in temperatures up to 1,100 degrees Celsus (2,012 degrees Fahrenheit).
HORN designed this coating to deliver outstanding performance with materials that are difficult to machine. The advantage of the tool coating have been proven on selected tool systems from HORN.
The Supermini® system 105 with SG3 coating is available from stock. In both cases, the IG6 and SG3 coatings are applied in-house, allowing for reduced delivery time.
HORN has developed a high level of expertise in coating precision tools since it began in-house coating processes. From five employees in the beginning to more than fifty employees, the aim has always been to create and invest in modern coating technologies for precision cutting tools.
The HORN team was the first in the world to take delivery of HiPIMS systems from CemeCon. The opportunities to develop hard and tough coating with a homogeneous structure has provided this team the flexibility to create advancements that benefit customers who demand precision tools in demanding applications.
Paul Horn GmbH is responding to the requirements of users with their product line expansion to the tool range for slot milling and slot cutting, .
Horn now offers the cutter body of the M310 milling system with an internal coolant supply. This increases the service life of the indexable inserts and therefore reduces tool costs. The internal coolant supply also allows a higher level of precision when slot milling as no heat is transferred from the cutting zone into the component.
What’s more, the flushing action of the coolant, combined with the geometry of the cutting edges, prevents chip jamming in deep grooves.
Horn offers two types of milling and slotting cutter. The screw-in milling cutter is available in diameters from 50 mm (1.969") to 63 mm (2.480") with widths from 3 mm (0.118") to 5 mm (0.197").
As an arbour milling cutter, the main bodies are available with diameters from 63 mm (2.480") to 160 mm (6.300"). The widths are also between 3 mm (0.118") and 5 mm (0.197"). The three-edged S310 carbide inserts are bolted on the left and right of the main body and therefore ensure a good distribution of the cutting forces.
In addition to further geometries for processing different materials, Horn is introducing inserts with a geometry for milling aluminium alloys.
As well as expanding the M310 system, Horn is rounding off the range of the M101 and M383 milling systems.
For the M101 tool, S101 inserts are available from stock with a width of 2.5 mm (0.098").
What’s more, new inserts with an 8-degree lead angle are available especially for slot cutting. For the 383 system, HORN is expanding the range of bodies with diameters of 125 mm (4.921") and 160 mm (6.300").
In February of last year we posted Horn USA's Construction Cam. If you check it now, you'll see the new USA Headquarters.
As a company of the international Horn Group, Horn USA has found its greatest successes by mimicking the positive examples of its parent company.
Just as Paul Horn GmbH has increased its manufacturing capacity for faster delivery and to better meet its customers’ requirements, Horn USA has also kept its finger on the pulse of customer needs while looking towards expansion
In September 2020, all of the company’s production capabilities were relocated to a new facility 0.5 miles from the original office suite. Interestingly, this substantial expansion has been on the company’s radar for many years.
In 2002, a new management team was established. One of the goals the team set during its first few months was to find a permanent location for Horn USA. Large buildings in the light industrial zone are not commonplace in the immediate area of Horn USA, so it took a while to find the ideal opportunity.
Finally, in 2016, 10.76 acres with a 101,000-square-foot light industrial building became available. In typical Horn fashion, advantages and disadvantages were analyzed and finally one came together to the conclusion that this real estate among other things because of its proximity to the existing plant, provided the ideal solution to the next stage of expansion.
In the third quarter of 2019, construction began to bring the facility to the standards expected of Horn. In total, this meant an investment volume in buildings, conversion and technical equipment of approx. 29,000,000 dollar (approx. 25,000,000 euro). Nearly 400 people in all have been involved in the 14-month construction project. The new building has a total area of 11,000 square meters and can accommodate up to 300 people. Horn USA currently employs 120 people.
According to Andreas Vollmer, President Horn USA,
“The new building in the USA makes a clear statement and demonstrates our commitment to the American market. Other than our home market of Germany, this is our strongest international market and has been for a long time. It is also one that holds huge potential for our solutions in the future. The new building provides us with the space we are going to need for this. We are very proud of taking this step and are convinced that it will ultimately benefit our customers as well — in the form of increased production capacity, larger training rooms and our new demonstration centre, for example.”
Horn USA ConstRuction Cam
Horn USA is very excited about their future home!
They would love if you stopped back here to check in on their progress!
The Horn USA construction camera was installed on September 11, 2019. The construction camera takes pictures at the top of every hour. An image taken within the past hour will load first.
Feel free to use the camera controls to view any of the images that are archived and feel free to share this page.
If the preview does not load, please visit the Horn USA public page on EarthCam.
HORN USA is proud to present the new 32T system for grooving and parting off on Swiss-type lathes and smaller fixed-head lathes. With a precision-sintered grooving insert and central clamping screw, the tool system offers high changeover accuracy for the cutting insert and direct entry into the insert seat of the tool carrier.
Additionally, there is no need for clamping elements, which may have a detrimental effect on chip flow. The screw head of the clamping bolt does not introduce interfering contours and therefore permits both grooving on a collar and parting off directly at the spindle.
The grooving insert can be used as a neutral insert, and as both a left-hand and a right-hand insert.
The 32T system completes HORN USA's portfolio of triple-edge cutting inserts by offering a solution for smaller-scale applications. By adding the new system to its range, the tool manufacturer is responding to customer requests for a triple-edge cutting insert system for Swiss-type lathes and other smaller turning machines, in particular in applications where space is at a premium.
The precision-sintered 32T insert is secured to the holder with a central screw, removing the need for additional exterior clamping components that negatively affect chip flow. Available in 2 and 2.5 mm (.079 and .098") widths with maximum depth of groove up to 4 mm (.157"). For grooving operations, the inserts are available with both straight and full-radius cutting edges.
HORN USA offers the indexable insert with a 15-degree chamfer for parting off. A cylindrically ground chip-breaker geometry makes for reliable chip removal.
The tool carrier is designed as a square shank measuring 10 x 10 mm or 12 x 12 mm. Both versions feature an internal coolant supply and are available in both left-hand and right-hand designs.
At IMTS 2018, HORN USA presented two new developments in the area of whirling processes.
The JET Whirling System is the first whirling tool to feature an internal coolant supply. This whirling system offers optimized cooling directly at the cutting edge and was developed by HORN USA in conjunction with W&F Werkzeugtechnik.
Another innovation is the High-Speed Whirling Technology, which delivers high levels of productivity. In this process, the speeds have been specially adapted so that preturning and thread whirling can be carried out in parallel using a single work operation.
Through the JET Whirling process, HORN USA is demonstrating its expertise in the area of thread whirling. As part of a collaboration with W&F Werkzeugtechnik in Großbettlingen, experts from both companies have jointly developed a whirling system with an internal coolant supply.
By cooling the cutting edges directly, this system enables long tool life to be achieved. What’s more, when used in conjunction with the stable whirling unit, the system achieves better surface quality on the workpiece. Thanks to the patented W&F interface with its coordinated contact system for the tapered and planar surfaces, the whirling head boasts a high changeover accuracy and is easy to change with just three screws. The internal coolant supply reduces the risk of chip build-up between the cutting inserts.
It takes less than a minute to change the whirling head on the whirling unit interface. This interface offers a radial and axial run-out of 0.003 mm. The maximum speed is 8,000 rpm. The whirling heads are available with type S302 triple-edged indexable inserts or with type 271 double-edged inserts. The cutting edges are available with diameters of 6 mm, 9 mm and 12 mm. The interfaces for adapting the whirling unit are available for all standard Swiss-type lathes.
HORN USA is proud to present another new technique in the form of high-speed (HS) whirling. This technology is being exhibited in collaboration with machine manufacturer Index-Traub. High-Speed whirling boosts productivity significantly by performing the turning and whirling operations in parallel. With this technique, the speed is high enough for a turning process to be carried out prior to whirling.
The turning tool, which is located upstream of the whirling tool, reduces the volume of material that would otherwise have to be removed by the whirling tool. This enables longer tool life to be achieved and improves surface quality. The whirling heads are very similar to conventional ones. The only difference lies in the geometry of the cutting inserts. Single-start and multi-start threads can be produced using just one cutter unit.
Highly Productive Technique
Thread whirling is generally used in the production of bone screws. In this application, the whirling head rotates at high speed as it travels over the slowly rotating workpiece. The whirling head is set for the required lead angle of the screw. The workpiece is fed axially and as this happens the whirling tool cuts the thread.
Due to the high level of screw quality required, special attention must be paid to precision and surface quality when it comes to whirling tools. In addition, special materials are used for bone screws to ensure that the body is able to tolerate them when they are implanted. These include stainless steels, titanium, or cobalt-chromium alloys, although the disadvantage of these materials is that they are difficult to machine.
Therefore, expertise and experience are required if these materials are to be machined productively. For instance, the carbide substrates, coatings, and cutting edge geometries all have to be tailored to the application concerned.
HORN USA offers further whirling technologies in addition to its JET Whirling and High Speed Whirling solutions. Of these, the most universal technology is the standard whirling method. The whirling head can be connected to any whirling unit. For faster whirling head and insert changes outside of the machine, HORN USA has developed a modular whirling system.
Thanks to the precision interface, there is no need to readjust the whirling head once it has been removed from the machine. In addition, the spacer rings make it possible to adapt the whirling tool to different interfaces. With HORN USA Turbo-Whirling, high productivity is a sure thing. The cutting division between the roughing and finishing inserts reduces the load on the whirling tool’s profile cutting inserts. As a result, the system offers faster process times and lower tool costs.
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