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Horn´S Customer Magazine

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Horn´S Customer Magazine Edition 2/11 HORN´S CUSTOMER MAGAZINE SUBJECT: SPECIAL TOOLS COMBINATION TOOLS TECHNOLOGY DETERMINES TIME AND COSTS n Interfaces for HORN tools n Innovations for EMO n Supermini® n Coating centre EDITORIAL CONTENTS HORN´S CUSTOMER MAGAZINE Dear Readers, Products The entire HORN team can be rightly proud of the under “Innovations and New Developments for the Interfaces for HORN tool systems 4 response to our Technology Days. But what I was EMO”. You can see these and other products in Hall especially pleased about was the comments from many 5, stand A42. The world's leading trade fair in Hanover Precise clamping, fast changing visitors after touring our production facilities: HORN will show trends in metalworking. We show how we stands for quality. When we add to this impression deal with these trends with our hardware and wide Special and combi-tools 5 the very well received mix of theory and practical range of tool-related services. Combining process and work flows in a time-saving and reliable way applications, we see confirmation for our belief that only powerful tools and the corresponding services We look forward to talking to you. From practical experience offer users real improvements in production. Besides 100 mm (3.937") throat depth securely in grip 9 the very large depth of in-house manufacturing, for us this includes all services connected with the tool, Reliable grooving and longitudinal turning from development to sales to service. Product Innovations Our customer magazine offers you a brief look EMO Outlook 12 into the many products developed under these criteria, such as those in the category “special and Lothar Horn EMO, 19 – 24 September 2011, Hanover combination tools”. For a long time now, we have General manager, Supermini®, small tools – large potential 17 expanded our “processing between the edges” to Hartmetall-Werkzeugfabrik Paul Horn GmbH, other high-technology applications, as we describe Tübingen Processing variety from 0.2 mm (0.008") bore hole diameter About us Investment for the future 19 New building for HORN-Hartstoffe almost completed Technology Days, 11 – 13 May 2011 20 Theory and practice a magnet for visitors The decisive coat 22 Coating centre enhances competitiveness Imprint: world of tools©, the HORN customer magazine, is published twice per year and sent to existing and potential customers. Publication date: September 2011. Printed in Germany. Publisher: Hartmetall-Werkzeugfabrik Paul Horn GmbH • Unter dem Holz 33-35 • D-72072 Tübingen Tel.: 07071 7004-0 • Fax: 07071 72893 • Email: [email protected] • website: www.phorn.de Rights: Reprints, whether in whole or in part, only with the written permission of the publisher and text and image note "Paul Horn Magazine world of tools©". Other picture credits: Fotolia Circulation: 20,000 in German, 5,000 in English Complete production: Werbeagentur Beck GmbH & Co. KG • Alte Steige 17 • 73732 Esslingen in cooperation with Schenk Marketing, Reutlingen 2 3 PRODUCTS PRODUCTS SPECIAL AND COMBI-tools 6 Tool interfaces from our 2 programme 6 Technology determines time 1 PSC (HORN-Capto) 2 HSK, HSK-T 2 With our special and combi-tools, complex workpieces can Work process: 3 KM be processed in a single cycle. Their product-specific format – Drilling with DD-drill Ø 12 mm (0.472") 4 4 VDI 3 increases productivity, raises product quality, reduces inspection – Milling of the inside contour with CNMU tangential 5 SK effort and simplifies tool handling. inserts 6 Square and – Circular milling of the inside groove with round shank 1 Increasing productivity and securing technological System 314 5 7 Regofix leadership is today also the basis for success in the – Grooving of the axial groove and chamfering global market. Our special and combi-tools make a of the outside edge with axial groove inserts 7 decisive contribution to producing globally competitive products. The merging of processing operations in Customer benefits: one special-tool insert or the combination of different – Tool magazine space saved in the machining centre inserts in one tool reduces tool changes, permits – Short cycle times parallel working and helps achieve the old saying: – Lower inspection effort INTERFACES FOR ‘Time is money.’ Technology determines costs. – High process reliability in serial production The pressure on our customers for ongoing innovation HORN tool systems is reflected in the variety of our tools. Their features include multiple cutting operations united in one tool, extremely fine adjustment, integrated cooling for chip Precise clamping, fast changing removal or design for minimal lubrication. All of these demand technological and design performance that Whether using process-specific or more flexible machines, processes. To meet these diverse requirements, we ultimately serve one goal: reduction of cutting costs. efficient machining is not possible without a reliable tool supply tooling systems as both standard and special Selected applications from various sectors illustrate holder and precise positioning of the cutter. tools, modular tooling systems with cassettes and in why we claim technological leadership in this area. monoblock design, in various sizes and dimensions. The variety of machines in which our tools can be All tools and tool holders distinguish themselves through Display of tool interfaces at used grows with the breadth of our tool programme their high quality, clamping security and reliability – Examples of combination our Technology Days. for turning, milling, drilling, reaming and other cutting characteristics that help you to optimise productivity. and special tools 1 Task: Interfaces of our tools Processing of a brake housing made of GG25. – Tool holder with square shank Customer instructions: – Tool holder with round shank Only one tool, if possible, due to limited capacity in – Machine-related tool holder the tool magazine – VDI tool holder – Short tool holder Solution: – KM16 micro, Kennametal system Special tool with integrated axial grooving capability – HSK-T basic holder with cassette for four operations. Internal coolant feed. – Collet chucks ER DIN 6499-A – Polygon shank taper (HORN-Capto) – HSK-A DIN 69839 for cutter heads – HSK-A DIN 69839 system holder BH for Urma 1 – ABS Komet system for cutter heads Picture top: Special tool – SK DIN 69871 system holder Urma BT without axial grooving tool. – Arbour-mounted slotting cutter Picture left: Partial view of the brake housing. 4 5 PRODUCTS PRODUKTE PRODUCTS 2 Task: 4 Task: Profile grooving in synchronizing ring for control sleeve, Plunge cuts of different forms and diameters in S117 material 20MnCr5. 50 mm-long turned parts (1.969") made of chrome nickel steel including chamfering of the outside contour. Solution: One profiled grooving insert for machining of three Customer benefits: external features: turning of the shoulders, turning of Diameter tolerance of all form and profile plunge cuts the groove and generation of the outside chamfer. +/– 0.02 mm (0.0008"). Fine adjustment Customer benefits: Solution: on cassette – high precision due to three form elements in a Special tool with form plunge cut insert S117 and form single profile grooving insert grooving insert S315, HSK-T holding fixture and internal S315 – Reduction of set-up time coolant feed. The triple-edge, profiled form grooving – Long tool life through use of the cutting edge over insert is seated in a cassette and can be positioned the complete width of the profile grooving insert relative to the cutting insert S117 in the µm-range. 2 – Shortening of processing time 4 – More efficient manufacturing in large-scale serial Customer benefits: Synchronizing ring Special tool with finely adjustable form grooving insert. production – Parallel processing with outside diameter – High process reliability in serial production 110 mm (4.331"), plunge – Tight tolerances are maintained depth max. 9 mm (0.354"). – Simple adjustment of the tools Profile grooving insert with – Long tool life due to internal coolant feed and ground geometry. TH35-coating with high Al percentage 3 Task: 5 Task: Generation of internal polygons in workpieces for Inside and outside machine of a connecting flange the oil industry. made of red brass. Wall thickness ≤ 1.1 mm (0.043"). Customer instructions: Solution: Complete machining on a lathe with interface Bell cutter with profile insert S117 for outside machining HSK 100. Max. dimensions of the inside polygon: and solid carbide shank cutter DS for inside machining. l = 280 mm (11.024"), key slot 180 mm (7.087"). Its angle of twist and the blade angle of the profile insert allow a pulling cut with low pressure, which is Solution: essential for machining the small wall thicknesses. Modular tool design with replaceable cassette, pre- The steep spiral of the milling cutter transports the cision interface and internal coolant feed for broaching chips away from the component. The outside forms different profiles. are cut one after another by setting the cutting insert. Two inserts were arrayed side-by-side to reduce the cutting forces – the inside diameters are pre-milled Work process: – and produce small, easily rinsed-out chips. Lower The tool plunges centrally into the flange and then cutting forces result from staggered broaching, first moves off-centre. The cutters for outside and inside of the left and then of the right polygon surface, with machining come into action sequentially, and the work- an advance of 0.12 mm (0.0047"). piece is machined parallel on the opposite sides. The 3 tool in action circulates once around the workpiece. 5 Customer benefits: already Picture top: Two cutting – Complete processing on one machine Customer benefits: machined Picture top: Inside and edges permit staggered outside machining actions. – Reclamping eliminated The bell cutter's actions permit cycle times that cannot broaching and reduce – Reliable manufacturing of polygon shapes of be achieved with conventional circular milling cutters. cutting forces. Picture left: Flange with different lengths inside and outside contour. Picture right: Cut through the – Simple replaceable inserts component made of 42CrMo4.
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