Edition 2/08 HORN‘S CUSTOMER MAGAZINE SPECIAL EDITION FOR AMB 2008 09.–13.09.2008 This months subject: AMB 2008: EXHIBITORS, NEWS, TRENDS n Successful machining, successful forming n New development for drilling n New production philosophy for standard and special solutions n Celebrating 10 years of HORN USA Hall 1, booth I 16 EDITORIAL Dear Readers, and work in Germany and know that this business location can only keep ahead of global competition Baden-Württemberg’s technology sector needs a modern by an ongoing process of review and optimisation. exhibition platform to market its products. Baden-Württemberg is the 3rd largest state of Germany and together with Bavaria A number of significant developments in processes they are the leaders of industrial know-how in Germany. The and manufacturing methods will be shown at AMB. new Stuttgart trade fair centre provides our businesses – mostly This special edition of our customer magazine is mid-sized enterprises – with the opportunity to present their meant to provide a small contribution on the potential products and services to an international audience in an of the machine manufacturers. atmosphere that suits the high-tech sector. That is why my employees and I have great expectations of the AMB exhibition, My thanks go to all the companies that provided to be staged at Stuttgart from 9-13 September 2008. current information for this edition and I hope that you, the readers of our special AMB edition, enjoy an informative read. Our involvement encompasses a variety of activities. One of them is the Horn customer magazine, “world of tools”, in which we provide you with product- and user-related information, technical developments and company events twice a year. For this AMB edition, we have changed the focus slightly, concentrating on our business partners – machine tool builders – and their range of services. Our objective is to Lothar Horn draw attention to the strength and performance of Managing Director Baden-Württemberg’s industry and publicising its Hartmetall-Werkzeugfabrik Paul Horn GmbH, capabilities to a wider audience. We also seek to Tübingen promote awareness among industry outsiders that our region is a centre for innovation, capable of P.S. Editors of the magazine “Maschine und Werkzeug“ meeting world market requirements now and in the asked my opinion to topics like Germany as an industrial future, primarily with innovative products produced base, employees, products and solutions, globaliza- by specialists with top-notch training. Most regional tion, trends and future business planning. You will find businesses are aware of this responsibility. They live the short version of this interview on page 6. CONTENTS HORN‘S CUSTOMER MAGAZINE Practical matters Successful machining, successful shaping 4 Efficient groove milling in clamping elements Press Statements from editors 6 Products News at the AMB 15 Grooving tough materials without snarl chips 17 New HR geometry breaks chips during roughing and finishing HORN technology now available for drilling 18 New development expands range of capability About us New production philosophy for standard and special solutions 19 Shorter product manufacturing times, higher flexibility in the production process Big county – small tools 22 Celebrating 10 years of HORN USA Financial and internal cost accounting 24 Our ladies from the reception desk 25 New production facility is setting standards 26 Environment-friendly production AMB 2008 Company portraits 27 Hall plan 75 Masthead: world of tools, HORN‘S customer magazine twice a year and is sent to customers and interested parties. Publisher: Hartmetall-Werkzeugfabrik Paul Horn GmbH • Postfach 17 20 • D-72007 Tübingen Tel.: 07071 7004-0 • Fax: 07071 72893 • E-Mail: [email protected] • Internet: www.phorn.de • copyright Paul Horn GmbH Print run: 20,000 in German and 10,000 in English Overall production: Werbeagentur Beck GmbH & Co. KG • Alte Steige 17 • 73732 Esslingen in cooperation with Schenk Marketing, Reutlingen 3 PRACTICAL MATTERS Installation situation on the upper beam: Top tool (a), clamping element for top tool (b), Safety-Click slots (c), Safety-Click actuation on the upper beam (d). SUCCESSFUL MACHINING, SUCCESSFUL SHAPING Efficient groove milling in clamping elements The cost-effectiveness of sheet material bending on press tool system. It can be used on press brakes from all brakes is influenced by the tool change for the top tools, manufacturers, meaning that it can continue to be used among other things. For the change to take place quickly if the customer changes brands, unlike manufacturer- and with high repeatability, the clamping system must meet specific systems. To ensure a precise connection stringent requirements. between the upper tool and the clamping element and thus also the functioning of the “Safety-Click” connection, machining of the clamping and contact Key competency: increasing press brake surfaces must be precise. productivity The modular tools are connected to the upper beam Wila BV in Lochem in the Netherlands has been manu- using 515 mm (20.276") long clamping elements made facturing clamping and crowning systems as well as of 1.2312 stainless steel. Gerrit Bruggink, Research tools and accessories for bending sheet material for Manager R&D, was on the lookout for new ways to 75 years. A host of patents and licenses underlines manufacture them with the aim of bringing critical the leading position of this globally operating enter- manufacturing operations in-house. This would bring prise with its 200 employees. One example of this high value-added processes fully under the control innovative strength is the “New Standard” modular of Wila personnel and enable faster, more flexible Picture left: After 23 clamping elements, the tools used for rough-milling are changed to ensure process reliability. Picture right: Following hardening, the CBN custom tool corrects thermal distortion of the 515 mm long parts, bringing them to a straightness of ≤ 0.02 mm. 4 PRACTICAL MATTERS response. The locating slot for the upper tool (20 x 37 mm) (.787 x 1.457") has been milled at Wila BV for some time and the next step was to machine the two slots at either side of the clamping elements. The “groove milling” strategy proved its worth, Since ‘conventional’ milling cutters cannot be used achieving satisfying results due to limited space, our representative Joop Nij- for the project team mem- land developed the following groove milling strategy bers: Roger Kasper/Export together with Erik Klein Beekman, Tool Manager at department Horn, Gerrit Wila BV: rough-milling of both slots in two passes Bruggink/Research Manager only, finishing and milling to the final dimension on R&D Wila BV, Joop Nijland/ all sides following hardening. Roger Kasper from our Horn representative at Harry export department in Tübingen took care that the Hersbach Tools, Erik Klein ideas were implemented rapidly and the know-how Beekmann/ Tool Manager transferred to Holland. Wila BV (from left to right). Cutting parameters for milling slots Reliable rough-milling with custom tools Production step Rough-milling Reworking Final machining Both slots in the clamping elements are 4 mm (.157") Carbide slot miller Carbide slot miller CBN slot miller deep and 6.5 mm (.256") wide. The distance from Tool 21.7 mm Ø 28 mm Ø 21.7 mm Ø the bottom of one slot to the bottom of the next one .854" Ø 1.102" Ø .854" Ø depends on the top tool. For rough-milling in the first Cutting edges No. 6 3 6 pass and the return pass, a customised 21.7 mm (.854") diameter slot mill with six cutting edges in v m/min 250 220 150 Cutting speed c the carbide grade TI 25 was chosen. Due to the high sfm 820 720 490 chip volume, it has offset cutting edges, meaning that three cutting edges always make contact at the same Speed rpm 2700 2500 1700 time. Tool life ranges from 25 to 30 milled clamping v mm/min 650 600 500 elements. However, the tool change is carried out Feed rate f v ipm 25.6 23.6 19.7 after 23 parts to ensure process reliability. f fz mm 0.08 0.8 0.05 The slot is rough-milled with a machining allowance of Feed rate/tooth fz . ["] .0031 .031 .002 about 1.25 mm (.049"), then finished to the hardening a mm 4 6.5 0.1 to 0.3 dimension in one pass. Also used here is a custom Width of cut e a . ["] .157 .256 .004 to .012 slot milling insert of 28 mm (1.102") diameter, with e 4, both sides three cutting edges and a chamfer of 45° at the top a mm 4 4 Depth of cut p simultaneously a . ["] .157 .157 cutting edge and 30° at the bottom cutting edge. p .157 Growing stock of Horn tools Precision work with the CBN miller The first goal has been achieved with these groo- Following hardening to 58 HRC, the final adjustments ve milling results: cost-efficient machining of about are made to the slot cross-section, straightness and 200 clamping elements for each size. Wila BV can parallelism. For this precision machining – the tole- now react flexibly to market demand. A peek into rances fall between 0.01 and 0.03 mm (.0004 and the tool cabinet also demonstrates that decision- .0012") – a custom CBN circular milling insert with six makers at Wila also count on HORN in other areas cutting edges was developed. It finishes the clamping of production. About 30 different types of inserts are plate to the finished dimension in 1.1 minutes, leaving stored there, approximately half of which are custom the surface as smooth as glass at Ra values of 0.4 to inserts. However, not only the quality and machining 0.8 μm and with a minimum tool life of 550 parts.