Crude oil is one of the most important and most widely used raw materials, particularly as a raw material in the chemical industry and as a fuel for transport and for generating energy. Due to the huge importance of crude oil, the crude oil industry is the largest in the world.
Special applications require special tools and technologies. HORN offers innovative system solutions for the oil and gas industries, which are tailored precisely to our customers' requirements – new manufacturing strategies for higher process reliability, considerably longer tool life and significantly reduced machining cycle times, and we ensure that everything is practical, and above all reliable.
Innovative system solutions from HORN include tools for pipe end machining seamlessly hot-rolled or welded steel pipes, for turning, peeling the cone, seal seat machining and thread cutting on API and premium connections.
Drilling, grooving, turning and milling features and contours in sintered carbide – without pre-treatment or subsequent treatment – is not possible with standard tool concepts available on the market. For such applications, CVD-D-tipped tools offer real advantages. Their geometrically defined cutting edges are adapted to the particular machining tasks – from extremely sharp and rounded, all the way up to positive and negative chamfers. Thanks to the flawless and geometrically optimized cutting edges, the CVD-D diamond can be used for anything from roughing to fine finishing.
Materials that are extremely difficultto machine can pose a significantmanufacturing and financialchallenge to cutting tools – particularly when it comes to small and miniature parts. To address the needs of these applications – in which tools from the Supermini product series machine holes with diameters from 0.2 mm – HORN has developed the EG3 and EG5 coatings.
The distinction between the two types rests in their substrates and layer thickness and they make it possible to achieve an extremely smooth layer – reducing the amount of heat that is transferred to the tool, and the cutting edge in particular, thanks to significantly lower friction. A golden wear layer provides a coating for improved wear detection.
The new coatings have been developed for the Supermini, Mini and 312 tool systems. Supermini is primarily used for boring and grooving of hole diameters ≥ 0.2 mm. The Mini tool system comes into play in similar processes, but for hole diameters starting from 6.0 mm. The triple-edged inserts of the 312 system are also used for grooving and parting off, as well as for external machining and similar machining processes involving hole diameters from 46 mm.
The new grooving systems are designed for internal machining of bores with diameters ≥ 16 mm (system 209) and ≥ 20 mm (system 216). At retraction distances up to 50 mm, a groove depth of max. 7.5 mm can be achieved. Key elements of both systems include tool holders with internal cooling and two-edged indexable inserts with cutting widths of 2 to 6 mm. The robust shank with elliptical cross-section of the boring bar neck ensures excellent damping properties. The g6-quality shanks are available from stock in a left-hand or right-hand design.
New products for the proven 25A axial grooving system with cartridge design and round shanks enhance its possible applications. Whereas the previous system with one-edged or two-edged indexable inserts achieved cutting widths of 2 to 4 mm, and a grooving depth of up to 18 mm from an external diameter of 15 mm, the further developed cartridge and round shank versions now allow for grooving diameters of 50 to 65 mm and from 65 to 80 mm with cutting widths of 3 and 4 mm.
Visitors at EMO will be informed that the most popular reamers are now available from stock: for H7 bores from 12 to 50 mm in diameter in millimeter increments and for bores from 52 to 100 mm in diameter in a further eleven sizes. Each size is available with two geometries: straight fluted for blind bores and left-hand helical for through-bores.
The option to order reaming inserts from stock will not be available in North America.
With the solid carbide tools from the DS milling cutter family, HORN is incorporating top-class products into its portfolio for machining copper, graphite, aluminum, plastics, fiber reinforced plastics, soft and hardened steels as well as titanium and superalloys. The end, torus, full radius, double radius, multi-edge and roughing cutters are available in diameters from 2 to 16 mm, and micro end mills have diameters ≥ 0.2 mm. The h5-quality tool shanks have impressive concentricity of 0.005 mm, which makes them ideal for finishing operations
The solid carbide milling cutters from the DCG series have been proving themselves in the production of threads sized from M3 to M12 for many years. As the single-row milling cutters can be used for different pitches, high operational flexibility is guaranteed.
At EMO Hannover, HORN is presenting the high-speed spindles from SFI Toodle, which have recently been added to its portfolio. With this addition, users do not just benefit from the advantages of these world-renowned spindles – in particular, they can reap the rewards of combining them with the solid carbide milling cutters from HORN's DS series. More than 600 DS milling cutters with cutting edge diameters of between 0.1 and 3 mm can be supplied with a pre-mounted Toodle spindle within one week. The milling cutters can be adapted to meet specific requirements more than simply in terms of their diameter. Thanks to the numerous versions with various geometries, coatings and carbide substrates, the tool best suited to the job can be selected for machining non-ferrous metals, steels, hardened steels, titanium alloys as well as other hard-to-cut materials.
HORN will introduce a range of solid carbide drills at EMO in Hannover. Two geometry variants with diameters from 4.0 mm to 18.0 mm are available.
The tools feature the excellent standard of precision that customers have come to expect from HORN. They are produced with particular attention paid to the surface quality, the precision of the ground geometry and the cutting edge preparation. Together with the various coating options, these aspects ensure that customers using the tools will achieve excellent, consistent results.
The ZETAtec 90N arbor milling cutters, featuring diameters of 50 mm to 160 mm, are equipped with five to ten inserts, each of which has six cutting edges. The excellent standards of reliability they achieve during rough machining are thanks to their negative geometry – while the positive rake angle ensures a smooth cut. What’s more, the milling cutters also prove a real asset for customers performing helical or linear plunging, despite the negative geometry. The benefits of the cutting insert’s properties truly come to the fore in cases where short-chipping materials are being machined – when milling anything from simple steels to cast materials, for example. To ensure that the correct cutting insert can be selected for the task at hand, two substrates and geometries are available: one steel grade for stainless steels and one for cast and non-ferrous metals.
The ETAtec 45P arbor milling cutters, featuring diameters of 50 mm to 160 mm, come equipped with between five and ten 7-edged inserts. The tools not only offer a 45° angle of attack and positive geometry, but also generate low cutting forces, all of which ensures a smooth machining process accompanied by high levels of productivity – an important user benefit, particularly in cases where less powerful machines and unstable clamping setups are being used. Thanks to the multifunctional concept – involving one tool holder for two different insert versions – the inserts designed for face milling can easily be swapped with round cutting inserts if profile milling needs to be carried out, for example.
HORN presents Boehlerit’s extended product portfolio for turning using tool holders with connections for internal coolant supply. The new tool holders are available with toggle clamp (ISO-P) and screw clamp (ISO-S) systems.
Boehlerit’s new tool holders with connections for internal coolant supply are available with a toggle clamp system (P) and screw clamp system (S). The P tool holders are suitable for all ISO indexable inserts. There are no loose parts and only a few spare parts are required, making them easier to handle.
The indexable inserts can be clamped quickly and safely. As no disruptive set-up is needed, unobstructed chip flow is guaranteed.
At the EMO trade fair, HORN's proven DA32 milling system will be on show with diamond-tipped inserts for the first time. This feature allows the tools to achieve outstanding results during shoulder milling, face milling, plunge milling and circular milling.The highly positive geometry of the inserts ensures a particularly smooth cut. This keeps the stress exerted on the workpiece and the tool to a minimum. As a result, a long tool life and virtually burr-free machining are guaranteed – particularly when it comes to long-chipping materials. The wide finishing radius creates the very best standards of surface quality, even at high feed rates. The coolant supply reliably ensures targeted cooling of the cutting edges as well as safe removal of the chips away from the working zone.
The latest expansion of the 315 grooving system from HORN covers hard machining applications. The single-edged, CBN-tipped insert ensures high rigidity in the tool. The insert seat has a large contact surface to direct the cutting pressure into the holder. Furthermore, the central clamping screw enables maximum tightening of the insert. These properties make the system ideal for counteracting the large forces generated during hard machining. The cutting material CBN is the second-hardest material in the world and is used as a substitute for diamond. Unlike diamond, this cutting material can be used to machine ferrous materials as no carbon diffusion occurs during the process. The inserts are available in grooving widths from 1 mm to 3 mm. In addition, the holder range is available in the monoblock design and as a cartridge system for HSK-T and PSC connections.
The new grooving blades are designed for universal use when producing small batch sizes. Six blades with cutting widths of 2.5/3 mm and 4 mm are available for these applications, with each pair of three blades measuring 26 mm and 32 mm high. Their projection length is universally adjustable.
The grooving blades hold two cutting inserts arranged in mirror symmetry. The self-clamping insert seat enables replacement that is straightforward and yet still highly precise. It is opened with a chuck key so that the cutting insert can be easily removed and a new one inserted. A prism in the insert and the groove blade ensures a secure connection. The inserts are available in all cutting widths with chipbreaker geometry.
The S64T insert with chipbreaker geometry is an evolution of the S64T insert that was unveiled at AMB 2016. In addition to the more extensive working range it offers, this precision tool with six cutting edges features a range of chipbreaker geometries and the new EG5 coating. Thanks to this coating, as well as the carbide substrate, the new insert is able to machine any kind of steel.
The new series of precision-sintered six-edged tools with ground inserts comprises a number of variants with different cutting widths.
For the high-productivity manufacturing of internal gear teeth, splines and other internal profiles,HORN is introducing tools for gear skiving. This machining method has a number of advantages:
- Considerably shorter processing times in comparison to gear tooth broaching
- Can be used on optimized milling centers
- No undercut necessary at the end of the gear tooth
- Turning and gear cutting possible in a single clamping
HORN has developed the new DA62 milling system for corner, face and plunge milling. The system from the precision tool manufacturer uses a new precision sintered six-edged indexable insert. Both sides of the insert can be used and it has three axial and radial cutting edges on each side. The precision-ground, trigonal insert boasts a large core cross-section and maximum cutting length. The design of the cutting edges produces a positive cutting geometry despite the negative insert angle. The six cutting edges on each indexable insert provide excellent value for money for each edge.
Horn tools for machining cast or forged aluminum wheels deliver high process reliability and excellent surface quality.
The tools, which are based on the tried and proven grooving and longitudinal turning system 229, are available as cutting inserts tipped with carbide and PCD. Furthermore, the portfolio is completed by the S29F system and a comprehensive range of ISO products, both of which are also available in PCD. Tool holders and cutting inserts for internal and external machining are included in the portfolio.
With a cutting edge geometry that has been customized for machining wheels, the cutting inserts are able to reduce burr formation and the formation of build-up edges as well as increase tool life and dimensional accuracy in series production.
HORN is extending the 960 modular system for the 845 interface by adding new cartridges to hold the S229 insert. The double-edged insert for grooving and parting off, as well as for longitudinal and contour turning, is available ex stock with various chipbreaker geometries and substrates. The maximum grooving depth of the cartridge is 25 mm with a machining diameter of 68 mm. Groove widths between 3 mm and 6 mm are available. All grooving cartridges are fitted with an internal coolant supply. Cooling takes place via the clamping finger and support.
The S100 single cutting edge insert and the S224 double cutting edge insert from HORN are available with internal coolant supply through the insert. The targeted coolant jet acts directly on the point of cutting, thus ensuring optimum cutting conditions. The funnel-shaped nozzle creates a coolant jet which actively supports chip formation and thus reduces the chance of chip jamming. Furthermore, this type of internal cooling significantly reduces the formation of built-up edges and fractures on the cutting edge. Unlike conventional cooling methods, this system therefore achieves higher cutting parameters, which allow the tool to be used even more economically and efficiently.
Our portfolio of products for boring now includes diamond-tipped tools with CVD-D and PCD cutting edges. These tools are used for boring, copying and grooving when working with sintered carbide, ceramics or abrasive plastics. They are also used for machining non-ferrous materials which are either highly abrasive due to their silicon content or have a tendency to exhibit chipping problems and form built-up edges. The chip geometry, which has been specially developed for this purpose, solves virtually all machining problems caused by uncontrolled formation of stringy swarf.
HORN has developed the new DA62 milling system for corner, face and plunge milling. The system from the Tübingen-based precision tool manufacturer uses a new six-edged indexable insert. Both sides of the insert can be used and it has three axial and radial cutting edges on each side. The precision-sintered, trigonal insert boasts a large core cross-section and maximum cutting length. The design of the cutting edges produces a positive cutting geometry despite the negative insert angle.
The new 262 tool system has been specially developed by HORN for cam-controlled lathes, with indexable inserts for holders with 6x6 and 8x8 mm cross-section.
The hard-milled insert seat ensures excellent stability, the ground contact surfaces of the indexable inserts ensure exceptional precision and two fastening screws ensure stable clamping. The system allows the centre height, width and length to be positioned precisely. A lateral insert seat offers maximum freedom when designing the cutting edge.
21 different cutting edge shapes are available as standard:
- for grooving with a width of 0.8 mm or more
- for grooving and longitudinal turning with a width of 0.8 mm or more
- or longitudinal turning: forwards and backwards
- and for face turning
The modular grooving system from HORN for grooving cartridges based on the systems interface 845 and 842 consists of:
Basic toolholder for turrets with BMT / MAZ connections or VDI holders for turrets and Star turrets
Basic toolholders for mill-turn centers
The modular system kit has a selection of basic toolholder for turrets with BMT connections, based on standard machine types. Alternatively VDI basic holders and basic toolholders for mill-turn centers are available in various sizes.
The matching grooving toolholders with integrated coolant supply allow the cartridge heights to be adjusted and their fastenings to be set in a normal or overhead position, on the left or on the right of the grooving toolholder.
The cartridge systems with system interface 845 and 842 serves as the holder for the S100, S101 and S224 grooving insert systems with a range of geometries and substrates. Grooving widths of 1.2 mm - 4 mm are available with grooving depths up to 55 mm. The cartridges are equipped with an integrated coolant supply in versions for clamping finger and support cooling.
The newly developed HORN turbowhirling® system optimizes the thread whirling process and increases efficiency.
HORN turbowhirling® can be applied to single-start and multi-start threads and profiles. What's more, during this process, the S271 precision-ground double-edged indexable inserts are tailored to the respective thread profile and the material to be machined. The indexable inserts are clamped in positive-fit, extremely stable insert seats either in the new modular whirling heads with optimized handling during insert replacement or conventionally in the Mono block tools.
When machining components with diameters starting from 0.2 mm (.008") using cutting depths that often measure 0.01 mm (.0004"), tools, tool systems and, primarily, cutting edge designs face extremely high requirements.
In order to ensure precision chip removal, even at the smallest depths, cutting edges must be incredibly sharp and chip free, with exceptionally ﬁne surface qualities. The machines employed in micro-machining usually offer signiﬁcantly less space for toolholders, requiring the use of holders designed speciﬁcally for them. Toolholder design featuring internal coolant supply guarantees maximum performance.
HORN's thread whirling technology with 6 or 9 effective cutting edges with whirling cutters type M271 is a highly effective and economical system to produce single or multi start threads and profiles. Due to very short machining time, the process of thread whirling much more cost effective when compared to conventional threading practices.
The newly developed modular thread whirling system gives the customer a great variety of possible tool combinations that is suitable for most popular sliding head machines and whirling units on the market. The high precision indexable inserts type S271 offers the possibility of conventional whirling using 6 inserts per tool or HORN Turbowhirling® having 9 inserts on the tool (3 roughing and 6 finishing inserts).
The funnel-shaped nozzle creates a coolant jet, which supports chip forming and thus reduces the chance of chip build-up.
This type of internal cooling largely prevents the formation of build-up edges and premature chipping of the cutting edge. Unlike conventional cooling methods, this system achieves higher cutting parameters, which allow the tool to be used more economically and effectively.
The insert S100 with chip geometry .3V and HP65 coating is specifically designed for grooving and parting off, stainless steel materials.
Supplying internal coolant to the cutting point guarantees efficient cooling and boosts chip flow.
The system has been expanded to include the 4 mm (.157") cutting width and can achieve grooving depths of up to 20 mm (.787"). Both one-edged and two-edged straight or full-radius inserts are available in the additional cutting widths. Indexable inserts have a "neutral" design and can therefore be used in left and right tool holders.
The 64T six-edged indexable insert is the latest addition to the HORN family of high performance tooling. The 64T insert is precision sintered and available in widths up to 3.29 mm (0.130") with geometry .00. As a neutral grooving insert, it can be used on either the left or the right in square shank holders with internal cooling. The holders measure 16 x 16 (0.630" x 0.630"), 20 x 20 (0.787" x 0.787") or 25 x 25 mm (0.984" x 0.984").
The 64T insert supports grooving depths of up to 3.5 mm (0.138") and a maximum workpiece diameter of 65 mm (2.559").
The new EG55 high-performance coating considerably improves the tool life and makes the grooving insert a perfect all-around choice for machining steel as well as a wide range of other materials.
Setting new standards with a new coating, new substrate and new micro-geometry for boring holes between 0.2 mm and 6.8 mm.
The Supermini® type 105 stands out thanks to the new TiAIN coating with gold-colored top layer to detect wear, outstanding hardness, extremely tight layer construction and excellent layer adhesion are features of this grade.
Standard availability for internal diameters 0.2 mm to 6.8 mm (.008" to .268") and in lengths up to 5 x D.
With the expansion of the gear milling systems up to module 30, we offer integrated tool systems from module 0.5 to module 30.
The gear range includes milling spur gears, milling shaft/hub connections, broaching internal toothing, milling worm shafts and milling customer-specific gear profiles. Depending on the module size (DIN 3972, basic rack profile 1), there are various milling systems for the area of application:
- Up to module 3: Inserts of type 606 to 636 (also as triple cutters)
- Up to module 4: M279 milling system single-row and two-row for wide profiles
- Up to module 6: NEW M121 milling system
- From module 7: Different systems for high feed milling
The new narrow triple-edge indexable insert for the 315 grooving system features a range of chip geometries for full and partial cuts with grooving widths of less than 2 mm (.079"). Available in cutting widths of 1.1/1.3/1.5 and 2 mm (.043/.051/.059 and .079") in left or right-hand design support grooving depths of up to 5.5 mm (.217").
The new EG55 high-performance coating grade, which has been developed in the HORN laboratory, is characterized by its outstanding adhesion to the carbide substrate, high homogeneity, wear resistance and incredibly long tool life in general steel machining applications.
HORN’s modular die for pipe threads (patent pending), which is available in sizes of G¾ and G1 inch, is an easy swap system consisting of one basic holder and individual inserts. In the event of wear, all you have to do is replace the inserts in the basic holder, thereby eliminating the regrinding work that would normally be required.
Face and corner mills are available in standard diameters 40 mm (1.575") to 250 mm (9.843") with a wide and narrow tooth pitch.
These products offer maximum performance for stringent requirements of machines and workpieces alike. The existing screw-in and shell end mills from the 406 system are to be supplemented by solutions with diameters ranging from 16 mm (0.630") to 40 mm (1.575") that have been specially developed for use with driven tools. This provides a comprehensive choice of efficient options for handling challenging machining tasks.
- Milling shanks
- Screw-in cutter
- 90° Milling shank and Shoulder mills - 45° and 60° Face mills
- Shell end mills
- Disc milling cutter
An impressive array of specialized tools for machining titanium materials.
With their sharp cutting edges, positive cutting angle, large relief angle and polished cutting edges, these tools overcome the main difficulties encountered during titanium machining. HORN developed the TSTK coating specifically for the DS line of endmills used in aviation/aerospace and medical technology industries.
HORN's patented tangential milling system has been specifically optimized for T-Slot production.
The cutters are available with diameters of 25 mm (.984”), 32 mm (1.260”), 40 mm (1.575”) and 50 mm (1.969”). All the different cutters have shanks which are compliant with DIN1835-B. The cutter bodies are extremely stable and designed with internal radial coolant supply, for efficient cooling and optimized chip evacuation.
Widths of cut, 11 mm (.433”), 14 mm (.551”), 18 mm (.709”) and 22 mm (.866”) are dependent on the cutting diameter.
The smallest patented quick-change reaming system in the world is a cost-effective alternative to solid carbide reamers.
Diameter Range: Ø 7.600 - 13.100 mm (Ø .29921 - .51575")
DR small cuts the costs per bore hole substantially, increases productivity and reduces logistics costs thanks to the easy swap system, which does away with the need for regrinding or timely size adjustment. The system enables a high level of force transmission to be achieved with repeatable precision of less than 5 μm (0.0001969").
The special construction of the geometry for trochoidal milling cycles ensures a quiet process due to the unequal division/split/ and helical cutting edges. The reduced pressure angle milling tools are designed with an extremely stable core diameter. in combination with the high performance coating these end mills are suitable for a wide range of wet and dry machining a variety of steels.