Custom Tooling
HORN develops custom tool solutions specific to your application.
Example 1:
Radial Multigrooving "Petrol Piston"
The grooves are machined with PCD-tipped inserts type 312 which are clamped in a multi-grooving toolholder of type 340.
Process:
- Pregrooving
- Finishing with a second set of inserts
Technical Information
Material: GD-AlSi12
Cutting data Pre-grooving:
Vc = 350 m/min
Vf = 0.07 mm
Cutting data Finishing:
Vc = 350 m/min
Vf = 0.03 mm
Example 2:
Face grooving on Gear wheel
Using Horn toolholder type 360 with polygon connection and special indexable insert Type 312. The size of the burrs along the teeth defines the tool life and creates a high technical demand on the tool itself.
Technical Information
Material: 20MnCr5
Cutting data:
Vc = 200 m/min
Vf = 0.06 mm
Example 3:
Grooving of Hardened Gear wheel
Special CBN-tipped insert type S117 is used to finish the width of the groove. The stock removal is approximately 0.15 - 0.2 mm (.006˝ - .008˝). The insert is ground to final width of the groove.
Both flanks are machined at the same time (Rz=2.3 μm). To obtain high surface finish, the insert has a wiper flat on both side cutting edges.Stable machining conditions are imperative. No coolant.
Technical Information
Material: 20MnCr5
Case hardened 58-62 HRC
Cutting data:
Vc = 140 m/min
Vf = 0.08 mm
Example 4:
Face grooving - Multitool
Based on the insert system S224. The the tool is used to do a front and back face grooving operation
The toolholder is equipped with exchangeable and adjustable cartridges.
Technical Information
Material: 20MnCr5
Cutting data:
Vc = 180 m/min
Vf = 0.16 mm
Example 5:
Groove Milling by Circular Interpolation
Grooving Head type 389 with HSK
Example: Wheel cylinder
Tool data:
Cutting edge Ø Ds = 39 mm
Number of teeth Z = 6
Technical Information
Material: C45
Cutting data:
Vc = 180 m/min
Vf 3 = 3913 mm
tg = 1.92 sec
Example 6:
Groove Milling Swivel Bearings with Circular Interpolation
Set of milling cutters of type M275 with different cutting diameters. Mounted on a HSK arbor with through coolant. All operations - Grooving and Facing - are done in one step. For multispindle use on transfer lines, the length adjustment is done by distance rings.
The example shows a detail of a swivel bearing with tool. Dry cutting.
Technical Information
Material: C45
Cutting data:
Vc = 140 m/min
Vf = 0.5 mm
Example 7:
Gear milling
Special milling cutter type M275 with indexable inserts type S275 and KM arbor.
Technical Information
Material: 20MnCr5
Cutting data:
Vc = 220 m/min
fz = 0.03 mm