Post on 14-Aug-2020
A very warm welcome (Arial, 24-point bold font)
Discover what's under the surface (Arial, 20-point bold font in italics)
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HORN Technology Days 2015
Technical presentation:
Form tools and special tools in series production
Speaker: Chris Smith
Applications Engineer
Horn Cutting Tools Ltd
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Contents
Form tools
Bell-type tool
Combination tool
Special tools
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Requirement
Why and when to use these tooling concepts?
Avoid machining on multiple machines / multiple set-ups
Reduce cycle time to machine each workpiece
Volume production
Cost of the tool can be justified
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Justification
Aspects to be considered?
Costs of special tools
Handling of complicated tools
Machine specifications
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Form tool type 117
External Applications: Profiling Profile width 10 - 45 mm Profile depth up to 13 mm Toolholders 10, 12, 14, 16, 20, 25 mm, AWN, PWP
Preferred application for high quantities of components
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Form tool type 117
Possible profile depths
Tmax up to 13.0 mm
with chipping angle of 0°
Width of groove 10 mm
Tmax up to 10.0 mm with
chipping angle of 5°
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Form tool type 117
Customised tool carriers with all standard interfaces can be manufactured
AWN system PWP system
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Form tool type 117
Internal machining of a hydraulic piston
with a type 117 profile grooving insert
Feed direction Increased cutting performance
ISO tool Horn form
tool
2000
parts
4000
parts
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Form tool type 117
Profile grooving ISO turning
Benefits: Drawbacks:
• Good form accuracy • Swarf problems
• High stability • Surface quality
• Good machining properties • Machine downtimes
Increased productivity
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Machining task
Creation of an external and internal form grooves
External diameter finished D = Ø 61 mm
A1
A2
Universal lathe:
2 tools for internal and external
Universal lathe
with HS and GS:
2 tools for internal and external
Parallel processing possible
Machining centre:
2 tools for internal and external
Groove Ø
DA = 59 mm
Groove Ø
DI = 54 mm
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Bell cutter
Creation of an external and internal form groove
in one process
• Adapting the cutting edges on the tool
DA = 64 mm and DI = 49 mm
• Defining the axial position of grooves A1/A2
A1
A2
Groove Ø
DA = 59 mm
Groove Ø
DI = 54 mm
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Bell cutter
Creation of an external and internal form grooves in one process
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2
1
2
Move centrally
to axial
position.
Radial infeed
2.5 mm
(2.5
mm
)
Creates a milling cutter
centre-point path
of Ø 5.0 mm
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HCT - Cutting data calculation
http://hct.phorn.de
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HCT - Cutting data calculation
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HCT - Cutting data calculation
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HCT - Cutting data calculation
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Cutting the
inner & outer
groove
Cutting the
outer groove
7.5
3 s
Insert Type 628
Bell cutter
HCT - Cutting data calculation
Inner groove cutting time (s)
Outer groove cutting time (s)
Combined cutting time (s)
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Combination tool 007
Special design
Tool adapted to workpiece
Machining process becomes more efficient
Significantly less time needed for tool
changing
Reduction in the amount of tool logistics
work required
Increased accuracy
Enormous potential savings
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Combination tool 007
Cutting data:
Cutting speed Vc: 160 m/min
No. of revolutions n: 1150 rpm
Feed rate Vf: 0.45 mm/rev
ISO indexable insert
Ø 5
8.1
5 m
m
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Combination tool 007
Cutting data:
Cutting speed Vc: 160 m/min
No. of revolutions n: 1150 rpm
Average chip thickness hm:0.05 mm
ISO indexable insert
0.2x45° 0.2x45°
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Combination tool 007
Cutting data:
Cutting speed Vc: 145 m/min
No. of revolutions n: 1250 rpm
Average chip thickness hm:0.05 mm
2.75
2.75
2.75
45°
Indexable
insert type
S274
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Combination tool 007
Cutting data:
Cutting speed Vc: 145 m/min
No. of revolutions n: 1500 rpm
Average chip thickness hm:0.03 mm
3.05
3.05
3.05
Finish milling groove,
groove flanks "burr-free".
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Form tools
Increased productivity, reducing setup and cycle time
Bell cutter
Process optimized & significantly higher productivity
Combination tools
Reduced tooling cost & fewer tool changes.
Summary
Improved quality
Increased process reliability
Increased machine capacity
Competitive advantage
Reduction in costs