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