Horn offers the solid CBN ISO S turning insert with eight cutting edges for roughing and finishing. Stable tool carriers are included in the offering and, depending on the operation and metal removal rate, in excess of 1,000 cast iron brake discs can be machined per insert corner.

They also make these and others like them. I’ve never used them so read reviews on quality. That middle shaft should fit through the holes you already have.

The production of bone screws must be carried out using a metalcutting process, as the material for this type of screw must not be compressed, as is the case when thread rolling, for example. Titanium in particular, which is widely used in the human body due to its biocompatibility, tends to burn if the material is unduly compressed. As a thread cutting process for the medical industry, thread whirling on Swiss-type lathes has been a standard procedure for many years.

This is the final test fit of the pin material. I’m going to cut it off at the appropriate length and then sand everything to the final finish.

Additionally, Horn has introduced two different tool solutions for machining the heat dissipation grooves in the discs. The CBN-tipped S117 profile grooving insert is ideal in terms of cutting speed and longevity for large batch production.

Sharp insert geometry ensures process reliability, even with very small infeed and cutting feed rates. The specially developed coating is suitable for stainless steels, non-ferrous metals and other metals.

I took your advice. I clamped my work piece to my drill press. I ran it at 2100 RPM and I oiled the cutting surface with 3-in-1 oil. I then drilled the holes by applying pressure with time for the bit to rest periodically.

The difference in doing it correctly with all the setup is a 3 second drill job vs 10minutes of hell or not at all. Also make sure you use drill bit from a reputable supplier not harbor freight or amazon.

BTW: The wood is long leaf pine from the deck of the Battleship Texas. The knife will be auctioned off along with a ton of other items in the Spring, to fund the restoration of the Battleship.

Is heating the tang and hot-punching or drifting open it an option? You could lower the blade into water and use a torch on the tang w/out losing the temper on the blade. Using the induction forge and perhaps quenching the blade before it shows any color should also allow you to isolate heat. The move to the anvil to enlarge the hole.

A new, high-performance, carbide grade from Horn, the SG3P, presents enhanced possibilities in terms of performance and tool life when whirling medical screws. It enables shorter cycle times for thread production thanks to higher cutting values, including when processing materials that traditionally are difficult to machine.

A carbide drill bit is the correct answer that said carbide drill bits can be pretty challenging to use. They are extremely sensitive and will break with any kind of misuse. You want to make sure you have a very rigid setup if you’re going to use a carbide drill bit.

Yeah, I didn’t want to apply any heat though. I ended up drilling with a masonry bit which I cooled with oil. It took a little work, but finally did a beautiful job. I just finished the sheath for it. I used one which was included in the knife kit. All I did was apply leather dye to it.

Paul Horn, the solid carbide tooling, carbide insert and toolholder manufacturer headquartered in Tübingen, Germany, has supplied more than 200,000 special tooling solutions over the years and currently offers 25,000 standard products, including five due to be introduced to the UK and Irish markets at MACH 2024.

The only thing I found to enlarge those holes are the cone-shaped diamond bits from Harbor Freight. They worked reasonably well but it took basically one bit per knife (three holes) to do it. Use a drill press and for Xenu’s sake, secure the blade WELL before putting it under a drill.

Horn is also launching a new tool range for manufacturing brake discs economically. It includes solid CBN (cubic boron nitride) ISO inserts, mainly used for cast iron machining, and CBN-tipped full-radius and shaped inserts. The grade has no metallic bonding phase and therefore has the highest hot hardness of all cutting materials.

As standard, Horn offers the boring bars from stock in length-to-diameter ratios of 5:1 and 8:1. Higher ratios are available as special tools. In the case of grooving, Horn offers the S224 double-edged system.

The Supermini Type 105 system insert requires only one toolholder for well over 1,000 insert variants, which applies equally to left-hand and right-hand versions. The carbide inserts are available coated or uncoated in various grades for a variety of applications, including hard machining up to 66 HRC.

From 30-31 October, ITC will again be exhibiting at the Advanced Engineering Exhibition on Stand T171 in Hall 3 at the NEC Birmingham.

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These are the bits I bought at Home Depot. They are primarily used with a hammer drill and for masonry, but they also list metal on the instructions on the back:

At the show an addition to the Horn Supermini boring, grooving and chamfering system will be announced, a variant with a precision-ground rake face designed for producing ultra-fine bores. The ground cutting edge is free from notches when viewed at a magnification of x200 and the tool can be used to machine components having an inside diameter from just 0.3mm.

Tooling manufacturer Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC. Due to the high flexural strength of the carbide substrate, the insert is also suitable for interrupted cutting.

Type DSR, with its very sharp cutting-edge geometry and short design, is suitable for very small parts and unstable workholding conditions, such as are frequently encountered in the medical and watchmaking industries.

The wholly-owned UK subsidiary of Horn Cutting Tools will be at the show to explain the reasons behind its launches and will also exhibit a broad cross section of the manufacturer's extensive tooling range.

TW Ward CNC Machinery (Ward CNC) is pleased to announce that Andrew Elliott has rejoined the company in the sales department and senior management team.

Due to their geometry and efficient chip breaking, the mills are suitable for machining numerous other materials as well. The combination of substrate, macro and micro geometry, and IG3 coating exhibits high cutting performance and long tool life. The coating in particular offers high temperature resistance for machining steels alloyed with chromium, nickel and molybdenum.

To help mitigate these difficulties, Horn has introduced a boring bar with adjustable damping so it can be set to match the amplitude of the oscillation generated by the machining process. Precise adjustment enables vibration-free turning, resulting in better surface quality of the machined component and a significant increase in insert life.

Horn has developed a new, solid carbide milling cutter range for machining stainless steels, widely used in the food, chemical and pharmaceutical sectors, as well as in the watchmaking and other precision engineering industries.

I would like to enlarge the holes in the knife from 5mm to 8mm so I can use a different set of pins. I’ve tried a number of bits I own, including a carbide, which is supposed to cut hardened steel, and cobalt bit, to no avail. The steel handle just won’t drill. I know I can heat it and ruin the heat treatment but I would think that somewhere there are bits that can make short work of drilling it. The description says it is stainless steel, but I don’t know the hardness from the description. (Maybe the bits are really carbide bits and I just need to get a higher quality bit)

In addition, the combination of an ultra-fine-grain carbide powder and a high-temperature-resistant coating raises process reliability and improves component quality. In-house coating of the inserts enables fast delivery times, and the carbide grade is available for all standard Horn thread whirling systems.

From 30-31 October, ITC will again be exhibiting at the Advanced Engineering Exhibition on Stand T171 in Hall 3 at the NEC Birmingham.

If you attempt to hand drill, use a non-rigid drill press, come in with too little pressure, use the wrong rpm, etc you are guaranteed to harden the exact spot you are trying to drill and damaging your drill bit.

Dustcontrol UK is set to exhibit its innovative dust extraction solutions at the Advanced Engineering Show 2024, taking place at the NEC Birmingham from 30-31 October.

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Another not yet mentioned option would be any of the abrasive techniques. A die grinder with an appropriate small diameter abrasive wheel or a waterjet.

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Submerge Just the blade in water to protect the temper of the blade and use an oxy torch (Or MAPP gas, but it’ll be slower) to heat the metal to bright red, then move the blade to the anvil and drift The holes open with an appropriately sized blacksmith drift.

If perfection of the hole isn’t a requirement I’d try a Dremel with a small diameter stone since this is a one off. It’ll take time and you’ll need to take care to frequently cool the work, but it will work.

During the process, each groove is produced in just under two seconds in a single operation. For greater flexibility, Horn's S229 full-radius, CBN-tipped inserts offer the option of copy turning the grooves in around four seconds. Regrinding and re-tipping are possible with both types.

The tools are offered in two types from stock. The DSHPR variant is suitable as both a finishing and a roughing tool and the geometry is adapted for trochoidal machining and plunging.

Paul Horn, the solid carbide tooling, carbide insert and toolholder manufacturer headquartered in Tübingen, Germany, has supplied more than 200,000 special tooling solutions over the years and currently offers 25,000 standard products, including five due to be introduced to the UK and Irish markets at MACH 2024. The wholly-owned UK subsidiary of Horn Cutting Tools will be at the show to explain the reasons behind its launches and will also exhibit a broad cross section of the manufacturer's extensive tooling range. Bore superfinishing At the show an addition to the Horn Supermini boring, grooving and chamfering system will be announced, a variant with a precision-ground rake face designed for producing ultra-fine bores. The ground cutting edge is free from notches when viewed at a magnification of x200 and the tool can be used to machine components having an inside diameter from just 0.3mm. Sharp insert geometry ensures process reliability, even with very small infeed and cutting feed rates. The specially developed coating is suitable for stainless steels, non-ferrous metals and other metals. Horn's new solid carbide milling system for stainless steel exhibits high performance and long tool life The Supermini Type 105 system insert requires only one toolholder for well over 1,000 insert variants, which applies equally to left-hand and right-hand versions. The carbide inserts are available coated or uncoated in various grades for a variety of applications, including hard machining up to 66 HRC. Stainless steel milling Horn has developed a new, solid carbide milling cutter range for machining stainless steels, widely used in the food, chemical and pharmaceutical sectors, as well as in the watchmaking and other precision engineering industries. Due to their geometry and efficient chip breaking, the mills are suitable for machining numerous other materials as well. The combination of substrate, macro and micro geometry, and IG3 coating exhibits high cutting performance and long tool life. The coating in particular offers high temperature resistance for machining steels alloyed with chromium, nickel and molybdenum. The tools are offered in two types from stock. The DSHPR variant is suitable as both a finishing and a roughing tool and the geometry is adapted for trochoidal machining and plunging. Type DSR, with its very sharp cutting-edge geometry and short design, is suitable for very small parts and unstable workholding conditions, such as are frequently encountered in the medical and watchmaking industries. The new SG3P carbide grade enables shorter thread whirling cycle times thanks to higher cutting values Thread whirling A new, high-performance, carbide grade from Horn, the SG3P, presents enhanced possibilities in terms of performance and tool life when whirling medical screws. It enables shorter cycle times for thread production thanks to higher cutting values, including when processing materials that traditionally are difficult to machine. In addition, the combination of an ultra-fine-grain carbide powder and a high-temperature-resistant coating raises process reliability and improves component quality. In-house coating of the inserts enables fast delivery times, and the carbide grade is available for all standard Horn thread whirling systems. The production of bone screws must be carried out using a metalcutting process, as the material for this type of screw must not be compressed, as is the case when thread rolling, for example. Titanium in particular, which is widely used in the human body due to its biocompatibility, tends to burn if the material is unduly compressed. As a thread cutting process for the medical industry, thread whirling on Swiss-type lathes has been a standard procedure for many years. Horn's new boring bar with adjustable damping carrying one of the manufacturer's grooving inserts Boring bar damping A long overhang can cause a turning tool to oscillate when boring internal geometries. In addition to causing chatter marks on the surface of the machined component, the vibrations can lead to a significant reduction in tool life. For unfavourable length-to-diameter ratios, even damped boring bars may vibrate under certain conditions. To help mitigate these difficulties, Horn has introduced a boring bar with adjustable damping so it can be set to match the amplitude of the oscillation generated by the machining process. Precise adjustment enables vibration-free turning, resulting in better surface quality of the machined component and a significant increase in insert life. As standard, Horn offers the boring bars from stock in length-to-diameter ratios of 5:1 and 8:1. Higher ratios are available as special tools. In the case of grooving, Horn offers the S224 double-edged system. For machining cast iron brake discs, Horn has introduced a new tool range that includes solid CBN (cubic boron nitride) ISO inserts, as well as CBN-tipped full-radius and shaped inserts, plus stable tool carriers Grades for discs Horn is also launching a new tool range for manufacturing brake discs economically. It includes solid CBN (cubic boron nitride) ISO inserts, mainly used for cast iron machining, and CBN-tipped full-radius and shaped inserts. The grade has no metallic bonding phase and therefore has the highest hot hardness of all cutting materials. Horn offers the solid CBN ISO S turning insert with eight cutting edges for roughing and finishing. Stable tool carriers are included in the offering and, depending on the operation and metal removal rate, in excess of 1,000 cast iron brake discs can be machined per insert corner. Additionally, Horn has introduced two different tool solutions for machining the heat dissipation grooves in the discs. The CBN-tipped S117 profile grooving insert is ideal in terms of cutting speed and longevity for large batch production. During the process, each groove is produced in just under two seconds in a single operation. For greater flexibility, Horn's S229 full-radius, CBN-tipped inserts offer the option of copy turning the grooves in around four seconds. Regrinding and re-tipping are possible with both types. Horn Cutting Toolswww.phorn.co.ukHall 6, Stand 210

If you don’t care about the precision/accuracy of the hole you could just try wallowing out the hole using a carbide burr in a die grinder. https://a.co/d/2n4FNEj

The holes in the tang for this knife were about 1/8” and I drilled them out to a little bigger than 1/4” just for aesthetics. Chewed up half a dozen drill bits until I found the diamond things at HF.

Manufacturers face an age-old paradox: manufacturing efficiency versus quality. After all, higher efficiency risks compromising quality while focusing on quality can reduce productivity – and this dilemma is becoming more challenging.

I’m meeting David Peart at DMS next Tuesday to deliver everything. I’ll post a picture of everything when I get it pulled together.

A long overhang can cause a turning tool to oscillate when boring internal geometries. In addition to causing chatter marks on the surface of the machined component, the vibrations can lead to a significant reduction in tool life. For unfavourable length-to-diameter ratios, even damped boring bars may vibrate under certain conditions.

Tooling manufacturer Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC. Due to the high flexural strength of the carbide substrate, the insert is also suitable for interrupted cutting.

I have done several of these. They are made out of some sort of alien space metal. I’ve never encountered anything so hard to drill through.

I’ve seen these before, too. I’ve never used them but they seem to solve a number of problems, including having to drill the holes larger in the knife handle. Thanks for the suggestion.

Manufacturers face an age-old paradox: manufacturing efficiency versus quality. After all, higher efficiency risks compromising quality while focusing on quality can reduce productivity – and this dilemma is becoming more challenging.

Jaguar Land Rover (JLR) is investing £500m to transform its historic Halewood facility into a state-of-the-art production site for electric vehicles (EVs), the company announced in September.