The Horn circular milling system offers users many advantages, including a high level of reproducible quality. It is fast, reliable and achieves good surface finish. During processing, the tool plunges into the material either at an angle or horizontally and is interpolated either in a circle, or helically to produce a thread.

Horn's SG3 coating is designed for machining titanium alloys and superalloys, as well as for hard turning and hard grooving applications. (Source: Horn)

The NeoMill-Alu-QBig indexable insert milling cutter from Mapal stands for top performance in high-volume milling of aluminium. The tool manufacturer thus offers a very economical solution for use on high-performance machines, such as those found primarily in the aerospace industry.

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A new side milling cutter for stepless adjustment of groove width has been introduced by Paul Horn, and is available through the firm's UK subsidiary, Horn Cutting Tools, Ringwood. The milling body features a central sleeve that enables the required groove width to be adjusted easily on a pre-setter.

Horn's SG3 coating is designed for machining titanium alloys and superalloys, as well as for hard turning and hard grooving applications. It can withstand temperatures of up to 1100°C and is designed to deliver high performance when working with materials that are difficult to machine. Now that the advantages of the tool coating have been proven on selected Horn tool systems, the 105 Supermini grooving and boring system products are available from stock.

The tools’ optimised face geometry reduces the cutting pressure during linear or circular ramping. Improved chip spaces ensure optimal process reliability during chip formation and removal. The system also demonstrates good performance during finishing. Smooth operation means that high surface quality can be achieved during side milling, for example. HPC milling of high strength steels at fast metal removal rates places significant demands on the tools. New carbide substrates and new tool coating technologies make this process feasible. Horn relies on the ES3P grade, again with a HiPIMS coating.

Babcock International Group (Babcock), the defence company, has been awarded a two-year contract extension by the UK Ministry of Defence (MOD) to continue to provide technical support services across the UK armed forces.

Horn’s DS system for dynamic HPC milling excels at dynamic roughing as well as during standard roughing cycles. (Source: Horn)

At the exhibition, Horn will explain the importance of two new, high-performance coatings, IG6 and SG3, it has introduced for the manufacture of carbide inserts used in turning applications. Despite being less than 0.005 mm thick, such coatings can extend service life by a factor of 10 or more compared to uncoated inserts.

The successful 406 and 409 type indexable inserts have been chosen for the application. They are precision ground and achieve outstanding surface quality at the base of the groove and on the flanks. Double positive axial and radial rake angles ensure a soft cut. The tangentially screwed cutting insert's trailing chamfer produces a secondary cutting edge, resulting in outstanding machined surfaces. An additional free-form surface chamfer provides a stable wedge angle and very smooth milling.

IG6 is a copper-coloured, aluminium-titanium-silicon nitride (AlTiSiN) coating for machining steels in groups P and M with Horn's S224 and S229 grooving systems. In conjunction with an adapted carbide substrate, the coating allows faster material removal rates and significantly extended service life. Standard inserts are available from stock, while for special designs, Horn Greenline orders can be delivered within five working days of the customer signing off on the drawing.

UK — At Mach 2022, Horn will present a modular system for reaming large diameter holes, an extended range of products for circular interpolation milling of holes down to 8 mm diameter, two new, high-performance coatings as well as an expanded range of solid carbide end mills.

Dimensional accuracy, stability and process reliability are assured, as the torque generated during machining is dissipated into the body. Horn offers two body types, the first having a cutting edge diameter of 100mm. It is equipped with 14 type 406 indexable inserts, which produce seven effective cuts ranging from 9.6mm to a maximum of 12.9mm wide. Milling depth is up to 20mm. The second body type is equipped with 12 cutting inserts of type 409 and has a cutting edge diameter of 125mm. On this tool, the cutting width with six effective cuts can be adjusted between 12.9mm and 18.8mm. Maximum milling depth is 32.5mm. The successful 406 and 409 type indexable inserts have been chosen for the application. They are precision ground and achieve outstanding surface quality at the base of the groove and on the flanks. Double positive axial and radial rake angles ensure a soft cut. The tangentially screwed cutting insert's trailing chamfer produces a secondary cutting edge, resulting in outstanding machined surfaces. An additional free-form surface chamfer provides a stable wedge angle and very smooth milling. www.phorn.co.uk

A new, modular system for reaming large diameter holes has been introduced by Horn and will be on show for the first time in the UK at Mach 2022 in Hall 20, stand 340. Offering high precision, flexibility and easy handling, DR-Large reamers have exchangeable cutter heads with multiple solid carbide inserts, resulting in high cutting values, short cycle times and low costs. The interface of the insert seats has been designed to offer precise interchangeability to within a few microns and tool setting is unnecessary when exchanging the cutter head.

The inserts are available in widths of 0.5 mm, 1 mm, 1.5 mm and 2 mm. For milling circlip grooves, Horn offers the system with cutting widths of 0.8 mm, 0.9 mm, 1.1 mm and 1.3 mm. In the case of the full radius versions, radii of 0.4 mm, 0.6 mm and 0.8 mm are offered. To enable the milling of chamfers, angles of 45, 30 and 15° are available. Regarding the substrates, Horn uses coated grade EG55 for general steel machining and IG35 for machining stainless steels and superalloys.

Reaming is an economical machining process. Compared to boring holes to tight tolerances, it is faster and can significantly reduce cost of production. Until now, reaming tools on the market in these larger sizes have been either special brazed tools or diameter-specific reamers with fixed inserts. With such tools, which tend to be delicate and heavy, replacing worn inserts is a complex process and calibration can be tricky for many users. Horn offers a practical alternative with its exchangeable-head, pre-calibrated DR-Large reaming tools and its customer service department offers quick and simple reconditioning.

Making its UK debut will be Horn's expanded DS range of solid carbide end mills with a new geometry for HPC (high-performance cutting) milling of high strength steels at elevated material removal rates. It particularly excels in dynamic roughing applications as well as in standard roughing cycles. Different helix angles create an irregular tooth pitch, making operation exceptionally smooth. The end mills are available in diameters from 2 mm to 16 mm as standard, with four or five flutes.

Tooling manufacturer, Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC.

The substrate and geometry of Horn's 304 circular interpolation milling system can be easily matched to the machining process. (Source: Horn)

The second body type is equipped with 12 cutting inserts of type 409 and has a cutting edge diameter of 125mm. On this tool, the cutting width with six effective cuts can be adjusted between 12.9mm and 18.8mm. Maximum milling depth is 32.5mm.

Dimensional accuracy, stability and process reliability are assured, as the torque generated during machining is dissipated into the body. Horn offers two body types, the first having a cutting edge diameter of 100mm. It is equipped with 14 type 406 indexable inserts, which produce seven effective cuts ranging from 9.6mm to a maximum of 12.9mm wide. Milling depth is up to 20mm.

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The versatile, interchangeable reaming system is suitable for bore diameters from 140 mm to 200.2 mm. Six cutter heads cover the range of diameters in 10 mm increments, with two sizes of head fitting on each size of reamer shank. Modular construction and an ABS-compatible interface means the tool can be extended to any length, in theory without limit. All reamers are equipped with direct internal coolant supply to each cutting edge.

In evidence also at the show for the first time will be Horn's extended range of products for circular interpolation milling of holes down to 8 mm diameter. The triple-edged 304 system offers a versatile, productive solution for internal groove, thread and profile milling as well as finish boring and chamfering. The insert has a cutting diameter of 7.7 mm. In conjunction with various vibration-damping carbide shanks, which feature an internal coolant supply, the tool is more economical and versatile than solid carbide milling cutters for machining smaller diameters.

In celebration of World Space Week, Space-Comm Expo has announced visitor registration is now officially live and open for the London ExCeL, event, running 11-12 March 2025.

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Walter has now launched its new X·treme Evo Plus drill from the DC180 Supreme product family that is now available up to 8XD for the first time.

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The Boeing X-37B spaceplane is to begin executing a series of novel manoeuvres, called aerobraking, to change its orbit around Earth, the US Space Force has announced.