Horn Cutting Tools Ltd, Ringwood (www.phorn.co.uk), has expanded its DTM lightweight milling system to include two new versions.

DTM.CX09 arbour milling cutters are designed as roughing tools for use in machining applications that involve high cutting depths — and little emphasis on surface quality.

The DTM.CX09.AL.F face-milling cutter for finishing adds an adjustable body to the existing product range (the axial run-out can be adjusted easily to micron accuracy, using a pre-setter).

The lightweight aluminium body of the tool-holders has a significantly lower mass than a steel one, resulting in reduced energy consumption during acceleration and deceleration, faster spindle speed changes and less wear on the spindle at high speeds.

Moreover, the cutter body features a protective hard coating to prevent wear caused by chip impact.

The arbour milling cutter bodies have diameters between 40 and 125mm, plus four to eight effective cutting edges. All versions feature an internal coolant supply and are designed for high-speed milling up to a maximum cutting speed of 5,000m/min.

Inserts are available from stock in several diamond materials and a variety of geometries, making it possible to obtain a cost-effective alternative to brazed face-milling systems, while chip-breaker geometries reduce chip volume and increase process reliability.

Inserts are available with a PCD or CVD-D coating. PCD grade PD75 is a useful all-rounder for aluminium machining applications, while Horn recommends substrate PD70 for alloys with a high silicon content. The substrate HD08 (CVD-D) is used for highly abrasive materials.

CVD-D consists of 99.9% diamond and offers maximum wear-resistance. All material versions are available in a range of geometries to suit various applications.