German cutting tool manufacturer
Horn has introduced a new, modular range of PCD (polycrystalline diamond) end mills for machining aluminium, plastics and other materials in groups N (non-ferrous) and O (non-metallic).
The system combines a reusable, solid carbide shank and a PCD-tipped, interchangeable steel head. Availability in the UK and Ireland is through Horn Cutting Tools, in Ringwood.
The manufacturer has designed the DM40 system to conserve resources and ensure cost-effective machining. The end cutting edges of the mill are among the main wear zones, while peripheral cutting edges longer than twice the tool diameter are susceptible to high lateral cutting forces, vibration and chipping.
The ability to change just the head reduces follow-on costs compared with conventional monobloc tools, especially as the worn, brazed-on, PCD tips can be resharpened up to twice.
By designing the cutter with a separate shank and head, Horn has ensured that the consumable cost is not only lower but also more predictable, making the tool system ideal for series production runs and automated lines. Users can quickly replace the head module on-site, so the tool is rapidly back into service, maximising spindle uptime.
The head is attached to the shank by a central clamping screw that provides both a force-fit and a form-fit connection. Colour coding facilitates the identification of components and a poka-yoke principle prevents assembly errors. The rigidity of the interface ensures precise machining, whether using a new or a resharpened tool, and the large axial rake angle enables smooth cutting and produces an excellent surface finish.