materials & tools Pure
materials & tools Pure machining HORN will be showcasing pure machining at EMO in Hanover. Four machines, four exciting components a wide variety of tool solutions – live in action and cutting chips throughout the entire exhibition. The following will be on display: the DMU65mB from DMG, an Index G220, a Citizen L12 and a GROB G150. In addition HORN will be displaying numerous exhibits and tool solutions and presenting innovations for 2025. Markus Horn, managing director of Paul Horn GmbH: “I am convinced that a visit to EMO will be worthwhile for our customers and interested parties – we will be presenting machining at the highest level. On the four machines we will be demonstrating the topics of finishing, machining lead-free materials, aluminum machining with rotating PCD tools and technology components with numerous turning operations.” Horn continues: “In my opinion the best results are achieved through dialogue, and EMO offers the ideal platform for this. Visit us in hall 5, booth A32.” In addition to live machining, Horn will be presenting nu merous innovations. Among them is the Mini system with sintered chip breaker geometry, which was unveiled for the first time at the Horn Technology Days in May 2025. The sintered I-geometry is particularly aimed at machining materials with poor chip formation properties. It is suitable for copy turning, longitudinal turning, back turning and facing. HORN will be showcasing pure machining on 580 m 2 in Hanover Especially with shallow depths of cut in steel and stainless steels, the tool system with this geometry demonstrates its strengths in chip control. It leads to higher process stability and longer tool life. When developing the I-geometry, HORN also took into account the machining of lead-free materials. As these materials will pose a challenge in the future due to their inferior chip formation, the tool manufacturer offers inserts with small corner radii starting from 0.05 mm for small lateral infeeds. Corner radii from 0.05 mm to 0.2 mm are available from stock. EMO 2025, hall 5, booth A32 New PCD milling program – end mills The new PCD milling program from Paul Horn GmbH, with a focus on productive and reliable machining of aluminum, includes a wide range of standard and special tools from end mills to complex and modular combination tools. as reliably high performance and a long tool life. With a semistandard tool, HORN also offers the fast and flexible option of customization to meet specific customer requirements. The PCD end mills in the DM20–DM33 series are universal all-rounders and, with their respective technical specifications, are suitable for a wide range of applications. DM20 The PCD end mills in the DM20 series are universal allrounders and are suitable for a wide range of applications. The double-edged PCD-tipped milling tools with center cutting capability cover almost the entire range of machining applications and are universally suitable for non-ferrous metals and non-metallic materials such as engineering plastics. The series is rounded off by a specially adapted body design for dry or wet machining. Different PCD substrates as well as modern and customized technologies for cutting edge preparation ensure productive machining processes, as well The double-edged PCD-tipped milling tools in the DM20 series with center cutting capability cover almost the entire range of machining applications 16 no. 3, September 2025
materials & tools The DM25 product range is particularly suitable for contour and finish milling operations on external and internal contours when high cutting feed rates are required The milling tools in the DM30 series are specially designed for cutting tall components With a positive-negative insert arrangement, coupled with internal cooling and center cutting, the tools in the DM27 series offer a coordinated overall package for universal milling applications The DM33 series PCD milling cutter is a milling concept designed for applications where there is a tendency for the formation of built-up edges and for above-average stress on the tool source HORN/Sauermann DM25 The DM25 product range with cutting edge lengths between 8 mm (0.314“) and 18 mm (0.708“) is particularly suitable for contour and finishing milling operations on external and internal contours when high cutting feed rates are required. The multi-edge design significantly reduces machining cycle times. While the R series with internal cooling is preferred for non-ferrous metals, the C series with an additional positive rake angle is suitable for machining abrasive materials through to graphite and fiber-reinforced plastics. DM27 Modern fiber-reinforced composites are lighter, stronger and more stable – which is why they are becoming increasingly important for industrial applications. When machining these abrasive materials, the focus is on the quality of the component edges. Fraying, delamination or chipping create stringent criteria for tool geometry and grade in order to be able to control these component-specific and wear-related conditions. The risk of vibration on thin-walled components or when trim cutting panels, taking into account down or up milling options, represents an additional consideration for stable milling. With a positive-negative insert arrangement, coupled with internal cooling and a center cut, the tools in the DM27 series offer a coordinated overall package for universal milling applications. DM30 Milling tools in the DM30 series are specially designed for cutting tall components. The PCD-tipped milling tools in a spiral design impress with their smooth, paring cutting action. The segmented design reduces cutting forces and machining noise. The precise positioning and arrangement of the PCD inserts ensures high surface quality milling without burrs. The tools are suitable for peripheral milling, trimming or circular milling operations and can be used at small to medium infeed depths, as well as for finishing operations with maximum utilization of the cutting edge length. The cutting edges are high quality and burr-free. DM33 Components made from high-strength and forged aluminum are challenging to machine and place stringent demands on the tool. In contrast to classic aluminum die casting, extruded and forged aluminum causes long chip formation due to the lack of silicon and a compressed material structure. In addition, there are built-up edges and above-average stress on the tool. With the DM33 series, HORN offers a customized milling concept. Whether for face milling or ramping, the tools are designed to produce bores or pockets by helical entry into solid material without pre-machining and with high infeed values. Holes, cut-outs, pockets or profiles can be produced reliably and economically using tools of 12 mm (0.472“) to 16 mm (0.630“) and 20 mm (0.787“) diameter. The tools are designed with a central coolant channel and offer reliable chip flow even during deep machining operations. For larger bores, larger screw-in diameters are available in the DG-V series in conjunction with tool holders of various lengths. This extensive expansion of the Horn portfolio in the area of ultra-hard cutting materials offers users the opportunity to obtain the appropriate, reliable tool solution for their machining applications. The focus is on cost-effectiveness and productivity combined with Horn technology, flexibility and reliability. further information: www.horn-group.com no. 3, September 2025 17
