processes Efficient
processes Efficient processing of modern materials The alloying of lead in metallic materials has a positive effect on the machining process. Due to the EU’s REACH and ROHS regulations, the time of these easy-to-machine materials is over in many applications. However, reliable machining must still be possible in the future. With its broad tool portfolio, Paul Horn GmbH has a suitable solution for almost every application. The main problem when machining lead-free alloys, be it brass or free-cutting steel, is the lack of reliable chip breaking. But what exactly is the effect of the alloy component lead, which is toxic to humans? During machining, the soft metal creates predetermined breaking points in the alloy, as lead forms small nests or inclusions in the alloy structure. These ensure good chip breaking and low cutting forces during machining. Furthermore the heavy metal acts like a lubricating film, which has a positive effect on tool wear. The changeover was initially a challenge. The good cutting properties of the lead-alloyed materials were lost. In addition, the wear on the cutting edge increased significantly. This was remedied by grooving and longitudinal turning with chip-breaking geometries from the steel sector and special laser-cut geometries. Extensive investigations show that chip-breaking geometries for steels with medium strength in particular work very well with lead-free materials. With the new type 105 Supermini, Horn has succeeded in developing a universal boring tool with sintered chip form geometry Adapted cutting edge geometries provide a high degree of process reliability when machining lead-free materials During internal boring, adapted geometries also ensure reliable chip breaking. One of the biggest challenges in internal machining is long chips. These often occur during bore machining. They wrap around the tool, clog bores or, in the worst case, lead to tool breakage. Previously specially lasered or ground chip form geometries were used for this purpose. However, this was associated with a corresponding cost factor for the cutting insert. With the new Type 105 Supermini and the Type Mini with I geometry, Horn has succeeded in developing universal boring tools with sintered chip form geometry. The tools offer high process reliability in use thanks to good chip control. The cutting edge geometry extends far into the corner radius of the insert. This ensures chip control even with small infeeds. The geometry can be used universally for different material groups and is suitable for internal, face, copy and reverse turning. further information: www.horn-group.com 34 no. 3, September 2025
processes Expanded gear cutting expertise Gear cutting specialist LMT Fette, a subsidiary of LMT Tools, is continuously expanding its range of products and services. New gear cutting tools, innovative solutions, additional manufacturing capac ities, and expanded knowledge including the integration of PWS’s expertise creates exciting opportunities and real added value for customers. LMT Fette’s gear cutting tools impress with their unique performance, high innovative strength and unparalleled efficiency, and have long been considered the ultimate in gear cutting. With its passionate commitment to precision, the company ensures that its industrial customers can deliver superior quality at the crucial interface between machine and workpiece. Technological progress and changing customer needs are the most important drivers of innovation. Expanded application, design and manufacturing expertise “Gear cutting processes are highly optimized these days. At the same time demands on performance, precision, process reliability, sustainability and cost efficiency are increasing” says André Bollow, head of the gear cutting product line at LMT Tools, emphasizing: “With our concentrated gear cutting expertise, our wealth of experience, our expanded product portfolio and our enhanced manufacturing capacities and processes, we now offer customers even greater flexibility in technology consulting, more design customization options and additional opportunities to further maximize the performance capabilities of our tools.” Focus on rolling shaving and rolling broaching The current focus is on rolling shaving and rolling broaching – two processes that are particularly suitable for internal and external gear teeth with interfering contours. LMT Fette’s strengths include special profiles and high-precision quality requirements that must be met with both cylindrical and conical tools. Specifically hobbing is becoming increasingly important thanks to its advantages in terms of productivity, quality and efficiency. Roll peeling is becoming increasingly important thanks to its advantages in terms of productivity, quality, and efficiency; LMT Tools supplies the right tools For example, the necessary gear modifications in electric drives in the automotive industry cannot be produced with the high quality required using conventional broaching methods. The gearing specialist supports rolling shaving with high-performance, process-reliable tools and specially developed simulation software – all from a single source. New peeling and cutting wheels The LMT portfolio includes cutting wheels for gear shaping made of PM material, peeling wheels for gear peeling made of PM, solid carbide and indexable insert versions, tools for gear peeling with modules from 0.5 to 8, hobbing tools with modules from 0.8 to 12, and indexable insert peeling wheels with modules from 3 to 8. Aviation, automotive – with a focus on BEV gear teethe – mechanical engineering and robotics are important areas of application. Technology consulting and tool solutions from a single source. “The new products complete our range of gear cutting tools with geometrically defined cutting edges. In addition we are now able to cover larger module ranges. This means we can now also manufacture tools with a module < 1 mm” explains André Bollow, adding: “We implement the optimal solution for our customers’ application-specific needs and get the best out of every process with customized tool and process design.” further information: www.lmt-tools.com no. 3, September 2025 35
