Modular PCD end mill
With the DM40 system, Horn is expanding its product range to include a modular PCD end mill series for universal milling applications in aluminium, die-cast aluminium and materials in Groups N and O. The tool system combines a permanently reusable, solid carbide toolholder with a PCD-tipped, interchangeable head based on a steel body.
Horn has specifically designed the system to reduce wear, conserve resources and ensure cost-effective processes. The modular design functionally separates long-lasting components from those subject to high wear. The face cutting edges, in particular, are among the main wear zones in milling applications. At the same time, cutting lengths exceeding twice the diameter increase the risk of edge chipping. In these areas, the interchangeable head system reduces material usage and lowers follow-on costs compared with conventional monoblock tools.
Source: Horn/Sauermann
Users can replace the cutting module directly on site. The tool can then be put back into service without any additional adjustment. This reduces machine downtime, replacement lead times and repair costs. The separation between the durable base toolholder and the replaceable head also ensures transparent and predictable maintenance costs. The system is therefore particularly suitable for series production and automated production lines.
Horn connects the PCD-tipped steel head to the toolholder via a central clamping screw, ensuring both a force-fit and a form-fit connection. Additional colour coding facilitates the identification of components during assembly. The integrated poka-yoke principle prevents assembly errors and enhances process reliability during use.
Source: Horn/Sauermann
The interface between the interchangeable head and the toolholder ensures precise, step-free milling results for both new tools and resharpened tool pairings. Worn interchangeable heads can be resharpened up to twice within specified diameter ranges. The ability to resharpen reduces resource consumption and further improves the system’s cost-effectiveness.
The high axial rake angle design enables smooth cutting and excellent surface finishes. At the same time, the geometry ensures stable and reliable milling across universal applications.
FACTS
- Sustainable and straightforward replacement of the main wear zone
- Cost-effective standard range with universally applicable replacement heads
- Cost reduction thanks to a durable, solid carbide toolholder
