Multi-tooth PCD cutter for high speed finishing

A new, high-feed milling system for productive finishing of non-ferrous metals and plastics has been introduced by Horn Cutting Tools, Ringwood. Designated DTM 1710, the tool system employs inserts with polycrystalline diamond (PCD) cutting edges brazed onto cassettes that can be finely tuned axially to micron precision via adjusting screws on the tool carrier. The PCD substrate is precisely laser-cut to achieve high surface quality during the finishing process. Axial run-out is set by Horn engineers before the tool is delivered.

Compared to other tools of this type on the market, the Horn milling system offers a higher number of cutting edges for any given size. The tools are available in the diameters 50 mm (z = 10), 63 mm (z = 14), 80 mm (z = 18), 100 mm (z = 24) and 125 mm (z = 30), z representing the number of inserts. All variants have an internal coolant supply directly to the cutting edge.

To achieve a high quality machined finish on the workpiece and to enable use at high speeds, the tool must be finely balanced with the tool holder, for which purpose balancing holes are provided around the cutter body. To achieve the best possible results, the entire machine environment must be taken into account and brought to the highest possible level of stability. The combination of the machine design, guideways, spindle and workholding system as well as the milling tool have a decisive influence on the result.

The aluminium alloy milling body is lightweight, minimising centrifugal force and hence prolonging spindle life. For long-term protection against abrasion from chips, the cutter body is surface treated.

The Horn high-performance PCD cutting material is composed of a mixture of different sizes of diamond grains. As the proportion of diamond by volume increases, so do the effective hardness, toughness and cutting edge quality. For the DTM 1710 milling system, Horn offers two different PCD substrates to suit the material to be machined.