Cutting tool manufacturer Horn is launching a new product range for the economic machining of brake discs. The range includes solid CBN ISO inserts, mainly for cast iron machining, and CBN-tipped full-radius and shaped inserts. The grade has no metallic bonding phase and therefore offers the highest hot hardness of all cutting materials. Stable tool carriers also feature in the offering.

For machining applications on a brake disc, Horn provides a solid CBN ISO S insert with eight cutting edges. In conjunction with the tool holder, the system is suitable for roughing and finishing. The neutral design of the inserts fully utilises the number of cutting edges. It means that eight cutting edges per ISO insert are available for most turning operations.

Cutting speeds of well over 1000 m/min, depths of cut of several millimetres and feed rates up to 0.7 mm/rev are typical when machining cast iron brake discs using a solid CBN insert. The tool system must be able to maintain high cutting performance and, above all, exhibit long tool life due to the cost per cutting edge of CBN. Depending on the operation and metal removal rate, it is possible to machine well over 1000 cast iron brake discs per insert corner.

Horn offers two different tool solutions for machining the heat dissipation grooves in the disc. The CBN-tipped S117 profile grooving insert is suitable for large batch production in terms of speed and tool longevity. During the process, each groove is produced in just under two seconds in a single operation. For greater flexibility, Horn’s S229 tipped, full-radius inserts offer the option of copy turning the grooves in around four seconds. Regrinding and re-tipping are possible with both types.For further information www.horn-group.com/uk

To overcome various machining challenges and boost productivity, Seco has introduced new extra-long solid-carbide drills,PCBN inserts, round carbide inserts and tool holders. These products are aimed at applications ranging from general ISO turning to high-volume hard turning and deep-hole drilling.

Manufacturers that drill holes at depths from 40xD to 60xD want to lengthen tool life and reduce tooling costs. Here, Seco says that its new X-tra Long solid-carbide drills provide more than 15% more tool life than other available solutions. Innovative tool geometry and coating technology eliminate chipping and sudden breakage, while minimising flank and centre wear.

According to Seco, the company’s two new PCBN insert grades offer optimal performance in the high-volume production of automotive and other industry components. With a substrate grade and proprietary Seco nano-laminate PVD coating,CH1050meets high surface quality requirements, while CH2581 achieves greater process stability and reduced tool breakage with a versatile, forgiving grade for semi-interrupted cuts.

Many round turning inserts suffer from poor chip control, but Seco’s MF2 chipbreaker on RCGT/RCMT inserts maintains favourable chip control at higher speeds and feeds, especially with dynamic turning. One series of stable, durable carbide round insert grades handles a wide range of turning operations from roughing to finish turning.

Seco has also utilised its proprietary 3D-printed coolant clamp to deliver Jetstream Tooling high-pressure cutting fluid directly to the cutting edge. With a range of single-screw coolant clamp options for specific applications and depths of cut, Seco-Capto MTM JETI toolholders for general ISO turningprovide fast set-up and indexing, making chip control less of a challenge on 45° B-axis multi-tasking machines. 
For further information www.secotools.com