André Gall, founder of German firm WireStyle, uses in-house developed machines to create works of art based on a photo or graphic using an average of 8000 nails and a long thread. The machines hammer 12 nails into a polystyrene sheet every second to create a canvas for the thread picture. Each nail is cut from a reel of aluminium wire by a pair of indexable carbide inserts from Horn’s S274 tool system.

WireStyle’s machines create a picture by a single thread measuring around 1200 m. To determine the exact path as winding around the nails takes place, the company’s team developed complex algorithms to identify and enhance the contrasting edges in the original image and calculate the individual nail pattern. More thread is used in the darker parts of the picture than in the lighter areas and the reproduction is better and less expensive than would ever be possible by hand.

Gall studied physics at the University of Karlsruhe and has always held an interest in mechanical and production engineering. He built the first prototypes of the nail and thread machines and WireStyle was born.

To make thread paintings affordable for customers, the machines have to operate at high speed. Due to rapid acceleration at up to 5 g, Gall favoured lightweight construction and employed lots of carbon fibre. The machine stretches about 50 cm of thread per second around the nails. During the process, the eye is barely able to follow the thread puller.

Two opposing S274 inserts from Horn clamp into the nailing head of a WireStyle machine. Precise cutting of the wire arrives courtesy of the sharpness of the inserts, which feature a small wedge angle.

For further information www.phorn.co.uk

When it comes to specialist tools for small-part machining, Floyd Automatic Tooling says it is the outright expert for delivering solutions. Now, a raft of new product lines from Hommel+Keller is available in the UK via the company.

The production of high-quality durable products often requires customised tooling solutions and Hommel+Keller has a series of new knurling, diamond burnishing, marking, broaching and gear-cutting products. For surface finishes below Rz 1 μm, the latest diamond burnishing tools are applicable to virtually any turning centre without separate work steps or equipment. This capability improves precision, repeatability and surface finishes for manufacturers that demand high-quality components.

Known as an industry expert in part marking, Hommel+Keller is also expanding the scope of its marking portfolio. Like the burnishing range, the part marking tools are suitable for use on all types of turning centre to create customised part marking in seconds. This technology enables manufacturers to eliminate secondary operations and deliver consistent high-quality marking that is flexible to the needs of the end user.

As an industry specialist in solutions for sliding-head and small part turning, Hommel+Keller also has a new series of broaching and gear cutting solutions. These lines deliver efficient technologies for complex internal and external profiles, providing precise and economical production in a single operation, reports Floyd Automation. All new ranges are specific to the customer and application.

In other news, the the Hirt Line range of stainless steel hoses available from Floyd Automatic now comes in a welded version. This Hirt Line 2.0 enhancement is characterised by its thermal stability that can work up to temperatures of 400°C while offering higher mechanical load capacity.

For further information www.floydautomatic.co.uk

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