HIGH-PERFORMANCE REAMING. HORN-System DR. License. Modular Tooling System Ø mm. In the UNITED STATES call us toll free HORN

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1 HIGH-PERFORMANCE REAMING R HORN-System DR License Modular Tooling System Ø mm R1

2 R HIGH-PERFORMANCE REAMING INSERT type DR straight fluted Cutting edge Ø Ds mm for through hole and blind hole for use with Reaming insert holder type MDR ADR Right hand version shown Part number Example: Ds Size Z recommended carbide grades recommended cermet grades MG10 HL3H AC4H AC5H AN2H AN4H AD3H DT2H H20 HL38 AD48 AC48 AC58 HL38 DT28 DR Straight DR Straight DR Straight DR Straight DR Straight DR Straight DR Straight DR Straight DR Straight DR Straight DR Straight DR Straight according customers requirements - Contact HORN USA for further information. R2

3 HIGH-PERFORMANCE REAMING R INSERT type DR left helical fluted Cutting edge Ø Ds mm Through hole for use with Reaming insert holder type MDR ADR Right hand version shown Part number Example: Ds Size Z recommended carbide grades recommended cermet grades MG10 HL3H AC4H AC5H AN2H AN4H AD3H DT2H H20 HL38 AD48 AC48 AC58 HL38 DT28 DR Helical DR Helical DR Helical DR Helical DR Helical DR Helical DR Helical DR Helical DR Helical DR Helical DR Helical DR Helical according customers requirements - Contact HORN USA for further information. R3

4 R HIGH-PERFORMANCE REAMING REAMING INSERT HOLDER Type MDR with through coolant supply Cutting edge Ø mm Material of shank: HM = Carbide ST = Steel for use with Insert Type DR Form A = Cylindrical shank DIN 1835-A Part number Ds Ds max l 1 d b Form Size MDR.016.ST A.D/S MDR.016.HM A.D/S A 016 MDR.016.ST A.D/S MDR.019.ST A.D/S MDR.019.HM A.D/S A 019 MDR.019.ST A.D/S MDR.024.ST A.D/S MDR.024.HM A.D/S A 024 MDR.024.ST A.D/S MDR.029.ST A.D/S MDR.029.HM A.D/S A 029 MDR.029.ST A.D/S MDR.036.ST A.D/S MDR.036.HM A.D/S A 036 MDR.036.ST A.D/S State D or S version Further sizes upon request 1 Set of screws, 1 Torx wrench - no separate order required! For torque specifications of the screw, please see Technical Instructions. Spare parts Reaming insert holder Screw MDR MDR C C R4

5 HIGH-PERFORMANCE REAMING R REAMING INSERT HOLDER Type MDR with through coolant supply Cutting edge Ø mm for use with Insert Type DR Form V = for use with shank type VDR, allowing for 0 runout adjustment. Part number Ds Ds max l 1 d 2 Form Size MDR V.D/S V 044 MDR V.D/S V 052 MDR V.D/S V 061 MDR V.D/S V 081 MDR V.D/S V 101 MDR V.D/S V 121 MDR V.D/S V 141 State D or S version Further sizes upon request 1 Set of screws, 1 Torx wrench - no separate order required! For torque specifications of the screw, please see Technical Instructions. Spare parts Reaming insert holder Screw MDR MDR C C R5

6 R HIGH-PERFORMANCE REAMING SHANK Type VDR with integrated compensation mechanism Cutting edge Ø mm for use with Insert Type DR Form A = Cylindrical shank DIN 1835-A B = Weldon shank DIN 1835-B E = Whistle-Notch DIN 1835-E BM = URMA Beta Modul (ABS) Part number Ds Ds max l 1 d 2 d Form Size VDR A 20 A VDR B 20 B VDR E 20 E 044 VDR BM 32 BM VDR A 20 A VDR B 20 B VDR E 20 E 044 VDR BM 32 BM VDR A 25 A VDR B 25 B VDR E 25 E 052 VDR BM 40 BM VDR A 25 A VDR B 25 B VDR E 25 E 052 VDR BM 40 BM VDR A 32 A VDR B 32 B VDR E 32 E 061 VDR BM 50 BM VDR A 32 A VDR B 32 B VDR E 32 E 061 VDR BM 50 BM Further sizes upon request Spare parts see page R7 R6

7 HIGH-PERFORMANCE REAMING R SHANK Type VDR with integrated compensation mechanism Cutting edge Ø mm for use with Insert Type DR Form A = Cylindrical shank DIN 1835-A B = Weldon shank DIN 1835-B E = Whistle-Notch DIN 1835-E BM = URMA Beta Modul (ABS) Part number Ds Ds max l 1 d 2 d Form Size VDR A 40 A VDR B 40 B VDR E 40 E VDR BM 50 BM VDR A 40 A VDR B 40 B VDR E 40 E VDR BM 50 BM VDR A 40 A VDR B 40 B VDR E 40 E VDR BM 63 BM VDR A 40 A VDR B 40 B VDR E 40 E VDR BM 63 BM Further sizes upon request / / 141 Spare parts Extension Adjustment Screw Bolt Locating pin VDR C Z Z VDR.052 C Z Z VDR.061 C Z Z VDR.081 C Z Z VDR.101 C Z Z R7

8 R ADDITIONAL EQUIPMENT EXTENSION Type VAM/VBM for alpha- and beta-modules Cutting edge Ø Ds mm Part number alpha-modul beta-modul L g d d 1 Weight SW VAM VAM Further sizes upon request kg 17 VBM kg VBM kg VBM kg VBM kg VBM kg VBM kg VBM kg VBM kg VBM kg - Spare parts Extension Locating pin Screw Bolt Threaded pin Key VBM Z Z Z VBM /070 Z Z Z VBM /070 Z C Z Z Z VBM /100 Z C Z Z Z VBM /125 Z C Z Z Z R8

9 ADDITIONAL EQUIPMENT R REDUCER Type RAM/RBM for alpha- and beta-modules Cutting edge Ø Ds mm Part number alpha-modul beta-modul L g l d d 1 Weight SW RAM kg 17 RBM / kg RBM / kg RBM / kg RBM / kg RBM / kg RBM / kg RBM / kg Further sizes upon request - Spare parts Reducer Locating pin Screw Bolt Threaded pin Key RAM Z Z Z RBM Z Z Z RBM Z C Z Z Z RBM Z C Z Z Z RBM Z C Z Z Z RBM Z C Z Z Z RBM Z C Z Z Z RBM Z C Z Z Z R9

10 R HIGH-PERFORMANCE REAMING SYSTEM HOLDER URMA Type BD Beta Module 25/32/40/50/63/80/100 Cutting edge Ø Ds mm CAT compatible / Metric retention threads Part number beta-modul L g l d Weight System BD1040A kg BD1040A kg BD1040A kg BD1040A kg BD1040A kg BD1040A kg BD1040A kg BD1050A kg BD1050A kg BD1050A kg BD1050A kg BD1050A kg BD1050A kg BD1050A kg Spare parts SK40 SK50 System Holder URMA Threaded pin BD10...A25... BD10...A32... BD10...A40... BD10...A50... BD10...A63... BD1050A BD1050A80070 Z Z Z Z Z Z Z R10

11 HIGH-PERFORMANCE REAMING R SYSTEM HOLDER URMA Type BD Beta Module 25/32/40/50/63/80/100 Cutting edge Ø Ds mm CAT compatible / Metric retention threads Part number beta-modul L g l d Weight System BD1040B kg BD1040B kg BD1040B kg BD1040B kg BD1040B kg BD1040B kg BD1040B kg BD1050B kg BD1050B kg BD1050B kg BD1050B kg BD1050B kg BD1050B kg BD1050B kg Spare parts SK40 SK50 System Holder URMA Threaded pin BD10...B25... BD10...B32... BD10...B40... BD10...B50... BD10...B63... BD1050B BD1050B80070 Z Z Z Z Z Z Z R11

12 R HIGH-PERFORMANCE REAMING SYSTEM HOLDER URMA Type BI Beta Module 40/63/100 Cutting edge Ø Ds mm Part number beta-modul L g l d Weight System BI kg BI kg BI kg BI kg BI kg BI kg SK40 SK50 Spare parts System Holder URMA Threaded pin BI BI BI Z Z Z R12

13 HIGH-PERFORMANCE REAMING R SYSTEM HOLDER URMA Type BT Beta Module 25/32/40/50/63/80/100 Cutting edge Ø Ds mm Part number beta-modul L g l d Weight System BT1040A kg BT1040A kg BT1040A kg BT1040A kg BT1040A kg BT1040A kg BT1040A kg BT1050A kg BT1050A kg BT1050A kg BT1050A kg BT1050A kg BT1050A kg SK40 SK50 Spare parts System Holder URMA Threaded pin BT1040A25060 BT10...A32... BT10...A40... BT10...A50... BT10...A63... BT1050A BT1050A80100 Z Z Z Z Z Z Z R13

14 R HIGH-PERFORMANCE REAMING SYSTEM HOLDER URMA Type BH Beta Module 25/32/40/50/63/80/100 Cutting edge Ø Ds mm Part number beta-modul L g l d Weight System BH1050A kg BH1050A kg BH1050A kg BH1063A kg BH1063A kg BH1063A kg BH1063A kg BH1063A kg BH10100A kg BH10100A kg BH10100A kg BH10100A kg BH10100A kg Spare parts HSK50 HSK63 HSK100 System Holder URMA Threaded pin Coolant tube Ordering note: Coolant tube is not included - separate order required! BH10100A Z H BH10100A40080 Z H BH10100A50080 Z H BH10100A63080 Z H BH10100A80090 Z H BH1050A25055 Z H BH1050A32060 Z H BH1050A40065 Z H BH1063A25055 Z H BH1063A32060 Z H BH1063A40065 Z H BH1063A50070 Z H BH1063A63080 Z H R14

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16 R HIGH-PERFORMANCE REAMING DIRECT MOUNTING URMA Type VDR with integrated compensation mechanism Cutting edge Ø mm CAT compatible / Metric retention threads Part number l L g d Weight System Size VDR BD kg 044 VDR BD kg 052 VDR BD kg SK VDR BD kg 081 VDR BD kg 101 VDR BD kg 044 VDR BD kg 052 VDR BD kg SK VDR BD kg 081 VDR BD kg 101 Further sizes upon request Extension VDR VDR.052 VDR.061 VDR.081 VDR.101 Adjustment Screw C C C C C R16

17 HIGH-PERFORMANCE REAMING R DIRECT MOUNTING URMA Type VDR with integrated compensation mechanism Cutting edge Ø mm Part number l L g d Weight System Size VDR BT kg 044 VDR BT kg 052 VDR BT kg SK VDR BT kg 081 VDR BT kg 101 VDR BT kg 044 VDR BT kg 052 VDR BT kg SK VDR BT kg 081 VDR BT kg 101 Further sizes upon request Extension VDR VDR.052 VDR.061 VDR.081 VDR.101 Adjustment Screw C C C C C R17

18 R HIGH-PERFORMANCE REAMING DIRECT MOUNTING URMA Type VDR with integrated compensation mechanism Cutting edge Ø mm Part number l L g d Weight System Size VDR A kg 044 VDR A kg 052 VDR A kg HSK VDR A kg 081 VDR A kg 101 VDR A kg 044 VDR A kg 052 VDR A kg HSK VDR A kg 081 VDR A kg 101 Further sizes upon request Extension Adjustment Screw Coolant tube Coolant tube VDR C H H VDR.052 C H H VDR.061 C H H VDR.081 C H H VDR.101 C H H R18

19 ADJUSTABLE HYDRAULIC EXPANSION TOOLHOLDER R SYSTEM HOLDER Type DRHD Adjustable run-out, with axial length adjustment, for automatic tool change HSK A DIN Part number l 1 l 2 l 4 l 5 X d 1 d 2 d 3 d 4 Weight System DRHD.12.A kg DRHD.20.A kg DRHD.32.A kg DRHD.12.A kg DRHD.20.A kg DRHD.32.A kg HSK-A 63 HSK-A 100 Ordering note: Coolant tube is not included - separate order required! Spare parts System Holder Screw TORX PLUS Wrench Coolant tube DRHD...A T15P T15PQ H DRHD...A T15P T15PQ H R19

20 R ADJUSTABLE HYDRAULIC EXPANSION TOOLHOLDER SYSTEM HOLDER Type DRHD Adjustable run-out, with axial length adjustment, for automatic tool change SK DIN69871 AD/B Part number l 1 l 2 l 4 l 5 X d 1 d 2 d 3 d 4 Weight System DRHD B DRHD B kg 1.4 kg DRHD B kg DRHD B Upon request 12 Upon request DRHD B kg DRHD B Upon request 32 Upon request SK 40 SK 50 Spare parts System Holder Screw TORX PLUS Wrench DRHD T15P T15PQ R20

21 ADJUSTABLE HYDRAULIC EXPANSION TOOLHOLDER R SYSTEM HOLDER Type DRHD Adjustable run-out, with axial length adjustment, for automatic tool change JIS-BT JIS B 6339 Part number l 1 l 2 l 4 l 5 X d 1 d 2 d 3 d 4 Weight System DRHD.12.BT kg DRHD.20.BT kg DRHD.12.BT kg DRHD.20.BT kg DRHD.32.BT50 Upon request 32 Upon request JIS-BT 40 JIS-BT 50 Spare parts System Holder Screw TORX PLUS Wrench DRHD T15P T15PQ R21

22 R ADJUSTABLE HYDRAULIC EXPANSION TOOLHOLDER SYSTEM HOLDER Type DRHD Adjustable run-out, with axial length adjustment, for automatic tool change HORN Polygon shank according to ISO Part number l 1 l 2 l 4 X d 1 d 2 d 3 d 4 Weight System DRHD.12.C kg DRHD.20.C040 Upon request 20 Upon request DRHD.12.C kg DRHD.20.C kg DRHD.32.C050 Upon request 32 Upon request DRHD.12.C kg DRHD.20.C kg DRHD.32.C kg C4 C5 C6 Spare parts System Holder Screw TORX PLUS Wrench DRHD T15P T15PQ R22

23 ADJUSTABLE HYDRAULIC EXPANSION TOOLHOLDER R SYSTEM HOLDER Type DRHD Adjustable run-out, with axial length adjustment, for automatic tool change ABS H Beta Modul Part number l 1 l 2 l 4 X d 1 d 2 d 4 Weight System DRHD.12.BM kg DRHD.20.BM kg DRHD.32.BM50 Upon request 32 Upon request ABS-H 50 Spare parts System Holder Screw TORX PLUS Wrench DRHD T15P T15PQ R23

24 R ADJUSTABLE HYDRAULIC EXPANSION TOOLHOLDER INTERMEDIATE SLEEVE Type DRZB For internal coolant supply Part number l 1 l 2 d 1 d 2 d 3 DRZB DRZB DRZB2006 DRZB DRZB DRZB DRZB DRZB DRZB R24

25 HIGH-PERFORMANCE REAMING R ADAPTOR Type ADR Cutting edge Ø ( mm) for use with Insert Type DR Part number Ds Ds max X l 1 Size ADR ADR ADR ADR ADR ADR ADR ADR Set of screws, 1 Torx wrench - no separate order required! For torque specifications of the screw, please see Technical Instructions. Spare parts Adaptor Screw ADR /02 ADR /04/05 ADR /07 C C C R25

26 R User guide The information below explains the proper handling and set up for reaming tools. Tool adjustments should be performed directly in the machine/spindle to achieve highest precision. Insert the reamer shaft into the Hydraulic Expansion Toolholder or reducer sleeve until it bottoms out. Tighten the clamping screw of the Hydraulic Expansion Toolholder with a hex wrench. R26

27 User guide R Turn the four adjusting screws with the TORX-PLUS wrench T15PQ until contact, and check the concentricity with a µm indicator inside the arbor by hand rotating the tool. Adjust the concentricity by turning the adjustment screws on their axis. Lay insert on shaft with positioning hole over the pin and tighten the screws lightly. Tighten the screws with a torque setter screw driver in a crisscross pattern. R27

28 R User guide Adjusting To achieve the best reaming results a tool with zero run-out is desirable. In order to compensate for any errors due to run-out from the tool holders or the machine spindle, the following holders are recommendend: compensation holders, hydraulic chucks, or shrink fit holders. DR reamers can be measured with different methods: Through insert holder short taper With the reamer disassembled measure directly on the insert holders short taper. High accuracy, simple handling. This is the most accurate and preferred method. Through circular land Measuring directly behind chamfer angle on external insert diameter. All interface errors are eliminated. This is the preferred method for small diameter inserts. On the external diameter of the insert holder DR tool holders are manufactured very accurately on all diameters. A method easy to handle that offers reasonable measuring results. Shanks with integrated compensation device These shanks with integrated comp. must be used for reaming diameters bigger than 35 mm R28

29 User guide R Handling Secure central locking screw (see value no 1). Measure run-out and set the cutting edge of the insert to the highest point. Compensate half of the total run-out by using the adjustment screws. Check runout and repeat the adjustment if necessary. Secure central locking srew according to value 2 in chart below. Parameter Md 1 Nm 2 Nm DR DR DR DR DR DR DR Changing inserts 1. Don't take the shank out of the taper holder. Remove clamping screws and used insert. 2. Clean short taper of the shank carefully and check for possible damages. 3. Set new insert on position (pay attention to the positioning pin) and slightly tighten the clamping screws. 4. If available, use the torxtorque screw driver to tighten the screws crosswise (see torque chart) 2 2 Parameter Md Nm DR DR DR DR DR DR DR DR DR DR Measuring of insert diameter DR inserts have an unequally spaced pitch. To measure the diameter line up the two marked cutting edges. Measure directly on the chamfered angle because the inserts are ground with taper. R29

30 R MATERIAL COMPARISON TABLE ISO Code Material P Unalloyed carbon steel General structural steel Low-alloy carbon steel, Structural-, Cast-hardened-, Tool-, Low-alloy steel Alloyed tool steel Nitride steel Rm N/mm 2 HB HRC < 500 < High alloyed steel < High alloyed steel < High speed steel M 5 Stainless steel, martenistic Stainless steel, austenitic 5.2 Stainless heat resisting steel K N 7 Grey cast iron Alloyed grey cast iron Spheroidal graphite cast iron (GGG40) Spheroidal graphite cast iron, ferritic/perlitic Malleable cast iron Aluminium < 10 % Si, Al-wrough alloys > 550 < Al-alloys 7.2 Non ferrous metals, Copper alloys, Brass, Bronze 7.3 Titanium 7.4 Nickelbased allyos S 8 Thermo-plastics, Duroplast 8.1 Fibre reinforced plastics R30

31 CUTTING MATERIAL R HORN- Grades ISO513 Properties Recommended applications Carbide HL3H HC ALCrN- Coating First choice for Steel and cast iron. Extremely high hot hardness and high resistance against oxidation. High lubricity with resistance to build up edge. For high cutting speed and with coolant or mist coolant. Copper colour. AC4H AC5H HC ALCrN- Coating Similar coating structure and application range to HL3H. Grey colour. AD3H AD4H HC TiALN- Coating Good hot hardness and resistance against oxidation with excellent lubricity properties. For medium to high cutting speed and mist coolant. Resistant to build up edge. MG10 HW uncoated (micro grain) Universal grade for most materials at low cutting speed. For Variopoint only. DT2H HC PVD-DLC- Coating "Diamond-Like-Carbon". Very good lubricity properties resistant to build up edge. Excellent chemical stability as well as very high hardness. Particularly suitable for Aluminum with less than 12 % Si at medium cutting speed. Cermet H20 HT uncoated Reaming of carbon and low alloyed steel of up to 1200 N/ mm 2 tensile strength and nodular cast iron at high cutting speed. Suitable for interrupted cuts due to high toughness. AD38 AD48 AC48 AC58 HL38 DT28 - coated Coatings similar to those for carbide with resistance to build up edge. Application specific combination of substrate, geometry and coatings for improved tool life. R31

32 R CUTTING DATA ISO Code Bore D* Bore *S Recommended radial cutting depth a p Left Helical Flutes 25 P M K N S 8 Straight Flutes 45 Ø <20 mm Ø <20-35 mm Ø >35 mm Uncoated HM / Cermet Coated HM / Cermet v c (m/min) f z (mm) v c (m/min) f z (mm) PCD Tipped - Available Upon request = Recommendation Bore D* = Through hole Bore S* = Blind Hole Note: Reduce f z up to 25% during interrupted cuts Description of cutting materials see page R30 R32

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34 R TROUBLESHOOTING SOLUTIONS Fault Hole too large Remedy 1. Reduce run-out error and use compensation holder 2. Reduce cutting speed 3. Increase feed rate, increase coolant mix 4. Reduce depth of cut 5. Check tool wear (especiall build-up edges) 6. Control reamer-ø Tapered hole 1. Reduce run-out error and use compensation holder 2. Reduce cutting speed and feed, check coolant mix 3. Improve pre-machining 4. Improve workpiece clamping 5. Measure bore in clamped and unclamped condition 6. Check chip flow Hole shows chatter marks 1. Reduce run-out error and use compensation holder 2. Change chamfer angle 3. Improve workpiece clamping 4. Reduce cutting speed 5. Increase feed rate R34

35 TROUBLESHOOTING SOLUTIONS R Fault Surface quality unsatisfactory Remedy 1. Check insert wear 2. Reduce run-out error and use compensation holder, check cutting data (pages R32-R33) 3. Use tool with internal coolant supply 4. Increase coolant mix Retention marks in hole 1. Reduce run-out error and use compensation holder 2. Check insert wear (build-up edges) 3. Reduce depth of cut 4. Use a sharper geometry 5. Reduce pull back feed Reamer jams 1. Reduce coolant mix 2. Increase depth of cut 3. Check insert wear 4. Change chamfer angle Hole too small 1. Change insert 2. Reduce coolant mix 3. Increase depth of cut 4. Increase cutting speed 5. Reduce feed rate R35

36 R FORMULAS Z = Number of teeth d = Cutting edge Ø [mm] L = Length of bore [mm] SL =Clearance distance [mm] n = Revolutions n = v 1000 c d ϖ [1/min] [RPM] v c = Cutting speed v c = d ϖ n [m/min] /.3048 = sfm 1000 f z = Feed/tooth f z = v f Z n [mm] / 25.4 = inch f = Feed per revolutions f = f z Z [mm/u] [mm/rev] v f = Feed rate v f = f z Z n [mm/min] / 25.4 = inch/min T c = Process time T c = L + SL [min] v f R36