New Geometry for Parting off Titanium, Monitored with Sensors

Horn and Kistler combine their expertise to ensure efficient turning.

At its Technology Days in Tübingen, for the very first time Horn is showcasing its new geometry for parting off titanium. This WT geometry designed specifically for titanium was developed based on extensive simulations. It proved its practical value straight away for parting off bone screws made from this challenging material.

In addition to reliable chip breaking, the adapted geometry ensures a soft cut. This means that higher feed rates are possible, resulting in faster machining times. What’s more, service life is increased – tests have shown that it can be boosted by up to 60 per cent. Type 224 inserts with the new WT geometry are available in increments of 2, 2.5 and 3 mm in grade IG35. They are designed for type H224 holders.

Kistler is the global market leader in dynamic measurement technology for recording pressure, force, torque and acceleration. Working closely with Paul Horn GmbH, the Kistler Group has developed a solution – the only one of its kind – for real-time monitoring of tools used in micro turning applications.

The Piezo Tool System (PTS) consists of a force sensor which is inserted into the turning tool and provides information on its condition during machining. The extremely small piezo sensor can measure even the tiniest cutting forces to a high resolution. The machine operator is therefore able to identify a defect in the material being cut or a tool breakage immediately, resulting in minimum waste and maximum quality.

The new system is suitable for use in turning, particularly in the micro range. In such applications, alternative measurement methods such as monitoring the drive power of the main spindle motor are not practical, as they cannot detect minute variations. Even measuring acoustic emissions would not deliver satisfactory results consistently when small workpieces are being machined.

Visual monitoring also has to be ruled out due to the use of coolant and the high rotational speeds involved in the machining process. The new solution is compatible with selected standard turning tool holders offered by Horn. It does not require any adjustment to be made at the control and can be used on any machine. The sensors can be replaced quickly and easily and using the PTS results in decreased production costs as well as increased production capacity.

The Piezo Tool System will be in action at the Horn Technology Days, where it will be monitoring the parting off of titanium using 224 type holders

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