With the DM40 system, Paul Horn GmbH expands its program to include a modular PKD end mill series for universal milling applications in aluminum, aluminum die casting, and materials from groups N and O. The tool system combines a permanently reusable base tool made of carbide with a replaceable PKD-tipped exchange head on a steel body.
The system specifically targets wear reduction, resource conservation, and economical processes. The modular design functionally separates durable and wear-intensive components. In particular, the end cutting edges are among the main wear zones in milling applications. At the same time, the risk of cutting edge breakage increases with high cutting lengths exceeding 2 times the diameter. The exchange head system reduces material usage in these areas and lowers follow-up costs compared to traditional monoblock tools.
Users can exchange the cutting module directly on-site. The tool can then be reused without additional adjustments. This reduces machine downtimes, procurement times, or repair efforts. The separation between the durable base tool and the interchangeable exchange head also creates transparent and calculable maintenance costs. The system is particularly suitable for series production and automated production lines.
Horn connects the PKD-tipped steel head to the base tool via a central clamping screw in a force- and form-locking manner. An additional color marking facilitates the assignment of components during assembly. The integrated Poka-Yoke principle prevents assembly errors and increases process reliability in application.
The interface between the exchange head and the base tool ensures precise and gap-free milling results for new tools as well as for re-sharpened tool pairs. Worn exchange heads can be re-sharpened up to twice within specified diameter ranges. The re-sharpenability further reduces resource consumption and improves the cost-effectiveness of the system.
The axis angle-focused design allows for smooth cuts and high surface qualities. At the same time, the geometry ensures stable and process-reliable milling operations for universal applications.
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