Chip breaking problems solved

Chip control remains one of the most critical challenges in precision boring operations. Depending on the material being machined, swarf can become tangled around the tool, clog boreholes, and in worst-case scenarios, even cause tool breakage. Recognising these challenges, Paul Horn GmbH has developed a reliable and cost-effective solution: the Supermini Type 105, a universal boring tool featuring a sintered chip-breaking geometry designed to ensure smooth and dependable performance.

With the Supermini 105, Horn introduces a tool that significantly improves chip control and process reliability across a variety of materials. Its sintered chip-breaking geometry ensures chips are efficiently broken and evacuated—even when taking shallow cuts—reducing downtime and extending tool life.

To enhance its versatility, Horn is expanding the Supermini 105 tool family by introducing two additional insert sizes, which will be officially unveiled at INTEC 2025. The toolmaker now offers inserts for boring diameters of 4mm, 5mm, and 6mm, broadening the application scope for users requiring ultra-precise internal machining.

The cutting-edge geometry extends deeply into the corner radius of the insert, ensuring excellent chip control even in delicate operations. Notably, the geometry is designed for universal use across multiple material groups and is well-suited for internal turning, face turning, copy turning, and reverse turning.

Enhanced Performance Through Smart Design

Beyond geometry, Horn has made several design optimisations to boost performance and longevity. The insert blank has been structurally enhanced for greater rigidity and cutting-edge stability, which translates into improved durability during high-demand operations.

The coolant delivery system has also been redesigned for more efficient cooling directly at the cutting zone—critical for maintaining tool life and part quality during extended machining. The new inserts are compatible with a wide range of Type 105 tool holders, offering users the flexibility to tailor the setup to their specific needs.

Horn provides the tools in three standard overhang lengths (15.0 mm, 20.0 mm, and 25.0 mm) and in TH35 and IG35 carbide grades. For inserts used in bores as small as 4 mm, overhangs of 15 mm and 20 mm are available, with a corner radius of 0.2 mm.

Despite its enhanced functionality, the Supermini Type 105 remains cost-efficient. Thanks to the sintered geometry, the insert offers similar pricing to standard cutting inserts without geometry—avoiding the higher costs typically associated with laser-machined alternatives.

A Complete System for Micro-Machining Needs

To further improve adaptability, Horn offers a broad portfolio of tool holder variants, including round, square, interface-based, and adjustable holders compatible with various machine tool manufacturers. Users can also select from four different clamping mechanisms:

• Traditional ball pressure screw clamping
• Face clamping element
• Lifting element clamping
• Slimline system using a union nut—ideal for tight spaces

The Supermini tool system is designed to support an extensive range of machining operations beyond boring, including profile turning, internal grooving, threading, chamfering, axial grooving, drilling, and face grooving.

The carbide inserts are capable of machining bore diameters from as small as 0.2 mm up to around 10 mm. A key feature of the tool’s design is the teardrop-shaped insert blank, which enhances surface contact with the holder, increasing system rigidity while also preventing insert rotation. This ensures consistently accurate centre height positioning and minimises deflection and vibration—particularly valuable when working with long overhangs.

Depending on the machining requirements and hole diameters, Horn provides the insert in three distinct sizes—Types 105, 109, and 110—as well as multiple blank configurations. All versions include internal coolant channels to deliver coolant directly to the cutting edge, ensuring consistent chip evacuation and thermal stability.

Horn’s Supermini line currently includes around 2,500 standard tool variants, reflecting the company's deep expertise in micro-machining. For more specialised requirements, Horn continues to work closely with customers to deliver customised solutions that address their unique production challenges.

With the Supermini Type 105 and its new insert sizes, Horn once again sets a benchmark in high-precision, small-diameter boring—offering manufacturers greater control, higher reliability, and lower operating costs.

Source: Paul Horn GmbH