Paul Horn GmbH is expanding its range of gear cutting products. Horn’s new tool system for milling bevel gear teeth allows the complete machining of bevel gears on universal turn-mill centres. The system was created in cooperation with machine manufacturer INDEX and means that users no longer need any special machines to manufacture gears of this kind. It also allows all functional surfaces to be produced together with the gear teeth in one clamping. This enables high component precision, short lead-times, a very cost-efficient process and short machining times as a result of controlled machining cycles. With a universal turn-mill centre from INDEX, components with bevel gear teeth can be efficiently and flexibly manufactured, including in small quantities. This also makes the process attractive to small and medium-sized companies that would previously have bought in gears or had them manufactured externally.

For the process, Horn relies on its S276 and S279 double-edged indexable inserts, which are screwed on tangentially. This makes it possible to achieve a stable insert seat, which is particularly important during form milling. The tool does not have to be remeasured after the inserts have been turned around or changed because the inserts are precision-ground on the circumference. The milling body can be equipped to allow for different numbers of teeth and outer diameters when cutting gears. The process of developing the complete system (cycle, tool and clamping) called for a great deal of expertise on the part of both the machine manufacturer and the tool manufacturer. To implement the process, various types of INDEX machine with a “bevel gear hobbing” cycle are required. Horn offers the milling cutter bodies with the HSK-T40 and HSK-T63 interfaces. The profiles of the inserts are module-dependent and precision-ground.