High metal removal rate, long threads having high surface quality, deep thread profiles, short chips, multi-start threads and low tool load are important advantages of the whirling process. However, in gaining these advantages, the user also faces technical challenges. One important aspect is the choice of materials, for example for bone screws. When machining titanium, stainless steels and other superalloys, the cutting edges of the whirling inserts are exposed to very high loads. In order to counteract cutting edge wear, while maintaining the desired high cutting rate and short machining time, tool manufacturers must constantly optimise and develop the tools and processes.

Horn demonstrates its expertise in thread machining with jet whirling. In cooperation with the company W&F Werkzeugtechnik from Großbettlingen, a whirling system with an internal coolant supply was jointly developed. The system delivers long tool life thanks to direct cooling of the cutting edges. Furthermore, in conjunction with the stable whirling unit, the system achieves an enhanced surface finish on the workpiece and reduces the risk of chip jamming between the inserts. Surface quality plays a major role in the production of bone screws. Any groove or burr can be a breeding ground for germs.

Horn is also demonstrating another process: high-speed (HS) whirling. This technology was developed in cooperation with the lathe manufacturer Index-Traub. HS whirling offers a significant increase in productivity thanks to concurrent turning and whirling. The speed of the process is so high that turning can take place before whirling. The turning tool, positioned in front of the whirling tool, reduces the volume of material that would otherwise have to be removed by the whirling tool. This enables longer tool life and leads to better surface quality. The whirling heads are similar to conventional whirling heads. Only the inserts differ in their geometry. The production of single- and multi-start threads is possible with a single tool.

Horn offers other whirling technologies in addition to jet and high-speed whirling. The most universally used technology is standard whirling. The whirling head can be connected to any whirling unit. Horn has developed the modular whirling system for rapid exchange of the whirling head and inserts outside the machine. Thanks to the precision interface, the whirling head does not have to be readjusted after removal from the machine. Furthermore, the whirling tool can be adapted to different interfaces using spacer rings. Horn turbo whirling promises high productivity. Using a cut distribution of roughing, pre-finishing and finishing, the load on the profiled inserts of the whirling tool is reduced. The system therefore offers faster processing times and reduced tool costs.