Horn is expanding its slot broaching system with the introduction of new Type 117 inserts, designed for internal diameters starting at 9mm. The system is more sustainable due to its reduced carbide content and offers a favorable cost per cutting edge. To support this development, Horn engineered a new carbide blank specifically for the 117-insert family.
“The development of this new carbide blank required innovative approaches in both production and metrology,” said Horn product manager Andreas Härle. “Due to the small size of the inserts, we had to make significant adjustments in handling, fixture grinding, and measurement systems.”
The system is suitable for a wide range of broaching applications, including gear broaching, polygonal broaching, and keyway broaching. Compared to solid carbide broaching tools, the new system offers a key advantage: its tool shanks enable the broaching of longer and deeper grooves. Tool lengths are available in 20mm, 30mm, and 40mm, and all variants feature internal coolant delivery directly to the cutting zone. Tool holder shank diameters are offered in 16mm and 20mm, and Horn also provides special holders compatible with broaching units from various manufacturers. Standard inserts are available in multiple configurations to accommodate different application needs.
The new broaching system has already proven its performance in real-world applications. In one case, a customer previously achieved a tool life of 120 pieces when broaching a serration in hardened steel. After switching to the new Horn system, tool life increased to 1,040 parts, while maintaining the same cutting parameters. In addition to the significant improvement in tool life, production costs were reduced due to the lower cost per cutting edge compared to the previously used carbide inserts.
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