Paul Horn GmbH has developed a process for precision deburring of gear teeth that represents a further advance in the world of gear production. Although gear teeth can be deburred relatively easily with brushes and discs, higher levels of precision and quality are being demanded, with the result that there is often no longer any scope for undefined chamfers at the tooth edges. So Horn has developed a technology – together with the associated production process – to enable the production of defined chamfers. It can be used, for example, to create a 45-degree chamfer on both sides of a module 1 gear wheel with 25 teeth in less than five seconds. A turn-mill centre with synchronised axes is required for this production process. However, users do not need any special workholding equipment. The solid carbide tools can be clamped in a standard collet, or in shrink-fit or hydraulic chucks.

The process is particularly suitable for machining gears in high volumes. The milling cutters are special tools and have to be individually designed for each gear tooth. Based on the application, Horn engineers will design the appropriate cutting edge geometry for the module, tip diameter and desired chamfer. Horn supplies the process data required for machining together with the cutter. Tool costs are low and quickly pay for themselves thanks to short machining times. The carbide substrate, tool coating and cutting edge geometry are all specially designed for each gear tooth material. As far as the actual machining process is concerned, the material is irrelevant. Chamfers can be milled into various steels, aluminium and plastics within seconds.