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_THREADINGWITHWALTERPROTOTYP
Walter GB Ltd. Bromsgrove,England +44(1527)839450,service.uk@walter-tools.com Walter Wuxi Co. Ltd. Wuxi,Jiangsu,P.R.China +86(510)82419399,service.cn@walter-tools.com Walter AG Singapore Pte. Ltd. +6567736180,service.sg@walter-tools.com Walter Korea Ltd. Anyang-siGyeonggi-do,Korea +82(31)3376100,service.kr@walter-tools.com Walter Tools India Pvt. Ltd. Pune,India +91(20)30457300,service.in@walter-tools.com Walter (Thailand) Co., Ltd. Bangkok,10120,Thailand +6626870388,service.th@walter-tools.com Walter Malaysia Sdn. Bhd. SelangorD.E.,Malaysia +60(3)80237748,service.my@walter-tools.com Walter Australia Pty. Ltd. Hallam,Victoria3803,Australia +61387931000,service.au@walter-tools.com Walter Tooling Japan K.K. Nagoya,Japan +81(52)7235800,service.jp@walter-tools.com Walter USA, LLC WaukeshaWI,USA +1800-945-5554,service.us@walter-tools.com Walter Canada Mississauga,Canada service.ca@walter-tools.com
PrintedinGermany6324002(11/2012)EN
CONTENTS
Threading
2 4 8
Index General introduction to the subject Product range overview 9 Threadtapping 12 Threadforming 13 Threadmilling
Index
Anglesandcharacteristics Threadtapping . . . . . . . . . . . . . . 81 Axialmiscutting Threadtapping . . . . . . . . . . . 87,91 Basictypes Threadtapping . . . . . . . . . . 74-75 Chamferforms Threadtapping . . . . . . . . . . . . . . 76 Chipcontrol Threadtapping . . . . . . . . . . . . . . 90 Chipcrosssections Threadtapping . . . . . . . . . . 77-78 Clampingdevices . . . . . . . . . . . . . . 64
Cuttingprocess Threadtapping . . . . . . . . . . 79-80 Drymachining Threadmilling. . . . . . . . . . . . 59,63 Feedratecorrection Threadmilling. . . . . . . . . . . . . . 103 Feedrateprogramming Threadtapping . . . . . . . . . . . . . . 87 Forces Threadtapping . . . . . . . . . . 86-87 Formulas . . . . . . . . . . . . . . . . . . . . 112 Hardnesscomparisontable . . . . . 117
ParadurTiPlus . . . . . . . . 11,24-25 ParadurXpertM. . . . . . . 10,22-23 ParadurXpertP. . . . . . . 10,20-21 Pilotholediameter General. . . . . . . . . . . . . . . . . . . . 70 Tapping.............. 114-115 Threadforming . . . . . . . . . . . . 70-71,96-97,116 Threadmilling. . . . . . . . . 114-115 Problemsandsolutions Threadforming. . . . . . . . . 99-100 Threadmilling. . . . . . . . . .110-111 Threadtapping . . . . . . . . . . 90-92 Processcomparison . . . . . . . . 48-49
PrototexEcoHT . . . . . . . . 9,14-15 PrototexHSC. . . . . . . . . . . . . . 11,26 PrototexSynchrospeed . . 9,16-17 PrototexTiNiPlus . . . . . . 11,24-25 PrototexXpertM . . . . . . 10,22-23 PrototexXpertP . . . . . . 10,20-21 Rprg.(programmingradius) Threadmilling. . . . . . . . . . . . . . 108 Specialfeatures Threadtapping . . . . . . . . . . 84-85 Synchronousmachining . . . . . 68-69 TMC . . . . . . . . . . . . . . . . . . 13,34-35 TMD. . . . . . . . . . . . . . . . . . 13,38-39 TME . . . . . . . . . . . . . . . . . . . . . . . . . 13 TMG. . . . . . . . . . . . . . . . . . . . . . 13,35 TMO. . . . . . . . . . . . . . . . . . 13,36-37 TMOHRC. . . . . . . . . . . . . . . . . . 13,37 Tolerancegrades. . . . . . . . . . . . . . 50 Toolcategories. . . . . . . . . . . . . . . . . 8 Torqueadjustment Threadtapping/forming . .118-119 WalterGPS ........ 5,102-103,107-108,111 Weldformations . . . . . . . . . . . . . . . 93
Increasededgezonehardening. . . 72 CNCprogramming Threadmilling. . . . . . . . . 107-108 Comparisonofgeometrydata Threadtapping . . . . . . . . . . 82-83 Coolingandlubrication. . . . . . 56-57 Threadforming. . . . . . . . . . 60-61 Threadmilling. . . . . . . . . . . . . . . 59 Threadtapping . . . . . . . . . . . . . . 58 Corehole General. . . . . . . . . . . . . . . . . . . . 70 Tapping.............. 114-115 Threadforming. . . 71,96-97,116 Threadmilling. . . . . . . . . 114-115 Coatings. . . . . . . . . . . . . . . . . .52-55 Threadforming. . . . . . . . . . . . . . 55 Cuttingpasses Threadmilling. . . . . . . . . 104-105 Minimumquantity lubrication................ 62-63 Miscutting Threadtapping . . . . . . . . . . . 86,91 Modifications Threadforming. . . . . . . . . . . . . . 98 Threadmilling. . . . . . . . . . . . . . 109 Threadtapping . . . . . . . . . . 88-89 Nomenclature.................. 8 ParadurEcoCI. . . . . . . . . . . . . 10,18 ParadurEcoPlus. . . . . . . . 9,14-15 ParadurHSC . . . . . . . . . . . . . . 11,27 ParadurHT. . . . . . . . . . . . . . . . 10,19 ParadurSynchrospeed . . . 9,16-17 Processprinciples Threadforming. . . . . . . . . . 94-95 Threadmilling. . . . . . . . . 101-105 Profiledistortion. . . . . . . . . . . . . . 106 ProtodynEcoLM. . . . . . . . . . . 12,30 ProtodynEcoPlus. . . . . . . . . . . . . 28 ProtodynHSC . . . . . . . . . . . . . . . . 33 ProtodynPlus. . . . . . . . . . . . . . . . 29 ProtodynSEcoInox . . . . . . . . 12,31 ProtodynSEcoPlus . . . . . . . . 12,28 ProtodynSHSC. . . . . . . . . . . . 12,33 ProtodynSPlus. . . . . . . . . . . . 12,29 ProtodynSSynchrospeed. . . 12,32
Introduction
Introduction
30%
7%
16%
25%
19%
existing withWalterPrototyp
45 % overall
savings
Productrangeoverview
Productrangeoverview
P
Page in handbook
M
Stainlesssteel
S
Difficult-to-cut materials
H
Hardmaterials
Thread depth
Thread tapping*
Application
NFmetals
Castiron
Steel
Type description
Prototex Tapwithspiralpoint
14 + 15
DL
3,5 x DN C C C C C C C C
Thread forming
Thread milling**
14 + 15
GL
3 x DN
CC
CC
CC
TM TM=ThreadMill
16 + 17
DL 3,0 x DN C C C C C C C C C C
16 + 17
GL 2,5 x DN C C C C C C
* Thread tapping exceptions: ParadurNwithchamferformDandParadurCombi:helicaltoolsforproducingthrough-hole threads ParadurHT,ParadurGGandParadurEngine:straight-flutedtoolsforblindholethreads (inmaterialswithgoodchipbreakingcharacteristics) NPT/NPTFtaps:right-handhelicaltoolsformachiningblindandthroughholes ** Thread milling exceptions: TME(ThreadMillExternal):toolforproducingexternalthreads 8 GL = blind hole machining DL = through hole machining
C C Primaryapplication C
Additionalapplication 9
Other
C C C C
Productrangeoverview
P
Page in handbook
M
Stainlesssteel
S
Difficult-to-cut materials
H
Hardmaterials
O
Page in handbook
M
Stainlesssteel
S
Difficult-to-cut materials
H
Hardmaterials
CC
Thread depth
Thread depth
Application
Application
NFmetals
NFmetals
Castiron
Castiron
Steel
Steel
Other
Type description
Type description
18
GL + DL
3 x DN
CC
CC
CC
24 DL 2 x DN
CC
19
GL 3,5 x DN C C
CC
24 + 25
GL
2 x DN
CC
20 + 21
DL
3 x DN
CC
20 + 21
DL
2 x DN
CC
CC
GL 3,5 x DN C C
22 + 23
DL
3 x DN
CC
GL
2 x DN
CC
CC
22 + 23
GL 2,5 x DN
CC
C C Primaryapplication C
Additionalapplication 11
Other
Productrangeoverview
Productrangeoverview
Thread formers
Workpiecematerialgroup
Thread mills
Workpiecematerialgroup
P
Page in handbook
M
Stainlesssteel
S
Difficult-to-cut materials
H
Hardmaterials
O
Page in handbook
M
Stainlesssteel
S
Difficult-to-cut materials
H
Hardmaterials
CC
Thread depth
Thread depth
Application
Application
NFmetals
NFmetals
Castiron
Castiron
Steel
Steel
Other
Type description
Type description
28
GL + 3,5 x DN C C DL
CC
CC
34 + 35
GL + DL
2 x DN
CC
CC CC
CC
CC
29
GL + 3,5 x DN C C DL
CC
CC
35
GL 1,5 x DN CC + 2 x DN DL
CC CC
CC
CC
30
GL + DL
2 x DN
CC
CC
36 + 37
GL + DL
2 x DN 3 x DN
CC
CC CC
CC
CC
GL + 3,5 x DN DL
CC
37
GL + DL
2 x DN
CC
32
GL + 3,5 x DN C C DL
CC
CC
38 + 39
GL + DL
2 x DN
CC CC
33
GL 3,5 x DN C C
CC
External thread
2 x DN
CC
CC CC
CC
CC
C C Primaryapplication C
Additionalapplication 13
Other
C C C C C
ProductinformationTapping
THLcoating (orTiN)
The tool universalhighperformancetap THLhardmaterialcoatingminimises builtupedgesandguaranteeslong toollife Prototex Eco HT: specialspiralpointformBguarantees highprocessreliability 3,5xDN P
CC
The application foruseinlongandshort-chipping materialswithatensilestrengthfrom approx.200N/mmtoapprox. 1300N/mm suitableforsynchronousmachiningand suitableforuseinfloatingchucks Your advantages reductionintoolinventorythanksto awideareaofapplication increasedproductivitythroughhigh cuttingspeedsandlongtoollife specialgeometryforsafeprocesses, eveninsoftmaterials MQLmachiningpossible
HSS-E-PM
M
CC
K
CC
N
CC
S
C
O
C
Variants:withoutIK,withKR*
Prototex Eco HT
Type:E2021342
45helixanglewith chamferformCorE
HSS-E-PM
THLcoating (orTiN)
3xDN P
CC
M
CC
K
CC
N
C
S
C
O
C
Variants:withoutIK,withKA,withKR*
Type:EP2051312
ProductinformationTapping
Weldon flat
The tool highfaceclearanceandshortthreading sectionforextremelyhighcutting speeds h6shanktolerance(e.g.forusein shrink-fitchucks) shankdiameteradaptedtostandard shrink-fitchuck Special features of the Paradur Synchrospeed: variantwithTiN/vapcoating:vaporised flutesforperfectchipformationand optimumchipremoval;TiNcoatingfor increasedwearresistance internalcoolingwithaxialoutputinthe standardproductrange
The application foruseonmachinetoolswithasynchronousspindle(notsuitablefor floatingchucksorcuttingunits) foruniversaluseinalllongandshortchippingmaterials Prototex Synchrospeed: canbeuseduptoapprox.1400N/mm Paradur Synchrospeed: canbeuseduptoapprox.1300N/mm
3,5xDN P
SpiralpointformB CC
M
CC
K
CC
N
CC
S
CC
O
C
Prototex Synchrospeed
40helixanglewith chamferformC
HSS-Ewith increasedhardness
Your advantages increasedproductivitythroughhigh cuttingspeedsandlongtoollife reducedtoolinventorycoststhrough universaluseinshort-andlongchippingmaterials excellentthreadsurfacethanksto verysharpcuttingedges miscuttingexcludedthrough s ynchronousmachining
Weldon flat
2,5xDN
TiN/vap coating (orTHL)
P
CC
M
CC
K
CC
N
C
S
C
O
C
Variants:withoutIK,withKA*
Paradur Synchrospeed
Type:S2051305
ProductinformationTapping
ProductinformationTapping
HSS-E
3xDN P
Highfaceclearance andsmallrakeangle
3,5xDN H O
CC TiNcoating Axialinternalcooling
K
CC
N
CC
P
CC
K
CC
N
C
O
C
Variants:withoutIK,withKA,withKR*
KAabsolutelyessential*
Paradur Eco CI The tool innovativesurfacetreatment Xtratreatforbestwearbehaviour whenmachiningabrasive,short-chippingmaterials increasednumberofflutesreduces cuttingedgeloadandproducesshort chips tolerancegrade6HXformaximum toollife versionswithaxialorradialcoolant outletsforoptimumchipevacuation withdeepblindandthroughhole threads The application blind-andthroughholethreadin short-chippingmaterials ISOK:primarilyforGJL(GG)materials; inGJS(GGG)materialsuptomaximum 2xDNthreaddepth;vermicularcast iron(e.g.GJV450) ISON:Mgalloys,andabrasiveAlSi alloyswithSicontent>12%
Type:E2031416 Your advantages lowerproductioncostsperthreadas resultofhighcuttingspeedsand longtoollife evenwearbehaviourandtherefore absoluteprocessreliability reducedtoolcosts,becauseitcan beusedforblind-andthroughhole threads MQLmachiningpossible
Paradur HT The tool cuttingedgegeometryproducesshort chipseveninlong-chippingmaterials axialinternalcoolingandstraightflutes enableoptimumtransportofshort brokenchips increasedfaceclearanceforhigher cuttingspeeds longversionswithelongatedflutesin thestandardproductrange The application blindholethreadinlongandshortchippingmaterials ISOP:steelmaterialwithtensile strengthof600-1,400N/mm, ISOK:greycastiron(GGG) ISON:AlSialloys>12%Sicontent, CualloysandMgalloys
Type:2031115 Your advantages highercuttingspeedandlongertool lifecomparedtoconventionalblind holetaps noswarfpacking,i.e.lessmachine stoppage extremelyhighprocessreliability evenwithdeepthreads Standardproductrangewithlarge sizes
ProductinformationTapping
3xDN P
SpiralpointformB CC
N
C
The application Prototex Xpert P ISOP: variantwith3flutes:tensilestrength <1000N/mm variantwith2flutes:tensilestrength <700N/mm(availableuptosizeM6) ISON:AlSialloyswithSicontent between0.5to12% versionwithreducednumberofflutesis ideallysuitedtosoft,long-chipping materials(optimumformachiningsoft structuralsteels,e.g.St37)dueto improvedchipformation Paradur Xpert P ISOP:steel<1000N/mm,particularly inlong-chippingmaterials ISON:AlSialloyswithSicontent between0.5to12%
Prototex Xpert P
Type:P2031005
TiNcoating (orbrightfinish)
HSS-E
Your advantages cost-efficientforsmallandmedium batchsizes highflexibilityandshortdelivery times,becauseofthecomprehensivestandardproductrange(diverse threadprofiles,sizesandtolerances instock) threadwithverygoodsurfacefinish qualitythankstowiderakeangle
3,5xDN
45helixanglewith chamferformC
P
CC
N
C
O
C
Paradur Xpert P
Type:P2051905
20
21
ProductinformationTapping
TiCNcoating (orTiN,vap)
HSS-E
3xDN P
SpiralpointformB C
M
CC
Prototex Xpert M
Type:M2021306
TiCNcoating (orTiN,vap)
HSS-E
2,5xDN P
40helixanglewithchamferformC C
M
CC
Paradur Xpert M
Type:M2051306
22
23
ProductinformationTapping
ACNcoating
The application forapplicationsinaerospacetechnology,aswellasmedicalindustry especiallyforhightensileandtitanium alloyswithatensilestrengthfrom700 to1400N/mmthattendtocause jamming Prototex TiNi Plus canalsobeusedonnickelalloys
HSS-E-PM
Largecorediameter
S
CC
Type:2021763
Your advantages oftenpossibletoworkwithemulsion insteadofoil highprocessreliabilitythroughhigh toolstability longtoollifethroughaninnovative hardmaterialcoatingandstable cuttingedges excellentthreadquality
ACNcoating
HSS-E-PM
2xDN P M K N S
CC
Paradur Ti Plus
Type:2041663
24
25
ProductinformationTapping
TiCNcoating
2xDN P
CC
2xDN H O
Axialinternalcooling
K
CC
P
CC
K
CC
H
CC
IKviaflutesontheshank*
KAabsolutelyessential*
Prototex HSC
Paradur HSC
Type:8041056 Your advantages minimumproductioncostsand extremelyhighproductivitythanksto acuttingspeedthatisupto3times higherwhencomparedtoHSS-Etaps fewertoolchangesresultingin optimummachineoutputduetolong toollife highprocessreliabilitythrough perfectchipbreaking
The tool specialsolidcarbidewithhighresistancetowearandextremetoughnessat thesametime longertoollifethroughanincreased numberofflutes Shanktoleranceh6(e.g.forusein shrink-fitchucks) The application ISOP:steelswithatensilestrength fromapprox.700to1400N/mm ISOK:primarilyGJS(GGG)materials massproductionwiththegoalof minimumcostsperthread large-scalemanufacturersfocusedon increasingproductivity
The tool specialchamfergeometryandreduced helixforshortbrokenchipsalsoin long-chippingmaterials Shanktoleranceh6(e.g.forusein shrink-fitchucks) The application ISOP/H:steelmaterialsfromapprox. 700N/mmto55HRC ISOK:castironworkpiecessuchas: GGG40,GJV450,ADI800 massproductionwithafocuson minimumcostsperthread large-scalemanufacturersfocusedon increasingproductivity
Requirements: internalcooling stableapplicationconditions modernmachiningcentresor moderntransferlines forcarbidetools,synchronous machiningandtheuseofadaptors withminimumcompensation(e.g. ProtoflexC)isrecommended (increasesthetoollifeandincreasesprocessreliability)
Requirements: SeePrototexHSConpage26
ProductinformationThreadforming
ProductinformationThreadforming
TiNcoating
HSS-E
M
CC
N
CC
S
C
O 3,5xDN 3xDN Type:EP2061745 Protodyn S Plus The tool innovativechamfergeometryforbetter running-inandevenwearbehaviour optimisedpolygonalformforreduced frictionandlongertoollife The application foruniversaluseinallformable m aterialsuptoapprox.1200N/mm P Protodyn S Plus C C Protodyn Plus C C M
CC C
CC
N
CC CC
S
C C
O 3,5xDN 3xDN
Variants:withoutIK,withKR* CC C CC C Variants:withoutIK,withKA*
Protodyn S Eco Plus The tool newtypeofTiNcoatingandadditional steamtreatmentforextremelylong toollifewithoutcoldwelding innovativechamfergeometryensures betterrunning-inandwearbehaviour specialsurfacetreatmentandoptimisedpolygonalformleadtolongertool lifethroughreducedfriction(important forMQL) versionswithradialinternalcoolingfor longthreaddepthsinthestandard productrange The application universalhigh-performancethread formerforuseinallformablematerials uptoapprox.1200N/mm specialvariantwithTiCNcoatingfor machiningcarbonsteels,aswellas abrasivealuminiumalloys
ProductinformationThreadforming
ProductinformationThreadforming
HSS-E
HSS-E
2xDN P
ChamferformC C
TiNcoating
3,5xDN P M
CC
N
CC
S
CC
O
ChamferformC
N
C
S
C
Protodyn Eco LM The tool titanium-freeCrNcoating Comment: Forthreads>2xDN,werecommend grindinglubricationgroovesintothe threadsection,madepossibleby semi-standardmodificationservices. The application forlong-chipping,softmaterialsandfor materialswithatendencytocause lubrication withatensilestrengthfromapprox. 200to700N/mm ISON:AlSialloyswithanSicontentup to12%andforlong-chippingcopper alloys ISOS:Tialloysuptoapprox. 1100N/mm(ifheavydutyoilisused) idealundermoderatelygoodlubrication conditionsinwhichTiNorTiCNhasa tendencytowardweldformations suitableforMQL
Protodyn S Eco Inox The tool specialpolygongeometrymakesit possibletomachinestainlesssteels withemulsion The application machiningstainlesssteelswith e mulsion Comment: Withconventionalthreadformers, stainlesssteelscanonlybemachined withoil.Machiningcentres,however, aregenerallyoperatedwithemulsion. Toformthreads,themachineswould havetobestoppedinordertomanuallylubricatethethreadwithoil.In additiontotheincreasedmachining time,thereistheriskoftheemulsion separatingbecauseoftheforeignoil beingadded. canbeusedinallformablematerials, howeverperformanceislowercompared touniversalthreadformers
30
31
ProductinformationThreadforming
ProductinformationThreadforming
Optimised polygonalform
Wear-resistant, toughmicrograincarbide
3,5xDN P
ChamferformC CC
P H O Protodyn S HSC
M
C
N
CC
S
C
CC
M
CC
N
CC
S
C
Variants:withKA* CC C CC C Variants:withoutIK*
Variants:withoutIK,withKR*
Protodyn S Synchrospeed The tool theshortthreadsectionensures reducedfrictionandhighforming speeds variantswithradialinternalcoolingfor deepthreadsinthestandardproduct range Shanktoleranceh6(e.g.forusein shrink-fitchucks) The application foruseonmachinetoolswithasynchronousspindle;notsuitablefor floatingchucksorcuttingattachments foruniversaluseinnearlyallformable materialsuptoapprox.1200N/mm suitableforMQL itisgenerallyrecommendedtouse adaptorswithminimumcompensation (e.g.ProtoflexC)(advantage:longer toollifeandincreasedprocessreliability)
The tool optimisedpolygonalformreduces frictionandincreasestoollife newtypeofchamfergeometryfor uniformwearpattern h6shanktolerance(e.g.forusein shrink-fitchucks) Protodyn S HSC: lubricationgroovesandaxialcoolant supplyfordeepblindholethreadsup to4xDN The application ISOP:steelwithatensilestrengthup to1200N/mm ISOM:stainlessmaterialswithatensile strengthupto1000N/mm(preferably withoil) ISON:AlSialloyswithanSicontentup to12%aswellasNialloyswithatensile strengthlessthan900N/mm
Your advantages extremelyhighproductivitydueto increasedformingspeeds fewertoolchangesbecauseofvery longtoollife attractiveprice/performanceratio onamass-productionscale bestpossibleuseofthedrilling depthbecausethetoolhasnopoint
ProductinformationThreadmilling
90countersinkstep
TiCNcoating orbrightfinish
Wear-resistant,tough m icrograincarbide
2xDN P
CC
M
CC
K
CC
N
CC
S
CC
O
C
Variants:withoutIK,withKA(fromsizeM4)*
Solid carbide thread mill TMC Thread MillCountersink The tool solidcarbidethreadmillwithcountersinkstep concentricity<10mforoutstanding threadqualityandlongtoollife The application foruniversaluseinawiderangeof materialswithatensilestrengthupto approx.1500N/mmand48HRC
Type:H5055016
The strategy:
TMCthreadmilling
180
360
180
5. Creatingthread using360helix
6. Exitloop180 backtocentre
ProductinformationThreadmilling
P
CC
M
CC
K
CC
N
CC
S
CC
O
C
S
C
H
CC
O
C
Variants:withoutIK,withKA(fromsizeM5)*
Thread mill TMO - Thread Mill Orbital The tool shortcuttingedge,smallerhelixangle andpositiverakeangleforreduced forcesandasoftcuttingaction largershankdiameterforvibration-free use,evenwithlongerclampinglengths stablebasicconstructionwithlarge corediameter The application foruniversaluseinabroadmaterial spectrumwithatensilestrengthupto 1500N/mmand48HRC excellentmachiningpropertiesevenfor high-strengthmaterialsthattendto causejamming(e.g.high-tensile stainlesssteelsandTialloys)
Type:H5087016 Your advantages longtoollifebecauseofinnovative millingstrategy smallanddeepthreads(e.g.M1,6, 3xDNdepth)canbeproduced reliably canbeusedprofitablywhereconventionaltoolshavereachedtheir limits: machiningdifficult-to-cutmaterialssuchasInconel producingdeepthreads solutionwhere(multiple)radial cuttingpasseswouldbenecessary withconventionalthreadmillsdue totheirconicalthreads The strategy: TMOorbital-threadmilling
ProductinformationThreadmilling
90countersinkstep
2xDN P
27helixangle threecoolantholes
K
CC
N
CC
NHC TAX
IKabsolutelyessential*
Your advantages greatercostefficiencyforlessthan 8identicalthreadspercomponent comparedtoconventionaltools** increasedproductivitybyshortening processingtimesbyupto50% spacesavingsinthetoolmagazine exactpositioningofcoreholeand thread
** theadvantagescanvarydependingonthe chip-to-chiptime
Solid carbide thread milling cutter TMD - Thread Mill Drill The tool solidcarbidethreadmillingcutter cuttinglengthandcountersinkstep matchedto2xDNthreaddepth TAXcoatingforISOKmaterials NHCcoatingforISONmaterials The application ISOK:castironworkpiecessuchas GG25(GGGmaterialscanonlybe machinedinexceptionalcases.Machiningthesematerialsismadepossiblein partbyadouble-edgedspecialtool.) ISON:castaluminiumwithanSi contentof7%andabove;short-chippingMgandCualloys Directmachiningofprecastcoreholes
Type:H5075018
The strategy:
TMDthreadmillingwithcountersinkstep
180
360
180
6. Exitloop180 backtocentre
ToolselectionTapping
ToolselectionTapping
P
Paradur Synchrospeed* (2.5 x DN)
P
Prototex Synchrospeed* (3 x DN)
M
Paradur Synchrospeed* (2.5 x DN)
M
Prototex Synchrospeed* (3 x DN)
K
Paradur Synchrospeed* (2.5 x DN)
K
Prototex Synchrospeed* (3 x DN)
N
Paradur Synchrospeed*
(2.5 x DN)
N
Prototex Synchrospeed*
(3 x DN)
200
400
600
800
1000
1200
1400
1600
200
400
600
800
1000
1200
1400
1600
Tensilestrength[N/mm]
Tensilestrength[N/mm]
HSS-EorHSS-E-PMcuttingtoolmaterial 40
*onlyforsynchronousmachining
HSS-EorHSS-E-PMcuttingtoolmaterial
*onlyforsynchronousmachining 41
ToolselectionTapping
ToolselectionTapping
P
Paradur Xpert P (3.5 x DN) Paradur Xpert M (2.5 x DN)
N
Paradur Eco CI** (3 x DN) Prototex Xpert P (3 x DN)
N
Paradur WLM (3 x DN)
S
Paradur Ti Plus (2 x DN)
0 200 400 600
S
0 200 400 600
800
1000
1200
*internalcoolingrequired ***onlyforshort-chippingmaterials 43
ToolselectionThreadforming
Thread formers
Thread depth Type Productinformation:Page Brinell hardness HB Structure of main material groups Tensile strength Rm N/mm2 2,0 x DN Protodyn Eco LM 30
3,5 x DN Protodyn S Protodyn S Protodyn S Protodyn S Protodyn S Plus Eco Plus Eco Inox Synchrospeed HSC 29 28 31 32 33
C C Primaryapplication C
Additionalapplication
Material group
Workpiece material annealed (tempered) free cutting steel tempered tempered tempered annealed hardened and tempered hardened and tempered ferritic/martensitic, annealed martensitic, tempered austenitic, duplex austenitic, precipitation hardened (PH) ferritic, pearlitic not precipitation hardenable precipitation hardenable, precipitation hardened 12% Si > 12% Si unalloyed, electrolytic copper brass, bronze, red brass Cu-alloys, short-chipping high-strength, Ampco Fe-based Ni or Co base Ni or Co base pure titanium and alloys, precipitation hardened alloys
P
High-alloy steel and high-alloy tool steel Stainless steel
210 220 300 380 430 200 300 400 200 330 230 300 245 365 200 30 100 90 130 70 100 90 110 300 280 250 350 200 375 410 300 300
700 750 1010 1280 1480 670 1010 1360 670 1110 780 1010 340 310 450 250 340 310 380 1010 940 840 1080 670 1260 1400 1010 1010
CC CC
CC CC CC C
CC CC CC C
C C C C
CC CC CC C
C C CC CC
CC CC
CC CC
C C
CC CC
C CC
CC CC CC C
CC CC CC C
CC CC CC C
CC CC CC C
CC CC CC C
M K
Stainless steel Grey cast iron Cast iron with spheroidal graphite GGV (CGI) Aluminium wrought alloys Cast aluminium alloys
CC CC CC
CC CC CC
CC CC CC
C C C
CC CC CC
CC CC CC
CC
Heat-resistant alloys
CC
CC
CC
CC
CC CC CC
44
45
ToolselectionThreadmilling
Thread mills
Thread depth
C C Primaryapplication C
Additionalapplication
Material group
Workpiece material annealed (tempered) free cutting steel tempered tempered tempered annealed hardened and tempered hardened and tempered ferritic/martensitic, annealed martensitic, tempered austenitic, duplex austenitic, precipitation hardened (PH) ferritic, pearlitic not precipitation hardenable precipitation hardenable, precipitation hardened 12% Si > 12% Si unalloyed, electrolytic copper brass, bronze, red brass Cu-alloys, short-chipping high-strength, Ampco Fe-based Ni or Co base Ni or Co base pure titanium and alloys, precipitation hardened alloys
P
High-alloy steel and high-alloy tool steel Stainless steel
210 220 300 380 430 200 300 400 200 330 230 300 245 365 200 30 100 90 130 70 100 90 110 300 280 250 350 200 375 410 300 300 50 HRC 55 HRC 60 HRC
700 750 1010 1280 1480 670 1010 1360 670 1110 780 1010 340 310 450 250 340 310 380 1010 940 840 1080 670 1260 1400 1010 1010 -
CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC C C CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC C CC CC
CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
M K
Stainless steel Grey cast iron Cast iron with spheroidal graphite GGV (CGI) Aluminium wrought alloys Cast aluminium alloys
Heat-resistant alloys
Hardenedsteel
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Technicalinformationgeneral
Disadvantages
chipremovalisoftenchallengingand requirestooldiversityaswellasspecial modifications(particularlywithdeep blindholethreadsinlong-chipping materials) reducedtoolstabilityduetoflutes;risk offractureincreases riskofworkpiecehavingtoberejectedif thetoolbreaks processmayreactsensitivelytobatchrelatedchangesinthepropertiesofthe workpiecematerials increasedriskofmachinestoppagedue tobirdnesting
Thread forming
highprocessreliability nochipsandthereforenoproblems withchipremoval:evendeep threadscanthereforebeproduced reliably lowriskoffracturebecauseof stabletools highthreadquality highstaticanddynamicstrengthof thethreadbecauseofcoldwork hardening verygoodthreadsurfacewithminor roughness
Threaddepth + ++
Universality/ flexibility
Machining speed
Toolcosts
Process r eliability
Toollife
highflexibility universaluseofthetoolsinthe mostvariedmaterials onetoolforblind-holeandthroughholethreads differentthreaddimensions(with thesamepitch)canbeproduced withonetool anytolerancegradescanbe producedwithonetool singleandmulti-startthreadsas wellasright-handandleft-hand threadscanbeproducedwithone tool
highprocessreliability noriskofbirdnesting workpiecedoesnothavetobe rejectedifthetoolbreaks lowtorqueevenwithlarge d imensions inclinedrun-inandrun-outare unproblematic machiningofthin-walledcomponentsispossiblethankstolow cuttingpressure
Thread milling
+ ++
+ +
+ ++
++ +
+ +
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Technicalinformationgeneral
Tolerance class of tool DIN designation for taps ISO1/4H ISO2/6H ISO3/6G 7G Company standards for taps and thread formers 4HX 6HX 6GX 7GX
Technical application
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Technicalinformationgeneral
Appearance
Features
CrN Primary areas of application threadtappinginAland Cualloys threadforminginTialloys machiningofductile steels reduces weldformations
NHC non-ferrousmetals (Cu-,brass-,bronze-and Ti-alloys) AlSialloyswithanSi contentupto12% reducesbuiltupedges resistanttoabrasivewear sharpcuttingedgesare possible,becauseofthe thinlayer
ACN
Appearance
Features
hightemperatureresistance universallayer
resistanttoabrasivewear
Technicalinformationgeneral
P M Material K N S H Surface treatment Thread tapping Thread forming Thread milling Thread mill drill
X X X
X X X X X X X X X
X X X
X X X X X X
X X X
X X X
X
THL TAX
bright finish
vap
TiN
CrN
NHC
DLC
Diamond
nid
ACN
TiCN
X X
X X X X
X X X X
X X
X X
TiCN
C C CC C C CC CC CC CC C CC CC CC
C CRecommendedCPossibleapplication
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Technicalinformationgeneral
Material group
Material
Thread cutting
Thread forming
Thread milling
Emulsion 5% Emulsion 5 - 10% Emulsion 10% or oil (Protofluid) Oil (Protofluid or Hardcut 525)
Emulsion 5 - 10% Emulsion 10% or oil (Protofluid) Emulsion 10% or oil (Protofluid or Hardcut 525) Forming generally not possible Oil (Protofluid) [emulsion 5-10% only possible with special tools (Protodyn S Eco Inox)] Forming not possible Emulsion 10% Emulsion 5 - 15% Emulsion 5 - 10% Forming only practical in exceptional cases Forming not possible at room temperature Emulsion 5 - 10% Oil (Hardcut 525) Oil (Protofluid or Hardcut 525) Forming not possible Forming does not produce dimensionally accurate threads
Emulsion/MQL/ air blast Emulsion/MQL/ air blast Emulsion/MQL/ air blast Emulsion/MQL/ air blast
Steel 1,200 - 1,400 N/mm Steel 1,400 - 1,600 N/mm equivalent to 44 - 49 HRC
Stainless steel
Emulsion
Emulsion/MQL/ air blast Emulsion/MQL/ air blast Emulsion/MQL/ air blast Emulsion/MQL/ air blast
Ductile cast iron GGG Aluminium up to max. 12% Si Aluminium over 12% Si
Emulsion 5 - 10%
N
Magnesium Copper Titanium alloys Oil (Protofluid) Emulsion 5 - 10% Emulsion 10% or oil (Protofluid or Hardcut 525) Emulsion 10% or oil (Protofluid or Hardcut 525) Oil (Hardcut 525) possible only with carbide tools Emulsion 5%
S
Nickel alloys
Emulsion
Dry/MQL
Synthetics
Emulsion/MQL
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Technicalinformationgeneral
Technicalinformationgeneral
Case 1: Short chips Thebestresultsintermsofperformance andprocessreliabilityareattainedifthe chipscanbebrokenwhenshort.These shortchipscanbeeasilyflushedoutof thethreadsusingcoolant.Thebestway tobreakthechipswhenshortiswith straight-flutedtaps(e.g.ParadurHT). TheKAisrecommendedforblindhole threads. Comment: Ifblindholethreadsarebeingproducedinshort-chippingmaterials withoutIK,thechipscollectatthe bottomofthehole.Ifthesafety marginhasbeenmeasuredtootight, thetoolrunsupagainstthechipsand maybreak.
Case 2: Long chips (chips cannot be broken) Withsteelslowerthan1000N/mmor withstainlesssteelsandotherverytough materialsingeneral,itisnormallynot possibletobreakthechipwhenshort.In thesecases,thechipmustberemoved usinghelicallyflutedtools.Ifthereis internalcooling,thecoolantonlyhelps withchipremoval.Insomecases,taps withashallowerhelixcanbeusedwhich increasesthetoollife.
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Technicalinformationgeneral
smoothsurfacefromexcellent lubrication
Therearebasicallytwodifferingtypesoftools:Thread formers with lubrication grooves and thread formers without lubrication grooves.Thedifferentareasof applicationareexplainedbelow.
Vertical through hole machining (> 1.5 x DN) Lubricationgroovesarerequired;internal coolantsupplyisnotnecessary.Externally suppliedcoolantcanpenetrateintothe threadprofilethroughthelubrication grooves(KRisrecommendedforvery deepthreads).
withoutlubrication grooves
withlubrication grooves
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Technicalinformationgeneral
Materials that are suitable for MQL machining nonorlowalloyedsteelsaswellascast steel<1000N/mm greycastiron brass AlSialloys copperalloys
Materials that are not suitable for MQL machining high-tensile,high-alloysteels TiandNialloys stainlesssteels
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Technicalinformationgeneral
Clamping devices
Tappingchucks(alsocalledtooladaptors) aretheconnectingpiecebetweenthe spindleandthetool. Tasks of the tool adaptor during thread tapping and thread forming: transmittingtorque axialand/orradialcompensationof differencesbetweenthespindlepositionandtooltargetposition,where required Tasks of the tool adaptor during thread milling: transmittingtorque minimisingthedeflectionofthetool (chuckmustberigidtoopposeradial forces) dampingvibration General tasks: transferringthelubricantfromthe spindletothetool protectingthespindlebearingsifthe toolbreaks protectingthetoolagainstbreakage (canonlybeachievedtoalimited extent) Intermsoftheinteractionbetweenthe spindleandthefeedrate,itiscrucial whenthreadtappingandthreadforming toknowifthespindlerotationspeedsand thefeedratearematchedtoeachother (synchronised)andtheirrelativeaccuracy. Comment: Allcurrentmillingchuckscanbeused forthreadmilling.Thespecialchucks forthreadtappingandthreadforming areshownbelow.
Quick change chuck with axial compensation Advantages: foruseinsynchronousandnon- synchronousmachines compensationofaxialandradial positiondeviations soliddesign Disadvantages: morecomplicatedtechnologythanfixed chucks miscuttingcannotbeprevented, becausethetoolmustguideitself Quickchangechucksareavailableinthe standardproductrangefromWalter.
Synchro chuck with minimum compensation Advantages: compensationofaxialforcesresultingin amarkedincreaseinthetoollife combinationofadvantagesfromboth fixedchucksandfloatingchucks Disadvantages: moreexpensivetopurchasethanfixed chucks onlyforuseonsynchronousmachine tools Synchrochuckswithminimumcompensationareavailableinthestandardproduct rangefromWalter.
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Technicalinformationgeneral
Tapping attachment Advantages: foruseinsynchronousandnon-synchronous machines protectsthespindle,becausethedirection ofrotationofthechuckcanbereversed veryshortcycletimes,becausethespindle doesnotneedtobeacceleratedordecelerated;forthisreasonitisofparticular interestformassproduction Disadvantages: complicatedtechnology highmaintenancecosts torquesupportrequired highprocurementcosts
Shrink-fit chucks, fixed collet chucks, Weldon chucks (from left to right) Advantages: simple,cost-effectiveandsoliddesign shrink-fitchuck:veryhighconcentricity Disadvantages: onlyforuseonsynchronousmachinetools minimumpitchdifferencescauseaxialforceswhich actonthetoolflanksandreducethetoollife
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Technicalinformationgeneral
ProtoflexCsynchronoustappingchuck
Flexorwithminimumcompensation
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Technicalinformationgeneral
Drillingdepth
Thread depth
Thread milling Whenselectingthedrillingandboringtool,thepermissible tolerancesforthecoreholelistedinthetablebelowmustalsobe notedtoensureareliableformingprocessandasuitabletoollife. neitherachamferareaoratip,which makesitpossibletohavethreadsthat almostgotothebottomofthehole. Miscuttingisexcludedfromthemilling processwhichiswhyanadditionalaxial safetymarginisnotnecessary.
Diameter of the core hole for thread tapping and thread milling Ruleofthumb: Holediameter=nominaldiameter-pitch ExamplesizeM10 Holediameter=10.0mm1.5mm=8.5 mm Diameter of the core hole for thread forming Ruleofthumb: Holediameter=nominaldiameterfxpitch tolerance6H:f=0.45 tolerance6G:f=0.42 ExamplesizeM10 Holediameter=10.0mm(0.45x1.5mm)=9.325mm=9.33 mm
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Technicalinformationgeneral
0.025mm
Newdrill: edgezoneisnearlyunchanged
Worndrill: influenceoftheedgezone
Summary: Thetoollifeofthethreadingtoolis reducedasthehardnessoftheedge zoneincreases. Thehardnessoftheedgezone escalatesaswearonthedrillingor boringtoolincreases.Highcutting parametersorroundedcutting edgesalsohaveaneffectonthe hardnessoftheedgezone.
Example: MaterialC70,tooldiameter8.5mm,drillingdepth24.5mm
Worndrill Edgezonehardness Edgezonewidth Toollifeoftap 450HV 0.065mm 70threads Newdrill 280HV 0 >350threads
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TechnicalinformationTapping
Basic types
Blind hole Short-chipping materials Straight-flutedtapsdonottransportchips.For thisreason,theycanonlybeusedwithshortchippingmaterialsorshortthreads. Comment: Thechipsaccumulateatthebottomofthe holeifinternalcoolingisnotused.Ifthe safetymarginhasbeenmeasuredtoo tight,thetoolmayrunupagainstthe chipsandbreak. Deepthreadsarepossiblewithstraight-fluted toolsifthetaphasanaxialcoolantsupply, becausethechipsareflushedoutagainstthe feeddirection.Aprerequisiteforthisisthatthe chipsarebrokenoffshort(e.g.:ParadurHT, threaddepthupto3.5xDN). Incomparisontohelicaltools,straight-fluted tapshavealongertoollife. Somestraight-flutedtoolscanalsobeusedfor throughholesinmaterialswithgoodchipbreakingproperties(e.g.ParadurEcoCI). Long-chipping materials Tapswithaspiralpointtransportthechips forwardinthefeeddirection. Tapswithaspiralpointarethefirstchoice whenproducingthroughholethreadsinlongchippingmaterials. Through hole
Long-chipping materials Right-handspiraltapstransportchipsback towardstheshank.Thetougherthematerialto bemachinedis(producinglongerchips)andthe deeperthethread,thegreaterthehelixangle required. Left-hand spiral taps (andtapswithaspiralpoint)transportthe chipsforwardinthefeeddirection. Toolswithleft-handspiralarepracticalonlyif chipscannotberemovedreliablywithaspiral point.Toolexample:ParadurNofthetype 20411and20461
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TechnicalinformationTapping
TechnicalinformationTapping
Form B
right-hand helical mediumandlongchippingmaterials short-chipping materials long-chipping materials short-chipping materials shortthreadrun-out inmediumandlongchippingmaterials shortthreadrun-outin short-chippingmaterials veryshortthreadrun-out inmediumandlongchippingmaterials veryshortthreadrunoutinshort-chipping materials
2-3threads
5
1st land 2nd land 3rd land
straight-fluted
6 8 Gnge
3.5-5threads
left-handhelical
straight-fluted
6 8 Gnge
1.5-2threads
right-hand helical
straight-fluted
1-1.5threads
right-hand helical
straight-fluted
23
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TechnicalinformationTapping
TechnicalinformationTapping
Thetoolbeginstoreverse.Thechipsremainwheretheyarefor thetimebeing.Thereversetorqueatthispointisvirtuallyzero.
Anadvantageofshortchamfersisthat fewerchipsareproduced.Inaddition,the largerchipcrosssectionisfavourablefor chiptransport. Short chamfer (e.g. form E) results in: lowtorque largechipcrosssection increasedstrainonthechamferteeth shortertoollife optimisedchiptransport
Form E
Thechiphasbeenshornoffandreversetorquedecreasestothe frictionbetweentheguideandthecutthread.
23
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TechnicalinformationTapping
TechnicalinformationTapping
Detail B
Detail A
Flankangle Lead
Detail B
Md
Spindlebraking
Time p rogression
Flankclearanceangle
Rootface(land) Slightincrease causedby a dditional f rictionin theguide Coefficientof frictioninthe guidepartof thetapduring reverseaction Rake (rakeface) Corediameter Chamferclearance angle
Rakeangle
Throughholetap withaspiralpoint
Chamferangle Spiralpoint angle
Blindholetap witharight-handhelix
Helixangle Chamferangle
Spiralpointlength
Lubrication grooves
Flute
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TechnicalinformationTapping
Paradur TiPlus
Paradur EcoCI
Paradur HSC
Paradur XpertM
Paradur EcoPlus
Flank clearance angle: Theflankclearanceanglemustbe matchedtothematerialtobemachined. Materialswithahighertensilestrength andmaterialsthattendtocausejamming requirealargerflankclearanceangle.The guidancecharacteristicsofthetoolworsenastheclearanceangleisincreased, whichiswhymiscuttingoccursinsoft materialsiffloatingchucksareused.
ParadurWLM
Practical tip: Check the flank clearance angle Atapshouldscreweasilyintothe previously-cutthreadwithoutany recutting.Ifthisisnotpossible,a tooltypewithalargerflankclearance angleshouldbeselected.
Spiral point angle: Thespiralpointangleislimitedbythe chamferlengthandnumberofflutes, becausewithalargerspiralpointangle, thelandwidthinthefirstthreadofthe chamferisreduced.Thiscausesthe stabilityofthecuttingedgetodecrease (theriskoffracturesaroundthechamfer increases).Anincreasedspiralpointangle facilitateschipremovalinthefeed direction.Ifthespiralpointangleistoo small,chipremovalbecomesproblematic. Left-handhelicaltoolsprovideasolution forthis.
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TechnicalinformationTapping
Threads with significantly deeper core hole than thread depth usethrough-holetapswithamodifiedspiralpoint: reducetheradialreliefofthechamfertothevalue ofablindholetap shortenthechamferlengthtoapprox.3threads Advantage:longertoollifethanblindholetapswith ahighhelixangle Disadvantage:chipsremaininthebore forshort-chippingmaterialssuchasGG25, straight-flutedtoolswithoutaspiralpointcanalso beused: ParadurEcoCI ofcourse,blindholetapswithahighhelixanglecan alsobeusedforthisapplication
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TechnicalinformationTapping
machineprogrammed at90-98%
vf=nxp
n=rotationspeed;p=threadpitch
Workpiece
Tap
Workpiece
Tap
axialforcefrom thetool
Programmingthetheoreticalfeedrate isrecommendedhere.
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TechnicalinformationTapping
Modifications
Negative chamfer (Secur chamfer) Reduced helix in the chamfer Inclined thread
Shortened chamfer
Bright rake
Chip formation
Chipsarerolledmore tightly,shorterchips
Chipsarerolledmore tightly,lesschips
Chipsarerolledmore tightly,shorterchips
uncoated:
Nochange
Chipsarerolledmore tightly,shorterchips
Tool life
coated:
uncoated:
Thread quality
coated:
Chip thickness
Torque Avoidanceofbirdnestinginstructuralsteels suchasSt52,C45,etc. ParadurSecur ParadurHSC PrototexHSC Threadsnearlytothe bottomofthehole, betterchipcontrol Alltoolswithchamfer formE/F Optimisedchipformationinsteelsand aluminium ParadurNi10 ParadurHSC Problemswithfractures orweldformationsin theguide ParadurEcoPlus ParadurXpertM ParadurSynchrospeed Optimisedchipformationinsteels,machining crankshafts Alluncoatedtools aswellasParadur S ynchrospeed(TiN-vap)
Application example
increases
remainsunchanged
decreases
decreasessharply
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TechnicalinformationTapping
regrindareducedhelixtoachieveshort chips reducetherakeangletoachievemore tightlyrolledchips iftoolswithashallowhelixorstraight threadformingorthreadmilling: flutesareused,theabove-mentioned materialsinwhichchipcontrolis measurescanbecombinedandcomdifficultwhiletappingblindholescanin plementedwithasupplyofaxialcoolant mostcasesbeproducedthrough whichhelpstoflushtheshortchipsout; forminginanon-chippingprocess.If inmassproductioninparticular,thisis threadformingisnotpermitted,thread aprovenmethodforincreasingprocess millingcanbeusedasaproblemsolver. reliabilityandproductivity Thisprocessproducesshortchips. regrindtherake,andgrindabright reducedhelix;thisproduceschipswhich canbebettercontrolled replacetheTiN/TiCNcoatingswithTHL, becauseTHLhasbetterchipformation characteristics;useofbrightorvaporisedtoolsinsteadofcoated shortenthechamfer(re-engineer) fewerandthickerchipsareproduced reducethenumberofflutes(new design);thechipthicknessincreases andthestabilityofthetoolisincreased useatoolwithanegativechamfer(e.g. ParadurSecur)
Remedy: synchronousmachining usetoolswhichhavebeenadaptedto thematerial chooseasuitablecoating(against radialmiscutting) Miscuttingismostlikelytooccurwith optimisechipcontrol(againstradial morehighlyspiralledblindholetaps.The miscutting) axialforceinthefeeddirectioncreated useatapwithasmallerhelixangle duetothehelixanglecanpullthetap useatapwhichhasbeenspecially morequicklyintotheholethanatarate treated: whichcorrespondsthantheactualpitch thisisreferredtoasthecorkscrew ParadurXpertP;ParadurEcoPlus effectandisknownasaxial miscut PrototexXpertP;PrototexEcoHT ting.Through-holetapsaresubjectto Threadmilling geometry-relatedaxialforcesagainstthe feeddirection,whichsimilarlymayleadto Threadforming axial miscutting.Thetendencytoward axialmiscuttingisincreasediftapswith alargeflankclearanceangleareused insoftmaterialsorifthecuttingedge treatmentisinappropriate.
Exampleoffracturesduetochipcontrol problems
Axiallymiscutblindholethreads
Axiallymiscutthroughholethreads
*Themodificationsareexplainedfullyandclearlyshownonpages88-89. 90 91
TechnicalinformationTapping
Optimisationofthethreadsurfaceduring threadcutting: usethreadformingorthreadmilling insteadofthreadcutting increasetherakeangle decreasethechipthicknessbyusinga longerchamferoranincreasednumber offlutes(withblindholetapsthis neverthelessworsenschipformation) asarule,TiNandTiCNproducethebest surfacesinsteel(brighttoolsorCrN andDLClayersproducethebest surfacesinAl)
TapwithTiCNlayer inAlSi7
TapwithDLClayer inAlSi7
concentrateemulsionoruseoilinstead ofemulsion supplylubricantdirectlytotheoperatingarea replacethetoolwithanewoneearlier Someofthesuggestedmeasuresmight leadtoanimprovementinthesurface quality,butareaccompaniedbyaworseninginchipcontrolwhichisproblematic withdeepblindholesinparticular.Here againacompromisethattakesthe customer'srequirementsintoaccount mustbechosen.
Weld formations on the tool: Specialcoatingsandsurfacetreatments arerecommendedasaproblemsolverdependentonthematerialtobemachined: AlandAlalloys: bright,CrN,DLC,WC/C softsteelsandstainlesssteels:vap softstructuralsteels:CrN
Exampleofweldformations
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TechnicalinformationThreadforming
Process principles
Threadformingisanon-chippingprocess thatusescoldformingtoproduce internalthreads.Displacementofthe materialforcesthematerialtoyield.This producesacompressedthreadprofile. Theflutesthatarerequiredinthread tappingcanbeomittedwhichincreases thestabilityofthetool. Threadformingispredestinedformass productionforexampleintheautomotiveindustry.Extremelyreliableprocessescanbeperformedbasedonthe non-chippingproductionofthreadsin combinationwithhighertoolstability fromtheclosedpolygonprofile.Moreover,incontrasttothreadtapping,higher cuttingparameterscanoftenbe achievedatthesametimeasachieving alongertoollife.Incomparisonwith threadtapping,threadformingrequires atorquethatisapprox.30%higher. grainprofileofformedthreads(compare pictureatthebottomright).Incontrast, theinterruptedgrainprofileisusedin threadtappingandthreadmilling(comparethepictureonthebottomleft). Thedifferentchamferformsareusefulin differentapplications: FormD,3.5-5.5thread: Throughholethreads FormC,2-3.5thread: Blindholeandthroughholethreads FormE,1.5-2thread: Deepholethreads Approx.65%ofallmachinedmaterialsin industryareformable.Thelimitsare illustratedbelow: brittlematerialswithelongationat fracturelowerthan7%suchas: GG SialloyswithanSicontent>12% short-chippingCu-Znalloys thermosettingplastics threadpitch>3mm(formingatpitches 1.5mmisparticularlycost-efficient) tensilestrength>1,200-1,400N/mm Typical materials used in thread forming are: Steel Stainlesssteel Softcopperalloys Aluminiumwroughtalloys
Formfolds
Comment: Comparedtothreadtappingand threadmilling,thetoleranceofthe coreholeistighterinthreadforming. Threadformingisthereforenot alwaysthemoreefficientoptionin allcases.Examiningindividualcases isthereforeabsolutelyessential. Refertopages70-71fortheformulasrequiredtocalculatethecore holes.
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TechnicalinformationThreadforming
Example for the permissible core diameter based on the dimension M6-6H Thread tapping
Toollife
5,25 5,2 5,15 Corediameterinmm 5,1 5,05 5 4,95 4,9 4,85 4,8 4,75 Minimum Maximum corediameter corediameter 6H 6H 4,917 4,917 5,153
Torque
Minimumdimension
Nominaldimension
Maximumdimension
min* max*
*ToleranceofthecorediameterproducedasperDIN13-50
Practical tip: Especiallyinmassproduction,itisworthoptimisingthe pilotdrilldiameter.Thefollowingapplies: The pilot drill diameter selected should be as large as possible, but only as small as necessary. Thelargerthepilotholediameter: thehigherthetoollifewillbe thelighterandmorereliabletheformingprocesswillbe thelowertherequiredtorquewillbe Ensurethatthethreadremainstruetogauge.
Comment: Dependency on the pilot drill diameter and thread core diameter: Ifthecoreholeisdrilledlargerby0.04mm,thethreadcorediameter (afterforming)enlargesbyatleast0.08mmhenceatleastbyafactorof2.
Therecommendedpilotholediameters canbefoundinthetableonpage116.
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TechnicalinformationThreadforming
TechnicalinformationThreadforming
Modifications
Diagram Action Side effect
Chamfer form D
longertoollife
slightlyincreased cycletime
Chamfer form E
decreasedtoollife
highertoolcosts
potentiallyhigher toolcosts
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TechnicalinformationThreadforming
TechnicalinformationThreadmilling
Process principles
Basic aspects of thread milling: amachinetoolwitha3DCNCcontrol systemisrequired(moreorlessa standardtoday) conventionalthreadmillingtoadepth of2.5xDNispossible,orbitalthread millingtoadepthofapprox.3xDN
Incontrasttothreadtappingandthreadforming,thepitchisproducedinthread m illingbytheCNCcontrolsystem.
P=Ppitch Ph=pitchheight=Ppitch
Theoretically,aninternalthreadmilling cuttercanalsobeusedtoproducean externalthread.Thethreadsproducedin thiswaydonotcomplywiththestandard, becausetheexternalthreadsarerounded tominimisethenotcheffectinthecore andtheexternaldiameterproducedis toosmall. However,becausethethreadringgauge teststhethreadonthepitchdiameter, thegaugeaccuracyismaintained.
screw
nut
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TechnicalinformationThreadmilling
Process principles
Incontrasttothreadtappingandthread forming,therequiredtorqueforthread millingonlyincreasesmoderatelyasthe threaddimensionincreases.Thismeans largethreadscanalsobeproducedon machineswithlessdrivepower. Feed rate correction Becausethreadmillingusesacircular path,andthecuttingedgetherefore travelsthroughalongerpaththanthe toolcentre,adistinctionmustbemade betweencontourfeedandtoolcentre feed. Becausethetoolfeedisalwaysbased onthetoolcentrepoint,themillingfeed mustbereduced.
Threadtapping
Torque
Threadmilling
Thread size
= na D omi n
d= mill
Therearetwofundamentallydifferentmillingprocesses:
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TechnicalinformationThreadmilling
Process principles
Thecutscanbemadeinanumberof passesinordertoreducetheradialforces actingonthetool:
Axial passes
theoreticalcontour
Radial passes 3/4 1stcut Up-cutmilling 4/4 2ndcut Climbmilling 1stcut 2ndcut
Tocounteractthisphysicallaw,the geometricdesignofthreadmillsisslightly conical.Nevertheless,underdifficultmachiningconditionsitmaybenecessaryto findaremedyusingoneofthefollowing measures: multipleradialcuttingpasses runallradialcutsintheopposite direction makeanon-cuttingorspringpass withoutadditionalinfeedattheendof theprocess
Comment: Asanalternative,orbitalthreadmills (TMO)canbeusedtoproducecylindricalthreadsrighttothebottomof thehole. Theabove-mentionedmeasuresmay increasethecycletime,buttheyare unavoidableinsomecasesiftrueto gaugethreadscannotbeguaranteedin anyotherway. Thisconicitymakesachievingtrueto gaugethreadsparticularlydifficultwith tighttolerancethreadsaswellaswith materialsthataredifficulttomachine (e.g.Inconel).
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TechnicalinformationThreadmilling
TechnicalinformationThreadmilling
Profile distortion
Diagonalmillingintheinclinationangle causesadistortionofthethreadprofile ofthetooltobetransferredontothe component.Thisso-calledprofiledistortionisshownbelowusingaclearexample.
CNC programming
CNC programming with Walter GPS Generallyitisrecommendedtocreate theCNCprogramusingWalterGPS.This makesperfectsensebecause,incontrast topreprogrammedmachinecycles,GPS includesthestabilityofthetoolinthe calculation,andareductioninthecutting dataoraradialcuttingpassisprovidedif anytoolisoverloaded. Comment: Itisadvantageoustomakearadial cuttingpassataconstantfeedper tooth,insteadofselectingacutand decreasingthefeedpertooth.Ata lowfeedpertooth,thewearonthe cuttingedgeinparticularisdisproportionatelyhigh. WalterGPSenableseveninexperienced userstocreateathreadmillingprogram for7differentcontrolsystemseasilyand reliably.IncontrasttothepreviousCCS, handlinghasbeengreatlysimplified.In addition,themostcost-effectivestrategy forproducingthreadsisrecommended automatically. Eachlineintheprogramhascomments sothatthemachinemovementsarealwaysunderstandable(differentlanguages canbeselected).Theexamplebelowis ofaCNCprogramformillinganinternal threadonacontrolsystemcomplying withDIN66025.
Noinclinationnoprofiledistortion
InclinationP=12profileisdistorted
Toproducetruetogaugethreads,thefollowingrulesmustbefollowed: Metric threads: Millingcutterdiameter2/3xthreadnominaldiameter Fine metric threads: Millingcutterdiameter3/4xthreadnominaldiameter Example of profile distortion in a M18 x 1.5 thread Threadmilldiameter inmm 16 14 Theoretically,anysizethreadcanbeproducedwithsmallthreadmills.However, thetoollifeisdecreasedasthethread Flankoffsetduetoprofile distortioninmm 0,0386 0,0167 dimensionincreases,andthestability ofthetoolandthelengthofthecutting edgesarelimitingfactors.
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TechnicalinformationThreadmilling
CNC programming
The programming radius Rprg. Theprogrammingradius,abbreviatedto Rprg.,isanimportantvariableforsetup. TheRprg.iscalculatedbasedonthepitch diameterofthethreadmillandenables truetogaugethreadstobeproduced instantly.Approximatingthecorrection valuecanbeomitted.TheRprg.canbe readfromthetoolshankandistobeenteredinthetooltableoftheCNCcontrol systemwhencreatingtheCNCprogram duringsetupofthemachine. TheRprg.isdefinedsothatwhenitis usedintheCNCprogram,themathematicallysmallestdimensionforthe threadtoleranceisattained.IftheCNC programiscreatedusingGPS,acorrectiondimensionisdisplayedwhichcanbe usedtoattainthetolerancecentreofthe selectedthreadtolerance.Thecorrection dimensionmustbesubtractedfromthe Rprg.,thenthecorrectedRprg.istobe enteredintotheCNCcontrolsystem. Duringthecourseofthetoolslife,the cuttingedgesbecomeworn,thetool isforcedbackmorestrongly,andthe threadsaretoonarrow.Thiswearcanbe compensatedforbyreducingtheRprg. andtruetogaugethreadscanstillbe produced.Correctionincrementsinthe orderof0.01mmarerecommended.In comparisonwithlargetools,itisoften notpossibletocorrecttheRprg.ofsmall tools,becausetheradialforcesincrease andthisincreasestheriskoftoolbreakage.Ifthetoolsaretobereground,itis recommendedtodothisafter80%ofthe toollifehasbeenreached.
Modifications
Diagram Modification Effect
countersinkandfacingstep
countersinkingandfacing stepinonetool
coolinggroovesontheshank
systematiccoolingwithout weakeningofthetoolcrosssectioninthecuttingarea
radialcoolantoutlets
systematiccoolingforthrough holethreads
threadsremoved
reducedcuttingforcesbut longermachiningtime,becausetwopassesarerequired
deburringcutter
firstthreadprofilelengthenedonthefaceside
chamferingofthecorehole
grindingoftheneck (necking)
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TMO specialists for complex tasks: ToolsfromtheTMOfamilycanoftenbeusedasa problemsolver,forexample,ifdeepthreadsmustbe produced,hardenedmaterialsaretobemachinedorif conventionalthreadmillscreateconicalthreads.Furtherinformationavailableonpages36and102-105. Conical threads: Explanationsandsolutionstoproblemscanbefound onpages102-105.
fzin[mm/tooth] Cuttingdata/strategy/adjustments vcin[m/min] Programming Synchronousrun Reverserotation Cuttingpass Programmingradius [Rprg.] Cooling Clampingarrangement Workpiece Pilotdrilldiameter Chipremoval Stability/geometry Projectionlength Tool Helixangle Coating Concentricity Key: investigate reduce improve/increase useispreferred
Cooling and lubrication: Problemsrelatedtocoolingandlubricationaswellas thecorrespondingremedialmeasuresaredescribed onpage59. Hard machining: speciallydesignedonlyforusewithtoolsthatare suitableforhardmachining(TMOHRCandthread millHart10) machininginreverserotationwherepossible(see WalterGPSrecommendation) selectthelargest,permissiblepilotdrilldiameter ifproblemswiththecylindricityofthethreads occurs,makeanon-cuttingpassorusetoolsfrom theTMOHRCfamily donotuselubricant,removethehardchipsfrom theboreusinganairblastorMQL
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TechnicalinformationAppendix
Formulas
Speed n[min-1] Cutting speed vc[m/min] Feed rate vf[mm/min] vf= pxn [mm/min] vc= d1xxn 1000 [m/min] n= vcx1000 d1x [min-1]
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TechnicalinformationAppendix
UNC
UnifiedCoarseThread Internal thread core diameter (mm) 2B min 2B max 1,694 2,156 2,642 3,302 3,683 4,976 6,411 7,805 10,584 13,376 16,299 1,872 2,385 2,896 3,531 3,962 5,268 6,734 8,164 11,013 13,868 16,833 Drill (mm) 1,85 2,35 2,85 3,50 3,90 5,10 6,60 8,00 10,80 13,50 16,50
5 3
UNF
UnifiedFineThread Internal thread core diameter (mm) 2B max 2,459 3,023 3,607 4,166 5,580 7,038 8,626 11,618 14,671 Drill (mm) 2,40 2,95 3,50 4,10 5,50 6,90 8,50 11,50 14,50
2B min 2,271 2,819 3,404 3,962 5,367 6,792 8,379 11,326 14,348
MF
ISOmetricfinepitchthread Internal thread core diameter (mm) 6H min 6H max 5,188 6,917 8,917 8,647 10,917 10,647 10,376 12,376 14,376 16,376 18,376 20,376 5,378 7,153 9,153 8,912 11,153 10,912 10,676 12,676 14,676 16,676 18,676 20,676 Drill (mm) 5,25 7,00 9,00 8,75 11,00 10,75 10,50 12,50 14,50 16,50 18,50 20,50
Nr.8-36 Nr.10-32
1 5 3 1
Designation as per DIN 13 M6x0,75 M8x1 M10x1 M10x1,25 M12x1 M12x1,25 M12x1,5 M14x1,5 M16x1.5 M18x1.5 M20x1.5 M22x1,5
/2-20
Internal thread core diameter (mm) min max 8,566 11,445 14,950 18,632 20,588 24,118 30,292 8,848 11,890 15,395 19,173 21,129 24,659 30,932
G /4 G1
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TechnicalinformationAppendix
TechnicalinformationAppendix
MF
metricISOfinethread,tolerance6H Designation as per DIN 13 Internal thread core diameter as per DIN 13 - 50 (mm) 6H min 7H max 5,188 6,917 8,917 10,917 10,376 12,376 14,376 5,424 7,217 9,217 11,217 10,751 12,751 14,751 Pilot drill (mm) 5,65 7,55 9,55 11,55 11,30 13,30 15,30
22 25 27 29 31 33 34 36 38 40 41 43 44 45 46 48 49 51 53 55 57 59 61 63 64 65 66 67 68 69
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Thread type
Size [mm]
Inclination [mm]
M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF M, MF
0,25 0,25 0,3 0,35 0,35 0,4 0,45 0,5 0,6 0,7 0,8 1,0 1,25 1,5 1,75 2,0 2,0 2,5 2,5 2,5 3,0 3,0 3,5 3,5 4,0 4,0 4,5 4,5 5,0 5,0 5,5
Notes
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