Walte-12-034 Gewinde HB en 150dpi

Walter AG DerendingerStrae53,72072Tbingen Postfach2049,72010Tbingen Germany www.walter-tools.
com
Product handbook Threading
_THREADINGWITHWALTERPROTOTYP
Precise, reliable, efficient
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
14 Product information 14 Threadtapping 28 Threadforming 34 Threadmilling
40 Tool selection 40 Threadtapping 44 Threadforming 46 Threadmilling
48 Technical information 48 General 74 Threadtapping 94 Threadforming 101 Threadmilling 112 Appendix
Index
Alphabetical keyword index

Page Page Page Page
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
Technology, trends and innovations in thread production

Therearedifferentprocessesforproducingathread.Inthishandbook,wefocus onthread tapping,thread formingand thread millingwithtoolsfromWalter Prototyp.Inaddition,thishandbookalso presentsgeneraltechnicalinformationon theseprocesses. Thread tapping isstillthemostfrequentlyusedprocessforproducinginternalthreads.Processreliability,qualityand productioncostsperthreadarethemain considerationswhendevelopingtools. Greateffortshavebeenmadeinthefield ofmacro/microgeometryaswellasinto coatings,inordertoguaranteeahigh levelofprocessreliabilityevenunder unfavourableconditions.Thecostsper threadcanbereducedsharplythrough theuseofourhigh-performancetools fromtheEcoandSynchrospeedseries. Evenlowercostsperthreadcanbe achievedwithsolidcarbidetools.Our HSClineissettingnewstandardsinthis regardeveninsteelmaterials. Thesetoolsarethefirstchoiceformass production,forexampleinthefasteneror automotiveindustries. Thread formingasaprocessforproducinginternalthreadshasdeveloped rapidlyinthelast20years.Whileinthe past,oilwaspredominantlyrequiredasa lubricantwiththesetools,today,thanks totargetedfurtherdevelopmentofthe shapededgegeometryandthecoating, itispossibletoformnearlyallformable materials(evenstainlesssteels)witha 5%emulsiononanymachiningcentre.In addition,thestaticandparticularlythe dynamictensilestrengthoftheformed threadhasbeenimprovedevenfurther throughtheuseofemulsion. Carbideasacuttingtoolmaterialfound itswayintothreadformingalongtime ago.Absolutepeakvaluesareachieved todayusingourProtodynHSCline. Thread formingisoftenthemostcostefficientmethodofproducinganinternal thread,providedthatthisprocessis permittedfortherespectivecomponent. Intermsofprocessreliabilityandthread quality,thread millingisunchallenged atthetop.Alongsidetheclassicmilling process,whatisknownasOrbitalthread millinghasmadeanamefor itselfinrecenttimes.Withthismethod, usersareabletoproduceverydeep(e.g. 3xDN)andmoreoververysmall(e.g. M1.6)internalthreadsevenindemanding materialswithabsolutereliability. Andonefinaltip:UseournewWalter GPSsoftware,thesuccessortothe provenCCS,toselecttheidealprocess. Here,youcancompareallproduction processeswitheachotheranddecideon themostcost-efficientalternative.
Introduction
Productive processes with Walter Prototyp

Nowadays,itispracticallyimpossibleto directlypassonincreasingproduction coststhroughincreasingper-partcosts straighttothecustomer.Thisapplies equallytoyourconsumablegoodsas wellastoproducedgoods.Successful companiesclosethisyieldgapthrough asystematicproductivityincreasein production. Asamanufacturerofprecisiontoolsused inmachining,wecancontributealot,as thechartshows.Thetoolcostsaccount foronly3%oftheoverallmachining costs.Themachiningtimewhichaccountsfor30%ofthemachiningcostsis neverthelessasignificantcostfactor. Thismeans:withefficientmetalcutting toolsfromWalterPrototyp,themachining costscanbereducedsignificantly.An increaseinthecuttingparametersleadsto enormouscostsavings.Becausethetool pricehasanalmostinsignificanteffecton theoverallmachiningcosts,toolsfromthe competencebrandWalter rototyparenot P measuredsolelyonthetoolpricealone, butontheoverproportionalincreasein productivityandthereforeonthesavings potentialforourcustomers. Forthisreason,atWalterPrototyp,we arestronglypromotingtheuseofHSC machining(HighSpeedCutting)withsolid carbidetoolsfromourproductrange. Therefore,whenmachininglowalloy steels,forexample,cuttingspeedsofup to50m/minarepossible.Forthreading, thisisaremarkableresult!Particularlydemandingcustomersforwhom maximumproductivityisoftheutmost importance,WalterPrototyphas,inadditiontotheHSCline,speciallydeveloped toolsforsynchronousmachining. Minimumquantitylubrication(MQL)is anadditionalfactortoconsiderwhen reducingthemachiningcosts,asshown inthechartopposite.WalterPrototyp alsooffersitcustomersspeciallyadapted coatingsforMQL. Inshort,theproportionofcostsspent purelyontoolsmayonlybe3%ofthe actualproductioncosts,butthetoolhas adecisiveeffectontheremaining97%of thecosts. Allowourexpertstodemonstratethesavingspotentialinproductiontobegained throughtheuseoftoolsfromWalter Prototyp. Machining costs in comparison
3% Tool
Machining time: Up to 80% saving throughincreasedcuttingspeed (e.g.ifsolidcarbidetoolsfromthe HSClineareused)
30%
Machine stoppage: approx. 50% saving throughreducedbirdnesting (e.g.iftheParadurEcoPlus isused)
7%
Coolant: Up to 10% saving throughMQL(e.g.iftheParadur EcoCIisused).Additionalbenefits, suchasenvironmentalsustainability arenotquantifiedhere.
16%
Tool change: approx. 50% saving throughlongertoollife (e.g.ifParadurHTisused)
25%
Other: approx. 25% saving (amongotherthings,attributableto thereducedstorageandlogistics costsbecauseofthewideareaof applicationoftheSynchrospeed family) Up to
19%
existing withWalterPrototyp
45 % overall
savings
Productrangeoverview
Walter Prototyp threading tool Nomenclature/tool categories
Taps for universal applications

Workpiecematerialgroup
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
Paradur Tapwithright-hand helicalflute
Paradur straight-flutedtools Prototex Eco HT universalapplication forwetandMQLmachining
14 + 15
DL
3,5 x DN C C C C C C C C
Thread forming
Thread milling**
Paradur Eco Plus universalapplication forwetandMQLmachining successortotheproven ParadurEcoHT
14 + 15
GL
3 x DN
CC
CC
CC
Protodyn Threadformerwithout lubricationgrooves
Protodyn S Threadformerwith lubricationgrooves
TM TM=ThreadMill
Prototex Synchrospeed synchronousmachining universalapplication h6shanktolerance
16 + 17
DL 3,0 x DN C C C C C C C C C C
Paradur Synchrospeed synchronousmachining universalapplication h6shanktolerance
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
Taps for special applications

Workpiecematerialgroup Workpiecematerialgroup
P
Page in handbook
M
Stainlesssteel
S
H
Hardmaterials
O
Page in handbook
M
Stainlesssteel
S
H
Hardmaterials
CC
Thread depth
Thread depth
Application
Application
NFmetals
NFmetals
Castiron
Castiron
Steel
Steel
Other
Type description
Type description
Paradur Eco CI forshort-chippingmaterials forwetandMQLmachining
18
GL + DL
3 x DN
CC
CC
CC
Prototex TiNi Plus + formachininghigh-tensileTiand 25 Nialloyswithemulsionthattend tocausejamming
24 DL 2 x DN
CC
Paradur HT forsteelswithmediumtohigh tensilestrength,andforshortchippingmaterials Internalcoolingrequired
19
GL 3,5 x DN C C
CC
Paradur Ti Plus formachininghigh-tensileTi alloyswithemulsionthattend tocausejamming
24 + 25
GL
2 x DN
CC
Prototex Xpert P formaterialswithlowtomedium tensilestrength
20 + 21
DL
3 x DN
CC
Paradur Xpert P formaterialswithlowtomedium tensilestrength
20 + 21
Prototex HSC forhigh-strengthandhightensile 26 steelmaterials h6shanktolerance Internalcoolingrequired Solidcarbide
DL
2 x DN
CC
CC
GL 3,5 x DN C C
Prototex Xpert M forstainlessand high-strengthsteels
22 + 23
DL
3 x DN
CC
Paradur HSC forhigh-strengthandhigh-tensile 27 steelmaterialsupto55HRC h6shanktolerance Internalcoolingrequired Solidcarbide
GL
2 x DN
CC
CC
Paradur Xpert M forstainlessand high-strengthsteels

10
22 + 23
GL 2,5 x DN
CC
GL = blind hole machining DL = through hole machining
Other
Thread formers
Thread mills
P
Page in handbook
M
Stainlesssteel
S
H
Hardmaterials
O
Page in handbook
M
Stainlesssteel
S
H
Hardmaterials
CC
Thread depth
Thread depth
Application
Application
NFmetals
NFmetals
Castiron
Castiron
Steel
Steel
Other
Type description
Type description
Protodyn S Eco Plus* Foruniversalapplication higherperformancecomparedto ProtodynSPlus forwetandMQLmachining
28
GL + 3,5 x DN C C DL
CC
CC
TMC thread mill withcountersinkforuniversal application
34 + 35
GL + DL
2 x DN
CC
CC CC
CC
CC
Protodyn S Plus* Foruniversalapplication
29
CC
CC
TMG thread mill withoutcountersink Foruniversalapplication
35
GL 1,5 x DN CC + 2 x DN DL
CC CC
CC
CC
Protodyn Eco LM Forsoftmaterialswithtendency tocausejamming
30
GL + DL
2 x DN
CC
CC
TMO orbital thread mill Foruniversalapplication inmachiningofsmalland deepthreads
36 + 37
GL + DL
2 x DN 3 x DN
CC
CC CC
CC
CC
Protodyn S Eco Inox* 31 especiallyformachiningstainless steelswithemulsion
GL + 3,5 x DN DL
CC
TMO HRC orbital thread mill Forsmallanddeepthreadsin hardmaterialsupto65HRC
37
GL + DL
2 x DN
CC
Protodyn S Synchrospeed* Foruniversalapplication Synchronousmachining h6shanktolerance
32
CC
CC
TMD thread milling cutter Foraluminiumandgreycastiron machining
38 + 39
GL + DL
2 x DN
CC CC
Protodyn S HSC* forhighformingspeeds h6shanktolerance Solidcarbide
33
GL 3,5 x DN C C
CC
TME thread mill 20 forexternalthreads
External thread
2 x DN
CC
CC CC
CC
CC
* Version with lubrication grooves, marked with an S 12
GL = blind hole machining DL = through hole machining
Other
C C C C C
ProductinformationTapping
The high-tech all-rounder

SpiralpointformB
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
Paradur Eco Plus: taperedguidereducesthetendency towardfractures threadnearlytothebottomofthehole withchamferformE
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*
Paradur Eco Plus
Type:EP2051312
*IK =internalcoolantsupply KA=internalcoolantsupplywithaxialcoolantoutlet KR=internalcoolantsupplywithradialcoolantoutlet 14 15
Wear-resistant, universal use

HSS-Ewith increasedhardness TiNcoating (orTHL)
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
Type:S2021305 Practical tip: Itisgenerallyrecommendedtouse adaptorswithminimumcompensation(e.g.ProtoflexC)forsynchronous machining(advantage:longertoollife andincreasedprocessreliability).
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
Extremely high speed in short-chipping materials

TiCNcoating (ornid) Chamfer formCorE HSS-E-PM
Short cycle time, optimum chip breaking

Chamfer formC
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
typicalareasofapplication: automotiveindustry(camshafts, crankshafts,connectingrods) largethreaddimensions(general mechanicalengineering,transmission shafts,housings,etc.)
Large product range, high cost efficiency

TiNcoating (orbrightfinish,TiCN)
The tool lowflankclearanceangleandtherefore nomiscuttinginsoftmaterials Prototex Xpert P variantswithreducednumberofflutes inthestandardproductrange

HSS-E
3xDN P
SpiralpointformB CC
Paradur Xpert P longflutesfordeepthreads Taperedguidepreventsfractures H O

C
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
Reliable in stainless steels

The tool raisedcoreguaranteestruetogauge threadsandensuresreliabledeburring inthethreadimportantaboveallfor machiningstainlessmaterials increasedflankclearanceanglefor machiningmaterialsthattendtocause jamming Special features of the Paradur Xpert M: taperedguidetopreventfractures H O The application ISOM:stainlesssteelsfrom350to 1200N/mm ISOP:verywellsuitedtosteelsfrom 700to1200N/mm Your advantages highprocessreliabilityinlong-chippingmaterialsthattendtocause jamming cost-efficientforsmallandmediumsizedbatches highflexibilityandshortdelivery times,becauseofcomprehensive standardproductrange(diverse threadprofiles,sizesandtolerances instock) lowertoolinventorybecauseofuse inISOMandISOPmaterials
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
Strong in high-tensile titanium

The tool especiallyformachiningISOSmaterials withageometrydesignedforemulsion veryhighflankclearanceanglefor reducingthefrictioninmaterialsthat tendtocausejamming designedformachininghardmaterials thankstosmallrakeangle wear-resistant,titanium-freeACN coatingreducesweldformations 2xDN P
SpiralpointformB
ACNcoating
The application forapplicationsinaerospacetechnology,aswellasmedicalindustry especiallyforhightensileandtitanium alloyswithatensilestrengthfrom700 to1400N/mmthattendtocause jamming Prototex TiNi Plus canalsobeusedonnickelalloys
HSS-E-PM
Largecorediameter
S
CC
Prototex TiNi Plus
Type:2021763
Your advantages oftenpossibletoworkwithemulsion insteadofoil highprocessreliabilitythroughhigh toolstability longtoollifethroughaninnovative hardmaterialcoatingandstable cuttingedges excellentthreadquality
ACNcoating
HSS-E-PM
Largecorediameter 15helixanglewith chamferformC
2xDN P M K N S
CC
Paradur Ti Plus
Type:2041663
24
25
Long tool life, extremely high speeds

Lubricationgrooves ontheshank 15helixanglewithspecial chamfergeometryformC TiCNcoating Optimised spiralpoint formB Special micrograincarbide Special micrograincarbide
TiCNcoating
2xDN P
CC
2xDN H O
Axialinternalcooling
K
CC
P
CC
K
CC
H
CC
IKviaflutesontheshank*
KAabsolutelyessential*
Prototex HSC
Type:8021006 Your advantages minimumproductioncostsand extremelyhighproductivitythanksto acuttingspeedthatisupto3times higherwhencomparedtoHSS-Etaps optimummachineoutputdueto longertoollife
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
The high-tech thread former

TiNcoating (orTiCN)
Low tool costs, good performance
Chamfer formCorE Optimised polygonalform
Innovativechamfer geometryformC HSS-E Steam-tempered surface Optimised polygonalform
TiNcoating
HSS-E
P Protodyn S Eco Plus
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 Eco Plus
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
Type:DP2061705 Your advantages lowerpurchaseprice(andlower performance)comparedto P rotodynSEcoPlus reductionintoolinventory,sinceit canbeuseduniversallyinabroad materialspectrum
Your advantages fewertoolchanges,optimummachineoutputandincreasedproductivitythroughhighformingspeeds andlongtoollife reducedcoolinglubricantcostsdue tothepossibilityforMQLmachining higherperformancecomparedto ProtodynSPlus
Ideal solution for soft materials
The specialist for machining stainless steel
Special polygongeometry CrNcoating
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
Type:E2061604 Your advantages increasedprocessreliabilityand highertoollifeduetoaminimised tendencytowardweldformations possibletomachinewroughtaluminiumandcastalloyswithemulsioninsteadofoil
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
Type:E2061305 Your advantages reductioninthemachiningtimeof stainlessmaterials,becauseno manualinterventioninthemachiningprocessisrequired theemulsiondoesnotseparate, becausenoforeignoilisused
30
31
Ideal for synchronous machining, universal use
Long tool life, extremely high speeds

Innovativechamfer geometryinformCorE TiCNcoating
TiNcoating (orTiCN) Weldon flat HSS-E
Optimised polygonalform
Wear-resistant, toughmicrograincarbide
3,5xDN P
ChamferformC CC
P H O Protodyn S HSC
M
C
N
CC
S
C
O 4xDN 3xDN Type:HP8061716
CC
M
CC
N
CC
S
C
Variants:withKA* CC C CC C Variants:withoutIK*
Protodyn HSC Protodyn S HSC
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)
Type:S2061305 Your advantages highproductivityduetohighforming speeds reductionininventorycostsdueto universaluse possibletousesimpleadaptors withoutcompensationmechanism
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
Universal with countersink step
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)*
Comment: Ifacountersinkstepisnotrequired, useofthreadmillsfromtheTMG familyisrecommended.Theirfieldof applicationisalignedwiththatofthe TMCfamily.TheTMCthreadmillsin thestandardproductrangebegin withsizeM3,thesmallestsizeinthe TMGfamilyisM6.
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
Your advantages longtoollifeandhighcuttingdata becauseofimprovedsubstrate verygoodoperationalsmoothness andsoftcuttingactionbecauseof optimisedgeometry
1. Positioningover 2. Plunging corehole andaxial c hamfering
3. Feedingback torequired threaddepth
4. Radialplunging intothethread 180/pitch
5. Creatingthread using360helix
6. Exitloop180 backtocentre
7. Retractingthe tooltothe startposition
Extremely high process reliability in the smallest of threads

Largeshankdiameter
Wear-resistant, toughmicrograincarbide Variantfor2xDNand variantfor3xDNinthe standardproductrange TiCNcoating (orbrightfinish)
Comment: OrbitalthreadmillsareavailableintheTMOHRCversion. Thesetoolsarespeciallydesignedformachininghardened andhigh-strengthmaterials. Primary area of application: hardenedsteelsupto 65HRC,steelsandalloyedsteelsfrom1400to1600N/mm P

CC
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
1.Positioningover 2.Feedinginto corehole threaddepth
3.Radialplunging intothethread 180/pitch
4.Producing threadsusing helicalinterpolation
5.Retracting thetooltothe startposition
Drilling, countersinking and threading in one operation
90countersinkstep
Specialdrillinggeometry withthreecuttingedges Wear-resistant, toughmicrograincarbide
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
Practical tip: UseofTMDispracticalifonesingle threadhasadifferentspecificationto alloftheotherthreadsinthecomponent. Example:13threadspercomponent.12 ofthemareM8,1threadisM6.Instead ofusingacore-holedrillandathreadingtool,thisthreadcanbemademore economicallywiththeTMD.
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
1. Positioningover 2. Spotdrilling, corehole drilling,countersinkingthe coreholeand chipremoval
3. Movingtothe startposition ofthethread millingcycle
4. Radialplunging intothethread 180/pitch
5. Creatingthread incounterrotationusing 360helix
6. Exitloop180 backtocentre
7. Retractingthe tooltothe startposition
ToolselectionTapping
Universal blind hole taps
Universal through-hole taps
Paradur Eco Plus (3 x DN)
Prototex Eco HT (3.5 x DN)
P
Paradur Synchrospeed* (2.5 x DN)
P
Prototex Synchrospeed* (3 x DN)
M
M
K
K
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
Blind hole taps for special applications
Through-hole taps for special applications
Paradur HSC* (2 x DN)
Prototex HSC* (2 x DN)
Paradur HT* (3 x DN)
Prototex Xpert P (3 x DN) Prototex Xpert M (3 x DN)
P
Paradur Xpert P (3.5 x DN) Paradur Xpert M (2.5 x DN)
Prototex Xpert M (3 x DN)
Paradur Xpert M (2.5 x DN)
Prototex HSC* (2 x DN)
Paradur HSC* (2 x DN)
Prototex Xpert P (3 x DN) Paradur Eco CI*** (3 x DN)
Paradur HT* (3.5 x DN) Paradur Eco CI** (3 x DN)
Paradur Eco CI*** (3 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
Prototex TiNi Plus (2 x DN)

800 1000 1200 1400 1600
S
0 200 400 600
Tensilestrength[N/mm] 1400 1600
800
1000
1200
Tensilestrength[N/mm] Solidcarbidecuttingtoolmaterial HSS-EorHSS-E-PMcuttingtoolmaterial 42 *internalcoolingrequired **onlyforshort-chippingmaterials; internalcoolingrecommended Solidcarbidecuttingtoolmaterial HSS-EorHSS-E-PMcuttingtoolmaterial
*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
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
Unalloyed and low alloy steel
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
Magnesium alloys Copper and copper alloys (bronze/brass)
CC
Heat-resistant alloys
CC
CC
CC
CC
CC CC CC
Titanium alloys Tungsten alloys Molybdenum alloys
44
45
ToolselectionThreadmilling
Thread mills
Thread depth
1,5 x DN 2,0 x DN TMG 35 Brinell hardness HB Tensile strength Rm N/mm2 TMC 34
2,0 x DN TMO HRC 37 TMD 38
2,0 x DN 3,0 x DN TMO 36
Type Productinformation:Page Structure of main material groups
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
Unalloyed and low alloy steel
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
Magnesium alloys Copper and copper alloys (bronze/brass)
Heat-resistant alloys
Titanium alloys Tungsten alloys Molybdenum alloys
Hardenedsteel
46
47
Technicalinformationgeneral
Comparison of the processes for producing threads
Advantages Thread tapping

nospecialrequirementsforthe machine almostallmachinablematerialscan beprocessed
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
longertoollifecomparedtothread tapping toolscanbeuseduniversally GLandDLthreadswithonetool
riskofworkpiecehavingtoberejectedif thetoolbreaks areaofapplicationlimiteddueto elongationatfracture,tensilestrength andthreadpitch
tightertoleranceofthecorehole increasestheproductioncosts;profitabilitycomparisonwiththreadtapping absolutelyessential notapprovedforuseinthefoodindustry,themedicalindustryandthe aerospaceindustry
lowspindlestressduetoasmooth sequenceofmovements verygoodthreadsurface
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
hightoolcostscomparedtoHSS-Etaps andthreadformers 3DCNCmachineabsolutelyessential morecomplexprogramming
inmassproduction,threadmillingis ofteninferiortothreadtappingand threadformingintermsofcost-effectiveness
Thread milling
Typicalbatchsize lowtoveryhigh lowtoveryhigh lowtomedium
Threadtapping Threadforming Threadmilling
+ ++
+ +
+ ++
++ +
+ +
Reference +higherthanreference ++significantlyhigherthanreference
48
49
Tolerance grades of taps and thread formers

Thetolerancegradeoftheinternalthread produceddependsnotonlyonthetool dimensions,butalsoonthematerialand themachiningconditions.Insomecases,it isbettertochoosetolerancesthatdeviate fromthestandard.Thistolerationis identifiedbytheXplacedafterthetoleranceclass(e.g.6HXinsteadof6H).Please notethattheseXgradesvaryfrommanufacturertomanufacturer,becausethey arebasedsolelyoncompanystandards. Taps,whicharedesignedfortoughmaterials,areproducedbyWalterPrototypinX gradesinordertocounteracttheresilient propertiesofthematerials.AtWalter Prototyp,thismeansincreasingthe dimensionsfortapsbyhalfatolerance grade.TheXpertMproductrangeused forstainlesssteelsisthereforedesigned inXgrade.Tapsforhigh-tensiletitanium andnickelalloysaremeasuredinXgrade forthesamereason. Ifabrasivematerialssuchasgreycast ironarebeingmachinedandmiscuttingis notaproblem,thenitalsoadvisableto producethetoolsinXgrade.Thetoollife isincreasedduetothetoleranceinX grade,becauseittakeslongerforthetool tobecomeheavilyworn.Forexample,the ParadurEcoCItapisproducedinthis tolerancegradeforpreciselythisreason. ThreadformersareproducedinXgrades, becausethematerialreboundsstronger whenformingthreadsthanwhencutting threads.TheXgradesforthreadformers differfromthosefortaps.Nevertheless, thisdoesnotaffectthetoleranceofthe femalethreadbeingproduced,ascanbe seeninthetablebelow. Thetoleranceclassofthetool(e.g.4H) complieswiththetolerancefieldofthe femalethreadforwhichthetoolhasbeen designed.Thetablebelowshowsthat thesetoolscanalsobeusedtoproduce othertolerancefields. Coatingsthataresubsequentlyappliedto thefemalethreadmustbecompensated foronthetapwithamaterialremoval calculation.Thematerialremovalcanbe calculatedusingthefollowingformula: A=Txfwheref= Example: metricthread,electroplatedcoating withathicknessof25m Withaflankangleof60,thisresults in:
fromthisitfollowsthat A=0.025mmx4=0.1mm Ifanormalscrewconnectionistobe achieved,atoolfromtoleranceclass 6H+0.1mustthereforebechosen.
Aisthematerialremovaltobecalculated, Tisthecoatingthicknessofthesubsequentlyappliedcoatingandistheflank angle.
Comment: Whenthreadmilling,onetoolcanbe usedtoproduceanytolerancegrades, becausethetolerancegradesare specifiedwhenprogramming.
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
Producible tolerance range of the female thread 4H 4G 5H 5G 6H 6G
Producible tolerance range of the female thread 7H 7G 8H 8G
Technical application
screwconnectionwithlittleclearance normalscrewconnection screwconnectionwithalotofclearance topreventdistortionduringheattreatment
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51
Coatings and surface treatments

bright finish verydeepblindholesin softsteels usedifthereareproblemswithchipremoval vap primarilyforstainless materials inmaterialsthataresoft, toughandhavea tendencytowardweld formations forverydeepblindhole threads nid (nit + vap) DL:Steelupto 1200N/mm,castiron andaluminiummachining; GL:onlyshort-chipping materials(GG,AlSialloys withSicontent>7%, C70);steelswithhigh pearlitecontent; notforstainlessmaterialsthattendtocause jamming longertoollifebecauseof increasedsurface hardness increasingbrittleness nidamisedmeansnitrided andvaporised TiN low-alloysteels stainlessmaterials suitableforNialloys TiCN alloyedandunalloyedsteels abrasivematerialssuchas greycastiron,AlSi(Si >5%),Cubronzealloys universallayerforGFRupto 48HRC suitableforNialloys THL steelsingeneraland stainlesssteelsinparticular deepblindholes MQLmachining GJS(GGG)
Primary areas of application
Appearance
Features
lowervc/shortertoollife comparedtocoatedtools moretightlyrolledchips
bettercoolantadhesion whichreducesweld formations lowervc/shortertoollife thancoatedtools betterchipremoval
universallayer suitableformanymaterials notforTialloys
wearresistanttoabrasive materials highlysuitedtosolidcarbide tools notforTialloys
betterchipformationthan TiNandTiCN tendencytowardweld formationsinmaterials containingmanganese
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
DLC Alalloyswithatendency tocausejamming Tialloys Nialloys
ACN
TAX useduniversallyforthread milling alsoforhardenedsteelsand HSCmachining
Diamond abrasivematerialssuchas AlSialloyswithanSi content>12%
GL = blind hole machining DL = through hole machining 52 53
Appearance
Features
significanttoollife increasesaresometimes possible
noaffinitytotitaniumalloys, becauseitisatitanium-free layer
hightemperatureresistance universallayer
resistanttoabrasivewear

Low to very high tensile strength
Low to medium tensile strength
Medium to high tensile strength
Low to high tensile strength
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
Selection of coatings for thread forming

Material Magneticsoftiron Structuralsteel Carbonsteel Alloyedsteel Temperedsteel Stainlesssteel Austenitic Ferritic,martensitic,duplex Highlyheat-resistant UnalloyedAl/Mg Al,alloyedSi<0.5% Al,alloyedSi<0.5%to10% Al,alloyedSi>10% TiN
CC CC C CC CC C C C C CC C C C
TiCN
C C CC C C CC CC CC CC C CC CC CC
C CRecommendedCPossibleapplication
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55
Cooling and lubrication

Weusuallytalkaboutcoolantwhen referringtothis,althoughwiththread cuttingandthreadforminginparticular, lubricationismoreimportantthancooling.Therearethefollowingdifferent methodsofcoolantsupply: externalcoolantsupply externalcoolantsupplyviaoutlets paralleltotheaxisonthechuck internalcoolantsupplyviafluteson theshank internalcoolantsupply(=IK) withaxialcoolantoutlet(=KA) internalcoolantsupply withradialcoolantoutlet(=KR) Externalcoolantsupplyisthemost commonmethodandworksinmost cases.Whenmachiningblindholethreads vertically,thecoreholefillswithcoolant (withtheexceptionofverysmalltool diameters)andthisfacilitatesthethread machiningprocess. Whenproducingthrough-holethreads, thecoreholeisunabletobefilledbecauseduringthreadtappingthechipsare transportedinthefeeddirectionand duringthreadformingnochipsare created;neverthelessthecoolantmay stillbeabletopenetraterighttothe chamferindeepthreads.Thecoolantflow shouldbesetascloseandparallelas possibletothetoolaxis. Supplyingthecoolantexternallybecomes difficultwhendeeperthreadsarebeing machinedwiththespindleinahorizontal position.Thecoolantcannotpenetrate righttothecuttingedgeinthiscase.The removalofchipsalsohindersthesupply ofcoolantduringblindholetapping. Thesupplyofcoolantparalleltotheaxis viacoolinggroovesintheshankhas significantadvantages,becausethe coolantisalwaysreliablysuppliedtothe cuttingedgeregardlessofthetoollength. Itmustonlybenotedthatastherotation speedsincreases,thecoolantisflung awayradiallyifthecoolantpressureistoo low. Theinternalcoolantsupplyensuresthat thecoolantreachesthecuttingedgeat alltimes.Optimumcoolingandlubrication ofthecuttingedgeisalwaysguaranteed andinmanycasesaidschipremoval.
Material group
Material
Thread cutting
Thread forming
Thread milling
Steel Steel 850 - 1,200 N/mm
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 5 - 10% or oil (Protofluid)
Emulsion
Grey cast iron GG
Emulsion 5% Emulsion 5% Emulsion 5 - 10%
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%
Dry Emulsion/MQL/ air blast Emulsion
S
Nickel alloys
Emulsion
Steel >49 HRC
Dry/MQL
Synthetics
Emulsion/MQL
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Cooling and lubrication Thread tapping

Therearetwocaseswhichapplytoblind hole tapping:
Cooling and lubrication Thread milling

Wetmachiningisgenerallyrecommendedforthread milling,howeveritshould onlybeappliedifevenlydistributed coolingcanbeguaranteed,otherwisethe emergingthermalshocksleadtothe formationofmicrocracks,whichinturn resultinfracturesandthisreducesthe toollife.Wetmachiningwithanexternallysuppliedlubricantoftenmeansthat evenlydistributedcoolingcannotbe guaranteed.Drymachiningwithcompressedairisgenerallypossiblewhen threadmilling,howeversometoollife islost. Whenblindholemachining,itisgenerally recommendedtouseatoolwithanaxial coolantoutlet.Thebestoptionistouse emulsion.Nothermalshocksoccur becausethetooliscompletelysubmerged.Inaddition,theflowofcoolant aidschipremovalandthereforeensures thattheprocessisreliable.Alternatively, internallysuppliedcompressedairorMQL canalsobeusedhere,howeverthis resultsinashortertoollife.Theuseof externallysuppliedemulsionwhenproducingblindholethreadsisnotrecommended,becausechipsmayaccumulate inthecoreholeandthishasanegative effectonthetoollife.Moreover,thereis anincreasedriskofthermalshocksif externallysuppliedlubricantisused. Externallysuppliedemulsion,MQLor compressedairisrecommendedfor producingthroughholethreads.Wet machiningmayneverthelessleadto problemshere,becauseexternallysuppliedcoolantcannotalwaysguaranteean evencoolingofthetool.Withsmall threaddimensionsinparticular,thereisa riskoftheexternallysuppliedcoolantnot beingabletoenterthenarrowholefully, withtheresultthatevencoolingofthe toolcannotbeguaranteed. Comment: Whenthreadmilling,havingno coolingislessofaproblemthan intermittentcooling.
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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Cooling and lubrication Thread forming

Coolingandlubricationinparticularareofcentralimportancewhenthreadforming. Insufficientlubricationcausesasharpdropinthesurfacequalityofthethread,as thesephotographsshow: Therearefourdifferentcasestoconsiderforthetooldesign:
flakedsurfacefrominsufficient lubrication;Remedy:Lubrication grooves
smoothsurfacefromexcellent lubrication
Therearebasicallytwodifferingtypesoftools:Thread formers with lubrication grooves and thread formers without lubrication grooves.Thedifferentareasof applicationareexplainedbelow.
Vertical blind hole machining Lubricationgroovesandinternalcoolant supplyarenotrequired;externalcoolant supplyissufficient(KAisrecommended forverydeepthreads).
Vertical through hole machining (> 1.5 x DN) Lubricationgroovesarerequired;internal coolantsupplyisnotnecessary.Externally suppliedcoolantcanpenetrateintothe threadprofilethroughthelubrication grooves(KRisrecommendedforvery deepthreads).
withoutlubrication grooves
withlubrication grooves
Horizontal blind hole machining Lubricationgroovesandinternalcoolant supplyarenecessary.Axialcoolantoutlet issufficient.
Theareaofapplicationfortoolswithout lubricationgroovesislimitedto: steelsheetextrusions throughholethreadsupto1.5xDN (becausecoolantcannotaccumulatein thecorehole) blindholethreadswhenmachining vertically(KAisrecommendedforvery deepblindholethreads)
Lubricationgroovesensureuniform lubricationevenatthebottomofthe threadwhichiswhythreadformerswith lubricationgroovescanbeuseduniversally.Verticalthroughholethreadsupto approx.3.5xDNcanbeproducedwith lubricationgroovesevenwheninternal coolingisnotused.
Horizontal through hole machining Lubricationgroovesarerequired.Internal coolantsupplywithradialoutletisrecommended.
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Minimum quantity lubrication

Coolantisusedinmachiningoperations toreducetoolwear,todissipateheat fromtheworkpieceandmachine,andto aidchipbreakingaswellaschipremoval. Moreover,theremnantsofchipsare removedfromtheworkpiece,toolandthe fixtures.Allofthesefactorsareimportantprerequisitesformanufacturinginan efficient,trouble-freeandcost-effective manner. Nevertheless,thecostsforprocuring, maintaininganddisposingofcoolant continuetorise.Thepoorenvironmental compatibilityoflubricantsandtheheath riskstheyrepresentformachineoperatorsareunderincreasingscrutiny.As statedonpage7,thecostsassociated withlubricantsamounttoapprox.16%of thetotalproductioncosts.Reducingthe consumptionoflubricantsforeconomical andenvironmentalreasonsistherefore veryimportantforsuccessfulcompanies whoareworkingtowardsustainability. ThisplancanbeachievedusingMinimum QuantityLubrication(MQL).WithMQL machining,asmallamountofhighly effectivelubricantisaddedtothecompressedair.Evenwithverysmalldosesof lubricant(approx.5-50ml/hr),weld formationsonmaterialsthattendto causejammingcanbeprevented.In addition,MQLcanbeusedtoreduce frictionwhichinturnreducestheprocess temperature. Inthemostsimplecase,thelubricantis suppliedexternally.Thismethodcanbe retrofittedinexpensivelytoexisting machines,howeverthelimitisreached withthreadsthathaveadepthgreater than1.5xDN.Itisbettertosupplythe lubricantthroughthespindleandthis shouldbetakenintoconsiderationwhen purchasingmachines. ThemodifiedtoolrequirementsforMQL mustbetakenintoconsiderationwhen thetoolsaredesigned.Forexample,the toolsmustbedesignedsothataslittle heataspossibleoccursduringmachiningsmallorevennegativerakeangles arethereforetobeavoided.Similarly,the geometryistobedesignedsothat reliablechipremovalcanbeachieved withoutthesupportiveeffectofalubricant.Thecoatinginparticularplaysa centralroleinMQLmachining,because thehardmateriallayertakesonthe lubricationfunctiontoalargeextent. Furthermore,thecoatingreducesfriction aswellasinsulatingthetoolagainstheat. Atthreaddepths>1.5xDN,theprerequisiteforMQLisaninternalcoolantsupply witharadialoutlet.Furthermore,the coolantchannelsinthetoolmustbe designedsothattheoil-airmixturedoes notbecomeseparated. ForMQLmachining,WalterPrototyp recommendsthespeciallydevelopedTHL coatingfortaps.Thiscoatingisavailable asstandardforParadurEcoPlus(successortotheprovenParadurEcoHT), PrototexEcoHTaswellasforParadur andPrototexSynchrospeedtools.The THLcoatinghasalubricantlayerwhich ensuresverygoodfrictionbehavioureven withMQLandalsopreventsbuild-upon thecuttingedges.Thelayeriscontinuouslypolishedduringthecourseofthe tool'slife. TheProtodynEcoPlus,EcoLMand Synchrospeedfamiliesaresuitablefor minimumquantitylubricationwhenthread forming. Your advantages from MQL machining with Walter Prototyp tools: reductioninproductioncostsandan increaseincompetitiveness reductioninlubricant,maintenance anddisposalcosts reductioninenergycosts preventionofhealthrisksforemployees oftennocompromiseinperformance comparedtowetmachining trough-likecomponentsdonotfill withlubricant lesseffortrequiredforcleaning components Comment: Incontrasttothreadtappingand threadforming,drymachiningis generallypossiblewiththreadmilling, howeversomelossoftoollifehasto beaccepted.Ifworkingdry,theuseof anairblastisrecommendedforchip evacuation.Whenthreadmilling,itis oftenbettertouseMQLinsteadof wetmachining,becausethetoolis notsubjecttothermalshocks.
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
Notes: High-tensileandhardenedmaterialscanbemachinedwithMQLduringthread milling. Inpractice,theremaybecaseswheretheabove-mentionedclassificationdoes notapply.
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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.
Important types of tool adaptors for taps and thread formers
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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Important types of tool adaptors for taps and thread formers
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
Shrink-fitchucks,colletchucksandWeldon chucksareinthestandardproductrange fromWalter.
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Synchronous machining for tapping and forming threads

Toreducetheprocesstimesinthread tappingandthreadforming,manufacturersareincreasinglyfavouringhigher rotationspeedsandcuttingspeeds (HSC).Thesynchronousmachining approachisrecommendedespeciallyfor achievinghighcuttingspeeds. Synchronoustappingrequiresamachine thatcansynchronisetherotarymotionof themainspindlewiththefeedmotion. Thethreadingtooldoesnotguideitself usingitsgeometry,butiscontrolledsolely bythefeedrateandthespindlerotation speedofthemachine.Nowadays,most machiningcentresaresuitableforsynchronousmachining. Basically,alltapsandthreadformerscan beusedsynchronously.Nevertheless,the toolrangefromWalterPrototypknownas Synchrospeedhasbeendesignedspecificallyforsynchronousmachining.Thekey characteristicsofthesetoolsaretheir extremelyhighflankclearanceangle,as wellastheirextrashortthreadingsection. ToolsintheSynchrospeedfamilycanonly beusedsynchronously.Incontrast,the toolsintheEcofamilyachieveverygood resultsbothsynchronouslyandconventionally. Synchronoustapsarecompatiblewith conventionalWeldonchucksaswellas colletchucks(wherepossiblewithsquare drive).Bothfixtureshavethedisadvantageofbeingunabletocompensatefor theaxialforcesthataregenerated. AbetteralternativeistheProtoflexCtappingchuckwithminimumcompensation. ProtoflexCisatappingchuckformachiningcentreswithsynchronouscontrollogic. Itguaranteesapreciselydefinedminimum compensationandismatchedtothe geometryofSynchrospeedtools. What is so special about Protoflex C? Unlikeconventionalsynchrotapping chucks,theProtoflexCdesignisbased onaprecision-machinedflexorwith highspringrate,whichcompensatesfor positiondeviationsinthemicronrange bothradiallyandaxially.Thepatented microcompensatorismadefromaspecial alloyoriginallydevelopedforNASAandis characterisedbyalongservicelifeandis maintenance-free.Conventionalsynchro chucksuseplasticpartsforthispurpose, buttheselosetheirflexibilityovertime,. Microcompensationisthennolonger provided. TheProtoflexCtappingchuckhelpsto considerablyreducethepressureforces thatactontheflanksofthetap.This resultsin: greaterprocessreliabilitythankstothe reducedriskofbreakage,particularly wheredimensionsaresmall alongertoollifeduetolessfriction improvedsurfacequalityontheflanks ofthethread ForcustomersusingtheProtoflexC tappingchuck,thismeansextremelyhigh productivitywhilesimultaneouslyreducing thetoolcosts,andthisistrueforboth threadtappingandthreadforming.
ProtoflexCsynchronoustappingchuck
Flexorwithminimumcompensation
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Notes on the core hole

Depth of the core hole Drillingdepthusablethreaddepth(+chamferlength)+safetymargin
Drillingdepth
Special notes on thread forming Comment: Therecommendeddiameterofthecoreholeismarkedon theshankofWalterPrototypthreadformers.
Drillingdepth
Thread depth Chamfer Safetymargin (~2threads)
Thread depth
Thread tapping, thread forming
Thread milling Whenselectingthedrillingandboringtool,thepermissible tolerancesforthecoreholelistedinthetablebelowmustalsobe notedtoensureareliableformingprocessandasuitabletoollife. neitherachamferareaoratip,which makesitpossibletohavethreadsthat almostgotothebottomofthehole. Miscuttingisexcludedfromthemilling processwhichiswhyanadditionalaxial safetymarginisnotnecessary.
Comment: Anyexistingtiponthethreadingtool mustbetakenintoaccountwhen calculatingtherequireddepthofthe corehole.Hereadistinctionmustbe madebetweenafullpointanda reducedpoint.Incontrasttotapsand threadformers,threadmillshave
Thread pitch 0.3mm >0.3mmto<0.5mm 0.5mmto<1mm 1mm
Tolerance of pilot drill diameter 0.01mm 0.02mm 0.03mm 0.05mm
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
Basedonthesetoleranceswhichincontrasttothreadcutting aretighter,threadformingisnotalwaysmoreeconomicalthan threadtapping.
Practical tip: Inthreadforming,thecorediameter ofthethreadiscreatedduringthe formingprocessandistherefore dependentontheflowcharacteristics ofthematerial.Incontrasttothis,the corediameterforthreadtappingand
threadmillingisalreadydeterminedby thecorehole.Aftertheformingprocess,itisthereforeabsolutelyessential togaugethethreadcorediameter.The tolerancesoftheinternalthreadcore diameterarelistedonpage116.
Comment: TheproductrangefromWalterTitexisalignedwiththepilotholediametersfor tappingandformingthreads.

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Increased edge zone hardening

Oftentheproductionofthreadsisseen asastand-aloneprocess.Thisisnot advisablebecausetheprecedingdrilling operationhasasignificantimpactonthe subsequentthreadingprocess. Whenthecoreholeisdrilled,theedge zoneoftheworkpieceiseffectedmechanicallyandthermally.Theresulting structuralchangescanbeseeninthe twophotomicrographs:
0.025mm
Newdrill: edgezoneisnearlyunchanged
Worndrill: influenceoftheedgezone
Thehardnessoftheedgezoneissignificantlygreaterusingaworndrillthan usinganewtool.Usinghighercutting parameterswhendrillingleadstoincreasedhardnessoftheedgezone.Even thoughtheincreasedhardnessonly occurswithinaverysmalldistancetothe holesurface,thiscausesasignificant reductioninthetoollifeofthethreading tool(comparetheexamplebelow).
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
Practical tip: Ifproblemsoccurwiththetoollife,in additiontoconsideringtheprocess usedtoproducethethreads,give considerationtotheprecedingdrilling processandthedrillingorboringtool itself.
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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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Chamfer forms based on DIN 2197

Please note: longerchamfersincreasethetoollife longerchamfersreducethecuttingedgeloadwhichgainsimportanceasthe m aterialstrengthincreases shortchamfersenablethreadstoalmostreachthebottomofthehole longerchamfersincreasetherequiredtorque
Form Threads per chamfer 6-8threads 6 8 Gnge
6 8 Gnge 6 8 Gnge
Chip cross sections

Forthroughholethreads,usuallylonger chamferformsareused. Long chamfer (e.g. form B) results in: longertoollife hightorque smallchipcross-section lowstrainonthechamferteeth
Execution and application short-chipping materials straight-fluted shortthroughholethread inmediumandlongchippingmaterials
3.5-5.5threads straight-fluted withaspiral point

6 8 Gnge
mediumand long-chipping materials
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
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Chip cross sections

Forblindholethreads,shorterchamfer formsareusuallyselected.Thisis justifiednotonlybythefactthatthe threadshouldoftenreachthebottomof thehole. Theshearingofthechipintheblindhole threadpresentsaparticularproblem.If thechipbecomestoothin,itsimply flattensduringreverseactionandcanno longerbecutthrough.Thechipbecomes trappedbetweenthecomponentand chamferflankface.Thismaybreakthe toolandthisiswhylongchamfersin formA,BandDarenotsuitableforblind holethreads,astheseformsproduce thinchips.
Cutting process for blind hole threads

Thetaphasbeencuttingandnowcomestoastop.Atthisvery moment,allcuttingedgesinthechamferarestillintheprocess offormingachip.
Thetoolbeginstoreverse.Thechipsremainwheretheyarefor thetimebeing.Thereversetorqueatthispointisvirtuallyzero.
Anadvantageofshortchamfersisthat fewerchipsareproduced.Inaddition,the largerchipcrosssectionisfavourablefor chiptransport. Short chamfer (e.g. form E) results in: lowtorque largechipcrosssection increasedstrainonthechamferteeth shortertoollife optimisedchiptransport
Thechipscomeintocontactwiththebackofthetrailingland ofthetap.Thereversetorquenowincreasessharply.Thechip hastobeshornoff.Asthechamferofthetaphasaclearance angleandwithdrawsfromthethreadaxiallywhenitbacksoutof thehole,itisinevitablethatthepurchasepointwillnolongerbe directlyattherootofthechip.Forthisreason,thechipwould requireacertainamountofstability(thickness)tobecut.
Form E
Thechiphasbeenshornoffandreversetorquedecreasestothe frictionbetweentheguideandthecutthread.
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1st land 2nd land 3rd land
Comment: Throughholetapscannotbeusedfor blindholemachining,becausethese haveahigherchamferclearanceangle andthechipmightnotbeshearedoff, butinsteadgetjammedbetweenthe chamferandthethread.Thiscould leadtospallingonthechamferand, inextremecases,tapbreakage.
Thechamferclearanceangleofblind holetapsisalwayssmallerthanthat ofthroughholetaps,becauseblind holetapsmustshearoffthechiproot duringreverseaction.
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Cutting process for blind hole threads

Torque curve during the blind hole thread tapping process
Angles and characteristics on the tap

Detail A
Neck Thread diameterDN Shank Shankdiameterd1
Detail B
HeadlengthLc Functionallengthl1 Squarelengthl9
Detail A
Flankangle Lead
Detail B
Md
Spindlebraking
Time p rogression
Corediameter Outsidediameter Pitchdiameter
Flankclearanceangle
Rootface(land) Slightincrease causedby a dditional f rictionin theguide Coefficientof frictioninthe guidepartof thetapduring reverseaction Rake (rakeface) Corediameter Chamferclearance angle
Rakeangle
Spindlespeedreaches zero,thespindlebegins toreverse
Hightorquepeaksindicate problemswithshearing offthechip;atoolwitha smallerchamferclearance angleshouldbechosen
Throughholetap withaspiralpoint
Chamferangle Spiralpoint angle
Blindholetap witharight-handhelix
Helixangle Chamferangle
Chamferenters: sharpincreasein torque
Firstcontactmadebetween remainingchipandbackof trailingland
Spiralpointlength
Lubrication grooves
Flute
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Comparison of geometry data

Asmallerrake angle: increasesthestabilityofthecutting edges(fracturesaroundthechamfer mayoccurwithlargerakeangles) normallyproduceschipsinamore controlledmanner producespoorersurfacesonthe component increasesthecuttingforcesandthe cuttingtorque isrequiredformachiningharder m aterials increasesthetendencytocompress thematerialtobemachined,i.e.thetap cutslesscleanlyandthereforeproducesslightlytighterthreads
Rake angle of blind hole tools
Paradur HT
Paradur TiPlus
Paradur EcoCI
Paradur HSC
Paradur XpertM
Paradur EcoPlus
Flank clearance angle: Theflankclearanceanglemustbe matchedtothematerialtobemachined. Materialswithahighertensilestrength andmaterialsthattendtocausejamming requirealargerflankclearanceangle.The guidancecharacteristicsofthetoolworsenastheclearanceangleisincreased, whichiswhymiscuttingoccursinsoft materialsiffloatingchucksareused.
Flank clearance angle of blind hole tools

ParadurXpertP ParadurWLM ParadurEcoCI ParadurXpertM ParadurHT ParadurEcoPlus ParadurHSC Paradur Synchrospeed ParadurTiPlus
Paradur Synchrospeed Paradur XpertP
ParadurWLM
Rake angle of through hole tools

PrototexEcoHT PrototexHSC PrototexTiNiPlus ParadurEcoCI Prototex Synchrospeed PrototexXpertP PrototexXpertM
Practical tip: Check the flank clearance angle Atapshouldscreweasilyintothe previously-cutthreadwithoutany recutting.Ifthisisnotpossible,a tooltypewithalargerflankclearance angleshouldbeselected.
Flank clearance angle of through hole tools

PrototexXpertP ParadurEcoCI PrototexXpertM PrototexEcoHT PrototexHSC
Alargerhelix angle: supportschipremoval reducesthestabilityofthetooland thislimitsthemaximumcuttingtorque reducesthestabilityoftheteeth reducesthetoollife
Helix angle of blind hole tools

Paradur EcoCI
ParadurHT ParadurTiPlus ParadurHSC ParadurWLM Paradur Synchrospeed ParadurXpertM ParadurEcoPlus ParadurXpertP
Spiral point angle: Thespiralpointangleislimitedbythe chamferlengthandnumberofflutes, becausewithalargerspiralpointangle, thelandwidthinthefirstthreadofthe chamferisreduced.Thiscausesthe stabilityofthecuttingedgetodecrease (theriskoffracturesaroundthechamfer increases).Anincreasedspiralpointangle facilitateschipremovalinthefeed direction.Ifthespiralpointangleistoo small,chipremovalbecomesproblematic. Left-handhelicaltoolsprovideasolution forthis.
Prototex Synchrospeed PrototexTiNiPlus
Spiral point angle of through hole tools

PrototexHSC PrototexTiNiPlus PrototexXpertM PrototexEcoHT Prototex Synchrospeed PrototexXpertP
Chamfer clearance angle: Throughholetapshaveapprox.3-times aslargeachamferclearanceangleas blindholetaps.Seepage80forthe reasonforthis.

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Special features of thread tapping

Recessed and deep blind hole threads wherepossibleusestraight-flutedtapswithaxial coolantsupplyorblindholetapswithasteephelix angleandabrightorvaporisedrake: ParadurHT(straight-fluted) ParadurSynchrospeedwithTin/vapcoating (helical) forstainlesssteelsandingeneralwerecommend threadformingasaproblemsolver;spiraltapsare absolutelyessentialfortappingthreadsinstainless steels: Threadforming:ProtodynSEcoInox Threadtapping:ParadurXpertM Inclined thread lead-out usetapswithaverylongguideandmaximum stability (e.g.PrototexXpertP,PrototexXpertM) Inclinationsofupto30arerelatively u nproblematic alternative:Threadmilling
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
Slotted threads slottedthreadsshouldbemachinedwithtoolswith ahighhelixangle: ParadurXpertM ParadurXpertP ParadurEcoPlus
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Process forces in thread tapping

Workpiece-relatedaxialforcesoccur whencuttingthreads.Right-handhelical tapsaresubjecttoanaxialforceinthe feeddirection.Ontapswithaspiralpoint, thisforceactsagainstthefeeddirection.
Programming the feed if floating chucks are used

Iftappingchuckswithlengthcompensationareused, theworkpiece-relatedaxialforceswhichoccurduring machiningmustbetakenintoaccount. Spiral blind hole tapscreateanaxialforceinthe feeddirection.Thisforcemustbecounteredwith minusprogramming.
Directionofrotation Cuttingforce Axialforce Radialforce
axialforcefrom thetool Processforcesinright-hand helicaltaps Processforcesintapswith aspiralpoint
machineprogrammed at90-98%
Theusualfeedvaluesforthisapplicationliebetween 90and98%ofthetheoreticalfeed.Thetheoreticalfeedratecanbecalculatedusingthefollowing formula:
Iffloatingchucksareused,theseaxial forcescancausethethreadtobecuttoo largethisisknownasaxialmiscutting. Thetendencytowardaxialmiscuttingis
increasediftoolswithahighhelixangle andalargeflankclearanceangleareused insoftmaterialsorifthecuttingedge treatmentisinappropriate.
vf=nxp
n=rotationspeed;p=threadpitch
Workpiece
Tap
Workpiece
Tap
Theconditionsarereversedwithleft-hand helical toolsandwithtaps with a spiral point,causingthe axialforcestoactagainstthefeeddirection.
Axialmiscuttingofthethread causedbyright-handhelicaltools: miscuttingofthebottomface oftheflank
Axialmiscuttingofthethread causedbyleft-handhelicaltapsor tapswithaspiralpoint:miscutting ofthetopfaceoftheflank
axialforcefrom thetool
machine rogrammed p at100%
Foradditionalinformationonmiscutting andforcountermeasures,seepage91 (Problemsandsolutionsforthreadtapping).
Programmingthetheoreticalfeedrate isrecommendedhere.
86
87
Modifications
Negative chamfer (Secur chamfer) Reduced helix in the chamfer Inclined thread
Shortened chamfer
Bright rake
Chip formation
Chipsarerolledmore tightly,shorterchips
Chipsarerolledmore tightly,lesschips
uncoated:
Nochange
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
Standard tools with appropriate modification
increases
remainsunchanged
decreases
decreasessharply
88
89
Problems and solutions

Chip control: Chipcontrolisamajortopicwhentapping blindholes,particularlywithdeepblind holesintough,long-chippingmaterials. Problemswithchipcontrolcanbeseen insnarlchips,randomlyoccurringtorque peaks,toothfracturesintheguideand/or totalbreakage. Remedy: Standardtapscanbemodified*ornew designscanbecreatedtooptimisechip control: In general, the following is true: Thehigherthematerialstrengthand thelowertheelongationatfracture ofthematerial,thegreaterthechip controlis.Chipcontrolismostdifficultwithsoftstructuralsteels,low alloysteelsandstainlesssteelswith alowtensilestrength. Themoreinterferencetochip formationfromtheaforementioned measuresresultsinaworseningof thequalityofthethreadsurface.For thisreason,itisessentialtomatch themeasureswiththecustomers requirements. Miscutting: Thegeometryoftapsiscustomisedto certainapplications.Ifusedimproperly, tapscanproducethreadsthataretoo largethisisknownasmiscutting. Tapsthatmiscutforthereasons mentionedabovesystematicallyproduce threadsthataretoolarge.Sporadic miscuttingmayoccurifsingle-sided radialforcesactonthetoolduetochip packingorbecauseofweldformations onthematerialthisisknownasradial miscutting.
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.
Comment: Miscuttingduringthreadforming, threadmillingandsynchronous threadcuttingislargelyexcluded.
Exampleoffracturesduetochipcontrol problems
Axiallymiscutblindholethreads
Axiallymiscutthroughholethreads
*Themodificationsareexplainedfullyandclearlyshownonpages88-89. 90 91

Thread surface: Thethreadsurfaceisdeterminedby: theproductionprocess:cutting, f orming,milling thewearonthetool thegeometry thecoating thematerialtobemachined thecoolantanditsavailabilityinthe operatingareaofthetool Comment: Inthreadcuttingandthreadforming,thereisalmostnopossibilityto influencesurfacefinishqualityusing thecuttingdata.Incontrasttothis, thecuttingandfeedratescanbe selectedindependentlyofeachother forthreadmilling. Wear: Ahighlevelofhardnessensuresahigh resistancetowearandthusalongtool life.Anincreaseinthehardnessnormally leads,however,toreducedtoughness. Ifsmalldimensionsandhighlyspiralled toolsareused,ahighleveloftoughnessisrequired,becauseotherwisetotal breakagecanoccur. Thehardnessofthetoolcannormallybe increasedwithoutdifficultyforthread formers,straight-flutedandlow-spiralled tools,aswellasformachiningabrasive materialswithalowtensilestrength.
Exampleofabrasivewear
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
92
93
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
Boththepull-outstrengthunderstatic loadaswellasthefatiguestrength underdynamicloadincreasessignificantlyduetocoldworkhardeningused incombinationwiththeuninterrupted
Formfolds
Comment: Comparedtothreadtappingand threadmilling,thetoleranceofthe coreholeistighterinthreadforming. Threadformingisthereforenot alwaysthemoreefficientoptionin allcases.Examiningindividualcases isthereforeabsolutelyessential. Refertopages70-71fortheformulasrequiredtocalculatethecore holes.
Pleasenotethatintheareaofthecrest onformedthreads,thereisalwaysa formfold.Forthisreason,threadforming isnotpermittedinallindustries.Specific restrictionsarelistedadjacently.
foodindustryandmedicaltechnology (germformationintheareaaroundthe formfold) automaticcomponentscrewconnections(screwmayjamintheformfold) notpermittedintheaircraftindustry
94
95
Influence of the pilot hole diameter

Thepre-drilleddiameterofthecorehole hasalargeinfluenceonthethread formingprocess.Ontheonehand,the requiredtorqueandthetoollifeofthe threadformerareaffected,butonthe otherhand,theformationofthethread isalsoeffected.Thegraphicillustrates theserelationshipsclearly. Largercorediametersarepermittedfor threadsformedaccordingtoDIN13-50 thanforthreadtapping.Forexample,for athreadformedwithtoleranceclass6H, theminimumthreadcorediametermust complywithtoleranceclass6H,however themaximumthreadcorediameteris basedontoleranceclass7H.Thiscorrelationisshownbywayofexampleinthe diagrambelow.
Example for the permissible core diameter based on the dimension M6-6H Thread tapping
Toollife
Thread forming 5,217
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
Diameter of the core hole
min* max*
Minimum Maximum corediameter corediameter 6H 7H
*ToleranceofthecorediameterproducedasperDIN13-50
Example:M16x1.5-6H,42CrMo4;Rm=1100N/mm2 Pilotdrill:15.22mm >Core:14.37mm Pilotdrill:15.3mm >Core:14.51mm Pilotdrill:15.34mm >Core:14.62mm
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.
96
97
Modifications
Diagram Action Side effect

Ingeneral,threadformingisextremely reliable.Thefulladvantagesofthread formingareachievedifthreadtappingis usedtoproducedeepblindholesinsoft andtoughmaterialsinwhichproblems withchipremovalaremorelikelytooccur. Forthisreason,threadformingcantruly beseenasaproblemsolver. Itisafortunatetechnicalcoincidence thatpreciselythematerialsthatmost frequentlyhaveproblemswithchipping, suchasSt52,16MnCr5,C15,canbe formedwell. Threadformingisalsoadvantageousifa veryhighsurfacefinishqualityisrequired. Thedepthsofsurfaceroughnessof formedthreadsarenormallymuchlower thanthoseofcutthreads. Despitetheadvantagesthatareachieved throughthenon-chippingproductionof threads,therearealsospecificpoints aboutthreadformingthatmustbenoted inordertoguaranteeareliableprocess: thepilotdrilldiameterhasatight tolerance(e.g.M60.05mm)comparedtocuttingthreads nochipsfromdrillingarepermittedto remaininthecorehole;thiscanbe ensuredusingatwistdrillwithinternal coolingorusingathreadformerwith axialcoolantoutlets;inthelattercase, thethreadformershouldbepositioned overthecoreholeforashortperiod withcoolantonbeforeformingstarts therequiredtorqueforformingthreads ishigherthanitisfortappingthreads; thechucksettingvalueisthereforeto beincreasedwhererequired moreattentionmustbedevotedtothe coolantandthesupplyofcoolant duringforming;theeffectsofbriefly runningdryaregreaterthanwith cuttingthreads.Thishastodowiththe highersurfacepressureactingonthe formededgesandthefactthatthe lubricationgroovesusedinforminghave anarrowercross-sectionthanthe flutesoftaps.Thesmallerlubrication groovesgivethethreadformergreater stability,whichisalsorequireddueto theincreasedtorque.Largerlubrication grooveswouldcausetheformededges tocrackeasilyduetothehigherforces applied.Detailedinformationoncorrect coolingandlubricationcanbefoundon page60. thecoefficientoffrictionofeach coatingisreducedasthetemperature increases;higherformingspeedscan thereforeleadtolongertoollife well-knownautomotivemanufacturers oftenstipulatethatthethreadsmust complywithaspecificthreadoverlap standardtoolscannotalwaysguarantee thiswithreliability Comment: WalterPrototypisabletomeet thespecialprofilerequirementsof automotivemanufacturersreliably.
Chamfer form D
longertoollife
slightlyincreased cycletime
Chamfer form E
threadsalmostto thebottomofthe holeandslightly shortenedcycle time
decreasedtoollife
Radial coolant outlets
improvedcooling andlubrication conditions(fordeep threadsanddemandingmaterials)
highertoolcosts
Lubrication grooves on the shank
bettercooling andlubrication conditions(notas efficientasradial coolantoutlets)
Increased total length
machiningofareas thataredifficultto access
coatingmatched tothespecific a pplication
potentiallyhigher toolcosts
98
99
TechnicalinformationThreadmilling

Borderline cases for thread forming: Itisdifficulttosetclearmaterialstrength Formfolds Theunavoidableformfoldsoccurringon limitswithforming,becausethereare thecrestofthethreadmaybecome alwaysexceptionswherelimitshavebeen problematicifautomatedprocessesare exceededsuccessfullyornoteven usedtoscrewinbolts.Thefirstthread reachedatall. pitchesaresometimesthreadedinto theformfold. Tensilestrength Formedthreadsincomponentsusedin Thelimitisapprox.1200N/mm thefoodindustryandmedicaltechnoldependingonthematerialandthe ogyarealsoavoided,becauseitisnot lubricationconditions.Nevertheless, possibletoreliablyeliminatecontamitherearenotablecasesinwhich nationintheformfoldcausedby formingcouldbeperformedsuccesswashing. fullyonstainlesssteelusingHSS-E threadformersandonhard-to-cut Inconel718usingsolidcarbidethread formers.Bothmaterialshadatensile strengthofapprox.1450N/mm. Elongationatfracture Ingeneral,aminimumvalueof7%is specifiedfortheelongationatfracture. Nevertheless,therearealsonotable casesheretoo,inwhichforexample GGG-70hasbeenformedwithan elongationatfractureofabout2%. However,inthiscasetinycracksinthe flankswereclearlyevidentwhichthe usercouldaccept.Insuchcases,an increasedstrengthduetoforming shouldnotbeassumed. Pitchandthreadprofile Withpitcheslargerthan3to4mm,the limitsfortheabove-mentionedtensile strengthsmustbecorrecteddownwards.Threadtypeswithsteepflanks (e.g.30trapezoidalthreads)mustbe examinedasanisolatedcase. Sicontent AlSialloyscanbeformedifthesilicon contentisnotgreaterthan10%. Nevertheless,therearealsonotable casesinwhichtheSicontentwas 12-13%.However,thisloweredthe surfacefinishqualityandthepull-out strengthofthethread.
100
Process principles
Basic aspects of thread milling: amachinetoolwitha3DCNCcontrol systemisrequired(moreorlessa standardtoday) conventionalthreadmillingtoadepth of2.5xDNispossible,orbitalthread millingtoadepthofapprox.3xDN
highercostscomparedtothread tapping millingthreadswithasmallpitchanda largedimensionisoftenquickerthanif threadtappingandthreadformingis used
Incontrasttothreadtappingandthreadforming,thepitchisproducedinthread m illingbytheCNCcontrolsystem.
P=Ppitch Ph=pitchheight=Ppitch
Comment: WalterPrototypisabletodesign specialtoolsinwhichtheform foldscanbeclosedunderspecificconditions.Therearenotable casesinwhichcustomerswho initiallywereagainstusingthread formingdecidedtopermititfor thisreason.
Thread tapping:ThethreadpitchPisproduced bythetap/threadformer.
Thread milling:ThethreadpitchPis producedbytheCNCcontrolsystem (circularprogram).
Threadprofile madewitha standardformer
Threadprofile madewitha specialformer
Theoretically,aninternalthreadmilling cuttercanalsobeusedtoproducean externalthread.Thethreadsproducedin thiswaydonotcomplywiththestandard, becausetheexternalthreadsarerounded tominimisethenotcheffectinthecore andtheexternaldiameterproducedis toosmall. However,becausethethreadringgauge teststhethreadonthepitchdiameter, thegaugeaccuracyismaintained.
screw
nut
Aerospaceindustry Threadformingisnotpermittedinthe aerospaceindustry.Changestothe structurethatoccurduringthread formingorweldingareavoidedin general.
101
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.
Comment: Therelationshipispreciselytheother wayaroundwhenmillingexternal screwthreads.
Threadtapping
Torque
Threadmilling
Contour feed (vf) Mid-point path (vm)
Thread size
= na D omi n
d= mill
Threadmillingisanextremelyreliable productionprocess. Shortchipsarenormallyproduced, whichiswhychipremovalisunproblem-
atic.Moreover,specialchucksarenot requiredforthreadmilling,andnearlyall standardmillingchuckscanalsobeused forthreadmilling.
Therearetwofundamentallydifferentmillingprocesses:
Up-cut milling fromtoptobottominright-handthreads) Up-cutmillingispreferredwhenmachining hardenedmaterials,orasaremedyagainst conicalthreads.
Synchronous milling (fromthebottomtothetopinright-hand threads) Synchronousmillingincreasestoollifeand preventschattermarks,whilepromotingthread conicity.
WalterGPSautomaticallyreducesthis whentheCNCprogramiscreated.Some CNCcontrolsystemsalsoreducethefeed automaticallyforthesamereason.Reductionofthefeedrateonthecircularpath mustthenbedeactivatedintheCNCprogramusingtheappropriateGcommand. ThecycletimecalculatedbytheGPScan becomparedwiththeactualcycletimein ordertodeterminewhetherthemachine automaticallycorrectsthefeed.
Practical tip: Theprogramcanbetestedduring feed-inwithoutoperationalengagementinordertodeterminewhether themachinetoolcorrectsthefeed automatically.Acomparisonofthe actualcycletimewiththetimedeterminedbyWalterGPSshowswhether thefeedmustbeadjustedintheCNC program.
Comment: WalterGPSautomaticallydeterminestherightprocessforthe relevantapplicationandtakesintoaccountthespecificdetails relatingtothetoolandthemachine.
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103
Process principles
Thecutscanbemadeinanumberof passesinordertoreducetheradialforces actingonthetool:
Axial passes
Comment: Ensurethatthethreadmillisalways movedbyamultipleofthepitchwhen makingaxialcuttingpasses.
Thecuttingforcesnormallydeflecta threadmilllessattheshankthantheydo atthefrontcuttingedge.Thisresultsin conicalthreads.Withaconventional threadmill,itisthereforenecessaryto
calculateaconicityofapprox.1/1000mm foreachmmofthreaddepthwhen machiningsteel.Thisisduetotheradial forcesactingonthethreadmill.
theoreticalcontour
actualcontour 1stcut 2ndcut
Radial passes 3/4 1stcut Up-cutmilling 4/4 2ndcut Climbmilling 1stcut 2ndcut
Advantages: longerthreaddepthscanbeproduced reducedriskoftoolbreakage threadmillingispossibleevenwitha relativelyunstableclampingarrangement counteractsconicalthreads Disadvantages: increasedtoolwear higherproductiontime
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).
104
105
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
Comment: Thecloserthemillingcutterdiameterapproachesthethreadnominaldiameter andthehigherthethreadpitch,themorepronouncedtheprofiledistortionis.
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.
Comment: Becauseofprofiledistortion,specialthreadsandthreadswithsmallflankangles needtobeassessedfortechnicalfeasibility.
106
107
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
removaloftheincomplete threadpitchatthethread run-inareawithoutanadditionaloperation
firstthreadprofilelengthenedonthefaceside
chamferingofthecorehole
grindingoftheneck (necking)
enablesaxialcuttingpasses tobemadepracticalfor deepthreads
108
109

Problem Accuracy to gauge Conical threads Chatter marks Tool breakage
Cutting edge breakaway
Low tool life
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
Comment: TheuseoftoolsfromtheTMOfamilyareavery goodoptionforproducingcylindricalthreads.
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
110
111
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]
112
Core diameter for thread tapping and thread milling M

ISOmetriccoarsepitchthread Designation as per DIN 13 M2 M2,5 M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M27 M30 M36 M42 Internal thread core diameter (mm) 6H min 6H max 1,567 2,013 2,459 3,242 4,134 4,917 6,647 8,376 10,106 11,835 13,835 15,294 17,294 20,752 23,752 26,211 31,670 37,129 1,679 2,138 2,599 3,422 4,334 5,153 6,912 8,676 10,441 12,210 14,210 15,744 17,744 21,252 24,252 26,771 32,270 37,799 Drill (mm) 1,60 2,05 2,50 3,30 4,20 5,00 6,80 8,50 10,20 12,00 14,00 15,50 17,50 21,00 24,00 26,50 32,00 37,50 Nr.4-48 Nr.6-40
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
Designation acc. to ASME B 1.1 Nr.2-56 Nr.4-40 Nr.6-32 Nr.8-32 Nr.10-24

1 5 3 1
/4-20 /16-18 /8-16 /2-13 /8-11 /4-10
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
Designation acc. to ASME B 1.1
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
/4-28 /16-24 /8-24 /8-18
/2-20
Pipethread Abbreviation according to DIN EN ISO 228 G /8 G /4 G /8 G /2

5 G /8 1 3 1 1
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
Drill (mm) 8,80 11,80 15,25 19,00 21,00 24,50 30,75
G /4 G1
114
115
Thread forming core diameters M

metricISOcoarsepitchthread,tolerance6H Designation as per DIN 13 M1,6 M2 M2,5 M3 M3,5 M4 M5 M6 M8 M10 M12 M14 M16 Internal thread core diameter as per DIN 13 - 50 (mm) 6H min 7H max 1,221 1,567 2,013 2,459 2,850 3,242 4,134 4,917 6,647 8,376 10,106 11,835 13,835 1,707 2,173 2,639 3,050 3,466 4,384 5,217 6,982 8,751 10,106 12,310 14,310 Pilot drill (mm) 1,45 1,82 2,30 2,80 3,25 3,70 4,65 5,55 7,40 9,30 11,20 13,10 15,10
Hardness comparison table

Tensile strength Rm in N/mm2 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 Brinell hardness HB [Brinell HB] 50 60 80 90 100 120 130 150 165 175 190 200 215 230 250 270 280 300 310 320 340 350 370 380 400 410 430 440 450 470 Rockwell hardness HRC Vickers hardness HV 50 60 80 95 110 125 140 155 170 185 200 220 235 250 265 280 295 310 325 340 360 375 390 405 420 435 450 465 480 495 530 560 595 635 680 720 770 800 830 870 900 940 980 PSI 22 29 37 43 50 58 66 73 79 85 92 98 105 112 120 128 135 143 150 158 164 170 177 185 192 200 207 214 221 228 247 265 283
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
M6x0,75 M8x1 M10x1 M12x1 M12x1,5 M14x1,5 M16x1.5
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
116
117
Torque setting for tapping chucks

Recommended values for torque adjustment of tapping chucks
Torque setting value for cutting threads [Nm] 0,03* 0,07* 0,1* 0,15* 0,24* 0,3* 0,5 0,7 1,2 1,7 3 5,5 12 20 35 50 60 100 110 125 190 220 320 350 460 500 700 750 900 1000 1300 Fracture torque of tap [Nm] 0,03 0,07 0,1 0,15 0,24 0,3 0,6 1 1,6 2,3 5 8,1 20 41 70 130 160 260 390 450 550 850 1100 1600 2300 Torque setting value for forming threads [Nm] 0,07* 0,12 0,16 0,25 0,3 0,4 0,6 1 1,5 2,4 4 8 17 30 50 75 85 150 160 170 260 290 430 470 650
Conversion for other materials

Material Soft steel Steel 1200 N/mm Steel 1600 N/mm Stainless steel GG/GGG Aluminium/copper Ti alloys Ni alloys
2
Factor 0,7 1,2 1,4 1,3 0,6 0,4 1,1 1,4
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
1 1,2 1,4 1,6 1,8 2 2,5 3 3,5 4 5 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 42 45 48 52 56
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
Thetableisusedtosetthetorqueoftappingchucks,insofarasthesecanbeset.If thetorqueissettoohigh,thereisariskoftoolbreakage.Ifthetorqueissettoolow, thetoolcanbecomejammedduringmachining,howeverthemachinecontinuestorun. Ifatthispointthepressurecompensationisnotsufficient,thetoolisdestroyedand themachinecanbedamaged.
Basisfortheabove-mentionedtable:Material42CrMo4,tensilestrength1000N/mm, threaddepth1.5xDN.Usingtheconversiontable,thevaluescanbecarriedoverto othermaterials.
Withdimensionsmarkedwitha*,thetorquerequiredtoproduceathreadwithadepthof1.5xDN exceedsthefracturetorqueofthetool.Remedy:producethethreadinseveraloperations. 118 119
Notes
120

Walte-12-034 Gewinde HB en 150dpi

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Walter AG DerendingerStrae53,72072Tbingen Postfach2049,72010Tbingen Germany www.walter-tools.

Product handbook Threading

Precise, reliable, efficient

14 Product information 14 Threadtapping 28 Threadforming 34 Threadmilling

40 Tool selection 40 Threadtapping 44 Threadforming 46 Threadmilling

48 Technical information 48 General 74 Threadtapping 94 Threadforming 101 Threadmilling 112 Appendix

Alphabetical keyword index

Technology, trends and innovations in thread production

Productive processes with Walter Prototyp

Machining time: Up to 80% saving throughincreasedcuttingspeed (e.g.ifsolidcarbidetoolsfromthe HSClineareused)

Machine stoppage: approx. 50% saving throughreducedbirdnesting (e.g.iftheParadurEcoPlus isused)

Coolant: Up to 10% saving throughMQL(e.g.iftheParadur EcoCIisused).Additionalbenefits, suchasenvironmentalsustainability arenotquantifiedhere.

Tool change: approx. 50% saving throughlongertoollife (e.g.ifParadurHTisused)

Other: approx. 25% saving (amongotherthings,attributableto thereducedstorageandlogistics costsbecauseofthewideareaof applicationoftheSynchrospeed family) Up to

Walter Prototyp threading tool Nomenclature/tool categories

Taps for universal applications

Paradur Tapwithright-hand helicalflute

Paradur straight-flutedtools Prototex Eco HT universalapplication forwetandMQLmachining

Paradur Eco Plus universalapplication forwetandMQLmachining successortotheproven ParadurEcoHT

Protodyn Threadformerwithout lubricationgrooves

Protodyn S Threadformerwith lubricationgrooves

Prototex Synchrospeed synchronousmachining universalapplication h6shanktolerance

Paradur Synchrospeed synchronousmachining universalapplication h6shanktolerance

Taps for special applications

Paradur Eco CI forshort-chippingmaterials forwetandMQLmachining

Prototex TiNi Plus + formachininghigh-tensileTiand 25 Nialloyswithemulsionthattend tocausejamming

Paradur HT forsteelswithmediumtohigh tensilestrength,andforshortchippingmaterials Internalcoolingrequired

Paradur Ti Plus formachininghigh-tensileTi alloyswithemulsionthattend tocausejamming

Prototex Xpert P formaterialswithlowtomedium tensilestrength

Paradur Xpert P formaterialswithlowtomedium tensilestrength

Prototex HSC forhigh-strengthandhightensile 26 steelmaterials h6shanktolerance Internalcoolingrequired Solidcarbide

Prototex Xpert M forstainlessand high-strengthsteels

Paradur HSC forhigh-strengthandhigh-tensile 27 steelmaterialsupto55HRC h6shanktolerance Internalcoolingrequired Solidcarbide

Paradur Xpert M forstainlessand high-strengthsteels

GL = blind hole machining DL = through hole machining

Protodyn S Eco Plus* Foruniversalapplication higherperformancecomparedto ProtodynSPlus forwetandMQLmachining

TMC thread mill withcountersinkforuniversal application

Protodyn S Plus* Foruniversalapplication

TMG thread mill withoutcountersink Foruniversalapplication

Protodyn Eco LM Forsoftmaterialswithtendency tocausejamming

TMO orbital thread mill Foruniversalapplication inmachiningofsmalland deepthreads

Protodyn S Eco Inox* 31 especiallyformachiningstainless steelswithemulsion

TMO HRC orbital thread mill Forsmallanddeepthreadsin hardmaterialsupto65HRC

Protodyn S Synchrospeed* Foruniversalapplication Synchronousmachining h6shanktolerance

TMD thread milling cutter Foraluminiumandgreycastiron machining

Protodyn S HSC* forhighformingspeeds h6shanktolerance Solidcarbide

TME thread mill 20 forexternalthreads

* Version with lubrication grooves, marked with an S 12

GL = blind hole machining DL = through hole machining

The high-tech all-rounder

Paradur Eco Plus: taperedguidereducesthetendency towardfractures threadnearlytothebottomofthehole withchamferformE

Paradur Eco Plus

*IK =internalcoolantsupply KA=internalcoolantsupplywithaxialcoolantoutlet KR=internalcoolantsupplywithradialcoolantoutlet 14 15

Wear-resistant, universal use

Type:S2021305 Practical tip: Itisgenerallyrecommendedtouse adaptorswithminimumcompensation(e.g.ProtoflexC)forsynchronous machining(advantage:longertoollife andincreasedprocessreliability).

*IK =internalcoolantsupply KA=internalcoolantsupplywithaxialcoolantoutlet KR=internalcoolantsupplywithradialcoolantoutlet 16 17

Extremely high speed in short-chipping materials

Short cycle time, optimum chip breaking

typicalareasofapplication: automotiveindustry(camshafts, crankshafts,connectingrods) largethreaddimensions(general mechanicalengineering,transmission shafts,housings,etc.)

*IK =internalcoolantsupply KA=internalcoolantsupplywithaxialcoolantoutlet KR=internalcoolantsupplywithradialcoolantoutlet 18 19

Large product range, high cost efficiency

The tool lowflankclearanceangleandtherefore nomiscuttinginsoftmaterials Prototex Xpert P variantswithreducednumberofflutes inthestandardproductrange

Paradur Xpert P longflutesfordeepthreads Taperedguidepreventsfractures H O