THREAD MILLING CUTTERS THE COMPLETE PROGRAMME

Transcription

1 EN Precision Cutting Tools THREAD MILLING CUTTERS THE COMPLETE PROGRAMME + NEW: Micro thread milling cutters from M1.4

2 ISO code P M K N S H Steel, high-alloyed steel Stainless steel Grey cast iron, spher. graphite iron/malleable cast iron Aluminium and other non-ferrous metals Special, super and titanium alloys Hardened steel and chilled cast iron Pictograms Tool material Solid carbide Surface A TiCN TiAlN Type GFR GFR S GFR U MGFR 1 MGFR 3 MGFRH 3 Thread depth 2xD 2,5xD 3xD Standard Cutting direction Shank form WN R right HA to Hartner Standard to DIN 6535 Thread type Through holes/blind holes Internal cooling with IC without IC Hartner GmbH P.O.Box D Albstadt Phone Fax:

3 Tool Selection Guide p. 4 GFR Thread milling cutters without chamfer p. 8 Simple option for thread milling one thread size Thread types: M, MF, UNF, UNC, NPT, G GFR S Thread milling cutters with 45 chamfer p. 16 High productivity thanks to countersinking and thread milling with one tool, high running smoothness and low lateral forces. Thread types: M, MF, G GFR U Universal thread milling cutter with recessed neck p. 20 For different thread sizes with equal pitch, e.g. thread M30x1.5, milling cutter Ø12xM1.5, Ø16xM1.5 or Ø20xM1.5 Thread types: internal threads: M, MF internal and external threads: G, NPT NEW MGFR Micro thread milling cutters p. 24 MGFR 3 Thread size and pitch are predetermined (3xD) M1.6 M16, G1/8" - G2", UNC, UNF, UNJC, UNJF, MJ, solid carbide TiCN MGFR 1 Universal production of nominal thread diameters up to maximum pitch (3xD) M1.4 M10, solid carbide TiCN MGFRH 3 Machining of hardened steels from 45 HRC 65 HRC (2xD 3xD) M2 M12, solid carbide TiAlN Our service p. 28 Free supply of CNC programmes Technical section General information & application recommendations p. 32

4 Tool Selection Guide Thread depth 2xD 2.5xD 2xD Tool material Solid carbide Type GFR GFR GFR GFR S Surface Coolant supply Shank form Spiral axial axial axial HA HA HA HA Through holes and blind holes Thread type Article no. M p p p p. 16 MF p p. 17 UNC p. 10 UNF p. 11 G p. 12 NPT p. 13 EG EG-threads can be produced with every thread milling cutter type and dimension Suitable lubricant So / No So / No So / No So / No So = Soluble oil A = Air No = Neat oil D = Dry

5 universal / internal thread universal / external thread 3xD Solid carbide GFR U GFR U MGFR 3 MGFR 1 MGFRH 3 A axial axial HA HA HA HA HA universal Hard machining Article no p p p p p p p p p p p p. 22 EG-threads can be produced with every thread milling cutter type and dimension So / No So / No So / No So / No A / D

6 What are the advantages of thread milling compared with tapping and thread forming? Different materials can be machined with one tool (aluminium, steel, cast iron, stainless steel, titanium, Inconel, max. HRC 65 and many more) Various diameters and tolerances are possible with one tool (e.g. 6H+0.1, 7G, EG and many more) One tool for through and blind holes as well as right- and left-hand threads Thread depth possible up to the base of the hole (0.5xP) No axial cross-cutting Saving tool locations (with type GFR S) Problem-free chips because short milling chips are produced Reduced tooling costs with the same pitch and large threads (type GFR U) Short cycle times thanks to high cutting speed and feed rate High process reliability even in the event of tool breakage as the thread milling cutter can be completely removed from the workpiece and the machine High economic efficiency thanks to Hartner s re-grind and re-coating service

7 GFR Thread milling cutters without chamfer Free CNC programming on request! Programming example Type GFR Article no TiCN Cutting speed [vc] 80 m/min Thread size Thread depth M10x(1) 20 mm / Blind hole Feed per tooth Processing sequence 0.05 mm Reverse rotation milling Material St- 37 Processing time 6.9 seconds CNC programme N10 M6 T1 N20 G90 G54 G00 X0 Y0 N30 Z2 S3203 M3 M8 N40 Z N50 G91 N60 G42 G01 X0 Y3.975 F50 N70 G02 X0 Y I0 J Z N80 G02 X0 Y0 I0 J5.030 Z F101 N90 G02 X0 Y9.005 I0 J4.503 Z N100 G40 G01 X0 Y N110 G90 N120 G00 Z2 M9 Position over workpiece Position for thread depth Incremental Radius compensation Entry cycle 180 Thread pitch 360 Withdrawal cycle 180 Radius compensation off Switch to absolute Rapid movement to start position N130 M30

8 Thread milling cutters without chamfer for ISO metric threads Article no P M K N S H GFR 2xD WN R ~HA without chamfer D d2 d1 l 1 l 2 P 60 d k D P d1 d2 dk l1 l2 Z Code no. mm mm mm mm mm mm M M M M M M M

9 Thread milling cutters without chamfer for ISO metric threads/fine threads Article no P M K N S H GFR 2xD WN R ~HA without chamfer D d2 d1 l 1 l 2 P 60 d k D P d1 d2 dk l1 l2 Z Code no. mm mm mm mm mm mm M M M8 x M M10 x M10 x 1, M M12 x 1, M M14 x 1, M M16 x 1, M M20 x 1,

10 Thread milling cutters without chamfer for UNC-threads Article no P M K N S H GFR 2xD WN R ~HA without chamfer D d2 d1 l 1 l 2 P 60 d k D d1 d2 dk l1 l2 Z Code no. mm mm mm mm mm / / / / / / /

11 Thread milling cutters without chamfer for UNF-threads Article no P M K N S H GFR 2xD WN R ~HA without chamfer D d2 d1 l 1 l 2 P 60 d k D d1 d2 dk l1 l2 Z Code no. mm mm mm mm mm / / / / / / /

12 Thread milling cutters without chamfer for BSP-threads Article no P M K N S H GFR 2xD WN R ~HA without chamfer D d2 d1 l 1 l 2 P d k D P d1 d2 dk l1 l2 Z Code no. inch mm mm mm mm mm G1/ G1/ G3/

13 Thread milling cutters without chamfer for NPT-threads Article no P M K N S H GFR WN R ~HA without chamfer D d2 d1 l 1 l 2 P 60 d k D P d1 d2 dk l1 l2 Z Code no. inch mm mm mm mm mm 1/ / / /

14 Thread milling cutters without chamfer for ISO metric threads Article no P M K N S H GFR 2,5xD WN R ~HA without chamfer D d2 d1 l 1 l 2 P 60 d k D P d1 d2 dk l1 l2 Z Code no. mm mm mm mm mm mm M M M M M M M

15 GFR S Thread milling cutters with 45 chamfer Free CNC programming on request! Programming example Type GFR S Article no TiCN Cutting speed [vc] 100 m/min Thread size M12x(1.5) Feed per tooth mm Thread depth 18 mm / Blind hole Processing sequence Reverse rotation milling Material 42CrMo4 Processing time 4.15 seconds CNC programme N10 M6 T1 N20 G90 G54 G00 X0 Y0 N30 Z2 S1600 M3 M8 N40 Z Position over workpiece Position for 45 countersinking N50 G01 Z F85 Chamfering 45 N60 G00 Z S3199 N70 G91 N80 G42 G01 X0 Y4.975 F85 Position for thread depth Incremental Radius compensation N90 G02 X0 Y I0 J Z Entry cycle 180 N100 G02 X0 Y0 I0 J6.040 Z-1.5 F169 Thread pitch 360 N110 G02 X0 Y I0 J5.508 Z Withdrawal cycle 180 N120 G40 G01 X0 Y N130 G90 N140 G00 Z2 M9 Radius compensation off Switch to absolute Rapid movement to start position N150 M30

16 Thread milling cutters with chamfer for ISO metric threads Article no P M K N S H GFR S 2xD WN R HA with chamfer 45 D d2 d1 d3 l 3 l 2 l 1 P 60 d k D P d1 d2 d3 dk l1 l2 l3 Z Code no. mm mm mm mm mm mm mm mm M M M M M M M M M M

17 Thread milling cutters with chamfer for ISO metric fine threads Article no P M K N S H GFR S 2xD WN R HA with chamfer 45 D d2 d1 d3 l 3 l 2 l 1 P 60 d k D P d1 d2 d3 dk l1 l2 l3 Z Code no. mm mm mm mm mm mm mm mm M4 x11, M5 x 0, M6 x 0, M6 x 0, M8 x 0, M8 x M10 x M10 x 1, M12 x M12 x 1, M14 x 1, M16 x 1,

18 Application example Application example type GFR U Material: AlSi7 Thread: M20 x 1.5 und M16 x 1.5 Thread depth: 12 mm / 13 mm Tool: GFR U, Article no Lubrication: Soluble oil 8 % Parameters: v c =260 m / min., f z =0.06 mm Milling method: Reverse rotation milling Tool life: threads 18

19 GFR U Universal thread milling cutter with recessed neck Free CNC programming on request! Programming example Type GFR U Article no Ø 12xM1 TiCN Cutting speed [vc] 60 m/min Thread size M28x1 Feed per tooth 0.05 mm Thread depth 12 mm / Blind hole Processing sequence Reverse rotation milling Material VA [1.4301] Processing time seconds CNC programme N10 M6 T1 N20 G90 G54 G00 X0 Y0 N30 Z2 S1598 M3 M8 N40 Z N50 G91 N60 G42 G01 X0 Y5.975 F92 Position over workpiece Position for thread depth Incremental Radius compensation N70 G02 X0 Y I0 J Z Entry cycle 180 N80 G02 X0 Y0 I0 J Z F184 Thread pitch 360 N90 G02 X0 Y I0 J Z Withdrawal cycle 180 N100 G40 G01 X0 Y N110 G90 N120 G00 Z2 M9 Radius compensation off Switch to absolute Rapid movement to start position N130 M30

20 Universal thread milling cutters for ISO metric threads Article no P M K N S H GFR U 2xD WN R ~HA universal thread milling cutters for internal threads M / MF D d2 d1 l 1 l 5 l 2 P 60 P D d1 d2 l1 l2 l5 Z Code no. mm mm mm mm mm mm > > > > > > > > > > > > > > > >

21 Universal thread milling cutters for BSP-threads Article no P M K N S H GFR U WN R ~HA Universal thread milling cutters for internal and external threads D D d2 d1 l 1 l 5 l 2 P 55 P D d1 d2 l1 l2 l5 Z Code no. inch mm mm mm mm mm > 1/ > 1/ >

22 Universal thread milling cutters for NPT-threads Article no P M K N S H GFR U WN R ~HA Universal thread milling cutters for internal and external threads D D d2 d1 l 1 l 2 P 60 P D d1 d2 l1 l2 Z Code no. inch mm mm mm mm /

23 MGFR Micro thread milling cutters Micro thread milling cutters Free CNC programming on request! Solid carbide micro thread milling cutters have been specially developed for the production of threads in small holes: excellent characteristics in higher-strength materials (e. g. titanium alloys, stainless steels, ) blind holes and through holes up to 3xD minimum cutting force very good thread quality short machining times also suitable for softer materials (e. g. aluminium or plastics) Programming example Type MGFR 3 Material Thread TiAl6V4 M3, depth 7.0 mm / Blind hole Tool MGFR 3 M3x(0.5) tool Ø 2.4 mm Z=3 Parameter v c = 40 m/min, f z = (Reverse rotation milling) v f = 398 mm/min, v m = 84 mm/min N10 M6 T1 N20 G90 G54 G00 X0 Y0 N30 Z2 S5305 M3 M8 N40 Z0.1 N50 G91 N60 G42 G01 X0 Y1.200 F42 N70 G02 X0 Y I0 J Z N80 G02 X0 Y0 I0 J1.520 Z F84 Number of repeats of set N80 =15 N90 G02 X0 Y2.720 I0 J1.360 Z N100 G40 G01 X0 Y N110 G90 N120 G00 Z2 M9 N130 M30

24 Micro thread milling cutters Article no P M K N S H MGFR 3 3xD WN R ~HA Thread size and pitch are predetermined l 5 D d2 d1 l 1 l 2 P 60 D P d1 d2 l1 l2 l5 Z Code no. mm mm mm mm mm mm M1, M1, M M2, M M3, M M M M M M M

25 Micro thread milling cutters Article no P M K N S H MGFR 3 3xD WN R ~HA Thread size and pitch are predetermined l 5 D d2 d1 l 1 l 2 P 60 D P d1 d2 l1 l2 l5 Z Code no. inch mm mm mm mm mm UNC No 2+UNF No UNC No 3+UNF No UNC No UNC No 5+UNF No UNC No UNF No UNC No UNF No UNC No10+UNC No UNF No UNF 1/ UNC 1/ UNF 5/16+UNF 3/ UNC 5/ UNC 3/ UNF 7/ UNF 5/

26 Micro thread milling cutters Article no P M K N S H MGFR 1 3xD WN R ~HA Universal production of nominal thread diameters up to maximum pitch l 5 D d2 d1 l 1 l 2 P 60 D P max. d1 d2 l1 l2 l5 Z Code no. mm mm mm mm mm mm M1.4 - M M2 - M M2.5 - M M3.5 - M M5 - M M8 - M

27 Micro thread milling cutters Article no P M K N S H A MGFRH 3 3xD WN R ~HA for hard machining HRC Thread size and pitch are predetermined l 5 D d2 d1 l 1 l 2 P 60 D P d1 d2 l1 l2 l5 Z Code no. mm mm mm mm mm mm M M2, M M M M M M M

28 Our Service Free Creation of CNC Programmes To make the machining with our thread milling cutters as easy as possible, we set up the suitable CNC programme for your individual application and machine control. For the programme creation we only require: thread type and size material to be machined desired Hartner article no. type of machine control We supply you with the programming data, which can be automatically recognised and read. The programming data is available for Sinumerik, Heidenhain, Fanuc, Mazatrol and Hurco. Furthermore, with each programme, you will receive a CNC data sheet with all parameters, see page on the right.

29 Free CNC programming CNC Data Sheet Hartner GmbH P.O. Box D Albstadt Tel.: / Fax: / Date Machining Task Material Thread Dimension M10 Structural- and free cutting steels, Length mm unalloyed tempered-/case hardened Countersink W=90 No Tool Cutting Values Description GFR 2xD without chamfer Milling Milling cutter diameter d1 = 7.95 mm Vc 90 m/min n /min Programmed Radius 3.94 mm fz mm/tooth Order-No _ Vf 486 mm/min Vm 100 mm/min NC-Options Cycle Time Machine Control Sinumerik [DIN] Total Time 7.05 sec. Cutting Path Center path, incremental Milling Process Conventional milling No. of passes One cut Note CNC programme serves as a programming example and should be tested by simulation before use on component. CNC-Code ; Tool= GFR 2xD without chamfer M10 ; Material= P1 ; Vc=90 m/min ; fz=0.045 mm/tooth ; Conventional milling ; One cut ; Thread Type= Internal Right-Hand Thread N10 M6 T1 N20 G90 G54 G00 X0.000 Y0.000 N30 Z2.000 S3604 M3 M8 Attention, for controls that refer to outer path, values in brackets to be used.

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31 TECHNICAL SECTION

32 Technical section The Hartner thread milling cutter types GFR Thread milling cutters without chamfer Simple and cost-efficient tool for the milling of internal threads 2-3 thread sizes with the same pitch can be produced over the specified nominal dimension Application in materials 1000 N/mm 2 Available with or without internal cooling Thread types: M, MF, UNC, UNF, G, NPT GFR S Thread milling cutters with 45 chamfer Countersinking and thread milling with only one tool Very smooth running and low lateral forces Designed for the application of difficult-to-machine materials also available w/o countersinking step 2-3 thread sizes with the same pitch can be produced over the specified nominal dimension Only available with internal cooling Thread types: M, MF, G GFR U Universal thread milling cutters with recessed neck Universal application possibilities For various thread sizes with the same pitch, e.g. thread M30x1.5 with milling cutter Ø 12xM1.5, Ø 16xM1.5 or Ø 20xM1.5 Only available with internal cooling Thread types: Internal thread: M, MF Internal- and external thread: G, NPT MGFR 3 Micro thread milling cutters Thread size and pitch are predetermined Excellent characteristics with high-tensile materials such as titanium, stainless steel etc. Suitable for the machining of hardened steel 45HRC 65HRC Threads up to 3xD Only available without internal cooling; with internal cooling on request Thread types: M, MF, UNC, UNF MGFR 1 Micro thread milling cutters Universal production of nominal thread diameters up to a maximum pitch Only available without internal cooling Thread types: M, MF 32

33 Technical section Difference between taps/fluteless taps and thread milling cutters Taps/fluteless taps Thread milling cutters P = Pitch T = Pitch The red lines show the pitch angle of the thread that is ground into the tool. This means the pitch is cut into the workpiece by the tool. The red lines show that the tool does not possess a pitch angle. The pitch is produced by the Z-axis of a CNC machine. Creation of the thread with thread milling CNC-axes CNC-axes Thread profile without axial feed (Z-axis) of the machine. A groove profile is created without pitch. A functioning thread is not created. Through the additional programming of the Z-axis the necessary pitch is produced. Note Due to diagonal milling in the pitch angle (Z-axis) the thread profile of the tool is transferred onto the component distorted. The more the milling cutter diameter (80 % of nom. Ø) approaches the nominal thread diameter and the higher the thread pitch the more pronounced the profile distortion is. 33

34 Technical section Distinction between two milling processes Reverse rotation milling clockwise, with G02 Synchronous milling anticlockwise, with G03 Reverse rotation milling is preferentially applied for the machining of harder materials or to remedy taper threads. Synchronous milling is applied with thread depths smaller than 1.5xD. Advantage: A better surface finish is achieved. Thread production with one tool Right-hand thread reverse rotation milling Thread production with one tool Left-hand thread reverse rotation milling Tool rotates clockwise from top to bottom. Tool rotates clockwise from bottom to top. Thread production with one tool Right-hand thread synchronous milling Thread production with one tool Left-hand thread synchronous milling Tool rotates clockwise from bottom to top. Tool rotates clockwise from top to bottom. 34

35 Technical section Thread milling cutter modifications Illustration Modification Effect Cooling slots on shank Targeted cooling, without weakening the tool cross-section in the cutting edge area Radial coolant exits Targeted cooling with through hole threads Threads removed Reduced cutting forces but longer machining time because two cycles are required De-burring cutting edge Removing the incomplete threads at the thread run-in without additional operating step First thread profile lengthened at the face Chamfering a tapping size hole Grinding collar Enables axial distribution of cuts useful for deep threads 35

36 Technical section Taping size holes for thread milling cutters Std. ISO metric threads DIN 13 Nom. Pitch Tapping Core diameter Ø P size hole Ø of int. thread 6H* DIN 336 min. max. mm mm mm mm M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M M Nom. x Pitch Tapping Core diameter Ø size of int. thread 6H P hole Ø DIN 336 min. max. mm mm mm mm M 2.5 x M 3.0 x M 3.5 x M 4.0 x M 4.5 x M 5.0 x M 5.5 x M 6.0 x M 7.0 x M 8.0 x M 8.0 x M 8.0 x M 9.0 x M 9.0 x M 10 x M 10 x M 10 x M 11 x M 11 x M 12 x M 12 x M 12 x M 14 x M 14 x M 14 x M 15 x M 15 x M 16 x M 16 x M 16 x M 17 x M 17 x M 18 x M 18 x M 20 x M 20 x M 20 x M 22 x ISO metric fine threads DIN 13 Nom. x Pitch Tapping Core diameter Ø size of int. thread 6H P hole Ø DIN 336 min. max. mm mm mm mm M 22 x M 22 x M 24 x M 24 x M 24 x M 25 x M 25 x M 25 x M 27 x M 27 x M 27 x M 28 x M 28 x M 28 x M 30 x M 30 x M 30 x M 30 x M 32 x M 32 x M 33 x M 33 x M 33 x M 35 x M 36 x UNC threads ASME B1.1 Nom. Threads Tapping Core diameter Ø size of int. thread 2B hole Ø per DIN 336 min. max. inch mm mm mm No No No No No No No No No / / / / / / / / / / / / / / * M 1.1 up to M 1.4 tapping size hole of int. thread 5H MJ threads DIN ISO 5855 Nom. x Pitch Tapping Core diameter Ø size of int. thread 5H* P hole Ø min. max. mm mm mm mm MJ 3 x MJ 4 x MJ 5 x MJ 6 x MJ 6 x MJ 6 x MJ 8 x MJ 8 x MJ 8 x MJ 8 x MJ 10 x MJ 10 x MJ 10 x MJ 12 x MJ 16 x UNJC threads ISO 3161 Nom. Threads Tapping Core diameter Ø size of int. thread 3B hole Ø per min. max. inch mm mm mm No No No No / / / / / / / UNJF threads ISO 3161 Nom. Threads Tapping Core diameter Ø size of int. thread 3B hole Ø per min. max. inch mm mm mm No No No No / / / / / / /

37 Technical section Taping size holes for thread milling cutters UNF threads ASME B1.1 Nom. Threads Tapping Core diameter Ø size of int. thread 2B hole Ø per DIN 336 min. max. inch mm mm mm No No No No No No No No No / / / / / / / / / / / / / BSW (Whitworth) threads BS84 Nom. Threads Tapping Core diameter Ø size of int. thread hole Ø per min. max. inch inch mm mm mm W 1 / W 3 / W 1 / W 5 / W 3 / W 7 / W 1 / W 5 / W 3 / W 7 / W 1 / W 9 / W 5 / W 3 / W 7 / W W 1 1 / W 1 1 / W 1 3 / W 1 1 / W 1 5 / W 1 3 / W (Whitworth) threads (to DIN-ISO 228-1) Nom. Threads Tapping Core diameter Ø size of int. thread hole Ø per DIN 336 min. max. inch inch mm mm mm G 1 / G 1 / G 1 / G 3 / G 1 / G 5 / G 3 / G 7 / G G 1 1 / G 1 1 / G 1 1 / G 1 3 / G Steel armoured conduit threads to DIN Nom. Threads Tapping Core diameter Ø size of int. thread hole Ø per min. max. inch mm mm mm Pg Pg Pg Pg Pg Pg Pg Pg Pg Pg NPT ANSI B 2.1 American tapered pipe thread 1:16 Version A (avoid if possible) Version B Nom. Threads Tapp. size hole Ø Tapp. size hole Ø Cutting depth Cutting depth Ø per cylindrical (A) conical (B) ET BT (min) inch d 1 D 1 mm mm d 1 BT 1:16 D 1 ET d 1 BT 1 / / / / / / / / / Metric/metric fine EG-threads (EG M14 x 1.25) for wire thread inserts DIN 8140 Nom. x Pitch Tapping Core diameter Ø size of int. thread P hole Ø min. max. mm mm mm mm EG M EG M EG M EG M EG M EG M EG M14 x EG M UNC (UNC-STI) EG-threads for wire thread inserts ASME B Nom. Threads Tapping Core diameter Ø size of int. thread hole Ø per min. max. inch mm mm mm EG No EG No EG No EG No EG 1 / EG 5 / EG 3 / EG 7 / EG 1 / EG 9 / EG 5 / EG UNF (UNF-STI) threads for wire thread inserts ASME B Nom. Threads Tapping Core diameter Ø size of int. thread hole Ø per min. max. inch mm mm mm EG No EG No EG No EG No EG 1 / EG 5 / EG 3 / EG 7 / EG 1 / EG 9 / EG 5 /

38 Technical section Practical application of thread milling cutters 1. Tool clamping good concentricity is important, therefore clamping as short and rigid as possible. 2. Enter tool data in machine memory a. Tool length from the front face, take drill/thread milling cutters (DTMC) rom point. b. Measure tool radius with tool pre-setting equipment. General rule: measured radius x pitch provides the input value in machine memory. 3. Input of CNC program in control (preferably integrated as sub-program at corresponding positions) a. Call-up of a self-controlling cycle (procedures should be known) b. Integration of data file from our threadmill-software (DIN or Haidenhain) 4. Trial run over workpiece a. Tool length dimension in memory extending by an approximate value dependent on contact length (e.g. 30 mm) or offset zero point. b. Run program in single set, visual check of travel path. c. Allow program to run in automatic mode. Attention With controls where it is not definitely clear what milling path is assigned it must be clarified if the feed is positioned on the external path v f or at the centre path v m. As a rule we specify the milling centre point path v m. 5. Application in workpiece Re-set the tool extension or the zero point. Then allow the program to run in the workpiece the feed regulation must be 100% selected. Should the thread not be true to gauge, the tool radius requires correction in the tool memory: Example: Thread too tight: Radius correction input Thread too large: Radius correction + input 38

39 Technical section Thread milling programming Program specifications Thread milling functions G00 Rapid movement G90 Absolute dimension G01 Feed G91 Incremental dimension G02 Circular interpolation (clockwise) M03 Spindle on (clockwise rotation) G03 Circular interpolation (anti-clockwise) M05 Spindle stop G17 Layer selection x-y axis M08 Coolant on G18 Layer selection z-x axis X Axis G19 Layer selection y-z axis Y Axis G40 Cancel tool correction Z Axis G41 Tool path correction (left of contour) I Thread pitch parallel to X-axis G42 Tool path correction (right of contour) J Thread pitch parallel to Y-axis G43 Tool length compensation (call-up) S Spindle speed G49 Tool length compensation (deselect) F Feed G54 Zero offset CNC internal thread milling 1. Moving to start position 2. Moving to thread depth in bore (Milling cutter) External path v f (Milling cutter) Centre point path v m descending loop to contour full circular movement of thread milling cutter exit loop to centre of bore d D 6. Rapid movement from bore to start position Entry cycle 180 (always half feed rate) Y + X + Y + X + Y + X + Formula of calculation v c = d.. n 1000 n = v c d. v f = n. z. f z v m = v. f (D - d ) D v b = n. f b v c = Cutting speed v f = Contour feed v m = Centre point path feed n = Revolutions z = Number of teeth f z = Feed per tooth f b = Feed per drill per revolution* v b = Drill feed rate* D = Ø nom. of thread [mm] d = Milling cutter nom. Ø [mm] * for drill/thread milling 39

40 Technical section Thread milling programming Programming process for micro thread milling (right-hand thread in reverse rotation) Starting point Tool starting position 180 entry cycle Thread milling 180 withdrawal cycle End position Y + Y + Y + X + X + X + Possibilities to reduce radial forces To reduce radial forces cut distribution can be undertaken: Advantage for larger thread depths counteracts taper threads for unstable clamping conditions Disadvantage increased tool wear longer production time Axial distribution of cut Radial distribution of cut 2/3 1/3 1 st step reverse rotation milling 2 st step reverse rotation milling 1 st step 2 st step 1 st step 2 st step 40

41 Special solutions Application examples Component Crankcase AlSi7 Component: Pump housing AlSi12 Machining Boring with 180 hole base, chamfering and Machining Drilling, chamfering, facing and thread milling, thread milling a pre-cast hole, blind hole M10x1, thread depth = 15 mm through hole M20x1.5, thread depth = 20 mm Tool Solid carbide drill thread milling cutters DTMZ Tool Solid carbide drill thread milling cutters DTMZ M20x1.5 with IC, 180 drill cutting edge M10x1 with IC and spot facer Cutting rates v c = 250 m/min, f b = 0.30, f z = 0.10 mm Cutting rates v c = 280 m/min, f b = 0.07, f z = 0.05 mm Tool life threads Tool life threads 41

42 Technical section Selecting the correct clamping chuck Correct tool clamping also plays an essential role with thread milling. Thread milling cutters should as a rule be clamped as short as possible. A compact and mechanical clamping force is preferable. The error in concentricity should not exceed 0.02 millimetres. Power chucks A power chuck excels thanks to extremely accurate concentricity. The high clamping forces and optimal smooth running are a perfect prerequisite for the production of threads in all materials including a high pitch. max. permissible error in concentricity: mm Side lock holders A side lock holder for HB and HE shanks is a robust, costefficient clamping chuck with a maximum clamping force. The clamping surface prevents the tool twisting or being pulled out during machining. Therefore, side lock holders are suitable for the production in all materials including a high pitch. max. permissible error in concentricity: mm Shrink fit chucks A shrink fit chuck creates a rigid connection with the shrink fitted tool. Incorrect shrink fitting or older shrink fit chucks can result in the pulling out of the tool. Tool breakage and possible loss of the component would be the consequence. Therefore, the shrink fit chuck is only suitable for a thread pitch < P = 1.5 mm. max. permissible error in concentricity: mm Hydraulic chucks A hydraulic chuck, similar to the shrink fit chuck, has only limited suitability for thread milling. Especially with high radial forces this clamping chuck reaches its limits. Therefore, the hydraulic chuck is recommended for softer materials such as aluminium and a thread pitch < P = 1.5 mm. max. permissible error in concentricity: mm Collet holders Collet chucks are very well suited for micro-thread milling because only axial stresses are created. The low clamping forces only permit the milling of softer materials. Consequently, collet holders are not suitable for conventional thread milling. max. permissible error in concentricity: 0.01 mm 42

43 Technical section Maximum economic efficiency thanks to reconditioning to original quality Even the most wear-resistant tool will wear sometime under heavy stresses. Thanks to the reconditioning to original geometries and coatings Hartner manages to reproduce the original performance of the tool. Re-grinding In our service centres, tools are re-ground on the front rake face according to the degree of wear. According to width of wear marks the re-grind service is possible two or three times (from milling part diameter d1 > 5.0 mm). In order to re-define the milling portion diameter d1, the number of regrinds is indicated by a notch on the end of the shank. This means every notch is assigned to a diameter and re-marked. Re-coating If a thread mill was enhanced with a coating, the tool is re-coated following the re-grind. This way, not only the wearand corrosion-protection as well as the glide characteristics are re-produced but also the tool life prolonged. 43

44 Application recommendations thread milling cutters and micro thread milling cutters ISO Material group Hardness Example materials Material no. Cutting speed v c (m/min) P M K N S H P1 Structural/free-cutting steels, unalloyed heat-treatable-/ case hardened steels < 800 N/mm² S235JR C15 11SMnPb P2 S355J Free-cutting steels, unalloyed case hardened N/mm² C steels, nitriding steels 31CrMo CrMo P3 Alloyed heat-treatable steels, 36CrNiMo N/mm² heat-treatable steels, high speed steels X36CrMo HS X5CrNi M1 Stainless steel sulfured, austenitic < 1000 N/mm² X6CrNiTi X8CrNiS M2 X17CrNi Stainless and acid-resit. steel steels, < 1000 N/mm² X90CrMoV martensitic X2CrTi X2CrNiMoN M3 Duplex and super duplex < 1300 N/mm² X2CrNiMoN X2CrNiMoCuWn EN-GJL K1 Cast iron 300 HB EN-GJL EN-GJL EN-GJS K2 Spher. graph. iron and mall. cast iron 350 HB EN-GJS EN-GJS EN-GJS K N/mm² ADI, GGV EN-GJV HB EN-GJV400 Al99,5H N1 Aluminium and wrought alloys < 450 N/mm² AlMgSi AlZn4,5Mg GD-AlSi5Cu1Mg N2 Aluminium cast alloys < 600 N/mm² GD-AlSi8Cu G-AlSi9Mg G-AlSi N3 Magnesium alloys < 500 N/mm² GDMgAl8Zn CuZn CuZn37Pb0, N4 Copper and copper alloys langspanend 130 kurzspanend CuZn43Pb N5 Copper special alloys < 1400 N/mm² Ampco 160 N6 Plastics [Thermoplastics, duroplastics] langspanend PMMA, POM,PVC kurzspanend Titanium S1 Titanium und titanium alloys < 1200 N/mm² TiAl5Sn TiAl6V Hasteloy C S2 Nickel, cobalt, iron alloys < 1400 N/mm² Inconel Nimonic H HRC Hardox 45 High tensile steels, hardened steels H HRC PM

45 Type GFR GFR S GFR U MGFR 3 MGFR 1 MGFRH 3 Milling part diameter [ d1 ] / feed per tooth [ fz ] [ Conventional milling ] Ø1 Ø2 Ø3 Ø4 Ø5 Ø6 Ø7 Ø8 Ø9 Ø10 Ø12 Ø14 Ø16 Ø18 Ø20 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm x x optimally suited suited not suitable 45

46 46 Notes

47 Notes 47

48 Precision Cutting Tools UNIVERSELL & WIRTSCHAFTLICH Precision Cutting Tools SPEZIALISTEN ZUR BEARBEITUNG ROSTFREIER STÄHLE Precision Cutting Tools AUS HSS-E-PM UND VOLLHARTMETALL Precision Cutting Tools VHM VORZUGSPROGRAMM Precision Cutting Tools DER MULTIFUNKTIONALE FRÄSER 16MnCr5 11SMn30+C Sz37 GG GGG C45 VA Aluminium Kupfer Bronze Messing Plexiglas PVC PE 1000 Makrolon DE DE DE DE Gewindewerkzeuge Das neue Komplettprogramm zur universellen Gewindeherstellung 2014 DE Precision Cutting Tools KOMPLETTPROGRAMM Precision Cutting Tools WECHSELPLATTEN-BOHRSYSTEM MIT INNENKÜHLUNG Precision Cutting Tools DAS WECHSELPLATTEN-BOHRSYSTEM FÜR BOHRUNGEN BIS 10 X D BIS DURCHMESSER 40,0 MM Precision Cutting Tools AUS VOLLHARTMETALL Precision Cutting Tools MIT KREUZAUSSPITZUNG NACH NAS 907 DE DE DE DE DE Our programme: FU500 FN500 TIEFLOCHBOHRER FU 500/FN 500 Gun Drills INOX-BOHRER MULTIPLEX INOX Drills Multiplex KLEINSTBOHRER MULTIPLEX HPC Micro Precision Drills Multiplex HPC TS-DRILLS TS-Drills TM Vending Machines Präzisionswerkzeuge NEU Threading Tools FRÄSWERKZEUGE Solid Carbide High Performance Milling Cutters TF 100 MULTI-MILL M42-Spiralbohrer TF 100 Multi-Mill M42 Twist Drills Hartner GmbH P.O. Box , D Albstadt Tel /1 25-0, Fax / /18010-VII-14 Printed in Germany 2018 No liability can be accepted for printing errors or technical changes of any kind. Our Conditions of Sale and Terms of Payment apply. Available on request.