Product handbook. Drilling & Threading. The perfect thread

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1 roduct hndbook Drilling & Threding _ Wlter Titex & Wlter rototyp The perfect thred

2 COTETS 2 Appliction exmples 2 Longitudinl member mchining 4 Ger mchining 6 roduct informtion 6 Wlter Titex X treme lus drills 8 X treme lus rnge 16 Wlter rototyp ECO-HT tp 18 ECO-HT rnge 44 Everything you need to know bout threds 44 Thred types in ccordnce with DI Chrt of tolernce positions 48 Tpped hole types 50 Chmfer forms of tps 51 Chip sections of chmfer forms 53 Chmfer clernce ngle 54 Thred clernce ngle 55 Blind hole tpping process 58 Specil thred cutting pplictions 60 Generl notes on core holes 62 Cooling nd lubriction 64 Guging femle threds 66 Synchronous mchining 68 The thred forming method 70 The thred milling method 72 Additionl informtion 72 X treme lus cutting dt 74 X treme lus driving power 75 ECO-HT tp cutting dt 76 TEC+CCS expert system 78 Thred tpping core dimeters 80 Thred forming core dimeters 82 Troubleshooting: drilling 88 Troubleshooting: threding 90 Clcultion Formuls 92 Wlter Titex CATexpress 94 Wlter Reconditioning Service

3 Wlter hs more to offer thn just drilling nd threding. A demnding process The production of femle threds is one of the most demnding mchining tsks in production engineering. Moreover, the threds re often not mde until the end of the production chin, which requires high level of process relibility. Yet, in mss production, mnufcturers demnd tht threds be produced ever more speedily nd economiclly, which necessittes continuous, ongoing development of processes nd of drilling nd threding tools. For femle threds, there re essentilly three production methods vilble: thred tpping, the proven method; thred forming, chipless lterntive; nd thred milling, method tht offers prticulrly high degree of relibility. Crucil to selecting the pproprite production method is hving s brod knowledge s possible of the dvntges nd disdvntges of ech method s well s their prcticl limittions. Ultimtely, the decision for or ginst prticulr production method will hve to be mde under considertion of technicl nd economic fctors. The perfect core hole Before the thred cn be creted, core hole hs to be drilled. The qulity of the core hole hs considerble bering on the cost efficiency nd process relibility of the subsequent threding opertion. Our experts not only offer comprehensive rnge of drilling nd reming tools, they know exctly wht is required to ensure results of consistently high qulity nd productivity. We offer innovtive nd dependble drilling solutions, whtever the dimeter, from ctlogue products to custom-mde specil tools. The perfect thred The better mtched the drilling nd threding tools re, the better the result will be. Our customers wnt mesurbly higher performnce. Higher performnce not only in terms of threding ccurcy, tolernces nd chip formtion, but lso in respect of voiding bird nesting nd oversizing. Wlter will show you how tools cn be used most efficiently. Only optimlly mtched, semless solutions produce the perfect thred. With the combined expertise of Wlter Titex nd Wlter rototyp, we re ble to deliver mximum efficiency in thred mnufcturing. Drilling & Threding 1

4 Appliction exmple 1: Longitudinl member mchining Wlter Titex X treme lus Through hole drilling Wlter rototyp rototex ECO-HT Through hole threding Tool: Cutting mteril: Dimeter: Drilling depth: A3389DL Solid crbide / DL Tool: Cutting mteril: Dimeter: Drilling depth: E M16 HSS-E-M / M16 25 Workpiece mteril: Tensile strength: Hole type: QStE380TM (~S355MC) 550 /² Through hole Workpiece mteril: Tensile strength: Hole type: QStE380TM (~S355MC) 550 /² Through hole Mchine type: Adptor: Mchining centre Hydrulic expnsion chuck Mchine type: Adptor: Mchining centre Floting holder Cutting dt: Competitor X treme lus n [1/min] 2,046 3,797 v c [m/min] f [] v f [/min] 573 1,291 Cutting dt: Competitor rototex ECO-HT n [1/min] v c [m/min] v f [/min] 597 1,194 Benefits for you: 85 % higher cutting speed Tool life incresed from 1,500 to 2,000 holes despite incresed cutting performnce Mchining time reduced from 111 hours to 50 hours 61 hours of spre mchine cpcity Benefits for you: Double the cutting speed for the sme tool life Mchining time reduced from 120 hours to 60 hours 60 hours of spre mchine cpcity Double the productivity Comprison: mchining time / hole Comprison: mchining time / thred Competitor -55% Competitor -50% X treme lus rototex ECO-HT 0 s 1 s 2 s 3 s 4 s 0 s 1 s 2 s 3 s 4 s 2 Drilling & Threding 3

5 Appliction exmple 2: Ger mchining Wlter Titex X treme lus Through hole drilling Wlter rototyp rototex ECO-HT Through hole threding Tool: Cutting mteril: Dimeter: Drilling depth: A3389DL Solid crbide / DL Tool: Cutting mteril: Dimeter: Drilling depth: E M8 HSS-E-M / M8 25 Workpiece mteril: Tensile strength: Hole type: 16MnCr ,000 /² Through hole Workpiece mteril: Tensile strength: Hole type: 16MnCr ,000 /² Through hole Mchine type: Adptor: Mchining centre Hydrulic expnsion chuck Mchine type: Adptor: Mchining centre Floting holder Cutting dt: Competitor X treme lus n [1/min] 4,681 8,098 v c [m/min] f [] v f [/min] 936 1,863 Cutting dt: Competitor rototex ECO HT n [1/min] 995 1,472 v c [m/min] v f [/min] 1,243 1,840 Benefits for you: Cutting speed incresed by 73 % Tool life incresed from 1,900 to 2,800 holes despite incresed cutting performnce Mchining time reduced from 110 hours to 60 hours 50 hours of spre mchine cpcity Benefits for you: Cutting speed incresed by 48 % Tool life incresed from 2,400 to 4,000 threds Mchining time reduced from 100 hours to 70 hours 30 hours of spre mchine cpcity Comprison: mchining time / hole Comprison: mchining time / thred Competitor -45% Competitor -30% X treme lus rototex ECO HT 0 s 1 s 2 s 3 s 0 s 1 s 2 s 3 s 4 Drilling & Threding 5

6 roduct informtion Wlter Titex X treme lus With this tool Wlter Titex is setting new stndrds in drilling with solid crbide tools. The drill incorportes welth of innovtions including the new ptent pending multifunctionl double coting (DL) tht hs outstnding properties. With Wlter Titex X treme lus you cn increse the productivity in the series production of steel nd cst iron components to new level. X Treme The new Wlter Titex X treme Series with unique double coting: extremely innovtive nd extremely productive. The tool solid crbide high performnce drilling tool with internl coolnt supply new type of multifunctionl double coting DL Double erformnce Line (ptent pending) drilling depth 5 x d (A3389DL) nd 3 x d (A3289DL) dimeter rnge from 3.0 to 20.0 The ppliction for ll steel nd cst iron mterils s well s for stinless steels nd non-ferrous metls HC mchining lso suitble for dry mchining with internl MQL supply Internl coolnt supply oint coting with excellent wer properties nd for high cutting speeds Specil point geometry, 140 point ngle X treme lus Optimised flute profile Bsic coting for outstnding chip removl Dimensions in ccordnce with DI 6537 L nd DI 6537 K Stndrd shnk DI 6535 HA Type: A3289DL, A3389DL Workpiece Costs - 50% Speed + 200% Cost svings nd increses in productivity with the X treme lus Your dvntges Mximum productivity; t lest double tht chievble using conventionl tools = more productivity, lower production costs Alterntive: Double the tool life with conventionl cutting dt = e.g. fewer tool chnges Excellent surfce finish High process relibility Vried ppliction possibilities with regrd to mterils nd ppliction (e.g. MQL) Ensures spre mchine cpcity roduct dvntges Bsic coting ew type of multifunctionl double coting DL Double erformnce Line (ptent pending), consisting of bsic coting for protecting the tool nd specil point coting. The combintion with the point coting not only mkes it possible to use t greter cutting speeds, it lso ensures outstnding tool life with conventionl cutting dt. Unique grinding with optimised microgeometry for lower power consumption nd optimum surfce qulity. Solid crbide cutting mteril micro grin K30F. Chip oint coting Crbide 6 Drilling & Threding 7

7 roduct informtion X treme lus rnge A3289DL Appliction: high performnce twist drill for mximum productivity in steel, stinless steel, non-ferrous metls nd cst iron mterils. Extremely high feed nd cutting speeds with superior process relibility nd surfce qulity. m7 Ø inches/ no. h6 mx. Order code A3289DL /8 I /8I /64 I /64I /32 I /32I /64 I /64I m7 Ø inches/ no. h6 mx. Order code A3289DL /16 I /16I /64 I /64I /32 I /32I /64 I /64I /4 I /4I /64 I /64I /32 I /32I Drilling & Threding 9

8 roduct informtion X treme lus rnge A3289DL m7 Ø inches/ no. h6 mx. Order code A3289DL /64 I /64I /16 I /16I /64 I /64I /32 I /32I /64 I /64I /8 I /8I /64 I /64I /32 I /32I /64 I /64I m7 Ø inches/ no. h6 mx. Order code A3289DL /16 I /1 I /64 I /64I /32 I /32I /64 I /64I /2 I /2I /32 I /32I /16 I /16I /8 I /8I /4 I /4I Drilling & Threding 11

9 roduct informtion X treme lus rnge A3389DL Appliction: high performnce twist drill for mximum productivity in steel, stinless steel, non-ferrous metls nd cst iron mterils. Extremely high feed nd cutting speeds with superior process relibility nd surfce qulity. m7 Ø inches/ no. h6 mx. Order code A3389DL /8 I /8I /64 I /64I /32 I /32I /64 I /64I m7 Ø inches/ no. h6 mx. Order code A3389DL /16 I /16I /64 I /64I /32 I /32I /64 I /64I /4 I /4I /64 I /64I /32 I /32I Drilling & Threding 13

10 roduct informtion X treme lus rnge A3389DL m7 Ø inches/ no. h6 mx. Order code A3389DL /64 I /64I /16 I /16I /64 I /64I /32 I /32I /64 I /64I /8 I /8I /64 I /64I /32 I /32I /64 I /64I m7 Ø inches/ no. h6 mx. Order code A3389DL /16 I /16I /64 I /64I /32 I /32I /64 I /64I /2 I /2I /32 I /32I /16 I /16I /8 I /8I /4 I /4I Drilling & Threding 15

11 roduct informtion Wlter rototyp ECO-HT tp Stright fluted with spirl point form B R45 helix ngle with chmfer form C or E Long flutes nd specil flute geometry hrd mteril coting Tpered thred runout HSS-E-M HSS-E-M Rdil internl cooling Specil surfce tretment Axil or rdil internl cooling Specil surfce tretment hrd mteril coting rototex ECO-HT Type: E rdur ECO-HT Type: E The tool Universl high-performnce HSS-E- M tp for use in long- nd shortchipping mterils with tensile strength of up to pproximtely 1,300 /² on conventionl mchines or mchine tools with synchronous spindle hrd mteril coting nd dditionl surfce tretment for outstnding tool life with no cold welding Versions with rdil coolnt outlet vilble s stndrd tool specificlly for use with minimum quntity lubriction (MQL) The ppliction Blind-hole or through-hole threds down to 3 x d ECO-HT tps re suitble for use with brod rnge of mterils: Long-chipping mterils hving moderte to high tensile strength Short-chipping mterils Abrsive mterils with tendency to weld Construction steel or high tensile steel (350 1,300 /²) Stinless steel odulr cst nd mlleble cst iron Long-chipping copper nd luminium lloys Your dvntges rototex ECO-HT through-hole thred: Specil form B spirl point gurntees excellent process relibility rdur ECO-HT blind hole thred: R45 helix ngle, long flutes nd specil flute geometry for optimum chip formtion nd good chip removl even in deep threds Thred lmost to bse of bore due to vrint with short chmfer form E Reduced risk of splling thnks to tpered thred runout Version vilble with xil internl cooling for optimum chip removl Secure chip control ensures excellent process relibility even with reltively deep blind hole or through-hole threds Reduction in tool diversity, since it cn be used universlly in wide rnge of mterils Fewer tool chnges nd optimum mchine output resulting from high cutting speeds nd long tool life Reduction in cooling lubricnt costs thnks to comptibility with dry or MQL mchining in steel, cst iron nd luminium lloys 16 Drilling & Threding 17

12 roduct informtion rototex ECO-HT rnge M DI13 M DI HSS-E M B= 3,5-5 RH / /42 HRC 500 HSS-E M B= 3,5-5 RH / /42 HRC 500 3,5 x d1 3,5 x d1 Dry Dry DI 371 6HX M M2 E M M2.5 M M3 M M4 M M5 M M6 M M8 M M10 DI 371 6GX M M2 E M M2,5 M M3 M M4 M M5 M M6 M M8 M M10 DI 376 6HX E M M12 M M14 M M16 M M18 M M20 M M24 M M27 M M30 DI 376 6GX E M M12 M M14 M M16 18 Drilling & Threding 19

13 roduct informtion rototex ECO-HT rnge M DI13 M DI HSS-E M B= 3,5-5 RH / /42 HRC 500 HSS-E M B= 3,5-5 LH / /42 HRC 500 3,5 x d1 3,5 x d1 Dry Dry DI 371 6HX M M6 M M8 E M M10 DI 376 6HX E M M12 M M16 DI 371 6HX M 3 LH M3 M 4 LH M4 M 5 LH M5 M 6 LH M6 M 8 LH M8 E M 10 LH M10 DI 376 6HX E M 12 LH M12 M 16 LH M16 M 20 LH M20 20 Drilling & Threding 21

14 roduct informtion rdur ECO-HT rnge M DI13 M DI HSS-E M C = 2-3 R45 RH / /38 HRC 500 HSS-E M C = 2-3 R45 RH / /38 HRC x d1 3 x d1 l4 Dry l4 Dry ~ DI 371 6HX M M2 E M M2,5 M M3 M M4 M M5 M M6 M M8 M M10 ~DI 371 6GX M M2 E M M2,5 M M3 M M4 M M5 M M6 M M8 M M10 DI 376 6HX E M M12 M M14 M M16 M M18 M M20 M M24 M M27 M M30 M M36 M M42 DI 376 6GX E M M12 M M14 M M16 22 Drilling & Threding 23

15 roduct informtion rdur ECO-HT rnge M DI13 M DI HSS-E M E=1,5-2 R45 RH / /38 HRC 500 HSS-E M C = 2-3 R45 RH / /38 HRC x d1 3 x d1 l4 Dry ~ DI 371 6HX M M4 M M5 M M6 M M8 E M M10 ~DI 371 6HX M M4 M M5 M M6 M M8 E M M10 DI 376 6HX E M M12 M M16 M M20 M M24 DI 376 6HX E M M12 M M16 M M20 M M24 24 Drilling & Threding 25

16 roduct informtion rdur ECO-HT rnge M DI13 M DI HSS-E M C = 2-3 R45 RH / /38 HRC 500 HSS-E M C = 2-3 L45 LH / /38 HRC x d1 3 x d1 Dry Dry DI 371 6HX M M8 E M M10 DI 376 6HX E M M12 M M16 ~ DI 371 6HX M 3 LH M3 M 4 LH M4 M 5 LH M5 M 6 LH M6 M 8 LH M8 E M 10 LH M10 DI 376 6HX E M 12 LH M12 M 14 LH M14 M 16 LH M16 M 18 LH M18 M 20 LH M20 26 Drilling & Threding 27

17 roduct informtion rototex ECO-HT rnge MF DI13 MF DI HSS-E M B= 3,5-5 RH / /42 HRC 500 HSS-E M B= 3,5-5 RH / /42 HRC 500 3,5 x d1 3,5 x d1 Dry Dry DI 374 6HX E M M6X0.75 M M8X1 M M10X1 M M12X1 M M10X1.25 M M12X1.25 M M12X1.5 M M14X1.5 M M16X1.5 M M18X1.5 M M20X1.5 M M22X1.5 DI 374 6HX E M M8X1 M M10X1 M M12X1 M M10X1.25 M M12X1.25 M M12X1.5 M M14X1.5 M M16X1.5 M M18X1.5 M M20X Drilling & Threding 29

18 roduct informtion rdur ECO-HT rnge MF DI13 MF DI HSS-E M C = 2-3 R45 RH / /38 HRC 500 HSS-E M C = 2-3 R45 RH / /38 HRC x d1 3 x d1 Dry Dry DI 374 6HX DI 374 6HX E E M M6X0.75 M M8X1 M M10X1 M M12X1 M M10X1.25 M M12X1.25 M M12X1.5 M M14X1.5 M M16X1.5 M M18X1.5 M M20X1.5 M M22X1.5 M M8X1 M M10X1 M M12X1 M M10X1.25 M M12X1.25 M M12X1.5 M M14X1.5 M M16X1.5 M M18X1.5 M M20X Drilling & Threding 31

19 roduct informtion rdur ECO-HT rnge MF DI HSS-E M E=1,5-2 R45 RH / /38 HRC x d1 Dry DI 374 6HX E M M8X1 M M10X1 M M12X1.5 M M14X Drilling & Threding 33

20 roduct informtion rototex ECO-HT rnge UC ASME B1.1 UC ASME B HSS-E M B= 3,5-5 RH / /42 HRC 500 HSS-E M B= 3,5-5 RH / /42 HRC 500 3,5 x d1 3,5 x d1 Dry Dry DI om 2B E o UC2 o UC4 o UC6 o UC8 o UC10 1/ UC1/4 DI om 2B E / UC5/16 3/ UC3/8 1/ UC1/2 5/ UC5/8 DI om 2B E / UC1/4 DI om 2B E / UC5/16 3/ UC3/8 1/ UC1/2 5/ UC5/8 34 Drilling & Threding 35

21 roduct informtion rdur ECO-HT rnge UC ASME B1.1 UC ASME B HSS-E M C = 2-3 R45 RH / /38 HRC 500 HSS-E M C = 2-3 R45 RH / /38 HRC x d1 3 x d1 l4 Dry Dry ~DI om 2B E o UC2 o UC4 o UC6 o UC8 o UC10 1/ UC1/4 DI om 2B E / UC5/16 3/ UC3/8 1/ UC1/2 5/ UC5/8 ~DI om 2B E / UC1/4 DI om 2B E / UC5/16 3/ UC3/8 1/ UC1/2 5/ UC5/8 3/ UC3/4 36 Drilling & Threding 37

22 roduct informtion rototex ECO-HT rnge UF ASME B1.1 UF ASME B HSS-E M B= 3,5-5 RH / /42 HRC 500 HSS-E M B= 3,5-5 RH / /42 HRC 500 3,5 x d1 3,5 x d1 Dry Dry DI om 2B E o UF4 o UF6 o UF8 o UF10 1/ UF1/4 DI om 2B E / UF5/16 3/ UF3/8 1/ UF1/2 5/ UF5/8 DI om 2B E / UF1/4 DI om 2B E / UF5/16 3/ UF3/8 1/ UF1/2 38 Drilling & Threding 39

23 roduct informtion rdur ECO-HT rnge UF ASME B1.1 UF ASME B HSS-E M C = 2-3 R45 RH / /38 HRC 500 HSS-E M C = 2-3 R45 RH / /38 HRC x d1 3 x d1 l4 Dry Dry ~DI om 2B E o UF4 o UF6 o UF8 o UF10 1/ UF1/4 DI om 2B E / UF5/16 3/ UF3/8 1/ UF1/2 5/ UF5/8 ~DI om 2B E / UF1/4 DI om 2B E / UF5/16 3/ UF3/8 1/ UF1/2 5/ UF5/8 40 Drilling & Threding 41

24 roduct informtion rototex ECO-HT rnge G DI E ISO 228 rdur ECO-HT rnge G DI E ISO HSS-E M B= 3,5-5 RH / /42 HRC 500 HSS-E M C = 2-3 R45 RH / /38 HRC 500 3,5 x d1 3 x d1 Dry Dry DI 5156 G-X DI 5156 G-X - om E om E G 1/ G1/8 G 1/ G1/4 G 3/ G3/8 G 1/ G1/2 G 5/ G5/8 G 3/ G3/4 G G1 G 1/ G1/8 G 1/ G1/4 G 3/ G3/8 G 1/ G1/2 G 5/ G5/8 G 3/ G3/4 G G1 42 Drilling & Threding 43

25 Everything you need to know bout threds Thred types in ccordnce with DI 202 The following tble provides n overview of the most importnt thred types. (Excerpt from DI 202) Type of thred rofile (digrm) Symbol Designtion (exmple) Rnge of nominl sizes As specified in Appliction ISO metric screw thred (single-strt or multi-strt) M M to 0.9 DI 14-1 to DI 14-4 Wtches nd precision engineering M 8 1 to 68 DI 13-1 Generl purpose screw threds M 24 x 4 2 DI 13,52 (corse pitch hreds) 60 D1 D M 6 x 0.75 M 8 x 1 LH 1-1,000 DI 13-2 to DI M 24 x 4 DI To be used where pitch of corse thred is too lrge M 64 x 4 64 nd 76 DI 6630 Externl brrel threds M 30 x 2 4H5H 1.4 to 355 L to L L nd L Aerospce industry ISO metric screw thred; helicl coil thred for inserts EG M EG M 20 2 to 52 DI Helicl coil thred (corse pitch nd fine pitch thred) for wire thred inserts Unified screw thred 60 UC UF o. 6 (0.138) - 32 UC-2A ASME B1.1 USA United Kingdom D1 D ¼ - 20 UC-2A or UC-2A ASME B1.1 BS 1580 USA United Kingdom rllel pipe thred where pressure-tight joints re not mde on the threds D1 55 D G G 1 ½ A G 1 ½ B G 1 ½ 1 /16 to 6 DI E ISO Externl screw threds for pipes nd pipe joint ssemblies Internl screw threds for pipes nd pipe joint ssemblies G ¾ ¾, 1, 2 DI 6630 Externl brrel threds 44 Drilling & Threding 45

26 t Everything you need to know bout threds Chrt of tolernce positions Exmple of thred former 6HX: The pitch dimeter of the thred former is significntly higher thn tht of the tp. It is lso in X-position. Exmple of tp 6H: The verge pitch dimeter for the tp is more or less in the bottom third of the tolernce rnge for the femle thred. 0,1t 0,2t ISO1/4H 3B 0,3t 0,5t 4HX 3B TII 0,4t 0,1t ISO2/6H 2B 0,5t 0,3t 0,7t 6HX 2B TII 0,6t ISO3/6G 4HX 3BX 0,7t 0,5t 6GX 0,2t 0,9t 4H 3B 7G 1B 0,2t 6HX 2BX 1,15t 5H 6GX 4G 7GX 0,2t 5G 6H 2B Tp 6H 6G 7H d2 = pitch dimeter of the bsic profile t = tolernce unit in ccordnce with DI 13 rt 15 ASI/ASME B1.1 Thred former 6HX 1B 8H Femle thred 4H to 8H Femle thred Tp Oversize tp Thred formers 8B Tolernce units in ccordnce with DI 13 rt 15 Femle threds 4G to 8G From the illustrtion (p. 46), it is cler tht 6H femle thred could be produced using, for exmple, 6G nd, theoreticlly, even 7G tp. The 6G tp is lmost exctly in the centre of the 6H femle thred tolernce rnge. However, even the slightest xil or rdil miscut would soon result in the workpiece hving to be rejected. Tps tht re designed for very tough mterils re currently produced for the X-position. The illustrtion shows tht, for Wlter rototyp products, this mens n increse by hlf tolernce position. Exmples include the IOX tps or the ECO-HT tps for high tensile steels. Even during thred cutting, high tensile titnium nd nickel lloys tend Tolernce clsses in ccordnce with DI/ISO Tolernce clss of the tp Designtion (DI) Designtion (DI) Tolernce rnge of the femle thred to be cut to spring bck, which is why the TI nd I tps re lso mnufctured in the X-position. Similrly, it is useful to mnufcture the tools in X-position where brsive mterils, such s grey cst iron, re being mchined nd miscutting does not present problem. An exmple of tool such s this is our rdur ECO-CI tp. The X-position helps to prolong tool life (by incresing the time before which the Go end of the thred guge becomes impossible to screw in). lese note: The X-position is not defined in ny prticulr stndrd. Dimensionl specifictions my vry by mnufcturer. 4H ISO 1 4H 5H 6H ISO 2 4G 5G 6H 6G ISO 3 6G 7H 8H 7G 7G 8G The bbrevition for the tolernce clss corresponds to the tolernce rnge of the femle thred for which the tp is predominntly used. It is not lwys identicl, therefore, to the tolernce rnge of the femle thred tht ws cut. 46 Drilling & Threding 47

27 Everything you need to know bout threds Tpped hole types: blind hole Tpped hole types: through hole Blind hole short-chipping mterils Through hole chip removl in feed direction Stright-fluted tps do not trnsport chips out of the hole. For this reson, they re suitble only for short-chipping mterils or for cutting short threds. Used for blind hole nd through-hole threds. Tps with spirl point (form B) or left-hnd spirl expel the chips forwrds in the feed direction. Used for through-hole threds in long-chipping mterils. Blind hole long-chipping mterils Through hole long-chipping mterils Right-hnd spirl tps trnsport chips bck towrds the shnk. The tougher the workpiece mteril (producing longer chips) nd the deeper the thred, the greter the helix ngle required. Used for tpping blind holes in long-chipping mterils. Tps with spirl point (form B) or left-hnd spirl expel the chips forwrds in the feed direction. Used for through-hole threds in long-chipping mterils. 48 Drilling & Threding 49

28 Everything you need to know bout threds Chmfer forms of tps Chip sections of chmfer forms Form Threds per chmfer Type of flute Used predominntly for Through-hole threds for long- nd short-chipping mterils A 6-8 threds stright-fluted Through holes in 6 8 Gänge medium- to long- 6 8 Gänge chipping mterils High torque Smll chip section Reduced strin on the chmfer teeth B threds stright-fluted with spirl point Through holes in medium- to longchipping mterils C 2-3 threds stright-fluted or spirl-fluted Blind holes in longnd medium-chipping mterils nd through holes in shortchipping mterils Form B 5 D threds stright-fluted or spirl-fluted E threds stright-fluted or spirl-fluted Blind holes with long thred runout nd through holes Blind holes with very short thred runout Tooth row st lnd 2nd lnd 3rd lnd 4-5 thred chmfer lese note: Longer chmfers reduce the strin on the cutting edge, which becomes more significnt with incresing mteril strength Longer chmfers increse the torque required Longer chmfers require somewht longer cycle time due to the incresed trvel Drilling & Threding 51

29 Everything you need to know bout threds Chip sections of chmfer forms Chmfer clernce ngle Blind hole threds for long-chipping mterils Low torque Lrge chip section Incresed strin on the chmfer teeth Blind hole tps hve smll chmfer clernce ngle becuse they need to sher off the chip root when they reverse. Through-hole tps (spirl point) hve lrger chmfer clernce ngle thn blind hole tps. Due to its greter chmfer clernce ngle, spirl point tp should be ble to cut stright through the through hole. Form E 23 Exmples: Tooth row 2 1 1st lnd 2nd lnd 3rd lnd Through-hole tps possible, but only with reduced chmfer clernce ngle becuse of need to sher off chip root. Secondry opertions required. 2-3 thred chmfer Blind hole tp required becuse chip hs to be trnsported in opposite direction to feed direction. o secondry opertions required. 52 Drilling & Threding 53

30 Everything you need to know bout threds Thred clernce ngle Blind hole tpping process It should be possible for tp to turn esily into the cut thred without it cusing further brsion. If this is not possible, tool with greter clernce ngle should be selected. The tp hs been cutting nd now comes to stop. At this very moment, ll cutting edges on the chmfer re still in the process of forming chip. Flnk clernce ngle rdur WSH, rdur WTH rototex H, rdur rototex IOX, rdur IOX rototex ECO-HT, rdur ECO-HT rototex Synchrospeed, rdur Synchrospeed The tool begins to reverse. The chips remin where they re for the time being. The reverse torque t this point is virtully zero. The chips come into contct with the bck of the triling lnd of the tp. The reverse torque now increses shrply. The chip hs to be shorn off. As the chmfer of the tp hs clernce ngle nd withdrws from the thred xilly when it bcks out of the hole, it is inevitble tht the purchse point will no longer be directly t the root of the chip. For this reson, the chip would require certin mount of stbility (thickness) to be cut. As result, tps hving long chmfer re not suitble for use in blind hole cutting becuse of their greter chmfer ngle. If tp such s this were used, there would be risk of the too thin chip not being shorn off, but simply flttened nd becoming trpped between the chmfer nd the thred. This could led to splling on the chmfer nd, in extreme cses, tp brekge. The chip hs been shorn off nd reverse torque decreses to the friction between the guidnce prt nd the cut thred. 54 Drilling & Threding 55

31 Everything you need to know bout threds Blind hole tpping process lese note: The shering of the chip in the blind hole thred presents prticulr problem. If the chip becomes too thin, it simply flttens nd cn no longer be cut through. Insted, it becomes trpped between the component nd chmfer flnk fce. Long chmfers (form A, form D or form B) nd high chmfer clernce ngles re therefore unsuitble for tpping blind hole threds. Torque curve during the blind hole tpping process Fst, relible, diverse, Toolshop. Our Toolshop gives you round-the-clock ccess to our complete rnge of stndrd tools of the Wlter, Wlter Titex nd Wlter rototyp brnds. Quick, esy nd up-to-dte. Why not visit Toolshop nd find out for yourself? M d Brking of spindle Expect more. Engineer wht you envision. Experience the new Wlter. Time Slight increse cused by the dditionl friction in the guidnce prt Shering of the remining chip Coefficient of friction in the guidnce prt of the tp during reverse ction Chmfer enters: shrp increse in torque Spindle speed reches zero, the spindle begins to reverse First contct mde between chip nd bck of triling lnd 56 Drilling & Threding 57

32 Everything you need to know bout threds Specil thred cutting pplictions Recessed nd deep blind hole threds Inclined thred led-out Where possible, use stright-fluted tp with xil internl coolnt supply or coted tp with bright finished rke: rdur HT For construction nd crbon steels from 500 to 850 /², use tp with specil cutting edge geometry: rdur Short Chip Soft Use tp with s long guidnce prt s possible nd mximum stbility Inclintions of up to 30 reltively unproblemtic Alterntive: thred milling For stinless steels, we recoend the thred forming method (preferbly with oil) or the use of spirl-fluted tp: Thred forming: rotodyn S ECO-IOX Thred tpping: rdur ECO-HT Thred with significntly deeper core hole thn thred depth Use tp with modified spirl point: Reduce chmfer clernce to tht of blind hole tp Shorten chmfer length to 3 threds Advntge: longer tool edge life thn blind hole tps Disdvntge: chips remin inside the hole 58 Drilling & Threding 59

33 Everything you need to know bout threds Generl notes on core holes Depth of the core hole for thred cutting / thred forming Specil notes on thred forming Drilling depth effective thred depth + chmfer length + sfety mrgin Drilling depth Thred depth Chmfer ~3 threds Sfety mrgin ~2 threds The core dimeter of the thred is produced by the thred former nd depends on the flow properties of the formed mteril. After the forming process, the core dimeter must be within the limits specified on pge 80. In the cse of Wlter rototyp products, the guide vlue for the pilot hole is specified on ech thred former. The following tolernces, reltive to this guide vlue, should be fulfilled: Led Tolernce 0.3 ± 0.01 lese note: For flt-bottomed core holes, tke into considertion the type of point tht the threding tool might hve (externl centre or externl centre with reduced point). > 0.3 to < 0.5 ± to < 1 ± ± 0.05 Dimeter of the core hole for thred cutting Rule of thumb: hole dimeter = nominl dimeter - led Exmple: M10 thred cutting Hole dimeter = = 8.5 After the forming process, it is essentil to guge the thred core dimeter. For notes on guging threds, plese refer to pges 64 nd 65. Rule of thumb: hole dimeter = nominl dimeter x led Exmple: M10 thred forming Hole dimeter = x 1.5 = = = Drilling & Threding 61

34 Everything you need to know bout threds Cooling nd lubriction Mteril group Mteril Suitble coolnt Thred cutting Suitble coolnt Thred forming Steel Emulsion 5 % Emulsion 5-10 % Steel 850-1,200 /² Stee,200-1,400 /² Stee,400-1,600 /² equivlent to HRC Emulsion 5-10 % Emulsion 10 % Oil (rotofluid) Emulsion 10 % Oil (rotofluid or Hrdcut 525) Oil (rotofluid) Emulsion 10 % Oil (rotofluid or Hrdcut 525) Forming generlly not possible M Emulsion 5-10 % Oil (rotofluid) Oil (rotofluid) Emulsion 5-10 %, possible only with smll leds up to 1.5 K Grey cst iron Emulsion 5 % Forming not possible odulr cst iron Emulsion 5 % Emulsion 10 % Aluminium up to mx. 12 % Si Emulsion 5-10 % Emulsion 5-15 % Aluminium over 12 % Si Emulsion 5-10 % Emulsion 5-10 %, but forming useful only in exceptionl cses Mgnesium Oil (rotofluid) Forming not possible t room temperture Copper Emulsion 5-10 % Emulsion 5-10 % Synthetics Emulsion 5 % Forming does not produce dimensionlly ccurte threds S H Titnium lloys ickel lloys Steel >49 HRC Oil (rotofluid or Hrdcut 525) Oil (Hrdcut 525) Emulsion 10 % Oil (rotofluid or Hrdcut 525) Oil (rotofluid or Hrdcut 525) Emulsion 10 % Oil (Hrdcut 525) possible only with crbide tools Forming not possible Minimum quntity lubriction (MQL) Most steel, luminium nd copper mterils re mchinble with MQL (cutting nd forming) Use internl MQL for thred depths >1.5 x d Flow rte: 5 to 20 ml/h MQL is not recoended for steel > 1,200 /², stinless steels or titnium/nickel lloys. Dry mchining Thred forming: not recoended Thred cutting: through hole mchining in steels of low or medium tensile strength nd in cst iron 62 Drilling & Threding 63

35 Everything you need to know bout threds Guging femle threds Thred guges re used to check thred dimensions fter the cutting or forming process. itch dimeter Core dimeter Go end thred Guge grip ogo end thred ogo end of the core hole guge Guge grip Go end of the core hole guge Go end of the thred guge Checks complince with the minimum dimension for the pitch dimeter including form errors, roundness errors nd strightness errors in respect of the thred xis. Checks the minimum dimension for the outside dimeter nd whether the length of the flnk portion is sufficient. The Go guge thred must be ble to be turned esily into the cut or formed thred. ogo end of the thred guge Checks whether the pitch dimeter of the femle thred in the workpiece exceeds the specified mximum vlue. It must not be possible to screw the ogo end of the guge into the workpiece thred from either side by more thn two turns by hnd without ny significnt mount of force. If the workpiece thred hs fewer thn three turns, it must not be possible to screw the ogo end ll the wy through. Brrel guge for checking the core dimeter Core hole guging is prticulrly importnt in thred forming becuse the core dimeter is produced by the thred former. In thred cutting, the core dimeter my become too nrrow due to burring during the tpping process. It must not be possible to insert the ogo end of the brrel guge more thn one full thred turn from either side. The femle thred is deemed to be true to guge if the following conditions re fulfilled: The Go end of the thred guge must be ble to be screwed esily down to the bottom. It must not be possible to screw in the ogo end of the thred guge by more thn 2 turns. It must be possible to insert the Go end of the core hole guge esily. It must not be possible to screw in the ogo end of the core hole guge by more thn one full thred turn. 64 Drilling & Threding 65

36 Everything you need to know bout threds Synchronous mchining To reduce process times in threding opertions, mnufcturers re incresingly fvouring higher rottion speeds nd cutting speeds (HSC). For high cutting speeds especilly, the synchronous mchining pproch is recoended. The Synchrospeed tool rnge from Wlter rototyp hs been optimised specificlly for this prticulr process. The key chrcteristics of these tools re their extremely high clernce, their extr short thred nd their shrp cutting edges. While Synchrospeed threding tools hve been developed exclusively for synchronous pplictions, ECO threding tools cn be used for both rigid nd conventionl tpping. Synchronous tpping requires mchine tht cn synchronise the rotry motion of the min spindle with the feed motion. Tody's mchining centres re usully equipped with this cpbility s stndrd. Synchronous tps re comptible with conventionl Weldon chucks s well s collet chucks (where possible with squre drive). Both fixtures hve the disdvntge of being unble to compenste for the xil forces tht re generted. rotoflex C synchronous tpping chuck A better lterntive is the rotoflex C tpping chuck with minimum compenstion. rotoflex C is tpping chuck for mchining centres with synchronous control logic. It gurntees precisely defined minimum compenstion nd is mtched to the geometry of Synchrospeed tools. Wht's so specil bout rotoflex C? Unlike ll other known tpping chucks, the rotoflex C design is bsed on precision-mchined flexor with high spring rte, which compenstes both rdilly nd xilly for microscopic deflections. The ptented microcompenstor is mde from specil lloy originlly developed for ASA. The conventionl synchro chucks on the mrket use plstic prts for this purpose, but these lose their flexibility over time, t which point they re no longer ble to provide microcompenstion. The rotoflex C helps to reduce considerbly the pressure forces tht ct on the flnks of the tp. This results in: improved surfce qulity on the flnks of the cut thred greter process relibility thnks to the reduced risk of brekge, prticulrly where dimensions re smll longer tool life due to less friction mximum utilistion of mchine power Flexor with minimum compenstion 66 Drilling & Threding 67

37 Everything you need to know bout threds The thred forming method Advntges o chips cold forming process Deep thred down to 4 x d possible s stndrd no problems ssocited with chip removl lese note: Discontinuity / incomplete thred An incompletely formed thred root or led-in cn cuse problems during utomtic screwing nd in the clening of threds Greter torque Around 30 % higher by comprison with thred tpping Improved thred surfce significntly less roughness in the flnks thn with thred cutting Aroun0 % higher brek-out resistnce under sttic lod due to strin hrdening of the thred flnks nd root More thn double the ftigue strength under dynmic lod due to strin hrdening nd uninterrupted fibre pttern Thred forming Torque (m) Mteril: 42CrMo4 (1,025 /²) Thred depth: 2.5 x d KSM: Emulsion 5 % Thred formers Tps Mximum possible mchining sfety thnks to tools of high stbility lrge core cross section without flutes Thred cutting Dimeter d () Significntly longer tool life thn tps rounded thred profile with no cutting edges Universl use in brod mteril spectrum round 65 % of ll mchined mterils in industry re formble 68 Drilling & Threding 69

38 Everything you need to know bout threds The thred milling method Advntges Universl ppliction in lmost ll long- or short-chipping mterils: steels, stinless steels, grey cst iron, nodulr cst iron, luminium nd AlSi lloys, nickel lloys nd titnium lloys Threds with inclined entry nd exit surfces possible Low torques lrge thred dimensions re strightforwrd to produce even on mchines with low driving power Different thred dimensions with just one tool, it is possible to produce different thred sizes with the sme thred pitch becuse the thred is not mde until the milling process Any thred tolernces cn be produced using single thred milling cutter becuse the thred tolernce is not produced by the tool but by the milling process lone With just one tool blind hole nd through-hole threds single-strt nd multi-strt threds right- nd left-hnd threds Best process relibility thnks to short chips (milling process) even with tough nd difficult mterils tool brekge does not necessrily result in workpiece rejection becuse the tool dimeter is lwys less thn the core dimeter of the thred Uniform motion no chnge in the direction of rottion (no reversing ction required) lower spindle strin nd thus less mchine wer Dimensionlly ccurte threds lmost ll the wy down to the root becuse thred milling cutters hve no chmfer unlike conventionl tps or thred formers no possibility of miscutting Torque lese note: Thred size Thred tpping Modern mchine tool with 3D CC control system required Tke tool dimeter into considertion (rdius correction) Higher tool costs thn with tps Generlly slower thn thred tpping or forming Thred milling 70 Drilling & Threding 71

39 Additionl informtion X treme lus cutting dt Mteril to be mchined Cutting speed v c (m/min) Feed f () for Ø () Mteril group Designtion Operting rnge Stndrd vlue Free cutting stee Soft construction steels up to 550 /² Low-lloy steel nd cst steel /² Low-lloy steel nd cst steel 700-1,000 /² Stee,000-1,300 /² Stee,300-1,600 /² Steel, hrdened HRC Tool steel, non-lloye Tool steel, low-lloye Tool steel, high-lloyed Stinless steel, ferritic, mrtensitic Stinless steel, ustenitic, sulphurised Stinless steel, ustenitic Stinless steel, hrdened i nd Co lloys up to 900 /² i nd Co lloys 900-1,200 /² i nd Co lloys over 1,200 /² Cst iron GG10-GG Cst iron GG25 - GG Cst iron GGG40 - GGG Cst iron GGG60-GGG Titnium nd titnium lloys up to 700 /² Titnium lloys over 700 /² The vlues listed pply to drilling depth of mx. 3 x d. The dt should be reduced by pprox. 5 % for vlues over 5 x d. Only the most importnt mterils re listed here. For dditionl mterils nd precise vlues, plese refer to TEC+CCS. 72 Drilling & Threding 73

40 Additionl informtion X treme lus driving power ECO-HT tp cutting dt Feed force F v (k) Construction steel ( /²) Tempering steel (700-1,000 /²) High tensile steel (1,000-1,300 /²) Austenitic stinless steel Cst iron (GG25 - GG35) Cst iron (GGG40 - GGG50) Mteril to be mchined TH v c (m/min) BH v c (m/min) Mteril group Designtion 1. stee.2 construction / cse-hrdened steel E,M stinless nd cidproof steel 1.3 crbon steel E,M lloyed / tempered E,O,M lloyed / tempered O,E lloyed / tempered O,E sulphurised E,O,M ustenitic E,O,M ferritic, ustenitic, mrtensitic E,O,M Dimeter d () 2.4 highly het-resistnt E,O,M cst iron 3.1 grey cst iron E,D grey cst iron E,D tempered nodulr cst iron O,E,M tempered nodulr cst iron O,E,M Driving power (k) 35 Construction steel ( /²) Tempering steel (1,000-1,300 /²) 30 High tensile steel (1,000-1,300 /²) Austenitic stinless steel 25 Cst iron (GG25 - GG35) Cst iron (GGG40 - GGG50) cst iron, vermiculr E,D copper 6.1 pure copper E luminium, mgnesium E = Emulsion O = Oil M = Minimum quntity lubriction D = Dry / compressed ir TH = Through hole BH = Blind hole 6.2 brss, bronze, red brss, short-chipping E brss, long chipping, wrought lloy E Al, lloyed, Si<0.5 %, wrought nd cst lloys E Al, lloyed, Si>=0.5 %<4%, wrought nd cst lloys E Al, lloyed, Si>=4 %<10%, wrought nd cst lloys E Our expert system, TEC+CCS, will recoend the cutting dt to suit your mchining needs. Dimeter d () All vlues refer to recoended cutting dt for the respective mterils. 74 Drilling & Threding 75

41 Additionl informtion TEC+CCS expert system TEC+CCS your expert system for economicl milling, drilling nd threding. The Wlter expert system, which incorportes the Wlter Titex nd Wlter rototyp brnds, hs become n indispensble softwre tool for mny metlworkers worldwide, helping them to select nd mke economicl use of milling, drilling nd threding tools. For over 15 yers, TEC+CCS hs been considered problem solver tht the mchining world cn depend on. TEC+CCS offers the following fetures: Tooling recoendtion nd disply of cutting dt fter user entry of the mchining tsk Electronic ctlogue of cutting dt Customisble dtbse of specil tools nd determintion of ssocited cutting nd performnce dt (CCS) Selection of pproprite core-hole drills vi direct link between CCS nd TEC Modifiction of tools, bility to store tools, nd determintion of ssocited cutting nd performnce dt (CCS) Ordering process, net prices, economic vibility nlyses, DXF Genertor for tool drwings, genertion of C progrms for thred milling nd much more Order the ltest version on CD-ROM free of chrge now. You will find further informtion t 76 Drilling & Threding 77

42 Additionl informtion Thred tpping core dimeters M ISO metric corse pitch thred Designtion (DI 13) Femle thred core dimeter () Drill size () min 6H mx M M M M M M M M M M M M M M M M M M MF ISO metric fine pitch thred Designtion (DI 13) Femle thred core dimeter () Drill size () min 6H mx M 6 x M 8 x M 10 x M 10 x M 12 x M 12 x M 12 x M 14 x M 16 x M 18 x M 20 x M 22 x UC (Unified Corse Thred) Designtion (ASME B 1.1) Femle thred core dimeter () Drill size () min 2B mx o o o o o / / / / / / UF Unified Fine Thred Designtion (ASME B 1.1) Femle thred core dimeter () Drill size () min 2B mx o o o o / / / / / G ipe thred Designtion (DI E ISO 228) Femle thred core dimeter () Drill size () min mx G 1 / G 1 / G 3 / G 1 / G 5 / G 3 / G Drilling & Threding 79

43 Additionl informtion Thred forming core dimeters M ISO metric corse pitch thred Designtion (DI 13) Femle thred core dimeter (DI 13-50) () ilot drill size () min 7H mx M M M M M M M M M M M M M MF ISO metric fine pitch thred Designtion (DI 13) Femle thred core dimeter (DI 13-50) () ilot drill size () min 7H mx M 6 x M 8 x M 10 x M 12 x M 12 x M 14 x M 16 x rotodyn ECO plus thred former the idel ddition to the ECO-HT tp rnge. 80 Drilling & Threding 81

44 Additionl informtion Troubleshooting: drilling Broken cutting edge corners Cutting edge corners destroyed Excessive corner wer Recondition promptly Cutting edge corners overheting Reduce cutting speed Excessive corner wer cusing corners to brek off Recondition promptly Workpiece springs up during through hole drilling, tool therefore ltches Reduce feed rte for through hole drilling (-50%) Centring with too smll point ngle, tool therefore drilling corner first recentre with point ngle > point ngle of drill Mechnicl overlod of corner cutting edges Reduce feed rte Centre region destroyed Excessive wer in the centre cusing it to spll Recondition promptly Inclined exit during through hole drilling results in interrupted cut Reduce feed rte for through drilling (-50%) Through hole drilling of cross hole results in interrupted cut Reduce feed rte for through drilling of the cross hole (-50% to -70 %) Mteril hs hrd surfce Reduce feed rte nd cutting speed for drilling on entry (nd, if pplicble, on exit if hrd on both sides) (-50% in both cses) Mteril too hrd Use specil tool for hrd/hrdened mterils Mechnicl overlod of point Reduce feed rte Mteril hs hrd surfce Reduce feed rte nd cutting speed for drilling on entry (-50%) Mteril too hrd Use specil tool for hrd/hrdened mterils 82 Drilling & Threding 83

45 Additionl informtion Troubleshooting: drilling Drill bit brekge Hole too lrge Excessive wer cusing brekge due to overloding Recondition promptly Crowding Check tht the flute length is t lest equl to drilling depth +1.5 x d Use drill bit with better chip trnsport properties Drill bit wnders on entry (e.g. becuse bit too long, entry surfce not flt, entry surfce inclined) Centre-mrk On lthes: lignment error between rotry xis nd drill xis Insted of solid crbide tool, use n HSS(-E) drill bit or drill bit with steel shnk ø Excessive centre wer or irregulr wer Recondition promptly Drill bit wnders on entry (e.g. becuse bit too long, entry surfce not flt, entry surfce inclined) Centre-mrk Rdil runout of the chuck or mchine spindle Use hydrulic expnsion chuck or shrink-fit chuck Check nd repir the mchine spindle Workpiece not clmped with dequte stbility Improve workpiece security Workpiece not clmped with dequte stbility Improve workpiece security Splling on cylindricl lnds Hole too smll Hndling error Keep tools in originl pckging Keep tools prt/prevent contct ø Excessive wer of cylindricl lnds or corners Recondition promptly Hole not round Reduce cutting speed 84 Drilling & Threding 85

46 Additionl informtion Troubleshooting: drilling oor surfce finish Burr on the bore exit Excessive wer of the corner cutting edge or cylindricl lnds Recondition promptly Excessive wer of the corner cutting edge Recondition promptly Crowding Check tht the flute length is t lest equl to drilling depth +1.5 x d Use drill bit with better chip trnsport properties oor chip formtion Entry position outside tolernce Excessive wer of the min cutting edge ffecting chip formtion Recondition promptly Chips too thin becuse feed rte too low Increse feed rte Indequte cooling cusing the chips to overhet Use internl cooling insted of externl Increse the pressure of the internl coolnt supply Incorporte dwell periods into the progrm if necessry ø Excessive centre wer Recondition promptly Drill bit wnders on entry (e.g. becuse bit too long, entry surfce not flt, entry surfce inclined) Centre-mrk 86 Drilling & Threding 87

47 Additionl informtion Troubleshooting: threding Axil miscutting of threds Rdil miscutting of threds Tp not cutting to pitch specifiction Reduce feed rte by pproximtely 5-10 % (for chucks with length compenstion) Contct pressure too low/high Adjust contct pressure Cutting edge geometry unsuitble for the work Select n pproprite tool recoended by the ctlogue or TEC+CCS Core hole position or ngle error Check workpiece security reduce feed rte on entry if necessry Tool life too short Unsuitble cutting edge geometry Select n pproprite tool recoended by the ctlogue or TEC+CCS Core hole strin-hrdened due to blunt preprtory tool Chnge drill bit/regrind promptly Tool lso cutting in the core Select lrge core dimeter Improve chip removl Use greter helix ngle Tp exhibits cold welding Use new tp, Improve lubriction (cooling) Select suitble surfce tretment or coting Indequte internl coolnt supply Improve lubricting gent or supply Thred too short Bell mouth Incorrect tool type Select n pproprite tool recoended by the ctlogue or TEC+CCS Tolernce not identicl to the tolernce specified on the drwing or thred guge Use tp with pproprite tolernce Core hole position or ngle error Check workpiece security reduce feed rte on entry if necessry Incorrect contct pressure With length compensting chuck, switch to expnsion 88 Drilling & Threding 89

48 Additionl informtion Drilling clcultion formuls Thred tpping/forming clcultion formule Speed n [rpm] n = v c 1,000 [rpm] Speed n [rpm] n = v c 1,000 [rpm] Cutting speed v c [m/min] v c = n 1,000 [m/min] Cutting speed v c [m/min] v c = n 1,000 [m/min] Feed per revolution f [] f = f z Z [] Feed rte v f [/min] v f = p n [/min] Feed rte v f [/min] v f = f n [/min] Metl removl rte Q [cm³/min] Q = v f ² 1,000 [cm³/min] 90 Drilling & Threding 91

49 Additionl informtion Wlter Titex CATexpress WHAT IS CAT express? Exmples of CATexpress specil solutions CATexpress is Wlter's express ordering nd delivery service for Wlter Titex specil tools. CATexpress covers defined rnge of specil tools. For these tools, we gurntee short led time of mximum of two weeks from the time of order intke. Wht's possible? Crbide drilling nd reming tools, e.g. Alph 2, Alph 4, X treme lus (+1 week), XD technology, XD-ilot, etc. Spirl nd stright-fluted tools Btch sizes of 3 to 50 pce. Dimeters from 3 to 20 Drilling depths down to 35 x d Stepped tools with up to two 2 steps Cotings, e.g. TFL, TFT, TF, etc. How does it work? Complete our specil forms for defining your specil tools These forms re vilble from your contct in the inhouse/field service You will find further informtion nd our forms t Twisted step drill X treme lus X treme DH, XD technology X treme ilot 180, pilot drill with XD technology Your dvntges Alph Jet step drill with 180 form E point Cost svings thnks to reduced storge More flexibility thnks to 2 weeks led time Fst feedbck thnks to quote returned within 24 hours Esy to use thnks to cutting dt recoendtions Reduction in errors in tool design s there is no need to plce the order until the desired component hs been defined All CATexpress tools re mnufctured in Germny to meet proven Wlter Titex qulity stndrds 92 Drilling & Threding 93

50 Additionl informtion Wlter Reconditioning Service Wlter Titex nd Wlter rototyp milling, drilling nd reming tools of originl qulity. Our Reconditioning Service for Wlter Titex nd Wlter rototyp tools mke n importnt contribution to reducing your production costs. On the one hnd, you obtin tools tht re s good s new but cost lmost third of the price of brnd new product. On the other hnd, you sve round 50 % of tool costs with the third regrinding especilly in the cse of high-qulity, high-tech tools. Top qulity, esy hndling nd prompt delivery. With our Reconditioning Service, not only do you sve costs nd time, you lso spre resources. This is how it works: You decide which tools need to be reground nd plce them in our Redbox. We rrnge for its collection nd then return your tools free of chrge nd restored to their originl qulity few dys lter. This mens: 100 % originl qulity, 50 % lower costs. REGROUD AD COATED Our delivery service Esy hndling with stndrdised delivery note nd brcode stickers Regrinding/recoting of ctlogue tools to restore originl geometry nd coting Regrinding of specil tools in ccordnce with drwing (price on request) Regrinding nd recoting pys off: 100 % ck the tools to be reground in the Wlter Titex nd Wlter rototyp shipping box provided free of chrge 75 % 50 % Tool costs -50 % You receive your tools restored to originl Wlter Titex nd Wlter rototyp qulity Collection of shipping box rrnged with one phone cll 25 % 0 % ew toost regrinding 2nd regrinding 3rd regrinding Delivery of the reconditioned tools Regrinding to the highest qulity stndrds by our experts Recoting for mximum performnce 94 Drilling & Threding 95

51 _Wlter worldwide How to find us. HEADQUARTERS Wlter AG Tübingen, Germny EUROE Wlter Deutschlnd GmbH Frnkfurt, Germny Werner Schmitt KD-Werkzeug GmbH iefern-öschelbronn, Germny TDM Systems GmbH Tübingen, Germny Wlter (Schweiz) AG Solothurn, Switzerlnd Wlter Benelux.V./S.A. Zventem, Belgium Wlter GB Ltd. Bromsgrove, Gret Britin Wlter Itli S.R.L. Fino Mornsco (CO), Itly Wlter Frnce Soultz-sous-Forêts, Frnce Wlter Tools Iberic S.A.U. El rt de Llobregt, Spin Wlter orden AB Hlmstd, Sweden Wlter CZ spol.sr.o. Kurim, Czech Republic Wlter olsk sp.z.o.o. Wrsw, olnd Wlter Hungári Kft. Budpest, Hungry Wlter Austri GmbH Vienn, Austri SC Montnwerke Wlter SRL Timisor, Romni Montnwerke Wlter GmbH - odru znic Trgovin Slovenij Miklv z n Drvskem olju, Sloveni Wlter LLC St. etersburg, Russi Wlter Slowkei, o.z. itr, Slovki Wlter Kesici Tkimlr Snyi ve Ticret Limited Sirketi Istnbul, Turkey

52 ORTH AMERICA Wlter USA, IC. Wukesh, WI, USA TDM Systems Inc. Schumburg, IL, USA Wlter Tools S.A. de C.V. Tllnepntl, Mexico Wlter Cnd South Americ Wlter do Brsil Ltd. Sorocb, Brzil Wlter Argentin S.A. Cpitl Federl, Argentin ASIA ACIFIC REGIO Wlter Wuxi Co. Ltd. Wuxi, Chin Wlter AG Singpore te Ltd. Singpore Wlter Kore Ltd. Ansn, Kore Wlter Tools Indi vt. Ltd. une, Indi Wlter Tooling Jpn KK goy, Jpn Wlter (Thilnd) Co. Ltd. Bngkok, Thilnd Wlter Mlysi Sdn. Bhd. Selngor, Mlysi Wlter Austrli ty. Ltd. Victori, Austrli Wlter ew Zelnd Ltd. Christchurch, ew Zelnd

53 Wlter AG Derendinger Strße 53, Tübingen ostfch 2049, Tübingen Germny Wlter GB LTD. Bromsgrove, Englnd +44 (0) Wlter Kesici Tkimlr Snyi ve Ticret Limited Sirketi Istnbul, Turkey +90 (216) bx Wlter Wuxi Co. Ltd. Wuxi, Jingsu,.R. Chin +86 (0) Wlter AG Singpore te Ltd Wlter Austrli ty. Ltd. Victori, Austrli +61 (0) Wlter ew Zelnd Ltd. Christchurch, ew Zelnd +64 (0) Wlter Tooling Jpn KK goy, Jpn +81 (0) Wlter USA, Inc. Wukesh (WI), USA Wlter Kore Ltd. Ansn, Kyungki-do, Kore +82 (0) Wlter Tools Indi vt. Ltd. une, Indi Wlter (Thilnd) Co., Ltd. Bngkok, Thilnd +662 (0) Wlter Mlysi Sdn. Bhd. Selngor D.E., Mlysi TDM Systems Inc. Schumburg (IL), USA Wlter Tools S.A. de C.V. Tllnepntl, Estdo de México +52 (55) Wlter Cnd rinted in Germny (08/2009) E

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