tool concepts - · pdf filex10nicralti32-20 [incoloy800] x12crniti18-9 x6crnimoti17-12-2...

Thread production in tapered cast holes

Tool concepts for reducing the number of machining jobs

Thread Cutting Technology

3


Finished thread, re-bored and cut to perfection in one work process

Tapered cast hole

1. 2.


Work piece examples

Tool concepts for reducing the number of machining jobs

With components of cast aluminium, cast iron or similar materials, threads must often be produced in tapered holesleft by the casting process in which the blanks for such parts are usually made. In order to cut down on productioncosts, the common aim in such cases is to avoid reboring the hole before thread production in a separate workprocess, and to produce the thread in one single work process instead.

There are different tool concepts available for achieving this aim, the construction of a specific tool always dependingon the special properties of the hole in the work piece. In accordance with this principle, all the geometric conditions of the work case must be known in order to design the perfect tool.

4



Application example: Component of cast aluminium GAL

For the machining of this casing, seven threading operations must be performed in tapered cast holes.

For this purpose, seven different tool concepts come into play.

A

C

D

B

F

E

G


5


Tool concept A Thread size: M6

Tool solution

Raw condition Finished condition

Tap with reaming device

Raw condition Twist drill Tap Finished condition

Conventional process sequence


Process sequence

6



Tool concept B Thread size: M18 x 1.5

Tool solution


Tap with reaming device and face chamfer




Process sequence

Twist drill Countersink Tap

7



Tool concept C Thread size: M5

Tool solution


Tap with face chamfer




Process sequence

Twist drill Tap

8



Tool concept D Thread size: M6

Tool solution


Drill Tap




Process sequence

Twist drill Tap

9



Tool concept E Thread size: M5

Tool solution


Tap with face chamfer




Process sequence

Twist drill Tap

Twist drill

10


Counterbore Thread milling cutter


Tool concept F Thread size: M 10 x 1

Tool solution


MoSys unit with thread milling cutter BGF




Process sequence

1/3 P


11



Tool concept G Thread size: M6

Tool solution


Thread milling cutter ZBGF




Process sequence

Twist drill Thread milling cutter

12


Engineering for your application case with questionnaire for work piece thread

Basically, it is always the strategy of EMUGE to supply a perfectly designed tool with cutting material, coating and geometrytailored exactly to work conditions like work piece material, lubrication, hole type, machining position etc.Tool construction is of special importance whenever blind holes have to be machined. Wherever work conditions permit theuse of standard tools these will be recommended as a preferred choice. In all other cases, we quote specially designedtools which are supplied as custom-made special solutions.

For giving us full information about the technical work conditions of your application, best use the technical questionnaire on page 13 of this brochure.

Tool programme

The tool programme is partly available as a standard stock programme, and partly as special production.

The standard stock programme includes:- Thread milling cutters BGF, thread milling cutters ZBGF- Combination drill taps (applicable for through hole threads)

As special production, we can supply:- Taps for blind hole threads, and special combination drill taps for through hole threads- Thread milling tools, especially with our easy-to-combine counterbore and stepped-bore system MoSys

Tool technology


13


Company: ····································································································································

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Contact: ········································································································································

Phone: ············································································································································

Fax: ··················································································································································

E-mail: ············································································································································

Size: ·················································································································································

Design: ···········································································································································

Article no.: ···································································································································

Project: ··········································································································································

Workpiece material:

Description: ································································································································

Condition during working: ································································································

Tensile strength: ··································································································· N/mm2

Thread hole:

Thread hole type – please enter dimensional specifications:

Raw condition Finished condition Raw condition Finished condition Raw condition Finished condition

Hardness: ················································· Elongation: ········································· %

Short-chipping

Long-chipping

Preferred work process:

Tapping Thread milling

Machine:

Manufacturer: ····························································································································

Type: ················································································································································

Spindle power: ··············································································································· kW

Horizontal Rotating tool

Vertical Sationary tool

Cutting data:

Speed/rpm n: ··········································································································· min-1

Cutting speed vc: ·································································································· m/min

Feed:

Pressure cam Hydraulic

Lead screw NC control

Synchronsous spindle Gear wheels

Others······································································································································

Feed for thread milling:

fz ................................................ fs ................................................fb .........................................

Tool holder:

Rigid Collet Thermic powRgrip®

Tapping attachment Manufacturer: ·········································

Tap holder Type: ······························································

With overload clutch

With length compensation

With axial-parallel floating

With internal coolant-lubricant supply Pressure: ························ bar

DIN 1835 / 6535 HB DIN 1835 / 6535 HE

Filled in by: ··································································································································

Spindle adaption:

MT / ISO taper / HSK / TR / Others ··········································································

DIN / ANSI / JIS / Others ··································································································

Cooling:

Oil Emulsion ·············· % Dry

Circulation Brush Mist

Minimum quantity lubrication Otherse: ··························

Tool information:

Design: ···········································································································································

Article no.: ···································································································································

Shank diameter: ··································· DIN: ································································

Special features: ······················································································································

······························································································································································

······························································································································································

Tools used until now (manufacturer): ·········································································

······························································································································································

······························································································································································

······························································································································································

Tool life: ··································································································· (No. of threads)

······························································································································································

Date/signature: ·························································································································

Technical questionnaire: Thread production in tapered cast holes

⎫⎬⎭

14

Range of application – Material groups for the available stock programme

Q-St37-3R-Fe809SMnPb28St37-2St70-2GS-25CrMo416MnCr5Ck45100Cr642CrMo4VX30WCrV5-3X38CrMoV5-3X155CrVMo12-155NiCrMoV645WCrV7X155CrVMo12-1X210CrW12X10NiCrAlTi32-20 [INCOLOY800]X12CrNiTi18-9X6CrNiMoTi17-12-2X45SiCr4X5NiCrTi26-15FerroTiCHardox500

GG 20GG 30GGG 40GGG 70GGV (80%Perlit)GGV (100%Perlit)GTW 40GTS 65

E-CuCuZn40 [Ms60]CuZn37 [Ms63]CuZn39Pb2 [Ms58]CuAl10Ni

GCuSn5ZnPb [Rg5]GCuSn7ZnPb [Rg7]Ampco16Ampco20

NiCu30Fe [MONEL400]NiCr19NbMo [INCONEL718]Haynes 25 (L605)

Al 99,5 [F13]AlCuMg1 [F39]G-AlMg3GD-AlSi9Cu3GD-AlSi12G-AlSi17Cu4

MgAl6GMgAl9Zn1

Ti3 [Ti99.4]TiAl6V4TiAl4Mo4Sn2

BAKELITHOSTALENCFK / GFK / AFK

C-8000W-Cu 80/20

11.1

1.2

1.3

1.4

1.5

1.61.71.81.91.10

1.111.121.13

22.1

2.2

2.3

2.4

2.533.13.2

3.33.4

3.5

3.63.744.14.24.355.1

5.25.3

5.466.16.277.1

7.288.18.28.399.19.2

Hole type

Thread depth bmax

Coolant-lubricant

500-700 N/mm2

340-470 N/mm2

700-900 N/mm2

650-950 N/mm2

500-700 N/mm2

600-800 N/mm2

700-900 N/mm2

1200-1400 N/mm2

1100 N/mm2

900-1100 N/mm2

900-1100 N/mm2

47-52 HRC56-57 HRC60-63 HRC63-64 HRC

610-850 N/mm2

500-700 N/mm2

500-730 N/mm2

900-1100 N/mm2

1200 N/mm2

800-900 N/mm2

1300-1400 N/mm2

120-220 HB220-270 HB

400 N/mm2

700-1050 N/mm2

220 HB230 HB

360-420 N/mm2

580-650 N/mm2

-400 HB

250-350 N/mm2

340-490 N/mm2

310-550 N/mm2

380-500 N/mm2

500-800 N/mm2

150-300 N/mm2

150-300 N/mm2

630 N/mm2

600 N/mm2

420-610 N/mm2

850-1190 N/mm2

1550-2000 N/mm2

100-250 N/mm2

300-500 N/mm2

130-190 N/mm2

240-310 N/mm2

220-300 N/mm2

180-250 N/mm2

300-500 N/mm2

300-500 N/mm2

700 N/mm2

700-900 N/mm2

900-1250 N/mm2

110 N/mm2

80 N/mm2

800-1500 N/mm2

60 N/mm2

230-250 HV

≤ 400 N/mm2

≤ 600 N/mm2

≤ 850 N/mm2

≤ 1100 N/mm2

≤ 1400 N/mm2

≤ 850 N/mm2

≤ 1400 N/mm2

≤ 1400 N/mm2

≤ 500 N/mm2

≤ 850 N/mm2

850-1400 N/mm2

> 1400 N/mm2

≤ 900 N/mm2

900-1250 N/mm2

1.01231.10141.07181.00371.00701.72181.71311.11911.35051.72251.25671.23671.23791.27131.25421.23791.24361.48761.48781.45711.47041.4980

0.60200.60300.70400.7070

0.80400.8165

2.00602.03602.03212.03802.0966

2.10962.1090

2.43602.4668

3.02553.13253.35413.21633.2582

3.56623.5912

3.70553.71643.7185

Abbreviation Coolant-lubricant

E Emulsion

Thread cutting oil

Thread cutting paste

O

P

Steel materials Cold-extrusion steels,Magnetic soft ironFree-cutting steels,General construction steelsFree-cutting steels, Construction steels,Alloyed steels, Steel castingsCementation steels,Heat-treatable steels,Nitriding steels, Cold work steelsHeat-treatable steels, Nitriding steels,Hot work steels,Hardened steels up to 44 HRCCold work steelsHardened steels > 44 - 55 HRCHardened steels > 55 - 60 HRCHardened steels > 60 - 63 HRCHardened steels > 63 - 66 HRCCorrosion-proof steels,Acid-proof steels,Heat-resistant steelsCorr.-/Acid-proof steels, Heat-resist. steelsCorr.-/Acid-proof steels, Heat-resist. steelsSpecial steel materials

Cast materialsCast iron

Cast iron with nodular graphite

Cast iron with vermicular graphite

Malleable cast iron

Hard castings up to 400 HBCooper, Cooper alloys, Bronze, BrassPure copper and low alloyed copperCopper-zinc alloys(brass, long-chipping)Copper-zinc alloys (brass, short-chipping)Copper-alum. alloys (alubronze, long-ch.)Copper-tin alloys (bronze, long-chipping)Copper-tin alloys(bronze, short-chipping)Special copper alloys, up to Q 18Special copper alloys over Q 18Nickel/Cobalt alloysNickel/Cobalt alloys heat-resistantNickel/Cobalt alloys high-heat resistantNickel/Cobalt alloys high-heat resistentAluminium alloysAluminium wrought alloys

Aluminium cast alloys Si ≤ 5%Aluminium cast alloys 5% < Si ≤ 12%

Aluminium cast alloys 12% < Si ≤ 17%Magnesium alloysMagnesium wrought alloysMagnesium cast alloysTitanium, Titanium alloysPure titanium,Titanium alloysTitanium alloysSyntheticsDuroplastics (short-chipping)Thermoplastics (long-chipping)Fibre-reinforced syntheticsMaterials for special applicationsGraphiteTungsten-copper alloys

≤ 1100 N/mm2


Raw condition

III

Blind hole

Finished conditionRaw condition

IIThrough hole

with reverse cut

Finished conditionRaw condition

I

Through hole

Finished condition


••

•

KOMBI

Taps

15


I, II I, II, III I, II, III I, II, III I, II, III

1 x d1 1.5 x d1 - 2.5 x d1 3 x d1 2 x d1 2 x d1

E / O E / O E / O E / O E / O

BGF ZBGF-T

•

•

••

•

•••

••

•

•

••••

••

ZBGF-H

••••

•

••

ZBGF-W

•

•

•

•

•

•

•

•••

•

•

•

•

••••

•

•••

••••

••

••

•

•

Thread milling cutters


ZP

1003

6 . G

B2,

5T 0

6200

7 E

w ·

Rev

. AP

rint

ed in

Ger

man

y

FRANKEN GmbH & Co. KG · Fabrik für PräzisionswerkzeugeFrankenstraße 7/9a · 90607 Rückersdorf · GERMANY · Tel. +49 (0) 911 / 9575-5 · Fax +49 (0) 911 / 9575-327

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