In order to make the spiral grooves in different fasteners, the thread turning process is a crucial rapid manufacturing step. Tapping, milling, and turning are the most common techniques for cutting metal threads. WayKen described many tooling, techniques and equipment used in thread turning services in this article, including taps and threading machines. Reading will help you learn about the right methods used for optimizing the thread turning process in both automated and hand threading, as well as the importance of precise thread creation in engineering and daily items.
Tools and Techniques Used in the Thread Turning Process
There are many specialized tools and equipment used to produce intricate and useful threaded components. Each threading technique and tool has advantages for precision thread turning process. Consumers should consider the following advice and pointers to optimize the thread turning process with the right tooling and techniques in carrying out efficient and excellent machining.
- Taps and Dies: They are essential for manually or mechanically cutting both exterior and interior threads, respectively.
- Turning Tools: These tools are used in CNC lathes and machining centers to cut threads on conical bodies.
- Thread Mills: Thread mills, which are used in CNC machining centers, offer precision and adaptability by handling varying thread sizes and pitches.
- Thread Whirling Machines: These machines, which rotate the cutting instrument around the workpiece at a high rate, are specialized in creating long, fine threads on components with thin walls.
- Thread Grinding Machines: These machines, which are used to produce high-precision threads, use grinding wheels to attain tight tolerances and delicate finishes.
- Thread Chasing Heads: These heads, which are utilized in both automated and manual processes, hold several cutters that cut identical threads on a workpiece at once.
It might be challenging to attain consistent tool durability, consistent component performance, and good chip control in the demanding process of thread turning. For developing internal or external threads that satisfy precise geometric and dimensional specifications, and selecting an appropriate tool for the thread turning services, you must consider:
- Consideration of any necessary clearance
- Reduction of the tool overhang to enable rapid clamping
- Choosing a blade with a lower force where there is inadequate rigid clamping
- Using appropriate coolant to improve and control cutting procedure
- Connection the coolant with ease by using a plug-and-play coolant adaptor
How to Measure and Improve the Quality of Thread Turning?
Through a cycle program, the majority of CNC thread turning machines are capable of using these feed methods to improve the quality. These include chips and conventional forms of turning, thick chips that only come into touch with one side of the blade and less heat transfer to the blade for the majority of threading operations.
1) Choosing the Thread Turning Techniques: Insert and Shim
You must take into account the insert category, flank/radial clearance, and insert design when selecting the best thread turning insert for your particular use. All of these elements affect the quality of the process.
Full shape, V-profile, and multi-point implants are the three primary insert kinds available when twisting a thread. Every kind has benefits and drawbacks.
The blade inclination should be taken into consideration while choosing the shim. The blade incline will depend on the diameter and pitch.
There are some other factors that should be considered in this manner:
- The life of the tool and blade wear
- Angle of blade inclination to provide a uniformly big gap
- Select the appropriate blade material based on the toughness and material specifications.
- Cutting factors: Adjust the number of passes and pace of cutting as needed.
2) Thread Turning Tooling Setups
Optimization of the thread process quality and threading efficiency are significantly impacted by the tool configuration.
The first rule is to employ as little overhang as you can.
Use a tool holder with the least amount of overhang to prevent vibration and get the best possible tool setup. If one is available, we advise using a tailstock or sub-spindle for support. Internal thread process is very sensitive. Since it is most widely operated with long overhangs, it is particularly crucial to place the bar correctly to guarantee adequate clamping contact while milling with long overhangs.
The design of the boring bar is very important. Because it may determine the advised clamping length. A stable tool setup will come from this. The collision, approach and structural tolerance between the tool and its holder are critical elements for the greatest boring bar performance. A holder that fully encloses the bar provides the best stability. It is not advised to use cylindrical holders with screws or V-type bar holders.
You should Make sure the blade geometry, infeed technique and tooling optimization in relation to depth and number of passes are accurate. Multi-tooth blades are the best option for ensuring optimal efficiency and tool life in the rapid manufacturing, followed by single-edge full-tooth blades, while V-tooth blades have the least performance and the shortest tool life.
Impact of Tool Geometry Angles on Thread Turning
Effective use of thread turning tooling and techniques is very important to optimize the quality of the process and it is necessary to consider the impact of tool geometry angles on the process.
In rapid manufacturing operate, the thread turning instrument is often secured onto an elastic tool holder. This serves as a buffer for shielding the tool tip from unequal stresses that may be experienced during cutting. Using the appropriate fluid during the process can lower the finished surface’s roughness value. This guideline can help you in this manner.
- Consider the appropriate cutting gap of the workpiece diameter before starting the process
- Add the crown space
- Consider the tool’s position that is properly arranged in relation with the workpiece
- Use the appropriate blade geometry.
- Choose the right blade pad to achieve the proper flank clearance in order to guarantee sufficient and consistent clearance.
- Examine the clamping as a whole, including the cutting tool, if the thread is not certified.
- Optimize the dimensions, number of passes, and feeding technique.
- Use the tool at a minimum distance related to the pitch before cutting.
- Suitable and high-lifespan coolant can be used to enhance chip control and improve the tool lifespan.
- Easy and quick clamping is guaranteed by the quick-change mechanism.
Preventing Axial Movement in Thread Cutting
Significant deviations in thread pitch can affect the ability of a processed thread to screw in properly. The lathe’s precision problems and operational faults, including the lengthy leadscrew’s severe axial movement, are the primary causes of thread pitch inaccuracies.
Because of their low stiffness, threads on thin shaft-like workpieces are prone to deviate when subjected to the back force. A uniform rest tool can be employed in addition to a follow rest to prevent and lessen this sort of thing.
To inspect the axial movement of the lead screw, a dial gauge is mounted with a magnet on the lathe bed. A steel ball is inserted into the leadscrew’s center hole, and the leadscrew is rotated. The half nut on the apron is checked for any movement along the lead screw to assess potential axial deviations.
When turning threads on thin workpieces, a lightweight, solid rest is used. Typically, a steady rod made of bronze material is attached to the tailstock, with a V-shaped notch at the end that contacts the spinning workpiece. This setup helps offset forces generated by the machining tool, improving stability and minimizing thread pitch inaccuracies.
Conclusion
As discussed in this post, you must optimize the conditions in different manufacturing processes such as thread turning if you want your products to be distinctive and long-lasting. Here at WayKen as an innovator in customized CNC machining, we are continuously strengthening the precision management and technological innovation of thread turning processes, to satisfy particular engineering requirements.
