Solid Carbide Thread Milling

Via: Walter Tools
Thread Milling is typically used when CNC machining hard metals for industries such as aerospace.
You can create threads for your part, while removing the risk of using a tap in hard metals.
What is CNC Machining?
CNC stands for computer numerical control. So, CNC machining is any kind of machining process controlled by a computer. Computerized automation allows parts to be made more quickly, accurately, precisely, and with more complex geometries than those produced via manual machining. CNC also reduces manual machining labor that would otherwise be done by humans. While they aren’t machining each part themselves, people are essential for programming and operating the machines, ensuring that every operation goes smoothly.
About the CNC Machining Process
CNC, or computer numerical control machining, is a subtractive manufacturing method that leverages a combination of computerized controls and machine tools to remove layers from a solid block of material. The desired cuts in the metal are programmed according to corresponding tools and machinery, which perform the machining task in an automated fashion.
Types of CNC Machining
Depending on the type of part that needs to be machined, there are different types of CNC machines best fit for the job. CNC milling utilizes CNC mills, which consist of a multi-axis system (three, four, or five axes, depending on the part complexity). CNC turning involves Lathe machines, which generally have two axes and cut pieces using a circular motion. Electric discharge machines (EDM) utilize electrical sparks into order to mold work pieces into the desired shape. Hobbing is another type of machining process used for cutting gears, splines, and sprockets. Additional CNC machine types include plasma cutters and water jet cutters.
How Does CNC Machining Work?
The programs used for CNC machining these days are written with G-code, and are usually automatically created by CAM software. CAM, or computer aided manufacturing software, generates the G-code for a 3D model with given tools and workpiece material. This G-code controls the CNC machines, i.e., the motion of the tool, the workpiece, and any tool changes. It even has commands to turn on or off the coolant and other auxiliary components.
CNC machining can be used for a wide variety of materials, with the most common being aluminum, steel, brass, ABS, Delrin, and nylon. But really, almost any hard material can be CNC machined. We’ll discuss the materials more in-depth later on.
CNC vs 3D Printing
Compared with parts manufacturing through additive methods, CNC machined parts are functionally stronger and typically have superior production quality and finish. Thus, CNC machining is typically used in the mid to late stages of development when parts are ready to be tested for functional accuracy.
CNC Design Considerations
While most of the details, such as tooling, spindle speed, cutter type, and depth of cut, and taken care of at the machine shop, there are some key things you can do while designing your parts to not only make sure they can be made but also ensure you develop a lean product that doesn't break the bank.
The primary advantages of CNC machining include rapid prototyping and the ability to produce full-scale production parts quickly. It offers a high level of precision and accuracy in manufacturing parts and allows for tight tolerance machining for CNC parts of all sizes. It also offers maximum flexibility across volume, pricing, lead times, and the range of materials and finishes being used.
The two primary CNC machining processes are CNC turning and CNC milling. Other machining processes include drilling, gear hobbing and electrical discharge machining, among others.
Industries that use CNC machining include aerospace, automotive parts manufacturing, medical machine manufacturing, transportation, defense, and marine industries, along with oil and gas industries and electronics. CNC machining has allowed these industries to become more efficient at mass-producing custom CNC parts.
The standard machining tolerance is ± 0.005" or 0.13mm. Tolerances are the allowable range for a dimension. If a CNC machining tool has a tolerance of ± 0.01 mm this means that the machining tool can have a deviation of 0.01 mm in every cut. With a drawing, Fictiv's CNC machining service can produce CNC parts with tolerance as low as ± 0.0002 in. Without a drawing, all CNC parts are produced to our ISO 2768 medium standard. We can also machine to tighter tolerances, ±0.025mm or ±0.001", with an attached engineering drawing calling out critical features.
#cnc #cncmachine #machining

[@ironic1767]

Dunno how I feel about full rapid into the hole like that but a nice demonstration

[@Convolutedtubules]

Just don't move your X/Y offsets and forget about it.

[@Cadaverine1990]

Not like going slow is going to make a difference, either way the bit will be broken.

[@ewildgoose]

I'm a recent Brother Speedio owner. If you think that's "rapiding into...", Then wait until you run a Speedio (or Robodrill)!! The machine needs to be accurate enough to fit the tap in the hole you drilled or the threads don't work. So really you might as well get a hustle on...

[@michaelslee4336]

If you’re worried about that then how could you trust ANYTHING the machine was doing? It’s all the same, some code telling some motors to do something.

[@eric4946]

Once you’re willing to move faster than 10-30mm/s you might as well go 80-90% of full speed. Either the machine knows where it is and it’s correct. Or it’s not .

[@dominicpecoraro6074]

I use a single flute carbide insert for different threads per inch. do it all in one pass.

[@charlesaubry8964]

Les nouvelles techniques sont surprenantes

[@dannydetonator]

Cette une c'est rien de noveau, mais threadmill á un coût exaggeré

[@gabilg20]

Las roscas con ese tipo de herramientas se hacen de abajo hacia arriba y más si son ciegos los taladros, para evitar que la viruta colapse la herramienta.

[@jasonruch3529]

😊 thanks,,saved me from saying that as well 😊

[@gabilg20]

@@jasonruch3529 👍🙋

[@arsham194]

that spindle should be one hell of a spindle!

[@Mike-ff7ib]

It looked like CGI but a few times watching it looks like a real demo.

[@chrisfisichella7665]

Very cool

[@stomp4423]

These are awesome until your drill breaks, your hole depth changes or you have a fixturing issue. Telling your lead man you need another is always a fun conversation.

[@namednot]

To me that sounds like a skill issue, not an issue with this cutter.

[@skuresture]

What brand cutter? It looks really good on hard materials. Less deflection.

[@parapatrio7220]

😊

[@p1pp3lc]

Looks like the ones from Kennmetall we use.

[@SciSenkra]

Really seems like there's already a thing for this, itscalleda tap

[@user-pk1og1dh3t]

Резьба фреза а есть чета по лучше ещё? И чем она отличается от грибковой

[@megatrondecepticon3348]

The tool path definitely looks weird... let us see the codes maybe the vendor has its own codes for this weird thread mill

[@Sketch1994]

What? Haven't you seen a circular interpolation cutter comp enable lead in move? PS: Likely not...Sinumerik is awesome

[@Convolutedtubules]

@@Sketch1994 I took me a while to figure out it was arcing in.

[@eric4946]

It’s not a weird path at all. It’s a circular motion with a fixed rate of travel down.

[@ferrumignis]

It's just a spiral motion, it only looks odd as you are seeing it from the side so you can only clearly see two dimensions.

[@stefanhauser2804]

​@@ferrumignisthis

[@andrezero1302]

Как же любят все усложнять

[@brianropel]

Why wouldn’t you start at the bottom of the hole and thread mill upwards. The chips fall down. Wouldn’t it make more sense?

[@ferrumignis]

Because then you have all the cutting edges engaged at the same time, cutting the same depth, so tool forces would be very high

[@reBorn7458X]

@@ferrumignisI’ve thread mill upwards. I just didn’t cut full depth but split it in 3 cuts. Comes out perfect.

[@ferrumignis]

@@reBorn7458X Why do three upward passes rather than one down pass?

[@reBorn7458X]

@@ferrumignis I did it just to do something different lol

[@TheSphongleface]

Using: A tap, would be way cheaper.

[@user-qh4og8gy9p]

음... 안정성에서는 불안감이 있기는 하지요..

[@dannydetonator]

Yes, you save money but in case of brakeage (more likely than with threadmill) you lose time, often lots of it. Try to extract a broken carbide thread former from a deep hole in stainless on a complex, nearly finished part and you'll see. But damn, threadmills can fuck up your vision and challenges your math skills while manual programming them. Then, one tiny input mistake and the mill is likely broken off, with barely perceptible icicle-breaking sound.

[@CursedLemon]

Frankly I would be concerned about chip evacuation above everything else

[@rsriprac]

It's a demo but thru-spindle coolant is normally used and it'll flush out the chips

[@lukem280]

Cool graphics. How do straight cutters make bent threads tho?

[@eric4946]

Bent threads ?

[@ferrumignis]

The cutter is moving down in a spiral path. This means the cutting edges have to be narrower than the thread form it cuts.

[@lukem280]

@@eric4946 threads run on angles

[@user-qh4og8gy9p]

나는 이 공구가 돌아가는 이유를 모르겠다... 이해는 가는데 깍인곳이 곳이 제대로 작동할지에 대한 불안감이 크다

[@a.k.2023]

Dieses Werkzeug gibt es auch wo man ohne vorbohren Gewinde fräsen kann. 👍🏻

[@danl.4743]

I don't know if Fusion360 knows how to do that..

[@floris6164]

Yes, it can

[@kalebstover-fb2ll]

It can, its the same as any other thread mill cycle, hell the hermles I run have a built in thread cycle

[@danl.4743]

@@kalebstover-fb2ll Good to know.

[@Bali25]

Traditional tap drilling farted on this one. Did anyone notice the right side of the thread depths being smaller than the left.

[@B_Kaiser_Local16]

Partial hole with clockwise spinning cutter. What you see is the burr that is remaining on the cutout.

[@user-lu6vk8ii1f]

Зачем так сложно, может по технологии?

[@arthurmorgan8966]

Can this do outer threads, too?

[@jonahhekmatyar]

Most likely

[@dannydetonator]

I've been milling for a while and this has never occurred to me. It seems wrong, but theoretically would work with the right program and settings. Never had a part on my mill requiring outer threads, all of these ones were always round and done on a lathe where threadmill wouldn't be efficient. That or for designing purposes, a non-round part would be added screws with necessary step, rather than milling out a pin, then threading it from the part itself. Also practically i see disadvantages of milling an outer thread, instead of forming or cutting it (like increased vibration due to a thin, long mill going around a work-pin not being the sturdiest of set-ups).

[@aaaooaao9949]

warum nicht direkt auf voller Zustellung? Die unteren Gewindegänge werden eh in einem Durchgang gefräst - da macht dann das vorherige rumgetanze keinen Sinn.

[@eric4946]

The threads are always milled in a single pass, the cutter never goes in the same trough twice. You don’t cut in one thread “step” because it’s too much force in many materials. Aluminum thread forming/rolling is better/easier. This is just a demonstration.

[@lankashri36]

M3

[@firestarter1281]

Lol

[@yanmi3956]

スゲー

[@yuukio5199]

Nice copy from Walter tool official movie 😅😅😅

[@darioalvares7350]

Fake .no da el paso

[@ferrumignis]

You are fake, cutter is real.

[@rsriprac]

Not fake, tunaloy makes them too: kzbin.info/www/bejne/qZWzoomjl7yAa6s

[@Convolutedtubules]

A lot of rubbing along the entire shank, can't be good for the spindle.

[@subtleusername5475]

what are you talking about lol, it's fine