Thread milling
Thread milling generates threads by rotating the tool's spiral cutter to cut the threads. The axial movement of the tool during one revolution creates the pitch of the thread.
Although not as widespread as thread turning, thread milling can be remarkably efficient and flexible in certain scenarios. Here are situations where thread milling shines:
Selection Criteria for Thread Cutting and Thread Milling Inserts:
● For asymmetric or hard-to-rotate parts: When traditional methods fail, thread milling can handle the task with ease, showcasing its unique advantages.
● Handling fragile or chip evacuation challenges: It manages chips effectively, preventing clogs, and ensuring a smooth machining process.
● Cutting tough materials: Even in the face of high cutting forces, thread milling maintains stability to ensure quality machining.
● Fine operations near part edges or hole bottoms: Whether cutting to a shoulder or deep into a blind hole, it achieves precision without leaving any flaws.
● Protector of thin-walled parts: For fragile thin-walled parts, it can machine them gently, reducing the risk of deformation.
● Solving fixture challenges: Even with unstable fixturing, thread milling's flexibility ensures machining accuracy.
● Optimizing inventory management: Reducing the number of tool types and lowering inventory costs for more efficient management.
● Protecting expensive parts from risks: In machining high-value parts, thread milling cutters can be retracted at any time to avoid unexpected losses like tap breakage.
● Multi-dimensional movement: It requires a machine capable of flexible movement in the X, Y, and Z axes, providing comprehensive control for a versatile and adaptable machining process.
1. Machining Precision and Complexity:
● For high precision and complex threads, such as variable pitch or multi-start threads, thread milling inserts are typically more suitable.
2. Material Being Machined:
● Thread milling provides more stable cutting conditions and better chip control for difficult-to-machine materials.
3. Machining Efficiency:
● For high-volume production of standard threads, thread inserts are often more efficient.
4. Thread Size:
● Small diameter threads are usually better suited for thread inserts.
● Large diameter threads are more efficiently processed with thread milling inserts.
5. Machine Tool Configuration:
● If the factory primarily uses lathes, thread inserts might be preferred.
● If the factory has milling machines, thread milling inserts offer more flexibility and machining range.
6. Cost Consideration:
● Thread inserts may have a lower initial investment cost, but thread milling inserts can save time and reduce tool changes, thus lowering overall costs, especially for complex thread machining.