operation samples
TRANSCRIPT
Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 1
Thread machining
in
OEM-Applications
Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 2
Engines Cylinder block, Cylinder head, Crankshaft, Camshaft, ConRod
Injection-SystemsPump case, Cylinder head, Rail, Injection-body
Braking-SystemsBraking disk, Braking saddle, Braking cylinder, ABS/ESP
GearsGearbox, flanges, gear rods
ChassisBracket wheels, axis
Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 3
Engines Cylinder block, Cylinder head, Crank shaft, Camshaft, Con Rod
Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 4
Cutting parameterwork piece: cylinder headmaterial: AlSi9
operation: thread: M10thread depth: 20 mmblind holemachine: CNC-centerSyncro chuck with colletlubrication: emulsion 8%, IK ax
tool:tap M10 article 302 PM HSSE, TiCN coated, IK ax cutting speed Vc= 30 m/mintool life: 12000 threads
tap M10 art 972 carbide, TiCN coated, IK ax cutting speed Vc= 50 m/mintool life: 100000 threads
PM-HSSE carbide
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Cutting parameterwork piece: cylinder head Kappamaterial: AlSi9Cu3
operation: thread: M6Thread depth: 20 mmblind hole
tool:tap M6carbide, with two flutes, IK ax
machine: CNC-centerSyncro chuck with colletlubrication: emulsion 9%, IK axcutting speed Vc: 50 m/mintool life: ????? threads
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Cutting parameterwork piece: cylinderheadmaterial: AlSi17
operation: thread: M6Thread depth: 15 mmblind hole
tool:tap M6carbide–K6UF, TiAlN coated, IK ax
machine: CNC-centerSyncro chuck with colletlubrication: emulsion 9%, IK axcutting speed Vc: 35 m/mintool life: 93000 threads
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Cutting parameterwork piece: balance housingmaterial: GG25
operation: thread: M10Thread depth: 20 mmblind holemachine: CNC-centerSyncro chuck with colletlubrication: emulsion 7%, IK ax
tool:tap M10 article 318 PM HSSE, TiCN coated, IK ax Vc= 20 m/mintool life: 10000 threads
tap M10 article 2311 carbide, TiCN IK ax Vc= 40 m/mintool life: 100000 threads
PM-HSSE carbide
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Cutting parameterwork piece: cylinderheadmaterial: GJV 450
operation: thread: M10Thread depth: 25 mmblindhole
tool:tap M10carbide, TiAlN coated, IK ax
machine: CNC-centercollet without compensationlubrication: emulsion 10%, IK axCutting speed Vc: 40 m/minTool life: 100000 threads
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Cutting parameterwork piece: crankshaftmaterial: GGG70
operation: thread: M12x1,5, M16x1,5thread depth: 20 mm, 35 mmblind hole
tool:tap M12x1,5, M16x1,5carbide, TiCN coated, IK
machine: CNC-centerHSK 63 – Syncro chuck with colletlubrication: emulsion 8%, IKcutting speed Vc: 30 m/mintool life: 36000 threads
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Cutting parameterwork piece: crankshaftmaterial: 42 CrMo4 Rm=800 N/mm2
operation: thread: M12x1,5thread depth: 20 mmblind hole
tool:Fluteless tap M12x1,5carbide, TiN coated, IK
machine: CNC-centerHSK 63 – Syncro chuck with colletlubrication: emulsion 8%, IKcutting speed Vc: 12 m/mintool life: 6000 threads
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Cutting parameterwork piece: crankshaftmaterial: C38
operation: thread: M16x1,5thread depth: 30 mmblind hole
tool:fluteless tap M16x1,5carbide, TiN coated, IK
machine: tranferlinie Excellocompensation chucklubrication: emulsion 8%, IKcutting speed Vc: 15 m/mintool life: 20000 threads
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Cutting parameterwork piece: crankshaftmaterial: C38
operation: thread: M12x1,5thread depth: 24 mmblind hole depth 26 mm
tool:thread milling cutter M12x1,5carbide, TiCN coated, IK
machine: CNC-centershrink fit holderlubrication: emulsion 8%, IKcutting speed Vc: 90 m/min,feed rate fz= 0,09 mmtool life: 3000 threads
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Cutting parameterwork piece: camshaftmaterial: St 52
operation: thread: M10x1thread depth: 20 mmblind hole
tool:fluteless tap M10x1PM HSSE, TiN coated, IK rad
machine: turning center DMGcollet without compensationlubrication: emulsion 8%, IK radcutting speed Vc: 12 m/mintool life: 750 thread
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Cutting parameterwork piece: camshaftmaterial: St 52
operation: thread: M16x1,5thread depth: 20 mmblind hole
tool:thread milling cutter M16x1,5carbide, TiCN coated, IK
machine: CNC-centerShrink fit holderlubrication: emulsion 6%, IK radcutting speed Vc: 80 m/min, feed rate fz= 0,1 mmtool life: 2000 threads
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Cutting parameterwork piece: conrodmaterial: C70
operation: thread: M9x1thread depth: 18 mmthrough hole
tool:tap M9x1PM HSSE, TiCN coated
machine: CNC-centerHSK 63 - Syncro chucklubrication: emulsion 8%cutting speed Vc: 15 m/mintool life: 2100 threads
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Cutting parameterwork piece: conrodmaterial: C70
operation: thread: M9x1thread depth: 18 mmthrough hole
tool:tap M9x1Carbide DK 700, TiCN coated
machine: CNC-centerHSK 63 - Syncro chucklubrication: emulsion 8%cutting speed Vc: 50 m/mintool life: 9000 threads
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Cutting parameterwork piece: conrodmaterial: C70
operation: thread: M8x1thread depth: 16 mmthrough hole / blind hole
tool:two taps M8x1PM HSSE, TiCN coated
machine: CNC-centerHSK 63 - Syncro chucklubrication: emulsion 8%cutting speed Vc: 15 m/mintool life: 2100 threads – through hole 600 threads – blind hole
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Cutting parameterwork piece: conrodmaterial: C70
operation: thread: M7x1thread depth: 14 mmblind hole
tool:fluteless tap M7x1carbide, TiCN coated, IK
machine: CNC-centerHSK 63 - Syncro chucklubrication: emulsion 10%cutting speed Vc: 25 m/mintool life: 5000 threads
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Cutting parameterwork piece: conrodmaterial: C70 S6 By
operation: thread: M12x1,25thread depth: 24 mmblind hole
tool:Fluteless tap M12x1,25carbide, TiCN coated
machine: threading machineHSK 63 - Syncro chucklubrication: oilcutting speed Vc: 30 m/mintool life: 10000 threads
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Cutting parameterwork piece: Pleuelmaterial: 42CrMo4 (< 48 HRC)
operation: thread: M10x1thread depth: 18 mmblindhole
tool:fluteless tapM10x1carbide, TiN coated, IC
Machine: M/CHSK 63 – Synchro chucklubrication: Emulsion 8%, 70 bar, ICcutting speed: 25 m/mintool life: 15000 threads
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Injection-SystemsPumpcase, Cylinderhead, Injection-body, Rail
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Cutting parameterwork piece: pump casematerial: 20MnSi5
operation: thread: M14x1thread depth: 22 mm
tool:thread milling cutter M14x1carbide
machine: CNC-centerweldonlubrication: emulsion 8%cutting speed Vc: 90 m/minfeed rate per teeth milling: 0,08 mmtool life: 3000 threads
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Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 24
Cutting parameterwork piece: cylinder head CP1Hmaterial: 20MnSi5
operation: thread: M6thread depth: 12 mmchamfer
tool:thread milling cutter M6carbide
machine: CNC turning-centershrink fit holderlubrication: emulsion 6%cutting speed Vc: 90 m/minfeed rate per teeth milling: 0,05 mmtool life: 2000 threads
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Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 26
Cutting parameterwork piece: cylinder head CP4material: C60
operation: thread: M18x1 externalthread depth: 16 mmchamfer
tool:thread milling cutter M18x1carbide with special cutting edge
machine: CNC turning-centershrink fit holderlubrication: emulsion 6%cutting speed Vc: 90 m/minfeed rate per teeth milling: 0,07 mmtool life: 3000 threads
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Cutting parameterwork piece: injection bodymaterial: 42CrMo4
operation: thread: M14x1,5thread depth: 18 mmblind hole
tool:fluteless tap M14x1,5carbide, TiCN coated, IK
machine: CNC-centerHSK 63 – Syncro chuck with colletlubrication: emulsion 8%, 70 bar, IKCutting parameter Vc: 25 m/mintool life: 8000 threads
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Braking-SystemsBraking disk, caliper, Braking cylinder, ABS/ESP
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Cutting parameterwork piece: ABS/ESP blockmaterial: AlSi7
operation: thread: M10x1, M12x1thread depth: 16 mmblind hole
tool:thread milling cutter M10x1carbide with special cutting edge
machine: CNC-centershrink fit holderlubrication: emulsion 8%cutting speed Vc: 200 m/minfeed rate per teeth milling: 0,08 mmtool life: 100000 threads
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Cutting parameterwork piece: caliper
material: AlSi7
operation: thread: M10x1, M12x1thread depth: 14 mmblind hole
tool:thread milling cutter M10x1carbide with special cutting edge
machine: CNC-centershrink fit holderlubrication: emulsion 8%cutting speed Vc: 200 m/minfeed rate per teeth milling: 0,08 mmtool life: 100000 threads
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Cutting parameterwork piece: braking disk for trucksmaterial: GG 25
operation: thread: M16x1,5Thread depth: 20 mmthrough hole
tool:Thread milling cutter TMC M16x1,5 2xD carbide, IK ax
machine: CNC-centerSK 40 - Weldonlubrication: without cutting speed Vc: 120 m/minFeed rate fz: 0,12 mmtool life: 80000 threads
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Cutting parameterwork piece: braking cylindermaterial: AlSi9
operation: thread: M10x1 / M12x1Thread depth: 20 mmblind hole
tool:Thread milling cutter TMZ M10x1 PCD, IK ax
machine: CNC-centerHSK 63 – Shrink fit holderlubrication: emulsion 8%cutting speed Vc: 400 m/minfeed rate fz: 0,04 mmtool life: 200000 threads
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Cutting parameterwork piece: braking cylindermaterial: AlSi7
operation: thread: M10x1, M12x1Thread depth: 18 mmblind hole
tool:Thread milling cutter TMC M10x1 carbide, IK ax
machine: CNC-centerShrink fit holderlubrication: emulsion 6%cutting speed Vc: 200 m/minfeed rate fz: 0,09 mmtool life: 100000 threads
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GearsGearbox, flanges, gear rods/axles
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Cutting parameterwork piece: gearboxmaterial: AlSi9
operation: thread: M22x1,5thread depth: 20 mmthrough hole with cyl. diameter, chamfer and back chamfer
tool:special drill thread milling cutter M22x1,5, carbide, IK ax
machine: CNC-centerWhistle Notch HElubrication: emulsion 9%, IK axcutting speed Vc: 300 m/minfeed rate F drill: 0,2 mm/Ufeed rate peer teeth milling: 0,12 mmtool life: 40000 threads
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Cutting parameterwork piece: flanche axlematerial: C45
operation: thread: M14x1,5thread depth: 20 mmthrough hole
tool:tap M14x1,5HSSE, TiCN coated
machine: CNC-centercompensation holderlubrication: emulsion 8%Cutting parameter Vc: 15 m/mintool life: 1200 threads
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ChassisBracket wheels, axis
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Bracket wheel forged steel PQ35
Cutting parameterWorkpiece: wheel bracketMaterial: 38MnSiVS5 BY forgedtensile strength 850-1000 N/mm
Application: M16x1,5; M14x1,5; M12x1,5; M6depth: 2xdiameter
Tool:Solid carbide fluteless taps with radial internal coolantminimal lubrication
Cutting data:Vc= 20 m/min
Machine: BAZ Lindenmaier
Tool life: 17000 threads
2
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In the middle of 2007 the material for PQ 35 was changed to the cheaper Cast IronSIBODUR 700-10SiBoDur is a new developed cast iron in the form GGG with the same E-Modul and a higher flexibility and tensile
Through the added alloys silicon and bor we achieve a higher tensile with the same flexibility, Therefore the name Si (Silicon) Bo (Bor) Dur (Durability = Haltbarkeit in English)
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SiBoDur bracket wheel PQ35
For the threading process SiBoDur they use now carbide-cast iron tapsCutting parameterWorkpiece: wheel bracketMaterial: Sibodur 700
Application: M16x1,5; M14x1,5; M12x1,5; M6depth: 2xdiameter
Tool:Solid carbide fluteless taps with radial internal coolantair lubrication
Cutting data:Vc= 20 m/min
Machine: BAZ Lindenmaier
Tool life: 1700 threads
Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 44
2009 VW Mexico bracket wheel PQ35
FCD 600 Ductile Cast Iron similar GGG60Hitachi casting in USA
Production forged steel1 line Lindenmaier
Production FCD 600new Anger machine
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Thread milling Thread forming
Tool TMZ D20x39xM1,5 GFO M24x1,5
302202659 302054727
Material Carbide Carbide
Coating TiCN TiCN
Thread M24x1,5 M24x1,5
Cutting speed 90 m/min 20 m/min
Feed rate 0,1 mm/z 1,5 mm/U
Cutting time 9,9 s 18 s
Tool life 2000 threads 4000 threads
1. Cutting comparison work piece Axis holder 42CrMo4 thread M22x1,5 and M24x1,5 Compare thread milling with thread forming
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2. Cutting comparison axis work piece GGG40 Compare thread M14x1,5 and M16x1,5 2,5xDThread milling Thread cutting Thread forming
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Cutting parameter axis work piece GGG40
Thread milling Thread forming Thread cutting
Tool TMC M16x1,5 2,5xD Form tap M16x1,5 Tap M16x1,5
Material Carbide Carbide Carbide
Coating TiCN TiCN TiCN
Thread M16x1,5 M16x1,5 M16x1,5
Cutting speed 120 m/min 20 m/min 20 m/min
Feed rate 0,06 mm/z 1,5 mm/U 1,5 mm/U
Cutting time 6,2 s 7.8 s 7.8 s
Tool life 40000 threads 20000 threads 60000 threads
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Reducing production costs 50% with thread milling
Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 50
Special tools for the best tool life