Operation Samples

Jörg Maier – Produktmanagement Gewindewerkzeuge Version Juli 2008 1

Thread machining

in

OEM-Applications


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


Engines Cylinder block, Cylinder head, Crank shaft, Camshaft, Con Rod


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


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


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


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


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


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


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


Cutting parameterwork piece: crankshaftmaterial: C38


tool:fluteless tap M16x1,5carbide, TiN coated, IK

machine: tranferlinie Excellocompensation chucklubrication: emulsion 8%, IKcutting speed Vc: 15 m/mintool life: 20000 threads


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


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


Cutting parameterwork piece: camshaftmaterial: St 52


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


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



operation: thread: M9x1thread depth: 18 mmthrough hole

tool:tap M9x1Carbide DK 700, TiCN coated




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



operation: thread: M7x1thread depth: 14 mmblind hole

tool:fluteless tap M7x1carbide, TiCN coated, IK



Cutting parameterwork piece: conrodmaterial: C70 S6 By


tool:Fluteless tap M12x1,25carbide, TiCN coated

machine: threading machineHSK 63 - Syncro chucklubrication: oilcutting speed Vc: 30 m/mintool life: 10000 threads


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


Injection-SystemsPumpcase, Cylinderhead, Injection-body, Rail


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



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



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





Cutting parameterwork piece: injection bodymaterial: 42CrMo4


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


Braking-SystemsBraking disk, caliper, Braking cylinder, ABS/ESP


Cutting parameterwork piece: ABS/ESP blockmaterial: AlSi7

operation: thread: M10x1, M12x1thread depth: 16 mmblind hole


machine: CNC-centershrink fit holderlubrication: emulsion 8%cutting speed Vc: 200 m/minfeed rate per teeth milling: 0,08 mmtool life: 100000 threads


Cutting parameterwork piece: caliper

material: AlSi7

operation: thread: M10x1, M12x1thread depth: 14 mmblind hole


machine: CNC-centershrink fit holderlubrication: emulsion 8%cutting speed Vc: 200 m/minfeed rate per teeth milling: 0,08 mmtool life: 100000 threads


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


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


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


GearsGearbox, flanges, gear rods/axles


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


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


ChassisBracket wheels, axis


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


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)


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


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


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


2. Cutting comparison axis work piece GGG40 Compare thread M14x1,5 and M16x1,5 2,5xDThread milling Thread cutting Thread forming



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


Reducing production costs 50% with thread milling


Special tools for the best tool life

Documents

Operation Samples