Product handbook

Threading

_ THREADING WITH WALTER PROTOTYP

Precise, reliable,
efficient

www.EngineeringBooksPdf.com
www.EngineeringBooksPdf.com
 CONTENTS
Threading

2 Index

4 General introduction to the subject

8 Product range overview

9 Thread tapping
12 Thread forming
13 Thread milling

14 Product information
14 Thread tapping
28 Thread forming
34 Thread milling

40 Tool selection
40 Thread tapping
44 Thread forming
46 Thread milling

48 Technical information
48 General
74 Thread tapping
94 Thread forming
101 Thread milling
112 Appendix

1
www.EngineeringBooksPdf.com
Index

Alphabetical keyword index

Page Page
Angles and characteristics Cutting process
Thread tapping . . . . . . . . . . . . . 81 Thread tapping . . . . . . . . . 79 - 80

Axial miscutting Dry machining

Thread tapping . . . . . . . . . . 87, 91 Thread milling . . . . . . . . . . . 59, 63

Basic types Feed rate correction

Thread tapping . . . . . . . . . 74 - 75 Thread milling . . . . . . . . . . . . . 103

Chamfer forms Feed rate programming

Thread tapping . . . . . . . . . . . . . 76 Thread tapping . . . . . . . . . . . . . 87

Chip control Forces

Thread tapping . . . . . . . . . . . . . 90 Thread tapping . . . . . . . . . 86 - 87

Chip cross sections Formulas . . . . . . . . . . . . . . . . . . . . .112

Thread tapping . . . . . . . . . .77 - 78
Hardness comparison table . . . . .117
Clamping devices . . . . . . . . . . . . . . 64
Increased edge zone hardening . . 72
CNC programming
Thread milling . . . . . . . . .107 - 108 Minimum quantity
lubrication . . . . . . . . . . . . . . . . 62 - 63
Comparison of geometry data
Thread tapping . . . . . . . . . 82 - 83 Miscutting
Thread tapping . . . . . . . . . . 86, 91
Cooling and lubrication . . . . . 56 - 57
Thread forming . . . . . . . . . 60 - 61 Modifications
Thread milling . . . . . . . . . . . . . . 59 Thread forming . . . . . . . . . . . . . 98
Thread tapping . . . . . . . . . . . . . 58 Thread milling . . . . . . . . . . . . . 109
Thread tapping . . . . . . . . . 88 - 89
Core hole
General . . . . . . . . . . . . . . . . . . . . 70 Nomenclature . . . . . . . . . . . . . . . . . . 8
Tapping . . . . . . . . . . . . . . 114 - 115
Thread forming . . .71, 96 - 97, 116 Paradur® Eco CI . . . . . . . . . . . . .10, 18
Thread milling . . . . . . . . . 114 - 115
Paradur® Eco Plus . . . . . . . .9, 14 - 15
Coatings . . . . . . . . . . . . . . . . . 52 - 55
Thread forming . . . . . . . . . . . . . 55 Paradur® HSC . . . . . . . . . . . . . . .11, 27

Cutting passes Paradur® HT . . . . . . . . . . . . . . . .10, 19

Thread milling . . . . . . . . 104 - 105
Paradur® Synchrospeed . . .9, 16 - 17

2
www.EngineeringBooksPdf.com
 Page Page
Paradur® Ti Plus . . . . . . . . 11, 24 - 25 Prototex® Eco Plus . . . . . . .9, 14 - 15

Paradur® X∙pert M . . . . . . 10, 22 - 23 Prototex® HSC . . . . . . . . . . . . . 11, 26

Paradur® X∙pert P . . . . . . . 10, 20 - 21 Prototex® Synchrospeed . . .9, 16 - 17

Pilot hole diameter Prototex® TiNi Plus . . . . . 11, 24 - 25

General . . . . . . . . . . . . . . . . . . . . 70
Tapping . . . . . . . . . . . . . . 114 - 115 Prototex® X∙pert M . . . . . 10, 22 - 23
Thread forming
. . . . . . . . . . . . 70 - 71, 96 - 97, 116 Prototex® X∙pert P . . . . . . 10, 20 - 21
Thread milling . . . . . . . . . 114 - 115
Rprg. (programming radius)
Problems and solutions Thread milling . . . . . . . . . . . . . 108
Thread forming . . . . . . . . 99 - 100
Thread milling . . . . . . . . . 110 - 111 Special features
Thread tapping . . . . . . . . . 90 - 92 Thread tapping . . . . . . . . . 84 - 85

Process comparison . . . . . . . 48 - 49 Synchronous machining . . . . 68 - 69

Process principles TMC . . . . . . . . . . . . . . . . . . 13, 34 - 35

Thread forming . . . . . . . . . 94 - 95
Thread milling . . . . . . . . .101 - 105 TMD . . . . . . . . . . . . . . . . . . 13, 38 - 39

Profile distortion . . . . . . . . . . . . . 106 TME . . . . . . . . . . . . . . . . . . . . . . . . . .13

Protodyn® Eco LM . . . . . . . . . . 12, 30 TMG . . . . . . . . . . . . . . . . . . . . . . 13, 35

Protodyn® Eco Plus . . . . . . . . . . . . 28 TMO . . . . . . . . . . . . . . . . . . .13, 36 - 37

Protodyn® HSC . . . . . . . . . . . . . . . . 33 TMO HRC . . . . . . . . . . . . . . . . . . .13, 37

Protodyn® Plus . . . . . . . . . . . . . . . . 29 Tolerance grades . . . . . . . . . . . . . . 50

Protodyn® S Eco Inox . . . . . . . .12, 31 Tool categories . . . . . . . . . . . . . . . . . 8

Protodyn® S Eco Plus . . . . . . . 12, 28 Torque adjustment

Thread tapping/forming . 118 - 119
Protodyn® S HSC . . . . . . . . . . . 12, 33
Walter GPS
Protodyn® S Plus . . . . . . . . . . . 12, 29 . . . . . . . . 5, 102 - 103, 107 - 108, 111

Protodyn® S Synchrospeed . . . 12, 32 Weld formations . . . . . . . . . . . . . . 93

3
www.EngineeringBooksPdf.com
Introduction

Technology, trends and innovations

in thread production
There are different processes for Great efforts have been made in the field
producing a thread. In this handbook, of macro/micro geometry as well as into
we focus on thread tapping, thread coatings, in order to guarantee a high
forming and thread milling with tools level of process reliability even under
from Walter Prototyp. In addition, this unfavorable conditions. The costs per
handbook also presents general technical thread can be reduced sharply through
information on these processes. the use of our high-performance tools
from the Eco and Synchrospeed series.
Thread tapping is still the most Even lower costs per thread can be
frequently used process for producing achieved with solid carbide tools. Our
internal threads. Process reliability, quality HSC line is setting new standards in this
and production costs per thread are the regard – even in steel materials.
main considerations when developing These tools are the first choice for mass
tools. production, for example in the fastener or
automotive industries.

4
www.EngineeringBooksPdf.com
Thread forming as a process for pro­ In terms of process reliability and thread
ducing internal threads has developed quality, thread milling is unchallenged
rapidly in the last 20 years. While in the at the top. Alongside the classic milling
past, oil was predominantly required as a process, what is known as “Orbital-
lubricant with these tools, today, thanks thread milling” has made a name for
to targeted further development of the itself in recent times. With this method,
shaped edge geometry and the coating, users are able to produce very deep (e.g.
it is possible to form nearly all formable 3 x DN) and moreover very small (e.g.
materials (even stainless steels) with a M1.6) internal threads even in demanding
5% emulsion on any machining center. In materials with absolute reliability.
addition, the static and particularly the
dynamic tensile strength of the formed And one final tip: Use our new Walter
thread has been improved even further GPS software, the successor to the
through the use of emulsion. proven CCS, to select the ideal process.
Here, you can compare all production
Carbide as a cutting tool material found processes with each other and decide on
its way into thread forming a long time the most cost-efficient alternative.
ago. Absolute peak values are achieved
today using our Protodyn® HSC line.

Thread forming is often the most cost-

efficient method of producing an internal
thread, provided that this process is
permitted for the respective component.

5
www.EngineeringBooksPdf.com
Introduction

Productive processes
with Walter Prototyp
Nowadays, it is practically impossible to For this reason, at Walter Prototyp, we
directly pass on increasing production are strongly promoting the use of HSC
costs through increasing per-part costs machining (High Speed Cutting) with
straight to the customer. This applies solid carbide tools from our product
equally to your consumable goods as range. Therefore, when machining low
well as to produced goods. Successful alloy steels, for example, cutting speeds
companies close this yield gap through of up to 160 SFM are possible. For
a systematic productivity increase in threading, this is a remarkable result!
production. Particularly demanding customers for
whom maximum productivity is of the
As a manufacturer of precision tools used utmost importance, Walter Prototyp
in machining, we can contribute a lot, as has, in addition to the HSC line, specially
the chart shows. The tool costs account developed tools for synchronous
for only 3% of the overall machining machining.
costs. The machining time which
accounts for 30% of the machining costs Minimum quantity lubrication (MQL) is
is nevertheless a significant cost factor. an additional factor to consider when
reducing the machining costs, as shown
This means: with efficient metal cutting in the chart opposite. Walter Prototyp
tools from Walter Prototyp, the machining also offers it customers specially adapted
costs can be reduced significantly. An coatings for MQL.
increase in the cutting parameters leads to
enormous cost savings. Because the tool In short, the proportion of costs spent
price has an almost insignificant effect on purely on tools may only be 3% of the
the overall machining costs, tools from the actual production costs, but the tool has
competence brand Walter ­Prototyp are not a decisive effect on the remaining 97% of
measured solely on the tool price alone, the costs.
but on the over proportional increase in
productivity and therefore on the savings Allow our experts to demonstrate the
potential for our customers. savings potential in production to be
gained through the use of tools from
Walter Prototyp.

6
www.EngineeringBooksPdf.com
 Machining costs in comparison

3%
Tool

Machining time:
30%
Up to 80% saving
through increased cutting speed
(e.g. if solid carbide tools from the
HSC line are used)

Machine stoppage:
7%
approx. 50% saving
through reduced bird nesting
(e.g. if the Paradur® Eco Plus
is used)

Coolant:
Up to 10% saving 16%
through MQL (e.g. if the Paradur®
Eco CI is used). Additional benefits,
such as environmental sustainability
are not quantified here.

Tool change: 25%

approx. 50% saving
through longer tool life
(e.g. if Paradur® HT is used)

Other:
approx. 25% saving
19%
(among other things, attributable to
the reduced storage and logistics
costs because of the wide area of
application of the Synchrospeed
family)

existing
Up to

45 %
overall
with Walter Prototyp

­savings

7
www.EngineeringBooksPdf.com
Product range overview

Walter Prototyp threading tool –

Nomenclature/tool categories

Thread tapping*

Prototex®… Paradur®… Paradur®…

Tap with spiral point Tap with right-hand Straight-fluted tools
helical flute

Thread forming Thread milling**

Protodyn®… Protodyn® S … TM …
Thread former without Thread former with TM = Thread Mill…
lubrication grooves lubrication grooves

* Thread tapping exceptions:

−− Paradur® N with chamfer form D and Paradur® Combi: helical tools for producing through-hole
threads
−− Paradur® HT, Paradur® GG and Paradur® Engine: straight-fluted tools for blind hole threads
(in materials with good chip breaking characteristics)
−− NPT/NPTF taps: right-hand helical tools for machining blind and through holes
** Thread milling exceptions:
−− TME (Thread Mill External): tool for producing external threads
8
www.EngineeringBooksPdf.com
Product range overview

Taps for universal applications

Workpiece material group

P M K N S H O

Page in handbook

Difficult-to-cut
Stainless steel

Hard materials
Thread depth
Application

NF metals

materials
Cast iron

Other
Steel
Type description

14
Prototex® Eco Plus + TH 3.5 x DN C C C C C C C C
−−universal application 15
−−for wet and MQL machining

Paradur® Eco Plus 14

−−universal application + BH 3 x DN CC CC CC CC
−−for wet and MQL machining 15
−−successor to the proven
Paradur® Eco HT

Prototex® Synchrospeed 16
−−synchronous machining + TH 3.0 x DN C C C C C C C C C C C
17
−−universal application
−−h6 shank tolerance

Paradur® Synchrospeed 16
−−synchronous machining + BH 2.5 x DN C C C C C C C C C
17
−−universal application
−−h6 shank tolerance

BH = blind hole machining C C Primary application

TH = through hole machining C Additional application
9
www.EngineeringBooksPdf.com
Product range overview

Taps for
special applications
Workpiece material group
P M K N S H O

Page in handbook

Difficult-to-cut
Stainless steel

Hard materials
Thread depth
Application

NF metals

materials
Cast iron

Other
Steel
Type description

BH
Paradur® Eco CI 18 + 3 x DN CC CC CC
−−for short-chipping materials TH
−−for wet and MQL machining

Paradur® HT
−−for steels with medium to high 19 BH 3.5 x DN C C CC C C
tensile strength, and for short-
chipping materials
−−Internal cooling required

20
Prototex® X·pert P + TH 3 x DN CC C C
−−for materials with low to medium 21
tensile strength

20
Paradur® X·pert P + BH 3.5 x DN C C C C
−−for materials with low to medium 21
tensile strength

22
Prototex® X·pert M + TH 3 x DN C CC
−−for stainless and 23
high-strength steels

22
Paradur® X·pert M + BH 2.5 x DN C CC
−−for stainless and 23
high-strength steels

10
www.EngineeringBooksPdf.com
 Workpiece material group
P M K N S H O

Page in handbook

Difficult-to-cut
Stainless steel

Hard materials
Thread depth
Application

NF metals

materials
Cast iron

Other
Steel
Type description

24
Prototex® TiNi Plus
+ TH 2 x DN CC
−−for machining high-tensile Ti and
25
Ni alloys with emulsion that tend
to spring back

24
Paradur® Ti Plus
+ BH 2 x DN CC
−−for machining high-tensile Ti
25
alloys with emulsion that tend
to spring back

Prototex® HSC
−−for high-strength and high tensile
steel materials 26 TH 2 x DN CC CC

−−h6 shank tolerance

−−Internal cooling required
−−Solid carbide

Paradur® HSC
−−for high-strength and high-tensile
steel materials up to 55 HRC 27 BH 2 x DN CC CC CC

−−h6 shank tolerance

−−Internal cooling required
−−Solid carbide

BH = blind hole machining C C Primary application

TH = through hole machining C Additional application
11
www.EngineeringBooksPdf.com
Product range overview

Thread formers

Workpiece material group

P M K N S H O

Page in handbook

Difficult-to-cut
Stainless steel

Hard materials
Thread depth
Application

NF metals

materials
Cast iron

Other
Steel
Type description

Protodyn® S Eco Plus* BH

−−For universal application 28 + 3.5 x DN C C CC CC C
−−higher performance compared to TH
Protodyn® S Plus
−−for wet and MQL machining

BH
Protodyn® S Plus* 29 + 3.5 x DN C C CC CC C

−−For universal application TH

BH
Protodyn® Eco LM 30 + 2 x DN C CC CC
−−For soft materials with tendency TH
to spring back

BH
Protodyn® S Eco Inox* 31 + 3.5 x DN C CC C C
−−especially for machining stainless TH
steels with emulsion

Protodyn® S Synchrospeed* BH
−−For universal application 32 + 3.5 x DN C C CC CC C

−−Synchronous machining TH

−−h6 shank tolerance

Protodyn® S HSC*
−−for high forming speeds 33 BH 3.5 x DN C C C CC C

−−h6 shank tolerance

−−Solid carbide

* Version with lubrication grooves, marked with an S

12
www.EngineeringBooksPdf.com
Product range overview

Thread mills

Workpiece material group

P M K N S H O

Page in handbook

Difficult-to-cut
Stainless steel

Hard materials
Thread depth
Application

NF metals

materials
Cast iron

Other
Steel
Type description

34 BH
TMC thread mill + + 2 x DN CC CC CC CC CC C
−−with countersink for universal 35 TH
application

BH
1.5 x DN
TMG thread mill 35 + CC CC CC CC CC C
2 x DN
−−without countersink TH
−−For universal application

36 BH
TMO orbital thread mill 2 x DN
+ + CC CC CC CC CC C
−−For universal application 3 x DN
37 TH
in machining of small and
deep threads

BH
TMO HRC orbital thread mill 37 + 2 x DN CC C CC C
−−For small and deep threads in TH
hard materials up to 65 HRC

38 BH
TMD thread milling cutter + + 2 x DN CC CC
−−For aluminum and grey cast iron 39 TH
machining
External thread

– 2 x DN CC CC CC CC CC C
TME thread mill 20
−−for external threads

BH = blind hole machining C C Primary application

TH = through hole machining C Additional application
13
www.EngineeringBooksPdf.com
Product information – Tapping

The high-tech all-rounder

Spiral point form B

THL coating
(or TiN)

HSS-E-PM

3.5 x DN

P M K N S H O
CC CC CC CC

Variants: without IK, with KR*

Prototex® Eco Plus Type: EP2021342

45° helix angle with

chamfer form C or E

HSS-E-PM

THL coating
3 x DN
(or TiN)
P M K N S H O
CC CC CC CC
Variants: without IK, with KA, with KR*

Paradur Eco Plus

®
Type: EP2051312

14
www.EngineeringBooksPdf.com
The tool The application
−−universal high performance tap −−for use in long and short-chipping
−−THL hard material coating minimises materials with a tensile strength from
built up edges and guarantees long approx. 72,500 PSI to approx.
tool life 188,500 PSI
−−suitable for synchronous machining and
Prototex® Eco Pluse suitable for use in floating chucks
−−special spiral point form B guarantees
high process reliability Your advantages
−−reduction in tool inventory thanks to
Paradur® Eco Plus: a wide area of application
−−tapered guide reduces the tendency −−increased productivity through high
toward fractures cutting speeds and long tool life
−−thread nearly to the bottom of the hole −−special geometry for safe processes,
with chamfer form E even in soft materials
−−MQL machining possible

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
15
www.EngineeringBooksPdf.com
Product information – Tapping

Wear-resistant, universal use

HSS-E with
increased hardness

TiN coating
(or THL)

Weldon
flat

3 x DN

P M K N S H O
Spiral point form B CC CC CC CC CC C

Prototex® Synchrospeed  Type: S2021305

40° helix angle with

chamfer form C HSS-E with
increased hardness

Weldon
flat

2.5 x DN
TiN/vap
coating P M K N S H O
(or THL) CC CC CC C C C
Variants: without IK, with KA*

Paradur® Synchrospeed Type: S2051305

16
www.EngineeringBooksPdf.com
The tool The application
−−high flank relief and short threading −−for use on machine tools with a
section for extremely high cutting synchronous spindle (not suitable for
speeds floating chucks or cutting units)
−−h6 shank tolerance (e.g. for use in −−for universal use in all long and short-
shrink-fit chucks) chipping materials
−−shank diameter adapted to standard
shrink-fit chuck Prototex® Synchrospeed:
−−can be used up to approx. 203,000 PSI
Special features of the
Paradur® Synchrospeed: Paradur® Synchrospeed:
−−variant with TiN/vap coating: steam −−can be used up to approx. 188,500 PSI
oxide flutes for perfect chip formation
and optimum chip removal; TiN coating
for increased wear resistance
−−internal cooling with axial output in the Your advantages
standard product range −−increased productivity through high
cutting speeds and long tool life
−−reduced tool inventory costs through
Practical tip: universal use in short and long
It is generally recommended to use chipping materials
adaptors with minimum compensa- −−excellent thread surface thanks to
tion (e.g. Protoflex C) for synchronous very sharp cutting edges
machining (advantage: longer tool life −−miscutting excluded through
and increased process reliability). ­synchronous machining

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
17
www.EngineeringBooksPdf.com
Product information – Tapping

Extremely high speed

in short-chipping materials

TiCN coating
(or nid)

Chamfer
form C or E

HSS-E-PM

3 x DN

P M K N S H O
High face clearance CC CC CC
and small rake angle
Variants: without IK, with KA, with KR*

Paradur Eco CI

®
Type: E2031416

The tool
Your advantages
−−innovative surface treatment
−−lower production costs per thread as
“Xtra·treat” for best wear behavior
result of high cutting speeds and
when machining abrasive, short-
long tool life
chipping materials
−−even wear behavior and therefore
−−increased number of flutes reduces
absolute process reliability
cutting edge load and produces short
chips −−reduced tool costs, because it can
be used for blind and through hole
−−tolerance grade 6HX for maximum
threads
tool life
−−MQL machining possible
−−versions with axial or radial coolant
outlets for optimum chip evacuation
with deep blind and through hole
threads

The application
−−blind- and through hole thread in
short-chipping materials
−−ISO K: primarily for GJL (GG) materials;
in GJS (GGG) materials up to maximum
2 x DN thread depth; vermicular cast
iron (e.g. GJV450)
−−ISO N: Mg alloys, and abrasive AlSi
alloys with Si content > 12%

18
www.EngineeringBooksPdf.com
Product information – Tapping

Short cycle time, optimum chip breaking

Chamfer
form C

HSS-E

3.5 x DN
TiN coating
P M K N S H O
Axial internal cooling CC CC C C
KA absolutely essential*

Paradur® HT Type: 2031115

The tool Your advantages

−−cutting edge geometry produces short −−higher cutting speed and longer tool
chips even in long-chipping materials life compared to conventional blind
−−axial internal cooling and straight flutes hole taps
enable optimum transport of short −−no chip packing, i.e. less machine
broken chips stoppage
−−increased face clearance for higher −−extremely high process reliability
cutting speeds even with deep threads
−−long versions with elongated flutes in −−Standard product range with large
the standard product range sizes

The application
−−blind hole thread in long and short-
chipping materials −−typical areas of application:
−−ISO P: steel material with tensile • automotive industry (camshafts,
strength of 87,000 - 203,000 PSI crankshafts,connecting rods)
−−ISO K: grey cast iron (GGG) • large product range (general
−−ISO N: AlSi alloys > 12% Si content, mechanical engineering, transmission
Cu alloys and Mg alloys shafts, housings, etc.)

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
19
www.EngineeringBooksPdf.com
Product information – Tapping

Large product range, high cost efficiency

TiN coating
(or bright finish, TiCN)

HSS-E

3 x DN

P M K N S H O
Spiral point form B CC C C

Prototex® X∙pert P  Type: P2031005

TiN coating
(or bright finish)

HSS-E

3,5 x DN

45° helix angle with P M K N S H O

chamfer form C
CC C C

Paradur® X∙pert P  Type: P2051905

20
www.EngineeringBooksPdf.com
The tool The application
−−low flank clearance angle and therefore Prototex® X∙pert P
no miscutting in soft materials −−ISO P:
• variant with 3 flutes: tensile strength
Prototex® X∙pert P < 145,000 PSI
−−variants with reduced number of flutes • variant with 2 flutes: tensile strength
in the standard product range < 58,000 PSI (available up to size M6)
−−ISO N: AlSi alloys with Si content
Paradur® X∙pert P between 0.5 to 12%
−−long flutes for deep threads −−version with reduced number of flutes is
−−Tapered guide prevents fractures ideally suited to soft, long-chipping
materials (optimum for machining soft
structural steels, e.g. A36) due to
improved chip formation

Paradur® X∙pert P
−−ISO P: steel < 145,000 PSI, particularly
in long-chipping materials
−−ISO N: AlSi alloys with Si content
between 0.5 to 12%

Your advantages
−−cost-efficient for small and medium
batch sizes
−−high flexibility and short delivery
times, because of the comprehensive
standard product range (diverse
thread profiles, sizes and tolerances
in stock)
−−thread with very good surface finish
quality thanks to wide rake angle

21
www.EngineeringBooksPdf.com
Product information – Tapping

Reliable in stainless steels

TiCN coating
(or TiN, vap)

HSS-E

3 x DN

P M K N S H O
Spiral point form B C CC

Prototex® X∙pert M  Type: M2021306

TiCN coating
(or TiN, vap)

HSS-E

2.5 x DN

P M K N S H O
40° helix angle with chamfer form C C CC

Paradur® X∙pert M  Type: M2051306

22
www.EngineeringBooksPdf.com
The tool The application
−−raised core guarantees true to gauge −−ISO M: stainless steels from 50,750 to
threads and ensures reliable deburring 174,000 PSI
in the thread – important above all for −−ISO P: very well suited to steels from
machining stainless materials 101,500 to 174,000 PSI
−−increased flank clearance angle for
machining materials that tend to spring
back Your advantages
−−high process reliability in long-
Special features of the Paradur® chipping materials that tend to
X∙pert M: spring back
−−tapered guide to prevent fractures −−cost-efficient for small and medium
sized batches
−−high flexibility and short delivery
times, because of comprehensive
standard product range (diverse
thread profiles, sizes and tolerances
in stock)
−−lower tool inventory because of use
in ISO M and ISO P materials

23
www.EngineeringBooksPdf.com
Product information – Tapping

Strong in high-tensile titanium

ACN coating

HSS-E-PM

2 x DN
Large core diameter
P M K N S H O
CC
Spiral point form B

Prototex® TiNi Plus  Type: 2021763

ACN coating

HSS-E-PM

2 x DN
Large core diameter
P M K N S H O
15° helix angle with
CC
chamfer form C

Paradur® Ti Plus  Type: 2041663

24
www.EngineeringBooksPdf.com
The tool The application
−−especially for machining ISO S materials −−for applications in aerospace technol-
with a geometry designed for emulsion ogy, as well as medical industry
−−very high flank clearance angle for −−especially for high tensile and titanium
reducing the friction in materials that alloys with a tensile strength from
tend to spring back 101,500 to 203,000 PSI that tend to
−−designed for machining hard materials spring back
thanks to small rake angle
−−wear-resistant, titanium-free ACN Prototex® TiNi Plus
coating reduces weld formations −−can also be used on nickel alloys

Your advantages
−−often possible to work with emulsion
instead of oil
−−high process reliability through high
tool stability
−−long tool life through an innovative
hard material coating and stable
cutting edges
−−excellent thread quality

25
www.EngineeringBooksPdf.com
Product information – Tapping

Long tool life, extremely high speeds

Lubrication grooves
on the shank

Optimized
spiral point
form B
Special
micrograin carbide

2 x DN
TiCN coating

P M K N S H O
CC CC
IK via flutes on the shank*

Prototex HSC
®
Type: 8021006

The tool Your advantages

−−special solid carbide with high −−minimum production costs and
resistance to wear and extreme extremely high productivity thanks to
toughness at the same time a cutting speed that is up to 3 times
−−longer tool life through an increased higher when compared to HSS-E taps
number of flutes −−optimum machine output due to
−−Shank tolerance h6 (e.g. for use in longer tool life
shrink-fit chucks)

−−The application
−−ISO P: steels with a tensile strength Requirements:
from approx. 101,500 to 203,000 PSI −−internal cooling
−−ISO K: primarily GJS (GGG) materials −−stable application conditions
−−mass production with the goal of −−modern machining centers or
minimum costs per thread modern transfer lines
−−large-scale manufacturers focused on −−for carbide tools, synchronous
increasing productivity machining and the use of adaptors
with minimum compensation (e.g.
Protoflex C) is recommended
(increases the tool life and
increases process reliability)

26
www.EngineeringBooksPdf.com
 15° helix angle with special
chamfer geometry form C

TiCN coating

Special
micrograin carbide

2 x DN

P M K N S H O
CC CC CC
Axial internal cooling
KA absolutely essential*

Paradur HSC
®
Type: 8041056

The tool Your advantages

−−special chamfer geometry and reduced −−minimum production costs and
helix for short broken chips also in extremely high productivity thanks to
long-chipping materials a cutting speed that is up to 3 times
−−Shank tolerance h6 (e.g. for use in higher when compared to HSS-E taps
shrink-fit chucks) −−fewer tool changes resulting in
optimum machine output due to long
The application tool life
−−ISO P/H: steel materials from approx. −−high process reliability through
101,500 PSI to 55 HRC perfect chip breaking
−−ISO K: cast iron workpieces such as:
GGG40, GJV450, ADI800
−−mass production with a focus on
minimum costs per thread Requirements:
−−large-scale manufacturers focused on See Prototex® HSC on page 26
increasing productivity

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
27
www.EngineeringBooksPdf.com
Product information – Thread forming

The high-tech thread former

TiN coating
(or TiCN)
Chamfer
form C or E

Optimized
polygonal form
HSS-E

Steam-tempered
surface

P M K N S H O
CC CC CC C
Protodyn S Eco Plus
®
3.5 x DN
Variants: without IK, with KR*
CC C CC C
Protodyn® Eco Plus 3 x DN
Variants: without IK, with KA*

Protodyn® S Eco Plus  Type: EP2061745

The tool Your advantages

−−new type of TiN coating and additional −−fewer tool changes, optimum
steam treatment for extremely long machine output and increased
tool life without cold welding productivity through high forming
−−innovative chamfer geometry ensures speeds and long tool life
better running-in and wear behavior −−reduced cooling lubricant costs due
−−special surface treatment and to the possibility for MQL machining
optimized polygonal form lead to longer −−higher performance compared to
tool life through reduced friction Protodyn® S Plus
(important for MQL)
−−versions with radial internal cooling for
long thread depths in the standard
product range

The application
−−universal high-performance thread
former for use in all formable materials
up to approx. 174,000 PSI
−−special variant with TiCN coating for
machining carbon steels, as well as
abrasive aluminum alloys

28
www.EngineeringBooksPdf.com
Product information – Thread forming

Low tool costs, good performance

TiN coating
Innovative chamfer
geometry form C

Optimized
polygonal form
HSS-E

P M K N S H O
Protodyn® S Plus C C CC CC C 3.5 x DN
Protodyn® Plus C C C CC C 3 x DN

Protodyn® S Plus Type: DP2061705

The tool Your advantages

−−innovative chamfer geometry for better −−lower purchase price (and lower
running-in and even wear behaviour performance) compared to
−−optimized polygonal form for reduced ­Protodyn® S Eco Plus
friction and longer tool life −−reduction in tool inventory, since it
can be used universally in a broad
The application material spectrum
−−for universal use in all formable
­materials up to approx. 174,000 PSI

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
29
www.EngineeringBooksPdf.com
Product information – Thread forming

Ideal solution for soft materials

CrN coating

HSS-E

2 x DN

P M K N S H O
C CC CC
Chamfer form C

Protodyn® Eco LM  Type: E2061604

The tool Your advantages

−−titanium-free CrN coating −−increased process reliability and
higher tool life due to a minimised
tendency toward weld formations
Comment:
−−possible to machine wrought
For threads > 2 x DN, we recommend
aluminum and cast alloys with
grinding lubrication grooves into the
emulsion instead of oil
thread section, made possible by
semi-standard modification services.

The application
−−for long-chipping, soft materials and for
materials with a tendency to cause
lubrication
−−with a tensile strength from approx.
29,000 to 101,500 PSI
−−ISO N: AlSi alloys with an Si content up
to 12% and for long-chipping copper
alloys
−−ISO S: Ti alloys up to approx.
159,500 PSI (if heavy duty oil is used)
−−ideal under moderately good lubrication
conditions in which TiN or TiCN has a
tendency toward weld formations
−−suitable for MQL

30
www.EngineeringBooksPdf.com
Product information – Thread forming

The specialist for machining stainless steel

Special
polygon geometry

HSS-E

3.5 x DN
TiN coating
P M K N S H O
C CC C C
Chamfer form C

Protodyn® S Eco Inox  Type: E2061305

The tool Your advantages

−−special polygon geometry makes it −−reduction in the machining time of
possible to machine stainless steels stainless materials, because no
with emulsion manual intervention in the machining
process is required
The application
−−the emulsion does not separate,
−−machining stainless steels with
because no foreign oil is used
­emulsion

Comment:
With conventional thread formers,
stainless steels can only be machined
with oil. Machining centers, however,
are generally operated with emulsion.
To form threads, the machines
would have to be stopped in order
to manually lubricate the thread
with oil . In addition to the increased
machining time, there is the risk of
the emulsion separating because of
the foreign oil being added.

−−can be used in all formable materials,

however performance is lower compared
to universal thread formers

31
www.EngineeringBooksPdf.com
Product information – Thread forming

Ideal for synchronous machining, universal use

TiN coating
(or TiCN)

Weldon
flat

HSS-E

3.5 x DN

P M K N S H O
CC CC CC C
Chamfer form C
Variants: without IK, with KR*

Protodyn S Synchrospeed 
®
Type: S2061305

The tool Your advantages

−−the short thread section ensures −−high productivity due to high forming
reduced friction and high forming speeds
speeds
−−reduction in inventory costs due to
−−variants with radial internal cooling for universal use
deep threads in the standard product
−−possible to use simple adaptors
range
without compensation mechanism
−−Shank tolerance h6 (e.g. for use in
shrink-fit chucks)

The application
−−for use on machine tools with a
synchronous spindle; not suitable for
floating chucks or cutting attachments
−−for universal use in nearly all formable
materials up to approx. 174,000 PSI
−−suitable for MQL
−−it is generally recommended to use
adaptors with minimum compensation
(e.g. Protoflex C) (advantage: longer
tool life and increased process
reliability)

32
www.EngineeringBooksPdf.com
Product information – Thread forming

Long tool life, extremely high speeds

Innovative chamfer TiCN coating

geometry in form C or E

Optimized
polygonal form
Wear-resistant,
tough micrograin carbide

P M K N S H O
CC C CC C
Protodyn S HSC
®
4 x DN
Variants: with KA*
CC C CC C
Protodyn® HSC 3 x DN
Variants: without IK*

Protodyn® S HSC Type: HP8061716

The tool Your advantages

−−optimized polygonal form reduces −−extremely high productivity due to
friction and increases tool life increased forming speeds
−−new type of chamfer geometry for −−fewer tool changes because of very
uniform wear pattern long tool life
−−h6 shank tolerance (e.g. for use in −−attractive price/performance ratio
shrink-fit chucks) on a mass-production scale
−−best possible use of the drilling
Protodyn® S HSC: depth because the tool has no point
−−lubrication grooves and axial coolant
supply for deep blind hole threads up
to 4 x DN

The application
−−ISO P: steel with a tensile strength up
to 174,000 PSI
−−ISO M: stainless materials with a tensile
strength up to 145,000 PSI (preferably
with oil)
−−ISO N: AlSi alloys with an Si content up
to 12% as well as Ni alloys with a tensile
strength less than 130,500 PSI

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
33
www.EngineeringBooksPdf.com
Product information – Thread milling

Universal with countersink step

90° countersink step

TiCN coating
or bright finish

Wear-resistant, tough
­micrograin carbide

2 x DN

P M K N S H O
CC CC CC CC CC C

Variants: without IK, with KA (from size M4)*

Solid carbide thread mill TMC – Thread Mill Countersink Type: H5055016

The tool
−−solid carbide thread mill with
The strategy:
countersink step

−−concentricity < 10 µm for outstanding
thread quality and long tool life

The application
−−for universal use in a wide range of
materials with a tensile strength up to
approx. 217,500 PSI and 48 HRC

Your advantages
−−long tool life and high cutting data
because of improved substrate
−−very good operational smoothness
and soft cutting action because of 1. Positioning over 2. Plunging
optimized geometry core hole and axial
­chamfering

34
www.EngineeringBooksPdf.com
 Comment:
If a countersink step is not required,
use of thread mills from the TMG
family is recommended. Their field of
application is aligned with that of the
TMC family. The TMC thread mills in
the standard product range begin
with size M3, the smallest size in the
TMG family is M6.

TMC thread milling

180° 360° 180°

3. Feeding back 4. Radial plunging 5. Creating thread 6. Exit loop 180° 7. Retracting the
to required into the thread using 360° helix back to center tool to the
thread depth 180°/¼ pitch start position

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
35
www.EngineeringBooksPdf.com
Product information – Thread milling

Extremely high process reliability

in the smallest of threads
Large shank diameter

Wear-resistant,
tough micrograin carbide

Variant for 2 x DN and

variant for 3 x DN in the
standard product range

TiCN coating
(or bright finish) P M K N S H O
CC CC CC CC CC C
Variants: without IK, with KA (from size M5)*

Thread mill TMO - Thread Mill Orbital Type: H5087016

The tool Your advantages

−−short cutting edge, smaller helix angle −−long tool life because of innovative
and positive rake angle for reduced milling strategy
forces and a soft cutting action
−−small and deep threads (e.g. M1,6,
−−larger shank diameter for vibration-free 3 x DN depth) can be produced
use, even with longer clamping lengths reliably
−−stable basic construction with large −−can be used profitably where
core diameter conventional tools have reached
their limits:
The application • machining difficult-to-cut
−−for universal use in a broad material materials such as Inconel
spectrum with a tensile strength up to • producing deep threads
217,500 PSI and 48 HRC • solution where (multiple) radial
−−excellent machining properties even for cutting passes would be necessary
high-strength materials that tend to with conventional thread mills due
spring back (e.g. high-tensile stainless to their conical threads
steels and Ti alloys)

36
www.EngineeringBooksPdf.com
 Comment:
Orbital thread mills are available in the TMO HRC version.
These tools are specially designed for machining hardened
and high-strength materials.
Primary area of application: hardened steels up to 65 HRC,
steels and alloyed steels from 203,000 to 232,000 PSI

P M K N S H O
CC C CC C

The strategy: TMO orbital-thread milling

1. Positioning over 2. Feeding in to 3. Radial plunging 4. Producing 5. Retracting

core hole thread depth into the thread threads the tool to the
180°/¼ pitch using helical start position
interpolation

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
37
www.EngineeringBooksPdf.com
Product information – Thread milling

Drilling, countersinking and threading in one operation

90° countersink step

Special drilling geometry

with three cutting edges
Wear-resistant,
tough micrograin carbide

2 x DN

P M K N S H O
27° helix angle
NHC CC

three coolant holes

TAX CC
IK absolutely essential*

Solid carbide thread milling cutter TMD - Thread Mill Drill Type: H5075018

The tool
−−solid carbide thread milling cutter
The strategy:
−−cutting length and countersink step

matched to 2 x DN thread depth
−−TAX coating for ISO K materials
−−NHC coating for ISO N materials

The application
−−ISO K: cast iron workpieces such as
GG25 (GGG materials can only be
machined in exceptional cases.
Machining these materials is made
possible in part by a two flute special
tool.)
−−ISO N: cast aluminum with an Si
content of 7% and above; short-
chipping Mg and Cu alloys
−−Direct machining of precast core holes 1. Positioning over 2. Spot drilling,
core hole drilling,
countersinking
the core hole
and chip
removal

38
www.EngineeringBooksPdf.com
 Your advantages Practical tip:
−−greater cost efficiency for less than Use of TMD is practical if one single
8 identical threads per component thread has a different specification to
compared to conventional tools** all of the other threads in the
−−increased productivity by shortening component.
processing times by up to 50% Example: 13 threads per component.
−−space savings in the tool magazine 12 of them are M8, 1 thread is M6.
−−exact positioning of core hole and Instead of using a core-hole drill and
thread a threading tool, this thread can be
made more economically with the TMD.

** the advantages can vary depending on the

chip-to-chip time

TMD thread milling with countersink step

180° 360° 180°

3. Moving to the 4. Radial plunging 5. Creating thread 6. Exit loop 180° 7. Retracting the
start position into the thread in counter- back to center tool to the
of the thread 180°/¼ pitch rotation using start position
milling cycle 360° helix

* IK = internal coolant supply

KA = internal coolant supply with axial coolant outlet
KR = internal coolant supply with radial coolant outlet
39
www.EngineeringBooksPdf.com
Tool selection – Tapping

Universal blind hole taps

Paradur® Eco Plus (3 x DN)

P
Paradur® Synchrospeed* (2.5 x DN)

Paradur® Eco Plus (3 x DN)

M
Paradur® Synchrospeed* (2.5 x DN)

Paradur® Eco Plus

(3 x DN)
K
Paradur® Synchrospeed* (2.5 x DN)

Paradur® Eco Plus

(3 x DN)
N
Paradur®
Synchrospeed*
(2.5 x DN)

0 29,000 58,000 87,000 116,000 145,000 174,000 203,000

Tensile strength [PSI]

HSS-E or HSS-E-PM cutting tool material  * only for synchronous machining

40
www.EngineeringBooksPdf.com
Tool selection – Tapping

Universal through-hole taps

Prototex® Eco HT (3.5 x DN)

P
Prototex® Synchrospeed* (3 x DN)

Prototex® Eco HT (3.5 x DN)

M
Prototex® Synchrospeed* (3 x DN)

Prototex® Eco Plus

(3.5 x DN)
K
Prototex® Synchrospeed* (3 x DN)

Prototex® Eco Plus

(3.5 x DN)
N
Prototex®
Synchrospeed*
(3 x DN)

0 29,000 58,000 87,000 116,000 145,000 174,000 203,000

Tensile strength [PSI]

HSS-E or HSS-E-PM cutting tool material  * only for synchronous machining

41
www.EngineeringBooksPdf.com
Tool selection – Tapping

Blind hole taps

for special applications

Paradur® HSC* (2 x DN)

Paradur® HT* (3 x DN)

P
Paradur® X·pert P (3.5 x DN)

Paradur® X·pert M
(2.5 x DN)

M Paradur® X·pert M (2.5 x DN)

Paradur® HSC*
(2 x DN)

Paradur® HT*
K (3.5 x DN)

Paradur® Eco CI** (3 x DN)

Paradur® Eco CI**

(3 x DN)
N
Paradur® WLM
(3 x DN)

S Paradur® Ti Plus (2 x DN)

0 29,000 58,000 87,000 116,000 145,000 174,000 203,000

Tensile strength [PSI]

Solid carbide cutting tool material * internal cooling required

** only for short-chipping materials;
HSS-E or HSS-E-PM cutting tool material internal cooling recommended

42
www.EngineeringBooksPdf.com
Tool selection – Tapping

Through-hole taps
for special applications

Prototex® HSC* (2 x DN)

P Prototex® X·pert P (3 x DN)

Prototex® X·pert M
(3 x DN)

M Prototex® X·pert M (3 x DN)

Prototex® HSC*
(2 x DN)

Prototex® X·pert P
K (3 x DN)

Paradur® Eco CI*** (3 x DN)

Paradur® Eco CI***

(3 x DN)
N
Prototex® X·pert P
(3 x DN)

S Prototex® TiNi Plus (2 x DN)

0 29,000 58,000 87,000 116,000 145,000 174,000 203,000

Tensile strength [PSI]

Solid carbide cutting tool material

* internal cooling required
HSS-E or HSS-E-PM cutting tool material *** only for short-chipping materials

43
www.EngineeringBooksPdf.com
Tool selection – Thread forming

Thread formers

Thread depth

Type
C C Primary
application
C Additional application
Product information: Page

Brinell hardness HB
Structure of main material groups
Material group

Workpiece material

annealed (tempered) 210

free cutting steel 220
Unalloyed and low alloy steel tempered 300
tempered 380
tempered 430
P annealed 200
High-alloy steel and
hardened and tempered 300
high-alloy tool steel
hardened and tempered 400
ferritic/martensitic, annealed 200
Stainless steel
martensitic, tempered 330
austenitic, duplex 230
M Stainless steel
austenitic, precipitation hardened (PH) 300
Grey cast iron 245
K Cast iron with spheroidal graphite ferritic, pearlitic 365
GGV (CGI) 200
not precipitation hardenable 30
Aluminum wrought alloys
precipitation hardenable, precipitation hardened 100
≤ 12% Si 90
Cast aluminum alloys
> 12% Si 130
N Magnesium alloys 70
unalloyed, electrolytic copper 100
Copper and copper alloys brass, bronze, red brass 90
(bronze/brass) Cu-alloys, short-chipping 110
high-strength, Ampco 300
Fe-based 280
Heat-resistant alloys Ni or Co base 250
Ni or Co base 350
pure titanium 200
S Titanium alloys α and β alloys, precipitation hardened 375
β alloys 410
Tungsten alloys 300
Molybdenum alloys 300

44
www.EngineeringBooksPdf.com
 2.0 x DN 3.5 x DN

Protodyn ®
Protodyn S Protodyn S Protodyn® S Protodyn® S Protodyn® S
® ®

Eco LM Plus Eco Plus Eco Inox Synchrospeed HSC

30 29 28 31 32 33
Tensile strength Rm
N/mm2

700 CC CC CC C CC C
750 CC CC CC C CC C
1010 CC CC C CC CC
1280 C C C C CC
1480
670 CC CC C CC C
1010 CC CC C CC CC
1360
670 CC CC CC CC CC
1110 CC CC CC CC CC
780 CC CC CC CC CC
1010 C C C C C
–
–
–
– CC CC CC C CC CC
340 CC CC CC C CC CC
310 CC CC CC C CC CC
450
250
340 CC C C C C C
310
380
1010
940
840 CC CC C CC CC
1080
670 CC
1260 CC
1400 CC
1010
1010

45
www.EngineeringBooksPdf.com
Tool selection – Thread milling

Thread mills

Thread depth

Type
C C Primary application
C Additional application
Product information: Page

Brinell hardness HB
Structure of main material groups
Material group

Workpiece material

annealed (tempered) 210

free cutting steel 220
Unalloyed and low alloy steel tempered 300
tempered 380
tempered 430
P annealed 200
High-alloy steel and
hardened and tempered 300
high-alloy tool steel
hardened and tempered 400
ferritic/martensitic, annealed 200
Stainless steel
martensitic, tempered 330
austenitic, duplex 230
M Stainless steel
austenitic, precipitation hardened (PH) 300
Grey cast iron 245
K Cast iron with spheroidal graphite ferritic, pearlitic 365
GGV (CGI) 200
not precipitation hardenable 30
Aluminum wrought alloys
precipitation hardenable, precipitation hardened 100
≤ 12% Si 90
Cast aluminum alloys
> 12% Si 130
N Magnesium alloys 70
unalloyed, electrolytic copper 100
Copper and copper alloys brass, bronze, red brass 90
(bronze/brass) Cu-alloys, short-chipping 110
high-strength, Ampco 300
Fe-based 280
Heat-resistant alloys Ni or Co base 250
Ni or Co base 350
pure titanium 200
S Titanium alloys α and β alloys, precipitation hardened 375
β alloys 410
Tungsten alloys 300
Molybdenum alloys 300
50 HRC
H Hardened steel 55 HRC
60 HRC

46
www.EngineeringBooksPdf.com
 1.5 x DN 2.0 x DN
2.0 x DN
2.0 x DN 3.0 x DN

TMG TMC TMO HRC TMD TMO

35 34 37 38 36
Tensile strength Rm
N/mm2

700 CC CC CC
750 CC CC CC
1010 CC CC CC
1280 CC CC CC
1480 CC CC CC CC
670 CC CC CC
1010 CC CC CC
1360 CC CC CC CC
670 CC CC CC
1110 CC CC C CC
780 CC CC CC
1010 CC CC CC
– CC CC CC CC
– CC CC CC CC
– CC CC CC CC
– CC CC CC CC
340 CC CC CC CC
310 CC CC CC CC
450 CC CC CC CC
250 CC CC CC CC
340 CC CC CC CC
310 CC CC CC CC
380 CC CC CC CC
1010 CC CC CC CC
940 CC CC CC
840 CC CC CC
1080 CC CC CC
670 CC CC CC
1260 CC CC CC
1400 CC CC CC
1010 CC CC C CC
1010 CC CC C CC
- CC
- CC
- CC

47
www.EngineeringBooksPdf.com
Technical information – general

Comparison of the processes for producing threads

Advantages

−− no special requirements for the −− almost all machinable materials can

Thread tapping

machine be processed

−− high process reliability −− longer tool life compared to thread

• no chips and therefore no problems tapping
with chip removal: even deep −− tools can be used universally
threads can therefore be produced −− BH and TH threads with one tool
reliably
Thread forming

• low risk of fracture because of

stable tools

−− high thread quality

• high static and dynamic strength of
the thread because of cold work
hardening
• very good thread surface with minor
roughness

−− high flexibility −− high process reliability

• universal use of the tools in the • no risk of bird nesting
most varied materials • workpiece does not have to be
• one tool for blind-hole and through- rejected if the tool breaks
hole threads • low torque even with large
Thread milling

• different thread dimensions (with ­dimensions

the same pitch) can be produced • inclined entry and exit are no
with one tool problem
• any tolerance grades can be • machining of thin-walled
produced with one tool components is possible thanks to
• single and multi-start threads as low cutting pressure
well as right-hand and left-hand
threads can be produced with one −− low spindle stress due to a smooth
tool sequence of movements
−− very good thread surface

48
www.EngineeringBooksPdf.com
 Disadvantages

−− chip removal is often challenging and −− risk of workpiece having to be rejected if

requires tool diversity as well as special the tool breaks
modifications (particularly with deep −− process may react sensitively to batch-
blind hole threads in long-chipping related changes in the properties of the
materials) workpiece materials
−− reduced tool stability due to flutes; risk −− increased risk of machine stoppage due
of fracture increases to bird nesting

−− risk of workpiece having to be rejected if −− tighter tolerance of the core hole

the tool breaks increases the production costs;
−− area of application limited due to profitability comparison with thread
elongation at fracture, tensile strength tapping absolutely essential
and thread pitch −− not approved for use in the food
industry, the medical industry and the
aerospace industry

−− high tool costs compared to HSS-E taps −− in mass production, thread milling is
and thread formers often inferior to thread tapping and
−− 3D CNC machine absolutely essential thread forming in terms of cost-
−− more complex programming effectiveness
Thread depth
Universality/
Machining

Tool costs
­reliability

flexibility
Process

Tool life
speed

Typical batch size

Thread tapping – + – – – + low to very high
Thread forming + + + ++ + ++ low to very high
Thread milling ++ – ++ + + – low to medium
– Reference
+ higher than reference
++ significantly higher than reference

49
www.EngineeringBooksPdf.com
Technical information – general

Tolerance grades of taps and thread formers

The tolerance grade of the internal thread

produced depends not only on the tool If abrasive materials such as grey cast
dimensions, but also on the material and iron are being machined and miscutting is
the machining conditions. In some cases, it not a problem, then it also advisable to
is better to choose tolerances that deviate produce the tools in X grade. The tool life
from the standard. This toleration is is increased due to the tolerance in X
identified by the X placed after the grade, because it takes longer for the tool
tolerance class (e.g. 6HX instead of 6H). to become heavily worn. For example, the
Please note that these X grades vary from Paradur® Eco CI tap is produced in this
manufacturer to manufacturer, because tolerance grade for precisely this reason.
they are based solely on company
standards. Thread formers are produced in X grades,
because the material rebounds stronger
Taps, which are designed for tough when forming threads than when cutting
materials, are produced by Walter Prototyp threads. The X grades for thread formers
in X grades in order to counteract the differ from those for taps. Nevertheless,
resilient properties of the materials. At this does not affect the tolerance of the
Walter Prototyp, this means increasing the female thread being produced, as can be
dimensions for taps by half a tolerance seen in the table below.
grade. The X∙pert M product range used
for stainless steels is therefore designed
in X grade. Taps for high-tensile titanium
and nickel alloys are measured in X grade
for the same reason.

Tolerance class of tool Producible tolerance

range of the female
Company standards for taps
Designation for taps thread
and thread formers

3B 3BX 3B

2B 2BX –

ISO1/4H 4HX 4H 5H

ISO2/6H 6HX 4G 5G

ISO3/6G 6GX – –

7G 7GX – –

50
www.EngineeringBooksPdf.com
 Example:
The tolerance class of the tool (e.g. 4H) metric thread, electroplated coating
complies with the tolerance field of the with a thickness of 25 µm
female thread for which the tool has been
designed. The table below shows that With a flank angle of 60°, this results
these tools can also be used to produce in:
other tolerance fields.

Coatings that are subsequently applied to

the female thread must be compensated
for on the tap with a material removal from this it follows that
calculation. The material removal can be
calculated using the following formula: A = 0.025 mm x 4 = 0.1 mm
A = T x f where f =
If a normal screw connection is to be
achieved, a tool from tolerance class
6H + 0.1 must therefore be chosen.
A is the material removal to be calculated,
T is the coating thickness of the
subsequently applied coating and α is the
flank angle. Comment:
When thread milling, one tool can be
used to produce any tolerance grades,
because the tolerance grades are
specified when programming.

Producible tolerance
range of the female Technical application
thread

– connection with tight tolerance

2B normal screw connection

– – – screw connection with little clearance

6H – – normal screw connection

6G 7H 8H screw connection with a lot of clearance

– 7G 8G to prevent distortion during heat treatment

51
www.EngineeringBooksPdf.com
Technical information – general

Coatings and surface treatments

bright finish vap nid (nit + vap)

– very deep blind holes in – primarily for stainless – TH: Steel up to

soft steels materials 174,000 PSI, cast iron and
areas of application

– used if there are – in materials that are soft, aluminum machining;

problems with chip tough and have a – BH: only short-chipping
removal tendency toward weld materials (GG, AlSi alloys
Primary

formations with Si content > 7%,

– for very deep blind hole C70); steels with high
threads pearlite content;
– not for stainless
materials that tend to
spring back

– lower vc/ shorter tool life – better coolant adhesion – longer tool life because of
compared to coated tools which reduces weld increased surface
Features

– more tightly rolled chips formations hardness

– lower vc/shorter tool life – increasing brittleness
than coated tools – nidamised means nitrided
– better chip removal and vaporised
Appear-
ance

CrN NHC DLC

– thread tapping in Al and – non-ferrous metals – Al alloys with a tendency

Primary areas
of ­application

Cu alloys (Cu-, brass-, bronze- and to spring back

– thread forming in Ti alloys Ti-alloys)
−− machining of ductile – AlSi alloys with an Si
steels content up to 12%

– reduces – reduces built up edges – significant tool life

weld formations increases are sometimes
Features

– resistant to abrasive wear

– sharp cutting edges are possible
possible, because of the
thin layer
Appear-
ance

BH = blind hole machining

TH = through hole machining
52
www.EngineeringBooksPdf.com
 TiN TiCN THL

– low-alloy steels – alloyed and unalloyed steels – steels in general and

– stainless materials – abrasive materials such as stainless steels in particular
– suitable for Ni alloys grey cast iron, AlSi (Si – deep blind holes
> 5%), Cu bronze alloys – MQL machining
– universal layer for GFR up to – GJS (GGG)
48 HRC
– suitable for Ni alloys

– universal layer – wear resistant to abrasive – better chip formation than

– suitable for many materials materials TiN and TiCN
– not for Ti alloys – highly suited to solid carbide – tendency toward built up
tools edge
– not for Ti alloys

ACN TAX Diamond

– Ti alloys – used universally for thread – abrasive materials such as

– Ni alloys milling AlSi alloys with an Si
– also for hardened steels and content > 12%
HSC machining

– no affinity to titanium alloys, – high temperature resistance – resistant to abrasive wear

because it is a titanium-free – universal layer
layer

53
www.EngineeringBooksPdf.com
Technical information – general

Coatings and surface treatments

Low to medium tensile strength

P X X X

M X X

K X X
Material

N X X X X X

S X

Surface treatment bright finish vap TiN CrN NHC

Thread tapping X X X X

Thread forming X X

Thread milling X

Thread mill drill X

54
www.EngineeringBooksPdf.com
 Low to
Medium to high Low to high very high
tensile strength tensile strength tensile
strength

X X X X

X X X X

X X X X

X X X

X X

DLC Diamond nid ACN TiCN THL TAX

X X X X X

X X

X X X X X

Selection of coatings for thread forming

Material TiN TiCN

Magnetic soft iron CC C

Structural steel CC C

Carbon steel C CC

Alloyed steel CC C

Tempered steel CC C

Stainless steel C CC

Austenitic C CC

Ferritic, martensitic, duplex C CC

Highly heat-resistant C CC

Unalloyed Al/Mg CC C

Al, alloyed Si < 0.5% C CC

Al, alloyed Si < 0.5% to 10% C CC

Al, alloyed Si > 10% C CC

CC Recommended C Possible application

55
www.EngineeringBooksPdf.com
Technical information – general

Cooling and lubrication

We usually talk about “coolant” when Supplying the coolant externally becomes
referring to this, although with thread difficult when deeper threads are being
cutting and thread forming in particular, machined with the spindle in a horizontal
lubrication is more important than position. The coolant cannot penetrate
cooling. There are the following different right to the cutting edge in this case. The
methods of coolant supply: removal of chips also hinders the supply
of coolant during blind hole tapping.
−−external coolant supply
−−external coolant supply via outlets The supply of coolant parallel to the axis
parallel to the axis on the chuck via cooling grooves in the shank has
−−“internal” coolant supply via flutes on significant advantages, because the
the shank coolant is always reliably supplied to the
cutting edge regardless of the tool length.
−−internal coolant supply (= IK)
It must only be noted that as the rotation
with axial coolant outlet (= KA)
speeds increases, the coolant is flung
−−internal coolant supply away radially if the coolant pressure is too
with radial coolant outlet (= KR) low.

External coolant supply is the most The internal coolant supply ensures that
common method and works in most the coolant reaches the cutting edge at
cases. When machining blind hole threads all times. Optimum cooling and lubrication
vertically, the core hole fills with coolant of the cutting edge is always guaranteed
(with the exception of very small tool and in many cases aids chip removal.
diameters) and this facilitates the thread
machining process.

When producing through-hole threads,

the core hole is unable to be filled
because during thread tapping the chips
are transported in the feed direction and
during thread forming no chips are
created; nevertheless the coolant may
still be able to penetrate right to the
chamfer in deep threads. The coolant flow
should be set as close and parallel as
possible to the tool axis.

56
www.EngineeringBooksPdf.com
Material

Material Thread cutting Thread forming Thread milling

group

Emulsion/MQL/
Steel Emulsion 5% Emulsion 5 - 10%
air blast
Steel Emulsion 10% Emulsion/MQL/
Emulsion 5 - 10%
850 - 1,200 N/mm² or oil (Protofluid) air blast
Emulsion 10% or
P Steel Emulsion 10% Emulsion/MQL/
oil (Protofluid or
1,200 - 1,400 N/mm² or oil (Protofluid) air blast
Hardcut 525)
Steel
1,400 - 1,600 N/mm² Oil (Protofluid or Forming generally Emulsion/MQL/
equivalent to Hardcut 525) not possible air blast
44 - 49 HRC
Oil (Protofluid)
[emulsion 5-10%
Emulsion 5 - 10% or only possible with
M Stainless steel
oil (Protofluid) specific tools
Emulsion
(Protodyn® S Eco
Inox)]
Forming not Emulsion/MQL/
Grey cast iron GG Emulsion 5%
possible air blast
K
Ductile cast iron Emulsion/MQL/
Emulsion 5% Emulsion 10%
GGG air blast
Aluminum up to Emulsion/MQL/
Emulsion 5 - 10% Emulsion 5 - 15%
max. 12% Si air blast
Emulsion 5 - 10%
Aluminum over Forming only Emulsion/MQL/
Emulsion 5 - 10%
12% Si practical in air blast
N exceptional cases
Forming not
Magnesium Oil (Protofluid) possible at room Dry
temperature
Emulsion/MQL/
Copper Emulsion 5 - 10% Emulsion 5 - 10%
air blast
Emulsion 10% or
Titanium alloys oil (Protofluid or Oil (Hardcut 525) Emulsion
Hardcut 525)
S
Emulsion 10% or
Oil (Protofluid or
Nickel alloys oil (Protofluid or Emulsion
Hardcut 525)
Hardcut 525)
Oil (Hardcut 525)
Forming not
H Steel >49 HRC possible only with
possible
Dry/MQL
carbide tools
Forming does
not produce
O Synthetics Emulsion 5%
dimensionally
Emulsion/MQL
accurate threads

57
www.EngineeringBooksPdf.com
Technical information – general

Cooling and lubrication – Thread tapping

There are two cases which apply to blind

hole tapping:

Case 1: Short chips

The best results in terms of performance
and process reliability are attained if the
chips can be broken into small pieces.
These short chips can be easily flushed
out of the threads using coolant. The best
way to break the chips is with straight-
fluted taps (e.g. Paradur® HT). The KA is
recommended for blind hole threads.

Comment:
If blind hole threads are being
produced in short-chipping materials
without IK, the chips collect at the
bottom of the hole. If the safety
margin has been measured too tight,
the tool runs up against the chips and
may break.

Case 2: Long chips

(chips cannot be broken)
With steels lower than 145,000 PSI or with
stainless steels and other very tough
materials in general, it is normally not
possible to break the chip when short. In
these cases, the chip must be removed
using helically fluted tools. If there is
internal cooling, the coolant only helps
with chip removal. In some cases, taps
with a shallower helix can be used which
increases the tool life.

58
www.EngineeringBooksPdf.com
Technical information – general

Cooling and lubrication – Thread milling

Wet machining is generally Externally supplied emulsion, MQL or

recommended for thread milling, compressed air is recommended for
however it should only be applied if producing through hole threads. Wet
evenly distributed cooling can be machining may nevertheless lead to
guaranteed, otherwise the emerging problems here, because externally
thermal shocks lead to the formation of supplied coolant cannot always guarantee
microcracks, which in turn result in an even cooling of the tool. With small
fractures and this reduces the tool life. thread dimensions in particular, there is a
Wet machining with an externally risk of the externally supplied coolant not
supplied lubricant often means that being able to enter the narrow hole fully,
evenly distributed cooling cannot be with the result that even cooling of the
guaranteed. Dry machining with tool cannot be guaranteed.
compressed air is generally possible
when thread milling, however some tool
life is lost.

When blind hole machining, it is generally Comment:

recommended to use a tool with an axial When thread milling, having no
coolant outlet. The best option is to use cooling is less of a problem than
emulsion. No thermal shocks occur intermittent cooling.
because the tool is completely
submerged. In addition, the flow of
coolant aids chip removal and therefore
ensures that the process is reliable.
Alternatively, internally supplied
compressed air or MQL can also be used
here , however this results in a shorter
tool life. The use of externally supplied
emulsion when producing blind hole
threads is not recommended, because
chips may accumulate in the core hole
and this has a negative effect on the tool
life. Moreover, there is an increased risk
of thermal shocks if externally supplied
lubricant is used.

59
www.EngineeringBooksPdf.com
Technical information – general

Cooling and lubrication – Thread forming

Cooling and lubrication in particular are of central importance when thread forming.
Insufficient lubrication causes a sharp drop in the surface quality of the thread, as
these photographs show:

flaked surface from insufficient smooth surface from excellent

lubrication; Remedy: Lubrication lubrication
grooves

There are basically two differing types of tools: Thread formers with lubrication
grooves and thread formers without lubrication grooves. The different areas of
application are explained below.

without lubrication with lubrication

grooves grooves

The area of application for tools without Lubrication grooves ensure uniform
lubrication grooves is limited to: lubrication even at the bottom of the
−−steel sheet extrusions thread which is why thread formers with
−−through hole threads up to 1.5 x DN lubrication grooves can be used univer-
(because coolant cannot accumulate in sally. Vertical through hole threads up to
the core hole) approx. 3.5 x DN can be produced with
lubrication grooves even when internal
−−blind hole threads when machining
cooling is not used.
vertically (KA is recommended for very
deep blind hole threads)

60
www.EngineeringBooksPdf.com
There are four different cases to consider for the tool design:

Vertical blind hole machining Vertical through hole machining

Lubrication grooves and internal coolant (> 1.5 x DN)
supply are not required; external coolant Lubrication grooves are required; internal
supply is sufficient (KA is recommended coolant supply is not necessary. Externally
for very deep threads). supplied coolant can penetrate into the
thread profile through the lubrication
grooves (KR is recommended for very
deep threads).

Horizontal
blind hole machining
Lubrication grooves and internal coolant
supply are necessary. Axial coolant outlet
is sufficient.

Horizontal
through hole machining
Lubrication grooves are required. Internal
coolant supply with radial outlet is
recommended.

61
www.EngineeringBooksPdf.com
Technical information – general

Minimum quantity lubrication

Coolant is used in machining operations The modified tool requirements for MQL
to reduce tool wear, to dissipate heat must be taken into consideration when
from the workpiece and machine, and to the tools are designed. For example, the
aid chip breaking as well as chip removal. tools must be designed so that as little
Moreover, the remnants of chips are heat as possible occurs during
removed from the workpiece, tool and the machining – small or even negative rake
fixtures. All of these factors are angles are therefore to be avoided.
important prerequisites for manufacturing Similarly, the geometry is to be designed
in an efficient, trouble-free and cost- so that reliable chip removal can be
effective manner. achieved without the supportive effect of
a lubricant. The coating in particular plays
Nevertheless, the costs for procuring, a central role in MQL machining, because
maintaining and disposing of coolant the hard material layer takes on the
continue to rise . The poor environmental lubrication function to a large extent.
compatibility of lubricants and the heath Furthermore, the coating reduces friction
risks they represent for machine as well as insulating the tool against heat.
operators are under increasing scrutiny.
As stated on page 7, the costs associated At thread depths > 1.5 x DN, the
with lubricants amount to approx. 16% of prerequisite for MQL is an internal coolant
the total production costs. Reducing the supply with a radial outlet. Furthermore,
consumption of lubricants for economical the coolant channels in the tool must be
and environmental reasons is therefore designed so that the oil-air mixture does
very important for successful companies not become separated.
who are working toward sustainability.
For MQL machining, Walter Prototyp
This plan can be achieved using Minimum recommends the specially developed THL
Quantity Lubrication (MQL). With MQL coating for taps. This coating is available
machining, a small amount of highly as standard for Paradur® Eco Plus
effective lubricant is added to the (successor to the proven Paradur® Eco
compressed air. Even with very small HT), Prototex® Eco HT as well as for
doses of lubricant (approx. 0.17-1.7 oz/hr Paradur® and Prototex® Synchrospeed
(5-50 ml/hr)), weld formations on tools. The THL coating has a lubricant
materials that tend to spring back can be layer which ensures very good friction
prevented. In addition, MQL can be used behaviour even with MQL and also
to reduce friction which in turn reduces prevents build-up on the cutting edges.
the process temperature. The layer is continuously polished during
the course of the tool's life.
In the most simple case, the lubricant is
supplied externally. This method can be The Protodyn® Eco Plus, Eco LM and
retrofitted inexpensively to existing Synchrospeed families are suitable for
machines, however the limit is reached minimum quantity lubrication when thread
with threads that have a depth greater forming.
than 1.5 x DN. It is better to supply the
lubricant through the spindle and this
should be taken into consideration when
purchasing machines.

62
www.EngineeringBooksPdf.com
Your advantages Comment:
from MQL machining with Walter In contrast to thread tapping and
Prototyp tools: thread forming, dry machining is
−−reduction in production costs and an generally possible with thread milling,
increase in competitiveness however some loss of tool life has to
−−reduction in lubricant, maintenance be accepted. If working dry, the use of
and disposal costs an air blast is recommended for chip
evacuation. When thread milling, it is
−−reduction in energy costs
often better to use MQL instead of
−−prevention of health risks for wet machining, because the tool is
employees not subject to thermal shocks.
−−often no compromise in performance
compared to wet machining
−−trough-like components do not fill
with lubricant
−−less effort required for cleaning
components

Materials that are suitable Materials that are not suitable

for MQL machining for MQL machining

– non or low alloyed steels as well as cast – high-tensile, high-alloy steels

steel < 145,000 PSI – Ti and Ni alloys
– grey cast iron – stainless steels
– brass
– AlSi alloys
– copper alloys

Notes:
−−High-tensile and hardened materials can be machined with MQL during thread
milling.
−−In practice, there may be cases where the above-mentioned classification does
not apply.

63
www.EngineeringBooksPdf.com
Technical information – general

Clamping devices

Tapping chucks (also called tool adaptors) General tasks:

are the connecting piece between the −−transferring the lubricant from the
spindle and the tool. spindle to the tool
−−protecting the spindle bearings if the
Tasks of the tool adaptor during tool breaks
thread tapping and thread forming:
−−protecting the tool against breakage
−−transmitting torque (can only be achieved to a limited
−−axial and/or radial compensation of extent)
differences between the spindle
position and tool target position, where
required In terms of the interaction between the
spindle and the feed rate, it is crucial
when thread tapping and thread forming
Tasks of the tool adaptor during
to know if the spindle rotation speeds and
thread milling:
the feed rate are matched to each other
−−transmitting torque (synchronised) and their relative accuracy.
−−minimising the deflection of the tool
(chuck must be rigid to oppose radial
forces) Comment:
−−damping vibration All current milling chucks can be used
for thread milling. The special chucks
for thread tapping and thread forming
are shown below.

64
www.EngineeringBooksPdf.com
Important types of tool adaptors
for taps and thread formers

Quick change chuck

with axial compensation
Advantages:
−−for use in synchronous and non-­
synchronous machines
−−compensation of axial and radial
position deviations
−−solid design
Disadvantages:
−−more complicated technology than fixed
chucks
−−miscutting cannot be prevented,
because the tool must guide itself

Quick change chucks are available in the

standard product range from Walter.

Synchro chuck with

minimum compensation
Advantages:
−−compensation of axial forces resulting in
a marked increase in the tool life
−−combination of advantages from both
fixed chucks and floating chucks
Disadvantages:
−−more expensive to purchase than fixed
chucks
−−only for use on synchronous machine
tools

Synchro chucks with minimum

compensation are available in the
standard product range from Walter.

65
www.EngineeringBooksPdf.com
Technical information – general

Important types of tool adaptors

for taps and thread formers

Tapping attachment
Advantages:
−−for use in synchronous and non-synchronous
machines
−−protects the spindle, because the direction
of rotation of the chuck can be reversed
−−very short cycle times, because the spindle
does not need to be accelerated or
decelerated; for this reason it is of particular
interest for mass production
Disadvantages:
−−complicated technology
−−high maintenance costs
−−torque support required
−−high procurement costs

66
www.EngineeringBooksPdf.com
Shrink-fit chucks, fixed collet chucks,
Weldon chucks (from left to right)
Advantages:
−−simple, cost-effective and solid design
−−shrink-fit chuck: very high concentricity
Disadvantages:
−−only for use on synchronous machine tools
−−minimum pitch differences cause axial forces which
act on the tool flanks and reduce the tool life

Shrink-fit chucks, collet chucks and Weldon

chucks are in the standard product range
from Walter.

67
www.EngineeringBooksPdf.com
Technical information – general

Synchronous machining
for tapping and forming threads
To reduce the process times in thread Synchronous taps are compatible with
tapping and thread forming, conventional Weldon chucks as well as
manufacturers are increasingly favoring collet chucks (where possible with square
higher rotation speeds and cutting speeds drive). Both fixtures have the
(HSC). The synchronous machining disadvantage of being unable to
approach is recommended especially for compensate for the axial forces that are
achieving high cutting speeds. generated.

Synchronous tapping requires a machine A better alternative is the Protoflex

that can synchronise the rotary motion of C tapping chuck with minimum
the main spindle with the feed motion. compensation. Protoflex C is a tapping
The threading tool does not guide itself chuck for machining centers with
using its geometry, but is controlled solely synchronous control logic. It guarantees a
by the feed rate and the spindle rotation precisely defined minimum compensation
speed of the machine. Nowadays, most and is matched to the geometry of
machining centers are suitable for Synchrospeed tools.
synchronous machining.

Basically, all taps and thread formers can

be used synchronously. Nevertheless, the
tool range from Walter Prototyp known as
Synchrospeed has been designed
specifically for synchronous machining.
The key characteristics of these tools are
their extremely high flank clearance angle,
as well as their extra short threading
section. Tools in the Synchrospeed family
can only be used synchronously. In
contrast, the tools in the Eco family
achieve very good results both
synchronously and conventionally.

68
www.EngineeringBooksPdf.com
What is so special about Protoflex C?
Unlike conventional synchro tapping The Protoflex C tapping chuck helps to
chucks, the Protoflex C design is based considerably reduce the pressure forces
on a precision-machined flexor with that act on the flanks of the tap. This
high spring rate, which compensates for results in:
position deviations in the micron range −−greater process reliability thanks to the
both radially and axially. The patented reduced risk of breakage, particularly
microcompensator is made from a special where dimensions are small
alloy originally developed for NASA and is −−a longer tool life due to less friction
characterised by a long service life and is
−−improved surface quality on the flanks
maintenance-free. Conventional synchro
of the thread
chucks use plastic parts for this purpose,
but these lose their flexibility over time,.
Microcompensation is then no longer For customers using the Protoflex C
provided. tapping chuck, this means extremely high
productivity while simultaneously reducing
the tool costs, and this is true for both
thread tapping and thread forming.

Protoflex C synchronous tapping chuck Flexor with minimum compensation

69
www.EngineeringBooksPdf.com
Technical information – general

Notes on the core hole

Depth of the core hole

Drilling depth ≥ usable thread depth (+ chamfer length) + safety margin

Drilling depth
Thread Thread
Drilling depth

depth depth

Chamfer
Safety margin
(~ 2 threads)

Thread tapping, Thread milling

thread forming

Comment:
Any existing tip on the threading tool neither a chamfer area or a tip, which
must be taken into account when makes it possible to have threads that
calculating the required depth of the almost go to the bottom of the hole.
core hole. Here a distinction must be Miscutting is excluded from the milling
made between a full point and a process which is why an additional axial
reduced point. In contrast to taps and safety margin is not necessary.
thread formers, thread mills have

Diameter of the core hole for thread tapping and thread milling
(metric thread profiles)

Rule of thumb:
Hole diameter = nominal diameter - pitch

Example size M10

Hole diameter = 10.0 mm – 1.5 mm = 8.5 mm

Diameter of the core hole for thread forming (metric)

Rule of thumb:
Hole diameter = nominal diameter – f x pitch
−−tolerance 6H: f = 0.45
−−tolerance 6G: f = 0.42

Example size M10

Hole diameter = 10.0 mm – (0.45 x 1.5 mm) = 9.325 mm = 9.33 mm

For inch profiles - see table on page 115

70
www.EngineeringBooksPdf.com
Special notes on thread forming

Comment:
The recommended diameter of the core hole is marked on
the shank of Walter Prototyp thread formers.

When selecting the drilling and boring tool, the permissible

tolerances for the core hole listed in the table below must also be
noted to ensure a reliable forming process and a suitable tool life.

Thread pitch Tolerance of pilot drill diameter

≤ 0.3 mm ± 0.01 mm

> 0.3 mm to < 0.5 mm ± 0.02 mm

≥ 0.5 mm to < 1 mm ± 0.03 mm

≥ 1 mm ± 0.05 mm

Based on these tolerances which in contrast to thread cutting

are tighter, thread forming is not always more economical than
thread tapping.

Practical tip:
In thread forming, the core diameter thread milling is already determined by
of the thread is created during the the core hole. After the forming pro-
forming process and is therefore cess, it is therefore absolutely essen-
dependent on the flow characteristics tial to gauge the thread core diameter.
of the material. In contrast to this, the The tolerances of the internal thread
core diameter for thread tapping and core diameter are listed on page 116.

Comment:
The product range from Walter Titex is aligned with the pilot hole diameters for
tapping and forming threads.

71
www.EngineeringBooksPdf.com
Technical information – general

Increased edge zone hardening

Often the production of threads is seen When the core hole is drilled, the edge
as a stand-alone process. This is not zone of the workpiece is effected
advisable because the preceding drilling mechanically and thermally. The resulting
operation has a significant impact on the structural changes can be seen in the
subsequent threading process. two photomicrographs:

0.001 inch

New drill: Worn drill:

edge zone is nearly unchanged influence of the edge zone

The hardness of the edge zone is

Summary:
significantly greater using a worn drill
than using a new tool. Using higher −−The tool life of the threading tool is
cutting parameters when drilling leads to reduced as the hardness of the edge
increased hardness of the edge zone. zone increases.
Even though the increased hardness only −−The hardness of the edge zone
occurs within a very small distance to the escalates as wear on the drilling or
hole surface, this causes a significant boring tool increases. High cutting
reduction in the tool life of the threading parameters or rounded cutting
tool (compare the example below). edges also have an effect on the
hardness of the edge zone.

Example: Material C70, tool diameter 8.5 mm, drilling depth 24.5 mm

Worn drill New drill
Edge zone hardness 450 HV 280 HV
Edge zone width 0.065 mm ≈0
Tool life of tap 70 threads > 350 threads

Practical tip:
If problems occur with the tool life, in
addition to considering the process
used to produce the threads, give
consideration to the preceding drilling
process and the drilling or boring tool
itself.

72
www.EngineeringBooksPdf.com
 73
www.EngineeringBooksPdf.com
Technical information – Tapping

Basic types

Blind hole

Short-chipping materials
Straight-fluted taps do not transport chips. For
this reason, they can only be used with short-
chipping materials or short threads.

Comment:
The chips accumulate at the bottom of the
hole if internal cooling is not used. If the
safety margin has been measured too
tight, the tool may run up against the
chips and break.

Deep threads are possible with straight-fluted

tools if the tap has an axial coolant supply,
because the chips are flushed out against the
feed direction. A prerequisite for this is that the
chips are broken off short (e.g.: Paradur® HT,
thread depth up to 3.5 x DN).

In comparison to helical tools, straight-fluted

taps have a longer tool life.

Some straight-fluted tools can also be used for

through holes in materials with good chip
breaking properties (e.g. Paradur® Eco CI).

Long-chipping materials
Right-hand spiral taps transport chips back
towards the shank. The tougher the material to
be machined is (producing longer chips) and the
deeper the thread, the greater the helix angle
required.

74
www.EngineeringBooksPdf.com
Through hole

Long-chipping materials
Taps with a spiral point transport the chips
forward in the feed direction.

Taps with a spiral point are the first choice

when producing through hole threads in long-
chipping materials.

Left-hand spiral taps

(and taps with a spiral point) transport the
chips forward in the feed direction.

Tools with left-hand spiral are practical only if

chips cannot be removed reliably with a spiral
point. Tool example: Paradur® N of the type
20411 and 20461

75
www.EngineeringBooksPdf.com
Technical information – Tapping

Chamfer forms based on DIN 2197

Please note:
−−longer chamfers increase the tool life
−−longer chamfers reduce the cutting edge load which gains importance as the
­material strength increases
−−short chamfers enable threads to almost reach the bottom of the hole
−−longer chamfers increase the required torque

Threads per
Form Execution and application
chamfer

A 6 - 8
6 –threads
8 Gänge short-chipping
materials

6 – 8 Gänge straight-fluted
short through hole thread
6 – 8 Gänge
in medium and long-
chipping materials

B 3.5 - 5.5 threads
straight-fluted medium and
with a spiral long-chipping
point materials

6 – 8 Gänge

C 2 - 3 threads right-hand medium and long-

helical chipping materials

short-chipping
straight-fluted materials
6 – 8 Gänge

D 3.5 - 5 threads long-chipping

left-hand helical materials

short-chipping
straight-fluted materials
6 – 8 Gänge

short thread run-out

E 1.5 - 2 threads right-hand in medium and long-
helical chipping materials

short thread run-out in

straight-fluted short-chipping materials

very short thread run-out

F 1 - 1.5 threads right-hand in medium and long-
helical chipping materials

very short thread run-

straight-fluted out in short-chipping
materials

76
www.EngineeringBooksPdf.com
Technical information – Tapping

Chip cross sections

For through hole threads, usually longer

chamfer forms are used.

Long chamfer
(e.g. form B) results in:
−−longer tool life
−−high torque
−−small chip cross-section
−−low strain on the chamfer teeth

Form B

5°

1st land
2nd land
3rd land

23°

77
www.EngineeringBooksPdf.com
Technical information – Tapping

Chip cross sections

For blind hole threads, shorter chamfer

forms are usually selected. This is
justified not only by the fact that the
thread should often reach the bottom of
the hole.

The shearing of the chip in the blind hole

thread presents a particular problem. If
the chip becomes too thin, it simply
flattens during reverse action and can no
longer be cut through. The chip becomes
5°
trapped between the component and
chamfer flank face. This may break the
tool and this is why long chamfers in
form A, B and D are not suitable for blind
hole threads, as these forms produce
thin chips.

An advantage of short chamfers is that

fewer chips are produced. In addition, the
larger chip cross section is favorable for
chip transport.
Short chamfer
(e.g. form E) results in:
−−low torque
−−large chip cross section
−−increased strain on the chamfer teeth
−−shorter tool life
−−optimized chip transport
Form E

23°

1st land
2nd land
3rd land

78
www.EngineeringBooksPdf.com
Technical information – Tapping

Cutting process for blind hole threads

The tap has been cutting and now comes to a stop. At this very
moment, all cutting edges in the chamfer are still in the process
of forming a chip.

The tool begins to reverse. The chips remain where they are for
the time being. The reverse torque at this point is virtually zero.

The chips come into contact with the back of the trailing land
of the tap. The reverse torque now increases sharply. The chip
has to be shorn off. As the chamfer of the tap has a clearance
angle and withdraws from the thread axially when it backs out of
the hole, it is inevitable that the contact point will no longer be
directly at the root of the chip. For this reason, the chip would
require a certain amount of stability (thickness) to be cut.

The chip has been shorn off and reverse torque decreases to the
friction between the guide and the cut thread.

Comment:
Through hole taps cannot be used for The chamfer clearance angle of blind
blind hole machining, because these hole taps is always smaller than that
have a higher chamfer clearance angle of through hole taps, because blind
and the chip might not be sheared off, hole taps must shear off the chip root
but instead get jammed between the during reverse action.
chamfer and the thread. This could
lead to spalling on the chamfer and,
in extreme cases, tap breakage.

79
www.EngineeringBooksPdf.com
Technical information – Tapping

Cutting process for blind hole threads

Torque curve during the blind hole thread tapping process

Md Spindle braking

Time
­progression

Slight increase Coefficient of

caused by friction in the
­additional guide part of
­friction in the tap during
the guide reverse action

Spindle speed reaches High torque peaks indicate

zero, the spindle begins problems with shearing
to reverse off the chip; a tool with a
smaller chamfer clearance
angle should be chosen

Chamfer enters: First contact made between

sharp increase in remaining chip and back of
torque trailing land

80
www.EngineeringBooksPdf.com
Technical information – Tapping

Angles and characteristics

on the tap

Detail A
Neck Shank Shank diameter d1

Thread
diameter DN

Head length Lc
Detail B
Square length l9
Functional length l1

Detail A Flank angle Detail B

Lead

Core diameter Outside diameter

Pitch diameter
Flank clearance angle

Root face (land)

Chamfer clearance
Rake angle
(rake face)

Core diameter Rake angle

Through hole tap Blind hole tap

with a spiral point with a right-hand helix

Chamfer angle Helix angle Chamfer angle

Spiral point
angle

Spiral point length Lubrication Flute

grooves

81
www.EngineeringBooksPdf.com
Technical information – Tapping

Comparison of geometry data

A smaller rake angle: Rake angle of blind hole tools

−−increases the stability of the cutting
Paradur® HT
edges (fractures around the chamfer
may occur with large rake angles) Paradur® Ti Plus
−−normally produces chips in a more Paradur® Eco CI
controlled manner
Paradur® HSC
−−produces poorer surfaces on the
component Paradur® X·pert M
−−increases the cutting forces and the Paradur® Eco Plus
cutting torque Paradur®
−−is required for machining harder Synchrospeed
­materials Paradur® X·pert P

−−increases the tendency to compress Paradur® WLM

the material to be machined, i.e. the tap
cuts less cleanly and therefore
produces slightly tighter threads
Rake angle of through hole tools

Prototex® HSC

Prototex® TiNi Plus

Paradur® Eco CI

Prototex® Eco Plus

Prototex®
Synchrospeed
Prototex® X·pert P

Prototex® X·pert M

A larger helix angle: Helix angle of blind hole tools

−−supports chip removal
Paradur® Eco CI
−−reduces the stability of the tool and
this limits the maximum cutting torque Paradur® HT

−−reduces the stability of the teeth Paradur® Ti Plus

−−reduces the tool life
Paradur® HSC

Paradur® WLM
Paradur®
Synchrospeed
Paradur® X·pert M

Paradur® Eco Plus

Paradur® X·pert P

82
www.EngineeringBooksPdf.com
Flank clearance angle: Flank clearance angle of blind hole tools
The flank clearance angle must be
Paradur® X·pert P
matched to the material to be machined.
Materials with a higher tensile strength Paradur® WLM
and materials that tend to spring back
Paradur® Eco CI
require a larger flank clearance angle.
The guidance characteristics of the Paradur® X·pert M
tool worsen as the clearance angle is Paradur® HT
increased, which is why miscutting occurs
in soft materials if floating chucks are Paradur® Eco Plus

used. Paradur® HSC

Paradur®
Synchrospeed
Practical tip: Paradur® Ti Plus
Check the flank clearance angle
A tap should screw easily into the
previously-cut thread without any
Flank clearance angle of
recutting. If this is not possible, a through hole tools
tool type with a larger flank clearance
angle should be selected. Prototex® X·pert P

Paradur® Eco CI

Prototex® X·pert M

Prototex® Eco Plus

Prototex® HSC
Prototex®
Spiral point angle: Synchrospeed
Prototex® TiNi Plus
The spiral point angle is limited by the
chamfer length and number of flutes,
because with a larger spiral point angle,
the land width in the first thread of the
chamfer is reduced. This causes the
Spiral point angle of
stability of the cutting edge to decrease through hole tools
(the risk of fractures around the chamfer
increases). An increased spiral point angle Prototex® HSC
facilitates chip removal in the feed Prototex® TiNi Plus
direction. If the spiral point angle is too
small, chip removal becomes problematic. Prototex® X·pert M

Left-hand helical tools provide a solution Prototex® Eco HT

for this. Prototex®
Synchrospeed
Prototex® X·pert P
Chamfer clearance angle:
Through hole taps have approx. 3-times
as large a chamfer clearance angle as
blind hole taps. See page 80 for the
reason for this.

83
www.EngineeringBooksPdf.com
Technical information – Tapping

Special features of thread tapping

Recessed and deep blind hole threads

−−where possible use straight-fluted taps with axial
coolant supply or blind hole taps with a steep helix
angle and a bright or vaporised rake:
• Paradur® HT (straight-fluted)
• Paradur® Synchrospeed with Tin/vap coating
(helical)
−−for stainless steels and in general we recommend
thread forming as a problem solver; spiral flute taps
are absolutely essential for tapping threads in
stainless steels:
• Thread forming: Protodyn® S Eco Inox
• Thread tapping: Paradur® X·pert M

Threads with significantly deeper core hole than

thread depth
−−use through-hole taps with a modified spiral point:
• reduce the radial relief of the chamfer to the
value of a blind hole tap
• shorten the chamfer length to approx. 3 threads
Advantage: longer tool life than blind hole taps with
a high helix angle
Disadvantage: chips remain in the bore
−−for short-chipping materials such as GG25,
straight-fluted tools without a spiral point can also
be used:
• Paradur® Eco CI
−−of course, blind hole taps with a high helix angle can
also be used for this application

84
www.EngineeringBooksPdf.com
Inclined thread lead-out
−−use taps with a very long guide and maximum
stability
(e.g. Prototex® X·pert P, Prototex® X·pert M)
• Inclinations of up to 30° are relatively
­unproblematic
−−alternative: Thread milling

Slotted threads
−−slotted threads should be machined with tools with
a high helix angle:
• Paradur® X·pert M
• Paradur® X·pert P
• Paradur® Eco Plus

85
www.EngineeringBooksPdf.com
Technical information – Tapping

Process forces in thread tapping

Workpiece-related axial forces occur feed direction. On taps with a spiral point,
when cutting threads. Right-hand helical this force acts against the feed direction.
taps are subject to an axial force in the

Direction of rotation

Cutting force

Axial force

Radial force

Process forces in right-hand Process forces in taps with

helical taps a spiral point

If floating chucks are used, these axial increased if tools with a high helix angle
forces can cause the thread to be cut too and a large flank clearance angle are used
large – this is known as axial miscutting. in soft materials or if the cutting edge
The tendency toward axial miscutting is treatment is inappropriate.

Workpiece Tap Workpiece Tap

Axial miscutting of the thread Axial miscutting of the thread

caused by right-hand helical tools: caused by left-hand helical taps or
miscutting of the bottom face taps with a spiral point: miscutting
of the flank of the top face of the flank

For additional information on miscutting

and for countermeasures, see page 91
(Problems and solutions for thread tapping).

86
www.EngineeringBooksPdf.com
Programming the feed if floating chucks are used

If tapping chucks with length compensation are used,

the workpiece-related axial forces which occur during
machining must be taken into account.

Spiral blind hole taps create an axial force in the

feed direction. This force must be countered with
minus programming.

axial force from machine programmed

the tool at 90 - 98%

The usual feed values for this application lie between

90 and 98% of the theoretical feed. The theoretical
feed rate can be calculated using the following
formula:
vf = n x p
n = rotation speed; p = thread pitch

The conditions are reversed with left-hand helical

tools and with taps with a spiral point, causing the
axial forces to act against the feed direction.

axial force from machine ­programmed

the tool at 100%

Programming the theoretical feed rate

is recommended here.

87
www.EngineeringBooksPdf.com
Technical information – Tapping

Modifications

Negative chamfer
Shortened chamfer
(Secur chamfer)

Chips are rolled more Chips are rolled more

Chip formation
tightly, shorter chips tightly, less chips

Tool life

Thread quality

Chip thickness

Torque

Avoidance of bird
Threads nearly to the
nesting in structural
Application example bottom of the hole,
steels such as St52,
better chip control
C45, etc.

Standard tools Paradur® Secur

All tools with chamfer
with appropriate Paradur® HSC
form E/F
­modification Prototex® HSC

increases remains unchanged decreases decreases sharply

88
www.EngineeringBooksPdf.com
 Reduced helix Inclined
Bright rake
in the chamfer thread

Chips are rolled more Chips are rolled more

No change
tightly, shorter chips tightly, shorter chips

uncoated:

coated:

uncoated:

coated:

Optimized chip Problems with fractures Optimized chip formation

formation in steels and or weld formations in in steels, machining
aluminum the guide crankshafts

Paradur® Eco Plus All uncoated tools

Paradur® Ni 10
Paradur® X·pert M as well as Paradur®
Paradur® HSC
Paradur® Synchrospeed ­Synchrospeed (TiN-vap)

89
www.EngineeringBooksPdf.com
Technical information – Tapping

Problems and solutions

Chip control:
In general, the following is true:
Chip control is a major topic when tapping The higher the material strength and
blind holes, particularly with deep blind the lower the elongation at fracture
holes in tough, long-chipping materials. of the material, the greater the
Problems with chip control can be seen chip control is. Chip control is most
in snarl chips, randomly occurring torque difficult with soft structural steels,
peaks, tooth fractures in the guide and/or low alloy steels and stainless steels
total breakage. with a low tensile strength.
Remedy: The more interference to chip
Standard taps can be modified* or new formation from the aforementioned
designs can be created to optimise chip measures results in a worsening of
control: the quality of the thread surface. For
this reason, it is essential to match
−−regrind a reduced helix to achieve short the measures with the customers
chips requirements.
−−reduce the rake angle to achieve more
tightly rolled chips
−−if tools with a shallow helix or straight
flutes are used, the above-mentioned −−thread forming or thread milling:
measures can be combined and com- materials in which chip control is
plemented with a supply of axial coolant difficult while tapping blind holes can in
which helps to flush the short chips out; most cases be produced through
in mass production in particular, this is forming in a non-chipping process. If
a proven method for increasing process thread forming is not permitted, thread
reliability and productivity milling can be used as a problem solver.
−−regrind the rake, and grind a bright This process produces short chips.
reduced helix; this produces chips which
can be better controlled
−−replace the TiN/TiCN coatings with THL,
because THL has better chip formation
characteristics; use of bright or vapo-
rised tools instead of coated
−−shorten the chamfer (re-engineer) –
fewer and thicker chips are produced
−−reduce the number of flutes (new
design); the chip thickness increases
and the stability of the tool is increased
−−use a tool with a negative rake on
cutting edge (e.g. Paradur® Secur)

Example of fractures due to chip control

problems

* The modifications are explained fully and clearly shown on pages 88 - 89.
90
www.EngineeringBooksPdf.com
Miscutting: Taps that miscut for the reasons
The geometry of taps is customised to mentioned above systematically produce
certain applications. If used improperly, threads that are too large. Sporadic
taps can produce threads that are too miscutting may occur if single-sided
large – this is known as miscutting. radial forces act on the tool due to chip
packing or because of weld formations
on the material – this is known as radial
Comment: miscutting.
Miscutting during thread forming,
thread milling and synchronous Remedy:
thread cutting is largely excluded. −−synchronous machining
−−use tools which have been adapted to
the material
−−choose a suitable coating (against
radial miscutting)
Miscutting is most likely to occur with
more highly spiralled blind hole taps. The −−optimise chip control (against radial
axial force in the feed direction created miscutting)
due to the helix angle can pull the tap −−use a tap with a smaller helix angle
more quickly into the hole than at a rate −−use a tap which has been specially
which corresponds than the actual pitch – treated:
this is referred to as the “corkscrew” • Paradur® X·pert P; Paradur® Eco Plus
effect and is known as axial miscut- • Prototex® X·pert P; Prototex® Eco
ting. Through-hole taps are subject to Plus
geometry-related axial forces against the
−−Thread milling
feed direction, which similarly may lead to
axial miscutting. The tendency toward −−Thread forming
axial miscutting is increased if taps with
a large flank clearance angle are used
in soft materials or if the cutting edge
treatment is inappropriate.

Axially miscut blind hole threads Axially miscut through hole threads

91
www.EngineeringBooksPdf.com
Technical information – Tapping

Problems and solutions

Thread surface:
The thread surface is determined by: Optimisation of the thread surface during
−−the production process: cutting, thread cutting:
­forming, milling −−use thread forming or thread milling
−−the wear on the tool instead of thread cutting
−−the geometry −−increase the rake angle
−−the coating −−decrease the chip thickness by using a
−−the material to be machined longer chamfer or an increased number
of flutes (with blind hole taps this
−−the coolant and its availability in the
nevertheless worsens chip formation)
operating area of the tool
−−as a rule, TiN and TiCN produce the best
surfaces in steel (bright tools or CrN
Comment: and DLC layers produce the best
In thread cutting and thread forming, surfaces in Al)
there is almost no possibility to
influence surface finish quality using
the cutting data. In contrast to this,
the cutting and feed rates can be
selected independently of each other
for thread milling.

Tap with TiCN layer Tap with DLC layer

in AlSi7 in AlSi7

−−concentrate emulsion or use oil instead

of emulsion
−−supply lubricant directly to the
operating area
−−replace the tool with a new one earlier

Some of the suggested measures

might lead to an improvement in the
surface quality, but are accompanied
by a worsening in chip control – which
is problematic with deep blind holes in
particular. Here again a compromise that
takes the customer's requirements into
account must be chosen.

92
www.EngineeringBooksPdf.com
Wear:
A high level of hardness ensures a high
resistance to wear and thus a long tool
life. An increase in the hardness normally
leads, however, to reduced toughness.

If small dimensions and highly spiralled

tools are used, a high level of toughness
is required, because otherwise total
breakage can occur.
Example of abrasive wear
The hardness of the tool can normally be
increased without difficulty for thread
formers, straight-fluted and low-spiralled
tools, as well as for machining abrasive
materials with a low tensile strength.

Weld formations on the tool:

Special coatings and surface treatments
are recommended as a problem solver
dependent on the material to be
machined:
−−Al and Al alloys:
bright, CrN, DLC, WC/C
−−soft steels and stainless steels: vap
−−soft structural steels: CrN

Example of weld formations

93
www.EngineeringBooksPdf.com
Technical information – Thread forming

Process principles

Thread forming is a non-chipping process

that uses cold forming to produce
internal threads. Displacement of the
material forces the material to yield. This
produces a compressed thread profile.
The flutes that are required in thread
tapping can be omitted which increases
the stability of the tool.

Both the pull-out strength under static uninterrupted grain profile of formed
load as well as the fatigue strength threads (compare picture at the bottom
under dynamic load increases right). In contrast, the interrupted grain
significantly due to cold work hardening profile is used in thread tapping and
used in combination with the thread milling (compare the picture on
the bottom left).

Form folds

Please note that in the area of the crest −−food industry and medical technology
on formed threads, there is always a (germ formation in the area around the
form fold. For this reason, thread forming form fold)
is not permitted in all industries. Specific −−automatic component screw
restrictions are listed adjacently. connections (screw may jam in the form
fold)
−−not permitted in the aircraft industry

94
www.EngineeringBooksPdf.com
Thread forming is predestined for mass The different chamfer forms are useful in
production – for example in the different applications:
automotive industry. Extremely reliable −−Form D, 3.5 - 5.5 thread:
processes can be performed based on Through hole threads
the non-chipping production of threads −−Form C, 2 - 3.5 thread:
in combination with higher tool stability Blind hole and through hole threads
from the closed polygon profile.
−−Form E, 1.5 - 2 thread:
Moreover, in contrast to thread tapping,
Deep hole threads
higher cutting parameters can often be
achieved at the same time as achieving
a longer tool life. In comparison with Approx. 65% of all machined materials in
thread tapping, thread forming requires industry are formable. The limits are
a torque that is approx. 30% higher. illustrated below:
−−brittle materials with elongation at
fracture lower than 7% such as:
Comment: • GG
Compared to thread tapping and • Si alloys with an Si content > 12%
thread milling, the tolerance of the • short-chipping Cu-Zn alloys
core hole is tighter in thread forming. • thermosetting plastics
Thread forming is therefore not −−thread pitch > 3 mm (forming at
always the more efficient option in pitches ≤ 1.5 mm is particularly cost-
all cases. Examining individual cases efficient)
is therefore absolutely essential.
−−tensile strength > 174,000 - 203,000
Refer to pages 70 - 71 for the
PSI
formulas required to calculate the
core holes.
Typical materials used in thread
forming are:
−−Steel
−−Stainless steel
−−Soft copper alloys
−−Aluminum wrought alloys

95
www.EngineeringBooksPdf.com
Technical information – Thread forming

Influence of the pilot hole diameter

The pre-drilled diameter of the core hole thread former are affected, but on the
has a large influence on the thread other hand, the formation of the thread
forming process. On the one hand, the is also effected. The graphic illustrates
required torque and the tool life of the these relationships clearly.

Tool life

Torque

Minimum dimension Nominal dimension Maximum dimension

Diameter of the core hole

min*

max*

* Tolerance of the core diameter produced as per DIN 13-50

Example: M16 x 1.5-6H, 42CrMo4; Rm = 1100 N/mm2

Pilot drill Ø: 15.22 mm Pilot drill Ø: 15.3 mm Pilot drill Ø: 15.34 mm
–> Core Ø: 14.37 mm –> Core Ø: 14.51 mm –> Core Ø: 14.62 mm

Comment:
Dependency on the pilot drill diameter and thread core diameter:
If the core hole is drilled larger by 0.04 mm, the thread core diameter
(after forming) enlarges by at least 0.08 mm – hence at least by a factor of 2.

96
www.EngineeringBooksPdf.com
Larger core diameters are permitted for comply with tolerance class 6H, however
threads formed according to DIN 13-50 the maximum thread core diameter is
than for thread tapping. For example, for based on tolerance class 7H. This
a thread formed with tolerance class 6H, correlation is shown by way of example in
the minimum thread core diameter must the diagram below.

Example for the permissible core diameter based on the dimension M6-6H
Thread tapping Thread forming
5.25 5.217
5.2
5.153
5.15
Core diameter in mm

5.1
5.05
5
4.95 4.917 4.917
4.9
4.85
4.8
4.75
Minimum Maximum Minimum Maximum
core diameter core diameter core diameter core diameter
6H 6H 6H 7H

Practical tip:
Especially in mass production, it is worth optimising the
pilot drill diameter. The following applies:
The pilot drill diameter selected should be as large
as possible, but only as small as necessary.
The larger the pilot hole diameter:
−−the higher the tool life will be
−−the lighter and more reliable the forming process will be
−−the lower the required torque will be
Ensure that the thread remains true to gauge.

The recommended pilot hole diameters

can be found in the table on page 116.

97
www.EngineeringBooksPdf.com
Technical information – Thread forming

Modifications

Diagram Action Side effect

Chamfer slightly increased

longer tool life
form D cycle time

threads almost to
the bottom of the
Chamfer
hole and slightly decreased tool life
form E
shortened cycle
time

improved cooling
and lubrication
Radial coolant conditions (for
higher tool costs
outlets deep threads
and demanding
materials)

better cooling
Lubrication and lubrication
grooves on the conditions (not as –
shank efficient as radial
coolant outlets)

machining of areas
Increased
that are difficult to –
total length
access

Coatings coating matched

potentially higher
and surface to the specific
tool costs
­treatments ­application

98
www.EngineeringBooksPdf.com
Technical information – Thread forming

Problems and solutions

In general, thread forming is extremely −−more attention must be devoted to the

reliable. The full advantages of thread coolant and the supply of coolant
forming are achieved if thread tapping is during forming; the effects of briefly
used to produce deep blind holes in soft running dry are greater than with
and tough materials in which problems cutting threads. This has to do with the
with chip removal are more likely to occur. higher surface pressure acting on the
For this reason, thread forming can truly formed edges and the fact that the
be seen as a “problem solver”. lubrication grooves used in forming have
It is a fortunate technical coincidence a narrower cross-section than the
that precisely the materials that most flutes of taps. The smaller lubrication
frequently have problems with chipping, grooves give the thread former greater
such as A572 Grade 50, 5115, 1018, can be stability, which is also required due to
formed well. the increased torque. Larger lubrication
grooves would cause the formed edges
Thread forming is also advantageous if a to crack easily due to the higher forces
very high surface finish quality is required. applied. Detailed information on correct
The depths of surface roughness of cooling and lubrication can be found on
formed threads are normally much lower page 60.
than those of cut threads. −−the coefficient of friction of each
coating is reduced as the temperature
Despite the advantages that are achieved increases; higher forming speeds can
through the non-chipping production of therefore lead to longer tool life
threads, there are also specific points −−well-known automotive manufacturers
about thread forming that must be noted often stipulate that the threads must
in order to guarantee a reliable process: comply with a specific thread form.
Check manufacturer requirements.
−−the pilot drill diameter has a tight
tolerance (e.g. M6 ± 0.05 mm)
compared to cutting threads
−−no chips from drilling are permitted to Comment:
remain in the core hole; this can be Walter Prototyp is able to meet
ensured using a twist drill with internal the special profile requirements of
cooling or using a thread former with automotive manufacturers reliably.
axial coolant outlets; in the latter case,
the thread former should be positioned
over the core hole for a short period
with coolant on before forming starts
−−the required torque for forming threads
is higher than it is for tapping threads;
the chuck setting value is therefore to
be increased where required

99
www.EngineeringBooksPdf.com
Technical information – Thread forming

Problems and solutions

Borderline cases for thread forming:

It is difficult to set clear material strength −−Form folds
limits with forming, because there are The unavoidable form folds occurring on
always exceptions where limits have been the crest of the thread may become
exceeded successfully – or not even problematic if automated processes are
reached at all. used to screw in bolts. The first thread
pitches are sometimes threaded into
−−Tensile strength the form fold.
The limit is approx. 174,000 PSI Formed threads in components used in
depending on the material and the the food industry and medical
lubrication conditions. Nevertheless, technology are also avoided, because it
there are notable cases in which is not possible to reliably eliminate
forming could be performed contamination in the form fold by
successfully on stainless steel using cleaning.
HSS-E thread formers and on hard-to-
cut Inconel 718 using solid carbide
thread formers. Both materials had a
tensile strength of approx. 210,250
PSI.
Comment:
−−Elongation at fracture Walter Prototyp is able to design
In general, a minimum value of 7% is special tools in which the form
specified for the elongation at fracture. folds can be closed under specific
Nevertheless, there are also notable conditions. There are notable
cases here too, in which for example cases in which customers who
GGG-70 has been formed with an initially were against using thread
elongation at fracture of about 2%. forming decided to permit it for
However, in this case tiny cracks in the this reason.
flanks were clearly evident which the
user could accept. In such cases, an
increased strength due to forming
should not be assumed.

Thread profile Thread profile

−−Pitch and thread profile
made with a made with a
With pitches larger than 3 to 4 mm, the standard former special former
limits for the above-mentioned tensile
strengths must be corrected
downwards. Thread types with steep
−−Aerospace industry
flanks (e.g. 30° trapezoidal threads)
Thread forming is not permitted in the
must be examined as an isolated case.
aerospace industry. Changes to the
structure that occur during thread
−−Si content forming or welding are avoided in
AlSi alloys can be formed if the silicon general.
content is not greater than 10%.
Nevertheless, there are also notable
cases in which the Si content was
12 - 13%. However, this lowered the
surface finish quality and the pull-out
strength of the thread.
100
www.EngineeringBooksPdf.com
Technical information – Thread milling

Process principles

Basic aspects of thread milling:

−−a machine tool with a 3D CNC control −−higher costs compared to thread
system is required (more or less a tapping
standard today) −−milling threads with a small pitch and a
−−conventional thread milling to a depth large dimension is often quicker than if
of 2.5 x DN is possible, orbital thread thread tapping and thread forming is
milling to a depth of approx. 3 x DN used

In contrast to thread tapping and thread forming, the pitch is produced in thread
­milling by the CNC control system.

P = P pitch Ph = pitch height = P pitch

Thread tapping: The thread pitch P is produced Thread milling: The thread pitch P is
by the tap/thread former. produced by the CNC control system
(circular program).

Theoretically, an internal thread milling screw nut

cutter can also be used to produce an
external thread. The threads produced in
this way do not comply with the standard,
because the external threads are rounded
to minimise the notch effect in the core
and the external diameter produced is
too small.

However, because the thread ring gauge

tests the thread on the pitch diameter,
the gauge accuracy is maintained.

101
www.EngineeringBooksPdf.com
Technical information – Thread milling

Process principles

In contrast to thread tapping and thread thread dimension increases. This means
forming, the required torque for thread large threads can also be produced on
milling only increases moderately as the machines with less drive power.

Thread tapping
Torque

Thread milling

Thread size

Thread milling is an extremely reliable atic. Moreover, special chucks are not
production process. required for thread milling, and nearly all
Short chips are normally produced, standard milling chucks can also be used
which is why chip removal is unproblem- for thread milling.

There are two fundamentally different milling processes:

Conventional milling Synchronous milling

from top to bottom in right-hand threads) (from the bottom to the top in right-hand
Up-cut milling is preferred when machining threads)
hardened materials, or as a remedy against Synchronous milling increases tool life and
conical threads. prevents chatter marks, while promoting thread
conicity.

Comment:
Walter GPS automatically determines the right process for the
relevant application and takes into account the specific details
relating to the tool and the machine.

102
www.EngineeringBooksPdf.com
Feed rate correction
Because thread milling uses a circular
path, and the cutting edge therefore Comment:
travels through a longer path than the The relationship is precisely the other
tool center, a distinction must be made way around when milling external
between contour feed and tool center screw threads.
feed.
Because the tool feed is always based
on the tool center point, the milling feed
must be reduced.

Contour feed (vf)

Mid-point path (vm)

lø
= na
D omi
n

d=
mill
ø

Walter GPS automatically reduces this

Practical tip:
when the CNC program is created. Some
The program can be tested during
CNC control systems also reduce the
feed-in without operational
feed automatically for the same reason.
engagement in order to determine
Reduction of the feed rate on the circular
whether the machine tool corrects
path must then be deactivated in the
the feed automatically. A comparison
CNC program using the appropriate G
of the actual cycle time with the time
command. The cycle time calculated by
determined by Walter GPS shows
the GPS can be compared with the actual
whether the feed must be adjusted in
cycle time in order to determine whether
the CNC program.
the machine automatically corrects the
feed.

103
www.EngineeringBooksPdf.com
Technical information – Thread milling

Process principles

The cuts can be made in a number of Comment:

passes in order to reduce the radial forces Ensure that the thread mill is always
acting on the tool: moved by a multiple of the pitch when
making axial cutting passes.
Axial passes

1st cut 2nd cut

Radial passes

3/4

1st cut
Conventional milling
4/4

2nd cut
Climb milling

1st cut 2nd cut

Advantages:
−−longer thread depths can be produced
−−reduced risk of tool breakage
−−thread milling is possible even with a
relatively unstable clamping
arrangement
−−counteracts conical threads

Disadvantages:
−−increased tool wear
−−higher production time

104
www.EngineeringBooksPdf.com
The cutting forces normally deflect a calculate a conicity of approx. 1/1000 mm
thread mill less at the shank than they do for each mm of thread depth when
at the front cutting edge. This results in machining steel. This is due to the radial
conical threads. With a conventional forces acting on the thread mill.
thread mill, it is therefore necessary to

theoretical contour

actual contour

To counteract this physical law, the

Comment:
geometric design of thread mills is
As an alternative, orbital thread
slightly conical. Nevertheless, under
mills (TMO) can be used to produce
difficult machining conditions it may be
cylindrical threads right to the
necessary to find a remedy using one of
bottom of the hole.
the following measures:
−−multiple radial cutting passes
−−run all radial cuts in the opposite The above-mentioned measures may
direction increase the cycle time, but they are
unavoidable in some cases if true to
−−make a non-cutting or spring pass
gauge threads cannot be guaranteed in
without additional infeed at the end of
any other way.
the process
This conicity makes achieving true to
gauge threads particularly difficult with
tight tolerance threads as well as with
materials that are difficult to machine
(e.g. Inconel).

105
www.EngineeringBooksPdf.com
Technical information – Thread milling

Profile distortion

Diagonal milling in the inclination angle the component. This so-called profile
causes a distortion of the thread profile distortion is shown below using a clear
of the tool to be transferred onto example.

No inclination – no profile distortion Inclination P = 12 – profile is distorted

Comment:
The closer the milling cutter diameter approaches the thread nominal diameter
and the higher the thread pitch, the more pronounced the profile distortion is.

To produce true to gauge threads, the following rules must be followed:

Metric threads:
Milling cutter diameter ≤ 2/3 x thread nominal diameter

Fine metric threads:

Milling cutter diameter ≤ 3/4 x thread nominal diameter

Example of profile distortion in a M18 x 1.5 thread

Thread mill diameter Flank offset due to profile

in mm distortion in mm
16 0.0386
14 0.0167

Theoretically, any size thread can the thread dimension increases, and the
be produced with small thread mills. stability of the tool and the length of the
However, the tool life is decreased as cutting edges are limiting factors.

Comment:
Because of profile distortion, special threads and threads with small flank angles
need to be assessed for technical feasibility.

106
www.EngineeringBooksPdf.com
Technical information – Thread milling

CNC programming

CNC programming with Walter GPS Walter GPS enables even inexperienced
Generally it is recommended to create users to create a thread milling program
the CNC program using Walter GPS. This for 7 different control systems easily and
makes perfect sense because, in contrast reliably. In contrast to the previous CCS,
to preprogrammed machine cycles, GPS handling has been greatly simplified. In
includes the stability of the tool in the addition, the most cost-effective strategy
calculation, and a reduction in the cutting for producing threads is recommended
data or a radial cutting pass is provided if automatically.
any tool is overloaded.
Each line in the program has comments
so that the machine movements are al-
Comment: ways understandable (different languages
It is advantageous to make several can be selected). The example below is
radial passes at a constant feed of a CNC program for milling an internal
to accomplish the required pitch thread on a control system complying
diameter rather than reducing the with DIN 66025.
feed per tooth and making a single
pass. At a low feed per tooth, the
wear on the cutting edge in particular
is disproportionately high.

107
www.EngineeringBooksPdf.com
Technical information – Thread milling

CNC programming

The programming radius “Rprg.” During the course of the tool’s life, the
The programming radius, abbreviated to cutting edges become worn, the tool
Rprg., is an important variable for setup. is forced back more strongly, and the
The Rprg. is calculated based on the pitch threads are too narrow. This wear can be
diameter of the thread mill and enables compensated for by reducing the Rprg.
true to gauge threads to be produced and true to gauge threads can still be
instantly. Approximating the correction produced. Correction increments in the
value can be omitted. The Rprg. can be order of 0.0004 inch are recommended.
read from the tool shank and is to be en- In comparison with large tools, it is often
tered in the tool table of the CNC control not possible to correct the Rprg. of small
system when creating the CNC program tools, because the radial forces increase
during setup of the machine. and this increases the risk of tool break-
age. If the tools are to be reground, it is
The Rprg. is defined so that when it is recommended to do this after 80% of the
used in the CNC program, the math- tool life has been reached.
ematically smallest dimension for the
thread tolerance is attained. If the CNC
program is created using GPS, a correc-
tion dimension is displayed which can be
used to attain the tolerance center of the
selected thread tolerance. The correction
dimension must be subtracted from the
Rprg., then the corrected Rprg. is to be
entered into the CNC control system.

108
www.EngineeringBooksPdf.com
Technical information – Thread milling

Modifications

Diagram Modification Effect

countersinking and facing

countersink and facing step
step in one tool

systematic cooling without

cooling grooves on the shank weakening of the tool cross-
section in the cutting area

systematic cooling for through

radial coolant outlets
hole threads

reduced cutting forces but

longer machining time,
threads removed
because two passes are
required

removal of the incomplete

thread pitch at the thread
deburring cutter
run-in area without an
additional operation

first thread profile

chamfering of the core hole
lengthened on the face side

enables axial cutting passes

grinding of the neck
to be made – practical for
(necking)
deep threads

109
www.EngineeringBooksPdf.com
Technical information – Thread milling

Problems and solutions

Problem

Accuracy to gauge
Conical threads
Chatter marks

Tool breakage
Cutting edge
Low tool life

­breakaway
fz in [mm/tooth]

vc in [m/min]
Cutting data/strategy/adjustments

Programming

Synchronous run

Reverse rotation

Cutting pass

Programming radius
[Rprg.]

Cooling

Clamping arrangement
Workpiece

Pilot drill diameter

Chip removal

Stability/geometry

Projection length
Tool

Helix angle

Coating

Concentricity

Key:
investigate reduce improve/increase use is preferred

110
www.EngineeringBooksPdf.com
TMO – specialists for complex tasks:
Tools from the TMO family can often be used as a
problem solver, for example, if deep threads must be
produced, hardened materials are to be machined or
if conventional thread mills create conical threads.
Further information available on pages 36 and
102 - 105.

Conical threads:
Explanations and solutions to problems can be found
on pages 102 - 105.

Comment:
The use of tools from the TMO family are a very
good option for producing cylindrical threads.

Cooling and lubrication:

Problems related to cooling and lubrication as well as
the corresponding remedial measures are described
on page 59.

Hard machining:
−−specially designed only for use with tools that are
suitable for hard machining (TMO HRC and thread
mill Hart 10)
−−machining in reverse rotation where possible (see
Walter GPS recommendation)
−−select the largest, permissible pilot drill diameter
−−if problems with the cylindricity of the threads
occurs, make a non-cutting pass or use tools from
the TMO HRC family
−−do not use lubricant, remove the hard chips from
the bore using an air blast or MQL

111
www.EngineeringBooksPdf.com
Technical information – Appendix

Formulas

Speed
vc x 12
n [rpm] n = [rpm]
Dc x ∏

Cutting speed
Dc x ∏ x n
vc [ft/min] vc = [ft/min]
12

Feed rate

vf [in/min] vf = pxn [in/min]

112
www.EngineeringBooksPdf.com
 113
www.EngineeringBooksPdf.com
Technical information – Appendix

Core diameter for thread tapping and thread milling

M ISO metric coarse pitch thread

Designation Internal thread core diameter Drill Ø
as per DIN 13 (mm) (mm)
6H min 6H max
M2 1.567 1.679 1.60
M 2.5 2.013 2.138 2.05
M3 2.459 2.599 2.50
M4 3.242 3.422 3.30
M5 4.134 4.334 4.20
M6 4.917 5.153 5.00
M8 6.647 6.912 6.80
M 10 8.376 8.676 8.50
M 12 10.106 10.441 10.20
M 14 11.835 12.210 12.00
M 16 13.835 14.210 14.00
M 18 15.294 15.744 15.50
M 20 17.294 17.744 17.50
M 24 20.752 21.252 21.00
M 27 23.752 24.252 24.00
M 30 26.211 26.771 26.50
M 36 31.670 32.270 32.00
M 42 37.129 37.799 37.50

MF ISO metric fine pitch thread

Designation Internal thread core diameter Drill Ø
as per DIN 13 (mm) (mm)
6H min 6H max
M 6 x 0.75 5.188 5.378 5.25
M 8x1 6.917 7.153 7.00
M 10 x 1 8.917 9.153 9.00
M 10 x 1.25 8.647 8.912 8.75
M 12 x 1 10.917 11.153 11.00
M 12 x 1.25 10.647 10.912 10.75
M 12 x 1.5 10.376 10.676 10.50
M 14 x 1.5 12.376 12.676 12.50
M 16 x 1.5 14.376 14.676 14.50
M 18 x 1.5 16.376 16.676 16.50
M 20 x 1.5 18.376 18.676 18.50
M 22 x 1.5 20.376 20.676 20.50

114
www.EngineeringBooksPdf.com
UNC Unified Coarse Thread
Designation Internal thread core diameter Drill Ø
acc. to ASME B 1.1 (mm) (mm)
2B min 2B max
Nr. 2-56 1.694 1.872 1.85
Nr. 4-40 2.156 2.385 2.35
Nr. 6-32 2.642 2.896 2.85
Nr. 8-32 3.302 3.531 3.50
Nr. 10-24 3.683 3.962 3.90
1
/4 -20 4.976 5.268 5.10
5
/16 -18 6.411 6.734 6.60
3
/8 -16 7.805 8.164 8.00
1
/2 -13 10.584 11.013 10.80
5
/8 -11 13.376 13.868 13.50
3
/4 -10 16.299 16.833 16.50

UNF Unified Fine Thread

Designation Internal thread core diameter Drill Ø
acc. to ASME B 1.1 (mm) (mm)
2B min 2B max
Nr. 4-48 2.271 2.459 2.40
Nr. 6-40 2.819 3.023 2.95
Nr. 8-36 3.404 3.607 3.50
Nr. 10-32 3.962 4.166 4.10
1
/4 -28 5.367 5.580 5.50
5
/16 -24 6.792 7.038 6.90
3
/8 -24 8.379 8.626 8.50
1
/2 -20 11.326 11.618 11.50
5
/8 -18 14.348 14.671 14.50

G Pipe thread
Abbreviation Internal thread core diameter Drill Ø
according to (mm) (mm)
DIN EN ISO 228 min max
1
G /8 8.566 8.848 8.80
1
G /4 11.445 11.890 11.80
3
G /8 14.950 15.395 15.25
1
G /2 18.632 19.173 19.00
5
G /8 20.588 21.129 21.00
3
G /4 24.118 24.659 24.50
G1 30.292 30.932 30.75

115
www.EngineeringBooksPdf.com
Technical information – Appendix

Thread forming core diameters

M metric ISO coarse pitch thread. tolerance 6H

Designation Internal thread core diameter Pilot drill Ø
as per DIN 13 as per DIN 13 - 50 (mm) (mm)
6H min 7H max
M 1.6 1.221 - 1.45
M 2 1.567 1.707 1.82
M 2.5 2.013 2.173 2.30
M 3 2.459 2.639 2.80
M 3.5 2.850 3.050 3.25
M 4 3.242 3.466 3.70
M 5 4.134 4.384 4.65
M 6 4.917 5.217 5.55
M 8 6.647 6.982 7.40
M 10 8.376 8.751 9.30
M 12 10.106 10.106 11.20
M 14 11.835 12.310 13.10
M 16 13.835 14.310 15.10

MF metric ISO fine thread. tolerance 6H

Designation Internal thread core diameter Pilot drill Ø
as per DIN 13 as per DIN 13 - 50 (mm) (mm)
6H min 7H max
M 6 x 0.75 5.188 5.424 5.65
M 8x1 6.917 7.217 7.55
M 10 x 1 8.917 9.217 9.55
M 12 x 1 10.917 11.217 11.55
M 12 x 1.5 10.376 10.751 11.30
M 14 x 1.5 12.376 12.751 13.30
M 16 x 1.5 14.376 14.751 15.30

Additional core hole diameters can be found in the 2012 General Catalog page D464.

116
www.EngineeringBooksPdf.com
Technical information – Appendix

Hardness comparison table

Tensile strength Brinell hardness Rockwell Vickers hardness

PSI
Rm in N/mm2 HB [Brinell HB] ­hardness HRC HV
150 50 50 22,000
200 60 60 29,000
250 80 80 37,000
300 90 95 43,000
350 100 110 50,000
400 120 125 58,000
450 130 140 66,000
500 150 155 73,000
550 165 170 79,000
600 175 185 85,000
650 190 200 92,000
700 200 220 98,000
750 215 235 105,000
800 230 22 250 112,000
850 250 25 265 120,000
900 270 27 280 128,000
950 280 29 295 135,000
1000 300 31 310 143,000
1050 310 33 325 150,000
1100 320 34 340 158,000
1150 340 36 360 164,000
1200 350 38 375 170,000
1250 370 40 390 177,000
1300 380 41 405 185,000
1350 400 43 420 192,000
1400 410 44 435 200,000
1450 430 45 450 207,000
1500 440 46 465 214,000
1550 450 48 480 221,000
1600 470 49 495 228,000
51 530 247,000
53 560 265,000
55 595 283,000
57 635
59 680
61 720
63 770
64 800
65 830
66 870
67 900
68 940
69 980

117
www.EngineeringBooksPdf.com
Technical information – Appendix

Torque setting for

tapping chucks

Recommended values for torque adjustment of tapping chucks

Torque Torque
Fracture
­setting value ­setting value
Size Inclination torque of
Thread type for cutting for forming
[mm] [mm] tap
threads threads
[Nm]
[Nm] [Nm]

M, MF 1 ≤ 0.25 0.03* 0.03 0.07*

M, MF 1.2 ≤ 0.25 0.07* 0.07 0.12
M, MF 1.4 ≤ 0.3 0.1* 0.1 0.16
M, MF 1.6 ≤ 0.35 0.15* 0.15 0.25
M, MF 1.8 ≤ 0.35 0.24* 0.24 0.3
M, MF 2 ≤ 0.4 0.3* 0.3 0.4
M, MF 2.5 ≤ 0.45 0.5 0.6 0.6
M, MF 3 ≤ 0.5 0.7 1 1
M, MF 3.5 ≤ 0.6 1.2 1.6 1.5
M, MF 4 ≤ 0.7 1.7 2.3 2.4
M, MF 5 ≤ 0.8 3 5 4
M, MF 6 ≤ 1.0 5.5 8.1 8
M, MF 8 ≤ 1.25 12 20 17
M, MF 10 ≤ 1.5 20 41 30
M, MF 12 ≤ 1.75 35 70 50
M, MF 14 ≤ 2.0 50 130 75
M, MF 16 ≤ 2.0 60 160 85
M, MF 18 ≤ 2.5 100 260 150
M, MF 20 ≤ 2.5 110 390 160
M, MF 22 ≤ 2.5 125 450 170
M, MF 24 ≤ 3.0 190 550 260
M, MF 27 ≤ 3.0 220 850 290
M, MF 30 ≤ 3.5 320 1100 430
M, MF 33 ≤ 3.5 350 1600 470
M, MF 36 ≤ 4.0 460 2300 650
M, MF 39 ≤ 4.0 500
M, MF 42 ≤ 4.5 700
M, MF 45 ≤ 4.5 750
M, MF 48 ≤ 5.0 900
M, MF 52 ≤ 5.0 1000
M, MF 56 ≤ 5.5 1300

Basis for the above-mentioned table: Material 42CrMo4, tensile strength 1000 N/mm²,
thread depth 1.5 x DN. Using the conversion table, the values can be carried over to
other materials.

With dimensions marked with a *, the torque required to produce a thread with a depth of 1.5 x DN
exceeds the fracture torque of the tool. Remedy: produce the thread in several operations.
118
www.EngineeringBooksPdf.com
Conversion for other materials

Material Factor

Soft steel 0.7

Steel 1200 N/mm 2

1.2

Steel 1600 N/mm 2

1.4

Stainless steel 1.3

GG/GGG 0.6

Aluminum/copper 0.4

Ti alloys 1.1

Ni alloys 1.4

The table is used to set the torque of tapping chucks, insofar as these can be set. If
the torque is set too high, there is a risk of tool breakage. If the torque is set too low,
the tool can become jammed during machining, however the machine continues to run.
If at this point the pressure compensation is not sufficient, the tool is destroyed and
the machine can be damaged.

119
www.EngineeringBooksPdf.com
Notes

120
www.EngineeringBooksPdf.com
www.EngineeringBooksPdf.com
Walter USA, LLC

N22 W23855 RidgeView Parkway West

Waukesha, WI 53188, USA

Phone: 800-945-5554 Fax: 262-347-2500

[email protected]

www.walter-tools.com/us
www.facebook.com/waltertools
www.youtube.com/waltertools

Walter Canada
[email protected]

Walter Tools S.A. de C.V.

Carr. Estatal KM 2.22 #431, Módulo 3, Interior 19 y 20
El Colorado Galindo, Municipio El Marqués,
Querétaro, C.P. 76246, México
Phone: +52 (442) 478-3500
[email protected]

TDM Systems Inc.

1665 Penny Lane
Schaumburg, IL 60173, USA
Phone: 847-592-7177 Fax: 847-592-7178
[email protected], www.tdmsystems.com

0757244292

Printed in the USA 757244-292, EDP-# 6656087 (03/2014)

www.EngineeringBooksPdf.com