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Thread milling: procedure and special features
The production of threads isn't limited to just cutting. There are several alternative methods, such as turning, whirling, shaping, rolling, or even erosion. While we're passionate about thread cutting, it's always beneficial to explore other techniques. That’s why today, we’re taking a closer look at an often-overlooked method: **thread milling**.
If you've ever used a thread cutting tool, you'll find many similarities between that and thread milling. Both are chip-removal processes, and the tools share some design elements. However, thread milling operates on entirely different principles. Let's dive into what makes this technique unique and how it works.
### Key Features of Thread Milling
Thread milling stands out from other thread production methods due to several distinct characteristics.
#### 1. The Design of a Thread Mill
At first glance, a thread mill might resemble a thread cutter. Both have a shaft with grooves. But if you take a closer look, you’ll notice that the milling part doesn’t have a thread. Instead, it has profiled grooves spaced at the pitch distance. This design allows for more flexibility in machining different types of threads.
#### 2. Requires 3-Axis CNC Control
To create a thread using a thread mill, the machine must be involved. The tool moves in a **helical motion** inside the drilled hole, carving out the thread from the material. The resulting thread is slightly larger than the tool itself. Precision is key—any deviation in the movement can lead to poor-quality threads. This level of accuracy is only possible with a **3-axis CNC-controlled machine**.
#### 3. Offers Great Versatility
One of the biggest advantages of thread milling is its versatility. Unlike traditional thread cutters, a thread mill can handle both left-hand and right-hand threads, through-holes and blind holes, and internal and external threads. Some tools can even produce multiple pitches and thread sizes with a single tool, reducing the number of tools needed in your workshop.
#### 4. Produces Small, Manageable Chips
Another benefit of thread milling is the shape of the chips produced. Instead of long, spiral-shaped chips, you get **small fragments**, which are easier to remove and reduce the risk of chip clogging or damage to the workpiece.
#### 5. Suitable for Large Diameter Threads
Because of its design, thread milling is not restricted by thread size. This means it can be used to create very large diameter threads that would be difficult or impossible to cut using traditional methods.
### How to Perform Thread Milling
The process of thread milling varies depending on the type of tool used. We’ll break it down into two main applications: with and without pre-drilling.
#### Thread Milling with a Pre-Drilled Hole
Some thread mills require a pre-drilled hole. Unlike with a thread cutting tool, there’s no strict formula for the core hole diameter—it can vary. Once the hole is prepared, the thread mill is inserted and starts with a **180° lead-in helix**. It then follows a **helical path** to cut the thread, followed by a **180° lead-out helix** before exiting the hole.
Another variation includes a **thread chamfer mill with a chamfering stage**, which performs the chamfering step during the milling process, eliminating the need for a separate operation.
#### Drill Thread Milling
Some thread mills are designed to drill their own core hole. These **drill thread mills** feature a drilling tip and a chamfering stage. They drill the hole, chamfer it, and then proceed with the thread milling process just like standard thread mills.
### Important Considerations
Precision is essential in thread milling. Even during pre-drilling, high positional and dimensional accuracy is crucial. The workpiece should also be securely and vibration-free mounted close to the milling area to ensure stability.
The machine used must have **high rotational accuracy**, and cutting speed and feed rates should be carefully selected. Since the tool moves in a circular path, the feed rate needs to be adjusted accordingly to avoid excessive stress on the tool and prevent breakage.
Also, keep in mind that thread depths are limited. Most thread mills can only handle depths up to **three times the tool diameter**. Additionally, with small thread angles or coarse pitches, there may be slight deviations in the thread profile, especially in specialized thread forms like trapezoidal, buttress, or knuckle threads.
### Is Thread Milling Right for You?
Thread milling offers many benefits when the right conditions are met. However, if you're not in mass production or don’t have access to a well-equipped workshop, simpler methods might be more practical. Not everyone has a CNC machine at home, and programming one correctly can be challenging, even for professionals.
If you occasionally need to produce threads or are working on a specific project, traditional thread cutting tools could still be the better option. With a wide range of products from **BAER**, a trusted screw tap manufacturer, you’re sure to find the right tool for your needs. Plus, our expert customer service is always here to help!
Induction forging system is a modern metal forming technology that utilizes the principle of electromagnetic induction heating to locally heat the metal without direct contact, followed by plastic deformation treatments such as forging and extrusion, in order to change the shape of the metal and enhance its physical properties. This method is widely used in various industries such as automotive, aviation, and military due to its high efficiency, precise control, and environmental protection characteristics.
Basic principles
The induction forging system mainly generates an alternating magnetic field in the induction coil through high-frequency or intermediate frequency current. The metal workpiece generates eddy currents under the action of the magnetic field, and the Joule heat generated by the eddy currents heats the workpiece to the desired temperature. Next, place the heated workpiece into the mold for forging, and use external force to cause plastic deformation, forming a predetermined geometric shape.
System composition
Induction heating unit: comprising an induction coil and a power supply device, used for heating metal workpieces.
Forging mechanism: Hammer head, press machine, etc., implementing external shaping force.
Control system: Monitor and adjust various parameters of the heating and forging process.
Cooling system: Ensure that equipment and workpieces operate at suitable temperatures.
Core advantages
Fast heating: Short heating time and higher efficiency than traditional methods.
Precise control: adjustable heating depth and temperature, conducive to refining grains and improving material properties.
Low energy consumption: Compared to flame heating, it saves energy consumption.
Environmentally friendly and clean: almost pollution-free, in line with green manufacturing standards.
Wide applicability: Suitable for various metals and their alloys.
Application scenarios
The induction forging system covers multiple industries, as follows:
Automotive industry: the molding of complex parts such as engine components, transmission shafts, connecting rods, etc.
Aerospace: High temperature alloy components, titanium alloy forgings.
Tool manufacturing: cutting tools, drill bits, mold steel.
Oil and gas: high-pressure fittings such as valves, flanges, and pipe fittings.
Military equipment: armored vehicles, ship structural components.
Development prospects
With the continuous advancement of new materials and technologies, induction forging systems are moving towards greater efficiency and intelligence. Digital and networked control systems enable remote monitoring and automated production; Adopting higher frequency induction heating technology to improve heating speed and accuracy; Explore new manufacturing models by combining additive manufacturing technologies such as 3D printing. These innovations will further promote the application of induction forging technology in the field of high-performance metal materials, promote industrial upgrading and sustainable development.