Spiralock Corporation Engineering Document

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DRAWN: A.B. 27 OCT 03 Engineering
CHIEF ENG.: B.J.M. 27 OCT 03
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Tapping
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1. Tapping

1.1. Cut Tapping

1.1.2. Spiral Point, Straight Flute

Tips have a spiral point ground in that force chips ahead of the tap
Decreases resistance to thrust, requiring less torque and allowing higher speeds
Plug chamfer is ideal for tapping deep through holes in non abrasive materials
Bottoming chamfer taps tend to form a tightly-curled broken chip
Comes standard with a con-eccentric relief depending on TPI and land width

1.1.3. Spiral Fluted

Recommended for tapping deep blind holes
Helical ground flutes pull chips out of the hole, reducing chip packing
Use for holes deeper than 2x diameter
Common spiral flute helix angles are 52 degrees (fast spiral, above left) and 30 degrees
(regular spiral, above right)

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Engineering Tapping Information

1.1.4. T-10
Optimum for lead-screw controlled, high production tapping of all grades of cast iron and
other abrasive materials, and for materials of 30-42 Rc.
Looks similar to general purpose style except for finish/color
Double nitrided
Full eccentric relief
Use for sizes #6 through 3/4 (nitriding will embrittle smaller sizes)

2. Tap Blank Standards

Tap sizes and shapes are determined according to various industrial and international
standards. These standards specify the shape and style of the tap blank, a featureless
shape to which the threads are added and the shank is ground to size. Common tap
blank standards used:
USCTI (United States Cutting Tool Institute) Table 302 (see Appendix A)
ISO (International Standards Organization) 529
DIN (Deutsches Institut fur Normung e.V.) 371 and 376
JIS (Japanese Industrial Standards)

3. Tool Steels
Tool steels (high-speed steels) are high-alloy, W-Mo-V-Co bearing steels designed to cut
other materials efficiently at high speeds, despite the extreme heat generated at the tool's
cutting edge. This heat can reach 1000 degrees F or more depending on cutting
conditions, coolants used and other operational factors. To provide good cutting tool
performance a tool steel must have three basic characteristics.

First, the capacity for heat treatment to a high hardness, usually from a minimum nominal
hardness of Rc 63 to a maximum nominal hardness of Rc 68. High hardness is
necessary for good wear resistance.

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Second, the capacity for maintaining high hardness at elevated temperatures. This is
called red hardness. Tool steels are subjected to considerable heat where the cutting
edge meets the work piece chip interface. Red hardness is essential.

Third, tool steels must have enough impact toughness to handle interrupted cut tooling
applications. They are notably tougher than carbide or ceramic materials.

Naturally, in addition to these three basic characteristics, tool steels must be capable of
being fabricated, hot worked, machined, and ground. Note: the balance percentage of the
materials listed below is always iron (Fe).

AISI M1 - molybdenum, chromium, vanadium alloy steel. It is one of the most widely
available tool steels in use today. It is similar in properties to the tungsten tool steels (T
series) at a lower cost.
C .83 Cr 3.75 V 1.15 W 1.70 Mo 8.50

AISI M7 - molybdenum type high speed steel designed with higher carbon and vanadium
to provide higher hardness after heat treatment and improved wear resistance compared
to M1 steel. Standard tool steel used for Spiralock taps and the most commonly used.
C 1.00 Cr 3.75 V 2.00 W 1.75 Mo 8.75

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3.1. CPM (Crucible Particle Metallurgy)

Molten metal is poured through a small nozzle and gas-atomized to produce a rapidly
solidified fine powder. The powder is screened and filled into steel containers which are
evacuated and sealed. The filled containers (compacts) are then hot-isostatically-pressed
(HIP) to achieve 100% density at approximate forging temperatures. Certain high-alloy
steels can only be manufactured through CPM. Superior wear resistance, toughness and
grindability. Many different grades and chemistries are available for different applications.
Not to be confused with powder metallurgy, which is pressed and sintered.
age of the

3.2. Carbide
A sintered material made by using a cobalt binder to cement micron-sized carbide
particles together, creating a dense composite. The hardness is from the carbide
particles and the wear resistance is from the cobalt bonding. Extremely resistant to
abrasion, wear, corrosion, compression and high temperature fluctuations. Is often given
a titanium nitride (TiN) coating to greatly increase lubricity and wear resistance.
Used both for special taps as well as thread turning inserts.

4. Cold Form Tapping (Thread Forming)

Forming taps and cutting taps produce threads that gage identically and are
interchangeable, but the way they produce these threads is completely different. Forming
taps displace material, whereas cutting taps remove material. Thread forming offers
several advantages over cut tapping:

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• Chipless Tapping
Since the thread is formed and not cut, there are no chip removal problems when tapping
blind holes.
• Stronger Threads
For materials that work-harden, such as steel and stainless steel, the grain flow of formed
threads follows the contour of the thread, resulting in greater thread strength.
• Better Thread Gaging
Because no material is cut away, the possibility of producing oversized threads is greatly
reduced.
• Stronger Taps
The absence of chips eliminates the need for flutes, resulting in a solid, stronger tap.
• Longer Tap Life
Because there is no cutting edge to dull, forming taps last 3 to 20 times longer than
cutting taps.
• Ideal for Non-Lead Screw Tappers
The ability to form their own leads makes form taps well-suited for machines without lead
screws.

Forming

4.1. Pre-Tap Hole Size

Thread forming taps require a larger pre-tap hole sizeImage
than© Balax, Inc. Used with permission.
cutting taps because they do
not produce a chip during tapping. The pre-tap hole size tolerance must also be more
tightly controlled to prevent after-tap minor diameter problems.
All formed threads have a cup or “U” in the crest due to the nature of the forming
process. A properly sized hole should result in a thread percentage of 65-75%. Tapping
with too small of a hole size results in excessive tapping torque, tap wear and possible
tap breakage.

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n tapping

of formed Images © Balax, Inc. Used with permission.

4.2. Materials
Aluminum, brass, copper, lead, 300/400 series stainless steels, steel, diecast zinc and
17-4 stainless are potential materials for cold-form tapping. In general, any material that
produces a stringy chip is a good candidate for cold forming.

4.3.Lubrication and Tapping Speeds

In general, the suggested cold-form tapping speed is the same as that of cutting taps. In
soft and fine pitch applications (20+ TPI), tapping speeds of 1.5 to 2 times higher may be
achievable.

The quality and type of lubrication becomes more important to tap life and thread quality
as speed increases. Cutting oils are generally preferred for lubrication because of their
lubricity compared to that of water soluble coolants. For non-ferrous materials, water
soluble may be used at increased concentrations. For steels and stainless steels, a high
sulfur/high chlorine tapping oil with a fat additive is recommended. TiN coatings are
recommended in softer and stainless steels in conjunction with water soluble coolants.

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Engineering Tapping Information

5. Common Surface Treatments for Taps

.

Titanium Nitride (TiN)

A thin, gold/bronze colored deposit, approximately .0001 thick, applied using PVD
(physical vapor deposition) technology. Increases surface hardness and wear resistance.
Increases tool life when cutting harder materials up to 32 Rc. Works well with water-
based cutting fluids.

Titanium Carbonitride (TiCN)

Dull gray colored coating that improves toughness for high speed and feed operations.
Works well on highly abrasive materials.

Titanium Aluminum Nitride (TiAlN)

Also Futura and Balinit. Dull gray/purple. Multi-layered coating for dry cutting and high
speed operations. Protects from wear and heat.

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6. Thread Milling

The increased use of CNC technology has created the conditions for a future-oriented
technology for the production of internal and external threads. Thread milling is a useful
alternative to thread cutting or thread forming in many cases. It offers the following
esistance. advantages:
• High cutting speeds and feeds
• Multi-functional designs reduce cycle times by combining drilling, chamfering and
threading
• Produces threads with excellent form, finish and dimensional accuracy
• Easy machining of difficult materials
• Eliminates tap breakage
• Full bottom threading
• Precise thread depth control
• Optimum positional accuracy
• Pitch diameter can be controlled by CNC offset
• One tool for both right and left-hand threads, as well as through or blind holes
• One cutter can produce varying diameters with the same thread pitch
• Produces small, controllable chips
• Smaller machines can produce larger threads due to less spindle torque
• Less cutting pressure for thin-walled workpieces

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6.1. Thread Milling Variables and Equations

vc = cutting speed in surface feet per minute, n = number of revolutions (min-1)
Vf = feed speed (inches/minute), f z = feed per tooth in inches
z = number of teeth, D = nominal thread diameter, d 1 = outside diameter of thread mill

Feed Rate Measured on Outside Diameter of Cutter

(Feed per tooth)(Number of flutes)(RPM) = Edge feed (inch/min)

Feed Rate Measured on Centerline of Cutter

(Edge feed)[(Thread major diameter – Cutter diameter) / Thread major diameter]

Calculation of Number of Revolutions

n = [(Vc x 12) / (d1 x π)] (min-1)

Calculation of the Feed on the Contour

Vf contour = fzzn (inch/min)

Speed Considerations:
Workpiece material and hardness
Type and size of thread
Style of thread mill,
Method of coolant application
Required thread finish
Depth of cut
Rigidity of workpiece
Machine tool size, power and rigidity
Use lower speeds for heat treated, exotic and abrasive material and maximum tool life
Use higher speeds for softer materials, better finishes, smaller diameters and fragile set-
ups

Spiralock Corporation CAGE CODE: ENG. STD. NO.:

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