ワンレボリューションスレッドミル AT-1 One Pass Thread Mill Vol.2 新価格体系 New Price 2018 年 6 月

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1 ワンレボリューションスレッドミル One Pass Thread Mill Vol.2 新価格体系 New Price 2018 年 6 月

1 The Secret to 1-Pass Cutting Evolution from conventional

vibration Left Hand Helix Conventional Thread Mill (Right Hand

in Japan Right-hand cut and left-hand helix geometry Prevents

Climb milling recommended Starts cutting from the tip Big

High-Grade Internal Threading EgiAs EgiAs Coating Exceptional

wear resistance and toughness 1 1-pass 2 Conventional Thread

2 1 The Secret to 1-Pass Cutting Evolution from conventional 2-pass cutting to 1-pass cutting by preventing bending, thus reducing cutting time PAT. in Japan Unequal spacing / variable lead flute Reduces vibration Left Hand Helix Conventional Thread Mill (Right Hand Helix) PAT. in Japan Right-hand cut and left-hand helix geometry Prevents bending Starts cutting from the shank side Reduced deflection Climb milling recommended Starts cutting from the tip Big deflection Cutting in 1-Pass! High-Grade Internal Threading EgiAs EgiAs Coating Exceptional wear resistance and toughness Ultra-Fine Grain Carbide High wear resistance and toughness 1 1-pass 2 Conventional Thread Mill 2-pass Size P3 6F Internal Thread Size M243 Work Material SUS304 Tapping Length 45mm Cutting Speed 40m/min646min -1 Coolant Water-Soluble Feed 14mm/min0.02mm/t Machine BT40 Horizontal Machining Center

Cutting Data Effects of left-hand helix Size Work Material Cutting Speed Feed 7.722 P1 4F SCM440 30HRC 100m/min4,136min -1 380mm/min0.

060 0.060 0.100 +0.120 +0.140 +0.120 +0.140 0 0.

3 Cutting Data Effects of left-hand helix Size Work Material Cutting Speed Feed P1 4F SCM440 30HRC 100m/min4,136min mm/min0.1mm/t Comparison of differences in internal thread pitch diameter at initial cutting stage Unit:mm Right Hand Helix Left Hand Helix Hole Entry Inner Hole Area Dia. Difference Internal Thread Size Drill Hole Size M101mm 918mm Through Pitch diameter measurement method : Step gauge 20m Handles pitch diameter differences of 20 μm or less. Threading Length Machining Method Coolant Machine 15mm 1 Climb milling 1-Pass Water-Soluble BT30 Vertical Machining Center The left-hand helixs small pitch diameter difference between the hole entry and inner hole allows a delay in gauge-out failure. Moreover, longer tool life can be achieved with zero cuttingfor correcting bending being eliminated. mm Pitch dia Changes in pitch diameter with time (rendered image) ,000 Number of processed thread holes Right Hand Helix Left Hand Helix EgiAs Effects of EgiAs coating Size P1 4F Cutting edge after threading 2,000 holes Work Material SCM440 Cutting Speed 80m/min3,307min -1 Feed 30mm/min0.01mm/t Internal Thread Size M101mm Drill Hole Size Threading Length 925mm Blind 19mm EgiAs EgiAs Coating WX WX Coating Coolant Water-Soluble Machine BT30 Vertical Machining Center

4 Cutting Data Work materials to are machined under the conditions shown below. Internal Thread Size Drill Hole Size Threading Length Coolant Machine M mm Blind 19mm Water-Soluble BT30 Vertical Machining Center 1. 20m Internal thread pitch diameter difference between hole entry and inner hole area: 20m or less Eg: step gauge passes completely, step gauge stops less than or equal to one revolution Fastest cutting condition (including number of passes) while fulfilling the requirement of Condition 1. SUS304 Machining SUS304 Tool Cutting Speed Feed Number of Passes Cutting Time P1 4F Competitor 120m/min 4,961min m/min 5,122min mm/min 0.05mm/t 200mm/min 0.1mm/t 1 Pass 2.26 sec 130% Efficiency 2 Passes 3.03 sec Number of processed thread holes Holes 1,200 1, Still Running 1, % Durability Over GP-OUT 567 Competitor S50C Machining S50C Tool Cutting Speed Feed Number of Passes Cutting Time P1 4F Competitor 160m/min 6,614min m/min 5,122min mm/min 0.02mm/t 20mm/min 0.01mm/t 1 Pass 4.28 sec 740% Efficiency 3 Passes 45.4 sec Number of processed thread holes Holes GP-OUT % Durability GP-OUT 491 Competitor SCM440 Machining SCM440 Tool Cutting Speed Feed Number of Passes Cutting Time P1 4F 80m/min 3,307min -1 Competitor 140m/min 5,122min -1 30mm/min 0.01mm/t 20mm/min 0.01mm/t 1 Pass sec 350% Efficiency 4 Passes sec Number of processed thread holes 2,500 Holes 2,000 1,500 1, Still Running 2,000 2,000 Still Running Competitor

5 SUS304 SUS304 durability test result Tool Work Material P1.5 5F SUS304 WX-ST-PNC P1.5 Holes 1,000 Number of processed thread holes Cutting Speed Feed 100m/min 3,283min -1 31mm/min 0.01mm/t 120m/min 4,021min -1 42mm/min 0.01mm/t Internal Thread Size M Drill Hole Size Threading Length mm Through 22.5mm 400 Coolant Water-Soluble 200 Machine Number of Passes BT30 Vertical Machining Center 1 Pass 3 Passes 0 WX-ST-PNC sec 50 Cutting Time % Efficiency 0 WX-ST-PNC

6 One Pass Thread Mill Type 1 Type 2 EgiAs 911 P8 No. EDP No. Min. Cutting Bore Dia. Pitch Dc L 13.5 n Ds Flutes Type Unit:mm Stock Yen ,800 M , , M , , , M , , , ,400 M , , ,600 B , M , , , , M , , M , ,400 M , , M , ,100 B=B=Standard stock item (M) is only for milling internal threads. Please select "Multi-feed" for the path type in ThreadPro. Guide for Icons 1 Tool Materials 3 Helix Angle 5 Thread Type Tungsten Carbide 911 Helix angle of flute for thread mill for Internal Thread 2 EgiAs Surface Treatment EgiAs Coating 4 Shank Tolerance for Shank Diameter for External Thread

7 One Pass Thread Mill Type 1 Type 2 EgiAs 911 P8 No. EDP No. Min. Cutting Bore Dia. T.P.I. Dc L n Ds Flutes Type Unit:mm Stock Yen , , , , , , , , , , , ,200 B , , , , , , , , , , , ,800 Available from Spring 2019 B=B=Standard stock item See p.5 for explanation of icons. (UUNJ) is only for milling internal threads. Please select "Multi-feed" for the path type in ThreadPro.

8 One Pass Thread Mill Type 1 Type 2 Type 3 Type 4 EgiAs 911 P8 No. EDP No. Range of Thread SizeDia. T.P.I. Dc L n Ds Flutes Type Unit:mm Stock Yen , , , B 46, , , ,000 No. EDP No. Range of Thread SizeDia. T.P.I. Dc L n Ds B=B=Standard stock item Flutes Type Unit:mm Stock Yen , , , B 39, , , ,000 No. EDP No. Range of Thread SizeDia. T.P.I. Dc L n Ds B=B=Standard stock item Flutes Type Unit:mm Stock Yen , , ,300 B , , ½ ,000 Available from Spring 2019 Available from Spring 2019 See p.5 for explanation of icons. Please select "Multi-feed" for the path type in ThreadPro. B=B=Standard stock item

9 Cutting Conditions Mild SteelLow Carbon Steel Work Material Cutting Speed m/min Feed Rate mm/t C0.25% Medium Carbon Steel C0.25%0.45% High Carbon Steel C0.45% Alloy Steel SCM Hardened Steel 2545HRC HRC 5560HRC Stainless Steel SUS304SUS Tool Steel SKD Cast Steel SC Cast Iron FC Ductile Cast Iron FCD Copper Cu Brass Bs Brass Casting BsC Bronze PB Aluminum Rolled Steel Al Aluminum Alloy Casting AC, ADC Magnesium Alloy Casting MC Zinc Alloy Casting ZDC Titanium Alloy Ti-6Al-4V Ni Ni-based Alloy Thermo Setting Plastic Thermo Plastic Inconel The indicated speeds and feeds are for water-soluble coolant. 2. Water-soluble coolant is not suitable for tapping magnesium alloy. 3. Please adjust the cutting conditions depending on the rigidity of machine, tool holders, and workpiece clamping. 4. If the tapping length is long, or when machining a large-pitch thread, select a smaller feed rate. 5. If the machined parallel internal thread is tapered and the gauge entry is poor, process at 75% during the first pass, finish it in the second pass. Formula for calculating the feed rate of thread mill fz z n Dm Dc v f = mm/min Dm v f :mm/min Feed Dm :mm Actual Dia. Dc :mm Tool Dia. Note Internal External z fz n : Number of Flutes :mm/t Feed Rate :min 1 Speed For the arc cutting process of machining external and internal threads, the feed rate at the tool center can be obtained by multiplying the linear cut feed rate with a coefficient. The formulas for calculating coefficients vary between external and internal thread cutting. The formula listed left are for calculating the tool feed rate during arc-cutting, including calculating the coefficients to be used for multiplication with the linear-cut feed rate.

10 3 Support Tools for Your Thread Milling Needs Reduce setup, machining time, and achieve stable tool life with 3 support tools. 2 Thread Milling ThreadPro Thread Milling NC Code Generator Software 1 RPRG Reference value of tool radius offset 3 DCT Diameter Correction Tool for Thread Mills Use RPRG to reduce the workload RPRG is the reference value of tool radius offset ISO-5H Internal Thread ISO-6H Internal Thread Example Tool diameter:7.7; Pitch: 1; Minimum cutting bore diameter: M10 (EDP No.: ) Internal thread size: M10 1 Tolerance for pitch diameter: 0 to (ISO-5H), 0 to (ISO-6H) Entered value of RPRG: Pitch Dia. Radius RPRG=3.806 Entered value of Radius: 3.85 Notes 1. RPRG are reference values. Optimal values for actual cutting depend on the machining environment. Determine optimal values after trial cutting. 2. RPRG values are optimally established to achieve ISO:5H (formerly Grade 1) internal thread limits for metric threads and ANSI:3B internal thread limits for unified threads. RPRG values established for taper pipes (R/Rc) are effective when using the thread milling NC code generator software ThreadPro available on our website. 3. For diameters of thread mills, RPRG values are calculated based on the minimum cutting bore diameter (the minimum cutting internal thread size of the tool diameter). To cut other diameters, it is necessary to use a smaller value than RPRG.

Revamped Thread Milling NC Code Generator Software "ThreadPro" Generate codes for complex machining couldn't be easier.

Achieve Stable Tool Life with the DCT for Accurate Diameter Measurement 100% 50% NP 75% OSG The internal thread effective diameter, which used to be difficult to determine, can now be measured with

Visibility of internal thread pitch diameter at entry enables the reduction of passes to minimize setup time significantly.

11 Revamped Thread Milling NC Code Generator Software "ThreadPro" Generate codes for complex machining couldn't be easier. Create machining programs at ease with OSG's revamped NC code generator software ThreadPro. Achieve Stable Tool Life with the DCT for Accurate Diameter Measurement 100% 50% NP 75% OSG The internal thread effective diameter, which used to be difficult to determine, can now be measured with readable values. Internal Thread 0%Internal GP DCT Unsure of diameter correction value. Increase passes which results in longer setup time. Visibility of internal thread pitch diameter at entry enables the reduction of passes to minimize setup time significantly. Moreover, the DCT is able to measure pitch diameter smaller than the tolerance limit. The DCT can measure the pitch diameter of the female internal thread even if it does not fit into the Go-Gauge. Troubled by the following problems? An incorrect diameter correction that result in a defective internal thread (gauge-out). Visibility of internal thread pitch diameter at entry enables reliable diameter corrections. The DCT is useful for reducing defective workpieces. Unstable tool life Digitized measurement ensures consistent internal thread pitch diameters after tool changes. The same starting and finishing position ensures consistent and stable tool life. DCT Solve them with the Diameter Correction Tool (DCT) Standard stock item Special order item Simple measurement of pitch diameter by visual judgment Low-cost type Measurement and calculation system High-performance type Digital display system Eliminate measurement and calculation with the combination of a digital display.

Advantages of using thread mills Smooth handling of chips to reduce problems Thread mills break chips into small pieces and

Chips from thread mill Chip from a spiral fluted tap Cuts large-diameter threads with a low-power machine The required torque is

strength and mechanical rigidity are sufficiently high. Thread mill 1234.5 P1.5 Spiral fluted tap for general purpose M161.

12 Advantages of using thread mills Smooth handling of chips to reduce problems Thread mills break chips into small pieces and eject them smoothly, ensuring stable, problem-free thread cutting. Chips from thread mill Chip from a spiral fluted tap Cuts large-diameter threads with a low-power machine The required torque is low compared with tapping, so thread mills can cut large-diameter threads with a lowpower machine if the workpiece holding strength and mechanical rigidity are sufficiently high. Thread mill P1.5 Spiral fluted tap for general purpose M Nm A single tool can be used to cut threads in various sizes of diameters. A single tool can cut different threads such as M10 1.5, M12 1.5, and M if their pitch is the same.

13 Thread mills are ideal for the following High-precision taper pipe threading (no stop marks) Airtight threads by having no stop marks. Stop Marks Thread cutting in drill holes with little allowance Carbide Drill AD-2D 5 Spiral Fluted Tap A-SFT M61 (2.5P) Carbide Flat Drill ADF-2D 5 Spiral Fluted Tap A-SFT M61 (1P) Carbide Flat Drill ADF-2D 5 Thread Mill P1 Even deeper Flat drill tool combination allows even greater depth!! Product Pickup Carbide Flat Drill ADF Highly Efficient Multi-Purpose Tap Series A-TAP Carbide Drill Series ADADO

FAQ about Thread Milling Why internal thread cutting tools cannot be used to cut external threads? Metric and unified threads have different thread profiles between internal and external threads.

14 FAQ about Thread Milling Why internal thread cutting tools cannot be used to cut external threads? Metric and unified threads have different thread profiles between internal and external threads. For these threads, internal thread cutting tools cannot be used to cut external threads because in their basic thread profiles, the crest and root shapes are not uniform. However, for pipe threads, which have uniform crests and roots, thread cutting tools can be shared for internal and external thread cutting. Example of basic thread profile (metric thread) Height of basic triangle Internal Thread External Thread Basic Height of Thread Compare the shapes of internal and external threads. 1/8 H 1/4 H Height cut off from crest: External Thread Internal Thread 1/4 H 1/8 H Height cut off at root: External Thread Internal Thread 5/8 H Both threads have the same basic height of thread (5/8H). However, their shapes are different from each other. What does the number "75" under "Fit %" mean, which is displayed on the data entry screen of ThreadPro? It means to aim at the acceptable range of threads. Default values are 75% (larger side) for internal threads and 25% (smaller side) for external threads in light of their engagement. You can change these to your desired values. What does aiming 75% fit mean? Narrowly acceptable on the larger side Narrowly acceptable on the smaller side 100% 75% 50% 25% 0% 75% of larger limit for internal thread Acceptable Accuracy of internal thread Aim here! Is ThreadPro compatible with NC programs developed for custom-made thread mills? Yes, please consult our sales representatives.

15 Proper Usage of Coolant When using external coolant, ensure that the cutting fluid is properly positioned so that it is supplied into the hole. If you are using a machining center with a through-spindle coolant system, the use of coolant through collet is recommended.

16 本社愛知県豊川市本野ケ原三丁目 22 番地 TEL(0533) cs-info@osg.co.jp Web : International Headquarters 3-22 Honnogahara, Toyokawa, Aichi, , JAPAN TEL : FAX : 東部営業部東京都大田区南馬込 TEL(03) 中部営業部愛知県名古屋市名東区貴船 1-9 TEL(052) 西部営業部大阪府大阪市西区新町号 TEL(06) 工具の技術的なご相談はコミュニケーションダイヤルよい工具は一番コミュニケーション FAX コミュニケーション 9:00 12:00 13:00 19:00 土日祝日を除く hp-info@osg.co.jp 仙台 TEL (022) 郡山 TEL (024) 新潟 TEL (025) 上田 TEL (0268) 諏訪 TEL (0266) 両毛 TEL (0270) 宇都宮 TEL (028) 八王子 TEL (042) 茨城 TEL (029) 東京 TEL (03) 厚木 TEL (046) 静岡 TEL (054) 浜松 TEL (053) 豊川 TEL (0533) 安城 TEL (0566) 名古屋 TEL (052) 岐阜 TEL (058) トヨタ TEL (0533) 三重 TEL (0594) 東海 TEL (052) 金沢 TEL (076) 京滋 TEL (077) 大阪 TEL (06) 明石 TEL (078) 岡山 TEL (086) 四国 TEL (087) 広島 TEL (082) 九州 TEL (092) 北九州 TEL (093) 熊本 TEL (096) 安全にお使いいただくために工具を使用する時は破損する危険があるので必ずカバー保護メガネ安全靴等を使用して下さい切れ刃は素手でさわらないで下さい切りくずは素手でさわらないで下さい工具の切れ味が悪くなったら使用を中止して下さい異常音異常振動が発生したら直ちに使用を中止して下さい工具には手を加えないで下さい加工前に工具の寸法確認を行って下さい OSG 代理店 Safe use of cutting tools Use safety cover, safety glasses and safety shoes during operation. Do not touch cutting edges with bare hands. Do not touch cutting chips with bare hands. Chips will be hot after cutting. Stop cutting when the tool becomes dull. Stop cutting operation immediately if you hear any abnormal cutting sounds. Do not modify tools. Please use appropriate tools for the operation. Check dimensions to ensure proper selection. 製品については常に研究改良を行っておりますので予告なく本カタログ掲載仕様を変更する場合があります Tool specifications are subject to change without notice. 本書掲載内容の無断転載複製を禁じます Copyright 2017 OSG Corporation. All rights reserved. N AH.DC(DN) 18.10

Thread Mill Series

Thread Mill Series Index Go to the following for the quick tool search. Guide to Icons Tool Materials Helix Angle Shank Tungsten Carbide Cobalt HSS Helix angle of flute for cutters Tolerance for shank