Thread machining in OEM-Applications

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Version Juli 2008

Engines
Cylinder block, Cylinder head, Crankshaft, Camshaft, ConRod

Injection-Systems
Pump case, Cylinder head, Rail, Injection-body

Braking-Systems
Braking disk, Braking saddle, Braking cylinder, ABS/ESP

Gears
Gearbox, flanges, gear rods

Chassis
Bracket wheels, axis
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Version Juli 2008

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

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Version Juli 2008

Cutting parameter
work piece: cylinder head material: AlSi9 operation: thread: M10 thread depth: 20 mm blind hole machine: CNC-center Syncro chuck with collet lubrication: emulsion 8%, IK ax tool: tap M10 article 302 PM HSSE, TiCN coated, IK ax cutting speed Vc= 30 m/min tool life: 12000 threads tap M10 art 972 carbide, TiCN coated, IK ax cutting speed Vc= 50 m/min tool life: 100000 threads
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PM-HSSE

carbide

Version Juli 2008

Cutting parameter
work piece: cylinder head Kappa material: AlSi9Cu3 operation: thread: M6 Thread depth: 20 mm blind hole tool: tap M6 carbide, with two flutes, IK ax machine: CNC-center Syncro chuck with collet lubrication: emulsion 9%, IK ax cutting speed Vc: 50 m/min tool life: ????? threads
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Version Juli 2008

Cutting parameter
work piece: cylinderhead material: AlSi17 operation: thread: M6 Thread depth: 15 mm blind hole tool: tap M6 carbideK6UF, TiAlN coated, IK ax machine: CNC-center Syncro chuck with collet lubrication: emulsion 9%, IK ax cutting speed Vc: 35 m/min tool life: 93000 threads
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Version Juli 2008

PM-HSSE

carbide

Cutting parameter
work piece: balance housing material: GG25 operation: thread: M10 Thread depth: 20 mm blind hole machine: CNC-center Syncro chuck with collet lubrication: emulsion 7%, IK ax tool: tap M10 article 318 PM HSSE, TiCN coated, IK ax Vc= 20 m/min tool life: 10000 threads tap M10 article 2311 carbide, TiCN IK ax Vc= 40 m/min tool life: 100000 threads
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Version Juli 2008

Cutting parameter
work piece: cylinderhead material: GJV 450 operation: thread: M10 Thread depth: 25 mm blindhole tool: tap M10 carbide, TiAlN coated, IK ax machine: CNC-center collet without compensation lubrication: emulsion 10%, IK ax Cutting speed Vc: 40 m/min Tool life: 100000 threads
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Version Juli 2008

Cutting parameter
work piece: crankshaft material: GGG70 operation: thread: M12x1,5, M16x1,5 thread depth: 20 mm, 35 mm blind hole tool: tap M12x1,5, M16x1,5 carbide, TiCN coated, IK machine: CNC-center HSK 63 Syncro chuck with collet lubrication: emulsion 8%, IK cutting speed Vc: 30 m/min tool life: 36000 threads
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Version Juli 2008

Cutting parameter
work piece: crankshaft material: 42 CrMo4 Rm=800 N/mm2 operation: thread: M12x1,5 thread depth: 20 mm blind hole tool: Fluteless tap M12x1,5 carbide, TiN coated, IK machine: CNC-center HSK 63 Syncro chuck with collet lubrication: emulsion 8%, IK cutting speed Vc: 12 m/min tool life: 6000 threads
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Version Juli 2008

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Cutting parameter
work piece: crankshaft material: C38 operation: thread: M16x1,5 thread depth: 30 mm blind hole tool: fluteless tap M16x1,5 carbide, TiN coated, IK machine: tranferlinie Excello compensation chuck lubrication: emulsion 8%, IK cutting speed Vc: 15 m/min tool life: 20000 threads
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Cutting parameter
work piece: crankshaft material: C38 operation: thread: M12x1,5 thread depth: 24 mm blind hole depth 26 mm tool: thread milling cutter M12x1,5 carbide, TiCN coated, IK machine: CNC-center shrink fit holder lubrication: emulsion 8%, IK cutting speed Vc: 90 m/min, feed rate fz= 0,09 mm tool life: 3000 threads

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Version Juli 2008

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Cutting parameter
work piece: camshaft material: St 52 operation: thread: M10x1 thread depth: 20 mm blind hole tool: fluteless tap M10x1 PM HSSE, TiN coated, IK rad machine: turning center DMG collet without compensation lubrication: emulsion 8%, IK rad cutting speed Vc: 12 m/min tool life: 750 thread
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Cutting parameter
work piece: camshaft material: St 52 operation: thread: M16x1,5 thread depth: 20 mm blind hole tool: thread milling cutter M16x1,5 carbide, TiCN coated, IK machine: CNC-center Shrink fit holder lubrication: emulsion 6%, IK rad cutting speed Vc: 80 m/min, feed rate fz= 0,1 mm tool life: 2000 threads

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Cutting parameter
work piece: conrod material: C70 operation: thread: M9x1 thread depth: 18 mm through hole tool: tap M9x1 PM HSSE, TiCN coated machine: CNC-center HSK 63 - Syncro chuck lubrication: emulsion 8% cutting speed Vc: 15 m/min tool life: 2100 threads
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Cutting parameter
work piece: conrod material: C70 operation: thread: M9x1 thread depth: 18 mm through hole tool: tap M9x1 Carbide DK 700, TiCN coated machine: CNC-center HSK 63 - Syncro chuck lubrication: emulsion 8% cutting speed Vc: 50 m/min tool life: 9000 threads
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Version Juli 2008

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Cutting parameter
work piece: conrod material: C70 operation: thread: M8x1 thread depth: 16 mm through hole / blind hole tool: two taps M8x1 PM HSSE, TiCN coated machine: CNC-center HSK 63 - Syncro chuck lubrication: emulsion 8% cutting speed Vc: 15 m/min tool life: 2100 threads through hole 600 threads blind hole
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Cutting parameter
work piece: conrod material: C70 operation: thread: M7x1 thread depth: 14 mm blind hole tool: fluteless tap M7x1 carbide, TiCN coated, IK machine: CNC-center HSK 63 - Syncro chuck lubrication: emulsion 10% cutting speed Vc: 25 m/min tool life: 5000 threads
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Version Juli 2008

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Cutting parameter
work piece: conrod material: C70 S6 By operation: thread: M12x1,25 thread depth: 24 mm blind hole tool: Fluteless tap M12x1,25 carbide, TiCN coated machine: threading machine HSK 63 - Syncro chuck lubrication: oil cutting speed Vc: 30 m/min tool life: 10000 threads
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Cutting parameter
work piece: Pleuel material: 42CrMo4 (< 48 HRC) operation: thread: M10x1 thread depth: 18 mm blindhole tool: fluteless tapM10x1 carbide, TiN coated, IC Machine: M/C HSK 63 Synchro chuck lubrication: Emulsion 8%, 70 bar, IC cutting speed: 25 m/min tool life: 15000 threads
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Injection-Systems
Pumpcase, Cylinderhead, Injection-body, Rail

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Cutting parameter
work piece: pump case material: 20MnSi5 operation: thread: M14x1 thread depth: 22 mm tool: thread milling cutter M14x1 carbide machine: CNC-center weldon lubrication: emulsion 8% cutting speed Vc: 90 m/min feed rate per teeth milling: 0,08 mm tool life: 3000 threads

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Version Juli 2008

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Jrg Maier Produktmanagement Gewindewerkzeuge

Version Juli 2008

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Cutting parameter
work piece: cylinder head CP1H material: 20MnSi5 operation: thread: M6 thread depth: 12 mm chamfer tool: thread milling cutter M6 carbide machine: CNC turning-center shrink fit holder lubrication: emulsion 6% cutting speed Vc: 90 m/min feed rate per teeth milling: 0,05 mm tool life: 2000 threads

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Version Juli 2008

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Jrg Maier Produktmanagement Gewindewerkzeuge

Version Juli 2008

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Cutting parameter
work piece: cylinder head CP4 material: C60 operation: thread: M18x1 external thread depth: 16 mm chamfer tool: thread milling cutter M18x1 carbide with special cutting edge machine: CNC turning-center shrink fit holder lubrication: emulsion 6% cutting speed Vc: 90 m/min feed rate per teeth milling: 0,07 mm tool life: 3000 threads

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Jrg Maier Produktmanagement Gewindewerkzeuge

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Jrg Maier Produktmanagement Gewindewerkzeuge

Version Juli 2008

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Cutting parameter
work piece: injection body material: 42CrMo4 operation: thread: M14x1,5 thread depth: 18 mm blind hole tool: fluteless tap M14x1,5 carbide, TiCN coated, IK machine: CNC-center HSK 63 Syncro chuck with collet lubrication: emulsion 8%, 70 bar, IK Cutting parameter Vc: 25 m/min tool life: 8000 threads
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Braking-Systems
Braking disk, caliper, Braking cylinder, ABS/ESP

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Version Juli 2008

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Cutting parameter
work piece: ABS/ESP block material: AlSi7 operation: thread: M10x1, M12x1 thread depth: 16 mm blind hole tool: thread milling cutter M10x1 carbide with special cutting edge machine: CNC-center shrink fit holder lubrication: emulsion 8% cutting speed Vc: 200 m/min feed rate per teeth milling: 0,08 mm tool life: 100000 threads

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Cutting parameter
work piece: caliper material: AlSi7 operation: thread: M10x1, M12x1 thread depth: 14 mm blind hole tool: thread milling cutter M10x1 carbide with special cutting edge machine: CNC-center shrink fit holder lubrication: emulsion 8% cutting speed Vc: 200 m/min feed rate per teeth milling: 0,08 mm tool life: 100000 threads

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Cutting parameter
work piece: braking disk for trucks material: GG 25 operation: thread: M16x1,5 Thread depth: 20 mm through hole tool: Thread milling cutter TMC M16x1,5 2xD carbide, IK ax machine: CNC-center SK 40 - Weldon lubrication: without cutting speed Vc: 120 m/min Feed rate fz: 0,12 mm tool life: 80000 threads
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Cutting parameter
work piece: braking cylinder material: AlSi9 operation: thread: M10x1 / M12x1 Thread depth: 20 mm blind hole tool: Thread milling cutter TMZ M10x1 PCD, IK ax machine: CNC-center HSK 63 Shrink fit holder lubrication: emulsion 8% cutting speed Vc: 400 m/min feed rate fz: 0,04 mm tool life: 200000 threads

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Version Juli 2008

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Cutting parameter
work piece: braking cylinder material: AlSi7 operation: thread: M10x1, M12x1 Thread depth: 18 mm blind hole tool: Thread milling cutter TMC M10x1 carbide, IK ax machine: CNC-center Shrink fit holder lubrication: emulsion 6% cutting speed Vc: 200 m/min feed rate fz: 0,09 mm tool life: 100000 threads

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Version Juli 2008

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Gears
Gearbox, flanges, gear rods/axles

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Version Juli 2008

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Cutting parameter
work piece: gearbox material: AlSi9 operation: thread: M22x1,5 thread depth: 20 mm through hole with cyl. diameter, chamfer and back chamfer tool: special drill thread milling cutter M22x1,5, carbide, IK ax machine: CNC-center Whistle Notch HE lubrication: emulsion 9%, IK ax cutting speed Vc: 300 m/min feed rate F drill: 0,2 mm/U feed rate peer teeth milling: 0,12 mm tool life: 40000 threads
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Version Juli 2008

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Cutting parameter
work piece: flanche axle material: C45 operation: thread: M14x1,5 thread depth: 20 mm through hole tool: tap M14x1,5 HSSE, TiCN coated machine: CNC-center compensation holder lubrication: emulsion 8% Cutting parameter Vc: 15 m/min tool life: 1200 threads
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Chassis
Bracket wheels, axis

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Version Juli 2008

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Bracket wheel forged steel PQ35

Cuttin param g eter

W orkpiece: w heel b racket Material: 38Mn S5 BY fo SiV rged 2 ten sile streng 850-1000 N/mm th Ap licatio : p n M16x1,5; M14x 1,5; M12x1,5; M6 d th 2xd ep : iamet er To o l: So carbid fluteless t s lid e ap with rad intern coo t ial al lan min imal lub ricatio n Cu g data: ttin Vc= 20 m/m in Mach e: BA L den aier in Z in m T o life: 17000 t ol hread s

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In the middle of 2007 the material for PQ 35 was changed to the cheaper Cast Iron SIBODUR 700-10
SiBoDur is a new developed cast iron in the form GGG with the same E-Modul and a higher flexibility and tensile Through the added alloys silicon and bor we achieve a higher tensile with the same flexibility, Therefore the name Si (Silicon) Bo (Bor) Dur (Durability = Haltbarkeit in English)
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Version Juli 2008

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SiBoDur bracket wheel PQ35

For the threading process SiBoDur they use now carbide-cast iron taps
C utting parameter
W orkpiece: wh b eel racket Material: Sibo ur 700 d Ap licatio : p n M16x1,5; M14x1,5; M12x 1,5; M6 d th 2xd eter ep : iam To o l: So carbide f teless tap lid lu s with rad in ial tern co lant al o air lu rication b Cu g d a: ttin at Vc= 20 m in /m Mach e: B L d maier in AZ in en T o life: 1700 th ol read s

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2009 VW Mexico bracket wheel PQ35

FCD 600 Ductile Cast Iron similar GGG60 Hitachi casting in USA Production forged steel 1 line Lindenmaier Production FCD 600 new Anger machine

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Version Juli 2008

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1. Cutting comparison work piece Axis holder 42CrMo4 thread M22x1,5 and M24x1,5 Compare thread milling with thread forming

Thread milling Tool Material Coating Thread Cutting speed Feed rate Cutting time Tool life TMZ D20x39xM1,5 302202659 Carbide TiCN M24x1,5 90 m/min 0,1 mm/z 9,9 s 2000 threads

Thread forming GFO M24x1,5 302054727 Carbide TiCN M24x1,5 20 m/min 1,5 mm/U 18 s 4000 threads

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

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Jrg Maier Produktmanagement Gewindewerkzeuge

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Cutting parameter axis work piece GGG40

Thread milling Tool Material Coating Thread Cutting speed Feed rate Cutting time Tool life Thread forming Thread cutting Tap M16x1,5 Carbide TiCN M16x1,5 20 m/min 1,5 mm/U 7.8 s 60000 threads

TMC M16x1,5 2,5xD Form tap M16x1,5 Carbide TiCN M16x1,5 120 m/min 0,06 mm/z 6,2 s 40000 threads Carbide TiCN M16x1,5 20 m/min 1,5 mm/U 7.8 s 20000 threads

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Reducing production costs 50% with thread milling

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Special tools for the best tool life

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