The following is a summary of some common problems and solutions in the thread milling process. The following are the four most prominent ones:
(1) Accelerated or excessive wear of thread cutters
1 Reason: The cutting speed and feed rate were not selected correctly. Remedy: Make sure to select the correct cutting speed and feed from the machining parameter table.
2 Reason: The tool is under excessive pressure. Solution: Reduce the amount of feed per tooth; shorten the time between tool changes; check for excessive tool wear - the thread at the start will wear the fastest.
3 Reasons: The coating used was incorrect and produced a built-up edge. Solution: Study the suitability of other coatings; increase the coolant flow rate and flow rate.
4 Reason: The spindle speed is too high. Solution: Reduce the spindle speed.
(2) cutting edge chipping
1 Reason: The cutting speed and feed rate were not selected correctly. Solution: Make sure to select the correct cutting speed and feed amount from the machining parameter table.
2 Reason: The thread cutter moves or slips on its holding device. Solution: Use hydraulic chucks.
3 Reasons: The rigidity of the processing machine is insufficient. Solution: Make sure that the workpiece is clamped reliably; if necessary, re-clamp the workpiece or increase the stability of the clamp.
4 Reason: Insufficient coolant pressure or flow. Solution: Increase the coolant flow rate and flow rate.
(3) Stairs appear on the thread profile
1 Reason: Feed rate is too high. Solution: Reduce the feed per tooth.
2 Reason: The ramp milling programming uses axial movement. Solution: Make sure that the thread milling cutter mills the profile at the large diameter of the thread without radial movement.
3 Reason: Excessive wear of the thread cutter. Solution: Reduce the tool change interval.
4 Reason: The tool machining area is too far away from the clamping area. Solution: Minimize the overhang of the tool on the holding device.
(4) There is a difference in test results between the workpiece and the workpiece
1 Reason: The tool machining area is too far away from the clamping area. Solution: Minimize the overhang of the tool on the holding device.
2 Reasons: The coating used was incorrect and produced a built-up edge. Solution: Study the suitability of other coatings; increase the coolant flow rate and flow rate.
3 Reason: Excessive wear of the thread cutter. Solution: Reduce the tool change interval.
4 Reason: The workpiece is displaced on the fixture. Solution: Make sure that the workpiece is clamped reliably; if necessary, re-clamp the workpiece or increase the stability of the clamp.
(1) Accelerated or excessive wear of thread cutters
1 Reason: The cutting speed and feed rate were not selected correctly. Remedy: Make sure to select the correct cutting speed and feed from the machining parameter table.
2 Reason: The tool is under excessive pressure. Solution: Reduce the amount of feed per tooth; shorten the time between tool changes; check for excessive tool wear - the thread at the start will wear the fastest.
3 Reasons: The coating used was incorrect and produced a built-up edge. Solution: Study the suitability of other coatings; increase the coolant flow rate and flow rate.
4 Reason: The spindle speed is too high. Solution: Reduce the spindle speed.
(2) cutting edge chipping
1 Reason: The cutting speed and feed rate were not selected correctly. Solution: Make sure to select the correct cutting speed and feed amount from the machining parameter table.
2 Reason: The thread cutter moves or slips on its holding device. Solution: Use hydraulic chucks.
3 Reasons: The rigidity of the processing machine is insufficient. Solution: Make sure that the workpiece is clamped reliably; if necessary, re-clamp the workpiece or increase the stability of the clamp.
4 Reason: Insufficient coolant pressure or flow. Solution: Increase the coolant flow rate and flow rate.
(3) Stairs appear on the thread profile
1 Reason: Feed rate is too high. Solution: Reduce the feed per tooth.
2 Reason: The ramp milling programming uses axial movement. Solution: Make sure that the thread milling cutter mills the profile at the large diameter of the thread without radial movement.
3 Reason: Excessive wear of the thread cutter. Solution: Reduce the tool change interval.
4 Reason: The tool machining area is too far away from the clamping area. Solution: Minimize the overhang of the tool on the holding device.
(4) There is a difference in test results between the workpiece and the workpiece
1 Reason: The tool machining area is too far away from the clamping area. Solution: Minimize the overhang of the tool on the holding device.
2 Reasons: The coating used was incorrect and produced a built-up edge. Solution: Study the suitability of other coatings; increase the coolant flow rate and flow rate.
3 Reason: Excessive wear of the thread cutter. Solution: Reduce the tool change interval.
4 Reason: The workpiece is displaced on the fixture. Solution: Make sure that the workpiece is clamped reliably; if necessary, re-clamp the workpiece or increase the stability of the clamp.
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