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MOTOREX Magazine 2003 70 EN

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  • Motorex
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MOTOREX_Magazine_2003_70_en

Industry Industry 10 12

Industry Industry 10 12 Cost-efficient and accurate: thread whirling Using a special whirling tool this 18.8 stainless steel bone screw can be manufactured with total accuracy in just one machining process. How does whirling work? Depth adjustment Workpiece Inclination angle +X +A Whirling ring +Y +C Photo: Tornos SA +Z Described as a special type of milling, thread whirling is gaining in popularity. And there is no shortage of convincing reasons to explain this popularity: Whirling is not just more cost-efficient and accurate than conventional thread milling, the technology has for the first time made it possible to machine very small internal and external threads on stainless steel or titanium parts. It’s hardly surprising, then, that in the prestigious dental and medical technology industry, about 60% of all screw threads are manufactured by whirling. This type of modern thread application has become widespread in other industrial sectors too, for example bar turning and the watchmaking industry. As with other machining The essential difference between external and internal whirling is that in external whirling, cutting is directed inwards rather than outwards – or to put it differently, whirling is milling with annular-toothed heads. The whirling head, which in the case of external whirling resembles a ring, determines the speed of cutting. It is eccentrically mounted and rotates at high speed around the slowly rotating workpiece. Here the appropriate longitudinal workpiece rotary feed and tool carrier feed for the thread pitch are assigned using an NC feed. Whirling produces short burrs with commashaped ends. processes, a flawless and cost-effective end product can be achieved with whirling only if the basic factors of machine tool, tool and machining fluid are perfectly attuned. Solid carbide special tools Today’s modern whirling tools embody a wealth of expertise accumulated in the course of decades of experience. Friedrich GLOOR AG of Lengnau in Switzerland is one of Europe’s leading manufacturers of solid carbide special tools, offering a successful and broad range of internal and external whirling tools in addition to a large number of mostly bespoke tools. In developing miniature internal thread whirling heads for the series production of titanium or stainless-steel internal threads (from M1 = 1.00 mm diameter) on CNC machining centers or lathes, Friedrich GLOOR AG solved a major challenge and revolutionized the market. It is now possible to manufacture finished parts in a single process with no supple- mentary machining by whirling them to their final dimension. Unlike conventional processes such as thread chasing or tapping, whirling only produces short burrs, a property which greatly simplifies the series machining of very small internal threads, or even makes it possible in the first place. As a result, any screw from a diameter of just 1 mm – or even less – can be efficiently threaded by whirling. Thread whirling produces very high surface finish qualities without any additional processing. Logarithmic relief a specialty All milling heads manufactured by Friedrich GLOOR AG have logarithmic relief and maintain a constant profile shape until the head is completely worn out. The relief and tooth face angles remain totally constant (at the tooth face) even after resharpening, guaranteeing ideal cutting conditions throughout the head’s entire service life. A special manufacturing process means that logarithmic relief can be incorporated into even the most complex profile shapes. Whirling is a continuous cutting process. Because it only produces short burrs, hard metals with a high proportion of carbides and nitrides can be used for the tools. As a result, their service lives are impressively long. The miniature internal thread whirling heads with logarithmic relief have extremely strong tooth backs, which further increase the tools’ service lives and productivity. Extremely important machining fluids With current levels of vertical integration and today’s manufacturing technology, efficient metal machining is only possible with machining fluids that are perfectly matched to the machining process. As manufacturing speeds and the quality of the materials being machined increases, so in-depth knowledge of the available lubricants and cutting oils becomes necessary. MOTOREX is therefore assisting leading machine and tool manufacturers with the development of new technologies, using cutting-edge products to ensure success in real-life situations. Its MOTOREX SWISSCUT ORTHO 400 chlorine- and heavy metal-free high-performance cutting oil has been a huge hit. With its high-tolerance lubricating film and total stability over an extremely wide temperature range, it is ideal for high feed and cutting rates. The basic fluids are lowaromatic, solvent-refined base oils combined with synthetic active constituents and special additives. This increases the tools lifespan and gives off an excellent surface finish. This also applies to difficult-to-machine materials such as: – chromium-nickel steel – chromium-molybdenum steel – silicon steel – 18.8 stainless steel – titanium – titanium alloys etc. Thread whirling is an ingenious machining method which, when combined with the ideal process parameters, has enormous potential as well as being very economical. To find out more, please visit www.motorex.com and www.gloorag.ch Photo: F. Gloor AG Photo: F. Gloor AG Logarithmic relief simplifies resharpening throughout the tool’s service life. A. Constant relief angle B. Constant tooth face angle C. Resharpened tooth face, relief angle and profile shape remain constant This single-tooth miniature internal thread whirling tool from Friedrich GLOOR AG is used on machines that use highfrequency spindles. It rotates at speeds of up to 60,000 rpm. 13

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