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The depth of the hole to be threaded is a third factor to consider. Particularly deep holes would take a very long time to thread using a single profile cutter, and therefore a multi-tooth cutter should be considered. Finally, the material being threaded will influence the best substrate and coating to choose for the cutting tool.

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Helical flute thread mill cutting tools have multiple rows of teeth, with flutes around the circumference to assist in evacuating chips. However, these flutes progress helically around the tool, usually at a 15-degree angle or a 30-degree angle. This helical arrangement of the flute reduces cutting side pressure by staggering the engagement of the teeth with the workpiece. It is best suited to high-speed milling.

The function of thread milling is to cut a thread into a workpiece. It is typically used for cutting threads inside holes, but can also be applied to cutting threads on the outside of parts. A thread milling tool has a set thread pitch (number of thread crests per inch) but can be used to create left-hand or right-hand threads, and for various flank angles.

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Bench Lathe with milling machine integrated, distance between the centers of 800 mm, maximum swing over bed 320 mm, milling head rotating and adjustable height, automatic cross slide-table performing metric and inch threads, motor of lathe 1500 W and motor of milling machine 750 W - Bearings SKF

Thread milling is a versatile process used to thread a huge variety of hole sizes, particularly larger diameter holes. It has some similarities to tapping but differs from tapping in that the tool is meaningfully smaller than the hole to be threaded. Thus the tool moves in a circular path around the circumference of the hole to cut the thread.

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Just as the holes that may exist in components are varied, the thread mill cutting tools are also varied. Different designs of cutters are suitable for different applications. Three main types are explained below:

Many different types of milling have been developed, and each type uses its own milling tools to remove material and shape the workpiece. Thread milling uses toothed cutting tools that are different from other milling tools. Some types of milling can be performed manually by moving the cutting tool using handwheels, but other types must be performed using a CNC milling machine. Thread milling requires the use of a CNC milling machine, as there are three coordinated movements of the tool to the workpiece. The tool has a constant rotational speed, and it moves at a constant z-axis (vertical) progression while having a circular path in the x-y (horizontal) plane to cut threads. Some other milling types require rotation of the tool together with movement predominantly in only one direction with the workpiece, such as end milling.

Thread milling is used mainly for cutting threads in materials that do not have good machinability. For softer materials or materials that are easily machined, conventional tapping would usually be used to cut threads into holes. Thread milling is also used for threading large diameter holes, or for threading to the bottom of a blind hole. These are applications in which tapping has weaknesses or is unable to be used. Thread milling has the flexibility to be used to thread the outside surface of an item as well.

Metalworking combo machine with distance from the centers lathe of 750 mm, swing over bed of 300 mm, milling head rotating and adjustable height, automatic cross slide-table performing metric and inch threads and two single-phase motor 750 W (one for the lathe and one for the milling machine) - Bearings SKF

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There are a few factors that influence the choice of thread milling cutter for a part production run. The first is the size of the batch to be produced. If it is a large batch, then speed will likely be an important factor, but with smaller batches, it is less important. With smaller batches, a cost-effective thread mill cutting tool could be used, even if slower feeds and speeds are required.

The choice of thread milling cutter will affect its performance in speed, quality, and cost-effectiveness. Time is money, and a shorter production time will always benefit a machine shop. Choosing the right thread milling cutter will allow the optimum production time to be achieved, with relatively high feeds and speeds without prematurely shortening the tool’s life. Extending tool life supports overall cost-effectiveness. A cutter should be selected for the hole and material to be threaded so that it does not experience excessive wear while still being able to thread at a reasonably high speed. This also affects quality. Heat buildup during threading can cause distortion, and other effects such as chatter and chip hammering can result in poor-quality threads.

Each thread milling application will take experience to set up the optimal CNC path. Listed below are some tips for thread milling:

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It is important to choose the right thread milling cutter as it will ultimately affect the cost-effectiveness of producing each part. Selecting the incorrect tool will cost a workshop in two main ways. Either the tools will wear out and need frequent replacement (causing additional cost and standing time), or the time taken for thread milling will be longer than optimum, hindering the production rate. It is also possible to damage and scrap a part if the incorrect thread milling cutter is chosen, as the threads can be cut poorly and render the part unusable.

Thread milling is a method for cutting threads into a part or workpiece, but with a tool that has a limited contact area with the workpiece. For internal threads inside holes, the thread milling cutting tool has a smaller diameter than the hole and rotates at a relatively high speed as it moves in a circular path around the circumference of the hole. In this way, thread milling is different from tapping, as a tapping tool has a diameter that matches the hole to be threaded, and is in contact with the workpiece along its entire circumference while tapping the hole.

Seco's range of threading taps covers a broad range of ISO P, M, N and K materials. Including straight-flute, spiral helix, helix point and form-type taps.

Xometry can help in choosing the right thread milling cutter through our team of in-house manufacturing specialists. Xometry can help customers source specialist materials and manufacturing processes for their parts, and our in-house specialists have the experience to advise on the best thread milling cutting tool to use for a particular material and geometry.

Combo machine with distance from the centers of 500 mm, swing over bed of 300 mm, milling head 360° rotating and adjustable height, automatic cross slide-table, single-phase motor 750 W. It can perform metric and inch threads - Bearings SKF

Bench Lathe with milling machine integrated with an indipendent motor, distance between centers of 700 mm, swing over bed of 250 mm, rotating milling head and cross slide-table automatic performing metric and inch threads Equipped with a single-phase motor 750 W for the lathe and a single-phase motor 550 W for the milling machine - Bearings SKF

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Second, the diameter of the hole may dictate whether to use an indexable tool or a full carbide tool. Indexable tools have removable carbide cutting inserts so that only the small cutting surfaces need to be replaced, rather than the whole tool. For larger diameters, using an indexable tool is usually more cost-effective than using a full carbide tool, where the whole tool needs to be replaced once it is worn.

These cutters have flutes between the cutting teeth that evacuate the chips. The flutes are straight (rather than at a helical angle). This means that each successive set of teeth engage the workpiece simultaneously, and therefore have relatively high levels of engagement with the workpiece material. This limits the speeds and feeds that can be used, and therefore this type of cutter is generally better suited to materials that are easy to machine. They tend to be the type of cutter best suited to general-purpose projects.

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The first step to thread milling is understanding the application, the material to be milled, and the geometry of the hole to be milled (depth, diameter, and desired thread dimensions). This allows the second step to be taken which is to select the best thread mill cutting tool for the job. Thirdly, the CNC programming must be undertaken. This programming is informed by calculations for the radial depth of cut and the acceptable feeds and speeds. To complete the programming, however, it is recommended to use CAD/CAM software for thread milling. Once this has been completed, it is best to set up a trial piece, to test the tool-path feeds and speeds without the risk of damaging a production part. Once the test has been completed satisfactorily, the production run can start.

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Thread milling works by using a cutting tool with a toothed profile that rotates relatively quickly. The spindle holding the tool moves in a circular path in the horizontal x-y plane, with a constant, low speed of vertical z movement. In this way, each rotating tooth of the cutting tool cuts a thread that progresses in the z direction through the hole. The thread can be completed in a single pass, or commonly in two (vertical) passes.

Metalworking machine with distance from the centers of 520 mm, swing over bed of 300 mm, milling head rotating and adjustable height, automatic cross slide-table performing metric and inch threads and two single-phase motor 750 W (one for lathe and one for the milling machine) - Bearings SKF

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Metalworking machine with distance from the centers of 750 mm, swing over bed of 300 mm, milling head rotating and adjustable height, automatic cross slide-table performing metric and inch threads and two single-phase motor 750 W (one for the lathe and one for the milling machine) - Bearings SKF

Combined Lathe-Milling Machine with distance between centers of 560 mm, maximum turning diameter of 220 mm, maximum diameter of the passing bar of 20 mm and 1.1 KW single-phase motor - It mounts SKF type bearings and supports 12 mm thick tools. On request it is possible to purchase the Italian style M turret.

Single profile thread mill cutters have a single tooth with which to cut the thread, with multiple flutes. A variation can have two rows of teeth. This type of cutter completes a thread much slower as it only cuts a single thread per revolution. However, the benefit of cutting a single thread is that much lower torque is needed on the tool, and less heat is generated. This type of thread milling cutter is therefore best suited to materials that are difficult to machine. It is the most versatile type of cutter.