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Thread milling can present a machinist many challenges. While thread mills are capable of producing threads with relative ease, there are a lot of considerations that machinists must make prior to beginning the job in order to gain consistent results. To conceptualize these features and choose the right tool, machinists must first understand basic thread milling applications.

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The primary function of a thread is to form a coupling between two different mechanisms. Think of the cap on your water bottle. The cap couples with the top of the bottle in order to create a water tight seal. This coupling can transmit motion and help to obtain mechanical advantages.  Below are some important terms to know in order to understand threads.

Root – That surface of the thread which joins the flanks of adjacent thread forms and is immediately adjacent to the cylinder or cone from which the thread projects.

Flank – The flank of a thread is either surface connecting the crest with the root. The flank surface intersection with an axial plane is theoretically a straight line.

Crest – This is that surface of a thread which joins the flanks of the thread and is farthest from the cylinder or cone from which the thread projects.

Pitch – The pitch of a thread having uniform spacing is the distance measured parallelwith its axis between corresponding points on adjacent thread forms in the same axial plane and on the same side of the axis. Pitch is equal to the lead divided by the number of thread starts.

Major Diameter – On a straight thread the major diameter is that of the major cylinder.On a taper thread the major diameter at a given position on the thread axis is that of the major cone at that position.

Minor Diameter – On a straight thread the minor diameter is that of the minor cylinder. On a taper thread the minor diameter at a given position on the thread axis is that of the minor cone at that position.

Helix Angle – On a straight thread, the helix angle is the angle made by the helix of the thread and its relation to the thread axis. On a taper thread, the helix angle at a given axial position is the angle made by the conical spiral of the thread with the axis of the thread. The helix angle is the complement of the lead angle.

Depth of Thread Engagement – The depth (or height) of thread engagement between two coaxially assembled mating threads is the radial distance by which their thread forms overlap each other.

External Thread – A thread on a cylindrical or conical external surface.

Internal Thread – A thread on a cylindrical or conical internal surface.

Class of Thread – The class of a thread is an alphanumerical designation to indicate the standard grade of tolerance and allowance specified for a thread.

Source: Machinery’s Handbook 29th Edition

## Types of Threads & Their Common Applications:

ISO Metric, American UN: This thread type is used for general purposes, including for screws. Features a 60° thread form.

British Standard, Whitworth: This thread form includes a 55° thread form and is often used when a water tight seal is needed.

NPT: Meaning National Pipe Tapered, this thread, like the Whitworth Thread Form, is also internal. See the above video for an example of an NPT thread.

UNJ, MJ: This type of thread is often used in the Aerospace industry and features a radius at the root of the thread.

ACME, Trapezoidal: ACME threads are screw thread profiles that feature a trapezoidal outline, and are most commonly used for power screws.

Buttress Threads: Designed for applications that involve particularly high stresses along the thread axis in one direction. The thread angle on these threads is 45° with a perpendicular flat on the front or “load resisting face.”

Threads must hold certain tolerances, known as thread designations, in order to join together properly. International standards have been developed for threads. Below are examples of Metric, UN, and Acme Thread Designations. It is important to note that not all designations will be uniform, as some tolerances will include diameter tolerances while others will include class of fit.

M12 x 1.75 – 4h – LH

In this scenario, “M” designates a Metric Thread Designation, 12 refers to the Nominal Diameter, 1.75 is the pitch, 4h is the “Class of Fit,” and “LH” means “Left-Hand.”

¾ 10 UNC 2A LH

For this UN Thread Designation, ¾ refers to the thread’s major diameter, where 10 references the number of threads per inch. UNC stands for the thread series; and 2A means the class of thread. The “A” is used to designate external threads, while “B” is for internal threads. For these style threads, there are 6 other classes of fit; 1B, 2B, and 3B for internal threads; and 1A, 2A, and 3A for external threads.

A 1 025 20-X

For this ACME Thread Designation, A refers to “Acme,” while 1 is the number of thread starts. The basic major diameter is called out by 025 (Meaning 1/4”) while 20 is the callout for number of threads per inch. X is a placeholder for a number designating the purpose of the thread. A number 1 means it’s for a screw, while 2 means it’s for a nut, and 3 refers to a flange.

Threads are measured using go and no-go gauges. These gauges are inspection tools used to ensure the that the thread is the right size and has the correct pitch. The go gauge ensures the pitch diameter falls below the maximum requirement, while the no-go gauge verifies that the pitch diameter is above the minimum requirement. These gauges must be used carefully to ensure that the threads are not damaged.

Thread milling is the interpolation of a thread mill around or inside a workpiece to create a desired thread form on a workpiece. Multiple radial passes during milling offer good chip control. Remember, though, that thread milling needs to be performed on machines capable of moving on the X, Y, and Z axis simultaneously.

## 5 Tips for Successful Thread Milling Operations:

### 1.  Opt for a Quality Tooling Manufacturer

There is no substitute for adequate tooling. To avoid tool failure and machining mishaps, opt for a quality manufacturer for High Performance Drills for your starter holes, as well as for your thread milling solutions. Harvey Tool fully stocks several types of threadmills, including Single Form, Tri-Form, and Multi-Form Thread Milling Cutters. In addition, the 60° Double Angle Shank Cutter can be used for thread milling.

### 2. Select a Proper Cutter Diameter

Choose only a cutter diameter as large as you need. A smaller cutter diameter will help achieve higher quality threads.

### 3. Ensure You’re Comfortable with Your Tool Path

Your chosen tool path will determine left hand or right hand threads.

Right-hand internal thread milling is where cutters move counterclockwise in an upwards direction to ensure that climb milling is achieved.

Left-hand internal thread milling a left-hand thread follows in the opposite direction, from top to bottom, also in a counterclockwise path to ensure that climb milling is achieved.

### 4. Assess Number of Radial Passes Needed

In difficult applications, using more passes may be necessary to achieve desired quality. Separating the thread milling operation into several radial passes achieves a finer quality of thread and improves security against tool breakage in difficult materials. In addition, thread milling with several radial passes also improves thread tolerance due to reduced tool deflection. This gives greater security in long overhangs and unstable conditions.

### 5. Review Chip Evacuation Strategy

Are you taking the necessary steps to avoid chip recutting due to inefficient chip evacuation? If not, your thread may fall out of tolerance. Opt for a strategy that includes coolant, lubricant, and tool retractions.

## In Summary

Just looking at a threading tool can be confusing – it is sometimes hard to conceptualize how these tools are able to get the job done. But with proper understanding of call, methods, and best practices, machinists can feel confident when beginning their operation.

## Experience the Benefits of Staggered Tooth Keyseats

Keyseat Cutters, also known as Woodruff Cutters, Keyway Cutters, and T-Slot Cutters, are commonly used in machine shops. Many machinists opt to use this tool to put a slot on the side of a part in an efficient manner, rather than rotating the workpiece and using a traditional end mill. A Staggered Tooth Keyseat Cutter has alternating right-hand and left hand shear flutes and is right-hand cut, whereas a traditional keyseat cutter has all straight flutes and is right-hand cut. Simply, the unique geometry of a Staggered Tooth Keyseat Cutter gives the tool its own set of advantages including the ability to index within the slot, increase feed rates, and achieve better part finish.

## Three Key Benefits

### Indexing

The alternating right-and-left-hand flutes of a Harvey Tool Staggered Tooth Keyseat Cutters are relieved on both sides of its head, meaning that it allows for both end cutting and back cutting. This adds to the versatility of the staggered tooth keyseat cutter, where one singular tool can be indexed axially within a slot to expand the slot to a specific uncommon dimension. This can save space in a machinist’s magazine and reduce machine time by eliminating the need to swap to a new tool.

### Increased Feed Rates

Due to the unique geometry of a Staggered Tooth Keyseat Cutter, chips evacuate efficiently and at a faster rate than that of a Straight Flute Keyseat Cutter. The unique flutes of Staggered Tooth Keyseat Cutters are a combination of right-and-left-hand shear flutes, but both types are right-hand cutting. This results in the tool’s teeth alternating between upcut and downcut. Chip packing and chip recutting is less of a concern with running this tool, and results in increased chip loads compared to that of a standard keyseat with the same number of flutes. Because of this, the tool can account for chiploads of about 10% higher than the norm, resulting in heightened feed rates and shorter cycle times overall.

### Better Part Finish

Staggered Tooth Keyseat Cutters have “teeth”, or flutes, that are ground at an angle creating a shear flute geometry. This geometry minimizes chip recutting, chip dragging and reduces the force needed to cut into the material. Chip recutting and dragging are minimized because chips are evacuated out of the top and bottom of the head on the side of the cutter that is not engaged in the material. Shear flutes also reduce vibrations that can lead to chatter and poor finish. By minimizing cutting forces, vibration, and chatter, a machinist can expect a better part finish.

Image courtesy of @edc_machining

## Staggered Tooth Keyseat Cutter Diverse Product Offering

On top of the higher performance one will experience when using the Stagger Tooth Keyseats, there are also multiple options available with various combinations to suit multiple machining needs. This style is offered in a square and corner radius profile which helps if a fillet or sharp corner is needed. There are also multiple cutter diameters ranging from 1/8” to 5/8”. The increased diameter comes with an increase of radial depth of cut, allowing deeper slots to be achievable. Within the most popular cutter diameters, ¼”, 3/8”, and ½” there are also deep slotting options with even greater radial depth of cuts for increased slot depths. On top of the diameters and radii, there are also multiple cutter widths to choose from to create different slots in one go. Finally, an uncoated and AlTiN coatings are available to further increase tool life and performance depending on the material that is being cut.

## Opt for a Smoother Operation

A Staggered Tooth Keyseat Cutter adds versatility to a tool magazine. It can be indexed axially to expand slots to make multiple widths, allowing machinists to progress operations in a more efficient manner where tool changes are not required. Further, this tool will help to reduce harmonics and chatter, as well as minimize recutting. This works to create a smoother operation with less force on the cutter, resulting in a better finish compared to a Standard Keyseat Cutter.

For more information on Harvey Tool Staggered Tooth Keyseat Cutters and its applications, visit Harvey Tool’s Keyseat Cutter page.

## How to Avoid Composite Delamination with Compression Cutters

Composites are a group of materials made up of at least two unique constituents that, when combined, produce mechanical and physical properties favorable for a wide array of applications. These materials usually contain a binding ingredient, known as a matrix, filled with particles or fibers called reinforcements. Composites have become increasingly popular in the Aerospace, Automotive, and Sporting Goods industries because they can combine the strength of metal, the light weight of plastic, and the rigidity of ceramics.

Unfortunately, composite materials present some unique challenges to machinists. Many composites are very abrasive and can severely reduce tool life, while others can melt and burn if heat generation is not properly controlled. Even if these potential problems are avoided, the wrong tool can leave the part with other quality issues, including delamination.

While composites such as G10 and FR4 are considered “fibrous”, composites can also be “layered,” such as laminated sheets of PEEK and aluminum. Layered composites are vulnerable to delamination, when the layers of the material are separated by a tool’s cutting forces. This yields less structurally sound parts, defeating the purpose of the combined material properties in the first place. In many cases, a single delaminated hole can result in a scrapped part.

Using Compression Cutters in Composite Materials

Composite materials are generally machined with standard metal cutting end mills, which generate exclusively up or down cutting forces, depending on if they have right or left hand flute geometry. These uni-directional forces cause delamination (Figure 1).

Conversely, compression cutters are designed with both up and down-cut flutes. The top portion of the length of cut, closest to the shank, has a left hand spiral, forcing chips down. The bottom portion of the length of cut, closest to the end, has a right hand spiral, forcing chips up. When cutting, the opposing flute directions generate counteracting up-cut and down-cut forces. The opposing cutting forces stabilize the material removal, which compresses the composite layers, combatting delamination on the top and bottom of a workpiece (Figure 2).

Since compression cutters do not pull up or press down on a workpiece, they leave an excellent finish on layered composites and lightweight materials like plywood. It is important to note, however, that compression cutters are suited specifically to profiling, as the benefits of the up and down-cut geometry are not utilized in slotting or plunging operations.

Something as simple as choosing a tool suited to a specific composite material can have significant effects on the quality of the final part. Consider utilizing tools optimized for different composites and operations or learn how to select the right drill for composite holemaking.