The « whirling process »

How to thread tough and difficult materials

used for aeronautic parts

Mr. Rolf Hergert

DIXI Polytool - GmbH
 A lot of components are made of super alloys
- the most difficult and costly materials to be machined

Inconel 718

Nimonic
Stellite

Inconel 625 Titaniums

 Different techniques for internal threading

Thread mill Spécial thread mill

Taps - whirling tool -
 Why whirling tools are more efficient than thread mills

Classical Thread Mills

With traditionel thread mills the

Cutting edge
complete length of the cutting edge is in
the material during the work process.
1° corrector As super alloys are extremly tough and
abrasive the threading operation has
therefore to be done in several steps
2° corrector and corrections.
Why whirling tools are more efficient than thread mills

Whirling tools DIXI 1730 « down milling »

With wirling tools the length of the cutting

edge which is in the material during
Cutting edge operation is substantially shorter.
As a result the lateral forces on the tool are
lower.
This is the reason why the thread can be
made in one infeed.

It is also possible to use these tools in «up milling »

 DIXI 1730 – Tool characteristics

Reinforced shank 2 profiles with Z3 or Z6 according to the

diameter

Neck

2 times nominal Ø
Short cutting length
with 2 profiles
 DIXI 1730 – Principle
« Up milling »

-1- -2- -3 – -4 – -5-

Move to starting Machining with a tool End of the thread Move towards the Move of the tool out
position. The X- path a spiral down to centre (corrector of the workpiece.
position corresponds the bottom of the cancellation)
to the final thread thread.
diameter(corrector -The thread is machined
hold) pitch per pitch.
The tool rotates.
 Tools – machining method

with 2 profiles Z=3

The core hole drill sizes are carried out to the minimal tolerance. The tool cuts
the complete profile of the thread.
 Machining examples

Thread milling : M 5 x 0.80

Depth : 10 mm
Material : Stainless steel
X4CrNiMo16 5 1, 1300 MPa

Whirling tool : DIXI 1730 SP TiAlN

Ø: 3.90 mm
Vc : 50 m/min.
n: 5’000 rpm.
fz 0.015 mm/tooth
Vf : 225 mm/min
Number of threads /: 600 threads M5

With a special DIXI 1730 TiAlN coated whirling tool, tool life is 25 workpieces: 600 threads
with one infeed.
The tool life with a standard thread mill used to be 20 threads (with 3 infeeds).
 Machining examples

Thread milling : M 4 x 0.70

Depth : 8 mm
Material : Nimonic (nickel alloy)

Whirling tool : DIXI 1730 standard (Z=4)

Ø: 3.20 mm
Vc : 50 m/min.
n: 5000 rpm.
fz 0.007 mm/tooth
Vf : 140 mm/min
100 threads M4
Number of threads :

In this case we had to machine 50 threads M4 in Nimonic. This was not feasible with a tap.
Result : we obtained 100 threads without any problem.
 Machining examples

Thread milling : 10 – 32 UNF EG 8 mm

Depth : 8.20
Material : Inconel 718

Whirling tool : DIXI 1730 Ø4.50 x 1.587 x

Ø6 x 57 – Z=3
Ø: 4.50 mm
Vc : 30 m/min.
n: 2’200 rpm.
fz 0.015 mm/tooth
Vf : 100 mm/min
Number of threads : 50 threads

The objective was to obtain the highest quantity of holes.

 Machining examples

Thread milling : M 8 x 1.25

Depth : 18 mm
Material : Staballoy AG17 (Heat resisting stainless
steel - 17% Cr, 18% Mn, 32 HRC)

Whirling tool : DIXI 1730 M8 x 1.25 without coating

Ø: 6.5 mm
Vc : 15 m/min.
n: 734 rpm.
fz : 0.03 mm/tooth
Vf : 132 mm/min
Number of threads : 1 Threads « up milling » / 70 Thread
« down milling »

A primary test has been made by the customer. The objective was to machine a thread in less than 3
minutes and to prove that a DIXI 1730 could be used in that kind of material. Moreover, the test revealed
that working as down milling in that material gives much better results than as up milling.
 Machining examples

Thread milling : M 4 x 0.70

Depth : 6 mm
Material : Tool steel 1.2344 - 56HRC

Whirling tool : DIXI 1730 M4 x 0.70

Ø: 3.20 mm
Vc : 23 m/min.
n: 2’250 rpm.
fz 0.0035 mm/dent
Vf : 23 mm/min
Number of threads : 55 Threads « down milling » / 65 Threads
« up milling »

For this customer we proved that it is possible to machine such tough

material with this threading method.
 Some observations – Whirling tools DIXI 1730

1- These tools are an excellent alternative to conventional thread mills or taps for internal threading. They
are especially suitable for very tough materials as titaniums, heat resisting stainless steels, special alloys
(Nimonic, Inconel……).

2 - These tools, with a longer neck, are efficient for relatively deep threads (around 2 to 4 times Ø to thread)

3 - Less problems with chips (short chips). It is not necessary to stop the machining process for chip
evacuation. In terms of productivity, the thread whirling process is more profitable than the tapping process.

4 - Higher precision in comparison to traditional tapping process. The thread is straight and tends much
less to be conical. Further it is possible to adjust the nominal diameter according to the required tolerances
(6H, 5H).

5 – As it is a milling process excellent surface finish can be obtained. It is possible to produce without burrs

6 -The thread can be machined very close to the bottom of blind holes.
DIXI 1730 M0.80 à M10 – ISO 60° (2xØnom.)
DIXI 1731 M0.80 à M10 – ISO 60° (3xØnom.)

3 x nominal diameter
3 x le Ø nominal
DIXI 1735 UN 60° (2xØnom.)
DIXI 1736 UN 60° (3xØnom.)

3 x nominal diameter
3 x le Ø nominal
DIXI 1739 S0.30 à S1.40 selon norme NIHS 06
Whirling tools DIXI 1730

On request we can manufacture whirling tools

according to any special profiles.