Thread

Milling
Handbook
Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About Thread Milling (general) ............... . . . . . . . . . . . . . . . . . . 4
Vargus Thread Milling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Advantages of the system and field of application . . . . . . . . . . . . . . . . . . . 5
Climb and conventional milling methods . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Infeed method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
External/Internal RH. LH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Coarse pitch threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fine pitch threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

How to find the correct toolholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tooling recommendation for given internal thread specification . . . . . . . . . . 10
Minimum bore diameters for thread milling . . . . . . . . . . . . . . . . . . . . . . . . . 14
TM Gen software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Toolholder styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Insert styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
The right insert for the job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

CNC program .. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Program check . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Conical threads . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Speed and feed . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Basic formulas for cutting conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Thread Milling insert standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Thread dimensions of BSP - B.S.2779: 1956 medium class . . . . . . . . . . . . . 23
Thread terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Specials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Manual CNC programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Classic questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Introduction
The most ingenious invention of the last millenium was actually the screw.
The industrial production of the screw only began in the 1850’s. It was invented by Vitold
Reabchinsky.

In the distant past, the tools were activated by muscle power and were very similar to
today’s tools. The ancient hammers looked like their modern counterparts and so did the
drills, planes, saws and files. The nails already served mankind in ancient times, mainly
by joining parts together (mostly from wood). For that reason, man needed the hammer.

The screw, however, is a relatively modern invention. The principle of the screw had already
been invented in the third century B.C. by Archimedes and screw-shaped fixtures were
used in ancient times for water pumping or compression, for example, for squeezing olives
or for torture instruments.

But screws for joining parts appeared only in the 16th century.

The early screws had a screwing head with one slot and the screwdriver only became
popular with carpenters after 1800. Back then, screws were regarded as expensive luxury
articles. The reason: production took place manually. Industrial production of the screw
started only after 1850.

Cheap screws are actually a modern creation. Not only screws for wood serve modern
civilization, but also screws designed for other materials, for example, steel that is used
in modern building.

Steel screws used in the building industry obtain their strength from the friction between
the screw and the nut. The screw presses the two workpieces together, and the more the
screw is fastened – the more the pressure is increased.

This invention enabled the building of ships and houses, cupboards and tables, and also
various domestic appliances.

The very accurate screw also enabled the building of amazingly accurate measuring
instruments such as microscopes with an accuracy of up to a hundredth of a millimeter
and transforming systems for telescopes that make accurate tracing of the
planets possible.

Without screws the industrial revolution that

rushed in the modern era would just
not have taken place!

Vargus 3
About Thread Milling (general)
Thread Milling is a method for producing a thread by a milling operation.

The most common way to produce a thread is still by tapping and turning but today
we see more and more milling and this is because CNC milling machines with three
simultaneous axes are very popular. These can now be found in every small workshop.

To perform a Thread Milling operation, a helical interpolation movement is required.

Helical interpolation is a CNC function producing tool movement along a helical path.
This helical motion combines circular movement in one plane (x,y coordinate) with a
simultaneous linear motion in a plane perpendicular to the first (z coordinate).

A
O
X

Vargus Thread Milling system

Vargus thread milling tools are based on indexable multitooth inserts. The cutter rotates
around itself at high speed and at the same time moves along the helical path. All the
teeth are machined simultaneously so every tooth creates one pitch. At the end of the
operation all pitches are combined into one complete thread and that by one pass only.
This result is achieved with Vardex high accuracy inserts and use of a CNC milling
machine.

p
α

α: helix angle
D: external diameter
p: pitch

4 Vargus
Advantages of the system
and field of application
• Enables machining of large work pieces which cannot be easily mounted on a lathe
• Non-rotatable and non-symmetrical parts easily machined
• Complete operation in one clamping
• Threading of large diameters requires less power than threading by taps
• No upper limits to bore diameter
• Chips are short
• Blind holes without a thread relief groove can be machined
• Thread relief groove unnecessary
• One holder used for both internal and external threads
• One tool used for both right hand and left hand thread
• Tooling inventory can be reduced to a minimum as small range of tooling covers a wide
range of thread profiles
• Interchangeable inserts
• Suitable for machining of hard materials
• Threads have a high surface finish
• Allows for correction of tool diameter and length
• Interrupted cuts easily machined
• One tool for a wide range of materials
• A better thread quality in soft materials where taps normally tear the material
• Short machining time due to high cutting speed and rapid feed rates
• Small cutting forces allow machining of parts with thin walls

Climb and conventional

There are two methods for the milling
operation - climb milling and conventional
milling.

For many years it was common practice

to mill against the direction of the feed due Climb Conventional
to the absence of backlash eliminating
devices and the use of high speed steel cutters. This method is called conventional milling.

In conventional milling, friction and rubbing occur as the insert enters into the cut, resulting in chip
welding and heat dissipation into the insert and workpiece.

Climb milling, the second method, is now generally recommended. The insert enters the workpiece
material with some chip load and proceeds to produce a chip that thins as it progresses towards
the finish. This reduces the heat by dissipating it into the chip.

Based on the above, Vargus recommends using the climb operation which will give you:
• reduced load from the cutting corner
• better tool life
• better surface finish

Vargus 5
Infeed method
How does the thread milling cutter enter and exit the workpiece?
Tangential arc approach - The best method ! ! !
With this method, the tool enters and exits the workpiece smoothly. No marks are left on
the workpiece and there is no vibration, even with harder materials.
Although it requires slightly more complex programming than the radial approach (see
below), this is the method recommended for machining the highest quality threads.
Internal Thread External Thread

Threading Tool
2
Workpiece

Workpiece
1 3 1
D1

D2
6 4
D1 4 6

1-2: rapid approach

2-3: tool entry along tangential arc, with simultaneous feed along z-axis
3-4: helical movement during one full orbit (3600)
4-5: tool exit along tangential arc, with continuing feed along z-axis
5-6: rapid return

Radial approach
This is the simplest method. There are two characteristics worth noting about the radial
approach:
• a small vertical mark may be left at the entry (and exit) point. This is of no significance
to the thread itself.
• when using this method with very hard materials, the tool may have a tendency to
vibrate as it approaches the full cutting depth.
Note: Radial feed during entry to the full profile depth should only be 1/3 of the subsequent
circular feed!...

Internal Thread External Thread

Threading Tool
Threading Tool

Workpiece
Workpiece

2 1
D1

D2

1 2
D1

D2

4 3 3 4

1-2: radial entry

2-3: helical movement during one full orbit (3600)
3-4: radial exit

6 Vargus
External/Internal RH. LH.
Vardex TM tools can produce external and internal,
RH or LH threads depending only on the tool path which is programmed.
The following drgs. will clarify it very easily.

For conical applications such as NPT or BSPT, left hand tools can be used.
In such a case the tool must be moved in the opposite direction.

Thread Milling methods

External Internal
Right Hand Right Hand
Thread - Thread -
Conventional Conventional
Milling Milling

Left Hand Left Hand

Thread - Thread -
Conventional Conventional
Milling Milling

Right Hand Right Hand

Thread - Thread -
Climb Climb
Milling Milling

Left Hand Left Hand

Thread - Thread -
Climb Climb
Milling Milling

Vargus 7
Coarse pitch threads
Internal

Coarse pitch threads are a combination of small thread dia. and

relatively large pitches. The thread milling operation is based on
three-axes simultaneous movement so the profile shape on the
workpiece is not a copy of the insert profile. In other words the
profile is generated and not copied which is contrary to the
thread turning operation.
This fact causes a profile distortion, especially when machining
coarse pitch internal threads.
The profile distortion depends on four main parameters:
• Thread dia. • Tool cut. dia. • Thread pitch • Profile angle

For internal threads, as a general rule, when the ratio between cutting tool dia. (D2) and
the thread dia. (minor dia.) is below 70% the profile distortion is neglected.
Above this ratio, however, the standard inserts will not give the correct profile.
We in Vargus have developed tools which correct the profile distortion and by that give
a solution for the coarse pitch threads.
The inserts are identified in the catalogue by the no. 028/... and the toolholders by the
number 124/... In our new catalog, tables can be found which indicate exactly which tools
to use for every standard thread.
E.g.: For M24x3.0 (coarse pitch thread) the right toolholder is TMC 25-4 124/002 + insert
4I3.0ISOTM 028/007.
But for M42x3.0 (non-coarse pitch thread) the right tool is TMC 25-5 holder +
5I3.0ISOTM2 insert.

External

In general, for external thread (such as ISO, UN, W) the profile distortion is neglected.
For small profile angle such as ACME (29 deg.) and TRAPEZ (30 deg.) every case should
be examined separately.

Fine pitch threads

Fine pitch threads are threads with small pitches.
It is dificult to produce multitooth inserts for small pitches
because of the small radius between the teeth.
Vargus developed inserts where every second tooth was
dropped to enlarge the radius between the teeth.

Important!

• All the fine pitch inserts are partial profile type (as a result of the enlarged radius).
• Two orbits are required to complete the thread because we dropped every second tooth.

8 Vargus
 How to find the correct toolholder?
In general, Vargus recommends using the largest possible toolholder with the shortest
overhang and with max. possible cutting edges. The inserts selection will be determined
according to the toolholder size and the thread type.
For that, and in order to avoid profile distortion, we have three methods:

1 Largest tool table method (p. 10-13)

These new and friendly tables located at the begining of our catalogue are your guide
and indicate the correct tool to use for every standard thread - coarse pitch and non-
coarse pitch threads.
The recommended toolholder is the largest (largest cutting dia.) for a given thread
application, smaller or equal dia. can also be used.
E.g.: For M25XI.5 (no need for bore dia. calculation) the largest offered tool is TMC 20-3
which means that every tool that has a smaller cutting dia. e.g. TMC 16-3 can
also give a suitable solution.
We recommend using the largest tool tables as they give you a quick answer on the right
tool for every std. thread covered by Vardex tools.

2 Minimum bore diameters for thread milling table (p. 14)

On page 14 of this handbook you will find a large table which gives you the minimum bore
diameter for any combination of thread pitch and toolholder.
Every dia. below that should be treated as a coarse pitch thread.
For coarse pitch threads, please see the insert section in our catalogue.
E.g.: M25x1.5 (bore diameter 23.37, should be calculated).
When you use TMC 20-3 holder, the table will show a min. bore dia. of 23.0, hence
the tool is suitable.
For BTMWC 25-3B holder, however, the min. bore dia. is 25.0 so the tool is not
suitable.

3 TM Gen software (p. 15)

This perfect software

developed by Vardex engineers
gives you the right tools
(all suitable tools)
for each application
and
also automatically
the CNC program.

Vargus 9
Tooling recommendation for given
internal thread specification (Largest tool table method)

ISO
Pitch Nominal Dia. Holder Insert L 1 -Toolholder D 2 -Tool h min. - Thread
mm mm overhang cutting dia.* Profile depth

0.75 10 TMMC12-6.0 6.0I0.75ISOTM...028/001 12.0 9.0

0.43
11 TMMC12-6.0 6.0I0.75ISOTM... 12.0 9.0
1.0 12-14 TMMC12-6.0 6.0I1.0ISOTM.. 12.0 9.0
15-18 TMMC12-2 2I1.0ISOTM2... 12.0 11.5
20 TMC16-3 3I1.0ISOTM2... 22.0 17.0
22 BTMC20-3B 3BI1.0ISOTM2... 29.0 19.0 0.58

24 TMC20-3 3I1.0ISOTM2... 43.0 20.0

25-28 TMLC25-3 3I1.0ISOTM2... 25.0 22.0
30 TM2C25-3 3I1.0ISOTM2... 43.0 26.0
1.25 12 TMMC12-6.0 6.0I1.25ISOTM...028/002 12.0 9.0
0.72
14 TMMC12-6.0 6.0I1.25ISOTM... 12.0 9.0
1.5 14-15 TMMC12-6.0 6.0I1.5ISOTM... 12.0 9.0
16-20 TMC12-2 2I1.5ISOTM2... 12.0 11.5
22 TMC16-3 3I1.5ISOTM2... 22.0 17.0
24 BTMC20-3B 3BI1.5ISOTM2... 29.0 19.0
25-26 TMC20-3 3I1.5ISOTM2... 43.0 20.0
27-30 TMLC25-3 3I1.5ISOTM2... 25.0 22.0
0.87
32-33 TM2C25-3 3I1.5ISOTM2... 43.0 26.0
35-42 TMC25-5 5I1.5ISOTM2... 52.0 30.0
45 TMC32-5 5I1.5ISOTM2... 58.0 37.0
48-55 TM2C32-5 5I1.5ISOTM2... 45.0 42.0
56-68 TMSH-D50-22-3 3I1.5ISOTM2... 50.0
70-80 TMSH-D63-22-5 5I1.5ISOTM2... 63.0
1.75 12 TMMC20-6.0 124/003 6.0I1.75ISOTM...028/003 15.0 9.0 1.01
2.0 14-20 TMC12-2 2I2.0ISOTM...028/004 12.0 11.5
22 TMNC16-3 3I2.0ISOTM2... 22.0 15.5
24 TMC16-3 3I2.0ISOTM2... 22.0 17.0
25 BTMC20-3B 3BI2.0ISOTM2... 29.0 19.0
27 TMC20-3 3I2.0ISOTM2... 43.0 20.0
28-32 TMLC25-3 3I2.0ISOTM2... 25.0 22.0
33-36 TM2C25-3 3I2.0ISOTM2... 43.0 26.0
1.15
39-42 TMC25-5 5I2.0ISOTM2... 52.0 30.0
45-48 TMC32-5 5I2.0ISOTM2... 58.0 37.0
50-56 TM2C32-5 5I2.0ISOTM2... 45.0 42.0
58-68 TMSH-D50-22-3 3I2.0ISOTM2... 50.0
70-85 TMSH-D63-22-5 5I2.0ISOTM2... 63.0
90-105 TMSH-D80-27-5 5I2.0ISOTM2... 80.0
110-130 TMSH-D100-32-5 5I2.0ISOTM2... 100.0
135-150 TMSH-D125-40-5 5I2.0ISOTM2... 125.0
2.5 20 TMC16-3 124/001 3I2.5ISOTM...028/005 20.5 15.50
1.44
22 TMC25-4 124/002 4I2.5ISOTM...028/006 30.0 18.0

10 Vargus
Tooling recommendation for given
internal thread specification (Largest tool table method)

ISO
Pitch Nominal Dia. L 1 -Toolholder D 2 -Tool h min. - Thread
Holder Insert
mm mm overhang cutting dia.* Profile depth
3.0 24-33 TMC25-4 124/002 4I3.0ISOTM...028/007 30.0 18.0
36-40 TMC25-5 5I3.0ISOTM...028/009 52.0 30.0
42-48 TMC25-5 5I3.0ISOTM2... 52.0 30.0
50-52 TMC32-5 5I3.0ISOTM2... 58.0 37.0
1.73
55-72 TM2C32-5 5I3.0ISOTM2... 45.0 42.0
75-90 TMSH-D63-22-5 5I3.0ISOTM2... 63.0
95-110 TMSH-D80-27-5 5I3.0ISOTM2... 80.0
115-135 TMSH-D100-32-5 5I3.0ISOTM2... 100.0
140-250 TMSH-D125-40-5 5I3.0ISOTM2... 125.0
3.5 30-33 TMC25-5 124/004 5I3.5ISOTM...028/008 40.0 25.0 2.02
4.0 36-42 TMC25-5 5I4.0ISOTM...028/010 52.0 30.0
45-52 TMC25-5 5I4.0ISOTM2... 52.0 30.0
55 TMC32-6B 6BI4.0ISOTM2... 55.0 35.0
56-58 TMC32-5 5I4.0ISOTM2... 58.0 37.0
60-65 TMC40-6B 6BI4.0ISOTM2... 65.0 46.0 2.31
68-76 TM2C40-6B 6BI4.0ISOTM2... 65.0 52.0
80-90 TMSH-D63-22-6B 6BI4.0ISOTM2... 63.0
95-110 TMSH-D80-27-6B 6BI4.0ISOTM2... 80.0
115-135 TMSH-D100-32-6B 6BI4.0ISOTM2... 100.0
140-300 TMSH-D125-40-6B 6BI4.0ISOTM2... 125.0
4.5 42-45 TMC25-5 5I4.5ISOTM...028/011 52.0 30.0 2.60
5.0 48-52 TMC25-5 5I5.0ISOTM...028/075 52.0 30.0
2.89
TMC32-6B 6BI5.0ISOTM2... 55.0 35.0
5.5 56 TMC32-6B 6BI5.5ISOTM2... 55.0 35.0
3.17
60 TMC40-6B 6BI5.5ISOTM2... 65.0 46.0
6.0 64-68 TMC40-6B 6BI6.0ISOTM2... 65.0 46.0
70-80 TM2C40-6B 6BI6.0ISOTM2... 65.0 52.0
85-100 TMSH-D63-22-6B 6BI6.0ISOTM2... 63.0 3.46
105-120 TMSH-D80-27-6B 6BI6.0ISOTM2... 80.0
125-145 TMSH-D100-32-6B 6BI6.0ISOTM2... 100.0
150-300 TMSH-D125-40-6B 6BI6.0ISOTM2... 125.0

Please note: those are just a few of the tables. You will find the complete range in our
catalogue.

Vargus 11
Tooling recommendation for given
internal thread specification (Largest tool table method)
UN
Pitch Nominal Dia. L 1 -Toolholder D 2 -Tool h min. - Thread
Holder Insert
tpi inch overhang cutting dia.* Profile depth

32 7/16-1/2 TMMC12-6.0 6.0I32UNTM... 12.0 9.0

9/16-11/16 TMC12-2 2I32UNTM2... 12.0 11.5
17.0 0.46
3/4-13/16 TMC16-3 3I32UNTM2... 22.0
7/8-15/16 TMC20-3 3I32UNTM2... 43.0 20.0
1 TMLC25-3 3I32UNTM2... 25.0 22.0
28 7/16-1/2 TMMC12-6.0 6.0I28UNTM... 12.0 9.0
9/16-3/4 TMC12-2 2I28UNTM2... 12.0 11.5
13/16-7/8 TMC16-3 3I28UNTM2... 22.0 17.0
0.52
15/16 TMC20-3 3I28UNTM2... 43.0 20.0
1-1 1/8 TMLC25-3 3I28UNTM2... 25.0 22.0
1 3/16-1 1/2 TM2C25-3 3I28UNTM2... 43.0 26.0
24 9/16-11/16 TMC12-2 2I24UNTM2... 12.0 11.5 0.61

20 7/16 TMMC12-6.0 6.0I20UNTM...028/012 12.0 9.0

1/2-9/16 TMMC12-6.0 6.0I20UNTM... 12.0 9.0
5/8-13/16 TMC12-2 2I20UNTM2... 12.0 11.5
7/8 TMC16-3 3I20UNTM2... 22.0 17.0
15/16-1 TMC20-3 3I20UNTM2... 43.0 20.0
1 1/16-1 1/8 TMLC25-3 3I20UNTM2... 25.0 22.0
0.73
1 3/16-1 5/16 TM2C25-3 3I20UNTM2... 43.0 26.0
1 3/8-1 5/8 TMC25-5 5I20UNTM2... 52.0 30.0
1 11/16-1 13/16 TMC32-5 5I20UNTM2... 58.0 37.0
1 7/8-2 1/8 TM2C32-5 5I20UNTM2... 45.0 42.0
2 1/4-2 5/8 TMSH-D50-22-3 3I20UNTM2... 50.0
2 3/4-3 TMSH-D63-22-5 5I20UNTM2... 63.0
18 9/16 TMC12-2 2I18UNTM...028/017 12.0 11.5
5/8 TMC12-2 2I18UNTM2... 12.0 11.5
1 1/16-1 3/16 TMLC25-3 3I18UNTM2... 25.0 22.0
0.81
1 1/4-1 3/8 TM2C25-3 3I18UNTM2... 43.0 26.0
1 7/16-1 5/8 TMC25-5 5I18UNTM2... 52.0 30.0
1 11/16 TMC32-5 5I18UNTM2... 58.0 37.0
16 7/16-5/8 TMMC12-6.0 6.0I16UNTM...028/014 12.0 9.0
11/16-13/16 TMC12-2 2I16UNTM2... 12.0 11.5
7/8-15/16 TMC16-3 3I16UNTM2... 22.0 17.0
1 TMC20-3 3I16UNTM2... 43.0 20.0
1 1/16-1 3/16 TMLC25-3 3I16UNTM2... 25.0 22.0
1 1/4-1 3/8 TM2C25-3 3I16UNTM2... 43.0 26.0 0.92
1 7/16-1 5/8 TMC25-5 5I16UNTM2... 52.0 30.0
1 11/16-1 7/8 TMC32-5 5I16UNTM2... 58.0 37.0
1 15/16-2 3/16 TM2C32-5 5I16UNTM2... 45.0 42.0
2 1/4-2 5/8 TMSH-D50-22-3 3I16UNTM2... 50.0
2 3/4-3 3/8 TMSH-D63-22-5 5I16UN TM2... 63.0

12 Vargus
Tooling recommendation for given
internal thread specification (Largest tool table method)

UN
Pitch Nominal Dia. L 1 -Toolholder D 2 -Tool h min. - Thread
Holder Insert
tpi inch overhang cutting dia.* Profile depth
16 3 1/2-4 TMSH-D80-27-5 5I16UNTM2... 80.0 0.92
14 7/16 TMC20-6.0 124/003 6.0I14UNTM...028/013 15.0 9.0
1.05
7/8 TMC12-2 2I14UNTM2... 12.0 11.5
13 1/2 TMC20-2 124/005 2I13UNTM...028/015 15.5 10.0 1.13
12 9/16-11/16 TMC20-2 124/005 2I12UNTM...028/016 15.5 10.0
3/4 TMNC16-3 3I12UNTM...028/020 22.0 15.5
13/16 TMC16-3 3I12UNTM...028/020 22.0 17.0
7/8 TMNC16-3 3I12UNTM2... 22.0 15.5
15/16 TMC16-3 3I12UNTM2... 22.0 17.0
1 BTMC20-3B 3BI12UNTM2... 29.0 19.0
1 1/16 TMC20-3 3 I12UNTM2... 43.0 20.0
1 1/8-1 1/4 TMLC25-3 3I12UNTM2... 25.0 22.0 1.22
1 5/16-1 7/16 TM2C25-3 3 I12UNTM2... 43.0 26.0
1 1/2-1 11/16 TMC25-5 5I12UNTM2... 52.0 30.0
1 3/4-1 15/16 TMC32-5 5I12UNTM2... 58.0 37.0
2-2 1/4 TM2C32-5 5I12UNTM2... 45.0 42.0
2 3/8-2 3/4 TMSH-D50-22-3 3I12UNTM2... 50.0
2 7/8-3 3/8 TMSH-D63-22-5 5I12UNTM2... 63.0
3 1/2-4 TMSH-D80-27-5 5I12UNTM2... 80.0
11 5/8 TMC20-2 124/006 2I11UNTM...028/018 15.5 12.0 1.33
10 3/4 TMC16-3 124/001 3I10UNTM...028/019 20.5 15.5 1.47
9 7/8 TMC25-4 124/002 4I9UNTM...028/021 30.0 18.0 1.63
8 1-1 3/16 TMC25-4 124/007 4I8UNTM...028/022 40.0 20.0
1 1/4-1 3/8 TMC25-5 124/004 5I8UNTM...028/024 40.0 25.0
1 7/16-1 5/8 TMC25-5 5I8UNTM...028/024 52.0 30.0
1 11/16-1 15/16 TMC25-5 5I8UNTM2... 52.0 30.0 1.83
2-2 1/8 TMC32-5 5I8UNTM2... 58.0 37.0
2 1/4-2 7/8 TM2C32-5 5I8UNTM2... 45.0 42.0
3-3 5/8 TMSH-D63-22-5 5I8UNTM2... 63.0
3 3/4-4 TMSH-D80-27-5 5I8UNTM2... 80.0
7 1 1/8-1 1/4 TMC25-4 124/002 4I7UNTM...028/023 30.0 18.0 2.09
6 1 3/8-1 9/16 TMC25-5 124/004 5I6UNTM...028/025 40.0 25.0
1 5/8-1 15/16 TMC25-5 5I6UNTM...028/025 52.0 30.0
2-2 1/8 TMC25-5 5I6UNTM2... 52.0 30.0
2 1/4 TMC32-5 5I6UNTM2... 58.0 37.0
2.44
2 3/8-2 1/2 TMC40-6B 6BI6UNTM2... 65.0 46.0
2 5/8-3 1/8 TM2C40-6B 6BI6UNTM2... 65.0 52.0
3 1/4-3 3/4 TMSH-D63-22-6B 6BI6UNTM2... 63.0
3 7/8-4 TMSH-D80-27-6B 6BI6UNTM2... 80.0
5 1 3/4 TMC25-5 5I5UNTM...028/077 52.0 30.0 2.93
4.5 2-2 1/4 TMC32-6B 6BI4.5UNTM2... 55.0 35.0 3.26
4 2 1/2 TMC40-6B 6BI4UNTM2... 65.0 46.0
3.67
2 3/4-3 TM2C40-6B 6BI4UNTM2... 65.0 52.0
3 1/4-4 TMSH-D63-22-6B 6BI4UNTM2... 63.0

Vargus 13
 Minimum bore diameters for thread milling
Pitch mm 0.5 0.6 0.7 0.75 0.9 1.0 1.25 1.5 1.75 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
0.80
48 44 36 32 28 26 20 18 14 13 11.5 10 9 7 6 5 4.5 4
Pitch tpi
24 19 16 12 11 8
Toolholder D2 Minimum Bore Diameter Di mm
TMMC 12-6.0 9.0 9.5 9.7 9.9 10.0 10.4 10.7 11.4 12.0
TMMC 20-6.0 9.0 9.5 9.7 9.9 10.0 10.4 10.7 11.4 12.0
TMMC 20-6.0 124/003 9.0 9.5 9.7 9.9 10.0 10.4 10.7 11.4 12.0
TMC 12-2 11.5 12.0 12.2 12.4 12.5 12.9 13.2 13.9 14.5 15.1
TMC 20-2 11.5 12.0 12.2 12.4 12.5 12.9 13.2 13.9 14.5 15.1
TMLC 25-2 11.5 12.0 12.2 12.4 12.5 12.9 13.2 13.9 14.5 15.1
TMSC 10-2 12.5 13.0 12.6 13.6 13.5 13.9 14.2 14.9 15.5 16.1
TMOC 20-2 14.5 15.1 15.2 15.3 15.4 16.0 16.4 17.0 17.8 18.6
TMNC 16-3 15.5 16.0 16.2 16.4 16.5 16.9 17.2 17.9 18.5 19.0 19.5 20.0
TMC 16-3 124/001 15.5 16.0 16.2 16.4 16.5 16.9 17.2 17.9 18.5 19.0 19.5 20.0
TMC 16-3 17.0 17.6 17.8 18.0 18.2 18.70 19.0 19.6 20.0 20.5 21.0 21.5
BTMC 16-3B 17.0 17.6 17.8 18.0 18.2 18.7 19.0 19.6 20.0 20.5 21.0 21.5
TM2C 20-2 17.0 17.6 17.8 18.0 18.2 18.7 19.0 19.6 20.0 20.5
BTMC 20-3B 19.0 19.7 20.0 20.2 20.4 20.8 21.0 21.6 22.0 22.5 23.0 23.5
TMNC 20-3 19.0 19.7 20.0 20.2 20.4 20.8 21.0 21.6 22.0 22.5 23.0 23.5
TMC 20-3 20.0 20.7 21.0 21.2 21.4 21.8 22.0 22.6 23.0 23.5 24.0 24.5
TMOC 20-3 20.0 20.7 21.0 21.2 21.4 21.8 22.0 22.6 23.0 23.5 24.0 24.5
BTMWC 25-3B 22.0 22.7 23.0 23.2 23.4 23.8 24.0 24.6 25.0 25.5 26.0 26.5
BTMLC 25-3B 22.0 22.7 23.0 23.2 23.4 23.8 24.0 24.6 25.0 25.5 26.0 26.5
TMLC 25-3 22.0 22.7 23.0 23.2 23.4 23.8 24.0 24.6 25.0 25.5 26.0 26.5
TMC 25-5 124/004 25.0 25.7 26.0 26.2 26.4 26.8 27.0 27.7 28.2 28.7 29.2 29.7 31.3 33.7 36.7 39.7 42.7
TM2C 25-3 26.0 26.7 27.0 27.2 27.4 27.8 28.0 28.7 29.3 29.8 30.3 30.8
BTM2C 25-3B 26.0 26.7 27.0 27.2 27.4 27.8 28.0 28.7 29.3 29.8 30.3 30.8
TMC 25-5 30.0 30.7 31.0 31.2 31.4 31.8 32.0 32.8 33.5 34.1 34.6 35.6 36.6 39.0 42.0 45.0 48.0
TMLC 25-5 30.0 30.7 31.0 31.2 31.4 31.8 32.0 32.8 33.5 34.1 34.6 35.6 36.6 39.0 42.0 45.0 48.0
TMOC 25-5 30.0 30.7 31.0 31.2 31.4 31.8 32.0 32.8 33.5 34.1 34.6 35.6 36.6 39.0 42.0 45.0 48.0
TMC 32-6B 35.0 50.0 53.4 42.5 50.0 44.6 57.5 56.6
TMC 32-5 37.0 38.0 38.2 38.4 38.6 39.1 39.5 40.4 41.0 41.5 42.0 43.0 44.0 46.5 49.0 52.0 55.5
TMLC 32-5 37.0 38.0 38.2 38.4 38.6 39.1 39.5 40.4 41.0 41.5 42.0 43.0 44.0 46.5 49.0 52.0 55.5
TMNC 32-5 37.0 38.0 38.2 38.4 38.6 39.1 39.5 40.0 41.0 41.5 42.0 43.0 44.0 46.5 49.0 52.0 55.5
TMSH D38-16-2 38.0 38.5 38.7 38.9 39.0 39.6 40.0 41.0 42.0 43.0
TM2C 32-5 42.0 43.2 43.4 43.6 43.8 44.5 45.0 46.0 46.5 47.0 47.4 48.2 49.0 52.0 54.5 57.5 61.0
TMVC 32-5 46.0 62.5
TMC 40-6B 46.0 55.6 55.0 52.5 54.0 54.5 57.5 56.6
TMLC 40-6B 46.0 55.6 55.0 52.5 54.0 54.5 57.5 56.6
TMSH D50-22-2 50.0 50.5 50.7 50.9 51.0 51.6 52.0 53.0 54.0 54.5
TMSH D50-22-3 50.0 50.5 50.7 50.9 51.0 51.6 52.0 53.0 54.0 54.5 55.0 55.5
TM2C 40-6B 52.0 63.0 64.0 66.0 67.0 67.6 69.0 70.0
TMSH D63-22-3B 63.0 63.5 63.7 63.9 64.0 64.6 65.0 66.0 67.0 67.5 68.0 69.0
TMSH D63-22-5 63.0 63.5 63.7 63.9 64.0 64.6 65.0 66.0 67.0 67.5 68.0 69.0 70.0 72.0 73.0 74.0 75.0
TMSH D63-22-6B 63.0 74.0 75.0 77.0 78.0 78.6 80.0 81.0
TMSH D80-27-5 80.0 80.5 80.7 80.9 81.0 81.6 82.0 83.0 84.0 84.5 85.0 86.0 87.0 89.0 90.0 91.0 92.0
TMSH D80-27-6B 80.0 91.0 92.0 94.0 95.0 95.6 97.0 98.0
TMSH D100-32-5 100.0 100.5 100.7 100.9 101.0 101.6 102.0 103.0 104.0 104.5 105.0 106.0 107.0 109.0 110.0 111.0 112.0
TMSH D100-32-6B 100.0 111.0 112.0 114.0 115.0 115.6 117.0 118.0
TMSH D125-40-5 125.0 125.5 125.7 125.9 126.0 126.6 127.0 128.0 129.0 129.5 130.0 131.0 132.0 134.0 135.0 136.0 137.0
TMSH D125-40-6B 125.0 136.0 137.0 139.0 140.0 140.6 142.0 143.0

14 Vargus
TM Gen software
To use the Thread Milling tools a CNC program is required.
Unfortunately most CNC milling machines today do not provide this option as a standard
in their controllers.
Vargus has developed new software (suitable for win95/98/nt) for CNC programming.
All the operator has to do is enter the basic thread parameters:
Thread type, thread standard, pitch, dia., thread length and workpiece material then follow
the computer instructions which will lead you to the correct choice of tool for the job in
hand.
The software then generates the helical interpolation for the CNC program.
Vargus supplies this software at no charge to their end-users through their local agents.

Vargus 15
Toolholder styles
Vargus has a wide range of standard toolholders and every style has been developed for
a specific application. All toolholders have a coolant through channel.
The cooling is used for two purposes:
• to reduce the temperature from the cutting edge
• to help the chip flow.

Toolholder: TMC - toolholders for std. thread application -

using TM2 inserts

Toolholder: TMLC - long series for long threads -

using TM2 inserts

Toolholder: TMC 124/... - toolholders with reduced cut. dia.

for coarse pitch applications -
using coarse pitch 028/... TM inserts

Toolholder: TMNC - toolholders for conical threads -

using BSPT, NPT, NPTF inserts
Note: L.H. toolholders are avaiable for the second
cutting edge of the insert

Toolholder: TM2C - twin flute toolholders with two cut. edges for
fast operation -
using TM2 inserts

Toolholder: TMOC - twin flute offset toolholders to complete long

thread in one cycle -
using TM2 inserts

Toolholder: TMSC - single point toolholders -

using thread turning IC 1/4” std. inserts

Toolholder: TMVC - single point toolholders for large pitches -

using thread turning IC 5/8” vertical std. inserts

Toolholder: TMSH - Shell Mill toolholders with multi cut. edges

for fast machining of large threads -
using TM2 inserts.

Toolholder: TMS - full Solid Carbide tool for small diameters

16 Vargus
Insert styles
Vargus provides the largest range of thread profiles:
ISO, UN, UNJ, W, BSPT, NPT, NPTF, NPS, PG, TRAPEZ and ACME.

All Vargus inserts are adapted for toolholders with one cut. edge or with multi cutting
edges. We have a wide range of insert types.

The right insert for the job

Insert: TM2
For standard threads

Insert: TM (BSPT, NPT, NPTF)

,
For tapered threads 1o47

Insert: Coarse Pitch 028/...TM2

For thread milling large pitch to bore diameter ratio

Insert: TM2F
For fine thread pitches

Insert: TM2 IC 3/8”B, IC 3/4”B

For long threads extra vibration resistance

Insert: TM IC 6.0 mm
For small bore diameters min 9.5 mm

Insert: IC 1/4” Laydown Thread Turning

Single point thread milling with laydown thread turning inserts
For very short thread or material with high hardness

Insert: IC 5/8”V (T=6) Vertical Thread Turning

Single point thread milling with vertical thread turning inserts, for large
pitches

Vargus 17
CNC program sample
(Thread: M60 x 1.5 x 20) List of “G” Codes (ISO)

% Code
IC Description
G00 Fast feed linear positioning
O0001 (TMINRH CLIMB CYCLES = 1)
Program no.
G01 linear interpolation
G02 Circular/Helical interpolation CW
(Fanuc 11M Controller.) G03 Circular/Helical interpolation CCW
Remark
G40 Cutter radius compensation-cancel
G90 G00 G57 X0 Y0 G41 Cutter radius compensation-left
Home (origin) set
G42 Cutter radius compensation-right
G43 H10 Z0 M3 S946 G43 Tool length compensation +
Tool length compensation-on and RPM set
G49 Tool length compensation-cancel
G91 G00 X0 Y0 Z-20.272 G57 Work coordinate system selection
Go down in Z-axis G90 Absolute command relative to work

G41 D60 X9.459 Y-20.595 Z0 coordinate origin

Tool diameter compensation-on G91 Incremental command relative to
tool position
G91 G03 X20.595 Y20.595 Z0.272 R20.595 F36
Entrance by tangential arc F Feed inch/min or mm/min
S Spindle speed RPM
G91 G03 X0 Y0 Z1.500 I-30.054 J0
Thread machining-HELICAL interpolation H Tool length compensation number
movement D Tool radius compensation number
X X coordinate
G91 G03 X-20.595 Y20.595 Z0.272 R20.595
Exit by tangential arc Y Y coordinate
Z Z coordinate
G00 G40 X-9.459 Y-20.595 Z0
Tool diameter compensation-off R Radius of travel
I X coordinate to centre of arc travel
G90 G49 G57 G00 Z200.000 M5
J Y coordinate to centre of arc travel
Tool length compensation-off and RPM close
M3 Spindle forward rotation
M30 M5 Spindle stop
End of program
M30 Program end & rewind
% O Program number
N Block number (can be avoided)
% Recognition code (ISO or EIA),
+End of tape
( Start of comment
) End of comment
18 Vargus
Program check
After generating the program with the TM Gen software the program can be tested on
the machine itself. It is very important that the program is very carefully tested in order
to avoid any errors.
Following, our recommendation, step by step :
• Run the TM Gen with your thread data. As a general rule please first key in V=100
and f=0.05. This data should be changed after the first thread.
• Check the TM data to be sure that all input data is correct.
• Where possible send the program direct from your PC to the CNC machine controller
in order to avoid any copying mistakes.
• Check the program without axis movement (not possible for every machine).
• Check the program above the workpiece in order to identify any tool route failures.
• Check the program inside the material in a single block option and reduce speed
by 50%.
• Cancel the single block option and run the program at a normal speed.
• Check the component with a standard gauge and compensate the tool radius if
necessary.

Conical threads
Our TM Gen also gives a solution for conical threads.
A parallel thread such as ISO, UN or Whitworth have thread constant radius, while the
conical thread has a radius which changes all the time.
Only a few controllers can handle this conical helical interpolation.
In view of this Vargus developed software which gives a solution to this complicated
movement. Vargus TM Gen divides the circle into eight sections and changes the radius
for every section and with this the conical movement can be described.
It is not necessary to drill the pre-bore drill with
the conical shape. It can be drilled parallel as
our inserts cut the full profile and machine the
minor dia.
Parallel pre hole for NPT
Nominal Pitch Pre hole
Size (in) (tpi) dia. (mm)
1/16 27 6.2 * *
1/8 27 8.5
1/4 18 11.0
3/8 18 14.5
1/2 14 17.8 L R
3/4 14 23
1 11 1/2 29
1 1/4 11 1/2 37.5
1 1/2 11 1/2 44 A A
2 11 1/2 56
2 1/2 8 66.5
3 8 82.5 LH Tool RH Tool

* Important! Tool offset length and diameter for conical inserts should be measured
on the first tooth.

Vargus 19
Speed and feed
For initial test we always recommend starting with V=100 m/min and f=0.05 mm.

Vardex Carbide grades and recommended cutting speeds (V)

Recommended Cutting Speed V (m/min)

Material Workpiece VSX V30 VKX* VK2 VBX

ISO P10-P30 ISO P20-P30 ISO K05-K20 ISO K10-K20 ISO P10-P20

Carbon Steel < 600 N/mm2 160-240 160-200 150-250 - 160-250

Carbon Steel 600-800 N/mm2 170-200 150-180 170-200 - 170-220
Alloy Steel 700-850 N/mm2 120-170 110-150 120-180 - 120-170
Alloy Steel 850-1100 N/mm2 110-150 100-130 110-150 - 110-190
Stainless Steel (Austenitic < 700 N/mm2) 160-200 150-180 160-200 - 160-220
Stainless Steel (Martensitic < 1100 N/mm2) 150-180 140-170 150-200 - 150-220
Stainless Steel (Ferritic < 800 N/mm2) 150-200 140-170 150-200 - 150-220
Cast Steel < 500 N/mm2 170-200 150-180 170-200 - 170-220
Cast Steel 700-1000 N/mm2 120-180 120-150 120-180 - 120-180
Cast or Malleable Iron 150 - 240 HB - - - 100-130 100-150
Cast Iron 100 - 200 HB - - 110-150 110-150 110-170
Bronze / Copper - - 120-180 120-170 -
Aluminium - - 200-400 200-300 -

VSX and VKX are PVD TiN coated, VBX is TiCN coated
The recommended feed per cutting edge per rotation “f” is between 0.05-0.3mm.
* For IC 3/4”B only VKX grade is available

Basic formulas for cutting conditions

Calculation of the rotational velocity N = 1000 X V (R.P.M.)

π X D2
V= cutting speed (m/min), D2= tool cutting dia. (mm), N= rotation velocity (R.P.M.)

Calculation of the cutting speed V = N X π X D2 (m/min)

1000

Calculation of the feed rate at the cutting edge F1 = f X Z X N (mm/min)

f= feeding per cutting edge per rotation, Z= number of cutting edges, N=rotational velocity (R.P.M.)

Calculation of feed rates at the tool centre line

On most CNC machines, the feed rate required for programming is that of the center-line
of the tool. When dealing with linear tool movement, the feed rate at the cutting edge and
the center line are identical, but with circular tool movement such is not the case.
The following equations define the relationship between feed rates at the cutting edge and
at the tool centre line. (The TM Gen software automatically gives the feed rate at the tool
centre).

20 Vargus
 ØD2

ØD2
Threading
Threading Tool
Tool
F1 X (Do - D2) F1 ØDi
F2=
Do F2 Thread
ØDo
F2 F2 X Do
F 1= F1 X (Di + D2) F2 X Di
Thread Do - D2 F2= F1=
Di Di + D2
F1
Internal Thread External Thread

Vibration
The cutting action of the TM tools is not continuous. During the milling operation, the
cutting edge of the insert enters and exits from the material very quickly. The tool cuts
only once per rotation and because of this the tool is sensitive to vibrations. Vibrations can
be identified very easily by the noise which, in this case, is extremely loud.

The results of the vibrations are: • bad thread surface quality

• low tool life
• breakages on the insert teeth

How to avoid vibrations

• Use the toolholder with the max cut. dia. (D2).

• Use the tool with the smallest overhang (L1).
• Use the tool with max. cutting edges -
TM2 tool or shell mill.
• Don't exceed the recommended cutting
speed.
• Always use cooling water during the
operation.
• Component must be well fixed to the
machine table.
• Divide the thread into several passes -
instead of only one, by using only part of
the insert length. It is also possible to use
part of the profile depth but this is
recommended only for large pitches.

Vargus 21
Thread milling insert standards

30° 30° Internal

NPT
Defined by:
USAS B2.1:1968
ISO Metric Tolerance class:
1/4P Internal Defined by: Standard NPT
60 ° R262 (DIN 13) 90° 1 ° 47'

Tolerance class: External

6g/6H

30 °
NPTF
1/8P External 30 ° Internal
Defined by:
ANSI 1.20.3-1976
American UN Tolerance class:
1/4P Internal Defined by: Standard NPTF
60° ANSI B1.1.74 1 ° 47'
90°
Tolerance class: External

Class 2A/2B

30° 30° Internal

NPS
1/8P External
Defined by:
USA NBS H28 (1957)
W for BSW, BSP Tolerance class:
Internal
R0.137P 55° BSW Defined by: Standard NPS
B.S.84:1956, DIN 259,
ISO228/1:1982 External

BSP Defined by:

R0.137P B.S.2779:1956 Internal Pg
External Tolerance class: R0.107P 80 ° Defined by:
BSW-Medium class A, DIN 40430
BSP-Medium class Tolerance class:
Standard
R0.107P
UNJ
5/16P Internal External
Defined by:
60° MIL-S-8879C
Tolerance class: ACME
h 3A/3B Internal Defined by:
30 °°
29 Internal
R max 0.18042P ANSI B1/5:1988
R min 0.15011P External
Tolerance class:
3G
R0.137P Internal British BSPT
27.5° 27.5 ° Defined by: External

B.S. 21:1985
Tolerance class: TR
Standard BSPT Internal Defined by:
30 °ϒ
30° Internal
90° 1 ° 47' R Trapez DIN 103
External Tolerance class:
7e/7H

External

22 Vargus
Thread dimensions of BSP
B.S.2779: 1956 medium class
Internal (Dimensions in inch)
BSP. Threads Lenght of Major Diametor Effective Diameter Minor Diameter
Nominal Size per Inch Engagement Min. Max. Tol. Min. Max. Tol. Min.
1/8 28 3/8 0.3830 0.3643 0.0042 0.3601 0.3483 0.0111 0.3372
1/4 19 1/2 0.5180 0.4892 0.0049 0.4843 0.4681 0.0175 0.4506
3/8 19 1/2 0.6560 0.6273 0.0050 0.6223 0.6051 0.0175 0.5886
1/2 14 5/8 0.8250 0.7849 0.0056 0.7793 0.7549 0.0213 0.7336
5/8 14 5/8 0.9020 0.8619 0.0056 0.8563 0.8319 0.0213 0.8106
3/4 14 3/4 1.0410 1.0013 0.0060 0.9953 0.9709 0.0213 0.9496
7/8 14 3/4 1.1890 1.1494 0.0061 1.1433 1.1189 0.0213 1.0976
1 11 7/8 1.3090 1.2573 0.0065 1.2508 1.2718 0.0252 1.1926
1 1/4 11 1 1.6500 1.5987 0.0069 1.5918 1.5588 0.0252 1.5336
1 1/2 11 1 1/8 1.8820 1.8310 0.0072 1.8238 1.7908 0.0252 1.7656
1 3/4 11 1 1/8 2.1160 2.0651 0.0073 2.0578 2.0248 0.0252 1.9996
2 11 1 1/8 2.3470 2.2961 0.0073 2.2888 2.2558 0.0252 2.2306
2 1/4 11 1 1/8 2.5870 2.5362 0.0074 2.5288 2.4958 0.0252 2.4706
2 1/2 11 1 1/8 2.9600 2.9094 0.0076 2.9018 2.8688 0.0252 2.8436
2 3/4 11 1 1/8 3.2100 3.1594 0.0076 3.1518 3.1188 0.0252 3.0936
3 11 1 1/8 3.4600 3.4095 0.0077 3.4018 3.3688 0.0252 3.3436
3 1/2 11 1 1/8 3.9500 3.8997 0.0079 3.8918 3.8588 0.0252 3.8336
4 11 1 1/8 4.4500 4.3998 0.0080 4.3918 4.3588 0.0252 4.3336
5 11 1 1/8 5.4500 5.4000 0.0082 5.3918 5.3588 0.0252 5.3336
6 11 1 1/8 6.4500 6.4502 0.0084 6.4418 6.3588 0.0252 6.3336

External (Dimensions in inch)

BSP. Threads Lenght of Major Diameter Effective Diameter Minor Diameter
Nominal Size per Inch Engagement Max. Tol. Min. Max. Tol. Min. Max. Tol. Min.

1/8 28 3/8 0.3830 0.0061 0.3769 0.3601 0.0042 0.3559 0.3372 0.0080 0.3292
1/4 19 1/2 0.5180 0.0072 0.5108 0.4843 0.0049 0.4794 0.4506 0.0095 0.4411
3/8 19 1/2 0.6560 0.0073 0.6487 0.6223 0.0050 0.6173 0.5886 0.0096 0.5790
1/2 14 5/8 0.8250 0.0083 0.8167 0.7793 0.0056 0.7737 0.7336 0.0109 0.7227
5/8 14 5/8 0.9020 0.0083 0.8937 0.8563 0.0056 0.8507 0.8106 0.0109 0.7997
3/4 14 3/4 1.0410 0.0087 1.0323 0.9953 0.0060 0.9893 0.9496 0.0113 0.9383
7/8 14 3/4 1.1890 0.0088 1.1802 1.1433 0.0061 1.1372 1.0976 0.0114 1.0862
1 11 7/8 1.3090 0.0095 1.2995 1.2508 0.0065 1.2443 1.1926 0.0125 1.1801
1 1/4 11 1 1.6500 0.0099 1.6401 1.5918 0.0069 1.5849 1.5336 0.0129 1.5207
1 1/2 11 1 1/8 1.8820 0.0102 1.8718 1.8238 0.0072 1.8156 1.7656 0.0132 1.7524
1 3/4 11 1 1/8 2.1160 0.0103 2.1057 2.0578 0.0073 2.0505 1.9996 0.0133 1.9863
2 11 1 1/8 2.3470 0.0104 2.3366 2.2888 0.0073 2.2815 2.2306 0.0134 2.2172
2 1/4 11 1 1/8 2.5870 0.0105 2.5765 2.5288 0.0074 2.5214 2.4706 0.0135 2.4571
2 1/2 11 1 1/8 2.9600 0.0106 2.9494 2.9018 0.0076 2.8942 2.8436 0.0136 2.8300
2 3/4 11 1 1/8 3.2100 0.0107 3.1993 3.1518 0.0076 3.1442 3.0936 0.0137 3.0799
3 11 1 1/8 3.4600 0.0107 3.4493 3.4018 0.0077 3.3941 3.3436 0.0137 3.3299
3 1/2 11 1 1/8 3.9500 0.0109 3.9391 3.8918 0.0079 3.8839 3.8336 0.0139 3.8197
4 11 1 1/8 4.4500 0.0110 4.4390 4.3918 0.0080 4.3838 4.3336 0.0140 4.3196
5 11 1 1/8 5.4500 0.0112 5.4388 5.3918 0.0082 5.3836 5.3336 0.0142 5.3194
6 11 1 1/8 6.4500 0.0114 6.4386 6.3918 0.0084 6.3834 6.3336 0.0144 6.3192

Vargus 23
Thread terminology

External thread Major diameter

A thread on the The largest diameter of a screw thread.
external surface of a
cylinder screw or External Thread Pitch diameter
cone On a straight thread, the diameter of an
Major Ø imaginary cylinder, the surface of which
Pitch Pitch Ø cuts the thread forms where the width
The distance between Minor Ø of the thread and groove are equal.
corresponding points on Minor diameter
adjacent thread forms measured Thread The smallest diameter of a screw
Pitch
parallel to the axis. This distance Angle thread.
can be defined in millimeters or Helix
Root Angle
by the tpi (threads per inch)
Crest
which is the reciprocal of the Helix angle
pitch.
For a straight thread, where the lead of
Depth of Thread the thread and the pitch diameter circle
circumference form a right angled
The distance between crest triangle, the helix angle is the angle
and root measured normal to opposite the lead.
the axis.

Nominal diameter Internal Thread Straight Thread

A thread on the internal
The diameter from which the surface of a cylinder or cone. A thread formed on a cylinder
diameter limits are derived by the
application of deviation allowances Taper Thread
and tolerances. A thread formed on a cone

Specials
Vargus offers special toolholders and inserts according to customer design or gives
solution for special applications.
In order to send fast and reliable answers Vargus asks for the following details for every
inquiry:
• Thread dias.: major, minor and effective
• Thread profile angle
• Radii of the profile (Root and Crest)
• Pitch
• Thread length
• Workpiece material
• Tolerances for all above (where possible)

Vargus is aware of the fact that in many cases the end user does not have all the thread
details as listed above but the min. info should include the major and minor dia. profile
angle, pitch, thread length - all the missing details - will be completed according to Vargus
design standards. Drawing for approval and confirmation will be sent to the customer.

Vargus manufactures a large quantity of special holders every year and most of them
with extra overhang (L1) for long thread machining, or for threads located at the bottom
of a deep bore.
In most cases Vargus gives a solution for the extra long toolholders but sometimes it is
not possible to offer because of expected vibration problems.

24 Vargus
Manual CNC Programming
Thread: M30 X 1.5 X 20 INTERNAL on Alloy Steel Insert: 3BI 1.5 ISO TM2
Cutting data: V = 150 m/min, f = 0.1 mm Holder: BTMC 20 - 3B (D2=19)
Step by step:
• Calculate the feed rates.
First find the R.P.M.
N = 1000 X V = 1000 X 150 = 2512 R.P.M.
π X D2 3.14 X 19
• Select the feed per tooth: choose 0.1 mm
• Next, calculate the feed rate at the insert cutting edge (F1):
F1 = f X Z X N = 0.1 X 1 X 2512 = 251.2 mm/min

• Finally, calculate the feed rate at the toolholder center line (F2):
y
D0
F2 = D1 X (D0 - D2) = 251.2 X (30 - 19) = 92.1 mm/min
D0 30
Ri
• Choose the thread milling method B
Chosen method: Climb milling O C x
• Calculate of the radius of the tangential arc Re Y R0
Assume a clearance CL = 0.5 mm CL Re
2 2 2 2
Re = (Ri - CL) + Ro = (14.19 - 0.5) + 15 = 13.747 mm
2Ro 2 X 15 β α
A
• Calculate the angle ß
0 0 0
β = 180 - arcsin (Ri - CL) = 180 - arcsin (14.19 - 0.5) = 95.22
Re 13.747
• Calculate the movement along the Z-axis during the entry approach (Za)
Zα = P [mm] X α0 = 1.5 X 90 = 0.375 mm
3600 360
• Calculate X and Y values of the start of the entry approach
X=0 Y = Ri + CL = -14.19 + 0.5 = -13.69 mm
• Define Z-axis location at the start of the entry approach
Z= -(L+Zα) = -(20+0.375) = -20.375 mm
z
• Define the starting point
Xa = 0 Ya = 0 y
The CNC Program (Fanuc 11M) x
%
N10 G90 G00 G57 X0. Y0.
N20 G43 H10 Z0. M3 S2512
N30 G91 G00 X0. Y0. Z-20.375
N40 G41 D60 X0. Y-13.690 Z0.
N50 G03 X15. Y13.69 Z0.375 R13.747 F92
N60 G03 X0. Y0. Z1.5I-15. J0.
N70 G03 X-15. Y13.69 Z0.375 R13.747
N80 G00 G40 X0. Y-13.690 Z0.
N90 G49 G57 G00 Z200. M5
N100 M30
%

Vargus 25
Classic Questions
• Is it possible to produce more than two starts with Vargus thread
milling tools?

Yes it is possible! You just have to insert the pitch in the TM Gen as pitch multiplied by
the no. of starts.
E.g.: Pitch 3.0 mm with two starts should be inserted as 6.0 mm pitch.

• Why does the non-cutting edge of the insert sometimes break?

This is a result of a vibration problems. Change the cutting conditions.

• Which tool is recommended for long threads TMO or TM2?

TM2!
TMO can machine long threads in one cycle but it is still one cut. edge tool.
TM2 can machine shorter thread but as it has two cutting edges you can increase the
speed.
We recommend TMO for light jobs like aluminum as the second pocket reduces
toolholder stability, and TM2 for heavy duty.

• What happens if I use larger tool (larger cut. dia.) than recommended
by Vargus tables?

A profile distortion will occur.

• Why is the CNC program for conical threads so long?

Vargus TM gen divides the circle into 8 sections in order to describe the conical helical
interpolation.

• What infeed method does Vargus use in the TM Gen?

We recommend and use the tangential ARC method.

• Which coordinate system does Vargus use in the TM Gen?

Incremental for parallel threads and absolute for conical threads.

• How can you machine several threads in the same component using
absolute program?

You have to move the program origin axis and locate it at the center of the hole for each
thread.

• How can a thread longer than the insert itself be machined?

You make one cycle then move the tool in a “z” direction and machine a second cycle.

26 Vargus
• What is the purpose of the carbide core in the TM toolholders?

The carbide core is used as an anti-vibration system.

• Is it necessary to produce a relief groove when using TM tools?

Not necessary, the tool can reach the bottom of a blind hole.

• I used std. inserts for coarse pitch thread and in spite of this I got the
correct thread, or I used a larger tool than recommended in your
tables and I got the correct thread?

When you follow Vargus recommendations, we can guarantee the thread form exactly
acc. to standard as Vargus take into consideration the std. tolerances with relation to
the tool tolerances. In many cases the customer demand is not for high accuracy and
that is why he can accept the thread even with profile distortion. Also many customers
check the thread with a home-made gauge and hence the thread is not measured
correctly.

• What is the max. length for special tools?

It is difficult to give a general answer because it depends on workpiece material, machine

conditions, pitch and clamping system.

• I have a three axes machine, why can’t I run the TM program?

Your machine does not have the option to control 3 axes at same time, you have to ask
your machine dealer to open this option (normally it exists in the machine software but
is protected by a code).

• How much does the TM Gen cost and how can I get it?

Free of charge from your local dealer.

• How much excess do I have to leave on the pre-drilled hole?

About 0.2 mm on the dia..

• Can I use the same insert for TM holder, TM2 holder and Shell Mill?

Yes!

• What is thread distortion?

The difference between the theoretical thread form and the actual thread form on the
workpiece.

Vargus 27
Trouble Shooting

Problem Possible Cause Solution

Increased Cutting speed too high reduce cutting speed/use coated insert
insert Chip is too thin increase feed rate
flank wear Insufficient coolant increase coolant flow rate

Chipping Chip is too thick reduce feed rate/use the tangential arc method/
of cutting increase rpm
edge
Vibration check stability

Material Incorrect cutting speed change cutting speed

build up on Unsuitable carbide grade use a coated carbide grade
the cutting
edge

Chatter / Feed rate is too high reduce the feed

Vibration Profile is too deep execute two passes, each with increased cutting depth/
execute two passes, each cutting only half the thread length
Thread length is too long execute two passes, each cutting only half the thread length

GO NOGO Insufficient Tool deflection reduce feed rate/execute a “zero” cut

thread
accuracy

Chipping Vibration check stability

of the non
cutting
edge

28 Vargus
 Worldwide
Australia Switzerland Greece Singapore
Vargus-Neumo Vargus Werkzeug- Carbocut Ltd. JEP Industrades Pte. Ltd.
Australia Pty. Ltd. Technik SNEL AG Tel: +30 (0) 1 34 75 111 Tel: +65 5454 222
Tel: +61 (0) 357 843 690 Tel: +41 (0) 41 784 21 21 Fax: +30 (0) 1 34 25 621 Fax: +65 5452 823
Fax: +61 (0) 357 843 533 Fax: +41 (0) 41 784 21 39
Holland South Africa
Denmark United Kingdom Cerametal & Co. Pilot Tools (PTY) Ltd.
Damstahl Tooling a/s Damstahl Tooling Tel: +31 (0) 165 550 800 Tel: +27 (0) 11 616 8130
Tel: +45 (0) 86 52 2800 Tel: +44 (0) 1952 58 32 22 Fax: +31 (0) 165 556 176 Fax: +27 (0) 11 616 7758
Fax: +45 (0) 86 51 0099 Fax: +44 (0) 1952 58 33 83
India Spain
France United States Hemant Tools Trans Inter S.A.
Vargus France sarl V.N.E. Corp. Ltd. Tel: +91 (0) 22 342 1174 Tel: +34 (0) 93 261 81 10
Tel: +33 (0) 1 46 60 82 20 Tel: + 1 800 828 8765 Fax: +91 (0) 22 342 8095 Fax: +34 (0) 93 335 81 86
Fax: +33 (0) 1 46 60 90 99 + 1 608 756 4930
Fax: +1 608 741 7125 Italy Taiwan
Germany Novatea S.p.A. Hung Chih Ltd. Co.
Neumo GmbH Belgium Tel: +39 015 582 1893, 5, 6 Tel: +886 (0) 6 225 2216
Tel: +49 (0) 7043 36 0 N.V. van Maele Fax: +39 015 582 1909 Fax: +886 (0) 6 220 5993
Fax: +49 (0) 7043 36 160 Tel: +32 (0) 9 386 55 92
Fax: +32 (0) 9 386 09 51 Japan Thailand
Israel Fuji Koeki Co. Ltd. P.S.C. Cutting Tools
Neumo-Vargus Ltd. Czechia Tel: +81 (0) 6531 5631 Tel: +66 (0) 2427 4535
Tel: +972 (0) 3 537 3275 ALBA Precision spol. s.r.o. Fax: +81 (0) 6531 5606 Fax: +66 (0) 2427 4534
Fax: +972 (0) 3 537 2190 Tel: +420 (0) 5 4522 6400
Fax: +420 (0) 5 4853 2689 New Zealand Turkey
Poland Alpine Industrial Teknik Hirdevat Evi
Neumo-Vargus Ltd. Croatia/Slovenia Tel: +64 (0) 9 262 3545 Tel: +90 (0) 212 210 2796
Tel: +48 (0) 46 833 4306 Okret d.o.o. Fax: +64 (0) 9 262 2798 Fax: +90 (0) 212 210 2961
Fax: +972 (0) 46 832 5626 Tel: +385 2122 8449
Fax: +385 2122 8464 Venezuela
Tuvenca
Tel/Fax: +58 (0) 993 3037

Your VARDEX dealer :

Vargus Ltd.
1 Hayotsr im St.
Nahar iya 22311, Israel
Tel. +972 (0)4 985-5111
Fax. +972 (0)4 982-5810
Web. http:\\www.vargus.co.il
E-mail: mr [email protected]
099EE
08/2000 edition 1 © Copyright 2000, EGMO-VARGUS Ltd.