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Hi guys, I've got a very complex part clamped down to my mill table, it takes up most of the table. I just realized I don't have an easy method of putting in two 1/2'-14 npt holes.
No way to hold the tap, no rigid tapping on machine anyway. I could thread mill them, but don't have a foolproof way to generate the gcode to do it with a single flute thread mill.
I can use a roundabout way to generate the tool path with my CAM program, but I've got so much work into this part I don't want to risk a mistake. Besides I'm kind of burned out for really clear thinking right now. I downloaded Vardex's thread milling code generator, unfortunately I don't see any options for single flute cutters. Looks like a nice program, but it's an info-mercial for Vardex tooling so it doesn't help since I don't have the correct insert. Anyone know of a thread mill code generator for tapered threads? Maybe I should just make up a tap guide block and hand tap these, it's aluminum and only 1/2' thick. Doug: I am with Mike!
I would use the sensitive quill on my Deckel with a center mounted in the tool holder to center the end of the tap and drive it in with a tap handle. If you don't have a sensitive quill or a hand feed knee (knee mill CNC) then just go back to being a machinist. Start the tap by hand, check for alignment with a squair in two planes and you are good to go. Maybe a 2 minute job.or screw around with programming a spiral. I would use the skip tooth style of tap. Much better thread and less effort to drive in.
Programming for Threadmilling npt or nptf pipe threads is much more than just a circle mill program with all three axis moving simotanusly. Because npt or nptf threads have a 1 degree 48 minute taper on the sides you must increase the radius of the circle mill as you pull out on the z axis up 1 pitch or.0714' I am at home now but i think the radius increases about.0016'? Per one pitch of threads. Whatever that number is you will have to figure that out, take that number and say if it is.0016' lay it out on cad and break up a 360 degree circle by 16 segments or 22 1/2 degrees lay out 16 arcs so the radius increases by.0001' every segment.
This will give you your start point end point and center of radius every time you go up 1/16 of the pitch or.0044625'. You have to arc in and out with z helix when you start and end the threads or you will end up with a side nicked thread. Why not just buy the proper thread mill? One arc into the side of the hole at the rate of pitch, one arc around the thread at rate of pitch, another arc out at rate of pitch, a rapid move to center and you're done.
Awhile ago I had to machine two manifolds each with 48 british standard 1/4' pipe theads in it made out of 316L stainless, and any kind of tap I could find was just worthless in it. The thread mill was sorta pricey, about 200 dollars, but it looked like new after two manifolds. Regular NPT thead mills are a lot cheaper than that one was. One part, two holes. Because of all the work already into the part I don't want to screw it up doing these holes. Given the situation I'm going to fabricate a simple tap alignment guide and do them by hand. I have a single flute thread mill that could do the job.
The part is fixtured accurately to the mill's table with no room for a vise to hold a test piece. So if I was to thread mill the part it'd be risky, one mistake and a lot of time/money down the drain. I was hoping to find a site with a code generator for npt threads, then at least I wouldn't have the risk of a faulty calculation on my part if I cobbled something together using my CAM software. As I mentioned Vardex has a free program to generate thread mill code, but it seems to only use insert tools.
They sell single flute thread mills, I don't see an option to generate the code with those though. Doug, I would tap also. No reason to possibly scrap the part after so much has gone into it.
Not for 2 holes anyway. Not even for 10 holes. FOr 50.well then buy the thread mill. One pass with a tapered thread mill, and voila (sp?).
Or.you could use a 1/2npt tap, and grind off 3 of the four flutes, and give the last a bunch of relief. Use that as a thread mill. Works in a pinch. I know, I just did it last week. One of my guys has a little spring loaded 'guide pin' that works great for centering up the tap. On a cnc mill it is hard to turn the tap, and drop the z simultaniously.
THis little gizmo is about 8' long, 3/8 od, with a smaller 5/16 od telescoping pin that is spring loaded. Happy new year. There is a good program to download that would help. I think the site is machinist program download or something.
Program works good if you wnat to purchase you sent the guy 15. Bucks I think.
Anyway I'll try and find the info for you later. However as easy as it will be. Don't use it now as you'd be crazy to funk around with it with so much work invested. Times like these the stupidest problem creep up and bite ya. Tap it manuelly then learn how to thread mill on some scrap. Its easy as most things are soon as you get it figured out. One thing I learned while trying to find a thread milling program was that no one does things the same.
Some people program for the center of the tool, some program for the print geometry. Some program the depth as L1+L3, some program as L1+L3+ 1 Pitch. Some set the tool length at the end of the tool, some set the tool length at the top. Basically what I'm saying is that I couldn't find what I wanted, so I wrote what I wanted in VBScript in a web page. You may see what I did. I made two calculators for manual processes on a Mazak control. I was using a full form cutter.
Mitsubishi (Mazak) has G03.1 which does the changing diameter automatically, but you can't enter G03.1 in a manual process, so I had to make four arcs the way thread mill people wrote their programs. What I should say is the way some thread mill people did because some break the circle into 4 arcs, some do eight arcs. I have this page written to always do programmed depth plus one pitch. It also requires the actual tool diameter to be entered in the offsets as the program calculates print geometry. There is also compensation so you can use the same tool length for any cutter which cuts more than one thread size.
You can see the NPT threadmill page by clicking. I also made a page to do single point straight threads.
Again, Mitsubishi has something that most controls don't. You can specify a P on a G03 line to specify the number of full circles. So if I wanted to cut 10 pitches, I'd put P10. On the single G03 line. This page doesn't have in built features like going one extra pitch. I did that because I also use it for circle milling holes to a specific depth rather drilling them. This page also calulates the endpoint of the circle so you never have to make full circles or a depth that is equally divisble into the pitch.
You can see Single Point thread by clicking. The page that ARB contains a Fanuc macro to do G01 moves to create a single point pipe thread hole. I took that macro and converted it to VBScript. I made some changes because the way it was, it didn't necessarily get to full depth depending on the variables input. There were also problems that if a degree was entered which didn't equally divide into 360, there'd be depth errors. I also set it up so it starts one pitch above the part rather than a constant.1 Since this page generates the text, it takes a little time to actually show the code.
Don't be surprised if you press compute with the default settings and it appears that the compute button sticks for a second or two. You can see this page by clicking.
I didn't actually cut anything with the generated code, but it looks correct. Try these inputs: Hole Diameter =11 Cutter=1 angle of rev=36 TPI=10 taper=45 Depth=-1 When Z is Zero, X should be 5. The steps should be.01 per line. When Z is -1, X should be 4.
Try something else also, it looks correct to me. Backplot it if you can.
Anyway, I'd consider creating/modifying one of these pages to suit you. However there is some many things that need to be stated. Do you use actual cutter diameter or centerline of tool? Do you have helical interpolation? If so, I'd prefer using 4 circular moves per line rather than all those G01's. Can you use R in a circular move rather than I and J? Do you have absolute or incremental arc centers?
Do you want your sub in absolute or incremental? I personally prefer incremental, so that depending on the control, you can use the same code and call it as a sub or copy and paste it. Even if the sub is written in absolute and the control has multiple fixture offsets or AXO's or G59's or G52's absolute is fine.
Vardex Thread Mill Program Generator
I'd suggest using comp in the code. When you are calling a sub, it is easy to modify a tool diameter and rerun it to get size. However, the way I have the last page written, if the hole wasn't correct, you'd have to repost the code and paste it in the program. Good luck, Bryan By the way, I wrote the first two pages in metric. The last page is for inch.
Also these page require a browser that processes VBScript. IE works, Netscape, Mozilla, AOL don't. View the source to see what the actual code looks like.
Vardex Thread Mill Program
Of course I realize this job is already done, but this was for future reference. Bringing this back to life if anyone is interested. We have come across a few npt threads that need run on a mill.
Some too big to tap. I decided to see if i could do it. I am using a Mazak 640m nexus control that has G2.1 and G3.1 capablility. The machine will not take a G3.1 in a manuel program so it had to be done in an eia/iso program. Its an external 3/4-14 npt. I programed from center of the spindle, but i think it should work with cutter comp. I used a 3/4 ID threading bar.
The radius checked.462 from center of the bar to insert cutting tip. I used the comparitor to get a rough thread minor rad of an existing part. In this case.473. And my -Z- starting P in this case is number of full threads to get off the end of the part.8x14=11.2. So have to use 12 full turns. THREAD pitch=.071428571x12=.8571 rounded off. So final poin in z=.0571.
I started my cut at x0 and y.935. Final point in y=.8571x1.7833tan=.02668 taper per side. 1.7833 being taper of an npt thread. So.935.02668=.9083 final point in y axis.
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Program reads like this G0G90Y-1.2M3 Z.1S1400 G1Z.8F50. Y.935F9.M8 G3.1Y.9083Z.0571I0J.935P12F18. M99 I used a mazatrol manuel program to call up my too and that provided Z cutter comp. You would have to use your own format depending on control type obviously.