Emuge Corp. introduced a line of tools for threading demanding titanium alloys, the high-hardness, high-value materials that are increasingly specified for aerospace, defense, and medical parts machining. Ranging from taps with novel, new geometry designs to solid carbide thread mills, the comprehensive program offers reliable options for high-value production programs.
The Emuge Titanium Program includes tap sizes from no. 0 to 1 in., in UNC, UNF and from 3x0.5 to 24x3.0 metric, 222 tools in total.
In addition, the program features C-Ti and D-Ti taps with new high-relief geometry (HRG) technology, which increases the space between the friction surfaces for enhanced lubrication and reduced torque load in both forward and reverse direction. HRG counteracts the high compressive forces produced by the extreme elastic memory of titanium.
An optimized flute angle and profile create tough, long chips that evacuate axially in one direction. Taps are manufactured from premium HSS-E steel for heat and wear resistance, and a modified bottoming chamfer provides reduced torque and increased tool life.
With advanced left-hand helical flute form and chamfer geometry, C-Ti taps optimize chip evacuation in the forward direction and add strength to the cutting teeth for enhanced tool life and process security.
The new D-Ti taps are available in STI thread sizes for jet engine components. Both C-Ti and D-Ti taps are available in a special NT2 coating with nitriding that provides increased edge hardness and a steam layer over the nitriding to promote lubricity to prevent cold welding. Taps also are available with a TiCN multi-layer PVD coating for increased edge hardness and surface lubricity.
"Emuge’s new HRG technology is ideal for threading tough, long chipping titaniums,” explained Mark Hatch, product director. “The optimized geometry provides extraordinary tool life, superior thread finish, and excellent guiding properties for true-to-gauge fit and significantly reduced chipped teeth or tap breakage."
The Titanium Program also offers a variety of thread mills. Threads-All Z-GF style thread mills require only eight stock standard tool sizes to produce 100+ commonly produced screw thread designations. They simplify machining of difficult materials, one tool for through and blind holes, and total control over pitch diameter limits. According to the developer, Shur-Thread GFI-IKZ thread mills with internal coolant offer a balance of performance and price with specially engineered multiple-spiral flutes to eliminate chatter, a large cutter diameter with high profile correction to ensure true-to-gauge threads, and an extended milling portion that allows for 2xD length of cut.
For optimal results, Emuge recommends that tools from the Titanium Program run on a CNC machine with a synchronous spindle utilizing a tap holder with minimal compensation, such as Emuge Softsynchro®, which features patented construction separation of the transmission of torque and axial force for the best imaginable tool life and thread surface quality.