Product category:
Threading tools
News Release from: Vargus Tooling UK | Subject: Solid carbide thread mills
Edited by the Manufacturingtalk Editorial
Team on 09 February 2006
Thread mill tooling avoids titanium
problems
Thread milling tooling is not only enabling a sub-contract machinist of orthopaedic components to avoid in situ broken tools and machine titanium parts in a single set-up 'with total confidence'.
The success of Vargus Tooling's Vardex MilliPro thread milling tooling is not only enabling LPE Medical, the market-leading sub-contract machinist of orthopaedic components, to avoid the traditional problem of in situ broken tools, and therefore high scrap rates, often associated with machining titanium, but the tooling has also allowed the component - a hip replacement femur part - to be produced after initial turning in a single set-up 'with total confidence According to Mike Harvey, director of manufacturing and process development at the Lymington, Hants, UK-based company - part of The Fullers Group - the success of the new tooling also looks set to pave the way for additional orders for similar components
This article was originally published on Manufacturingtalk on 27 Jan 2006 at 8.00am (UK)
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"When the part, one of a family of components of similar design but different sizes, finally reaches the thread milling sequence, the value of turning and milling machining content per part is very high - and coupled with material cost, this means that errors at the thread milling stage would be disastrous," he says.
"Thread milling of titanium is notoriously problematic, especially with tool snapping when producing a series of M6 threads to 10mm deep, as we wanted to achieve.
We have traditionally produced such threads via drill and tap processes, but because of its shape this component (a new contract) was impracticable to fixture on a lathe/turn-mill machine.
Further reading
Indexable thread-milling cutter saves time
A multiple-flute, indexable thread-milling cutter is designed to reduce cycle times on the generation of large threads through the use of long inserts and multiple flute holders.
Indexable cutter cuts thread milling cycle times
Multi-flute indexable thread milling cutter is designed to reduce cycle times on the generation of large threads through the use of long inserts and multiple flute holders.
Insert tooling halves thread turning times
Thread turning insert tooling has cut thread generation cycle times from 8 min to an amazing 3.5 min, extended tool life and completing the job in a single set-up.
"Our strong working relationship with Trucut Tools, Vargus Tooling's local distributor that offers all-round engineering solutions rather than just tooling, soon saw the Vardex MilliPro recommended - and we immediately applied the tooling." Designed for the creation of internal threads as small as M1.6 x 0.35, every style in the MilliPro range of solid carbide thread mills has three flutes each having three teeth.
MilliPro is designed for the consistent production of thread depths up to three times diameter.
Also available from Vargus Tooling is the Vardex MiniPro threading and grooving range, for the production of threaded bores as small as 3.2mm diameter and up to 13mm diameter.
The range of indexable inserts comprises the Micro and Mini 3 (IC4), Mini L and Mini 3 (IC 6) styles for pitches from 0.9mm to 2mm.
The VHX insert style is complemented by VMX and VKP (TiN coated general use carbide), VBX (TiCN coated carbide for IC 4) ideal for steel, and VTX (TiAIN coated carbide for IC 4) for machining stainless steel.
With over 1,000 components produced, Harvey says he has no regrets in investing in the new tooling, since the success of LPE Medical (since it was established the company has enjoyed 25% year-on-year growth) has been built on an ethos of superlative process control and underwritten by regular capital equipment investment (GBP 250,000 alone during the past year).
In addition, the company's policy of continuous improvement in every aspect of the business is endorsed by an ongoing skills training programme that has created a multi-tasking workforce and, crucially says Harvey, all this is underpinned by the application of stringent component quality.
Indeed, 25% of the direct workforce are involved in quality control since, as Harvey says, "We simply cannot afford to get anything wrong".
This attitude of total commitment to component quality - most components are machined to 10 microns as a matter of course and supported by inspection technology that can measure to within two microns - is, he says, an aspect of component supply that nowadays cannot be charged for.
"Quality control is paramount," he says, and as part of that not only does LPE Medical work within quality systems under its BS EN ISO 9001:2000/BS EN 13488 accreditation's, but it also needs to keep 20-year records of every part produced and the processes used.
"Combined, it is these aspects that set us apart, complemented by the fact that we offer clients the total service from forging to package - we are able to supply components to companies such as Biomet, DePuy and Smith and Nephew as 'ready to use' items for surgery." As Harvey concludes: "Everything we do is designed to protect our 100% record on component quality and delivery - and the Vargus Vardex tooling is the latest example of that.".
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