What Is Whirling Machine?
CNC Whirling Machine is a high-speed thread whirling machine used with an ordinary lathe. The thread whirling method of milling threads from the workpiece is performed with a carbide-forming cutter mounted on a high-speed rotating cutter plate. Because of its high milling speed (up to 400m/min), processing efficiency, and the use of compressed air for chip cooling. It is cutting splash in processing such as cyclone and named -Whirling Machines.
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Whirling Milling Tool Determination Process
1.Determine part shape
2.Determine tool shape based on part
3.Make the corresponding blade
4.Attach the blade to the cutterhead
Whirling Machine Process
1.It consists of cyclone milling cutter head, workpiece and guide sleeve.
2.Adjust the installation deflection angle according to the helix angle ϕ of the thread.
The installation declination angle determines the size of the thread pitch, and a large installation declination angle processes large pitch threads.
3. Down milling
The rotation direction of the cyclone milling cutter head is opposite to the rotation direction of the machine tool spindle (part), which is down milling, so that good surface quality can be processed. On the contrary, it is reverse milling, and the processed surface quality is poor.
5 Movements of Whirling Milling
Whirling Milling and lathe supporting in the machining process need to complete five processing motions:
- the cutter disk-driven carbide molding cutter rotating at high speed (the main movement)
- lathe spindle-driven workpiece slow rotation (auxiliary movement)
- Whirling milling according to the workpiece pitch or lead along the workpiece axial movement (feed movement)
- Whirling milling in the lathe drag plate driven by radial movement (cutting motion)
- Whirling milling in a certain angle range and spiral angle of freedom of adjustment. (Rotary motion)
- In the high-speed Whirling of the molding milling cutter, the tip of the rotary circle is always in contact with the outer diameter of the internal thread in the state of internal contact. The cutter disk has a number of molding cutters; each cutter, in turn, participates in the cutting, and cutting thickness progressive changes in the cutting force to reduce.
Application of Whirling Machine
1.Medical industry (implants)
Medical industry, medical bone nails, etc.
2. Automobile industry
Automobile automatic transmission shafts, such as those on automatic seats, etc.
3.Machine tool industry and others
The screw of the machine tool is processed by cyclone milling, which will be very efficient.
Advantages of Thread Whirling
- High processing efficiency, more than 10 times higher than traditional processing efficiency
- Product-knife forming, eccentric cutting without tool retraction
- No changes to the lathe structure, the helix angle is adjustable, and the installation is easy
- The surface roughness can reach Ra0.8 micron, and the processing accuracy is improved by 2 levels.
- The axial feed of the lathe is slow, easy to operate, and reduces the professional skills of the workers.
Type Of Whirling Milling
The cutting forms of cyclone milling are divided into:
- Endocution type
- Exocution type
What different Thread Whirling And Thread Milling?
Thread whirling is similar to a thread milling process, the difference is that the inserts are mounted on the inside of a cutting ring rather than outside of a milling tool. The thread whirling ring rotates around a cylindrical component to cut the thread in one pass. Thread whirling is a productive method and is often used for special thread forms that needs to be produced quickly and at high tolerances. Typical components are medical bone screws, implants, feed screws, worm gears and other micro-components.
Troubleshooting Of Whirling Machine
Use this list of causes and solutions for successful thread whirling. It is recommended to use a thread whirling calculator for correct programming.
| 1. Wrong thread dimension, follow step 1a to 1d | Reason | Solutions |
| 1 a. Profile depth too shallow | Uncentred tool | Measure the insert offset versus the swivel axis and set the tool centred to the component. Preferably use a thread whirling calculator |
| 1 b. Too narrow profile | Wrong tool setting angle | Increase or decrease tool setting angle |
| 1 c. Wrong outer diameter (OD) | Wrong diameter setting in the program | Adjust tool diameter and/or component diameter setting in the program |
| 1 d. Wrong thread length | Wrong tool Z setting in the program | Adjust tool Z setting in the program |
| 2. Faceted surface | Too high feed | Reduce the tooth feed. Preferably use a thread whirling calculator |
| 3. Vibrations | Too high feedBar too loose in guide bushToo long overhang of component | Reduce the tooth feed. Preferably use a thread whirling calculatorTighten the guide bush properly, or replace the bar (if bar is of too low dimensional quality)a) Move the whirling unit closer to the guide bush b) Move the whirling ring closer to the guide bush, use one of following options: – Insert an adapter/shim between the whirling ring and the whirling unit – Change to a thicker whirling ring, often a engineered ring will be needed. This will create a bigger offset to the swivel axis that will need to be compensated for. Also ensure clearance for the component through the ring, adaptor/shim and drive unit. |
