Overview

This technical document from DC Swiss SA focuses on swarf breaker threading tools, specifically taps with TiCN coating designed for efficient chip breaking and removal during thread cutting operations. It includes material specifications, application guidelines, tool dimensions, cutting parameters, and safety recommendations.

1. Material Specifications and Application Groups

The document lists a comprehensive range of materials categorized by tensile strength and type, including free-cutting steels, structural steels, carbon steels, alloy steels (both soft and hardened), cast irons (grey, spheroidal graphite, malleable), brass, bronze, copper alloys, and aluminum alloys with silicon or magnesium. Materials are identified by standard numbers (e.g., 1.0711, 0.6015) and corresponding common names or grades (e.g., S235JR, GG 15).

Materials are grouped by tensile strength ranges (e.g., <850 N/mm², 850-1150 N/mm²) to guide tool selection and cutting parameters.

2. Application Range and Use Cases

The swarf breaker taps are recommended for machining rotors, wheel hubs, gear wheels, and other parts with blind holes having tapping depths less than 4 times the nominal diameter (D1), including counterbores. Suitable materials include structural and cementation steels, spheroidal graphite and malleable cast iron, alloy steels up to 1150 N/mm² tensile strength, grey cast iron, and aluminum alloys.

The design prevents swarf nesting by breaking chips into small fragments that are flushed out by coolant through extended straight flutes, ensuring a clean and reliable tapping process. This is especially advantageous for horizontal machining operations.

3. Tool Design and Cutting Geometry

DC Swiss taps feature a TiCN coating and a special cutting geometry optimized for swarf breaking. The geometry supports both classical thread cutting with axial compensation and rigid (synchronous) tapping.

Key tool dimensions and parameters are provided for various metric thread sizes (M6 to M42), including pitch (P), overall length (l1), flute length (l2), thread length (l9), shank diameter (d2), and chamfer angle (a). Recommended cutting speeds (Vc) vary by thread size and material hardness.

4. Cutting Parameters and Requirements

• Minimum coolant pressure of 20 bar at the tap exit is required for optimal chip evacuation and tool performance.
• Cutting speeds are specified according to thread size ranges and material hardness categories.
• Both internal coolant supply and tool holders with through-spindle coolant capability are recommended.

5. Safety and Handling

The document emphasizes strict adherence to safety regulations due to the risk of tool breakage or shattering, which can endanger operators. Wearing safety glasses is mandatory. Grinding of threading tools must be conducted under rigorous safety standards to avoid hazardous dust exposure.

6. Technical Questionnaire

A detailed technical questionnaire is included for customers to provide information about tool type, thread size, material group and hardness, thread type (blind or through hole), cutting speed, feed, machine setup, lubrication, and reasons for tool change. This facilitates tailored tool recommendations and troubleshooting.

7. Contact and Legal Notices

Contact details for DC Swiss offices in Germany, Italy, Switzerland, and the UK are provided. The document includes disclaimers about possible technical data errors and prohibits unauthorized reproduction of content.