- 500 - Bass Tool & Supply, Inc. Houston Email Fax Toll Free www.basstool.com (713) 682-1889 [email protected] (713) 681-4931 800-442-0042 UNDERSTANDING EMUGE TAPS: TYPES, GEOMETRIES, COATINGS & APPLICATIONS TYPES OF EMUGE TAPS ● 35 - 50° right hand spiral flutes ● Chamfer form E (1.5-2 threads) ● Chamfer form C (2-3 threads) ● For blind hole threads in long-chipping materials Enorm Note: Typical tool for blind hole threads in long-chipping materials. The fast spiral flutes provide good chip removal from the blind hole. Depending on design and size, threads up to 3 x d1 can be cut. Not to be recommended for threads beginning with an increased diameter. ● Straight flutes with spiral point ● Chamfer form B (4-5 threads) ● For through hole threads Rekord B Note: Typical tool for through hole threads in long-chipping material. The spiral point pushes the tightly rolled chips ahead and prevents clogging of the flutes. Coolant-lubricant can flow freely. Do not use this tap type for a reverse cut! VA AVAILABLE IN: Enorm, Rekord A With tough and long-chipping materials, the chips must be transported in an axial direction in order to avoid chip jams. An increased profile relief angle reduces friction and with it, the danger of cold welding. HCUT AERO AVAILABLE IN: Rekord B Negative rake angle values give a very strong cutting edge. Especially in tough materials with high tensile strength this will lead to a safe tapping process. ● 10 - 15° right hand spiral flutes ● Chamfer form E (1.5-2 threads) ● Chamfer form C (2-3 threads) ● For blind hole threads Rekord D Note: Especially to be recommended on automatic lathes and multi-spindle machines. The slow spiral flutes will be especially helpful in thread holes beginning with an increased diameter (counterbore or enlarged bore). Provided with internal coolant supply, this tap type will help to solve chip problems on CNC machines. ● 10 - 15° right hand spiral flutes ● Additional helix correction “F” (relief) ● Chamfer form C (2-3 threads) ● For blind hole threads Rekord DF Note: Especially to be recommended on automatic lathes and multi-spindle machines. The slow spiral flutes will be especially helpful in thread holes beginning with an increased diameter (counterbore or enlarged bore). The additional helix correction “F” relief produces smaller, and tightly rolled chips. Provided with internal coolant supply, this tap type will help to solve chip problems on CNC machines. ● Provided with a hollow face ● Chamfer form C (2-3 threads) ● For blind hole and through hole threads Robust 2X Note: The special crown-shaped front portion of this tool provides excellent accuracy even in the first stage of the cutting process. Extra clean and accurate threads can be cut in this way. The sward is collected in the hollow face of the tap (internal chip collector) when cutting blind hole threads. For this tool, we recommend using paste lubrication wherever possible. Please make sure to cover not only the tool but also the walls of the hole with paste! Oil lubrication is possible only in vertical machining, if the blind hole can be completely filled with oil. ● 8 - 15° left-hand spiral flutes ● Chamfer form D (4-5 threads) ● For through hole threads Rekord C Note: The left-hand spiral flutes push the chips ahead. As opposed to the spiral-point design (Rekord B), the rake angle remains constant over the complete length of the chamfer. This means extramely stable chamfer teeth for high strength materials. ● Straight flutes ● Chamfer form D (2-3 threads) ● Chamfer form E (1.5-2 threads) ● For blind hole and through hole threads Rekord A Note: Especially for short-chipping material. The flutes can hold only a part of the chips. There is practically no chip transport in an exial direction. We do not recommend using this tap type in deep blind hole or through hole threads in long-chipping material. For stainless steel materials and steel materials For hardened steels For tough materials with high tensile strength GEOMETRIES OF EMUGE TAPS NI AVAILABLE IN: Rekord C, Rekord DF Nickel alloys are usually very tough, clamping and of high tensile strength, e.g. Inconel 718. Negative rake angles, very high relief angles and a hard surface coating are an unconditional necessity. Lubrication with paste or oil is necessary in most cases. For nickel alloys TI AVAILABLE IN: Rekord C, Rekord D These alloys are usually very strong, long-chipping and clamping. Small rake angles and very high relief angles are necessary. Often, it is necessary also to specially adjust the tool to the individual alloy and the specific work conditions. For titanium STEEL AVAILABLE IN: Enorm, Rekord B, Rekord D, Rekord A Geometry with very good proper guidance for true-to-gauge thread cutting on all machines. Available ex stock in many thread systems and sizes. By combination with hard surface coatings, cutting data and tool life increases can be achieved. ● Rekord B-STEEL-L For low strength steels For steel materials AVAILABLE IN: Rekord A This geometry with its specially adjusted flute profiles and its special rake and relief angles makes thread cutting in hardened steel possible. Made of cutting material HSS-E- PM, these tools are suitable for a material hardness of 44-55 HRC, while solid carbide tools will work in a hardness of 55-63 HRC. TILG For titanium alloys AVAILABLE IN: Rekord DF Titanium alloys are becoming more and more popular in modern industry. The geometry of this tool has been specially adjusted to the machining of these materials. Cold welding is prevented by the extra high relief angle values. A helix correction provides short chips. AL For aluminum wrought alloys AVAILABLE IN: Enorm, Rekord B In the machining of long-chipping aluminum, it is absolutely necessary to provide chip transport in an axial direction. In addition to the large rake angle, these tools are made with a reduced number of flutes so that there is even more rool for the swarf. This helps to avoid clogging of the flutes. GAL For aluminum cast alloys AVAILABLE IN: Rekord D, Rekord A In order to achieve a long tool life in this highly abrasive material, all the tools are provided with a hard surface coating. Internal coolant supply also is very helpful. GG AVAILABLE IN: Rekord A Since cast iron is a very abrasive material, these taps are always provided with a surface treatment in addition to a low rake angle. In general, straight flutes are sufficient for such short-chipping materials. For cast iron GJV For cast iron with vermicular graphite AVAILABLE IN: Rekord A Newly developed cast materials often show very special grain structures. In combination with an increased number of flutes and a specially adjusted geometry, these tools permit long tool life even in these highly abrasive materials as well as in normal cast iron. H AVAILABLE IN: Rekord B Relatively high relief angle values in combination with a surface treatment or a hard surface coating ensure extra long tool life in abrasive materials. For materials of high tensile strength Z AVAILABLE IN: Enorm, Rekord B, Rekord D, Rekord A This very keen cutting geometry with elevated rake and relief angles is suitable for a multitude of long- chipping materials. It is designed especially for CNC-controlled machine tools. Synchronous feed control, especially in connection with our collet holders of the Softsynchro® series will bring out the full performance potential of these tools. For CNC-controlled machines SPEED AVAILABLE IN: Enorm, Rekord B, Rekord D, Rekord A CNC machines, especially in combination with our Speedsynchro®, make very high speeds possible. The special geometry of these tools, combined with a hard surface coating, offers you the chance to do your machining at the highest speeds your machine can manage. For high-speed tapping PVC AVAILABLE IN: Rekord D, The chamfer of this tool has been optimized in order to ensure a safe shearing off of the chip root in the thread. An elevated tolerance, combined with a hard surface coating, guarantees true-to-gauge threads in these elastic materials. For long-chipping synthetics EXAMPLE: Enorm VA NE2 ◄ ◄ ◄ TYPE GEOMETRY COATING EMUGE COATINGS & SURFACE TREATMENTS NE2 In a special installation, the tools are exposed to hot steam. This leads to the formation of a dark oxide layer on the tool surface. This oxide layer protects the surface, and acts as a good carrier of lubricants. Cold welding which occurs especially with low-carbon, soft steels, can be prevented in this way. Oxidation NT In a thermo-chemical treatment, the surface is enriched with nitrogen to a depth of approx. 0.03 to 0.05 mm. Since the surface becomes very hard (1000-1250 HV) and brittle, nitrided tools can be used with certain restrictions only in blind holes and in all work cases which necessitate reversing. In abrasive materials like cast iron, spheroidal cast iron, cast aluminum and duroplastics, tool life can be increased in a decisive manner. Nitriding TICN In a PVD process (500°C) a coating thickness of 2-4 μm can be realized. The hardness is approx. 3000 HV. The TICN coating will resist up to approx. 400°C. Titanium carbonitride (blue-grey) NT2 The surface of the tools is first nitrided and then oxidised (NT + NE2). This treatment combines increased surface hardness with an improved lubricant- holding capacity. Nitriding and oxidation TIN In a PVD process (500°C) a coating thickness of 3-7 μm can be realized. The coatings feature a high adhesion strength and TIN-typical properties against cold welding. TIN coating systems with additional code number (e.g. TIN-60, TIN-70) are optimized with regard to substrate and application. Titanium-nitride (gold-yellow) GLT-1 In a PVD process (500°C) a coating thickness of 2-4 μm can be realized. The combination of a hard surface coating (approx. 3000 HV) with a superimposed anti-friction layer yields decisive tool life advantages. Also, the chip flow can be very positively influenced. Please note: Before re-coating, tools need to be de-coated! Hard surface coating with anti-friction layer (dark-grey) GLT-8 In a PVD process a coating thickness of 1-2 μm can be realized. The hardness is approx. 2500 HV. This mono-layer coating is an excellent choice for the machining of non-ferrous metals and aluminum with a low silicon content (< 7% Si). Thanks to the low friction, material adhesion is drastically reduced. This coating will remain resistant up to approx. 350 °C. Diamond-like, amorphous carbon coating (black-grey) OTHER EMUGE ABBREVIATIONS IKZ The axial exit of coolant-lubricant provides optimum cooling and lubrication in the chamfer area. Chips are evacuated easily from blind holes. Internal coolant supply, axial (DIN designation: KA) IKZN Radial exit of coolant-lubricant is the safest solution for providing coolant supply in the chamfer area even in through holes. Internal coolant supply, axial, with coolant exiting in the flutes (DIN designation: KR) BF With bright face “Bright Face” grinding in combination with a special edge preperation ensures that chips will break in steel materials. Short chips will be evacuated without “birdnesting”. X With back taper Tooth chipping due to chip jams can be prevented by grinding off the tooth crests in the guide thread area.
