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Fig. 1 1 High efficiency of machining We know that it is very difficult to increase the machining efficiency in large-volume thread processing because of the relatively low cutting speed of the tap and the reverse retraction after the thread has been machined. However, if we use a thread mill (eg VARGUS's MiTM), not only does it have a very high milling speed, but its multi-slot design increases the number of cutting edges so that the feed rate can be easily increased. Processing efficiency. In the machining of long threads, we can also choose a blade with a longer blade to reduce the axial feed distance (equivalent to making the thread shorter) to further improve the machining efficiency (see Figure 1). 2 Excellent surface quality and dimensional accuracy When tapping with a tap, it is difficult to obtain a good surface finish and thread accuracy due to lower cutting speeds and difficult chip breaking. However, everything is not a problem for thread milling! The high cutting speed, the small cutting force makes the cutting surface smooth; the fine cutting chips can be easily punched out of the workpiece by the cooling fluid without scratching the processed surface. For workpieces with high requirements for thread accuracy, since the thread milling cutter is guaranteed by spiral interpolation to ensure accuracy, the required high-precision thread can be easily obtained just by adjusting the procedure. This feature has absolute advantages in precision threading. 
Fig. 2 3 Stability, safety and reliability When processing difficult-to-machine materials such as titanium alloys, high-temperature alloys and high-hardness materials, the taps are often distorted or even broken in the parts due to excessive cutting forces. In the long chip material processing, once the chip is not smooth, the chip will wrap around the tap or plug the hole, often resulting in the tap break or broken in the parts. Taking out broken taps is not only time-consuming and laborious but also can damage the parts. To solve this problem we can use thread milling cutters. As the thread milling cutter gradually cuts into the material, it produces less cutting force and rarely breaks the blade. Even in the event of a broken knife, because the cutter diameter is much smaller than the threaded hole, the broken part can be easily removed from the part without damaging the part (see Figure 2). 
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Fig. 6 4 Wide range of use, low processing costs Thread milling cutters are flexible and can be used in a variety of operating conditions. For example, we can use the same thread milling cutter to machine the left-hand thread or the right-hand thread. We can process both external and internal threads. All this has to do is adjust the interpolation procedure (see Figure 3). With taps, taps of different diameters are required if the part has multiple threaded holes of different diameters but the same pitch. This not only requires a large number of taps but also many tool change times. If a thread milling cutter is used, since it uses helical interpolation for machining, it is only necessary to change the machining program to complete the machining of all diameter threads, which greatly saves the tool cost and tool change time (see Figure 4). In order to ensure the accuracy of the thread, different taps are required when tapping different materials. However, there is no such limitation when using a thread cutter. The same thread milling cutter can machine most of the material and obtain very high precision threads. This can also greatly reduce tooling costs. When machining threads that are close to the bottom of a blind hole, tapping with a tap will make it difficult to obtain a complete thread at the bottom. It is also possible that the tool will continue to move forward a little distance (floating tapping) during the period of attacking the bottom tap to stop reversing. This will easily cause the tap to break. This problem can be avoided by using a thread mill - the thread mill is smaller than the hole and does not have to reverse the retraction and remains a complete thread shape at the tool tip. In this way we can obtain a complete and accurate thread depth (see Figure 5)! In some processes, thread milling can help us solve many problems. For example, in the machining of large, non-circular parts, if machining on a lathe requires complex clamping and balancing to avoid vibration. At this time, it can be processed on the machining center, with the parts not moving and the thread milling cutter rotating to avoid the balance problem (see Figure 6). For example, when processing intermittent threads, the impact of vibration on the blade is very large and cracks easily. The use of thread milling cutters, because the tool is gradually cutting into the material intermittent, thus avoiding a large impact, extending tool life. Thread milling is a versatile new type of advanced machining technology, but it also has its limitations. First of all, it requires the use of a 3-axis CNC machine tool. Second, it can only machine threads with a depth of about 3 times. Furthermore, a single thread milling cutter is more expensive than a tap—although it costs less than a tap in batch processing. Finally, the programming of thread milling is cumbersome, which is one of the important factors limiting its wide application. However, VARGUS, the world leader in thread machining, has solved this problem. Its free and easy-to-use TM GEN Thread Milling Expert System can quickly and easily generate milling programs that can be used directly by the machine tool according to machining requirements. This will greatly facilitate the wide application of the new technology of thread milling. In general, thread milling is a very new technology. When to use a tap and when to try a thread mill? The only selection criteria for us is - to produce qualified threads quickly and inexpensively!
Thread Milling Features and Applications
As China has gradually grown into a global manufacturing center, a large number of orders and advanced technologies and equipment have also entered China. CNC machine tools are widely used in various factories in China. The bottleneck in the widespread application of thread milling has also been weakened, and the previously difficult and time-consuming threading processes have been greatly changed. As a new type of thread processing technology, thread milling has unique advantages compared with tapping, and more versatile and flexible use methods and applications. Next let's take a look.