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Troubleshooting for thread whirling

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 steps 1a to 1d

1 a. Profile depth too shallow
  • Uncentered tool
  • Measure the insert offset versus the swivel axis, and set the tool centered to the component.
    Use a thread whirling calculator
1 b. Profile too narrow
  • 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
  • Feed too high
  • Reduce the tooth feed. Use a thread whirling calculator

3. Vibrations
  1. Feed too high
  2. Bar too loose in guide bush
  3. Overhang of component too long
  1. Reduce the tooth feed. Use a thread whirling calculator
  2. Tighten the guide bush properly, or replace the bar (if the dimensional quality of the bar is too low )
  3. 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 for which will need to be compensated.
    Also ensure clearance for the component through the ring, adapter/shim, and drive unit.

4. Insert wear

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