Analytical and Graphical Profiling of Thread-Milling Cutters for Forming Internal Threads

Accurate profiling of thread-milling cutters is one of the main prerequisites of high-precision internal thread production. Despite the accuracy of analytical methods, their complexity in most instances makes practical application an issue. The current research addresses a graphical profiling method, the Tangent Circles Method, introduced by the authors for the facilitation of thread-milling tool geometric design. Several thread-milling cutters were designed employing this method, and their working surface profiles were compared with those obtained analytically. The comparison showed a good match, with profile deviations within acceptable manufacturing limits. CAD-based simulations also demonstrated that rake angle and relief height parameters significantly influence the resulting tool geometry. The results validate the Tangent Circles Method as a mathematically sound and industrially viable tool-profiling method for industry use. Its easy application and precision make it a reliable choice over analytical methods in internal thread-milling cutters’ industrial design.